Final Report - TK06

UNIVERSITAS INDONESIA
PRODUCTION OF VITAMIN B12 FROM MOLASSES
Final Report
GROUP TK06
GROUP PERSONNEL:
ACHMAD RAYHAN (1706985640)
ATHALIA LIMBONG (1706038443)
CHRISTOPHER REYNALDO (1706038512)
MERINDA INNAYAH F (1706038626)
MUHAMMAD NABIL HIFZHAN (1706038582)
NUR ELISTIANI EKSADITA (1706985823)
CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
November, 2020
LIST OF GROUP MEMBERS
1. Name : Athalia Limbong

NPM : 1706038443
Date of Birth : Ambon, 8 August 1999
Address : Villa Citra Bt. Jati A1 No.35 Bogor
2. Name : Achmad Rayhan

NPM : 1706985640
Date of Birth : Jakarta, 17 Juli 1999
Address : Jl. Margasatwa No. 29A, Pondok Labu, Jakarta Selatan
3. Name : Christopher Reynaldo

NPM : 1706038512
Date of Birth : Jakarta, 16 Maret 1999
Address : Kalideres Permai Blok C3 No.7, Jakarta Barat
4. Name : Merinda Innayah Fawwazita

NPM : 1706038626
Date of Birth : Bengkulu, 18 August 1999
Address : Meranti 2 No.34 Bengkulu
5. Name : Muhammad Nabil Hifzhan

NPM : 1706038582
Date of Birth : Jakarta, 15 November 1999
Address : Jl. Bumi, Gg Berdikari No. 4, Jakarta Selatan
6. Name : Nur Elistiani Eksadita

NPM : 1706985823
Date of Birth : Surabaya, 8 September 1999
Address : Jl. Pulau Dewata, Kelapa Gading Barat, Jakarta Utara
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FOREWORD
First of all, we would like to thank God for all His blessings and goodwill, and
for giving us the courage and strength to finish the final report of the GHDHD
assignment. This final report represents the GGDGDG. Throughout all this we
have encountered and surmounted numerous challenges which we could not do by
ourselves, and thus we would like to extend our gratitude to the following
persons:
1. Dr. Tania Surya Utami, S.T., Dr. rer nat. Ir. Yuswan Muharam M.T., Prof.
Dr. Ir. Widodo Wahyu Purwanto, and Ir. Dijan Supramono, M.Sc who has
given their best guidance to the writer in writing a great quality report and
well developed chemical plant design.
2. Our families, for the support throughout the whole process.
3. Our friends from Chemical Engineering Department Batch 2017, for all
the times that we spent together.
4. And others who have helped and supported us in ways that are not
immediately apparent.
Finally, we realized and aware that this report may be lacking in certain areas.
We appreciate all the suggestion and criticism from reader in order to improve the
content. And may through this report, we hope that will be used to the
development of industry, especially foods and agricultural industry.
Depok, December 2020
Group TK 06
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PRODUCTION OF VITAMIN B12 FROM MOLASSES
Achmad Rayhan, Athalia Limbong, Christopher Reynaldo, Merinda Innayah
Fawwazita, Muhammad Nabil Hifzhan, Nur Elistiani Eksadita
Department of Chemical Engineering, Faculty of Engineering, Universitas

Indonesia, Depok 16424, Indonesia
ABSTRACT
Cyanocobalamin, often referred to as vitamin B12 is a dietary supplement

and a prescription medication often for those with impaired absorption.
Production of vitamin B12 is limited through biosynthesis from microorganism,
where it will require a carbon source, often pure-grade sucrose. However, this
leads to high-medium costs, in which an alternative source must be employed.
This plant utilizes sugarcane molasses as the main carbon source to produce
vitamin B12 using Pseudomonas denitrificans which will be done via aerobic
fermentation. The methods are fermentation, separation, and purification of
vitamin B12. This plant is in Malang, East Java. The capital expenditure of this
plant is USD 25,129,796 with annual operating expenditure of USD 2,514,284.
Annual revenue from this plant is approximately 9,378,600. With vitamin B12’s
price at USD 3500/kg, the NPV is calculated to be USD 16,017,103 with an IRR
of 13.46% and a WACC of 6.60%. The payback period is estimated at 7.2 years,
with a BEP of 17,139 kg vitamin B12 sold.
Keywords: Cyanocobalamin, Molasses, Pseudomonas Denitrificans,

Fermentation,
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EXECUTIVE SUMMARY
Vitamin B12 or Cyanocobalamin is a water-soluble vitamin that naturally
come from animal products such as meats, fish, poultry, eggs and dairy and from
some vitamins fortified vegetable products such as cereal and breads. Vitamin B 12
can be produced by fermentation process, either aerobic or anaerobic fermentation
depends on the bacteria that is used. Based on its advantages, Pseudomonas
denititrificans is chosen for this project. The fermentation process also need a
carbon source. Molasses have been used as an alternative as a carbon source for
vitamin B12 production because they contain high contents of sucrose. It is also a
low-cost fermentation medium. Sucrose is a carbohydrate needed to ferment
molasses into vitamin B12. The type of molasses that are used for this production
is sugarcane molasses, which are abundant in Indonesia.
The process for the vitamin B12 production consists of three major process:
fermentation of molasses with microorganism, separation, and purification. The
fermentation stage is where the molasses is introduced into the main bubble
column fermenter with which aerobic fermentation occurs with the
microorganism. The separation process utilizes centrifuges to separate solid waste
and a centrifugal extractor to separate liquid waste. Lastly, the use of an ion
exchange chromatography helps purify the vitamin from the mixture. Vitamin B12
is then precipitated from the solution by using a freeze drier.
In order to properly achieve the expected vitamin B12 production rate, plant
equipment is to be sized which includes its dimensions, construction materials,
operating conditions, and supplementary materials. Each unit from each section of
the process, including utilities are also provided with a mechanical drawing. Also,
the calculation methods for most units are provided in the appendix, with the
assumptions that are used to estimate their size.
With the sizing completed, a proper and detail view of the whole process
is shown on a piping and instrumentation diagram. This diagram shows what and
where control instrumentation is used in certain equipment to adjust certain
variables in accordance to other variable to achieve the optimal or safe condition.
In it is also shown the pipe size, length, fittings and valve that are present in the
plant equipment. The objective of such diagram is to illustrate the optimum and
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feasible plant design and also to make future maintenance and operation more
accessible as each instrument is listed on the diagram so it can be maintained
easily.
From the raw material availability and the facilities required, the authors
choose Malang, East Java as the plant location. This plant is chosen as it is a
strategic location, where it is close to different transportation infrastructures
which will help minimize distribution cost. The plant area is 7350 m 2 including
the main process, utility, and other supporting buildings. The area in the plant and
the operation details are designed to prioritize safety and the workers. Therefore, a
set of guidelines are used, such as battery limit, mandatory personal protective
equipment, and referring back to material safety data sheet.
To calculate whether this plant is profitable or not, an economic analysis is

performed. The capital expenditure or CAPEX is calculation cost for designed
chemical plant with summarize of total bare module costs, direct permanent
investment costs, total depreciable capital costs, and total permanent investment.
The total CAPEX calculated for this plant is USD 25,126,033. After CAPEX, an
operational expenditure or OPEX is performed. Operational Cost is including the
raw material, direct labors, indirect employee, utilities, assurance, maintenance,
and other cost spent for operating the plant. This plant has an OPEX of USD
4,616,512 per year.
The weighted average cost of capital or WACC is calculated to determine

the value of MARR for profit analysis. The value of WACC for this plant is
7.38%. The plant is expected to operate for 20 years, while the products are to be
sold at USD 3500 / kg with a capacity of 2,680 kg / year. With these, a forecast of
the sales and profit potential are calculated, where the value of internal rate of
return (IRR) is 13.9% with the return on investment (ROI) being 8.48%. The net
present value (NPV) of this plant is USD 14,462,779. The expected payback
period based on the annual revenue of about USD 9,378,600 is supposed to be 7.1
years, with the break-even point (BEP) reaching 17,313 kg vitamin B12. Last, a
sensitivity analysis against product selling price is attempted, where it is
concluded that exports are essential to maintain price levels from saturating.
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vii Universitas Indonesia
TABLE OF CONTENT
LIST OF GROUP MEMBERS.............................................................................ii
FOREWORD........................................................................................................iii
ABSTRACT...........................................................................................................iv
EXECUTIVE SUMMARY....................................................................................v
TABLE OF CONTENT.......................................................................................vii
LIST OF FIGURES............................................................................................xiii
LIST OF TABLES...............................................................................................xv
CHAPTER 1 INTRODUCTION..........................................................................1
1.1. Background..............................................................................................1
1.2. Literature Review....................................................................................2
1.2.1. Vitamin B12........................................................................................2
1.2.2. Fermentation Process..........................................................................6
1.2.3. Bacteria for Fermentation Process......................................................7
1.2.4. Molasses.............................................................................................9
1.3. Market and Capacity Analysis.............................................................10
CHAPTER 2 PROCESS DESCRIPTION.........................................................13
2.1. Process Alternatives..................................................................................13
2.1.1. Fermentation Section........................................................................13
2.1.2. Separation and Purification...............................................................16
2.2. Process Selection........................................................................................17
2.2.1. Process Material................................................................................17
2.2.2. Fermentation.....................................................................................20
2.2.3. Separation.........................................................................................22
2.3. Selected Process Description.................................................................25
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2.3.1. Cell Culture.......................................................................................25
2.3.2. Medium Mixing................................................................................25
2.3.3. Sterilization.......................................................................................26
2.3.4. Seed Fermentation............................................................................26
2.3.5. Product Fermentation........................................................................26
2.3.6. Centrifugation...................................................................................27
2.3.7. Extraction..........................................................................................27
2.3.8. Ion Exchanged Chromatography......................................................28
2.3.9. Freeze Drying...................................................................................29
2.1. Block Flow & Process Flow Diagram..................................................29
2.2. Mass Balance..........................................................................................29
2.3. Energy Balance......................................................................................30
2.4. Plant Efficiency......................................................................................30
2.5. Utility.......................................................................................................31
2.8.1. Water Utility.....................................................................................31
2.8.2. Air Utility..........................................................................................32
2.8.3. Electricity Utility..............................................................................33
2.8.4. Fuel Utility........................................................................................35
2.8.5. Wastewater Treatment......................................................................36
CHAPTER 3 EQUIPMENT DESIGN...............................................................38
3.1. Cell Culture Flask..................................................................................38
3.2. Medium Blender....................................................................................38
3.2.1. Seed Medium Blending....................................................................38
3.2.2. Fermentation Medium Blending.......................................................39
3.2.3. Blending Storage..............................................................................40
3.3. Sterilizer..................................................................................................41
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3.3.1. Semi-Continuous Sterilizer...............................................................41
3.3.2. Batch Sterilizer.................................................................................45
3.4. Fermenters..............................................................................................46
3.4.1. Pre-Seed Fermenter..........................................................................46
3.4.2. Seed Fermenter.................................................................................47
3.4.3. Main Fermenter................................................................................49
3.5. Centrifugation........................................................................................50
3.6. Centrifugal Extractors..........................................................................51
3.7. Ion Exchange Chromatography...........................................................51
3.8. Freeze Dryer...........................................................................................52
3.9. Belt Conveyor.........................................................................................53
3.10. Cyanocobalamin Storage Tank............................................................53
3.11. Compressors...........................................................................................54
3.12. Air Filtration..........................................................................................54
3.13. Water Utility...........................................................................................55
3.14. Wastewater Utility.................................................................................55
3.15. Steam Utility...........................................................................................55
3.15.1. Demineralized Water Storage Tank..................................................56
3.15.2. Fuel Storage Tank.............................................................................57
3.15.3. Compressor.......................................................................................58
3.15.4. Boiler................................................................................................58
3.16. Pump.......................................................................................................59
CHAPTER 4 PROCESS CONTROL STRATEGY.........................................60
4.1. Pipeline Specification.............................................................................60
4.2. Production Process Piping and Instrumentation Diagram................66
CHAPTER 5 PLANT LAYOUT........................................................................69
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5.1. Location Analysis...................................................................................69
5.2. Overall Plant Layout.............................................................................72
5.2.1. Equipment Layout............................................................................74
5.2.2. Area Layout......................................................................................75
5.3. Water Utility Plant Layout...................................................................76
5.4. Main Process Plant Layout...................................................................77
5.5. Wastewater Treatment Plant Layout..................................................78
5.6. Storage Room Plant Layout..................................................................79
5.7. Steam Utility Plant Layout....................................................................80
CHAPTER 6 HEALTH, SAFETY, AND ENVIRONMENTAL

PROTECTION.....................................................................................................81
6.1. Hazard Identification Study (HAZID).................................................81
6.2. Hazard and Operability Study (HAZOP)...........................................82
6.3. Operational Details................................................................................82
6.3.1. Start-Up Procedure...........................................................................83
6.3.2. Commissioning.................................................................................84
6.3.3. Pre-start-up Safety Review (PSSR)..................................................84
6.3.4. Acceptance Test Run (ATR)............................................................84
6.3.5. Shut-Down Procedure.......................................................................85
6.4. Personal Protective Equipment............................................................85
6.5. Material Safety Data Sheet...................................................................86
6.6. Area Classification.................................................................................87
6.7. Emergency Action Plan.........................................................................87
6.7.1. Emergency Operating Procedures and Training...............................87
6.7.2. Emergency Alarm and Fire Fighting Strategy..................................89
6.7.3. Emergency Escape Strategy.............................................................90
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6.8. Waste Management...............................................................................91
6.8.1. Liquid Waste Management...............................................................91
6.8.2. Solid Waste Management.................................................................92
6.8.3. Gas Waste Management...................................................................92
CHAPTER 7 ECONOMIC ANALYSIS...........................................................94
7.1 Cost Estimate Assumption....................................................................94
7.2 Cost Index...............................................................................................94
7.3 Capital Expenditure..............................................................................95
7.3.1 Total Bare Module Cost....................................................................96
7.3.2 Land Site Development Cost..........................................................102
7.3.3 Building Cost..................................................................................103
7.3.4 Supporting Facilities Cost...............................................................104
7.3.5 Contingency Cost and Contractor Cost..........................................109
7.3.6 Plant Startup Cost...........................................................................109
7.3.7 Working Capital..............................................................................110
7.3.8 Capital Expenditure Summary........................................................110
7.4 Capital Expenditure............................................................................111
7.4.1 Raw Material Cost..........................................................................111
7.4.2 Labor Salary Cost...........................................................................114
7.4.3 Utility Cost......................................................................................116
7.4.4 Maintenance Cost...........................................................................119
7.4.5 Tax and Insurance Cost..................................................................119
7.4.6 Safety Cost......................................................................................124
7.4.7 General Cost...................................................................................124
7.4.8 Depreciation....................................................................................129
7.4.9 Operational Expenditure Summary................................................132
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7.5 Economic Evaluation...........................................................................135
7.5.1 Benchmark......................................................................................135
7.5.2 Investment Feasibility Analysis......................................................135
7.5.3 Profitability Analysis......................................................................142
7.6 Sensitivity Analysis..............................................................................145
7.6.1 IRR Sensitivity Analysis.................................................................148
7.6.2 NPV Sensitivity Analysis...............................................................148
7.6.3 PBP Sensitivity Analysis................................................................149
7.6.4 Result..............................................................................................149
CHAPTER 8 CONCLUSION...........................................................................151
REFERENCES...................................................................................................152
APPENDICES....................................................................................................155
APPENDIX A BFD AND PFD......................................................................155
APPENDIX B MASS BALANCE.................................................................161
APPENDIX C ENERGY BALANCE...........................................................173
APPENDIX D WATER UTILITY SPECIFICATION...............................175
APPENDIX E WASTEWATER UTILITY SPECIFICATION................180
APPENDIX F STEAM UTILITY SPECIFICATION................................187
APPENDIX G PUMP SPECIFICATION....................................................191
APPENDIX H MECHANICAL DRAWING...............................................207
APPENDIX I HAZID & HAZOP ANALYSIS............................................216
APPENDIX J MATERIAL SAFETY DATA SHEET................................240
APPENDIX K PLANT CASHFLOW..........................................................378
APPENDIX L CONTROL TABULATION.................................................380
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LIST OF FIGURES
Figure 1. 1. Chemical Structure of Vitamin B12.....................................................3

Figure 1.2. Mechanism of Absorption of Vitamin B12 (cobalamin) in the GI Tract
..................................................................................................................................5
Figure 1.3. Molasses................................................................................................9
Figure 3.1. Semi-Continuous Sterilizer Combination............................................41
Figure 4.1. P&ID Fermentation Section................................................................67
................................................................................................................................68
Figure 4.2. P&ID Separation Section.....................................................................68
Figure 5.1. Plant Location......................................................................................72
Figure 5.2. Overall Plant Layout............................................................................73
Figure 5.3. Water Utility Plant Layout..................................................................76
Figure 5.4. Main Process Plant Layout..................................................................77
Figure 5.5. Wastewater Treatment Plant Layout...................................................78
Figure 5.6. Storage Room Plant Layout.................................................................79
Figure 5.7. Steam Utility Plant Layout..................................................................80
Figure 6.1. NFPA Rating Explanation...................................................................86
Figure 6.2. Audible Alarms....................................................................................89
Figure 6.3. Visible Alarm......................................................................................90
Figure 7.1. Chemical Engineering Plant Cost Index..............................................94
Figure 7.2. Pick Up Box.......................................................................................128
Figure 7.3. Cost Breakdown................................................................................139
Figure 7.4. Cashflow............................................................................................141
Figure 7.5. Cumulative Cashflow........................................................................142
Figure 7.6. Payback Period..................................................................................144
Figure 7.7. Effect of Parameter Deviation on IRR..............................................148
Figure 7.9. Effect of Parameter Deviation on PBP..............................................149
Figure A.1. Block Flow Diagram of Vitamin B12 Production..............................155
Figure A.2. Process Flow Diagram of Fermentation Section..............................156
Figure A.3. Process Flow Diagram of Separation Section..................................157
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Figure A.4. Process Flow Diagram of Steam Utility...........................................158
Figure A.5. Process Flow Diagram of Wastewater Treatment Facility...............159
Figure A.6. Process Flow Diagram of Water Treatment Facility........................160
Figure H.1. Mechanical Drawing of Boiler.........................................................207
Figure H.2. Mechanical Drawing of Seed Medium Blending.............................208
Figure H.3. Mechanical Drawing of Freeze Dryer..............................................209
Figure H.4. Mechanical Drawing of Clarifier......................................................209
Figure H.5. Mechanical Drawing of Ion Exchange Chromatography.................210
Figure H.6. Mechanical Drawing of Pre-Seed Fermenter...................................211
Figure H.7. Mechanical Drawing of Seed Fermenter..........................................212
Figure H.8. Mechanical Drawing of Main Fermenter.........................................213
Figure H.9. Mechanical Drawing of Aeration Tank............................................214
Figure H.10. Mechanical Drawing of Centrifuge................................................214
Figure H.11. Mechanical Drawing of Sterilizer...................................................215
Figure H.12. Mechanical Drawing of Centrifuge Extractor................................215
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LIST OF TABLES
Table 1.1. Physical and Chemical Properties of Vitamin B12.................................3

Table 1.2. Selected Food Sources of Vitamin B12..................................................4
Table 1.4. Demand of Vitamin B12 in the World..................................................10
Table 1.5. Demand of Vitamin B12 in Indonesia..................................................11
Table 2.1. Process Material Scoring Parameter Scale...........................................18
Table 2.5. Process Material Scoring......................................................................18
Table 2.3. Fermentation Scoring Parameter Scale.................................................21
Table 2.4. Fermentation Method Scoring..............................................................22
Table 2.5. Separation Scoring Parameter Scale.....................................................23
Table 2.6. Separation Method Scoring...................................................................24
Table 2.7. Seed and Main Fermentation Medium Composition............................25
Table 2.8. Operating Condition of Mixers.............................................................25
Table 2.9. Operating Condition of Sterilizers........................................................26
Table 2.10. Operating Condition of Seed Fermenters...........................................26
Table 2.11. Operating Condition of Product Fermenter........................................27
Table 2.12. Operating Condition of Decanter Centrifuge......................................27
Table 2.13. Operating Condition of Decanter Centrifuge......................................28
Table 2.14. Operating Condition of Ion Exchange Chromatography....................29
Table 2.15. Operating Conditions of Freeze Drying..............................................29
Table 2.16. Overall Mass Balance.........................................................................30
Table 2.17. Total Water Requirement....................................................................31
Table 2.18. Air Consumption in Cyanocobalamin Plant.......................................32
Table 2.19. Specification of Air Blower................................................................32
Table 2.20. Specification of Pre-Filter...................................................................33
Table 2.21. Specification of Membrane Filter Cartridge.......................................33
Table 2.22. Electricity Process and Utility Unit Calculation.................................34
Table 2.22. Electricity Process and Utility Unit Calculation (cont’d)...................35
Table 2.23. Generator Specification......................................................................36
Table 3.1. Cell Culture Sizing................................................................................38
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Table 3.2. Seed Medium Blending Sizing.............................................................38
Table 3.3. Fermentation Medium Blending Sizing................................................39
Table 3.4. Blending Storage Sizing.......................................................................40
Table 3.5. ST-101 Semicontinuous Sterilizer Specification..................................42
Table 3.8. ST-103 Autoclave Sterilizer Specification...........................................45
Table 3.9. Pre-Seed Fermenter Sizing...................................................................46
Table 3.10. Seed Fermenter Sizing........................................................................47
Table 3.11. Main Fermenter Sizing.......................................................................49
Table 3.12. Centrifugal Separator Sizing...............................................................50
Table 3.13. Centrifugal Extractors Sizing..............................................................51
Table 3.14. Ion Exchange Chromatography Specification....................................51
Table 3.15. Freeze Dryer Specification.................................................................52
Table 3.16. Belt Conveyor Specification...............................................................53
Table 3.17. Cyanocobalamin Storage Tank Specification.....................................53
Table 3.18. Compressor Sizing..............................................................................54
Table 3.19. Air Filtration Sizing............................................................................54
Table 3.20. Air Filtration Sizing (cont’d)..............................................................55
Table 3.41. Pump (P-101) Specification................................................................56
Table 3.37. Demineralized Water Storage Tank Specification..............................57
Table 3.38. Fuel Storage Tank Specification.........................................................57
Table 3.39. Compressor Specification...................................................................58
Table 3.40. Boiler Specification............................................................................58
Table 4.1. Legend for Piping Table.......................................................................60
Table 4.2. Pipeline Specification for Fermentation Section..................................61
Table 4.3. Pipeline Specificatioin for Separation Section.....................................64
Table 4.4. Pipeline Specification for Gas Phase in Separation Section.................65
Table 5.1. Distribution of Sugar Factories in Indonesia........................................69
Table 5.2. Distribution of Sugar Factories in East Java.........................................70
Table 5.2. Workers Availability in Malang...........................................................71
Table 5.3. Equipment Area....................................................................................74
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Table 5.4. Facilities Area.......................................................................................75
Table 6.1. HAZID Risk Matrix..............................................................................81
Table 6.2. Waste Identifications............................................................................91
Table 6.3. Carbon Dioxide Concentration Calculation..........................................93
Table 7.1. Chemical Engineering Plant Cost Index...............................................95
Table 7.2. Purchase Cost Equations.......................................................................96
Table 7.3. Bare Module Factor..............................................................................98
Table 7.4. Final Cost of Process Equipment..........................................................99
Table 7.5. Land Cost............................................................................................102
Table 7.6. Total Land and Site Cost.....................................................................103
Table 7.7. Indoor Facilities Area.........................................................................104
Table 7.8. Building Cost......................................................................................104
Table 7.9. Supporting Facilities Cost...................................................................105
Table 7.10. Utility Installation Cost.....................................................................109
Table 7.11. Contingency and Contractor Costs...................................................109
Table 7.12. Plant Startup Cost.............................................................................109
Table 7.13. Working Capital Cost.......................................................................110
Table 7.14. Capital Expenditure Summary..........................................................110
Table 7.15. Raw Material Cost............................................................................112
Table 7.16. Workers Availability in Malang in 2020..........................................114
Table 7.17. Labor Required for Plant Operations................................................114
Table 7.18. Labor Salary Cost.............................................................................115
Table 7.19. Salary Increase Rate Calculation......................................................115
Table 7.20. Direct Labor Salary Cost Calculation...............................................116
Table 7.21. Electricity of Main Equipments Cost................................................117
Table 7.22. Electricity of Support Equipments Cost...........................................118
Table 7.23. Water Requirement Cost...................................................................118
Table 7.24. Fuel Requirement Cost.....................................................................118
Table 7.25. Summarized of Utility Cost..............................................................119
Table 7.26. Maintenance Cost..............................................................................119
Table 7.27. Insurance Cost...................................................................................120
Table 7.28. Land and Building Tax.....................................................................120
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Table 7.29. Salary Tax.........................................................................................121
Table 7.30. Basic Safety Cost..............................................................................124
Table 7.31. Safety Equipment Cost.....................................................................124
Table 7.32. Executive Salary Cost.......................................................................125
Table 7.33. Executive Salary Calculation............................................................127
Table 7.34. Marketing Cost..................................................................................128
Table 7.35. Communication Cost........................................................................128
Table 7.36. Pick Up Box Specification................................................................128
Table 7.37. Distribution Cost...............................................................................129
Table 7.38. Depreciation......................................................................................131
Table 7.39. Salvage Value...................................................................................132
Table 7.40. OPEX Summary................................................................................133
Table 7.41. Benchmark........................................................................................135
Table 7.42. Source Proportion of Capital Investment..........................................136
Table 7.43. Loan Interest from Bank...................................................................136
Table 7.44. Loan Interest from Investor..............................................................137
Table 7.45. Total Loan Interest............................................................................137
Table 7.46. Revenue Calculation.........................................................................138
Table 7.47. Cost Breakdown................................................................................138
Table 7.48. WACC Calculation...........................................................................140
Table 7.49. Product Price Deviation Effect.........................................................145
Table 7.50. Maintenance Price Deviation Effect.................................................146
Table 7.51. Utility Price Deviation Effect...........................................................146
Table 7.52. Sensitivity Slope of Deviation with IRR..........................................147
Table 7.53. Sensitivity Slope of Deviation with NPV.........................................147
Table 7.54. Sensitivity Slope Deviation with PP.................................................147
Table B.1.1. Mass Balance of SFR-103...............................................................161
Table B.1.2. Mass Balance of ST-103.................................................................161
Table B.2.1. Mass Balance of V-101...................................................................162
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Table B.2.5. Mass Balance of ST-104 (cont’d)...................................................164
Table B.3.3. Mass Balance of FR-101.................................................................167
Table B.4.1. Mass Balance of DC-101................................................................168
Table B.5.1. Mass Balance of CX-101................................................................169
Table B.6.1. Mass Balance of INX-101...............................................................170
Table B.7.1. Mass Balance of FDR-101..............................................................171
Table B.8.1. Mass Balance of G-101...................................................................172
Table B.8.2. Mass Balance of AF-101.................................................................172
Table C.1. Energy Balance of Cell Culture.........................................................173
Table C.2. Energy Balance of Seed Fermentation...............................................173
Table C.3. Energy Balance of Main Fermentation..............................................173
Table C.4. Energy Balance of Centrifugation......................................................173
Table C.5.1. Energy Balance of Extraction.........................................................174
Table C.6.1. Energy Balance of Ion Exchange Chromatography........................174
Table C.7.1. Energy Balance of Freeze Drying...................................................174
Table C.8.1. Energy Balance of Air System........................................................174
Table C.9.1. Total Energy Balance......................................................................174
Table D.1. Average Clarifier Parameter Values..................................................175
Table D.2. Clarifier Specification........................................................................176
Table D.3. Sand Filter Tank Specification...........................................................176
Table D.4. Activated Carbon Tank Specification................................................177
Table D.5. Water Softener Tank Specification....................................................178
Table D.6. Reverse Osmosis Specification..........................................................178
Table E.1. Water Screen Equipment....................................................................180
Table E.2. Primary Clarifier Sizing.....................................................................181
Table E.3. Aeration Tank Sizing..........................................................................181
Table E.4. Secondary Clarification.....................................................................182
Table E.5. UV Chamber Sizing...........................................................................183
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Table E.6. Tertiary Clarifier Sizing.....................................................................184
Table E.8. Anaerobic Digester Sizing..................................................................185
Table E.9. Sludge Storage Tank Sizing...............................................................185
Table E.10. Sludge Dewatering...........................................................................186
Table F.1. Condenser Specification.....................................................................187
Table F.2. Demineralized Water Storage Tank Specification.............................188
Table F.3. Fuel Storage Tank Specification.........................................................188
Table F.4. Compressor Specification...................................................................189
Table F.5. Boiler Specification............................................................................189
Table F.1. Pump (P-101) Specification................................................................191
Table F.10. Pump (P-110) Specification..............................................................196
Table F.18. Pump (PM-101) Specification..........................................................201
xxi Universitas Indonesia

Table K.1. Cashflow............................................................................................378
Table L.1. Control Tabulation Fermentation Section..........................................380
Table L.2. Control Tabulation Separation Section..............................................398
xxii Universitas Indonesia

CHAPTER 1
INTRODUCTION
1.1. Background
The human body is a constructed system of many complex mechanism, this
system is fueled by the things that we consume but not every person has the
insight or privilege to choose the things that their body needs, which in turn could
lead to several deficiency of certain nutrient. One such nutrient is vitamins which
act as a catalyst in our body which helped releasing energy from protein, fat and
carbohydrates.
According to MedlinePlus (2019), vitamins are separated into two category
according to how they are absorbed into the body: fat-soluble vitamins and water-
soluble vitamins, the fat soluble vitamins are vitamins A, D, E, K and as their
name suggest they need to be dissolved in fat first before they can be used, these
type of protein are stored in the body for a long period of time in the liver. The
water-soluble vitamins are vitamin C, thiamin, riboflavin, niacin, vitamin B6,
folacin, vitamin B12, biotin, and pantothenic acid, these vitamins are absorbed
and used immediately as they can easily be carried by the blood stream and the
excess vitamins will be washed by the kidney into urine.
B12 is quite a unique case in this matter, B12 is water soluble but it needs
the help of intrinsic factor, a protein that is produced by the stomach membrane to
be able to be absorbed and then stored in the liver to be used for a long period of
time just like a fat soluble vitamins. In essence it acts like water soluble vitamins
but stored like fat solube vitamins.
Cobalamin or widely known as Vitamin B12, which naturally come from
animal products such as meats, fish, poultry, eggs and dairy and from some
vitamins fortified vegetable products such as cereal and breads. Because of the
selectivity sourcing from mostly animals’ product, people with strict vegetarian
diet could suffer from vitamin B12 deficiency quite easily. Another highly
potential victims of vitamin B12 are the elderly people, because vitamin B12
reliance to stomach mucus to be able to be absorbed, people with low stomach
1 Universitas Indonesia
2
activity will likely be unable to produce enough intrinsic factor to process the
minimum amount that the body need.
This is where vitamin supplement comes in, for people who cannot afford
their daily intake of vitamins through their diet. The supplement act as a substitute
to fulfill their daily intake. These supplements can be synthesis by two means,
natural and artificial. Natural synthesis of vitamin B12 uses bacteria in a medium
as the producer which will be fermented in a series of fermentation chamber to
increase the yield and quality and following the fermentation are extraction and
purification of the vitamin B12 from other substances. While Artificial synthesis
uses chemical synthesis to make a molecule that has similar structure and function
as natural vitamin B12.
The current production of vitamin B12 rely on natural production of said
bacteria which limits the capability of mass production, the component that we
can modify is the type of bacteria and the medium it ferment on, by using a cheap
medium such as molasses, a fast reacting bacteria and an optimized fermentation
condition, we can push the cost further down and reduce the time consumed on
making the product which in turn increasing our profit.
1.2. Literature Review
1.2.1. Vitamin B12
Vitamin B12 is an essential vitamin that is widely used in medical and food
industries. Vitamin B12 is a water-soluble vitamin that is naturally present in
some foods, added to others, and available as a dietary supplement and a
prescription medication. Specific name for vitamin B12 is Cobalamin.
"Cobalamin" actually refers to a group of compounds (corrinoids) with a near-
identical structure. Cobalamins are characterized by a porphyrin-
like corrin nucleus that contains a single cobalt atom bound to
a benzimidazolyl nucleotide and a variable residue (R) group. There are two types
of vitamin B12 that active in human metabolism, namely Methylcobalamin and 5-
deoxyadenosylcobalamin. Vitamin B12 has molecular weight of over 1000 that
makes it the largest of the B complex vitamin.
Universitas Indonesia
3
Figure 1. 1. Chemical Structure of Vitamin B12

(Source: pubchem.ncbi.nlm.nih.gov, 2020)
Table 1.1. Physical and Chemical Properties of Vitamin B12

Properties Value
Molecular Weight 1356.4 g/mol
Color Dark red crystals or an amorphous or crystalline red
powder
Odor Odorless
Boiling Point 300 °C
Solubility Soluble in alcohol; insoluble in acetone, chloroform,
ether
Stability Hydrated crystals are stable to air, max stability in
pH range 4.5-5, light sensitive
pH 4.5-7 (commercially available for injection)
(source: https://pubchem.ncbi.nlm.nih.gov/, 2020)
Vitamin B12 cannot be synthesized by plants. Meanwhile, most

microorganisms, including bacteria and algae, synthesise vitamin B12. The vitamin
B12 synthesised in microorganisms enters the human food chain through
incorporation into food of animal origin. Vitamin B12 synthesizing
microorganism grows in animal gastrointestinal system. The vitamin is then
absorbed and incorporated into the animal tissues, mainly in liver. Products from
herbivorous animals, such as milk, meat, and eggs, constitute important dietary
sources of vitamin B12. Omnivores and carnivores, including humans, derive
4
dietary vitamin B12 from animal tissues or products (i.e., milk, butter, cheese,
eggs, meat, poultry.
Table 1.2. Selected Food Sources of Vitamin B12
Micrograms
Percent
Food (mcg)
DV*
per serving
Clams, cooked, 3 ounces 84.1 3,504
Liver, beef, cooked, 3 ounces 70.7 2,946
Trout, rainbow, wild, cooked, 3 ounces 5.4 225
Salmon, sockeye, cooked, 3 ounces 4.8 200
Trout, rainbow, farmed, cooked, 3 ounces 3.5 146
Tuna fish, light, canned in water, 3 ounces 2.5 104
Nutritional yeasts, fortified with 100% of the DV
2.4 100
for vitamin B12, 1 serving
Cheeseburger, double patty and bun, 1 sandwich 2.1 88
Haddock, cooked, 3 ounces 1.8 75
Beef, top sirloin, broiled, 3 ounces 1.4 58
Milk, low-fat, 1 cup 1.2 50
Yogurt, fruit, low-fat, 8 ounces 1.1 46
Cheese, Swiss, 1 ounce 0.9 38
Beef taco, 1 soft taco 0.9 38
Breakfast cereals, fortified with 25% of the DV
0.6 25
for vitamin B12, 1 serving
Ham, cured, roasted, 3 ounces 0.6 25
Egg, whole, hard boiled, 1 large 0.6 25
Chicken, breast meat, roasted, 3 ounces 0.3 13
(source: USDA FoodData Central, 2018)
DV in table above is an abbreviation of Daily Value. The U.S. Food and

Drug Administration (FDA) developed DVs to help consumers compare the
nutrient contents of foods and dietary supplements within the context of a total
diet. The DV for vitamin B12 on the new Nutrition Facts and Supplement Facts
labels and used is 2.4 mcg for adults and children age 4 years and older.
Efficiency of absorption of Vitamin B12 in gastrointestinal tract depends on
the molecular state in which the vitamin B12 is introduced into the body. Vitamin
B12 bound to protein in foods must undergo an initial separation reaction before it
5
can be absorbed in the ileum. On the other hand, if vitamin B12 is ingested in
its free (or nonprotein bound form) state, it will bind to a carrier protein known as
R-binders or transcobalamin I that is secreted by salivary gland and gastric
mucosal cells in stomach. The vitamin B12-R binder complex will remain until it
reaches the second segment of the duodenum. If the vitamin B12 is ingested in its
protein bound form, then it must first undergo a proteolytic cleavage in the
stomach or duodenum where it will bind to an R-binder and then enter into the
duodenum for further cleavage. Upon entry into the second segment of the
duodenum, the pancreas will secrete additional protease, which will then degrade
the R-binders holding onto the vitamin B12. It is at this point the vitamin B12
will bind to (or complex with) intrinsic factor for the remainder of its journey to
the ileum.
Figure 1.2. Mechanism of Absorption of Vitamin B12 (cobalamin) in the GI Tract

(source: https://www.ebmconsult.com, 2015)
Vitamin B12 helps keep nerve cells and blood cells healthy and also helps
in DNA synthesis process. Deficiency of vitamin B12 can cause megaloblastic
anemia, fatigue, weakness, constipation, loss of appetite, and weight loss.
Neurological changes, such as numbness and tingling in the hands and feet, can
also occur. Typically, vitamin B12 deficiency is treated with vitamin B12
injections and oral treatments.
6
The main causes of vitamin B12 deficiency include vitamin B12

malabsorption from food, pernicious anemia, postsurgical malabsorption, and
dietary deficiency. Population at risk for Vitamin B12 deficiency includes
vegetarians, people with pernicious anemia and people with atrophic gastritis.
Strict vegetarian is at risk of vitamin B12 deficiency because plants do not
synthesize Vitamin B12. Meanwhile, people with Pernicious anaemia cannot
properly absorb vitamin B12 in their gastrointestinal tract. People with atrophic
gastritis usually also have hypochlorhydria. where there is a progressive reduction
with age of the ability of the parietal cells to secrete hydrochloric acid. It is
claimed that perhaps up to one-quarter of elderly subjects could have various
degrees of hypochlorhydria as a result of atrophic gastritis.
1.2.2. Fermentation Process
Fermentation refers to the metabolic process by which organic molecules
(normally glucose) are converted into acids, gases, or alcohol by the action of
enzymes, complex organic catalyst, which are produced by microorganism
Enzyme act by breaking down complex organic molecules to form smaller
compound and nutrient. The term “fermentation” has gone through many
developments in its definition along with the development of science.
French chemist and microbiologist, Louis Pasteur, in the 19th century used
the term fermentation to describe the changes brought by yeast and other
microorganisms growing in the absence of air. In 1930, glycolysis is further
defined as form of fermentation. The term “fermentation” now denotes the
enzyme-catalyzed, energy-yielding pathway in cells involving the anaerobic
breakdown of molecules such as glucose.
There are two types of fermentation based on presence of oxygen. They are
aerobic fermentation and anaerobic fermentation. Aerobic fermentation is is a
metabolic process by which cells metabolize sugars via fermentation in the
presence of oxygen and occurs through the repression of normal respiratory
metabolism. In vitamin B12 production process, while using aerobic fermentation,
cobalt is inserted late in the pathway. Pseudomonas denitrificans can be used for
aerobic fermentation. In anaerobic fermentation, where there is no presence of
7
oxygen in the process, cobalt insertion is the first committed step toward
cobalamin synthesis. Propionibacterium can be used in anaerobic fermentation.
1.2.3. Bacteria for Fermentation Process
There are several bacteria that are usually used for fermentation process in
the production of vitamin B12, which are Pseudomonas denitrificans,
Propionibacterium, and Sinorhizobium meliloti.
1.2.3.1. Pseudomonas denitrificans
Pseudomonas denitrificans is a polar flagellated, rod-shaped,
heterotrophic, gram-negative aerobic bacterium that performs denitrification, or
reduction process of nitrate ( NO 3 ) to become a nitrogen gas ( N 2). Pseudomonas
−¿¿
denitrificans has the ability to produced vitamin B12 and is one of the few
microorganisms that cam synthesize vitamin B12 under aerobic conditions. P.
denitrificans showed a more rapid cell growth and efficient vitamin B12
productivity. Pseudomonas denitrificans is one of the few microorganisms that
can synthesize Vitamin B12 de novo under aerobic conditions and has been best
studied in. However, if it is not being subjected to an acidification and heat
pretreatment, the production of vitamin B12 using beet molasses will result in an
unstable fermentation process by the inhibitory effect on the cell growth of
Pseudomonas denitrificans, such as coloring substances, heavy metals and
unknown compounds. Based on paper by Xia, W. et al. (2014), the industrial
productions of vitamin B12 with Pseudomonas denitrificans in maltose syrup and
corn steep liquor, yield could be achieved and 198.27 ± 4.60 mg/L.
1.2.3.2. Propionibacterium
Propionibacterium is a gram-positive, anaerobic, rod-shaped genus of
bacteria named for their unique metabolism. Propionibacterium are able to
synthesize propionic acid by using unusual transcarboxylase enzymes. Members
of this genus are widely used in the production of vitamin B12, tetrapyrrole
compounds, and propionic acid, as well as in the probiotics and cheese industries.
The most common used for production of vitamin B12 are Propionibacterium
freundenreichii, Propionibacterium acidiproponici, and Propionibacterium
shermanii. In production of vitamin B12, Propionibacterium have the capacity to
grow and synthesize metabolites on substrates containing different industrial
8
waste products, which considerably elevates the economic profitability of

biotechnological processes (Piwowarek, K. et al., 2017). All Propionibacterium
strains are capable of active production of vitamin B12 may produce it only in the
presence of oxygen, related to the oxygen-dependency of DMBI ligand. Based on
paper by Piwowarek, K. et al. (2017), production of vitamin B12 using selected
strains from Propionibacterium genus that produce the most vitamin B12 is
Propionibacterium shermanii PZ-3 in glucose carbon source with 52 mg/L,
followed by Propionibacterium freudenreichii CICC 10019 in glucose and corn
extract carbon source with 42.6 mg/L, and Propionibacterium DSM 8250 in beet
molasses carbon source with 34.8 mg/L.
1.2.3.3. Sinorhizobium meliloti
Sinorhizobium meliloti is a gram-negative bacterium which fixes
atmospheric nitrogen. Sinorhizobium meliloti exist either as a free-living member
of rhizosphere or as an intracellular nitrogen-fixing symbiont of legumes of the
genera Medicago, Trigonella, and Melilotus. Sinorhizobium meliloti and root cells
of legumes share a symbiotic relationship in which bacterial cells fix atmospheric
nitrogen into a usable form by the root cells. In return the plant cells produce
reduced carbon compounds that Sinorhizobium meliloti can uptake as their carbon
sources. Cobalamin for production of vitamin B12 has been isolated from
Sinorhizobium meliloti and shown to contain DMBI as the lower ligand. The
Sinorhizobium meliloti genome contains a complete set of genes involved in
aerobic cobalamin biosynthetic pathway. Thus, Sinorhizobium meliloti is one of
many bacteria that are capable of synthesizing cobalamin de novo through an
oxygen-dependent pathway. Based on research from Dong, H. et al. (2016), the
production of vitamin B12 using Sinorhizobium meliloti in sucrose and corn steep
liquor carbon source resulting 140 mg/L vitamin B12 produced.
9
1.2.4. Molasses
Figure 1.3. Molasses

(source: healingthebody.ca)
Molasses or black treacle is a viscous product resulting from refining

sugarcane or sugar beets into sugar. Molasses varies by the amount of sugar,
method of extraction, and age of the plant. Sugarcane molasses are primarily used
for sweetening and flavoring foods in the United States, Canada, and many more.
Molasses made from sugar beets differs from sugarcane molasses because only
the syrup left from the final crystallization stage is called molasses. Beet molasses
is 50% sugar by dry weight, predominantly sucrose, but contains significant
glucose and fructose amounts. The non-sugar content includes many salts, such as
calcium, potassium, oxalate, and chloride. It contains betaine and the trisaccharide
raffinose. Based on the data from USDA nutrition table, molasses comprises 22%
water, 75% carbohydrates, and no protein or fat (table). In a 100-gram reference
amount, molasses is a rich source (20% or more of the Daily Value, DV) of
vitamin B6 and several dietary minerals, including manganese, magnesium, iron,
potassium, and calcium (table). The sugars in molasses are sucrose (29% of total
carbohydrates), glucose (12%), and fructose (13%).
Molasses have been used as an alternative as a carbon source for vitamin
B12 production because they contain a mass of ingredients favorable for vitamin
B12 production, such as sucrose, glutamate, and betaine. Molasses, as a primary
substrate for fermentation, was established as a low-cost fermentation medium,
which makes the fermentation cost highly reduced.
10
1.3. Market and Capacity Analysis

Market analysis is the most fundamental in the design of a factory. This
analysis needs to be done to determine the potential of the product in the market.
Results of market analysis that has been done can be used to determine the design
capacity of the plant, and the factory will be built. Things are done in this market
analysis is to determine supply, demand and plant capacity.
Based on the data obtained, the total world demand of vitamin B12 in 2008
was 35,000 kg. Vitamin B12 demand has an average growth percentage of 3.6%
per year, we plan to operate the plant or make the production in the beginning of
2022, so the projection of vitamin B12 needs in the world from 2008 - 2022 as
shown in the table below.
Table 1.4. Demand of Vitamin B12 in the World
Years Demand of
Vitamin B12 in
the world (kg)
2008 35,000
2009 36,260
2010 37,565
2011 38,918
2012 40,319
2013 41,770
2014 43,274
2015 44,832
2016 46,446
2017 48,118
2018 49,850
2019 51,645
2020 53,504
2021 55,430
2022 57,425
The data above showed demand of Vitamin B12 in the world at about
57,425 kg in 2022. But the data that we needed is the demand for Vitamin B12 in
Indonesia. Therefore, in order to get the data, we should know the percentage of
Indonesia market in the world. Based on Statista, percentage of Indonesia market
in the world at about 1.7%. The table gives the amount of vitamin B12 demand in
Indonesia from 2008-2022.
11
Table 1.5. Demand of Vitamin B12 in Indonesia

Years Demand of Vitamin B12 in
Indonesia (kg)
2008 595
2009 616
2010 639
2011 662
2012 685
2013 710
2014 736
2015 762
2016 790
2017 818
2018 847
2019 878
2020 910
2021 942
2022 976
The data above showed demand of Vitamin B12 in Indonesia at about 976
kg in 2022. Taking note that the rule of thumb for new plant is around 10-30%,
the plant will produce 1950 kg of vitamin B12 per year with the market share of
20% in Indonesia at about 195 kg per year and market share of 3% in world at
about 1755 kg per year. This number is chosen based on two assumptions. First,
the involving fermentation process takes lot of times so the operation of the plant
can’t be run day and night like other kind of plant. Second, the consideration that
there will be more vitamin B12 plant establishment in the future that will take
some of the market share left.
This production capacity is very small when compared to the leading
companies in cyanocobalamin in the world, such as Hebei Yuxing Bio-
Engineering Co., Ltd, NCPC Victor Co., Ltd and France Aventis Pharmaceutical
Co., Ltd. In 2008, Hebei Yuxing Bio-Engineering Co., Ltd can produce
cyanocobalamin at about 15,000 kg/year, NCPC Victor Co., Ltd can produce
cyanocobalamin at about 7,000 kg/year and Aventis Pharmaceutical Co., Ltd can
produce cyanocobalamin at about 5,000 kg/year.
CHAPTER 2
PROCESS DESCRIPTION
2.1. Process Alternatives

Vitamin B12 produced through fermentation of selected microorganisms,
that include but are not limited to: Pseudomonas denitrificans, Propionibacterium
freudenreichii subsp. shermanii, Rhodopseudomonas protamicus, etc. These
organisms have been successfully applied to the commercial production of
vitamin B12 because of its rapid growth and high productivity. There are several
pathways regarding how we should approach the fermentation and subsequent
processes such as separation and purification to synthesize vitamin B12.
2.1.1. Fermentation Section
Fermentation is a metabolic process that produces chemical changes in
organic substrates through the action of enzymes. In biochemistry, it is narrowly
defined as the extraction of energy from carbohydrates in the absence of oxygen.
In this section, microorganisms are first cultured to grow and increase its quantity
and then provided with the molasses extract through a medium that acts as the
source of carbohydrate (and other nutrients) which will be synthesized into
vitamin B12. Vitamin B12 has the potential to be produced via two major de novo
biosynthetic pathways, aerobic and anaerobic fermentation. Some strains can also
synthesize cobalamin by absorbing corrinoids via a salvage pathway.
Anaerobic fermentation: In the industrial level, one microorganism that
follows this pathway is Propionibacterium shermanii. This microorganism can
only produce the precursor for further synthesis only when no oxygen is present.
There are two ways to synthesize vitamin B12 by Propionibacterium: in the first
method, bacterial cultures are used, which are responsible for the enrichment of
certain fermented food products with vitamin B12 (Van Wyk et al. 2011). Second,
the chemical pathway of vitamin B12 production, which is labor intensive and
rather expensive, is replaced with microbial synthesis.
Using Propionibacterium, a two-step fermentation is usually carried out,
where it is initially done under anaerobic conditions and produces cobinamide (an
13
intermediate precursor of vitamin B12 which lacks the 5,6-dimethylbenzimidazole

(DMBI) group) for the first 3 days, and then preserve its process by having the
active cobinamide aerated gently a further 1-3 days (turns into an aerobic
condition) during which the DMBI is synthesized and conjugated further with
previously generated cobinamide into vitamin B12. The advantage of such
fermentation is that it not only reduces the feedback inhibition which would slow
down the cell growth, but it also reduces the time of fermentation as well.
It is also important to maintain neutral pH and proper temperature at
around pH of 7.0 and temperature at 30 oC (Miyano et al. 2000; Leman 2007) of
the production environment for efficient production. It is, therefore, necessary to
remove propionic and acetic acid that is generated during the fermentation. The
culture media should also be supplemented with important compounds or
precursors during the biosynthesis of vitamin B12, such as cobalt ions, DBMI,
glycine, threonine, betaine (present in beet molasses), and choline, regardless of
the production strains used (Roman et al. 2001).
Aerobic fermentation: The microorganism that is used most often that
follows this pathway is Pseudomonas denitrificans, where the fermentation is
carried out under low oxygen conditions because higher levels of oxygen oxidize
the intracellular environment, which represses formation of early enzymes in the
pathway. The whole process is done in a three-step fermentation process, which
involves two stages of seed growth and one stage of vitamin B 12 production. The
culture is consistently aerated during the whole fermentation process of about 2–3
days at 30 °C and pH values are maintained at 6–7 (Eggersdorfer. 1996; Scott.
1998).
Where the pathway between aerobic and anaerobic differs, is first due to
the period difference of the cobalt insertion into precorrin (one of the precursors),
where this chelation reaction in the oxygen-dependent part occurs only after nine
further reaction steps. The second difference between the two method, is the
promotion of the ring-contraction process, with the removal of C-20 from the ring.
The oxygen-dependent path, the precursor precorrin-3A is oxidized by molecular
oxygen, sustained by a Fe4S4 cluster containing protein (CobG), with the
subsequent release of C-20 as acetate. Under anaerobic conditions, the ring
14
contraction process is likely to be mediated via the complexed cobalt ion with its
ability to assume different valence states (+1 to +3) to assist in the oxidation,
resulting in the release of C-20 as acetaldehyde. (Scott et al. 1999)
Independent of the employed production strains and culture conditions, it
seems to be necessary to add some essential compounds to the culture medium for
efficient vitamin B12 biosynthesis. The addition of cobalt ions and DMBI are
frequently described.
Salvage pathway: Many prokaryotic species cannot biosynthesize
adenosylcobalamin, but can make it from cobinamide. These organisms are
capable of cobalamin transport into the cell and its conversion to the required
coenzyme form. Escherichia coli is a well-characterized prokaryote that has been
used as a microbial cell factory for many chemicals. E. coli can synthesize
cobalamin through the salvage pathway, thus saving resources and energy. E. coli
has been used to produce δ-aminolevulinate (ALA), a precursor to many
tetrapyrrole compounds, in many studies. A sufficient ALA supply is necessary
for the vitamin B12 biosynthesis. This implies that E. coli may be a suitable host
for vitamin B12 production. In terms of commercial production, salvage pathway
hasn’t been discussed as intricately, due to the infancy of its process being
discovered and researched. This maybe suited to further utilization of waste of the
fermentation, yet it remains to be proven.
Both processes are then scored to be selected on which will be used, the
parameters that are used and the scoring table respectively:
a. Accessibility: The variety of microorganism that able to do the process and
tested, proven able to do it on industrial scale.
b. Efficiency: The energy that the bacteria need to use in order to perform the
process, this is illustrated as the number of steps the bacteria need to do in
order to finish the process.
c. Maturity: How long has the process been tried, tested, and optimized to be
industrialized.
15
2.1.2. Separation and Purification

Separation process are needed to separate main products from its byproduct
and to get the right concentration. Separation of fermentation products poses
difficult challenges because of very dilute solution of target molecules and similar
properties between target molecules and byproducts. Hence, separation process
often requires multistep. The methods that can be used for vitamin B 12 productions
are centrifugation, chromatography, microfiltration, and ultrafiltration.
Purification is a series of processes intended to isolate vitamin B12 molecules
from broth that contains more complex mixture. Fermentation broth are complex
aqueous mixtures of cells, soluble extracellular products, intracellular products,
and converted substrate or unconvertible components. The purification stage is
carried out to increase the purity of vitamin B12 from 80% after the separation
process to around 98%. In the earliest era, many purification methods used
extraction with organic solvents such as ethanol or chloroform. However, this
method requires very large amount of solvent makes it less economical.
Centrifugation is a technique used for separation of particles from a solution
according to their size, shape, density, viscosity of the medium, and rotor speed.
The particles are suspended in a liquid medium and placed in a centrifuge tube,
then the tube placed in a rotor and spun at a define speed. In a solution, particles
that have a higher density than the solvent will sink, and the particles that are
lighter than it will float to the top. If the density difference is greater, then they
will move faster.
Chromatography is one of the separation methods involving stationary
phase and mobile phase. Usually, the stationary phase is a porous solid packed
into a glass or metal tube or that constitutes the walls of an open tube capillary.
The mobile phase flows through the packed bed or column. The sample is injected
at the beginning of the column and then transported by the mobile phase. In their
travel through the column, the different substances distribute themselves
according to their relative affinity for the two phases. The components interacting
more strongly with the stationary phase requiring more extended periods for
elution. At present, chromatography is the most effective method for separating
organic substances and, along with electrophoresis, is most widely used for
16
biological substances. The most common chromatography method used for the
separation of vitamin is ion exchanged chromatography.
Microfiltration is a separation technique for removing micron-sized
particles, like bacteria, yeast cells, colloids, and smoke particles from suspension
or gases. The process uses membrane filters with pores in the approximate size
range to 0.1 to 10 µm, which permeable to the fluid, but it is retain the particles,
thus causing separation. In terms of approximate molecular weight these
membranes can separate macromolecules of molecular weights generally less than
100,000 g/mol.
Ultrafiltration is a separation method that uses a permeable membrane to
separate macromolecules based on the pore size (5-20nm) and their molecular
weight cut-off at low transmembrane pressures. This separation process is usually
used in industry and research areas, for purifying and concentrating
macromolecular solutions, especially protein solutions.
2.2. Process Selection
The concept selection method used is the weighted concept rating and
scoring. Each of manufacturing process will be weighted based on operation
parameter settings. Each process also will be rated to narrow them down to get the
best process among other processes. The process that has the highest score will be
chosen to produce vitamin B12. There are three main steps that will be rated,
fermentation, separation, and purification.
2.2.1. Process Material
As there are two common materials that are considered as molasses, one
should be picked as the main material for this plant. A set of parameters will be
used to compare both materials which will yield the most optimal material. These
parameters are described in the following, from most sought to the least,
respectively:
a. Availability: The material’s supply quantity.
b. Substrate composition: Main component that would be utilized for the
process.
c. Raw Material Cost: The supply price for a given amount of material.
The scoring parameter and scoring table are shown in the tables below.
17
Table 2.1. Process Material Scoring Parameter Scale
Score Parameter Scale

No Criteria Value
1 2 3 4 5
Available Available
Available Available
molasses to be molasses to be Available molasses
molasses to be molasses to be
1 Availability Quantity bought is bought is to be bought is
bought is between bought is between
below 6 between 6-8 above 12 ton/day
8-10 ton/day 10-12 ton/day
ton/day ton/day
Substrate Between 30-
2 %Sucrose Below 30% Between 40-50% Between 50-60% Above 60%
Composition 40%
Price is Price is between
Raw Material Price is below Price is between Price is below $800
3 Price between $1200 $1000 - 1200 /
Cost $1400 / ton $800 - 1000 / ton / ton
- 1400 / ton ton
Table 2.5. Process Material Scoring
Sugarcane Molasses Beet Molasses

No. Criteria Percentage
Rating Score Rating Score
1 Availability 60% 5 3 1 0.6
2 Substrate Composition 25% 4 1 5 1.25
3 Raw Material Cost 15% 4 0.6 4 0.6
Total 100% 4.6 2.45
Rank 1 2
18
Although the average of sucrose content in beets is greater than sugarcane,

the availability in Indonesia is very difficult compared to sugarcane. This is
shown by the production of sugarcane in Indonesia reaching 2.5 million tons /
year in 2015, while beet production in Indonesia is only 80 tons / year (Ananti,
2008). Based on these reasons, we chose molasses from sugarcane as the
carbohydrate source.
The type of molasses used is blackstrap molasses. Blackstrap molasses is
the byproduct from a sugarcane factory or raw sugar refinery. Apart from that,
blackstrap molasses also has the most health benefits which can be useful for the
fermentation of vitamin B12. Blackstrap molasses is easy to find in Indonesia, this
is because there are 59 sugarcane factories operating in Indonesia until now.
2.2.2. Fermentation
After reviewing all the possible processes and methods, each options must
be scrutinized under a set of given parameters, all of which condone to the
factories requirements. These parameters are described in the following, from
most sought to the least, respectively:
a. Effectivity: the effectivity of the process relating to the high amount of
product that could be obtained
b. Capacity: considering the capacity of each method from laboratory it can be
scaled up or not
c. Process time: considering how long the process will be done
d. Energy requirement: analyze the energy needed by the equipment and
handling
e. Maturity: considering how long the process has been used for the production
before
f. Capital Cost: considering the capital investment of plan
Design parameters refer to the paper by Li (2013), where the capacity is 120 m 3
with total fermentation time 238 h.
19
Table 2.3. Fermentation Scoring Parameter Scale

No. Criteria
1 2 3 4 5
Production of Production of Production of vitamin Production of vitamin Production of vitamin

1. Effectivity vitamin B12 can vitamin B12 can B12 can reach 70-120 B12 can reach 120-170 B12 can reach >170
reach <20 mg/L reach 20-70 mg/L mg/L mg/L mg/L
Fermenter size Fermenter size
Fermenter size ranges Fermenter size ranges Fermenter size is
2. Capacity is less than 20 ranges from 20-49
from 59-79 m3 from 80-109 m3 more than 110 m3
m3 m3
Process Requires more Requires between Requires between 9-11 Requires between 7-9 Requires less than 7
3.
Time than 13 days 11-13 days days days days
Energy Utilizes more Utilizes between Utilizes between 300- Utilizes between 200- Utilizes less than
4.
Requirement than 500 kW 400-500 kW 400 kW 300 kW 200kW
Lab scale, Pilot scale, research Commercial scale, Commercial stage,
Pilot scale, proven
5. Maturity theoretical stage prototype proven
(TRL 5)
(TRL 1) (TRL 3) (TRL 7) (TRL 9)
Costs more than Costs between $175 Costs between $150 Costs between $100 Costs less than
6. Capital Cost
$200/m3 -200/m3 -175/m3 -125/m3 $100 /m3
*TRL = Technology Readiness Level, EU standard.
20
Scoring for fermentation method selection is shown on the table below.

Table 2.4. Fermentation Method Scoring
Submerged Solid-State
No. Criteria Percentage Fermenter Fermenter
Rating Score Rating Score
1. Effectivity 25% 5 1.25 3 0.75
2. Capacity 10% 5 0.5 3 0.3
3. Process Time 15% 4 0.6 5 0.75
Energy
4. 15% 2 0.3 5 0.75
Requirement
5. Maturity 15% 5 0.75 5 0.75
6. Capital Cost 20% 4 0.8 3 0.6
Total 100% 4.2 3.9
Rank 1 2
2.2.3. Separation
The separation process is needed to separate the main products from
its byproduct and get the right concentration. To choose the best separation
method for vitamin B12 production, all possible methods will be scored by
several parameters. The parameters will have a different weight based on
its importance. The total score will be obtained from the multiplication
between the score for each parameter and its weight. Parameters that will
be used to evaluate the separation methods are:
a. Effectivity: the effectivity of the process to separate solutions
b. Capacity: considering the capacity of each method from laboratory it can be
scaled up or not
c. Process Time: considering how long the process will be done
d. Energy Requirement: analyze the energy needed by the equipment and
handling
e. Maturity: considering how long the process has been used for the production
before
f. Capital Cost: considering the capital investment of plant
21
Table 2.5. Separation Scoring Parameter Scale

No. Criteria
1 2 3 4 5
Separating
Separating materials Separating materials Separating materials Separating materials
1. Effectivity materials into <
into 60-70%purity into 70-80% purity into 80-90% purity into >90% purity
50% purity
2. Capacity < 5 m3 5-10 m3 10-15 m3 15-20 m3 > 20 m3
Process
3. > 10 hours 8.10 hours 6.8 hours 4-6 hours > 4 hours
Time
Energy Utilizes more Utilizes between Utilizes between 300- Utilizes between 200- Utilizes less than
4.
Requirement than 500 kW 400-500 kW 400 kW 300 kW 200kW
Lab scale, Pilot scale, research Commercial scale, Commercial stage,
Pilot scale, proven
5. Maturity theoretical stage prototype proven
(TRL 5)
(TRL 1) (TRL 3) (TRL 7) (TRL 9)
Costs more than Costs between $175 Costs between $150 Costs between $100 Costs less than
6. Capital Cost
$200/m3 -200/m3 -175/m3 -125/m3 $100 /m3
*TRL = Technology Readiness Level, EU standard.
22
Table 2.6. Separation Method Scoring
Ion Exchanged
Centrifugation Microfiltration Ultrafiltration Extraction
No. Criteria Percentage Chromatography
Rating Score Rating Score Rating Score Rating Score Rating Score
1. Effectivity 25% 4 1 5 1.25 3 0.75 3 0.75 3 0.75
2. Capacity 10% 5 0.5 5 0.5 3 0.3 4 0.4 5 0.5
3. Process Time 15% 4 0.6 3 0.45 2 0.3 4 0.6 4 0.6
Energy
4. 15% 4 0.6 3 0.45 5 0.75 4 0.6 5 0.75
Requirement
5. Maturity 15% 5 0.75 4 0.6 2 0.3 2 0.3 5 0.75
6. Capital Cost 20% 5 1 3 0.6 4 0.8 3 0.6 3 0.6
Total 100% 4.45 3.85 3.2 3.25 3.95
Rank 1 3 5 4 2
23
2.3. Selected Process Description

2.3.1. Cell Culture
To begin fermentation process, the required microorganism must grow and
multiplied itself into a sufficient amount to be capable to produce vitamin B 12. By
creating an environment that is favorable to the microorganism’s needs, it could
grow optimally, ensuring that the strain’s quality of the microorganism be
maintained. In this process, we use Pseudomonas denitrificans strain that have
already established. After enough cell growth has been identified, the cells are
ready to be used for inoculation in the seed fermenter.
2.3.2. Medium Mixing
A medium is a mixture that contains nutrients for microorganisms to
consume, allowing it to grow further. It usually contains a carbon source, nitrogen
source, water, salts, and micronutrients. For nutritional requirement purposes, the
medium that is used for the seed and main fermentation is composed of slightly
different substances. Medium mixing is conducted in a stainless-steel blending
tank.
Table 2.7. Seed and Main Fermentation Medium Composition
PURPOSE SEED MEDIUM MAIN MEDIUM
CARBON SOURCE Sucrose Sucrose
(Molasses)
NITROGEN SOURCE Peptone Betaine
MICRONUTRIENTS KH2PO4 (NH4)2SO4,
(NH4)2SO4 MgSO4·7H2O,
(NH4)2HPO4 ZnSO4·7H2O
MnSO4·H2O CoCl2·6H2O
MgSO4·7H2O DMBI
ZnSO4·7H2O
CoCl2·6H2O
5,6-Dimethylbenzimidazole
(DMBI)
(Source: Li et al., 2015)
Table 2.8. Operating Condition of Mixers

Parameters Seed Mixer Main Mixer
pH 7 7.2
Temperature 25oC 25oC
Process Time 15 minutes 20 minutes
24
2.3.3. Sterilization
Once the medium is mixed homogenously, the discharge is first flown
through a sterilizer before it reaches the fermenters. In the thermal batch sterilizer,
the system goes through 3 steps: heating, holding, and cooling. Heating requires
the addition of energy throughout the entire medium volume. This is done by
flowing steam through a jacket on the vessel. The temperature is increased until it
reaches 120 oC then it is held for a set period. During this phase, most of the
unwanted microorganisms are destroyed. Finally, the system is cooled to bring the
sterile media back to the desired temperature.
Table 2.9. Operating Condition of Sterilizers
Parameters Sterilizer
Heating Temp. 120oC
Final Exit Temp. 32oC
Process Time 5 minutes
2.3.4. Seed Fermentation

After sufficient growth, the pre-culture is used to inoculate the seed
fermentation media. Because industrial fermentations tend to be large (typically
150–250 m3), the inoculum is built up through several successively larger stages,
to 5–10% of the working volume of the production fermenter.
Table 2.10. Operating Condition of Seed Fermenters
Parameters Pre-Seed Seed
Temperature 28oC 28oC
Aeration rate 3 m3 h-1(0.45 VVM) 120 m3 h-1 (0.45 VVM)
Process Time 40 hours 30 hours
2.3.5. Product Fermentation

A submerged, stirred-tank fermenter (SmF) is used due to its capability in
providing both mass and heat transfer effectivity, and that it also allows aeration
through spargers and homogenous mixing with its impellers. Submerged
fermenter is used almost universally in the fermentation industry.
The fermenter is equipped with three 3-bladed propeller impellers, a

sparger, a heating jacket, and probes used to monitor the operating conditions. A
25
continuous stream of air is flown into the fermenter to provide aeration for the
process. As the process requires additional nutrients to maintain its production
rate, after a given amount of time the fermenter is fed with extra nutrients, which
includes a carbohydrate source and nitrogen source.
Table 2.11. Operating Condition of Product Fermenter
Parameters Value
Temperature 32oC
Aeration rate 1600 m3 h-1 (0.341 VVM)
Process Time 168 hours
2.3.6. Centrifugation
Centrifugation is a technique used to separate particles from a solution
according to their size, shape, density, viscosity of the medium, and rotor speed.
In a solution, particles that have a higher density than the solvent will sink, and
the particles that are lighter than it will float to the top. For separating
cyanocobalamin from fermentation mixture, a decanter centrifuge is usually used.
The advantages of using decanter centrifuge are having a clean appearance, have
little to no odor problems, easy to install and only require a small area for
operation, can operate with higher throughput capacity than smaller machines, and
it requires low continuous maintenance and operator attention.
Table 2.12. Operating Condition of Decanter Centrifuge
Parameters Value
Temperature 33.5oC
2.3.7. Extraction
Extraction is a process in which two phases come into contact with the
objective of transferring a solute or particle from one phase to another. The
extraction process usually using solvent extraction or liquid-liquid extraction
(LLE), which separates compounds based on their relative solubility in two
different immiscible liquids, usually water (polar) and organic solvent (non-
polar). The most used extractors in biotechnological industry are reciprocating-
plate extraction column and centrifugal extractor. For this process, we use
centrifugal extractor, because centrifugal extractor can be used where the large of
26
volumes of fermentation mixture that must be processed are easily emulsified.

Centrifugal extractors can avoid emulsions and can separate liquid phases with
small density differences. The solvent that are used for extraction process is
cresol.
Table 2.13. Operating Condition of Decanter Centrifuge
Parameters Value
Temperature 33.5oC
Pressure 1.013
2.3.8. Ion Exchanged Chromatography

Ion Exchange Chromatography (IEC) separates biomolecules with
differences in surface charge to give high-resolution separation with high sample
loading capacity. Ion Exchange Chromatography is based on the binding of an ion
between the stationary phase (polymer resin) and the mobile phase (solvent
containing opposite ions).
The process involved in ion-exchange chromatography is divided into five
different stages such as equilibration, adsorption, elution and regeneration.
Equilibration stage aims to prepare the column to the desired start condition. The
pH and ionic strength of the initial buffer is selected to ensure that, when the
solution is loaded, the desired biomolecules binds to the media and as many
impurities as possible do not bind.The second stage is adsorption. The goal in this
step is to bind the target molecules to the resin. Mobile phase buffer (in broth
solution) and initial buffer (in column) should have the same pH and ionic
strength to bind all target molecules. The third stage is elution. All bound
molecules from previous stage need to be eluted. Usually, elution is done by
increasing ionic strength (salt concentration) of the buffer or by changing the pH.
In this process, water and ammonia is used as the eluent. The last step is
regeneration. In this stage a final wash with high ionic strength buffer to
regenerates the column and removes any molecules still bound. The column is
then re-equilibrated in start buffer before starting the next run. In the process of
producing vitamin B12, 0.03 M HCl is used for the final wash.
Table 2.14. Operating Condition of Ion Exchange Chromatography
27
Parameters Value
Bed Height to Diameter Ratio 0.660
Bed Volume 652.10 L
Column Height 1.425 m
2.3.9. Freeze Drying

Freeze-drying is a process that removes water from a frozen material via
sublimation and generally used for biological products that have high sensitivity
to heat. The process involved in freeze-drying is divided into three stages:
freezing, primary drying, and secondary drying. In the first step, the aqueous
mixture of vitamin B12 cooled to 12oC and pressure reduced below its triple point.
The second step is the primary drying. Water is contained within the products in
two forms, unbound or free water and bound water. Unbound water is open to be
in equilibrium with water in the vapor phase. The primary drying stage would
remove all the unbound water by sublimation. A higher shelf temperature and
additional time are required to remove the bound water in the secondary drying
phase.
Table 2.15. Operating Conditions of Freeze Drying
Parameters Value
Final Solid Temperature 12oC
Pressure 1.013 bar
2.1. Block Flow & Process Flow Diagram

The Block Flow Diagram and Process Flow Diagram of this plant will be
shown in Appendix A.
2.2. Mass Balance

The calculation of the mass balance is conducted using SuperPro V 10.
Reactions of the cultivation of bacteria is also inputted and calculated using
stoichiometric equation. The mass balance is based on unit operation and can be seen
in Appendix B.
Table 2.16. Overall Mass Balance
Process Equipment Flow In Flow Out
(kg/batch) (kg/batch)
28
Cell Culture SFR-103 0.219 0.219

SR-103 0.219 0.219
Seed Fermentation V-101 5251.8270 5251.7903
ST-101 102.9763 102.9763
SFR-101 244.6798 233.5951
ST-104 5148.8141 5148.8141
SFR-102 9486.1967 8346.2636
Main V-102 80570.125 79401.53235
Fermentation ST-102 79401.53235 79401.53235
FR-101 430298.5661 430396.3744
V-103 84757.49971 84757.49971
Centrifugation DC-101 84757.49969 84757.49969
Extraction CX-101 74464.71675 74464.71668
Ion Exchange INX-101 23204.81456 23204.81456
Freeze Drying FDR-101 1311.53347 1311.53347
2.3. Energy Balance

The energy balance of the unit operation will be shown in the appendix. In this
section, energy balance refers to the enthalpy flow unit obtained from simulation
results or multiplying mass flow with mass enthalpy for each stream. Heat Duty
was obtained by comparing the enthalpy flow input and output.
2.4. Plant Efficiency
The efficiency of energy consumption is calculated by calculating the ratio
of heating requirement and heat removal requirement. The energy efficiency is as
shown below:
Heating Requirement
η= ×100 %
Heat Removal Requirement
122,309,969.7
η= ×100 %=95,09 %
128,627,072.2
The total energy required per total product is as shown below:
122,309,969.7 kJ
=8,920,481.426 kJ /kg
13.71114 kg
2.5. Utility
2.8.1. Water Utility
As the plant is in the industrial side of the city, a local firm, PT. Perum Jasa
Tirta I, could be a potential water provider for the plant. Unfortunately, the water
29
obtained would be most likely still be slightly contaminated and not sterile, which
requires treatment before it could be utilized. As the fermentation process is
operated under 3 fermenters, a cycle schedule is implemented, in which each
cycle of batch is started every 2.38 days (in reference, one batch is 11.77 days).
The rate of any given water utility requirement is given per unit cycle hours. In
this section the total water requirements is shown in table below, while the details
of the water requirements for each process will be shown in the appendix.
Table 2.17. Total Water Requirement
Flowrate
Specification
(kg/cycle/h)
Main Process Water 1540.62
Boiler 124.36
Cooling Water 165357.04
Chilled Water 1516.27
Make-Up Water 8349.88
Domestic Water 37.5
TOTAL 176,925.67
As the water that is used in the whole process is supplied from a local firm,
PT. Perum Jasa Tirta I, a supplementary water treatment is essential to ensure no
contaminants would disrupt the process. Problems that might arise include
corrosion or erosion inside pipes, fouling formation in heating and cooling units,
and harmful microorganisms that disturb the fermentation processes. To tackle all
these problems at once, the plant will use reverse osmosis technology to provide
clean, process water to ensure sustainability of the plant.
a. Water is sent to clarifier to purify water at first step to remove solids that
may be presented in water, resulting a clearer and more pure water effluent.
b. Water from the clarifier then filtered using sand filter to remove small
particles (e.g. sand, small stones, debris). The sand filter consists of layers
of sand and soil in decreasing thickness and specific weight from bottom to
top.
30
c. After filtered by sand filter, water is then treated with activated carbon as
purifying attempt to remove chlorine and particles such as sediment, volatile
organic compound, taste and odor from water.
d. Demineralization occurs by water softener to reduce the amount of ions and
minerals from water, so pure water can be obtained. This step required
cationic and anionic resins that kept in separated vessel or tank.
e. Water then treated with reverse osmosis as purifying attempt. The principle
of reverse osmosis is to give water containing particles enough pressure so it
can move through semipermeable thin wall against its concentration
gradient. Minerals such as dissolved salts, lead, mercury, calcium, etc. more
than 90% is removed
2.8.2. Air Utility
In this Cyanocobalamin plant, air is mostly used as oxygen supply to the
seed culture. The supply air supply came from blower.
Table 2.18. Air Consumption in Cyanocobalamin Plant
No Equipment Rate of air consumption (kg/batch)
.
1 Pre-seed Fermenter 141.48
2 Seed Fermenter 4,244.93
3 Main Fermenter 346,691.45
Total 351,077.86
Table 2.19. Specification of Air Blower

Type YWL 4E – 200 G
Voltage 220 V
Speed 1360 rpm
Air Flow Rate 1,500 m3/h
Power 330 W
Sound Pressure Level 62 dB
(Source: www.cnmarinefan.com)
The air used for the fermentation process is sterile air. Air inlet filter
systems must be designed to sterilize remove contaminants such as dust, bacteria,
and viruses-particularly bacteriophage. This plant uses an air filter system
consisting of a pre filter and a membrane filter.
Table 2.20. Specification of Pre-Filter
31
Parameter Specification
Removal Rating 1-25 µm
Filter Medium Polypropylene
Brand Domnick Hunter
Type PEPLYN AIR (ZCPH)
Feature(s) Excellent dirt holding capacity
Comprehensive micron range to match
contamination profile
(Emflon® PFR membrane filter cartridge, 2020)
Table 2.21. Specification of Membrane Filter Cartridge

Parameter Specification
Removal Rating 0.2 µm
Membrane Material PTFE
Brand Emflon PFR
Industry-Specific Certification Pharmaceutical Grade
Sterilization Option(s) Suitable for Autoclave or SIP
Gasket / O-Ring Material Ethylene Propylene Rubber
(Emflon® PFR membrane filter cartridge, 2020)
2.8.3. Electricity Utility

This plant’s main electricity is supplied by an energy facility, PT.
Perusahaan Listrik Negara (PLN), Persero, which is the national supplier for
electricity in Indonesia. Beside the main electricity being supplied by PLN, this
plant own backup generators also, in case the main electricity supply failed.
Table 2.22. Electricity Process and Utility Unit Calculation

No Equipment Quantity Usag Amount of Power Power
. e work/cycle (kW) Required
Time (kWh/cycle)
(h)
1 Agitation in 1 0.25 3 0.51 0.3825
seed medium
blending
2 Agitation in 1 0.25 3 7.61 1.9025
fermentation
medium
blending
3 Agitation in 1 0.17 3 1.32 0.6732
32
blending (P-
13)
4 Blower for 1 232 1 0.33 76.56
fermentation
5 Fermentation 1 40 3 0.01 1.2
in pre-seed
fermentation
6 Fermentation 1 24 3 15.35 1,105.2
in seed
fermentation
7 Fermentation 3 168 1 247.55 124,765.2
in main
fermentation
8 Centrifugation 1 4 3 68.8 825.6
9 Ion Exchange 1 5 3 52.05 52.05
10 Centrifugal 1 6 3 0.18 0.18
Extraction
11 Freeze 1 8 3 6.72 6.72
Drying
Table 2.22. Electricity Process and Utility Unit Calculation (cont’d)

No. Equipment Quantity Usag Amount of Power Power
e work/cycle (kW) Required
Time (kWh/cycle)
(h)
12 Pump in 9 12 1 7.5 810
main
process
13 Pump in 3 24 1 3 216
water
treatment
utility
14 Pump in 4 9 1 3 108
steam
utility
15 Pump in 3 24 1 3 216
waste water
treatment
utility
16 Compressor 1 57.23 1 19.95 1,141.739
for air
Total 33 613.9 32 381.69 129,327.4
The table above shows the electricity requirements in the process that run on
electricity. There are 300 operational days per year that has been calculated
33
before. For the process be able to run for 271 hours, it requires a total 129,327.4
kWh/cycle. Therefore, the total power required per year can be calculated, which
is 3,436,005 kWh/year.
2.8.4. Fuel Utility
In the previous section, the power requirement for one batch was
calculated, which is 129,327.4 kWh per batch. One batch consists of 271 hours, so
the estimated electricity power required for one day is 478 kW. The fuel to run the
generator is high speed diesel. Based on the specifications of the equipment, the
consumption of diesel fuel is148L/hr. For the anticipation measure, fuel
consumption is calculated as 160 L/h so that the diesel requirement for one day is
3,840 L.
Table 2.23. Generator Specification
Generator Characteristics Specification
Brand Honny Power
Type HGM688
Prime Rated Power Output 500 kW/625kVA
Rated speed 1500 rpm
Fuel Diesel
Fuel Consumption at 100% PRP 148 L/hr
Efficiency 94.1%
(Source: http://www.honnypower.ru/, 2020)
Aside from backup generator requirement, fuel is also needed for

combustion in boiler for steam generation requirement. For the boiler, the mass
flow rate of steam needed is known from the simulation that is 1657.38 kg/hr.
From the boiler specification, diesel consumption rate is 192 L/hr.
2.8.5. Wastewater Treatment
Wastewater that is produced in the process needs to be treated as it contains
chemical and biological components that could pollute the environment if
disposed of immediately. In order to comply with this ruling, the treatment uses a
combination of physical and biological processes to purify wastewater
a. Preliminary Treatment
The preliminary treatment is a physical process of using large bars or
screens to remove large pieces of garbage from the incoming wastewater
(influent).
34
b. Primary Treatment
At this stage, settling solids particle is carried out in clarifier tank. The
settled solids (primary sludge) are pumped to another area for additional
processing. The floating materials are skimmed off.
c. Secondary Treatment
The secondary treatment (activated sludge process) is a biological phase.
Air is introduced into the wastewater aeration tanks. The air flow stirs the
wastewater and sludge, and the growth bacteria and other beneficial organisms
that naturally that will breakdown and consume the organic materials. The aerated
wastewater moves into a secondary clarifier, where additional particles can sink to
the bottom (secondary sludge) and be physically removed.
d. Disinfection Treatment
The disinfection treatment is done using a UV chamber, whereby harmful
microorganisms and biomass that were produced inside the aerobic tanks are
killed, allowing the wastewater to be free of microorganisms. Upon completion of
this process, the treated wastewater is moved to the last clarifier, whereby the
clarified stream is now referred to as “effluent” and is approved for release into
local waterways (streams, rivers, lakes).
e. Sludge Treatment
This treatment phase combines the primary sludge and secondary sludge,
where they are moved into the “digestion” stage, which involves an anaerobic
digestion that will consume any organic materials left, which uses more time and
steps to make it safer for the environment. The sludge is then dried through a
screw press disc which allows further separation of water, resulting in a dried
sludge ready for disposal.
35
CHAPTER 3
EQUIPMENT DESIGN
3.1. Cell Culture Flask

Table 3.1. Cell Culture Sizing
Cell Culture
Equipment Specification
Name Greiner Bio-One
Code SFR-103
Function For shaking suspension cell, aerobic bacteria, and
microorganisms
Amount 1
Closure Type Filter screw cap
Material Polypropylene
Design Specification Unit
Volume 50 mL
In order to shaking suspension cell, aerobic bacteria, and microorganisms,
we choose cell culture that available in the market. Manufacturer: Greiner Bio-
One 2227245.
3.2. Medium Blender

3.2.1. Seed Medium Blending
Table 3.2. Seed Medium Blending Sizing
Seed Medium Blending

Code V-101
Number of Unit 1
Function Mixing sucrose, water, and other nutrients
Operating Condition
Storage Time (day) 0.11
Flowrate (kg/batch) 5,251.78
Capacity (L) 7,083.38
Temperature (oC) 25
Pressure (bar) 1
Specification Design
Type Vertical Sylinder Tank
Material Stainless Steel 316
Inside Diameter (m) 1.68
Tank Height (m) 2.53
Table 3.2. Seed Medium Blending Sizing (cont’d)
36
HEAD TYPE TORISPHERICAL HEAD

HEAD HEIGHT (M) 0.28
TOTAL HEIGHT 2.81
SHELL THICKNESS (M) 0.009
HEAD THICKNESS (M) 0.006
AGITATOR
IMPALLER TYPE Pitch Blade
NUMBER 1
DIAMETER (M) 0.56
SHAFT DIAMETER (M) 0.07
DISTANCE FROM TANK BOTTOM (M) 0.84
ROTATION SPEED (RPM) 200
POWER (W) 9.67
3.2.2. Fermentation Medium Blending

Table 3.3. Fermentation Medium Blending Sizing
Fermentation Medium Blending

Code V-102
Number of Unit 1
Mixing molasses, water, and other
Function nutrients
Operating Condition
Capacity (L) 105,699.77
Temperature (oC) 25
Pressure (bar) 1
Head Type Torispherical Head
Head Height (m) 0.69
Total Height 6.92
Shell Thickness (m) 0.019
Head Thickness (m) 0.012
Table 3.3. Fermentation Medium Blending Sizing (cont’d)
37
Agitator
Impeller Type Pitch Blade
Number 1
Diameter (m) 1.38
Shaft Diameter (m) 0.17
Distance from Tank Bottom
(m) 2.07
Rotation Speed (rpm) 200
Power (W) 887.24
3.2.3. Blending Storage

Table 3.4. Blending Storage Sizing
Blending Storage
Code V-103
Number of Unit 1
Function Storage tank after fermentation
Operating Condition
Capacity (L) 29,196.27
Temperature (oC) 32
Pressure (bar) 1
Head Type Torispherical Head
Head Height (m) 0.48
Total Height 4.86
Shell Thickness (m) 0.014
Head Thickness (m) 0.008
Agitator
Impaller Type Pitch Blade
Number 1
Diameter (m) 0.97
Shaft Diameter (m) 0.12
Distance from Tank Bottom 1.45
(m)
Table 3.4. Blending Storage Sizing (cont’d)
38
Rotation Speed (rpm) 200

Power (W) 583.03
3.3. Sterilizer
The sterilizer in the process is used to prepare the medium broth by killing
any potential microorganisms that might tamper the fermentation process. In
terms of sterilizer type that is used, there are: 1. (Semi) continuous sterilizers and
2. Batch sterilizers. The semi-continuous sterilizer is used to adequately heat large
amounts of medium under a short amount of time, although it requires a
combination of units to achieve optimal conditions. The batch sterilizer in this
plant is used to prepare inoculation of agar slants containing the microorganism
into the fermenter.
3.3.1. Semi-Continuous Sterilizer

The proposed unit combination for the semi-continuous sterilizer is shown
in the following figure, in which it is divided into four sections: Pre-heating
section of feed medium, heating section of medium with direct injection of steam,
holding section, and cooling section with an expansion valve to separate steam
and heat exchanger with water.
Figure 3.1. Semi-Continuous Sterilizer Combination

The individual units and the detailed operating conditions for each sterilizer
combinations are shown in the following table:
39
Table 3.5. ST-101 Semicontinuous Sterilizer Specification
ST-101
Section Technique
Pre-Heating Pre-Heat S&T Heat Exchanger
Heating Direct Steam Injection
Holding Coil
Cooling Expansion Valve & Flash Chamber + Cooling
S&T Heat Exchanger
Detailed Conditions
1. Preheat Section
Q [kW] 27.33
Feed Medium Temperature 25.00
[C]
Pre-heat Medium 110.00
Temperature [C]
Heat transfer surface area 0.91
[m2]
Shell-and-Tube Pass 1 by 1
Tube diameter [in] 0.50
Tube length [m] 1.00
Number of tubes 24
Material SS304
2. Heating Section
Q [kW] 6.67
Steam flowrate [kg/h] 11.39
Heated Medium 130.00
Temperature [C]
3. Holding Section
Holding time [s] 116.70
Holding tube diameter [in] 0.50
Holding tube length [m] 80.00
Material SS304
4. Cooling Section
Expansion Chamber Outlet 2.70
Pressure [bar]
Q [kW] 5.67
Water flowrate [kg/h] 971.43
Sterile Medium Temperature 28.00
[C]
Heat transfer surface area 0.16
[m2]
Table 3.5. ST-101 Semicontinuous Sterilizer Specification (cont’d)
40

Number of tubes 8
Material SS304
ST-102
Section Technique
Holding Coil
Expansion Valve & Flash Chamber + Cooling
Cooling S&T Heat Exchanger
Detailed Conditions
1. Preheat Section
Q [kW] 3541.67
Feed Medium
Temperature [C] 25.00
Pre-heat Medium
Heat transfer surface area
[m2] 104.17
Number of tubes 112
Material SS304
2. Heating Section
Q [kW] 833.33
Heated Medium
41
3. Holding Section
Holding time [s] 132.45
Material SS304
4. Cooling Section
Expansion Chamber Outlet Pressure [bar] 2.70
Q [kW] 541.67
Sterile Medium Temperature [C] 32.00
Heat transfer surface area [m2] 30.35
Number of tubes 64
Material SS304
ST-104
Section Technique
Holding Coil
Expansion Valve & Flash Chamber + Cooling
Cooling S&T Heat Exchanger
Detailed Conditions
1. Preheat Section
Q [kW] 455.56
Feed Medium
Pre-heat Medium
Heat transfer surface area
[m2] 13.40
Number of tubes 86
Material SS304
42
2. Heating Section
Q [kW] 111.11
Heated Medium Temperature [C] 130.00
3. Holding Section
Holding Time [s] 125.88
Material SS304
4. Cooling Section
Expansion Chamber Outlet Pressure [bar] 2.70
Q [kW] 94.44
Sterile Medium Temperature [C] 28.00
Heat transfer surface area [m2] 2.64
Number of tubes 34
Material SS304
3.3.2. Batch Sterilizer

As for the batch sterilizer, the design calculation is used to pick the right model of
a lab-sized autoclave sterilizer, which is shown below:
Table 3.8. ST-103 Autoclave Sterilizer Specification
Equipment Name Autoclave Sterilizer
Equipment Code ST-103
Model B4000-M (BioClave™ Mini)
Vendor BioClave
Operation Specification
Max. Pressure [bar] 2
Operating Temperature [C] 130
Material Specification
Chamber Dimensions H x D [mm] 90 x 137.5
Chamber Volume [L] 8
External Dimensions W x H x D [mm] 220 x 175 x 157
Power [W] 950
Power Supply 115 or 230V 50-60 Hz
3.4. Fermenters
43
For vitamin B12 production, there are three fermenters used, for pre-seed
fermentation, seed fermentation, and main fermentation process. Fermenters that
are used for these processes are a bubble column reactor with agitator.
3.4.1. Pre-Seed Fermenter

Table 3.9. Pre-Seed Fermenter Sizing
Specification of the Equipment

Name Pre-Seed Fermentation
Code SFR-101
Function First Step Fermetation
Amount 1
Operation Batch
Type Storage Tank
Material Stainless Steel
Equipment -
Operation Data
Mass flow rate (kg/batch) 103.195
3
Mixture density (kg/m ) 1.052
o
Temperature ( C) 32
Pressure (bar) 1.013
Working volume (%) 80%
Construction Data
Capacity (L) 122.65
Diameter of tank (m) 0.42
Height of cylinder (m) 0.62
Thickness of cylinder (m) 0.01
Head Type Ellipsoidal
Height of head (m) 0.10
Head thickness (m) 0.01
Total height (m) 0.73
Height of liquid in tank (m) 0.58
Hysdrostatic pressure (atm) 0.06
Pressure design (atm) 2.23
Agitator Data
Impeller type Propeller
Agitator Diameter (m) 0.139
Agitator Blade Width (m) 0.028
Height of agitator from the bottom of tank (m) 0.139
Table 3.9. Pre-Seed Fermenter Sizing (cont’d)
44
Stick Diameter (m) 0.023

Baffle width (m) 0.035
Impeller Power (kW) 0.0022
Jacket Design
Jacket Space (m) 0.918
Outer Radius of Jacket (m) 2.259
Inside Radius of Jacket 2.08×E-05
Corner of Radius Closure (m) 11.257
Thickness of Radius Closure (m) 3.752
Length Jacket (m) 0.108
Bubble Column Design
Aeration Rate (m3/s) 0.000833
Orifice Diameter (m) 0.003
Orifice Area (m2) 0.000007065
Gas Velocity every Orfice (m/s) 117.95
Gas Bubble Diameter (m) 0.00305
Gas Hold up 0.202
Total Orifice 8948.33
3.4.2. Seed Fermenter

Table 3.10. Seed Fermenter Sizing

Name Seed Fermentation
Code SFR-102
Function Second Step Fermetation
Amount 1
Operation Batch
Type Storage Tank
Equipment -
Operation Data
Mass flow rate (kg/batch) 5,241.27
3
o
Temperature ( C) 28
Construction Data
Capacity (L) 6228.91
Table 3.10. Seed Fermenter Sizing (cont’d)

45

Agitator Data
Jacket Design
Inside Radius of Jacket (m) 2.00.E-05
3
Aeration Rate (m /s) 0.0333
Gas Hold up 0.0724
46
3.4.3. Main Fermenter

Table 3.11. Main Fermenter Sizing

Name Seed Fermentation
Code SFR-102
Function Second Step Fermetation
Amount 1
Operation Batch
Type Storage Tank
Equipment -
Operation Data
Mass flow rate (kg/batch) 83.607,119
3
o
Temperature ( C) 28
Construction Data
Capacity (L) 191350.42
Agitator Data
Jacket Design
47
Table 3.11. Main Fermenter Sizing (cont’d)
Inside Radius of Jacket (m) 1.94E-05

3
Aeration Rate (m /s) 0.44
Gas Hold up 0.0325
3.5. Centrifugation
Centrifugal separator is used to separate dissolved solids, especially
biomass, from fermentation product solution. Separation using centrifugal force
can provide a faster separation time than separation by gravity settling.
Table 3.12. Centrifugal Separator Sizing
Centrifugal Separator
Item Centrifuge
Type Disc Stack Centrifuge
Vendor SHBIO
Number of Unit 1
Function Separate solid particle (cell mass) from solution
Material SS 316
Mode of Operation Continuous
Design Spesification Unit
Mass flow 1481.12 kg/h
Rotation speed (n) 6930 rpm
Basket diameter 0.23 m
Angular Velocity (w) 725.34 rad/s
Centrifugal accelaration (Ac) 60503.58 rad^2/s
G-number 61,738.35
Drum Dimension (L*W*H) 850*625*985 mm
Capacity 1500 L
Power 2.20 kW
3.6. Centrifugal Extractors

48
Table 3.13. Centrifugal Extractors Sizing
Centrifuge Extraction
Item Centrifuge extraction
Number of Unit 1
Function Separate liquid waste and product
Material Stainless steel
Mass flow 74.464.717 kg/batch
Temperature (P-13) 33.5 degC
Temperature (P-15) 29.5 degC
Temperature (Heavy Solvent) 33.5 degC
Pressure (P-13) 8.968 bar
Pressure (P-15) 1.013 bar
Pressure (Heavy Solvent) 1.013 bar
Maximum Volumetric Flowrate 0.03 m3/hr
Inner Diameter 0.3 m
Maximum Rotation Speed 10,000 rpm
Volume 0.6x10-3 m3
In order to separate liquid waste and product, we choose centrifugal

extractors that available in the market. Manufacturer: Podbielniak.
3.7. Ion Exchange Chromatography

Ion exchange chromatography is used to purify vitamin B12 by adsorbing it
with a negatively-charged resin, in which the cobalt ion from the vitamin will
become attracted to it. The specification for the ion exchange chromatography is
shown below.
Table 3.14. Ion Exchange Chromatography Specification
Equipment Name Ion Exchange Chromatography
Equipment Code INX-101
Type Cation Exchange
Operating Pressure [bar] 4
Operating Temp. [C] 33
Pressure Drop [bar] 0.5
Empty-Bed Contact Time [min] 4.5
Table 3.14. Ion Exchange Chromatography Specification (cont’d)
49
Column Height [mm] 2500

Bed Height [mm] 1250
Diameter [mm] 450
Resin Dowex-50W
Resin Density [kg/L] 768.8
Resin Mass [kg] 155
Particle size [mm] 0.6-0.8
pH range 0-14
Total exchange capacity [meq/mL] 1.1
Producer DOW
3.8. Freeze Dryer

Freeze dryers use to remove a solvent usually water from dissolved or
dispersed solids. Table below will show the specification of freeze dryer.
Table 3.15. Freeze Dryer Specification
Type FD1500
Vendor Cuddon Freeze Dry
Chamber – Overall Dimensions 7.15 m Long x 2.79 m Wide x 2.47 m High
Vapour Condenser Capacity 1500 kg in a 24 hr
Number of Shelves 16 heat plates
2
Usable Shelf Area (m ) 137
Ice Capacity (kg) 1500
Shelf Dimensions (Depth is 1025 1500 mm
mm)
Shelf Spacing (mm) 35
Shelf Temperature -20oC – 70oC
Shelf Cooling Rate (min) ≤60
o
Shelf Heating Rate ( C/min) 1
Product Trays S/S 2B Finish – 270 per set (2 sets
supplied)
Energy Consumption 2 kWh/kg of wet product, 2.2 kWh/kg of
wet product if air cool condenser is used
Heating/Cooling Medium Glycol
Power Requirement 230 kW, 50 or 60 Hz, 3-phase
Weight (unloaded) 20,400 kg
3.9. Belt Conveyor
50
Conveyor is aim to load solid that has been crushed through a belt. The
specification of turbine is shown from table below.
Table 3.16. Belt Conveyor Specification
Design Specification
Equipment Name Belt Conveyor
Equipment Code E-83
Type Flat & Roll
Inclination degree 5o
Width (inches) 14
Length (ft) 25
Power (hp) 1.083
Maximum velocity (ft/min) 366.67
Maximum capacity (ton/hr) 2.85
Material of Belt Polymer or Plastic
3.10. Cyanocobalamin Storage Tank

Table 3.17. Cyanocobalamin Storage Tank Specification
Equipment Name Tank for Cyanocobalamin
Equipment Code STR-101
Type Vertical Cylinder
Construction data
Mass Flow Rate 13.7 Kg/h
Volume of Tank 20.57 L
Tank Diameter 0.33 m
Height of Cylinder (Hs) 0.65 m
Height of Ellipsoidal (Hh) 0.05 m
Height of Tank (HT) 0.76 m
Pressure Design
Pressure Design 127.573 kPa
Tank Thickness
Cylinder Thickness 6.54 mm
Head Thickness 6.54 Mm
3.11. Compressors
51
Compressor is used to supply gas that are needed for fermentation

processes. There is one compressor used.
Table 3.18. Compressor Sizing
EQUIPMENT SPECIFICATION
NAME Air Compressor
CODE G-101
FUNCTION Supply Gas for fermentation
STAGE 1
TYPE Centrifugal Gas Compressor
OPERATION CONDITION
TEMPERATURE IN (°C) 298.1
PRESSURE INLET (KPA) 101.3
PRESSURE OUTLET (KPA) 111.3
3
FLOW RATE (M /H) 5202.6122
COMPRESSION RATIO 1.1
POWER (KW) 19.95
HEAD (M) 827.4
3.12. Air Filtration

Table 3.19. Air Filtration Sizing
EQUIPMENT SPECIFICATION
NAME Air Filtration
CODE AF-101
FUNCTION To sterilize remove contaminants
AMOUNT 1
TYPE PTFE Membrane
DESIGN SPECIFICATION Unit
PRESSURE 5.3 bar
TEMPERATURE 20 degC
FLOW RATE 351077.86 kg/batch
PRESSURE DIFFERENTIAL 1 bar
VOLUMETRIC FLOW 14074115.9 L/h
OSMOTIC PRESS DIFFERENTIAL 0.8 bar
MEMBRANE WATER FLUX 17592645 L/h/m2
MEMBRANE AREA 0.8 m^2
MATERIAL COMPOSITION polytetrafluoroethylene
LIFETIME 10 years
CAPACITY 2 m3/h
Table 3.20. Air Filtration Sizing (cont’d)
52
Name Air Filtration

Code AF-101
Function To traps large particles, pipescale, and rust
Amount 1
Type Pre-Filter
Design Specification Unit
Pressure 3.5 barg
Temperature 20 degC
Flow Rate 351077.86 kg/batch
Pressure Differential 1 bar
Volumetric Flow 14074115.9 L/h
Osmotic Press Differential 0.8 bar
Membrane Water Flux 28722685,51 L/h/m2
Membrane Area 0.49 m^2
Material Composition Polypropylene
Lifetime 10 years
Capacity 2 m3/h
In order to sterilize remove contaminants, we choose air filtration that

available in the market. Manufacturer: Lenntech and Parker Indonesia.
3.13. Water Utility

Water utility is used to make the water suitable to use in the process unit. The
units that present in this plant’s water treatment process are clarifier, sand filter,
activated carbon, water softener, and reverse osmosis. All of those units’ specification
are shown in the appendix.
3.14. Wastewater Utility

Wastewater utility is used for treating the by-product of manufacture. The units
that present in this plant’s wastewater treatment process are screening and grit
handling, clarifiers, aeration tank, UV chamber, anaerobic digester, sludge storage
tank, and sludge dewatering. All of those units’ specification are shown in the
appendix.
3.15. Steam Utility

Steam utility is used for providing all the steam needed for process. The units that
present in this plant’s steam utility are condenser, demineralized water storage tank,
fuel storage tank, compressor, and boiler. All of those units’ specification are shown
in the appendix.
53
Table 3.41. Pump (P-101) Specification
Equipment Name Heat Exchanger
Equipment Code HX-101
Type Shell and Tube
Operating Condition
Data Shell Side Tube Side
Fluid Stream Inlet 1 5
Fluid Stream Outlet 2 6
Fluid Flow (kg/h) 226,363 1,658
Temperature in (oC) 5 152
Temperature out (oC) 10 90
Operating pressure (kPa) 101 180
No. of passes 1 6
Fouling factor (m2 oC/W) 0.0002 0.00009
Heat Duty (MW) 1.113
∆T LMTD (oC) 111.073
Overall U (W/m2 oC) 1,319.574
Type of unit Fixed tube
Material SS-316 atau SA-240
Heat Transfer Area (m2) 7.596
Tube OD (mm) 19.050
Tube Length (m) 4.880
Shell ID (m) 0.540
Tube Pitch (mm) 24
Tube Thickness (mm) 0.710
Number of tubes 4
Tube arrangement Triangular
3.15.1. Demineralized Water Storage Tank

This tank use for collecting water from condenser and makeup water. The water
from this tank is used for cooling and heating system. Table below will show the
specification of the tank.
Table 3.37. Demineralized Water Storage Tank Specification
54
Equipment Name Tank for Demineralized Water

Equipment Code V-101
Construction data
Mass Flow Rate 3,315.4 Kg/h
Volume of Tank 3,978.48 L
Pressure Design
Tank Thickness
3.15.2. Fuel Storage Tank

This tank use to accommodate fuel in steam utility. The fuel from this tank is used
for combustion in boiler. Table below will show the specification of the tank.
Table 3.38. Fuel Storage Tank Specification
Equipment Name Tank for Fuel
Construction data
Mass Flow Rate 163 Kg/h
Table 3.38. Fuel Storage Tank Specification (cont’d)
Pressure Design
55
Tank Thickness
Head Thickness 5.2 mm
3.15.3. Compressor
Table below shows the specifications of air compressor for combustion in boiler.
Table 3.39. Compressor Specification
Equipment Name Air Compressor
Equipment Code E-16
Type Centrifugal Compressor
Stage 1
Operation Data
Temperature 298.15 K
Pressure Inlet 101.325 kPa
Pressure Outlet 301.325 kPa
Flowrate 2,418 m3/hr
Compression Ratio 2.97
Construction data
Power 124.2 kW
3.15.4. Boiler
Table 3.40. Boiler Specification
Equipment Name Boiler
Equipment Code SG-101
Heat Release Rate per Unit Volume
ṁc (kg/h) 163
ṁc (kg/s) 0.045277778
LHV (kJ/kg) 49725.27
qv (kW/m3) 230
V (m3) 9.788912385
Heat Release Rate per Unit Cross Sectional Area
ṁc (kg/h) 163
Table 3.40. Boiler Specification (cont’d)
ṁc (kg/s) 0.045277778
qf (kW/m3) 2130
56
Fgrate (m2) 1.057018708

Hfu+Hb 9.260869565
Heat Release Rate per Unit Wall Area of Burner
qb (kW/m3) 1400
b (m) 0.980268381
Hb (m) 0.390606942
Hfu (m) 8.870262624
a (m) 1.078295219
Type of Burner
Power produced (kW) 2251.44985
Determination of Furnace Size
α 30
β 45
γ 50
E (m) 0.8
d (m) 0.2450671
Furnace Material
Inner case material SS-304
Furnace wall Fire brick
3.16. Pump
Pump is one of many utilities equipment that support production process of
Cyanocobalamin. This plant utilizes 27 pumps for main process and also other
utilities.
CHAPTER 4
PROCESS CONTROL STRATEGY
4.1. Pipeline Specification
Piping is a system consists of pipes used to convey fluids (both liquid and
gases) from one location to another. There are several in-line components along
industrial process piping such as fittings, valves, and other devices like control
devices. In this plant, all the fluids transportation involves pipes.
Calculation for piping is done with instructions from several sources, most
notably Towler (2008). The plant will use stainless steel pipes, which can
accommodate higher pressures and temperatures usually required in the industry
with ease. The advantages of using stainless pipe are strength, durability, relative
cost, weldability and corrosion resistance. It is also a good choice in high-
temperature environments and is resistant to UV radiation. Additional operations
can be done to make the stainless-steel pipe resistant to microbial growth, which
helps making it easier to clean and get sterilized.
Table 4.1. Legend for Piping Table
Colo
Stream
r
Liquid
Gas
58
Table 4.2. Pipeline Specification for Fermentation Section
Total
Materia Elevatio
Pipe Size ΔP
m l n (m)
Strea ṁ ρ (psi)
From To (kg/batch t (h) L (m)
m (kg/h) (kg/m3) Thicknes
) NPS ID OD Sc
s
(in) (in) (in) h
(in)
0.0 1263.4 30.8 1.31 11.0
1 V-101 380.17 4562.04 1.0 1.05 0.133 40 SS304 2
Nutrients 8 0 0 5 7
Storage 12097.1 0.2 1388.1 31.6 13.8
2 V-102 48388.60 3.0 3.07 3.5 0.216 40 SS304 5.6
5 5 9 8 4
0.0 112020.0 1000.0 40.4 5.56
3 Purified V-101 4667.50 5.0 5.05 0.258 40 SS304 2.1 4.99
4 0 0 6 3
Water
65473.0 0.6 1000.0 35.9 5.56
4 Storage V-102 98209.50 5.0 5.05 0.258 40 SS304 5.8 9.64
0 7 0 6 3
0.0 1040.0 34.0 2.87
5 V-101 204.00 24480.00 2.5 2.47 0.203 40 SS304 2.2 6.53
NaOH 1 0 8 5
Storage 0.1 1040.0 29.5 2.87 11.3
6 V-102 3000.00 22500.00 2.5 2.47 0.203 40 SS304 6
3 0 8 5 0
0.0 1029.7 19.0
7 P-101 5148.80 61785.60 4.5 4.51 5 0.247 40 SS304 0 0.53
8 6 2
V-101
0.0 1029.7
8 P-102 103.00 6180.00 6.23 1.5 1.61 1.9 0.145 40 SS304 0 0.39
2 6
HEX- 0.0 1029.7
9 P-101 5148.80 61785.60 3.00 4.0 4.03 4.5 0.237 40 SS304 0.2 0.44
103 8 6
SFR- 0.0 1029.7
10 HEX-104 5148.80 61785.60 8.11 4.0 4.03 4.5 0.237 40 SS304 2 3.32
102 8 6
HEX- 0.0 1029.7 1.2
11 P-102 103.00 6180.00 2.50 1.38 1.66 0.14 40 SS304 0.1 0.48
101 2 6 5
59
Table 4.2. Pipeline Specification for Fermentation Section (cont’d)
Total
Materia Elevatio
Pipe Size ΔP
m l n (m)
Strea ṁ ρ (psi)
) NPS ID OD Sc
s
(in) (in) (in) h
(in)
SFR- 0.0 1029.7 1.2
12 HEX-102 103.00 6180.00 7.75 1.38 1.66 0.14 40 SS304 0.4 1.63
101 2 6 5
SFR- 0.1 1029.7 10.0
13 SFR-101 92.46 599.74 0.5 0.62 0.84 0.109 40 SS304 1.8 3.73
102 5 6 3
0.1 1026.4 3.0
14 SFR-102 P-104 4114.50 30858.75 4.95 3.07 3.5 0.216 40 SS304 0 0.25
3 0 0
0.1 1026.4 18.0 2.5 2.87 12.6
15 FR-101 4114.50 30858.75 2.47 0.203 40 SS304 6.8
3 0 9 0 5 5
0.1 1026.4 16.2 2.5 2.87 12.3
16 P-104 FR-102 4114.50 30858.75 2.47 0.203 40 SS304 6.8
3 0 1 0 5 7
0.1 1026.4 19.0 2.5 2.87 12.8
17 FR-103 4114.50 30858.75 2.47 0.203 40 SS304 6.8
3 0 9 0 5 0
79400.0 1.0 1058.7 18.4 5.0 5.56
18 V-102 P-103 79400.00 5.05 0.258 40 SS304 0 0.45
0 0 0 5 0 3
HEX- 79400.0 1.0 1058.7 4.5
19 P-103 79400.00 6.00 4.51 5 0.247 40 SS304 0.3 0.71
105 0 0 0 0
79400.0 1.0 1058.7 5.0 5.56
20 HEX-106 P-106 79400.00 3.00 5.05 0.258 40 SS304 0 0.07
0 0 0 0 3
21 P-106 FR-101 79400.0 1.0 79400.00 1058.7 20.6 4.5 4.51 5 0.247 40 SS304 6.8 11.1
0 0 0 6 0 2
60
79400.0 1.0 1058.7 35.6 4.5 11.7

22 FR-102 79400.00 4.51 5 0.247 40 SS304 6.8
0 0 0 0 0 7
Table 4.2. Pipeline Specification for Fermentation Section (cont’d)
Total
Materia Elevatio
Pipe Size ΔP
m l n (m)
Strea ṁ ρ (psi)
) NPS ID OD Sc
s
(in) (in) (in) h
(in)
79400.0 1.0 1058.7 31.1 4.5 11.5
23 FR-103 79400.00 4.51 5 0.247 40 SS304 6.8
0 0 0 0 0 7
83616.0 1.0 1024.6 26.0 5.0 5.56
24 FR-101 P-105 83616.00 5.05 0.258 40 SS304 0 0.73
0 0 2 5 0 3
83616.0 1.0 1024.6 14.5 5.0 5.56
25 FR-102 P-105 83616.00 5.05 0.258 40 SS304 0 0.41
0 0 2 5 0 3
83616.0 1.0 1024.6 16.0 5.0 5.56
26 FR-103 P-105 83616.00 5.05 0.258 40 SS304 0 0.45
0 0 2 5 0 3
773994. 0.0780 3.0
26 - 4947.28 9.84 3.00 3.50 0.22 40 SS304 0 0.43
G-101 AF-101 3 3 7
AF-101 SFR- 40. 0.0780 54.9 0.6
27 311.92 7.80 0.50 0.84 0.11 40 SS304 0 0.03
101 00 3 1 2
SFR- 24. 0.0780 51.2 1.0
28 9358.46 389.94 1.00 1.32 0.13 40 SS304 0 4.69
102 00 3 8 5
764323. 168 0.0780 116. 3.0
29 4549.55 3.00 3.50 0.22 40 SS304 0 4.71
FR-101 92 .00 3 71 7
30 FR-102 764323. 168 4549.55 0.0780 76.2 3.0 3.00 3.50 0.22 40 SS304 0 2.99
92 .00 3 3 7
61
764323. 168 0.0780 113. 3.0

31 4549.55 3.00 3.50 0.22 40 SS304 0 4.59
FR-103 92 .00 3 96 7
Table 4.3. Pipeline Specificatioin for Separation Section
SIZE TOT
M Ρ
STRE T Ṁ L MATER ELEVAT AL
FROM TO (KG/BAT (KG/M NPS ID OD Thickness
AM (H) (KG/H) 3 (M) Sch IAL ION (M) ΔP
CH) ) (in) (in) (in) (in) (PSI)
2 Cyanide P-111 0.25 832.00 628 1.00 0.50 0.62 0.84 0.109 40 SS304 0.3 0.55
208
Storage
2 P-111 V-103 208 0.25 832.00 628 4.00 0.50 0.62 0.84 0.109 40 SS304 3.5 4.25
1 P-109 V-103 84893.5 1.00 84893.50 1000 8.00 4.00 4.03 4.50 0.237 40 SS304 3.5 8.03
3 V-103 P-112 81662.43 1.00 81662.43 1026 1.00 5.00 5.05 5.56 0.258 40 SS304 0.3 1.23
3 P-112 DC-101 85101.53 1.00 85101.53 1040 5.25 4.50 4.51 5.00 0.247 40 SS304 1 3.17
4 DC-101 Solid 1.00 30983.64 1056 1.00 2.00 2.07 2.38 0.154 40 SS304 0.3 5.07
30983.644
waste
5 DC-101 P-113 74681.33 1.00 74681.33 1014 1.50 4.50 4.51 5.00 0.247 40 SS304 0.3 0.88
5 P-113 CX-101 74681.33 1.00 74681.33 1014 6.00 4.00 4.03 4.50 0.237 40 SS304 0.5 3.37
6 Solvent CX-101 100 1.00 100.00 1014 3.00 0.13 0.27 0.41 0.068 40 SS304 0.5 1.89
7 CX-101 Solvent 1.00 52850.94 1023 10.43 3.50 3.55 4.00 0.226 40 SS304 0.3 2.04
52850.94
discharge
8 CX-101 P-114 21929 1.00 21929.00 1014 1.00 2.50 2.47 2.88 0.203 40 SS304 0.3 0.94
62
8 P-114 INX-101 21929 1.00 21929.00 1014 8.05 2.00 2.07 2.38 0.154 40 SS304 1.5 7.52
9 Water P-115 0.17 7773.90 997 2.00 1.50 1.61 1.90 0.145 40 SS304 0.3 1.07
1295.65
tank
9 P-115 INX-101 1295.65 0.17 7773.90 997 49.12 1.00 1.05 1.32 0.133 40 SS304 1.5 51.10
Table 4.3. Pipeline Specification for Separation Section (cont’d)
SIZE TOT
M Ρ
STRE T Ṁ L MATER ELEVAT AL
FROM TO (KG/BAT (KG/M NPS ID OD Thickness
AM (H) (KG/H) 3 (M) Sch IAL ION (M) ΔP
CH) ) (in) (in) (in) (in) (PSI)
10 HCl INX-101 1.94 0.17 11.64 1.49 1.00 1.25 1.38 1.66 0.14 40 SS304 1.5 0.01
Ammon 0.17 5.40 0.73 9.00 1.25 1.38 1.66 0.14 40 SS304 6.8 0.02
11 INX-101 0.9
ia
INX- 0.02 951.96 800 1.00 0.50 0.62 0.84 0.109 40 SS304 0.3 1.00
13 P-116 15.866
101
13 P-116 FDR-101 15.866 0.02 951.96 800 8.27 0.50 0.62 0.84 0.109 40 SS304 2 6.12
Liq 0.50 128.00 808 1.00 0.13 0.27 0.41 0.068 40 SS304 0 0.80
16 P-117 64
nitrogen
16 P-117 FDR-101 64 0.17 384.00 808 2.00 0.25 0.36 0.54 0.088 40 SS304 2 5.92
Table 4.4. Pipeline Specification for Gas Phase in Separation Section
STREA FROM TO M T Ṁ Ρ L PIPE SIZE MATERIA ELEVATIO TOTA
63
NP Thicknes
(KG/BATC (KG/H (KG/M3 (M ID OD Sc L ΔP
M (H) S s L N (M)
H) ) ) ) (in) (in) h (PSI)
(in) (in)
FDR- Outle 1.0 2855.2 3.0 3.0 3.5
14 2855.1952 0.05 1 0.22 40 SS304 0 5.99
101 t 0 0 7 0 0
64
4.2. Production Process Piping and Instrumentation Diagram
The production process piping and instrumentation diagram are divided into
fermentation section and separation section. In it, details regarding the piping
(which has been described in Chapter 4.1) together with the instrumentation and
control devices are added. The instrument symbols used in these drawings are
based on International Society of Automation (ISA) Standard S5.1.
The purpose of creating a P&ID is to provide a basis for the development of

system control schemes, also allowing easier safety and operational investigations,
such as HAZOP. They also play a significant role in the maintenance and
modification of the process after initial build. Thus, it is critical that a P&ID be
developed, as it could demonstrate the physical sequence of equipment and
systems, as well as how these systems connect. Details regarding the control
mechanism are tabulated in Appendix P.
65
Figure 4.1. P&ID Fermentation Section
66
Figure 4.2. P&ID Separation Section
CHAPTER 5
PLANT LAYOUT
5.1. Location Analysis
The selection of plant location is based on several factors to ensure efficient

plant production. The parameters are raw material location, infrastructure and
access to market, regulations by government, workers’ availability and land
development availability.
 Raw Material Location
The most important part of the selection of plant location is the availability of
raw material which is sugarcane molasses. Sugarcane molasses is byproduct
of sugar factory, so the availability of raw material can be seen in the
production capacity of sugar factory from each province as seen below.
Table 5.1. Distribution of Sugar Factories in Indonesia
Province Number of Sugar Factory Production Capacity (TCD)

West Java 5 13,030
Central Java 10 25,160
East Java 31 90,430
Sumatera 8 58,240
Sulawesi 4 10,980
(Source: Studi Konsolidasi Pergulaan Nasional (P3GI), 2008)
The province that provides the highest production capacity of sugarcane is

East Java, which is 90,430 tons cane per day (TCD). East Java is a province that is
quite wide and has many districts, the following table shows the amount of sugar
factory in each district and its production capacity.
68
Table 5.2. Distribution of Sugar Factories in East Java
District Number of Sugar Production Capacity

Factory (TCD)
Tulunganggung 1 3,000
Lumajang 1 10,000
Malang 2 25,000
Magetan 2 8,000
Pasuruan 2 6,200
Probolinggo 3 7,750
Jombang 2 7,050
Ngawi 1 4,000
Sidoarjo 3 9,800
Mojokerto 1 7,200
Madiun 3 12,000
Situbondo 4 10,731
Nganjuk 1 4,000
Jember 1 7,500
Bondowoso 1 4,000
Kediri 2 15,350
(Source: Refleksi Akhir Tahun PG Rajawali I, 2018)
It can be seen from the table above, the district in East Java with the highest
sugar production is Malang. Thus, Malang is one of the most probable city
for establishing this factory.
 Infrastructure and Access to Market
Good support infrastructure, such as transportation acccess, ports, bank,
energy, and utilities supply are integral for the success of the plant. It
facilitates the supply and product delivery chain from the producers and to the
consumers respectively. Tanjung Perak port is a very supportive
infrastructure for the supply of our products to customers outside Java.
Besides that, the Pandaan - Malang toll road is also the infrastructure that
supports access to Tanjung Perak Port.
 Regulations by Government
Government regulations ensure production success, as it backs up the
integrity of the plant by law. The plant site is built in an industrial estate
which has been set by the government as a factory area, to ensure the citizen
will not be disturbed.
69
 Workers Availability
The availability of the workers is important for the plant’s success, to ensure
smooth operation. The proximity of the plant needs to be able to supply local
labor forces that can be employed in the plants, without having to pay for
additional fees, such as transportation.
Table 5.2. Workers Availability in Malang
Total Labors 1,854,459

Minimum Wage Rp3,018,053
(Source: Badan Pusat Statistika Jawa Timur, 2019)
 Land Development Availability

The land development availability is to enable future expansion to consider
the increasing demand of vitamin B12, and any potential increasing production
capacity. Based on the considerations, the plant will be located in Malang,
East Java. This location is close enough to raw material supplier PT. PG.
Rajawali 1 (9.3 km) and PG. Kebon Agung (2.2 km). The location can be
seen by the figure below.
70
Figure 5.1. Plant Location

5.2. Overall Plant Layout
Layout is an important decision that determines the efficiency of an

operation in the long term. The layout has many strategic impacts for the layout
determining the competitiveness of companies in terms of capacity, processes,
flexibility, and cost and quality of the work environment. effective layout can help
organizations achieve the strategy that supports the differentiation, low cost, or a
quick response.
112
Figure 5.2. Overall Plant Layout
112
5.2.1. Equipment Layout

Table 5.3. shows equipment area in cyanocobalamin plant.
Table 5.3. Equipment Area
Area Equipment Length (m) Width (m) Total Area (m2)

V-101 1.7 1.7 2.8
V-102 4.2 4.2 17.3
V-103 2.9 2.9 8.5
ST-101 1.0 0.5 0.5
ST-102 2.0 1.0 2.0
ST-103 0.2 0.2 0.0
ST-104 1.0 0.5 0.5
Main SFR-101 0.4 0.4 0.2
Process SFR-102 1.5 1.5 2.4
SFR-103 4.8 4.8 23.3
DC-101 0.9 0.6 0.5
CX-101 2.5 1.4 3.3
INX-101 2.0 2.0 4.0
FDR-101 7.2 2.8 19.9
G-101 1.5 2.0 3.0
AF-101 1.0 1.5 1.5
CR-201 13.9 13.9 192.1
SF-201 2.2 2.2 4.8
Water
AC-201 1.0 1.0 1.0
Utility
WS-201 1.5 1.5 2.3
RO-201 3.0 1.5 4.5
WS-202 0.6 0.6 0.4
CR-202 1.5 1.5 2.1
AT-201 1.4 1.4 1.8
CR-203 1.4 1.4 2.0
Wastewater
UV-201 1.5 1.0 1.5
Treatment
CR-204 1.3 1.3 1.7
AD-201 0.9 0.9 0.8
ST-201 1.0 1.0 0.9
DW-201 2.6 1.1 2.7
HX-101 1.2 0.5 0.6
V-101 1.9 1.9 3.6
Steam
V-102 0.7 0.7 0.5
Utility
SG-101 3.0 3.0 9.0
E-16 2.8 1.8 5.0
73
5.2.2. Area Layout

Table 5.4. shows facilities area in cyanocobalamin plant.
Table 5.4. Facilities Area
Plant Area Component Length (m) Width (m) Area (m2)

Main Process Room 39.5 38.5 1520.75
Steam Utility 11 14.5 159.5
Water Utility 12 9 108
WWTP 11 20 220
Raw Material Storage Room 7.5 11 82.5
Product Storage Room 14 8.5 119
Office 16.5 38.5 635.25
Control room 7.5 23.5 176.25
Laboratory 7.5 15 112.5
Functional Hall 19 11 209
HSE Room 7.5 9.5 71.25
Maintenance Room 6 7.5 45
Power Plant 9 6 54
Clinic 4.5 15 67.5
Mosque 9 15 135
Canteen 13.5 9.5 128.25
Parking Area 6 27.5 330
Green Area 4.5 13.5 303.75
Assembly Point 6 6 72
Security Post 6 5.5 33
Toilet 6 4 48
112
5.3. Water Utility Plant Layout
The water utility plant layout as shown in figure below
Figure 5.3. Water Utility Plant Layout

75
5.4. Main Process Plant Layout
The major factor that influenced total area of the plant is cyanocobalamin processing equipment as shown in figure below
Figure 5.4. Main Process Plant Layout

76
5.5. Wastewater Treatment Plant Layout
The wastewater treatment plant layout as shown in figure below.
Figure 5.5. Wastewater Treatment Plant Layout

77
5.6. Storage Room Plant Layout
The storage room plant layout as shown in figure below
Figure 5.6. Storage Room Plant Layout

78
5.7. Steam Utility Plant Layout
The steam utility plant layout as shown in figure below.
Figure 5.7. Steam Utility Plant Layout

112
CHAPTER 6
HEALTH, SAFETY, AND ENVIRONMENTAL PROTECTION
6.1. Hazard Identification Study (HAZID)
HAZID procedure are used to identify main hazards, to review the

effectiveness of selected safety measures and, where required, to expand the
safety measures in order to achieve a tolerable residual risk. Hazard that may
presence in workplace happen because of several factors such as:
a. Flammability and reactivity

b. Explosion
c. Physical activity (fall, impact, mechanical failure, vibration and noise above
allowed level, pressure)
d. Changes in temperature
e. Electrical contact
f. Biological
Recent condition on hazard presence in plant along with its possible effect,
frequency, and act of prevention will be analyzed further. HAZID is not only
applied in main process area, but also in utilities and other areas that may contain
possible hazard. Classification in HAZID is available in form of HAZID risk
matrix as provided in Table 6.1.
Table 6.1. HAZID Risk Matrix
Consequence Frequency (F)

s (C) Rare Unlikely Possible Very Likely Certain
/Likely to Occur
Catasthropic Moderate Moderate High Critical Critical

Major Low Moderate Moderat High Critical
e
Moderate Low Moderate Moderat Moderate High
e
Minor Very Low Low Moderat Moderate Moderate
e
Insignificant Very Low Very Low Low Low Moderate
80
The complete HAZID analysis is tabulated in Appendix J.

6.2. Hazard and Operability Study (HAZOP)
HAZOP is a systematic technique for identifying all plant or equipment

hazards and operability problems where each equipment is studied carefully about
all possible deviations that may happen from its normal and design operation
condition. The possible deviations are generated by rigorous questioning,
prompted by several standard of guide word applied to exist design. Procedures in
conducting HAZOP are:
a. List all process and equipment involved, along with detailed information
related to each process
b. Collect all possibilities of deviation in each process in form of systematic
question to make analysis a lot easier
c. Write down the effect of each deviations and the action to overcome that
deviations from happening.
In order to generate systematic questions for HAZOP analysis, usually

there are 2 types of keyword that will be used, there are:
a. Primary keyword: Describe things such as parameter and any conditions

that may possible happen to process in an equipment. Example: level,
pressure, temperature, fire, explosion, clogged, etc.
b. Secondary keyword: Combination of primary keyword that will present the
probability of deviation that possibly happen. Example: more, less, as well
as, etc.
The complete HAZOP analysis is tabulated in Appendix J.
6.3. Operational Details
Plant constructions consist of several parts, such as basic process

engineering, detailed engineering, procurement, construction, operations training,
mechanical completion (construction), pre-commissioning, commissioning, and
acceptance test run. Since the process above is done in sequence, therefore
operations training such as project management, HAZID, HAZOP, and other
trainings must be done when the plant is being constructed. After the plant
81
construction is completed, pre-commissioning and commissioning steps are

planned and commenced. Phases in plant commissioning and start-up are listed as
follow:
a. Preparing and planning equipment for pre-commissioning (Mechanical

Completion/Testing)
b. Clean and pressure test systems
c. Check and prepare major mechanical equipment, instrumentation, and also
protection system
d. Final preparation for start-up commissioning
e. Charge with feedstock and other materials. Plant start-up and operation
f. Performance test and plant acceptance
Later on, plant commission can be considered as successful if has at least 4 parts,
there are:
a. No loss time accident: Commissioning must be done safely to be considered

as success since safety is the most important things from the very beginning
b. No equipment damage: Required lots of disciplines, design, construction
operations, and commissioning team
c. On test product within reasonable period: Testing the product less than 2
days considered as very good, 7 days would be acceptable, and more than
14 days is less than acceptable
d. No environmental incidents: By successfully test on product within
reasonable period can reduce possible environmental impact
6.3.1. Start-Up Procedure

Before the plant operates for the first time, several procedures needed to be
done so the plant can run safely. Details procedures description are available as
follow:
a. Mechanical Completion (MC)

Any unit or facility inside plant will be considered as Mechanically
Complete (MC) when it has been erected in accordance with applicable
drawings and specifications.
82
b. Punch List
It is an integral part of the mechanical completion and is a critical step to
verifying the status of systems completion. The category of a punch list item
determines if a system is ready to move into the next phase of
commissioning.
c. System Turn Over
Develop turnover procedure and schedule must be arranged in order to
define how system will be turned over from construction to commissioning
and any information related to it. Usually, utilities and outside battery limit
will be scheduled first, followed by process area or inside battery limit.
d. Pre-commissioning
After a system or sub-system achieved MC, pre-commissioning/static
commissioning can be done and monitored by using different types of fluids
such as water, air, nitrogen, hydrocarbons that being introduced into several
section in facilities.
6.3.2. Commissioning
If all facilities inside plant have already been designed, procured, fabricated,
installed, tested, and prepared for operation in accordance with design and
specifications, commissioning as a verification process should be done.
6.3.3. Pre-start-up Safety Review (PSSR)

This procedure will be conducted prior to start-up after all construction is
already complete. Things that checked up in PSSR are:
 Accordance of construction and equipment with the design specifications

 Procedures such as safety, operating, maintenance, and emergency are in
place, adequate, and functioning properly
 Process hazard analysis has been performed and recommendations have
been implemented before start-up
6.3.4. Acceptance Test Run (ATR)

The test run will be held after commissioning and an approved procedure
will be developed and utilized.
83
6.3.5. Shut-Down Procedure

Procedures for plant shut-down are available in 2 conditions, which are
planned shut-down (for maintenance and evaluation equipments) and unplanned
shut-down (in case of emergency). In both cases, safety precautions for shut-down
activities needed to be taken into account. It is required to prevent all potential
hazards that commonly appear during plant shut down.
6.4. Personal Protective Equipment
PPE is used to minimize the possible exposure to various types of hazards.

In order to provide the suitable types of PPE, employer need to identify both
physical and health hazard in workplace and its level. It is better for employer to
provide PPE with higher protection level from the result of hazard assessment.
Basic PPE examples in workplace are gloves, foot protection, eye protection
(goggles), protective hearing devices (earplug and muff), hard hat, respirators, and
full body suits. Since the plant is categorized as enzyme plant, therefore the basic
PPE are respiratory, eye and face, hand and foot, and body protection.
a. Respiratory Protection
Respiratory protection is used in instances where engineering and work
practice controls are not able to sufficiently control airborne enzyme to a
safe level (AIHA, 1992).
b. Eye and Face Protection
Since there are also other potentials for eye and face contact with
enzyme, PPE such as safety glasses, goggles, and face shield can be used.
c. Hand and Foot Protection
Hand and foot as movement organ of the body that easily contact with
hazard or harmful substances and able to cause burns, bruises,
inflammation, etc. Hand and arm can be protected using gloves, elbow-
length gloves, and arm covering, with several considerations such as type of
chemical handled, duration of contact, size, and protection area. For foot
and leg area, protection from hot or dangerous material can be achieved
using protective footwear.
84
d. Body Protection
Body as a large area can be protected using protective clothing such as
coveralls, laboratory coats, surgical gowns, and full-body suits.
6.5. Material Safety Data Sheet
Material Safety Data Sheet (MSDS) is a document describing the health and
safety of each components and materials that is involved in the process of vitamin
B12 production. This data sheet will be used for workers or civilians to prevent
any danger to the individual. It is also intended to provide workers with
procedures for handling or working with that substance in a safe manner, which
includes information, such as physical data, toxicity, health, effects, first aid,
reactivity, storage, disposal, protective equipment, and spill-handling procedures.
The key to the hazards associated with the numerical ratings is provided in Figure
6.1. MSDS for major substances is tabulated in Appendix K.
Figure 6.1. NFPA Rating Explanation

(source: myusf.usfca.edu)
85
6.6. Area Classification
Area classification is a method of analyzing and classifying the environment

where explosive gas atmospheres may occur. The main purpose is to facilitate the
proper selection and installation of apparatus to be used safely in that
environment, considering the properties of the flammable materials that will be
present. Hazardous areas are classified into zones based on an assessment of the
frequency of the occurrence and duration of an explosive gas atmosphere as
follows:
 Zone 0: An area in which an explosive gas atmosphere is present

continuously or for long periods
 Zone 1: An area in which an explosive gas atmosphere is likely to occur in
normal operation
 Zone 2: An area in which an explosive gas atmosphere is not likely to occur
in normal operation and, if it occurs, will only exist for a short time.
6.7. Emergency Action Plan
Emergency is an unplanned situation that may cause injury, loss of lives,

damage to the property, and/or interfere with normal activities of a worker and
pedestrians. Because of these multiple dangers present in the plant, immediate and
remedial actions need to be taken. Emergencies often occur because of
malfunction of equipment, unsafe act, or even natural disaster, such as floods,
fires, and toxic gas releases.
Emergency Action Plan (EAP) is a written procedure detailing the

appropriate response to various types of emergencies. The idea for these actions is
that it will help to provide guidelines in dire times. At a minimum, emergency
action plan must include the following things: an evacuation policy and
procedure, a preferred method for reporting fires and other emergencies,
emergency escape procedures and route assignments.
86
6.7.1. Emergency Operating Procedures and Training

Emergency procedure should include instructions for dealing with fire, leaks, and
spills. The procedure should describe how to raise the alarm and call the fire
brigade, tackle a fire or control spills and leaks, evacuate the site and if necessary
nearby premises.
These instructions consist of a four-step procedure that employees should

follow during a fire. The procedure must be memorized by all employees.
Experience has demonstrated that the best response to a plant fire is to sound the
alarm, then let others know there is a fire, then to combat the fire if it safe, and
finally to evacuate if necessary. The plan is shortened into an acronym, such as
SAFE.
 S – Sound the alarm

You can sound the alarm by yourself or call out someone to sound it.
This will allow the fire department to be on its way while other activities
are being performed.
 A – Alert others
Quickly tell others who in the area of the fire. Do this calmly and with
firm manner. Do not cause a panic. Secure the area for the fire
department. Close all doors and windows to prevent the spread of smoke
and flames. Call security to give verification and information about
location of fire.
 F – Fight the fire
Do this only when in the case of a manageable fire, the one that you
have the training and experience to fight. For example, fire in a
wastebasket. If possible, two employees should fight the fire together
using two fire extinguishers. If you have any doubt about your ability, it
is better to not attempt to combat it.
 E – Evacuate the area
If necessary, the burned are should be evacuated until the authorities
come. Alarm which is used for evacuation system is an alarm system
standard from OSHA. It applies to provide an early warning for
87
emergency actions or reaction time for employees to safely escape the

workplace, the immediate work area, or both.
6.7.2. Emergency Alarm and Fire Fighting Strategy

The emergency plan must include a way to alert employees using an alarm
system, which are installed to indicate the abnormal conditions and problems of
the plant and equipment to operators, enabling them to take preventive actions and
bring the plant back to normal conditions. The alarm must be distinctive and
recognized by all employees as a signal to evacuate the work area or perform
actions identified in the plan. The alarm to be used for the evacuation system has
been met by the standard from OSHA. Type of alarms that are used in the plant
are audible alarm and visible alarm.
1. Audible Alarm
Audible alarm is an alarm that includes bells, horns, sirens, voice
announcement systems, and other devices that can be distinguished above
and apart from the normal sound level within the workplace. This alarm
serves as the first sign of emergency.
Figure 6.2. Audible Alarms

(source: pfannenbergusa.com)
2. Visible Alarm
Visible or visual alarm is an alarm that use steady, flashing, or strobe lights
to alert workers to an emergency situation in areas where noise levels are
high, especially where ear protection must be worn and audible signals may
not be heard or may be misunderstood.
88
Figure 6.3. Visible Alarm

(source: oshatrain.org)
For the firefighting strategy, the plant should be installed with equipment,
such as light fire extinguisher (APAR), hydrant, and safety shower. Firefighting
equipment is equipment designed to extinguish fires or protect the user from fire.
It may be used by trained fire fighters, untrained users at the scene of a fire, or
built into a building's infrastructure.
6.7.3. Emergency Escape Strategy

Primary and secondary evacuation routes and exits must be provided when
preparing an emergency action plan. Exit route is a continuous and unobstructed
path of exit travel from any point within a workplace to a place of safety. The
purpose of the escape procedure is to help the employee evacuate to be
predetermined assembly areas whenever the alarm sounds. The procedure of the
emergency escape are as follows:
 In the event of an emergency, employees shall activate fire pull stations

without exposing themselves to serious hazards and leave the work area
as soon as possible via the emergency route assignments posted in your
immediate work area.
 All primary emergency escape routes and designated meeting locations
shall be provided to each employee by departmental managers as part of
the emergency planning process. These primary route and designated
meeting locations must be approved by the plant manager.
89
 An orderly evacuation shall be supervised by departmental managers,

line supervisors, and designated wardens who will check all
rooms/enclosed spaces and report any problems via telephone or radio
to plant security.
 Each local manager or supervisor shall provide for the specialized
evacuation of any handicapped employees.
6.8. Waste Management
Production processes in industry processing will almost always generate

waste in the form of solid, liquid, and/or gas. These types of waste must be further
treated before ejected into the environment, as they contained toxic chemicals
which is fatal when thrown nonchalantly. In the main production line, the waste,
as stated above, have three kinds of phase, which are: solid, liquid, and gas. All
three phases have different treatments.
Table 6.2. Waste Identifications
No Waste Origin Main Components Classification

.
1 Vent Gas Fermenters Carbon dioxide, Gas Waste
nitrogen, oxygen
2 Biomass Centrifuge Water and other Solid Waste
nutrients
3 Reject Stream Centrifugal Water and heavy Liquid Waste
Extractors solvents
4 Reject Stream Ion Exchange Water and others Liquid Waste
6.8.1.Liquid Waste Management

The liquid waste from this plant, which is from the reject stream from
centrifugal extractors and ion exchange chromatography, will be utilized by the
wastewater treatment utilities of this plant. The treatment uses a combination of
physical and biological processes to purify wastewater. These treatment processes
are broken down into five major phases: Preliminary treatment, Primary
treatment, Secondary treatment, Disinfection treatment, and Sludge treatment.
The preliminary treatment is a physical process of using large bars or

screens to remove large pieces of garbage from the incoming wastewater
90
(influent). Primary treatment is done by sedimentation of wastewater through

clarifier, which permits heavier solids to settle to the bottom of the tank, while
lighter particles float to the top. The secondary treatment (activated sludge
process) is a biological phase where microorganism breaks down organic
particles. The aerated wastewater moves into a secondary clarifier, where
additional particles can sink to the bottom (secondary sludge) and be physically
removed. The remaining wastewater now passes into the disinfection phase. The
disinfection treatment is done through the use of a UV chamber, whereby harmful
microorganisms and biomass that were produced inside the aerobic tanks are
killed, allowing the wastewater to be free of microorganisms. Upon completion of
this process, the treated wastewater is moved to the last clarifier, whereby the
clarified stream is now referred to as “effluent” and is approved for release into
local waterways (streams, rivers, lakes).
6.8.2. Solid Waste Management

The solid waste from the production of vitamin B12 is the biomass waste
from the separation process using centrifuge. Based on Peraturan Pemerintah
Republik Indonesia No. 18 Tahun 1999 about Pengelolaan Limbah Bahan
Berbahaya, from industrial are temporary keep in temporary shelter and are sent
to third party for further treatment.
6.8.3. Gas Waste Management

The gas waste from this plant is from fermenters and freeze dryer. The
gaseous waste consists of carbon dioxide, and regular air. Based on Keputusan
Menteri Negara Lingkungan Hidup No. Kep-13/MENLH/1995 about Baku Mutu
Emisi Sumber Tidak Begerak, the standard of carbon dioxide waste that can be
released to the air is 5000 ppm. To determine if the gas waste has bad impact or
not to the environment, it is needed to see the concentration of the components of
ammonium, HCl, and carbon dioxide in the waste.
Table 6.3. Carbon Dioxide Concentration Calculation
Concentration
Component
g/L ppm
91
Carbon dioxide from Pre-Seed Fermenter 0.00377 3.77

Carbon dioxide from Seed Fermenter 0.06954 69.54
Carbon dioxide from Main Fermenter 0.01242 12.42
Because the concentration of carbon dioxide released is less than the

standard or 5000 ppm, we can directly release the gas waste into the environment
through regular venting for carbon dioxide emission because it is not dangerous
for the environment.
CHAPTER 7
ECONOMIC ANALYSIS
7.1 Cost Estimate Assumption

There are certain assumptions to be used in the project, which can be seen as
follows:
 The plant will be constructed from the start to end of 2021
 The plant manufacturing will start at the beginning of 2022, and the
plant lifetime will be until 2041.
 The exchange rate from USD to IDR is 1 USD = IDR 14,200
 There are 330 days in 1 operation year.
 The production capacity is 2,680kg/ year
 MARR is assumed to be the same as WACC
 Income tax is constant at the rate of 25%
7.2 Cost Index

The index used for capital estimation is the Chemical Engineering Plant
Cost Index (CEPCI). In this analysis, this index is used to predict equipment price
in current year.
CEPCI vs. Year

800
700
600 f(x) = 9.67 x + 199.55
R² = 0.94
500
400
CEPCI
300
200
100
0
Year
CEPCI Linear (CEPCI) Linear (CEPCI) Linear (CEPCI)
Figure 7.1. Chemical Engineering Plant Cost Index

(source: CEPCI Online, 2018)
93
Table 7.1. Chemical Engineering Plant Cost Index
Year CEPCI Year CEPCI

1976 192.1 1999 390.6
1977 204.1 2000 394.1
1978 218.8 2001 394.3
1979 238.7 2002 395.6
1980 261.2 2003 402
1981 297 2004 444.2
1982 314 2005 468.2
1983 317 2006 499.6
1984 322.7 2007 525.4
1985 325.3 2008 575.4
1986 318.4 2009 521.9
1987 323.8 2010 550.8
1988 342.5 2011 585.7
1989 355.4 2012 584.6
1990 357.6 2013 567.3
1991 361.3 2014 576.1
1992 358.2 2015 556.8
1993 359.2 2016 541.7
1994 368.1 2017 567.5
1995 381.1 2018 603.1
1996 381.7 2019 636.4
1997 386.5 2020 671.5
1998 389.5 2021 708.5
(source: CEPCI Online, 2018)
7.3 Capital Expenditure

The calculation of capital expenditure follows the preliminary method
named Modular Guthrie Method:
C TCI =1.18 ( CTBM +C site +Cbuildings +C offsite facilites ) + CWC
The nomenclature used in the formula interprets the total bare modul cost
(CTBM), site cost (Csite), building cost, (Cbuildings), and offsite facilities (Coffsite facilities)
to be classified as fixed capital. The factor 0.18 implies the estimation of
contingency and contractor fee. It is noted that the cost for start-up is not included
in this equation and will be counted at the overall capital investment.
94
7.3.1 Total Bare Module Cost

Total bare-module cost, CTBM, refers to the summation of bare-module costs
for all items of process equipment. The bare-module cost is based on the f.o.b.
equipment purchase cost, to which is factored in direct field materials and labor,
and indirect expenses such as freight, insurance, taxes, overhead, and engineering.
The f.o.b. price obtained must be adjusted to inflation to when the equipment will
be bought, as the price of equipment might fluctuate over time. The approach is to
convert the cost using the cost index described beforehand.
Bare module factor includes all costs contributing to the equipment prior to
the installment in the plant. The bare-module factors for widely used for
equipment are tabulated on the Appendix B.
7.3.1.1 Purchase Cost Calculation

The purchase cost is done through equations provided by Seider, et al.
(2016). The cost estimation is done using factored-cost methods based on the free
on board (f.o.b) purchase cost of the process equipment, which is provided for the
most widely used chemical processing equipments. The equipment costs are based
on a number of literature articles and book chapters that have been presented since
1949, in which it will include the cost index at the time to be adjusted for inflation
at the time of choosing. For less widely used equipments, the purchase cost is
obtained directly from vendors, corrected by the capacity and inflation if
necessary. The equations used in calculating the purchase cost of each process
equipments are tabulated below. Note: Constants an should be referred to Seider’s
Product and Process Design Principles: Synthesis, Analysis, and Evaluation, pg.
449-485 (2016).
Table 7.2. Purchase Cost Equations
Equipment Equation
Fermenter, Mixers, and Separator C P =F M C V +C PL
(Vertical Pressure Vessel) C V =exp ⁡{a1 +a 2 [ ln ( W ) ] + a3 ¿
C PL =410 ( D i )0.74 ( L )0.706
Centrifuge C P =2,440 ( D )1.11
95
Dryer C P =4,400 ( A )0.35

Table 7.2. Purchase Cost Equations (cont’d)
Equipment Equation
Storage Tank (Spherical, 0-30 psig) C P =68 (V )0.72
Air Filter (Gas permeation) C P =51(A )
Clarifier (Steel) C P =3,460 ( A )0.58
Clarifier (Concrete) C P =2,450 ( A )0.58
Pump C P =F T F M C B
C B=exp ⁡{a 1+ a2 [ ln ( S ) ]+ a3 ¿
Electric Motor (for Pump) C P =F T C B
C B=exp ⁡{a 1+ a2 [ ln ( PC ) ] +a3 ¿
Heat Exchanger (S&T, Floating head) C B=exp ⁡{a 1+ a2 [ ln ( A ) ]+ a3 ¿

Heat Exchanger (Double pipe) C B=exp ⁡{a 1+ a2 [ ln ( A ) ] }
Activated Carbon C P =41(S)
Sterilizer C P =F M C B
C B=3(W )
Reverse Osmosis Unit C BM =3.1(Q)
Ion Exchange Unit Graph
Wastewater Treatment C P =99,790 (Q )0.64
Fired heater (Furnace) C P =F P F M C B
C B=exp ⁡{a 1+ a2 [ ln ( Q ) ] }
Agitator C P =3,740 ( S )0.17
7.3.1.2 Total Bare Module-Factor Estimation

The purchase f.o.b. equipment price data obtained through equation,
historical data, or real data is converted into installed price with the factor known
as bare-module factor. This factor includes all cost contributing to the equipments
prior to the installment in the plant. The bare-module factor for widely used
equipments are tabulated as follow.
96
Table 7.3. Bare Module Factor

Description Bare-Module Factor (FBM)
Furnaces and direct-fired heaters,
2.19
shop fabricated
Furnaces and direct-fired heaters,
1.86
field-fabricated
Shell-and-tube heat exchangers 3.17
Double-pipe heat exchangers 1.8
Fin-tube air coolers 2.17
Vertical pressure vessels 4.16
Horizontal pressure vessels 3.05
Pumps and drivers 3.3
Gas compressors and drivers 2.15
Centrifuges 2.03
Horizontal conveyors 1.61
Bucket conveyors 1.84
Crushers 1.39
Mills 2.3
Crystallizers 2.06
Dryers 2.06
Evaporators 2.45
Filters 2.32
Flakers 2.05
Screens 1.73
Splitters and mixers 2.03
Storage 1.83
Acid gas removal 1.56
Heliostat field and Towers 1.25
The final price of the equipment that have been multiplied by the bare-
module factors are tabulated below.
97
Table 7.4. Final Cost of Process Equipment
COS
T
PRICE
INDE
IN PRICE TOTAL TOTAL
QT X IN
CODE Y
YEAR IN 2021 FBM PRICE PRICE
YEA
BASIS (USD) (USD) (IDR)
R
(USD)
BASI
S
FERMENTER & MIXER
SFR-
1 567 15,675 19,587 4.16 8,148 115,705,599
101
SFR-
1 567 58,348 72,910 4.16 303,304 4,306,920,210
102
FR-
101/FR- 80,701,758,77
3 567 364,438 455,386 4.16 5,683,222
102/FR- 4
103
V-101 1 567 59,997 74,970 4.16 311,874 4,428,614,269
20,680,993,68
V-102 1 567 280,177 350,098 4.16 1,456,408
5
11,289,912,18
V-103 1 567 152,951 191,121 4.16 795,064
2
STERILIZER
ST-101 1 567 564 705 1.8 1,269 18,014,784
ST-102 1 567 10,048 12,556 1.8 22,600 320,921,594
ST-103 1 708.5 3,500 3,500 1 3,500 49,700,000
ST-104 1 567 3,870 4,836 1.8 8,705 123,613,707
SEPARATOR
EXC-
1 567 60,551 75,661 4.16 314,752 4,500,948,290
101
EXC-
1 567 237,292 296,511 4.16 1,233,485 17,638,833,955
102
EXC-
1 567 142,519 178,085 4.16 740,836 10,593,948,807
103
BLOWER
G-101 1 567 32,270 40,323 2.15 86,694 1,239,727,917
E-16 1 567 9,829 12,282 2.15 26,406 377,606,351
PUMP
P-101 1 567 2,825 3,530 3.3 11,651 166,603,660
P-102 1 567 2,328 2,909 3.3 9,600 137,282,900
P-103 1 567 3,026 3,781 3.3 12,478 178,432,041
P-104 1 567 2,509 3,136 3.3 10,348 147,975,259
P-105 1 567 3,040 3,798 3.3 12,534 179,233,493
P-106 1 567 3,117 3,894 3.3 12,851 183,773,262
P-111 1 567 2,337 2,920 3.3 9,638 137,816,298
P-112 1 567 3,157 3,945 3.3 13,019 186,167,832
98
Table 7.4. Final Cost of Process Equipment (cont’d)
COS
T
IND PRICE
EX IN PRICE TOTAL
QT TOTAL
CODE Y
IN YEAR IN 2021 FBM PRICE
PRICE (IDR)
YEA BASIS (USD) (USD)
R (USD)
BAS
IS
P-113 1 567 3,047 3,807 3.3 12,564 179,660,344
P-114 1 567 2,442 3,051 3.3 10,068 143,967,656
P-115 1 567 2,313 2,890 3.3 9,536 136,363,080
P-116 1 567 2,730 3,412 3.3 11,259 161,000,135
P-117 1 567 2,790 3,486 3.3 11,503 164,492,388
PM-101 1 567 2,500 3,125 3.3 10,311 147,446,065
PM-102 1 567 2,213 2,765 3.3 9,125 130,493,438
PM-103 1 567 2,717 3,396 3.3 11,206 160,239,689
PM-104 1 567 2,524 3,153 3.3 10,406 148,806,211
P-201 1 567 3,829 4,784 3.3 15,788 225,774,537
P-202 1 567 3,900 4,873 3.3 16,081 229,963,774
P-203 1 567 2,448 3,058 3.3 10,093 144,328,380
P-204 1 567 2,626 3,282 3.3 10,830 154,866,477
P-205 1 567 2,586 3,231 3.3 10,662 152,467,572
P-206 1 567 2,566 3,206 3.3 10,580 151,292,288
STORAGE TANK
STR-
1 567 500 625 1 625 8,934,347
101
ST-201 1 567 2,401 3,001 1.83 5,491 78,527,611
V-104 1 567 5,045 6,304 1.83 11,536 164,965,592
V-105 1 567 11,656 14,565 1.83 26,654 381,154,765
V-106 1 567 24,542 30,666 1.83 56,119 802,505,424
V-107 1 567 10,185 12,727 1.83 23,291 333,060,765
HEAT EXCHANGER
HX-101 1 567 5,094 6,366 1.8 11,458 163,851,372
HX-102 1 567 3,632 4,539 1.8 8,170 116,828,510
HX-103 1 567 67,914 84,863 3.17 269,015 3,846,909,162
HX-104 1 567 6,328 7,908 1.8 14,234 203,544,598
HX-105 1 567 114,309 142,836 3.17 452,790 6,474,900,500
HX-106 1 567 76,627 95,750 3.17 303,527 4,340,432,524
AIR FILTER UNIT
AF-101 1 567 439.17 549 1 549 7,847,416
AF-102 1 567 268.99 336 1 336 4,806,542
99
COS
T
IND PRICE
EX IN PRICE TOTAL
QT TOTAL
CODE Y
PRICE (IDR)
R (USD)
BAS
IS
CENTRIFUGAL UNIT
19,500.0
DC-101 1 567 24,366 2.03 49,464 707,332,287
0
EXTRACTION UNIT
CX-101 1 567 6,182 7,725 2.03 15,682 224,257,629
ION EXCHANGE UNIT
INX-
1 567 12,450 15,557 1.83 28,469 407,111,410
101
WS-201 2 567 17,535 21,911 1.83 80,194 1,146,778,887
FREEZE DRYING UNIT
FDR-
1 567 56,558 70,673 2.06 145,586 2,081,880,128
101
CLARIFYING UNIT
CR-201 1 567 17,835 22,286 1.83 40,784 583,213,713
CR-202 1 567 1,843 2,302 1.83 4,214 60,253,066
CR-203 1 567 1,772 2,214 1.83 4,051 57,933,617
CR-204 1 567 1,628 2,034 1.83 3,723 53,238,239
ADSORPTION UNIT
AC-201 2 567 5,676 7,092 1.83 25,958 371,192,314
FILTRATION UNIT
SF-201 2 567 15,376 19,213 1.83 70,318 1,005,553,411
REVERSE OSMOSIS UNIT
RO-201 2 747.6 7,200 6,823 1 13,647 195,150,241
WASTEWATER TREATMENT UNIT
GT-201
+ AT-
1 747.6 336,049 318,473 1 318,473 4,554,168,691
201 +
UV-201
BOILING UNIT
SG-201 1 567 57,906 72,357 1.86 134,584 1,924,555,592
AGITATOR
SFR-
1 567 1,389 1,736 1 1,736 24,822,138
101
SFR-
1 567 3,576 4,469 1 4,469 63,901,877
102
100
COS
T
IND PRICE
EX IN PRICE TOTAL
QT TOTAL
CODE Y
PRICE (IDR)
R (USD)
BAS
IS
FR-
101/FR-
3 567 8,444 10,552 1 31,655 452,669,143
102/FR-
103
V-101 1 567 1,787 2,233 1 2,233 31,926,391
V-102 1 567 3,852 4,813 1 4,813 68,831,040
V-103 1 567 3,587 4,482 1 4,482 64,090,665
USD IDR
TOTAL EQUIPMENT COST 13,426,728 191,142,796,509
7.3.2 Land Site Development Cost

The plant is located at Kabupaten Malang, East Java. The plant has an
overall area of 7,350 m2. Site cost is obtained from the calculation of land cost and
site development. The land price in the area is in the average of Rp450.000, and
the land will be bought, not rented. The cost for land is estimated as follow.
Table 7.5. Land Cost
PRICE PER M2 PRICE PER M2 AREA TOTAL COST

(RP) (USD) (M2) (USD)
450,000 31.69 7,350 232,900
Cost for site preparation and development are consists of making land
survey, dewatering and drainage, surface clearing, rock blasting, excavation,
grading, piling, addition of fencing, roads, sidewalks, sewer lines, and
landscaping. Costs for site preparation and development. Cost for site preparation
and development can be substantial for grass-roots plants, in the range of 10-20%
of the total bare-module cost of the equipment, and 4-6% for an addition to and
integrated complex. Based on this, we could assume the site development cost is
15% of CTBM. The total result for site cost (Csite) is the land cost and site
development cost.
101
102
Table 7.6. Total Land and Site Cost
Description Total Cost (USD)

Land 232,900
Csite (15% CTBM) 2,014,009
Cland and site 2,246,909
7.3.3 Building Cost

The building components are construction labor, equipment installation,
insulation, foundation or support, safety device, etc. Building costs include
process buildings and non-process buildings. The assumption for the building cost
is based on Seider, et al. 2003. For the process building cost, the first
consideration is whether some or all the process equipment must be housed in
buildings because of weather or other conditions. If the equipment is housed, the
cost of process buildings may be estimated at 10% of C TBM. If a grass-roots plant
is being considered, the non-process buildings may be estimated at 20% of C TBM.
If the process is to be an addition to an integrated complex, the non-process
buildings may be estimated at 5% of CTBM. The area needed for building is
calculated based on indoor facilities area given on the table below.
103
Table 7.7. Indoor Facilities Area
FACILITY DIMENSION (M) AREA (M2)

MAIN PROCESS ROOM 39.5 38.5 1520.75
STEAM UTILITY 11 14.5 159.5
WATER UTILITY 12 9 108
WWTP 11 20 220
RAW MATERIAL STORAGE ROOM 7.5 11 82.5
PRODUCT STORAGE ROOM 14 8.5 119
OFFICE 16.5 38.5 635.25
CONTROL ROOM 7.5 23.5 176.25
LABORATORY 7.5 15 112.5
FUNCTIONAL HALL 19 11 209
HSE ROOM 7.5 9.5 71.25
MAINTENANCE ROOM 6 7.5 45
POWER PLANT 9 6 54
CLINIC 4.5 15 67.5
MOSQUE 9 15 135
CANTEEN 13.5 9.5 128.25
SECURITY POST 6 5.5 33
TOILET 6 4 24
TOTAL 3900.75
The calculation of building cost is tabulated as follow.
Table 7.8. Building Cost
Price per m2 Price per m2 Area Total Cost

Description
(Rp) (USD) (m2) (USD)
Building 2,500,000 176.06 3,901 686,752
Foundation 10% from land cost 23,300
Contractors 3% from land cost 7,000
Total 717,052
7.3.4 Supporting Facilities Cost

Supporting facilities include the supporting equipment cost for clerical work
and utility installation cost. Supporting facilities are the equipment needed to
accelerate production process directly and indirectly. Supporting facilities
includes the equipment in office, personal protection equipment, transportation
and many more.
104
Table 7.9. Supporting Facilities Cost
Equipment Specification Qty Unit Price Total Price Total Price

(IDR) (IDR) (USD)
Main Process Room
CCTV Hikvision DS-2CD1123G0E-I IPCam IPCamera 4 583,000 2,332,000 164
LED Lamps PHILIPS 31093 TrunkLinea 4W 250lm 3000K wall 12 62,900 754,800 53
lamp LED
Fire APAR Chemguard 6 kg 4 265,000 1,060,000 75
Extinguisher
Control Room
Computer Set Lenovo M72E 2 6,872,000 13,744,000 968
Air Panasonic CS-LN7UKJ 1 3,349,000 3,349,000 236
Conditioner
CCTV Hikvision DS-2CD1123G0E-I IPCam IPCamera 1 583,000 583,000 41
Office Desk F - Center 2 899,000 1,798,000 127
Office Chair Fantoni 2 570,000 1,140,000 80
Telephone Sahitel Single Line S75 1 175,000 175,000 12
LED Lamp PHILIPS 31093 TrunkLinea 4W 250lm 3000K wall 1 62,900 62,900 4
lamp LED
Laboratory Set 1 30,000,000 30,000,000 2,113
Utility Room
lamp LED
Fire APAR Chemguard 6 kg 3 265,000 795,000 56
Extinguisher
105
Table 7.9. Supporting Facilities Cost (cont’d)

(IDR) (IDR) (USD)
Storage Room 0 0
lamp LED
Fire Extinguisher APAR Chemguard 6 kg 1 265,000 265,000 19
Clinic, Musholla, and Canteen
Kitchen Tool Oxone OX 963 1 165,000 165,000 12
Dispenser MASPION WATER DISPENSER MD-106 PAS-HNC 2 775,000 1,550,000 109
LED Lamp PHILIPS 31093 TrunkLinea 4W 250lm 3000K wall 8 62,900 503,200 35
lamp LED
Table & Chair Krisbow 4 778,050 3,112,200 219
Air Conditioner Panasonic CS-LN7UKJ 4 3,349,000 13,396,000 943
Clock Sakana 3 85,000 255,000 18
Carpet Roll 2 518,000 1,036,000 73
Medical 1 80,000,000 80,000,000 5,634
Facilities
Kitchen Set 1 2,500,000 2,500,000 176
Office
Telephone Sahitel Single Line S75 8 175,000 1,400,000 99
Air Conditioner Panasonic CS-LN7UKJ 6 3,349,000 20,094,000 1,415
Desktop Lenovo M72E 15 6,872,000 103,080,000 7,259
Computers
106

(IDR) (IDR) (USD)
Photocopy Set Kyocera ECOSYS M2040dn 2 6,000,000 12,000,000 845
Projector and 1 5,000,000 5,000,000 352
Screen
Whiteboard Keiko White Board Double Face Stand Papan Tulis [60 2 798,000 1,596,000 112
x 120 cm]
Sofa 1 3,200,000 3,200,000 225
Office Chairs 35 364,000 12,740,000 897
Office Desks 30 565,000 16,950,000 1,194
Meeting Table 1 3,860,000 3,860,000 272
Fax Panasonic KX-FT983 CX 1 2,050,000 2,050,000 144
Printer and Canon G2000 10 850,000 8,500,000 599
Scanner
Clock Sakana 6 85,000 510,000 36
Trashbin 10 79,200 792,000 56
Locker 1 2,159,900 2,159,900 152
lamp LED
Receptionist Modera MRB 1112 1 4,537,000 4,537,000 320
Desk
Functional Hall
107
Equipment Specification Qt Unit Price Total Price Total Price

y (IDR) (IDR) (USD)
lamp LED
Air Conditioner Panasonic CS-LN7UKJ 4 3,349,000 13,396,000 943
Chair Chitose 40 146,500 5,860,000 413
Toilet
Toilet Seat and 6 3,500,000 21,000,000 1,479
Bidet Spray
Wastafel 4 1,025,000 4,100,000 289
Led Lamp Hikvision DS-2CD1123G0E-I IPCam IPCamera 4 62,900 251,600 18
Urinal 6 2,368,000 14,208,000 1,001
Others
Mobil Box Daihatsu Grand Max 2019 1 139,800,000 139,800,000 9,845
Hydrant Pillar ZEKI Two Way Hydrant Pillar 2 3,250,000 6,500,000 458
Hydrant Box Hydrant Box Type C 2 960,000 1,920,000 135
Emergency Stainless material 2 5,800,000 11,600,000 817
Eyewash and
Shower Set
TOTAL 588,976,000 41,477
The utility installation is tabulated as follow.
Table 7.10. Utility Installation Cost
Utilities Notes Cost (IDR) Cost (USD)

Electricity PLN Installation Cost 200,000,000 14,085
Water PDAM Installation Cost 100,000,000 7,042
Fire Alarm System 1,750,000 123
Hydrants 100,000,000 7,042
TOTAL 401,750,000 28,292
7.3.5 Contingency Cost and Contractor Cost

Contingency cost is an unanticipated cost incurred during the construction
of a plant. To account the cost of contingencies, it is common to set aside 15% of
direct permanent investment. The value of direct permanent investment is the sum
of equipment cost, site cost, building cost, and offsite facilities cost. In addition,
Guthrie (1969) also adds a contractor fee of 3% of the direct permanent
investment. The contingency and contractor cost are tabulated as follow.
Table 7.11. Contingency and Contractor Costs
Description Notes Cost (USD)

Direct Permanent Investment
CTBM+Csite+Cbuilding+Coffsite 16,462,923
(CDPI)
Contingency 15%CDPI 2,469,438
Contractor Fee 3%CDPI 493,888
7.3.6 Plant Startup Cost

Plant startup cost accounts for two main objects, those incurred by contractor in
checking equipment performance, calibrating controller, and other plant
equipment, and commissioning the plant, and those incurred by the plan operating
personnel when starting up and shutting down the plant. The plant startup cost is
estimated at 10% of the total depreciable capital.
Table 7.12. Plant Startup Cost

CDPI + Contingency and
Total Depreciable Capital (CTDC) 19,426,249
Contractor Fee
Plant Startup 10% CTDC 1,942,625
109
7.3.7 Working Capital

Working capital is funds needed by a company to meet its obligations until
payments are received from others for goods they have received. It is fairly
standard to provide working capital for a one-month period of plant operation,
because those buying the product are usually given 30 days to make their
payments, while the company has 30 days to pay for raw materials. Inventories of
products may be much less than 30 days. Here, 7 days is assumed (Seider, 2009).
Working capital can be calculated in two methods. First, calculate the operation
cost needed until the plant receive its first income, typically the periode of
working capital is one month. Second, as with the Lang-factor method, the
working capital can be estimated at 15% of the total capital investment, which is
equivalent to 17.6% of the total permanent investment.
Table 7.13. Working Capital Cost

Total Permanent Investment (CTPI) CTDC + Plant Startup 21,368,874
Working Capital (CWC) 17.6%CTPI 3,760,922
7.3.8 Capital Expenditure Summary

The capital expenditure summary of the plant is as follows.
Table 7.14. Capital Expenditure Summary
Description Cost (USD)

Equipment Cost (CTBM) 15,481,503
Site Cost (Csite) 2,555,125
Building Cost (Cbuilding) 717,052
Offsite Facilities (Coffsite) 72,234
Direct Permanent Investment (CDPI) 18,825,914
Contingency 2,823,887
Contractor Fee 564,777
Total Depreciable Capital (CTDC) 22,214,579
Plant Startup 2,221,458
Total Permanent Investment (CTPI) 24,436,037
Working Capital (CWC) 4,300,742
Total Capital Investment (TCI) 25,129,796
7.4 Capital Expenditure

110
7.4.1 Raw Material Cost

The cost for raw materials used in the plant, are as follows, which considers
the supplier, price of raw material, and shipping cost.
111
Table 7.15. Raw Material Cost
Price of
Needs Needs Shipping Total Total
Needs Raw Shipping
Raw per per Cost per Shipping Cost per
Supplier per year Material Distance
Material batch month kg per km Cost year
(kg) per kg (km)
(kg) (kg) (USD) (USD) (USD)
(USD)
PT. Sinar
Molasses 178.49 469.71 5,636.53 0.50 0.017 25 2,423.71 5,221.68
Mas
CV. Kimia
Nutrients 5,073.29 13,350.7 160,209 0.80 0.003 450 213,078.1 341,613.9
Asia
P.
Mikrobiologi
denitrific 0.001 0.003 0.03 10.64 0.003 860 0.08 0.42
Shop
ans
CV. Anugrah
NaOH Mineral 2,956.49 7,780.24 93,362.8 0.50 0.003 290 74,690.27 121,371.6
Industri
PT. Insoclay
NaCN Acidatama 8 21.05 252.63 0.08 0.007 200 341.05 361.64
Indonesia
PT. Pelita
NaNO2 Abadi 200 526.32 6,315.79 0.03 0.001 960 8,526.32 8,732.15
Sentosa
112
Table 7.15. Raw Material Cost (cont’d)
Price of
Needs Needs Shipping Total Total
Raw Shipping
Raw per per Needs per Cost per Shipping Cost per
Supplier Material Distance
Material batch month year (kg) kg per km Cost year
per kg (km)
(kg) (kg) (USD) (USD) (USD)
(USD)
PT. Guna
Cresol Mulia 100 263.16 3,157.89 0.20 0.002 840 4,263.16 4,883.43
Medika
PT. Rosma
HCl 1.95 5.13 61.58 0.01 0.002 1365 157.03 157.69
Bana Utama
PT.
Insoclay
Ammonia 0.91 2.39 28.63 0 0.007 200 38.65 38.74
Acidatama
Indonesia
PT. Artha
Liquid
Gemilang 64.00 168.42 2,021.05 0.40 0.0017 1365 4,729.26 5,537.68
nitrogen
Utama
TOTAL 308,247.71 487,919.1
113
7.4.2 Labor Salary Cost

The labors that will be working in the plant can be divided into 2 groups,
which are direct and indirect labor. Direct labors are in charge of operational
processes in the plant, wherein the indirect labors are responsible for monitoring
of the plant and maintaining good relationship with its stakeholders.
The wage for the labor are based on its minimum wage, which is in
Malang, East Jawa which can be seen as follows.
Table 7.16. Workers Availability in Malang in 2020
Total Labours 141,906

Minimum Wage Rp2,895,502
(Source: Reproduced from Badan Pusat Statistika Malang, 2020)
On this section will be discussed the direct labor cost, wherein the indirect
labor cost will be discussed in the general cost section. The direct labor cost is
based on the number of labors present, such as operators, control room labor, and
analyst, which ensures smooth operation of the plant. The cost covers the direct
wage and benefits of the operators. The estimations of all labor-related operations
are based on Seider et al. (2003) in the range of 10 – 100 bb/day of products,
which can be seen as follows.
Table 7.17. Labor Required for Plant Operations
(Source: Seider et al., 2003)
The operation in the plant is batch operation, which 2 main process

operator, 2 separation and purification operator, 3 utility operator, 1 foreman, 1
controller labor, and 5 warehouse labor. The detailed table can be seen as below.
Table 7.18. Labor Salary Cost

114
Salary per month Total Salary

Position Amount (person)
per person (USD) (USD)
Main process
2 213 5.538
operator
Separation and
purification 2 213 5.538
operator
Utility operator 3 213 8.307
Foreman 1 284 3.692
Controller
1 284 3.692
labor
Warehouse
5 213 13.845
labor
TOTAL DIRECT LABOR COST 40.612
In estimating the cost of labor salary, we consider the increase in wages

each year. The amount of the wage increase is determined by looking at the
history of wage for Malang City in the previous year which are showed in the
table below. From the data on wage increases in the last five years, we assume
that labor salary will increase by 8 percent annually. From the total present value
calculated, the annual value of 79,133 USD is obtained for Labor Salary Cost.
Table 7.19. Salary Increase Rate Calculation
YEAR MINIMUM INCREASE

SALARY RATE (%)
(UMK)
2015 1,882,250
2016 2,099,000 11.5%
2017 2,272,170 8.3%
2018 2,470,073 8.7%
2019 2,668,420 8.0%
2020 2,895,502 8.5%
2021 2,970,502 2.6%
AVERAGE INCREASE 8.0%
Table 7.20. Direct Labor Salary Cost Calculation
Total Salary per Year

Years Present Value
(Future Value)
115
2022 40,612 38,099

2023 43,861 38,602
2024 47,370 39,110
2025 51,159 39,626
2026 55,252 40,148
2027 59,672 40,677
2028 64,446 41,213
2029 69,602 41,757
2030 75,170 42,307
2031 81,184 42,865
2032 87,678 43,430
2033 94,693 44,002
2034 102,268 44,582
2035 110,449 45,170
2036 119,285 45,765
2037 128,828 46,368
2038 139,134 46,979
2039 150,265 47,599
2040 162,286 48,226
2041 175,269 48,862
Total 1,858,485 865,386
7.4.3 Utility Cost

Utility costs are needed to support main process of plant, it can be
categorized to electricity, water, and fuel cost. Electricity of the plant is obtained
from PLN with classification of i-1/3500 VA s.d. 14 kVA as the cost of electric
per kWh is 0.079 USD. Water cost consisted of water consumption by domestic
water, water for process, water for steam generation, cooling water, chilled water,
and makeup water. Fuel is used to produce steam at boiler and backup generator.
While type of fuel used for this plant is natural gas. Here are the summary of
utilities cost.
Table 7.21. Electricity of Main Equipments Cost
Pow
Workin Total Total Total Total
er
Qt g Power/ba Power/ Power/y Cost/y
Equipments (kW
y Time/ba tch day ear ear
) per
tch (h) (kWh) (kWh) (kWh) (USD)
unit
0.38
Seed Medium Blender 1 0.25 0.0956 1.08 356.32 28.15
3
Fermentation Medium 1.90
1 0.33 0.63 7.16 2,363 186.68
Blender 3
Cyanide Blender 1 0.67 0.17 0.11 1.29 426.45 33.69
116
3
Batch Sterilizer 1 0.95 0.08 0.08 0.89 294.99 23.3
Pre-Seed Fermenter 1 1.20 40.00 48.00 542.00 178,86 14,129
15.3
Seed Fermenter 1 30.00 460.50 5199.8 1,715,9 135,55
5
247.
Main Fermenter 3 168.00 124,765 11049 3,646,2 288,05
55
68.8
Centrifuge 1 4.00 275.20 3107.4 1,025,4 81,011
0
Freeze Dryer 1 6.72 8.00 53.76 607.04 200,32 15,825
Pump 27 0.61 17.25 284.63 3213.8 1,060,5 83,786
Blower 2 0.33 57.23 37.77 426.51 140,74 11,119
UV light 6 0.70 4.00 16.80 189.70 62,601 4,945.5
Condenser 1 26.7 2.00 53.40 602.98 198,98 15,719
TOTAL ELECTRICITY COST FOR MAIN EQUIPMENTS 650,42
Beside electric requirement for process equipment in the plant, supporting

equipment at office such as computer, air conditioner, lamp, etc. also considered
in total electric cost calculation.
Table 7.22. Electricity of Support Equipments Cost
Work Total
Power Total Total
Time/ Power/
Equipments Qty (kW)/ Power/year Cost/yea
week week
unit (kWh) r (USD)
(h) (kWh)
1,221,942.8
Computer 40 13.5 48 25,920 96,533.51
6
Telephone 12 0.2 168 403.2 19,008.00 1,501.63
CCTV 36 0.75 168 4,536 213,840.00 16,893.36
Photocopy
Machine,
6 2.5 48 720 33,942.86 2,681.49
Scanner, and
Printer
117
Projector and
7 2 48 672 31,680.00 2,502.72
screen
Dispenser 7 0.7 168 823.20 38,808 3,065.83
Television 5 3 48 720 33,942 2,681.49
Lamp 60 1.44 168 14,515 684,288 54,058.77
Total electricity cost for support equipments 179,918.8
Table 7.23. Water Requirement Cost

Water
Water Needs L/day m3/year Cost/year
(USD/m3)
Domestic water 38 12 13
Water for process 302 100 101
Water for steam
1,657 547 555
generation and HE
Cooling Water 291,199 96,096 97,566
Chilled Water 61,510 20,298 20,609
Makeup water 17,718 5,847 5,936
TOTAL 372,424 122,900 124,780
Table 7.24. Fuel Requirement Cost
Fuel Supply Mass Flow

No Code
Equipment (L/h)
1 Steam Boiler SG-101 192
2 Backup Generator 148
Working day/year 330
Total fuel needed (liter) /year 549,504
Total Price (USD)/year 346,342
Table 7.25. Summarized of Utility Cost
Summarized Utility Cost

Main Equipment Electricity 650,424
Support Equipment Electricity 179,919
Water Cost 124,780
Fuel Cost 346,342
Total Utilities 1,301,466
7.4.4 Maintenance Cost

Processing equipment must be kept in acceptable working order, with
repairs and replacement of parts made as needed. Maintenance is required for
118
production plant, office, and supporting equipment in order to achieve

continuously and optimal production activity. Maintenance cost for designed
vitamin B12 plant per year can be estimated as follow. This maintenance cost
doesn’t include periodic startup cost.
Table 7.26. Maintenance Cost
Type Cost (USD) Maintenance Cost (USD)

Supporting Facilities
Maintenance (3% of 41,477 1,244
Supporting Facilities Cost)
Factory, Warehouses and
Buildings (1% of cost of Csite, 2,963,961 29,640
DCs, and Cbuilding)
Equipments Maintenance (8%
13,426,728 1,007,005
of Total Bare Modul Cost)
Total (USD) 1,037,888.50
(Source: Gavin Towler, 2009)
7.4.5 Tax and Insurance Cost

The tax and insurance cost can be divided into 2 sections: the tax and
insurance section. The insurance section discusses the cost that is paid to protect
the company’s asset, in this case the employees, to the insurance company. The
calculation of insurance is based on Peraturan Pemerintah No. 84 Year 2010,
which can be calculated as below. The amount of tax is also calculated in the land
and building tax and salary tax.
Table 7.27. Insurance Cost
INSURANCE
Insurance Type Measurement Annual Cost (USD)
Plant Insurance 1% of TCI 251,297.96
Jaminan Kesehatan (BPJS
4% salary per month 563.66
Kesehatan)
Jaminan Kecelakaan Kerja
0.54% salary per month 76.09
(JKK)
Jaminan Kematian (JK) 0.3% salary per month 42.27
Total Insurance 251,979.99
Table 7.28. Land and Building Tax
Description Area (m2) Cost (USD)

NJOP Earth 7,350 232,922.54
119
NJOP Building 3,901 686,751.76

Total NJOP 919,674.30
NJOPTKP 704.23
NJOP for PBB 918,970.07
NJKP (40% NJOP) 367,588.03
Debted PBB (0.5% NJKP) 1,837.94
120
Table 7.29. Salary Tax
Salary
per Net Net
Total Salary
Amount month Insurance Bruto Position Income Income Taxable
Position Insurance Tax per
(person) per per month Income Cost per per Income
per year year
person Month year
(USD)
President
1 1,408 68.17 818.03 1,476.6 73.83 1,402.7 16,833 12,396.8 619.84
Director
Vice President
1 1,268 61.35 736.23 1,328.9 66.45 1,262.5 15,150 10,713.5 535.67
Director
Secretary of
President 1 563 27.27 327.21 590.65 29.53 561.12 6,733.3 2,296.77 114.84
Director
Finance
Accounting 1 599 28.97 347.66 627.56 31.38 596.19 7,154.2 2,717.60 135.88
Manager
Assistant
Finance 1 493 23.86 286.31 516.82 25.84 490.98 5,891.7 1,455.09 72.75
Manager
Legal Manager 1 634 30.68 368.11 664.48 33.22 631.25 7,575 3,138.44 156.92
Legal Staff 2 317 15.34 368.11 332.24 16.61 315.63 3,787.5 0.00 0.00
SCM Manager 2 634 30.68 736.23 664.48 33.22 631.25 7,575 3,138.44 313.84
Security 4 211 10.23 490.82 221.49 11.07 210.42 2,525 0.00 0.00
Receptionist 1 197 9.54 114.52 206.73 10.34 196.39 2,356.6 0.00 0.00
Cleaning
2 197 9.54 229.05 206.73 10.34 196.39 2,356.6 0.00 0.00
Service
121
Table 7.29. Salary Tax (cont’d)
Salary
per Net Net
Total Salary
per year year
person Month year
(USD)
Procurement &
Contract 1 563 27.27 327.21 590.65 29.53 561.12 6,733.3 2,296.77 114.84
Manager
Human
Resources 1 634 30.68 368.11 664.48 33.22 631.25 7,575 3,138.44 156.92
Manager
Human
Resources
Planning and 1 352 17.04 204.51 369.15 18.46 350.70 4,208.3 0.00 0.00
Recruitment
Coordinator
HSE Manager 1 634 30.68 368.11 664.48 33.22 631.25 7,575 3,138.44 156.92
Safety Engineer 2 528 25.56 613.52 553.73 27.69 526.05 6,312.5 1,875.93 187.59
Production &
Maintenance 1 634 30.68 368.11 664.48 33.22 631.25 7,575 3,138.44 156.92
Manager
Process
2 528 25.56 613.52 553.73 27.69 526.05 6,312.5 1,875.93 187.59
Engineer
Staff Engineer 2 528 25.56 613.52 553.73 27.69 526.05 6,312.5 1,875.93 187.59
Laboratory
1 634 30.68 368.11 664.48 33.22 631.25 7,575 3,138.44 156.92
Manager
122
Table 7.29. Salary Tax (cont’d)
Salary
per Net Net
Total Salary
per year year
person Month year
(USD)
Laboratory Staff 2 282 13.63 327.21 295.32 14.77 280.56 3,366.6 0.00 0.00
Product
Planning &
1 634 30.68 368.11 664.48 33.22 631.25 7,575 3,138.44 156.92
Development
Manager
Quality Control
1 317 15.34 184.06 332.24 16.61 315.63 3,787.5 0.00 0.00
Team
Quality Control
1 352 17.04 204.51 369.15 18.46 350.70 4,208.3 0.00 0.00
Supervisor
Marketing
1 634 30.68 368.11 664.48 33.22 631.25 7,575 3,138.44 156.92
Manager
Marketing Staff 2 317 15.34 368.11 332.24 16.61 315.63 3,787.5 0.00 0.00
Total 37 14,092 682.03 10,487.12 14,773.5 738.68 14,034.9 168,418 62,611.8 3,568.9
123
7.4.6 Safety Cost

The safety cost for the plant considers the basic safety and safety equipment cost
as follows.
Table 7.30. Basic Safety Cost
Price Total Price

Total Price Estimation
Equipments Qty per Unit per Unit
per Year (USD)
(USD) (USD)
First Aid Kit 15 7.41 111.15 333.45
Hydrant 15 88.86 1,332.90 1,332.90
TOTAL 1,666.35
Table 7.31. Safety Equipment Cost
PPE Cost
Price per Unit Amount of Total Cost per Year
Unit
(USD) Unit (USD)
Helmet 5.65 20 112.962
Ear plug 0.25 60 14.826
Gloves 0.09 60 5.507
Respirator 4.59 20 91.781
Safety
8.47 20 169.442
wear
Safety
10.00 20 200.000
shoes
Mask 17.65 60 1059.015
Eye wear 7.06 20 141.202
Total 1,795
7.4.7 General Cost

General cost are secondary costs that is outside of production activities. It
consists of executive salary cost, marketing and communication cost, and
distribution cost.
7.4.7.1 Executive Salary Cost

Executive salary cost is the salary cost of executives, such as the CEO,
VP, and so on. The list of the cost is shown in the table below.
Table 7.32. Executive Salary Cost

124
Executive Salary and Clerical Wage

Total
Salary/ Bonus and
Amount Salary/
Qualification Month Allowances
(Person) Year
(USD) (USD)
(USD)
President
1 1,408.4 - 16,901
Director
Vice
President 1 1,267.6 - 15,211
Stakeholder
Director
Secretary of
President 1 563.38 - 6,760.5
Director
Finance
Accounting 1 598.59 - 7183
Finance Manager
Department Assistant
Finance 1 492.96 - 5915.4
Manager
Legal
Legal 1 633.80 - 7605.6
Manager
Department
Legal Staff 2 316.90 - 3802.8
General Support
SCM
and Service 2 633.80 - 7605.6
Manager
Department
Security 4 211.27 - 2535.2
Receptionist 1 197.18 - 2366.1
General Support Cleaning
and Service 2 197.18 - 2366.1
Service
Department Procurement
& Contract 1 563.38 - 6760.5
Manager
Human
HRD
Resources 1 633.80 - 7605.6
Department
Manager
Human
Resources
HRD
Planning and 1 352.11 - 4225.3
Department
Recruitment
Coordinator
HSE
1 633.80 - 7605.6
Manager
HSE Department
Safety
2 528.17 - 6338
Engineer
Table 7.32. Executive Salary Cost (cont’d)
Qualification Amount Salary/ Bonus and Total

125
Salary/
Month Allowances
(Person) Year
(USD) (USD)
(USD)
Production
&
1 633.80 - 7605.6
Maintenance
Production and
Manager
Maintenance
Process
Department 2 528.17 - 6338
Engineer
Staff
2 528.17 - 6338
Engineer
Laboratory
Research and 1 633.80 - 7605.6
Manager
Development
Laboratory
Department 2 281.69 - 3380.2
Staff
Product
Planning &
1 633.80 - 7605.6
Developmen
Product Planning t Manager
and Quality
Development Control 1 316.90 - 3802.8
Department Team
Quality
Control 1 352.11 - 4225.3
Supervisor
Marketing
Sales and 1 633.80 - 7605.6
Manager
Marketing
Marketing
Department 2 316,90 - 3802.8
Staff
TOTAL INDIRECT WORKER COST 169,09
The calculation of executive salaries also uses the assumption that each
year there is a salary increase of 8%. By knowing that there is an 8% increase in
salary, we can predict the future value of wages for each year over the next 20
years. This value is then converted into present value, then into annual value.
From the total present value, the annual value of 329,491 USD is obtained for
Executive Salary Cost.
Table 7.33. Executive Salary Calculation
126
Total Salary per Year

Years Present Value
(Future Value)
2022 169,098.59 158,636
2023 182,262.48 160,727
2024 197,236.6 162,846
2025 213,015.52 164,992
2026 230,056.77 167,167
2027 248,461.31 169,37
2028 268,338.21 171,603
2029 289,805.27 173,865
2030 312,989.69 176,156
2031 338,028.87 178,478
2032 365,071.18 180,83
2033 394,276.87 183,214
2034 425,819.02 185,629
2035 459,884.54 188,075
2036 496,675.3 190,554
2037 536,409.33 193,066
2038 579,322.08 195,611
2039 625,667.84 198,189
2040 675,721.27 200,801
2041 729,778.97 203,448
Total 7,738,283.71 3,603,258
7.4.7.2 Marketing and Communication Cost

The marketing and communication cost are the cost used for marketing the
products and communication cost of the plant. The table is shown as below.
127
Table 7.34. Marketing Cost
Media Type Total Cost/year

Market Research 2535.21
Printed 676.06
Electronic 868
TOTAL MARKETING COST PER YEAR 4,079
Table 7.35. Communication Cost
Communication Cost (USD)

Mail 0
Internet and Telephone Operation 1680
Internet and Telephone Installation 280
Annual Communication Cost 1960
7.4.7.3 Distribution Cost

The finish product is distributed by the pickup box with the figure and
specification below:
Figure 7.2. Pick Up Box

(Source: Kargo Tech, 2019)
Table 7.36. Pick Up Box Specification
Specification
Type Pick Up Box
Brand Granmax
Power Diesel
Transmission Type Manual
Tank Volume 1298 cc
Total Pick Up Box 1
128
With the consideration of 13.04 kg/batch vitamin B12 produced, the pretty
light capacity truck, 0-2,722 kg was chosen. Therefore, the vehicle used for
product distribution is 1 truck.
Furthermore, the cost of distribution is seen as below.
Table 7.37. Distribution Cost
Product Distribution
Routes per month 2
Routes per year 24
Truck Needed per Route 1
Fuel needed per route (Litre) 1
Fuel price (Solar) per Litre (USD) 0.43
Fuel needed per year (Litre) 12
Total fuel cost 5.16
courier service per route (USD) 6.67
Total courier service per year (USD) 160.00
Total Distribution Cost per Year 165.16
7.4.8 Depreciation
Depreciation is a decrease in an asset's value, may be caused by a number of
other factors as well such as unfavorable market conditions, etc. The capital
investment in the beginning of the project will lose its fraction of value into
salvage value at the end of the project. Salvage value is the estimated trade-in or
market value at the end of the asset’s useful life. The salvage value, S expressed
as an estimated dollar amount or as a percentage of the first cost, may be positive,
zero, or negative due to dismantling and carry-away costs. In general, all property
with a limited useful life of more than 1 year that is used for the production of
income, is depreciable. Physical facilities, including such costs as design and
engineering, shipping, and field erection, are depreciable.
Depreciation is calculated throughout the process equipment, supporting

equipment, and buildings, with Declining Balance Method. The declining balance
method is an accelerated depreciation system of recording larger depreciation
expenses during the earlier years of an asset’s useful life and recording smaller
129
depreciation expenses during the asset's later years. Factor used to calculate
depreciation is 10% for process and supporting equipment, and 3% for building.
130
Depreciation=Current Book Value × Depreciation RateTable 7.38. Depreciation

TOTAL
NO. PROCESS EQUIPMENT SUPPORTING EQUIPMENT BUILDING DEPRECIATI
YEA
OF ON
R
YEAR Depreciati Initial Depreciati Book Depreciatio Book
Initial Value Book Value Initial Value
on (USD) Value on (USD) Value n (USD) Value
2021 0 13,426,728 72,234 686,752
2022 1 13,426,728 1,342,673 12,084,055 72,234 7,223 65,011 686,752 20,603 666,149 1,370,499
2023 2 12,084,055 1,208,405 10,875,649 65,011 6,501 58,510 666,149 19,984 646,165 1,234,891
2024 3 10,875,649 1,087,565 9,788,084 58,510 5,851 52,659 646,165 19,385 626,780 1,112,801
2025 4 9,788,084 978,808 8,809,276 52,659 5,266 47,393 626,780 18,803 607,976 1,002,878
2026 5 8,809,276 880,928 7,928,348 47,393 4,739 42,654 607,976 18,239 589,737 903,906
2027 6 7,928,348 792,835 7,135,514 42,654 4,265 38,388 589,737 17,692 572,045 814,792
2028 7 7,135,514 713,551 6,421,962 38,388 3,839 34,549 572,045 17,161 554,884 734,552
2029 8 6,421,962 642,196 5,779,766 34,549 3,455 31,094 554,884 16,647 538,237 662,298
2030 9 5,779,766 577,977 5,201,789 31,094 3,109 27,985 538,237 16,147 522,090 597,233
2031 10 5,201,789 520,179 4,681,610 27,985 2,799 25,187 522,090 15,663 506,427 538,640
2032 11 4,681,610 468,161 4,213,449 25,187 2,519 22,668 506,427 15,193 491,234 485,873
2033 12 4,213,449 421,345 3,792,104 22,668 2,267 20,401 491,234 14,737 476,497 438,349
2034 13 3,792,104 379,210 3,412,894 20,401 2,040 18,361 476,497 14,295 462,203 395,545
2035 14 3,412,894 341,289 3,071,605 18,361 1,836 16,525 462,203 13,866 448,336 356,992
2036 15 3,071,605 307,160 2,764,444 16,525 1,652 14,872 448,336 13,450 434,886 322,263
2037 16 2,764,444 276,444 2,488,000 14,872 1,487 13,385 434,886 13,047 421,840 290,978
2038 17 2,488,000 248,800 2,239,200 13,385 1,339 12,047 421,840 12,655 409,185 262,794
2039 18 2,239,200 223,920 2,015,280 12,047 1,205 10,842 409,185 12,276 396,909 237,400
2040 19 2,015,280 201,528 1,813,752 10,842 1,084 9,758 396,909 11,907 385,002 214,519
2041 20 1,813,752 181,375 1,632,377 9,758 976 8,782 385,002 11,550 373,452 193,901
131
132
The salvage value in year 2040 is obtained through non-residential real property
and land.
Table 7.39. Salvage Value
Salvage Value
Category
(USD)
Building 373,452
Land 232,900
Process equipment 1,632,377
Suppoerting equipment 8,782
Total 2,247,510
7.4.9 Operational Expenditure Summary

Operating cost (OPEX) can be obtained by summed up the total of direct
production cost, fixed cost, plant overhead cost, and general expense, excluding
maintenance and depretiation. The summary of total OPEX can be shown in table
below.
133
Table 7.40. OPEX Summary
PRODUCTION COST 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031
Raw Material 536,711 487,919 487,919 487,919 487,919 487,919 487,919 487,919 487,919 487,919
DIRECT
PRODUCTIO Labor Salary 79,133 79,133 79,133 79,133 79,133 79,133 79,133 79,133 79,133 79,133
N COST 1,301,46 1,301,46 1,301,46 1,301,46 1,301,46 1,301,46 1,301,46 1,301,46 1,301,46 1,301,46
Utility 6 6 6 6 6 6 6 6 6 6
Local Tax 5,407 5,407 5,407 5,407 5,407 5,407 5,407 5,407 5,407 5,407
FIXED COST
Insurance 251,980 251,980 251,980 251,980 251,980 251,980 251,980 251,980 251,980 251,980
PLANT
OVERHEAD Safety and
COST Protection 3,461 3,461 3,461 3,461 3,461 3,461 3,461 3,461 3,461 3,461
Executive Salary 329,491 329,491 329,491 329,491 329,491 329,491 329,491 329,491 329,491 329,491
Distribution 165.16 165 165 165 165 165 165 165 165 165
GENERAL Marketing 4,079 4,079.27 4,079.27 4,079.27 4,079.27 4,079.27 4,079.27 4,079.27 4,079.27 4,079.27
EXPENSE
Communication 1,960 1,960.00 1,960.00 1,960.00 1,960.00 1,960.00 1,960.00 1,960.00 1,960.00 1,960.00
2,048,07 1,843,27 1,638,46 1,433,65 1,228,84
Loan Interest 8 1 3 5 7 819,231 614,424 409,616 204,808 0
TOTAL OPEX (excluding
4,510,26 4,262,30 4,068,07 3,873,85 3,679,62 3,291,18 3,096,95 2,902,73 2,708,50 2,514,28
Maintenance and Depreciation)
1,037,88 1,037,88 1,037,88 1,037,88 1,037,88 1,037,88 1,037,88 1,037,88 1,037,88 1,037,88
MAINTENANCE
9 9 9 9 9 9 9 9 9 9
1,370,49 1,234,89 1,112,80 1,002,87
DEPRECIATION
9 1 1 8 903,906 814,792 734,552 662,298 597,233 538,640
134
Table 7.40. OPEX Summary (cont’d)
PRODUCTION COST 2032 2033 2034 2035 2036 2037 2038 2039 2040 2041
Raw Material 487,919 487,919 487,919 487,919 487,919 487,919 487,919 487,919 487,919 487,919
DIRECT
PRODUCTIO Labor Salary 79,133 79,133 79,133 79,133 79,133 79,133 79,133 79,133 79,133 79,133
N COST 1,301,46 1,301,46 1,301,46 1,301,46 1,301,46 1,301,46 1,301,46 1,301,46 1,301,46 1,301,46
Utility 6 6 6 6 6 6 6 6 6 6
Local Tax 5,407 5,407 5,407 5,407 5,407 5,407 5,407 5,407 5,407 5,407
FIXED COST
Insurance 251,980 251,980 251,980 251,980 251,980 251,980 251,980 251,980 251,980 251,980
PLANT
OVERHEAD Safety and 3,461 3,461 3,461 3,461 3,461 3,461 3,461 3,461 3,461 3,461
COST Protection
GENERAL Executive Salary 329,491 329,491 329,491 329,491 329,491 329,491 329,491 329,491 329,491 329,491
EXPENSE Distribution 165 165 165 165 165 165 165 165 165 165
Marketing 4,079.27 4,079.27 4,079.27 4,079.27 4,079.27 4,079.27 4,079.27 4,079.27 4,079.27 4,079.27
Communication 1,960.00 1,960.00 1,960.00 1,960.00 1,960.00 1,960.00 1,960.00 1,960.00 1,960.00 1,960.00
Loan Interest 0 0 0 0 0 0 0 0 0 0
TOTAL OPEX (excluding 2,514,28 2,514,28 2,514,28 2,514,28 2,514,28 2,514,28 2,514,28 2,514,28 2,514,28 2,514,28
Maintenance and Depreciation) 4 4 4 4 4 4 4 4 4 4
1,037,88 1,037,88 1,037,88 1,037,88 1,037,88 1,037,88 1,037,88 1,037,88 1,037,88 1,037,88
MAINTENANCE
9 9 9 9 9 9 9 9 9 9
DEPRECIATION 485,873 438,349 395,545 356,992 322,263 290,978 262,794 237,400 214,519 193,901
135
7.5 Economic Evaluation
7.5.1 Benchmark
There are few plants that produces cyanocobalamin in the world and there is
very little information about the plant size and capital investment on the internet.
There are studies showing other plants for their economic analysis, which are as
follows.
Table 7.41. Benchmark
Variable BASF Fermenta Biotech

Product Vitamin E Vitamin D3
Plant Size 6000 tonne/yr 5000 kg/yr
Capital $93 M $12.2 M
Investment
Price of Product $15/kg $216/kg
7.5.2 Investment Feasibility Analysis

Cost estimation is conducted to be analyzed by economic calculation.
Through economic analysis, the issue regarding project feasibility and
profitability can be analyzed. Basically, all the analysis is held through a media
named cashflow, which gives a lot of economic information about the project.
Moreover, through economic analysis, the appropriate product price can be
determined as well as the cost breakdown. To make an economic analysis,
economic foundation including project source, revenue, cost breakdown, and
cashflow must be produced and arranged beforehand.
7.5.2.1 Loan Interest

As mentioned in the earlier section, capital investment is usually obtained
through the combination of bank and investor as the capital provider. In this
project, the capital investment is assumed to be obtained from bank with the
fraction of 70% and from the investor with another fraction of 30%. The bank
chosen is Citibank with the lower interest rate compared to other banks, and the
capital obtained from investor is assumed to have interest paid periodically by a
factor of 12%
Table 7.42. Source Proportion of Capital Investment
136
Capital Share
Capital Source Percentage Interest Rate
(USD)
Citibank 70% 17,588,223 6.50%
Investor 30% 7,537,810 10.6%
The loan is paid with the assumption of 10 years, with each year paid the
same value of initial loan. This mechanism provides the small value of loan
payment. The detailed calculation regarding loan interest is provided below
Table 7.43. Loan Interest from Bank
Initial Loan Loan Total Loan after

Ye
Loan Interest Payment Payment Payment
ar
(USD) (USD) (USD) (USD) (USD)
0 17,588,223 17,588,223
1 17,588,223 1,143,235 1,758,822 2,902,057 15,829,401
2 15,829,401 1,028,911 1,758,822 2,787,733 14,070,579
3 14,070,579 914,588 1,758,822 2,673,410 12,311,756
4 12,311,756 800,264 1,758,822 2,559,086 10,552,934
5 10,552,934 685,941 1,758,822 2,444,763 8,794,112
6 8,794,112 571,617 1,758,822 2,330,440 7,035,289
7 7,035,289 457,294 1,758,822 2,216,116 5,276,467
8 5,276,467 342,970 1,758,822 2,101,793 3,517,645
9 3,517,645 228,647 1,758,822 1,987,469 1,758,822
10 1,758,822 114,323 1,758,822 1,873,146 0
137
Table 7.44. Loan Interest from Investor
Initial Loan Loan Total Loan after

Ye Loan Interest Payment Payment Payment
ar (USD) (USD) (USD) (USD) (USD)
0 7,537,810 7,537,810
1 7,537,810 799,008 753,781 1,552,789 6,784,029
2 6,784,029 719,107 753,781 1,472,888 6,030,248
3 6,030,248 639,206 753,781 1,392,987 5,276,467
4 5,276,467 559,306 753,781 1,313,086 4,522,686
5 4,522,686 479,405 753,781 1,233,186 3,768,905
6 3,768,905 399,504 753,781 1,153,285 3,015,124
7 3,015,124 319,603 753,781 1,073,384 2,261,343
8 2,261,343 239,702 753,781 993,483 1,507,562
9 1,507,562 159,802 753,781 913,583 753,781
10 753,781 79,901 753,781 833,682 0
Table 7.45. Total Loan Interest
Year Interest (USD)

1 1,942,242
2 1,748,018
3 1,553,794
4 1,359,570
5 1,165,345
6 971,121
7 776,897
8 582,673
9 388,448
10 194,224
Total 10,682,333
7.5.2.2 Revenue
The plant produces cyanocobalamin as main product. The calculation of
revenue considers the production capacity and market price of product. The
revenue is determined to be 9,378,600 USD/year, with detail calculation provided
in the following table.
138
Table 7.46. Revenue Calculation
Capacity Capacity Price Revenue

Product
(kg/day) (kg/year) (USD/kg) (USD)
Cyanocobala
8.12 2,680 3,500 9,378,600
min
7.5.2.3 Cost Breakdown

For the basic of sensitivity analysis, it is important to know which expense
shares the most to produce one unit of product. Hence, cost breakdown analysis
must be conducted. The share percentage is calculated on the basis of annual cost.
Since capital investment comes only in year 2021. The calculation process is
tabulated below.
Table 7.47. Cost Breakdown
Average Annual Cost Share Percentage

Component
(USD) (%)
Capital Investment 2,443,055 34.20
Raw Material 537,401 8.00
Labour Salary 40,612 0.60
Utility 1,301,466 19.37
Maintenance 1,037,889 15.45
Local Tax 5,407 0.08
Insurance 251,980 3.75
Safety and Protection 1,666 0.08
Executive Salary 169,099 2.52
Marketing and
Communication 6,039 0.09
Distribution 165 0.00
Loan Interest 1,068,233 15,90
TOTAL 6,717,286 100.00
139
Share Percentage (%)

0.00 Capital Invesetment
15.90
0.09 Raw Material
2.52 34.20 Labour Salary
0.02 Utility
3.75 Maintenance
0.08 Local Tax
Insurance
15.45
Safety and Protection
Executive Salary
8.00 Marketing and Communication
19.37 Distribution
Loan Interest
0.60
Figure 7.3. Cost Breakdown
7.5.2.4 WACC
Weighted Average Cost Capital (WACC) is the measure of minimum return
of capital investment that must be paid by the company to investors, banks, or
other capital investment provider. WACC is then set as equal to Minimum
Attractive Rate of Return.
The calculation of WACC is provided below.
E D
WACC= R e+ R
E+ D E+ D d
Re =Risk free rate−β ( market return−risk free rate )
Rd =bank interest rate(1−tax rate)
with:
E
= rate of equity = fraction of investment coming from investor
E+ D
140
D
= rate of debt = fraction of investment coming from loan
E+ D
Re = cost of equity
Rd = cost of debt
Cost of debt refers to the effective rate a company pays on its current debt.
On the other hand, cost of equity is the return a firm theoretically pays to its
equity investors to compensate for the risk they undertake by investing their
capital. For calculation, risk-free rate and market return is obtained from data of
market risk premia for Indonesia up to October 2020, with risk-free rate equals
6.61% and market return equals 9.55%. Beta equity is taken for Drug
(pharmaceutical) product as the closest estimate to the product category with the
value of 1.36. The calculation process gives WACC value to 6.60%, as can be
seen on the table below.
Table 7.48. WACC Calculation
Cost of Equity
Risk-free Rate 6.61%
Beta Equity 1.36
Market Return 9.55%
Cost of Equity 10.61%
Rate of Equity 30%
Cost of Debt
Bank Interest Rate 6.50%
Tax Rate 25%
Cost of Debt 4.88%
Rate of Debt 70%
WACC 6.60%
7.5.2.5 Cashflow
Cash flow visualizes the inflow and outflow in the form of cash through
periode of time from the beginning to the end of the project. In making cash flow,
the component used are listed below.
- Year
- Capacity and Price
141
- Revenue = Total income

- OPEX
- Maintenance Cost
- Depreciation
- Cash Expenses
- Total Expenses = Cash Expenses + Depreciation
- Before Tax Cash Flow = Gross Profit = Revenue – Cash Expenses
(without depreciation)
- Net Profit Before Tax (NPBT) = Revenue – Total Expenses
- Net Profit After Tax (NPAT) = Revenue – Total Expenses – Income Tax
- Income Tax = (Revenue – Total Expenses) x Tax
- After Tax Cash Flow = Net profit + Depreciation = Revenue – Cash
Expenses – Income Tax
- Cumulative Cash Flow
To simplify, there are two segments in the cashflow, which are after tax
cashflow and before tax cashflow. The inflow of the cashflow comes from the
revenue of selling the product, and the outflow of the cashflow comes from capital
and operating cost. To calculate income tax, depreciation must be included as it
will be reducing factor to the income tax. Income tax is taken with the rate of
25%. The profit after inclusion of depreciation is called the net profit. Production
capacity is determined to be 70% and 90% in the initial operation (first two
years), followed by full capacity, and closed by 90% and 70% at the end of
production time (last two years). The cash flow is tabulated in the appendix, and
visually represented in the following figure.
142
CASHFLOW
6,000,000
-2,000,000
21 23 25 27 29 31 33 35 37 39 41
20 20 20 20 20 20 20 20 20 20 20
-10,000,000
-18,000,000
-26,000,000
Year
Before Tax Cash Flow After Tax Cash Flow
Figure 7.4. Cashflow
Cumulative Cashflow
70,000,000
60,000,000
50,000,000
40,000,000
30,000,000
20,000,000
10,000,000
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
-10,000,000
-20,000,000
-30,000,000
Figure 7.5. Cumulative Cashflow

From graph it can be seen that the first seven years of production, negative
cash flow happens in the project. As the project goes on, a positive cash flow is
obtained. Whether the project is advantageous economically will be analyze in
profitability analysis using the cash flow.
143
7.5.3 Profitability Analysis

Profitability analysis is a component that forecasts/anticipates the sales and
profit potential. Profitability analysis contains of 5 points to determine if the
project is profitable or not, which are rate of investment, internal rate of return,
net present value, payback period, and breakeven point.
7.5.3.1 Return of Investment (ROI)

Return of investment (ROI) is the annual profit generated by one unit of
capital invested. The formula to calculate ROI is shown below
annual net profit
% ROI = x 100 %
total capital investment
Annual net profit is obtained either before or after taxes, in this case after tax net
profit is used. Annual Net Profit used is the after-tax annual net profit of
$2,149,806 and invested capital of $25,126,033. the calculation is shown by
equation below:
2,149,806
% ROI = x 100 %
25,126,033
So, the average annual ROI obtained from this plant was 8.56%. From the ROI
calculation, we can see that our plant is attractive to investors because it has a
pretty high rate of return value, higher than bank deposit rate in Indonesia (around
4-6% per year).
7.5.3.2 Internal Rate of Return (IRR)

Internal Rate of Return (IRR) is a measure of the maximum interest rate
paid on project that still break even at the end of the project life. In other words,
the IRR is the interest rate when NPV = 0. The formula used to calculate IRR is
shown below:
n=T
C Fn
NPV =∑ −TCI =0
n=1 ( 1+r )n
In the equation above, the IRR value is symbolized using the letter r. After
calculating the cash flow in Microsoft Excel, we obtain the IRR value of 13,46%
for this plant. Compared to the WACC value (6.6%), the WACC value is quietly
lower than the IRR value.
144
7.5.3.3 Net Present Value (NPV)

Net Present Value (NPV) shows the net benefits received by a project over
the life of the project at a certain interest rate. NPV can also be interpreted as the
present value of the cashflows generated by the investment. In calculating the
NPV is necessary to determine the relevant interest rate.
A project can be counted as feasible if the NPV>0, which means the project
is profitable or provide benefits if implemented. If NPV<0, the project is not
eligible to run because it does not generate profit. Cashflow in year-n drawn into
present value with a reasonable interest rate by using the following formula:
C Fn
C F n ,0=
( 1+i )n
IRR value for our product is 13.46%, then we obtained that the NPV value
is $16,017,103. If the NPV is negative the project will be stopped. Our NPV is
positive and high. It means that the project can be implemented.
7.5.3.4 Payback Period (PBP)

Payback period indicates the time needed until the plant’s revenue can
recover all the investment made when starting the plant. It can be presented best
using the cumulative present worth chart, stretching from year 0 until the plant
lifetime. The chart can be seen below.
Payback Period
$70000000.00000
$60000000.00000
$50000000.00000
Cummulative Cash Flow
$40000000.00000
$30000000.00000
$20000000.00000
$10000000.00000
$.00000
0 2 4 6 8 10 12 14 16 18 20
-$10000000.00000
-$20000000.00000
-$30000000.00000
Year
Figure 7.6. Payback Period
145
From the diagram above, it can be seen that the payback period for this plant
is 7.26 years. The payback period matches the rule of thumb. According to the
rule of thumb. the tolerable payback period is about 10 years and should be done
after all the loan are fully paid.
7.5.3.5 Breakeven Point (BEP)

Breakeven point is a measurement system that calculates the margin of
safety by comparing the amount of revenues or units that must be sold to cover
fixed and variable costs associated with making the sales. A project will be
profitable by equating its total revenue with its total expense. The breakeven point
is a point where the total costs (expenses) and total sales (revenue) are equal,
which means there are no net profit or loss at this point. To calculate BEP the
equation used is:
BEP=Total ¿ Cost ¿
Price per unit −Variable cost per unit
In this case the BEP can be previously seen from the graph, Payback Period
occurs on 7.26 years when the cumulative production reached 17,139 kg
cyanocobalamin, equals to USD 59,984,929.
7.6 Sensitivity Analysis
In this section, sensitivity analysis from cashflow will be explained. Three

major variable that are selected for this analysis are as follow: product selling
price, utility cost, maintenance cost. The reason as for why these three are selected
is because selling price will greatly determine the revenue and will greatly affect
cashflow, meanwhile utility and maintenance cost have a great share in the total
operation cost (OPEX) taking 19.37% and 15.45% share, respectively. Parameters
that are tested in the analysis are NPV, IRR and payback period with the results
shown below.
Table 7.49. Product Price Deviation Effect
Product Selling Price Fluctuation

Product Price
Deviation IRR (%) NPV (USD) PP (years)
per unit (USD)
-20% $2,800 7.63% 2,221,698 10.48
146
-15% $2,975 9.17% $5,670,549 9.45

10.65%
-10% $3,150 $9,119,400 8.6
-5% $3,325 12.08% $12,568,252 7.88
0% $3,500 13.46% $16,017,103 7.26
5% $3,675 14.82% $19,465,955 6.72
10% $3,859 16.21% $23,087,249 6.24
15% $4,052 17.64% $26,889,607 5.80
In the table above it is shown that the deviation ranges from 0 to 15%
either increasing or decreasing, it is common for consumer goods price to sway
around, a spike increase in price is also possible, according to
Singleprice.com(2020) a B12 vitamin retail cost on average 16$ in December
2019 and its price increase to 17.4$ in February but went down to 14.88$ in the
following month and hit 13$ at it lowest point in May, it has recovered over time
and in November 2020 it has become 16.5$, so a deviation of 5% should be an
acceptable range for selling price fluctuation. An IRR of 7.63% is still higher than
the MARR of 6.6% and it shows that even at the worst possible state of selling
price and it could still go down which in turn could go below MARR and risk of
being a failure project. As it could potentially shift to –20% and beyond, product
selling price is a key component of either making a profit or failure therefore it
classified as a high-risk profile.
Table 7.50. Maintenance Price Deviation Effect
Maintenance Price Fluctuation

Deviation Maintenance Cost IRR (%) NPV (USD) PP (years)
-3% $1,006,752 13.56% $16,256,681 7.22
-2% $1,017,131 13.53% $16,176,820 7.23
-1% $1,027,510 13.50% $16,096,960 7.24
0% $1,037,889 13.46% $16,017,103 7.26
1% $1,048,267 13.43% $15,937,247 7.27
2% $1,058,750 13.40% $15,856,586 7.28
3% $1,069,338 13.37% $15,775,118 7.30
In the table above it is shown that the deviation ranges from 0% to 3%

either increasing or decreasing, the small deviation of maintenance is caused by
how it is calculated, it is based on percentile of equipment and facilities purchase
147
value. In theory it should not deviate at all but, it can be because of repair material
shortage and or inflation of specialized maintenance service cost, that is why the
deviation here is as small as 1% per step.
Table 7.51. Utility Price Deviation Effect
Utility Price Fluctuation

Deviation Utility (USD) IRR (%) NPV (USD) PP (years)
-12% $1,145,290 13.92% $17,165,734 7.07
-8% $1,197,348 13.77% $16,782,857 7.13
-4% $1,249,407 13.62% $16,399,980 7.19
0% $1,301,466 13.46% $16,017,103 7.26
4% $1,353,524 13.31% $15,634,226 7.32
8% $1,407,665 13.15% $15,236,034 7.39
12% $1,463,972 12.99% $14,821,915 7.46
In the table above it is shown that the deviation ranges from 0% to 12%
either increasing or decreasing, although electricity bill for industry is quite stable
for a long time now there has been a time where the price spiked from Rp 967 on
May 2016 to Rp 1.009 on July 2016 which is a 4% increase in just 2 months and
in 2006 there is a sharp increase of 12.5% according to detikfinance.com(2005)
although they did not clearly state what kind of tariff is increased it shows that
there is a possibility of a sharp increase, not only that another factor is that the
current price is subsidized by the government which show that the real price is
higher and there can be a situation where they stop subsidizing and in turn will
increase the electricity bill. In the hindsight of subsidizing, it can also apply vice
versa where it can reduce the cost of electricity bill, for example because of the
Covid-19 pandemic the price for electricity is relieved by a certain degree.
Table 7.52. Sensitivity Slope of Deviation with IRR
Deviation vs IRR
Selling Price Maintenance Cost Utility Cost
Slope 1%
0.28% -0.03% -0.04%
Table 7.53. Sensitivity Slope of Deviation with NPV
Deviation vs NPV
Slope 1%
$700,589 -$80,174 -$97,240
Table 7.54. Sensitivity Slope Deviation with PP
148
Deviation vs PP
Slope 1%
-0.131 0.013 0.016
149
7.6.1 IRR Sensitivity Analysis

20.00%
18.00%
16.00%
14.00%
IRR%
12.00%
10.00%
8.00%
6.00%
-25% -20% -15% -10% -5% 0% 5% 10% 15% 20%
Deviation
Selling Price Fluctuation Maintenence Fluctuation Utility Price Fluctuation
Figure 7.7. Effect of Parameter Deviation on IRR

From the Chart above it is shown that IRR is greatly affected by the product
selling price while maintenance and utility only affect it slightly. The IRR will
increase by 0.28% every +1% deviation of selling price while it will lose 0.03%
and 0.04% IRR for every -1% deviation of maintenance and utility cost
respectively.
7.6.2 NPV Sensitivity Analysis

$30000000.000
$25000000.000
$20000000.000
NPV (USD)
$15000000.000
$10000000.000
$5000000.000
$.000
-25% -20% -15% -10% -5% 0% 5% 10% 15% 20%
Deviation

F
igure 7.8. Effect of Parameter Deviation on NPV
150
The chart above shows the same trend as the IRR chart in which selling
price deviation shows the greatest effect on NPV and it increase alongside with
the increase of deviation while maintenance and utility only affect it slightly and
decrease alongside the increase of deviation. The NPV will increase by $700,589
every +1% deviation of selling price while it will lose $80,174 and $97,240 NPV
for every -1% deviation of maintenance and utility cost respectively.
7.6.3 PBP Sensitivity Analysis

11.00
10.00
9.00
PP (Years)
8.00
7.00
6.00
5.00
4.00
-25% -20% -15% -10% -5% 0% 5% 10% 15% 20%
Deviation
Figure 7.9. Effect of Parameter Deviation on PBP

It is shown here that an increase of selling price on each nodes of deviation
will lower payback period significantly every 1% increase of deviation will
shorten the payback period by 0.131 years whereas 1% increase of deviation in
maintenance and utility cost will lengthen the payback period by 0.013 years and
0.016 years respectively which is quite insignificance (only 5 days and 6 days
respectively every 1% deviation).
7.6.4 Result
Based on those three figures above, in can be concluded that the most
affecting variable of all is the product selling price. The fluctuation of the selling
price can affect the revenue of the plant so badly that it can shorten or lengthen
the payback period up to 2 years, although the IRR will not hit below MARR in
the case of -20% deviation of selling price, it can still post a challenge for investor
to invest in this plant. One way of controlling the price is exporting to avoid
saturating the domestic market which will keep the price afloat, the potential of
151
selling in other countries is big especially those who have a big population of
older people and vegetarian, according to Globenewswire.com(2020) growing
health concern and lifestyle change could be a potential drive on consuming more
vitamins B12, these vegan lifestyle and older age population is much more
thriving in developed country such as Japan3 or those that are hindered to eat meat
because of tradition such us India and Israel which has approximately 38% and
12% population a vegetarian based on Benjamin (2019).
CHAPTER 8
CONCLUSION
From this report, we can conclude that several things:

 Based on the calculation of production capacity, our proposed plant will
produce 1960 kg of vitamin B12 per year using molasses as the substrate
for fermentation.
 For the production of vitamin B12 from molasses, there are three
fermenters will be used for three steps of fermentation.
 The fermenters that are used are a bubble column reactor.
 There are three mixing tanks used in this plant, for seed medium blending,
fermentation medium blending, and for blending cobalamin with cyanide.
 The separation process used several equipment, which are centrifuge,
centrifugal extractors, ion exchange chromatography.
 Belt conveyor and storage tank also used to move final product
cyanocobalamin to the storage and to store the product.
 The plant uses nine pumps for main process, four pumps for steam utility,
three pumps for wastewater treatment utility, and three pumps for water
utility.
 There are two compressors used in this plant, one is for air compression
used on fermentation and one is for steam utility.
 Capital expenditure of the plant is USD 25,129,796 with an annual
operating cost of USD 2,514,284 and an estimated revenue of USD
9,378,600 annualy.
 According to our profitability analysis, our plant is feasible to build
because it has a ROI of 8.56%, and IRR of 13.46% while the WACC is at
6.6% and a NPV of $16,017,103, having a payback period of 7.26 years
and selling 17.139kg of cyanocobalamine.
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APPENDICES
APPENDIX A
BFD AND PFD
Figure A.1. Block Flow Diagram of Vitamin B12 Production

157
Figure A.2. Process Flow Diagram of Fermentation Section
158
Figure A.3. Process Flow Diagram of Separation Section
159
Figure A.4. Process Flow Diagram of Steam Utility
160
Figure A.5. Process Flow Diagram of Wastewater Treatment Facility
161
Figure A.6. Process Flow Diagram of Water Treatment Facility
APPENDIX B
MASS BALANCE
B.1 Mass Balance of Cell Culture

Table B.1.1. Mass Balance of SFR-103
Stream Cell Culture In P-5
Temperature (°C) 25 25
Pressure (bar) 1.013 1.137
Component Flow In (kg/batch) Flow Out (kg/batch)
(NH4)2HPO4 0.00033 0.00033
Agar 0.00436 0.00436
(NH4)2SO4 0.00005 0.00005
MnSO4.H2O 0.00002 0.00002
Peptone 0.00218 0.00218
Sucrose 0.00654 0.00654
ZnSO4.H2O 0.00002 0.00002
Water (H2O) 0.2045 0.2045
Biomass 0.001 0.001
Total 0.219 0.219
Table B.1.2. Mass Balance of ST-103

Stream P-5 P-19
(NH4)2HPO4 0.00033 0.00033
Agar 0.00436 0.00436
(NH4)2SO4 0.00005 0.00005
MnSO4.H2O 0.00002 0.00002
Peptone 0.00218 0.00218
Sucrose 0.00654 0.00654
ZnSO4.H2O 0.00002 0.00002
Water (H2O) 0.2045 0.2045
Biomass 0.001 0.001
Total 0.219 0.219
B.2 Mass Balance of Seed Fermentation

Table B.2.1. Mass Balance of V-101
Stream Seed Input P-4a P-4b
163
Temperature (°C) 25 25 25
Pressure (bar) 1.013 10.132 8.613
(NH4)2HPO4 4.07997 0.08000 3.99997
(NH4)2SO4 10.19993 0.20000 9.99993
CoCl2 0.102 0.00200 0.1
DMBI 0.02295 0.00045 0.0225
KH2PO4 25.49983 0.50000 24.99983
MgSO4.H2O 7.64995 0.15000 7.49995
MnSO4.H2O 1.01999 0.02000 0.99999
Peptone 152.99893 2.99998 149.99895
Sucrose 178.49876 3.49998 174.99878
ZnSO4.H2O 0.102 0.00200 0.1
Water (H2O) 4667.61746 91.52191 4576.09555
NaOH 203.99857 3.99997 199.9986
Total 5251.7903 5251.7903

Stream P-4a P-6
Pressure (bar) 10.132 10.132
(NH4)2HPO4 0.08000 0.08000
(NH4)2SO4 0.20000 0.20000
CoCl2 0.00200 0.00200
DMBI 0.00045 0.00045
KH2PO4 0.50000 0.50000
MgSO4.H2O 0.15000 0.15000
MnSO4.H2O 0.02000 0.02000
Peptone 2.99998 2.99998
Sucrose 3.49998 3.49998
ZnSO4.H2O 0.00200 0.00200
Water (H2O) 91.52191 91.52191
NaOH 3.99997 3.99997
Total 102.9763 102.9763

STREAM P-19 P-6 P-9A P-1 VENT #1
TEMPERATURE 32 32 36.6 28 28
164
(°C)
PRESSURE (BAR) 1.137 10.132 1.113 1.013 1.013
COMPONENT Flow In (kg/batch) Flow Out
(kg/batch)
(NH4)2HPO4 0.0003 0.08 0 0.07082 0
3
AGAR 0.0043 0 0 0.00389 0
6
(NH4)2SO4 0.0000 0.2 0 0.17760 0
5
BIOMASS 0.001 0 0 0.00006 0
BIOMASS #1 0 0 0 0.86855 0
COCL2 0 0.00200 0 0.00096 0
DMBI 0 0.00045 0 0.00040 0
KH2PO4 0 0.50000 0 0.44513 0
MGSO4.H2O 0 0.15000 0 0.13296 0
MNSO4.H2O 0.0000 0.02000 0 0.01703 0
2
PEPTONE 0.0021 2.99998 0 2.67768 0
8
NAOH 0 3.99997 0 3.56765 0
SUCROSE 0.0065 3.49998 0 2.84420 0
4
WATER (H2O) 0.2045 91.5219 0 81.6483 0
1 9
ZNSO4.H2O 0.0002 0.00200 0 0.00097 0
CARBON DIOXIDE 0 0 0 0 0.45567
NITROGEN 0 0 108.5351 0 108.6266
9 2
OXYGEN 0 0 32.94918 0 32.05656
TOTAL 244.6798 233.5951

Stream P-4b P-18
(NH4)2HPO4 3.99997 3.99997
(NH4)2SO4 9.99993 9.99993
CoCl2 0.1 0.1
DMBI 0.0225 0.0225
165
Table B.2.5. Mass Balance of ST-104 (cont’d)

KH2PO4 24.99983 24.99983
MgSO4.H2O 7.49995 7.49995
MnSO4.H2O 0.99999 0.99999
Peptone 149.99895 149.99895
Sucrose 174.99878 174.99878
ZnSO4.H2O 0.1 0.1
Water (H2O) 4576.09555 4576.09555
NaOH 199.9986 199.9986
Total 5148.8141 5148.8141

Stream P-1 P-18 P-10a P-2 Vent #2
Temperature (°C) 28 28 36.6 28 28
Pressure (bar) 1.013 8.613 1.113 1.013 1.013
(NH4)2HPO4 0.07082 3.99997 0 3.10355 0
Agar 0.00389 0 0 0.00304 0
(NH4)2SO4 0.17760 9.99993 0 7.87770 0
Biomass 0.00006 0 0 0.00005 0
Biomass #1 0.86855 0 0 0.60009 0
Biomass #2 0 0 0 20.52056 0
CoCl2 0.00096 0.1 0 0 0
DMBI 0.00040 0.0225 0 0.01790 0
KH2PO4 0.44513 24.99983 0 19.81351 0
MgSO4.H2O 0.13296 7.49995 0 5.88835 0
MnSO4.H2O 0.01703 0.99999 0 0.71617 0
Peptone 2.67768 149.99895 0 119.36003 0
NaOH 3.56765 199.9986 0 159.14469 0
Sucrose 2.84420 174.99878 0 112.01863 0
Water (H2O) 81.64839 4576.09555 0 3656.44406 0
ZnSO4.H2O 0.00097 0.1 0 0.07854 0
Carbon Dioxide 0 0 0 0 25.22996
Nitrogen 0 0 3256.3589 0 3260.99464
Oxygen 0 0 988.56747 0 954.45212
Total 9486.1967 8346.2636
166
B.3 Mass Balance of Main Fermentation

Stream Medium Input P-7
(NH4)2SO4 147.82439 147.82439
Ash 960.85856 960.85856
Betaine 554.34148 554.34148
CoCl2 10.34771 10.34771
DMBI 5.54341 5.54341
Fructose 720.64392 720.64392
Glucose 720.64392 720.64392
MgSO4.H2O 110.8683 110.8683
NaOH 2956.48787 2956.48787
Sucrose 6282.53672 6282.53672
Sulfur 480.42928 480.42928
Water (H2O) 66445.09381 66445.09381
ZnSO4.H2O 5.91298 5.91298
Total 79401.53235 79401.53235

Stream P-7 P-12
Pressure (bar) 10.132 10.132
(NH4)2SO4 147.82439 147.82439
Ash 960.85856 960.85856
Betaine 554.34148 554.34148
CoCl2 10.34771 10.34771
DMBI 5.54341 5.54341
Fructose 720.64392 720.64392
Glucose 720.64392 720.64392
MgSO4.H2O 110.8683 110.8683
NaOH 2956.48787 2956.48787
Sucrose 6282.53672 6282.53672
Sulfur 480.42928 480.42928
Water (H2O) 66445.09381 66445.09381
167
ZnSO4.H2O 5.91298 5.91298

Total 79401.53235 79401.53235
168
Table B.3.3. Mass Balance of FR-101

Stream P-12 FM- P-2 P- P-3 Vent #3
A 10b
Temperature 32 25 28 36.6 32 32
(°C)
Pressure (bar) 10.132 1.013 1.013 1.113 1.013 1.013
(NH4)2HPO4 147.82439 0 3.10355 0 1.68216 0
Agar 0 0 0.00304 0 0.00304 0
(NH4)2SO4 0 0 7.87770 0 98.84655 0
Ash 960.85856 0 0 0 960.85856 0
Betaine 554.34148 0 0 0 0
Biomass 0 0 0.00005 0 0.00005 0
Biomass #1 0 0 0.60024 0 0.60024 0
Biomass #2 0 0 20.52053 0 19.09914 0
Biomass #3 0 0 0 0 2935.1670 0
4
Cobalamin 0 0 0 0 14.92458 0
CoCl2 10.34771 0 0 0 3.24077 0
DMBI 5.54341 0 0.01790 0 5.56131 0
Fructose 720.64392 0 0 0 720.64392 0
Glucose 720.64392 46.7 0 0 767.34392 0
KH2PO4 0 0 19.81351 0 18.39212 0
MgSO4.H2O 110.8683 0 5.88835 0 3.04558 0
MnSO4.H2O 0 0 0.71617 0 0.71617 0
Peptone 0 0 119.36003 0 119.36003 0
NaOH 2956.4878 0 159.14468 0 3115.6325 0
7 5
Sucrose 6282.5367 0 112.01862 0 4.7038 0
2
Sulfur 480.42928 0 0 0 480.42928 0
Water (H2O) 66445.093 53.3 3656.4439 0 75277.521 0
81 5 55
ZnSO4.H2O 5.91298 0 0.07854 0 1.72735 0
Carbon Dioxide 0 0 0 0 0 3719.517
2
Table B.3.3. Mass Balance of FR-101 (cont’d)
Stream P-12 FM-A P-2 P-10b P-3 Vent #3
Componen Flow In (kg/batch) Flow Out (kg/batch)
t
Nitrogen 0 0 0 265953.2062 0 266028.18698
9
Oxygen 0 0 0 80738.2406 0 76099.17049
Total 430298.5661 430396.3744
169

Stream P-3 Cyanide P-13
Pressure (bar) 1.013 1.013 8.986
(NH4)2HPO4 1.68216 0 1.68216
Agar 0.00304 0 0.00304
(NH4)2SO4 98.84655 0 98.84655
Ash 960.85856 0 960.85856
Biomass 0.00005 0 0.00005
Biomass #1 0.60009 0 0.60009
Biomass #2 19.09918 0 19.09918
Biomass #3 2935.16704 0 2935.16704
Cobalamin 14.92458 0 0
Cyanocobalamin 0 0 14.92458
CoCl2 3.24077 0 3.24077
DMBI 5.56131 0 5.56131
Fructose 720.64392 0 720.64392
Glucose 767.34392 0 767.34392
KH2PO4 18.39212 0 18.39212
MgSO4.H2O 3.04558 0 3.04558
MnSO4.H2O 0.71617 0 0.71617
NaCN 0 8 7.45981
NaNO2 0 200 199.23949
Peptone 119.36003 0 119.36003
NaCl 0 0 1.3007
NaOH 3115.63255 0 3115.63255
Sucrose 4.7038 0 4.7038
Sulfur 480.42928 0 480.42928
Water (H2O) 75277.52165 0 75277.52165
ZnSO4.H2O 1.72736 0 1.72736
Total 84757.49971 84757.49971
B.4 Mass Balance of Centrifugation

Table B.4.1. Mass Balance of DC-101
Stream P-13 P-14 Solids Out
Temperature (°C) 28 33.5 33.5
Pressure (bar) 8.754 8.968 1.013
170
(NH4)2HPO4 1.68216 1.54734 0.13482

Agar 0.00304 0 0.00304
(NH4)2SO4 98.84655 90.92454 7.92201
Ash 960.85856 0 960.85856
Biomass 0.00005 0.00001 0.00004
Biomass #1 0.60009 0.06001 0.54008
Biomass #2 19.09918 1.90992 17.18926
Biomass #3 2935.16704 0 2935.16704
Cyanocobalamin 14.92458 13.72846 1.19612
CoCl2 3.24077 2.98104 0.25973
DMBI 5.56131 5.1156 0.44571
Fructose 720.64392 662.88826 57.75566
Glucose 767.34392 705.84551 61.49841
KH2PO4 18.39212 16.9181 1.47402
MgSO4.H2O 3.04558 2.80149 0.24409
MnSO4.H2O 0.71617 0.65877 0.0574
NaCN 7.45981 6.86195 0.59786
NaNO2 199.23949 183.27154 15.96795
Peptone 119.36003 109.79398 9.56605
NaCl 1.30069 1.19645 0.10424
NaOH 3115.63255 2865.93168 249.70087
Sucrose 4.7038 4.32682 0.37698
Sulfur 480.42927 441.9255 38.50377
Water (H2O) 75277.52165 69244.44084 6033.08081
ZnSO4.H2O 1.72736 1.58892 0.13844
Total 84757.49969 84757.49969
B.5 Mass Balance of Extraction

Table B.5.1. Mass Balance of CX-101
Stream P-13 P-15 Heavy Solvent

Temperature (°C) 33.5 29.5 33.5
Pressure (bar) 8.968 1.013 1.013
(NH4)2HPO4 1.54735 0 1.54735
171
(NH4)2SO4 90.92454 10.35849 80.56605

Biomass 0.00001 0 0
Biomass #1 0.06001 0.018 0.04201
Biomass #2 1.90992 0.57298 1.33694
Cyanocobalamin 13.72846 13.56831 0.16014
CoCl2 2.98104 0.33961 2.64142
Cresol 100 30 70
DMBI 5.1156 0.58279 4.53281
Fructose 662.88826 75.51892 587.36934
Glucose 705.84552 80.41278 625.43273
KH2PO4 16.9181 1.92738 14.99072
MgSO4.H2O 2.80149 0.10208 2.69941
MnSO4.H2O 0.65877 0.024 0.63476
NaCN 6.86195 2.05858 4.80336
NaNO2 183.27154 6.67791 176.59363
Peptone 109.79398 0.00002 109.79396
NaCl 1.19645 0.1363 1.06015
NaOH 2865.93168 859.7795 2006.15217
Sucrose 4.32682 0.49293 3.83389
Sulfur 441.9255 50.34594 391.57956
Water (H2O) 69244.44084 20773.33225 48471.10859
ZnSO4.H2O 1.58892 0.0579 1.53102
Total 74464.71675 74464.71668
B.6 Mass Balance of Ion Exchange Chromatography

Table B.6.1. Mass Balance of INX-101
Stream P-15 New Input P-17 Waste

Temperature (°C) 33.5 25 25 33.5
Pressure (bar) 1.013 1.013 1.013 1.013
(NH4)2SO4 10.35849 0 0 10.35849
Biomass #1 0.018 0 0 0.018
172
Biomass #2 0.57298 0 0 0.57298

Cyanocobalamin 13.56831 0 13.02558 0.54273
CoCl2 0.33961 0 0 0.33961
Cresol 30 0 0 30
DMBI 0.58279 0 0 0.58279
Fructose 75.51892 0 0 75.51892
Glucose 80.41278 0 0 80.41278
KH2PO4 1.92738 0 0 1.92738
MgSO4.H2O 0.10208 0 0 0.10208
MnSO4.H2O 0.024 0 0 0.024
NaCN 2.05858 0 0 2.05858
NaNO2 6.67791 0 0 6.67791
Peptone 0.00002 0 0 0.00002
NaCl 0.1363 0 0 0.1363
NaOH 859.7795 0 0 859.7795
Sucrose 0.49293 0 0 0.49293
Sulfur 50.34594 0 0 50.34594
Water (H2O) 20773.33225 1295.65996 1295.65996 20773.33225
ZnSO4.H2O 0.0579 0 0 0.0579
Ammonia 0 0.9067 0.9067 0
HCl 0 1.94123 1.94123 0
Total 23204.81456 23204.81456
B.7 Mass Balance of Freeze Drying

Table B.7.1. Mass Balance of FDR-101
Stream P-17 Vapour Final Products

Pressure (bar) 1.013 1.013 1.013
Cyanocobalamin 13.02558 0 13.02558
Water 1295.65996 1294.9744 0.68556
Ammonia 0.9067 0.9067 0
173
HCl 1.94123 1.94123 0

Total 1311.53347 1311.53347
B.8 Mass Balance of Air System

Table B.8.1. Mass Balance of G-101
Stream Air P-8
Temperature (°C) 25 36.6
Air 351077.85764 0
Nitrogen 0 269318.10039
Oxygen 0 81759.75725
Total 351077.85764 351077.85764
Table B.8.2. Mass Balance of AF-101

Stream P-8 P-11
Temperature (°C) 36.6 36.6
Nitrogen 269318.10039 269318.10039
Oxygen 81759.75725 81759.75725
Total 351077.85764 351077.85764
174
APPENDIX C
ENERGY BALANCE
C.1. Energy Balance of Cell Culture

Table C.1. Energy Balance of Cell Culture
Equipment Flow In Flow Out Heat Duty (kJ/batch)
(kJ/batch) (kJ/batch)
SFR-103 22.05 22.05 0
ST-103 22.05 28.2 -6.15
C.2. Energy Balance of Seed Fermentation

Table C.2. Energy Balance of Seed Fermentation
V-101 524,105.3400 524,082.8900 22.45
ST-101 10,276.14 13,140.41 -2,864.27
SFR-101 18,406.5 14,432.8 3,973.7
ST-104 513,806.75 575,215.12 -61,408.37
SFR-102 742,694.24 586,262.63 156,431.61
C.3. Energy Balance of Main Fermentation

Table C.3. Energy Balance of Main Fermentation
V-102 7,544,139.02 7,434,451.91 109,687.11
ST-102 7,434,451.91 9,506,916.74 -2,072,464.83
FR-101 22,810,033.64 22,790,804.39 19,229.25
V-103 10,751,544.89 10,753,218.46 -1,673.57
C.4. Energy Balance of Centrifugation

Table C.4. Energy Balance of Centrifugation
DC-101 10,753,218.46 11,248,122.04 -494,903.58
175
C.5. Energy Balance of Extraction

Table C.5.1. Energy Balance of Extraction
CX-101 10,063,636.81 10,063,860.06 -223.25
C.6. Energy Balance of Ion Exchange Chromatography

Table C.6.1. Energy Balance of Ion Exchange Chromatography
INX-101 3,132,734.47 3,132,734.47 0
C.7. Energy Balance of Freeze Drying

Table C.7.1. Energy Balance of Freeze Drying
FDR-101 138,016.26 3,341,126.97 -3,203,110.71
C.8. Energy Balance of Air System

Table C.8.1. Energy Balance of Air System
G-101 8,886,335.62 12,997,254.48 -4,110,918.86
AF-101 12,997,254.48 12,997,254.48 0
FSP-101 12,997,254.48 12,997,254.48 0
FSP-102 12,992,016.59 12,992,016.59 0
C.9. Total Energy

Table C.9.1. Total Energy Balance
Flow In (kJ/batch) Flow Out (kJ/batch) Heat Duty (kJ/batch)
122,309,969.7000 128,627,072.2000 -6,317,102.5
176
APPENDIX D
WATER UTILITY SPECIFICATION
D.1. Clarifier
The purpose of the clarifier is to settle heavy & suspended particles from
the raw water, as well as a raw water storage tank. Parameters that are required to
be calculated for the clarifier sizing is defined below.
2. Detention Time (DT): Time required for a given drop of fluid to flow from
inlet into outlet of clarifier.
3. Surface Overflow Rate (SOR): Amount of fluid flowing into the clarifier
per day per square meter of surface area.
4. Weir Overflow Rate (WOR): Amount of fluid flowing into the clarifier per
meter of weir length.
5. Solids Loading (SL): Amount of solids inflow per day per square meter of
surface area.
The clarifier sizing is done in consideration of average values, which are shown
below:
Table D.1. Average Clarifier Parameter Values
Parameter Values
Avg. DT 2-3 hours
Avg. SOR 400-800 gal/day/ft2 16.3 - 32.6 m3/day/m2
Avg.
WOR 10000 gal/day/ft 124.1933 m3/day/m
Avg. SL Max 30 lbs/day/ft2 Max 146.473 kg/day/m2
Below are the resulting clarifier parameter values and the size:
177
Table D.2. Clarifier Specification
Equipment Name Clarifier
Equipment Code CR-201
Type Circular Clarifier
DT [hours] 2.75
SOR [m3/day/m2] 28
WOR [m3/day/m] 100
SL [kg/day/m2] 13.002
Tank Vol. [m3] 484
Surface Area [m2] 150.86
Length of Weir [m] 42.24
Height [m] 3.21
Diameter [m] 13.86
Weir Diameter [m] 13.45
D.2. Sand Filter
The purpose of using a sand filter is to separate fine silica and sand
particles by filtering it through quartz and/or gravel.
Table D.3. Sand Filter Tank Specification
Equipment Name Sand Filter Tank
Equipment Code SF-201
Type Pressure Filter
Model YL-SF-2200
Jiangsu YLD Water Processing Equipment Co.,
Vendor
Ltd.
Capacity [m3/hr] 115-190
Operating Pressure 6 - 16 bar
Operating Temperature <40
[oC]
Max Pressure Drop Less Than 0.02%
Water Output <5 Ntu (<20 TSS)
Style Ground Mounted
Material CS, SS304
Filtration Material Quartz Sand
Diameter [mm] 2200
178
Height [mm] 2250

Inlet-Outlet Size DN150 (6 in)
D.3. Activated Carbon
The purpose of using an activated carbon tank is to adsorb odor, color,

chlorine, and organic compounds by means of diffusion. As the flowrate of the
process is around 175 kg/hr, the total required activated carbon tanks are 4 units.
Table D.4. Activated Carbon Tank Specification
Equipment Name Granule Activated Carbon Tank
Equipment Code AC-201
Model YLD-MF-2400
Total Units 4
Vendor Jiangsu YLD Water Processing Equipment Co.,
Ltd.
Operating Pressure [bar] 6 - 10
Operating Temperature <40
[oC]
Max Pressure Drop [bar] 0.5
Water Output <5 Ntu (<20 TSS)
Style Vertical
Material CS, SS304
Filtration Material Granular Activated Carbon
Diameter [mm] 1000
Height [mm] 5000
Carbon required [kg] 1700
D.4. Water Softener
The purpose of a water softener tank is to remove calcium and magnesium

ions to reduce hardness level in the water by means of ion exchange adsorption.
As the flowrate of the process is around 175 kg/hr, the total required water
softener tanks are 2 units.
179
Table D.5. Water Softener Tank Specification
Equipment Name Water Softener Tank
Equipment Code WS-201
Model AD/2000GV
Vendor Idrobios SRL, Ltd.
Total Units 2
Power Supply 230 V (±10%) - 50Hz (± 3%)
Salt Consumption [kg] 200-300 kg
Regeneration Time [min] 100
Type Strong Cation Ion Exchanger
Operating Pressure [bar] 2-6
Operating Temperature [oC] 5-30
Max Pressure Drop 0.8 bar (based on 72 m3/hr)
Length [mm] 1500
Height [mm] 2700
Inlet-Outlet Size DN100 (4 in)
Style Vertical
Material S275JR steel
D.5. Reverse Osmosis
Reverse Osmosis is the final step of the water treatment utility; whereby
pre-treated water is pressured through a semi-permeable membrane in a way that
diffusion occurs against the concentration gradient (particles flow from a higher
concentrated solution to a smaller concentrated solution).
Table D.6. Reverse Osmosis Specification
Equipment Name Reverse Osmosis
Equipment Code RO-201
Model KYRO-3000
Vendor Guangzhou Kaiyuan Water Treatment Equipment
Co., Ltd.
Power 4.5 kW
Power Supply AC220V 18A / 380V 9A 50HZ
Salt Rejection 99%
Water Recovery 55-60%
Filter Replacement Approx. every 1.5 years
180
Capacity [m3/hr] 3
Operating Temperature 32
[oC]
Operating Pressure [bar] 8.62
Max Pressure Drop [bar] 1.0
Membrane Vessel SS304
Brand Domestic
RO Membrane LCLE-4040
Brand DOW
APPENDIX E
WASTEWATER UTILITY SPECIFICATION
E.1. Screening and Grit Handling
Screening is the first unit operation used at wastewater treatment unit.

Screening removes solid particles to avoid damage and clogging of downstream
equipment, piping, and appurtenances. Grit removed to reduce the inorganic
particles to prevent damage to the pumps, and to prevent their accumulation in
sludge digestors.
Table E.1. Water Screen Equipment
Item Rotary Drum Screen
Equipment Code WS-202
Number of Unit 1
Function Solid and grit removal
Vendor GNGTHISM
Model GNZG-600
Operation Data
Mass flow 1,485 kg/h
o
Temperature 32 C
Pressure 1.010 kPa
Mesh 0.5 mm
Drum diameter 600 mm
Drum Length 500 mm
o
Instalation angle 35
E.2. Primary Clarifier
Primary clarifier is use after preliminary treatment. In The principal process

in primary clarifier is sedimentation, where the solids are allowed to settle to the
bottom. Primary clarifier function is to separate the settleable solids from the raw
wastewater. The specification of the primary clarifier is shown below.

182
Table E.2. Primary Clarifier Sizing
Item Primary Clarifier
Number of Unit 1
Function Solid and liquid removal
Type Open tank
Head None
Bottom Flat
Operation Data
o
Temperature 32 C
Pressure 1.010 kPa
Liquid Density 1,061.00 kg/m3
Working Volume 2.77 L
Detention Time 2 h
Surface Overflow Rate 20 m /day/m2
3
Weir Overflow Rate 100 m3/day/m

Construction Data
Tank Volume 3.32 m3
Surface Area 1.6610 m2
Length of Weir 0.332207682 m
Height 2.0 m
Diameter 1.45 m
Weir Diameter 0.105745 m
E.3. Aeration tank
Aeration is part of the stage known as the secondary treatment process in

wastewater treatment. Aeration work principle based on pumping air into a tank,
which promotes the microbial growth in the wastewater. The microbes feed on the
organic material, forming flocks which can easily settle out. The specification of
aeration tank is shown below.
Table E.3. Aeration Tank Sizing
Item Aeration Tank
Equipment Code AT-201
Number of Unit 1
Function Facilitate the biological treatment of
wastewater
183
Type Open tank

Head None
Bottom Flat
Mode of Operation Batch
Operation Data
o
Temperature 32 C
Pressure 101.325 kPa
Liquid Density 1,061.00 kg/m3
Working Volume 1,215.52 L
Construction Data
Tank Volume 1.46 m3
Tank Height 2.71 m
Pressure design 154.43 kPa
Tank Thickness 7.31 mm
E.4. Secondary Clarification
The function of the secondary clarifier is to separate the activated sludge

solids from the mixed liquor.
Table E.4. Secondary Clarification
Item Secondary Clarifier
Number of Unit 1
Function Remove activated sludged
Type Clarifier
Operation Data
o
Temperature 32 C
Pressure 1.010 kPa
Liquid Density 997.00 kg/m3
Detention Time 2 h
Surface Overflow Rate 20 m3/day/m2
Construction Data
Tank Volume 3.10 m3
Height 2.0 m
Diameter 1.41 m
184
E.5. UV Chamber
This process aims to kill microorganisms in the solution by placing the UV

lamp in the solution. The process adds nothing to the water but UV light, and
therefore, has no impact on the chemical composition or the dissolved oxygen
content of the water. The use of UV has the advantage of being environmentally
friendly compared to chemicals.
Table E.5. UV Chamber Sizing
Item UV Chamber
Equipment Code UV-201
Number of Unit 1
Function Disinfection of microorganisms
Material SA-516 gr 60
Type Open tank
Head None
Bottom Flat
Operation Data
Mass flow 1114.8 kg/h
o
Temperature 32 C
Pressure 101.33 kPa
Working Volume 1,118.14 L
Construction Data
Length 1.5 m
Width 1 m
Height 0.893 m
Thickness 0.229769317 in
Capacity 1.34 m3
185
E.6. Tertiary Clarifier
Tertiary treatment of effluent involves a series of additional steps after

secondary treatment to further reduce organics, turbidity, nitrogen, phosphorus,
and pathogens.
Table E.6. Tertiary Clarifier Sizing
Item Tertiar Clarifier
Number of Unit 1
Reduce organics, turbidity, nitrogen,
Function
phosphorus, metals, and pathogens
Type Clarifier
Operation Data
o
Temperature 32 C
Pressure 1.010 kPa
Detention Time 2 h
Surface Overflow Rate 20 m /day/m2
3

Construction Data
Tank Volume 2.68 m3
Height 2.0 m
Diameter 1.31 m
E.7. Anaerobic Digester
Anaerobic digestion is the biological degradation of organic matters in the

absence of oxygen and converts the chemical energy in organic carbon to biogas.
In this process, the solution containing organic material will be degraded by
bacteria in a closed space so that the organic content will decrease.
186
Table E.8. Anaerobic Digester Sizing
Equipment Name Anaerobic Digester
Equipment Code AD-201
Construction data
Mass Flow Rate 385.0 Kg/h
Height of Ellipsoidal
0.15 m
(Hh)
Pressure Design
Tank Thickness
Cylinder Thickness 7 mm
E.8. Sludge Storage Tank
The sludge storage tank functions to store or accommodate the sludge

formed after the aeration process.
Table E.9. Sludge Storage Tank Sizing
Equipment Name Sludge Storage Tank
Equipment Code ST-201
Material HDPE
Type Closed tank
Head Elipsoidal
Bottom Flat
Construction data
Mass Flow Rate (kg/h) 625.0
Volume of Tank (L) 535.71
Tank Diameter (m) 0.97
Height of Cylinder (m) 1.94
Height of Ellipsoidal (m) 0.16
187
Height of Tank (m) 2.26

Pressure Design
Pressure Design (kPa) 152.626
Tank Thickness
Cylinder Thickness 10.4
(mm)
Head Thickness (mm) 11.33
E.9. Sludge Dewatering
The sludge dewatering process aims to reduce sludge volume and to achieve
overall cost efficiency for disposal. This process is done by means of a filter press.
Table E.10. Sludge Dewatering
Sludge Dewatering
Item Belt Filter Press
Vendor Vinson
Equipment Code DW-201
Number of Unit 1
Function Reduce sludge's wight and volume
Material Stainless steel
Mass flow 625 kg/h
Length 2600 mm
Width 1050 mm
Height 21050 mm
Capacity 3-5.2 m3/hr
Power
1 HP
consumption
APPENDIX F
STEAM UTILITY SPECIFICATION
F.1. Condenser
The table shows the specification of the condenser used to reduce temperature of
water from 152oC to 90oC in the steam utility.
Table F.1. Condenser Specification
Equipment Name Heat Exchanger
Equipment Code HX-101
Type Shell and Tube
Operating Condition
Data Shell Side Tube Side
Fluid Stream Inlet 1 5
Fluid Stream Outlet 2 6
Fluid Flow (kg/h) 226,363 1,658
Temperature in (oC) 5 152
Temperature out ( C)
o
10 90
Operating pressure (kPa) 101 180
No. of passes 1 6
Fouling factor (m2 oC/W) 0.0002 0.00009
Heat Duty (MW) 1.113
∆T LMTD (oC) 111.073
Overall U (W/m2 oC) 1,319.574
Type of unit Fixed tube
Material SS-316 atau SA-240
Heat Transfer Area (m2) 7.596
Tube OD (mm) 19.050
Tube Length (m) 4.880
Shell ID (m) 0.540
Tube Pitch (mm) 24
Tube Thickness (mm) 0.710
Number of tubes 4
Tube arrangement Triangular

189
F.2. Demineralized Water Storage Tank

This tank use for collecting water from condenser and makeup water. The water
from this tank is used for cooling and heating system. Table below will show the
specification of the tank.
Table F.2. Demineralized Water Storage Tank Specification
Equipment Name Tank for Demineralized Water
Construction data
Mass Flow Rate 3,315.4 Kg/h
Volume of Tank 3,978.48 L
Pressure Design
Tank Thickness
F.3. Fuel Storage Tank

This tank use to accommodate fuel in steam utility. The fuel from this tank is used
for combustion in boiler. Table below will show the specification of the tank.
Table F.3. Fuel Storage Tank Specification
Equipment Name Tank for Fuel
Construction data
Mass Flow Rate 163 Kg/h
190

Pressure Design
Tank Thickness
F.4. Compressor
Table below shows the specifications of air compressor for combustion in boiler.
Table F.4. Compressor Specification
Equipment Name Air Compressor
Equipment Code E-16
Type Centrifugal Compressor
Stage 1
Operation Data
Temperature 298.15 K
Pressure Inlet 101.325 kPa
Pressure Outlet 301.325 kPa
Flowrate 2,418 m3/hr
Compression Ratio 2.97
Construction data
Power 124.2 kW
F.5. Boiler
Table F.5. Boiler Specification
Equipment Name Boiler
Equipment Code SG-101
Heat Release Rate per Unit Volume
ṁc (kg/h) 163
ṁc (kg/s) 0.045277778
LHV (kJ/kg) 49725.27
qv (kW/m3) 230
V (m3) 9.788912385
191
Heat Release Rate per Unit Cross Sectional Area

ṁc (kg/h) 163
ṁc (kg/s) 0.045277778
qf (kW/m3) 2130
Fgrate (m2) 1.057018708
Hfu+Hb 9.260869565
Heat Release Rate per Unit Wall Area of Burner
qb (kW/m3) 1400
b (m) 0.980268381
Hb (m) 0.390606942
Hfu (m) 8.870262624
a (m) 1.078295219
Type of Burner
Power produced (kW) 2251.44985
Determination of Furnace Size
α 30
β 45
γ 50
E (m) 0.8
d (m) 0.2450671
Furnace Material
Inner case material SS-304
Furnace wall Fire brick
APPENDIX G
PUMP SPECIFICATION
F.1. Pump for Main Process
Table below will be shown the specification of pump for main process.
Table F.1. Pump (P-101) Specification
Name P-101
P in 51,300 Pa
P out 101,300 Pa
ΔP 50,000 Pa
Δh 0 m
ρ 1,263 kg/m3
g 9.8 m/s2
L pipe 3 m
F 1.074 m2/s2
ṁ 0.1056 kg/s
Flow 8.36E-05 m3/s
η 0.75
W theo 4.29 Watt
W act 5.72 Watt
Head 4.15 m
Type Rotary
P atm 101,325 Pa
P vap 3,110 Pa
NPSHa 3.892753 m
NPSHr 3.892184 m
Name P-102
P in 81,300 Pa
P out 201,300 Pa
ΔP 120,000 Pa
Δh 0 m
ρ 1,030 kg/m3
g 9.8 m/s2
L pipe 3 m
F 1.318 m2/s2
ṁ 1.4302 kg/s
Flow 0.00138889 m3/s
193
η 0.7
W theo 168.55 Watt
W act 240.79 Watt
Head 12.03 m
Type Axial
P atm 101,325 Pa
P vap 3,717 Pa
NPSHa 7.792207 m
NPSHr 7.687842 m
Name P-103
P in 71,300 Pa
P out 261,300 Pa
ΔP 190,000 Pa
Δh 0 m
ρ 1,029 kg/m3
g 9.8 m/s2
L pipe 7 m
F 3.079 m2/s2
ṁ 0.0286 kg/s
2.78078E-
Flow 05 m3/s
η 0.6
W theo 5.37 Watt
W act 8.95 Watt
Head 19.16 m
Type Rotary
P atm 101,325 Pa
P vap 3,717 Pa
NPSHa 6.704192 m
NPSHr 6.704151 m
194
Name P-104
P in 91,300 Pa
P out 261,300 Pa
ΔP 170,000 Pa
Δh 0 m
ρ 1,006 kg/m3
g 9.8 m/s2
L pipe 5 m
F 2.249 m2/s2
ṁ 0.0257 kg/s
Flow 2.553E-05 m3/s
η 0.6
W theo 4.40 Watt
W act 7.33 Watt
Head 17.47 m
Type Rotary
P atm 101,325 Pa
P vap 4,685 Pa
NPSHa 8.785586 m
NPSHr 8.785552 m
Name P-105
P in 51,300 Pa
P out 351,300 Pa
ΔP 300,000 Pa
Δh 0 m
ρ 1,026 kg/m3
g 9.8 m/s2
L pipe 7 m
F 3.085 m2/s2
ṁ 1.1403 kg/s
Flow 0.00111095 m3/s
η 0.75
W theo 336.80 Watt
W act 449.07 Watt
Head 30.14 m
Type Reciprocating
P atm 101,325 Pa
P vap 3,717 Pa
NPSHa 4.796861 m
195
NPSHr 4.730522 m
Name P-106
P in 51,300 Pa
P out 101,300 Pa
ΔP 50,000 Pa
Δh 0 m
ρ 1,025 kg/m3
g 9.8 m/s2
L pipe 3 m
F 1.325 m2/s2
ṁ 23.4860 kg/s
Flow 0.0229216 m3/s
η 0.75
W theo 1177.19 Watt
W act 1569.59 Watt
Head 5.11 m
Type Centrifugal
P atm 101,325 Pa
P vap 4,685 Pa
NPSHa 32.784731 m
NPSHr 4.642338 m
Name P-107
P in 71,300 Pa
P out 351,300 Pa
ΔP 280,000 Pa
Δh 0 m
ρ 1,056 kg/m3
g 9.8 m/s2
L pipe 5 m
F 2.142 m2/s2
ṁ 22.0560 kg/s
0.0208851
Flow 5 m3/s
η 0.75
W theo 5,895.09 Watt
W act 7,860.11 Watt
Head 27.27 m
196
Centrifuga
Type l
P atm 101,325 Pa
P vap 4,685 Pa
NPSH
a 31.256302 m
NPSHr 6.436612 m
Name P-108
P in 51,300 Pa
P out 101,300 Pa
ΔP 50,000 Pa
Δh 0 m
ρ 1,388 kg/m3
g 9.8 m/s2
L pipe 3 m
F 0.978 m2/s2
ṁ 3.3603 kg/s
Flow 0.002421 m3/s
η 0.8
W
theo 124.32 Watt
W act 155.40 Watt
Head 3.78 m
Reciprocati
Type ng
P atm 101,325 Pa
P vap 3,110 Pa
NPSH
a 4.118379 m
NPSH
r 3.542272 m
Name P-109
P in 51,300 Pa
P out 101,300 Pa
ΔP 50,000 Pa
Δh 0 m
ρ 995 kg/m3
g 9.8 m/s2
197
L pipe 3 m
F 1.364 m2/s2
ṁ 18.1869 kg/s
Flow 0.0182838 m3/s
η 0.7
W theo 939.01 Watt
W act 1341.44 Watt
Head 5.27 m
Type Centrifugal
P atm 101,325 Pa
P vap 3,110 Pa
NPSHa 21.819310 m
NPSHr 4.943548 m
Name P-110
P in 51,300 Pa
P out 101,300 Pa
ΔP 50,000 Pa
Δh 0 m
ρ 1,913 kg/m3
g 9.8 m/s2
L pipe 3 m
F 0.709 m2/s2
ṁ 0.8333 kg/s
0.00043
Flow 6 m3/s
η 0.7
W
theo 22.37 Watt
W act 31.95 Watt
Head 2.74 m
Type Rotary
P atm 101,325 Pa
P vap 3,110 Pa
NPSH 2.60545
a 0 m
2.57002
NPSHr
0 m
198
Name P-111
P in 51,300 Pa
P out 101,300 Pa
ΔP 50,000 Pa
Δh 0 m
ρ 1,956 kg/m3
g 9.8 m/s2
L pipe 3 m
F 0.694 m2/s2
ṁ 0.0578 kg/s
Flow 2.95E-05 m3/s
η 0.7
W theo 1.52 Watt
W act 2.17 Watt
Head 2.68 m
Type Rotary
P atm 101,325 Pa
P vap 3,110 Pa
NPSHa 2.514216 m
NPSHr 2.514045 m
Name P-112
P in 31,300 Pa
P out 151,300 Pa
ΔP 120,000 Pa
Δh 0 m
ρ 1,026 kg/m3
g 9.8 m/s2
L pipe 5 m
F 2.205 m2/s2
ṁ 23.5438 kg/s
0.02295115
Flow 1 m3/s
η 0.85
W
theo 2,806.05 Watt
W act 3,301.24 Watt
Head 12.16 m
Type Axial
199
P atm 101,325 Pa
P vap 4,685 Pa
NPSH
a 30.928488 m
NPSH
r 2.647459 m
Name P-113
P in 121,300 Pa
P out 151,300 Pa
ΔP 30,000 Pa
Δh 0 m
ρ 1,021 kg/m3
g 9.8 m/s2
L pipe 3 m
F 1.330 m2/s2
ṁ 20.6569 kg/s
0.0202397
Flow 2 m3/s
η 0.7
W theo 634.66 Watt
W act 906.66 Watt
Head 3.14 m
Type Centrifugal
P atm 101,325 Pa
P vap 5,101 Pa
NPSH 33.388312 m
a
NPSHr 11.617602 m
Name P-114
P in 101,300 Pa
P out 151,300 Pa
ΔP 50,000 Pa
Δh 0 m
ρ 1,014 kg/m3
g 9.8 m/s2
L pipe 3 m
F 1.338 m2/s2
ṁ 6.0851 kg/s
200
Flow 0.00599894 m3/s

η 0.85
W theo 308.09 Watt
W act 362.46 Watt
Head 5.17 m
Reciprocatin
Type g
P atm 101,325 Pa
P vap 5,101 Pa
NPSH
a 11.566455 m
NPSHr 9.677259 m
Name P-115
P in 51,300 Pa
P out 101,300 Pa
ΔP 50,000 Pa
Δh 0 m
ρ 995 kg/m3
g 9.8 m/s2
L pipe 3 m
F 1.364 m2/s2
ṁ 0.3599 kg/s
0.00036
Flow 2 m3/s
η 0.75
W
theo 18.58 Watt
W act 24.78 Watt
Head 5.27 m
Type Rotary
P atm 101,325 Pa
P vap 3,110 Pa
NPSH 4.95015
a 7 m
4.94354
NPSHr
8 m
Name P-116
P in 51,300 Pa
201
P out 101,300 Pa
ΔP 50,000 Pa
Δh 0 m
ρ 995 kg/m3
g 9.8 m/s2
L pipe 3 m
F 1.364 m2/s2
ṁ 0.3643 kg/s
Flow 0.00036625 m3/s
η 0.75
W theo 18.81 Watt
W act 25.08 Watt
Head 5.27 m
Type Rotary
P atm 101,325 Pa
P vap 3,110 Pa
NPSHa 4.950319 m
NPSHr 4.943548 m
Name P-117
P in 51,300 Pa
P out 101,300 Pa
ΔP 50,000 Pa
Δh 0 m
ρ 313 kg/m3
g 9.8 m/s2
L pipe 3 m
F 4.332 m2/s2
ṁ 0.4167 kg/s
Flow 0.0013299 m3/s
η 0.75
W
theo 68.30 Watt
W act 91.07 Watt
Head 16.73 m
Reciprocati
Type ng
P atm 101,325 Pa
P vap 3,110 Pa
NPSH
a 15.704188 m
NPSH 15.695330 m
202
F.2. Pump for Utilities

F.2.1. Steam Utility
Table below will be shown the specification of pump for steam utility
Table F.18. Pump (PM-101) Specification
Name PM-101
P in 101,325 Pa
P out 300,000 Pa
ΔP 198,675 Pa
Δh 0 m
ρ 1,007 kg/m3
g 9.8 m/s2
L pipe 3 m
F 1.348 m2/s2
ṁ 0.4603 kg/s
Flow 0.0004571 m3/s
η 0.7
W theo 91.43 Watt
W act 130.62 Watt
Head 20.27 m
Type Rotary
P atm 101,325 Pa
P vap 3.11E+03 Pa
NPSH
9.963083 m
a
9.9522728
NPSHr m
7
Name PM-102
P in 300,000 Pa
P out 505,000 Pa
ΔP 205,000 Pa
Δh 0 m
ρ 982 kg/m3
203
g 9.8 m/s2
L pipe 5 m
F 2.303 m2/s2
ṁ 0.9208 kg/s
Flow 0.000937392 m3/s
η 0.8
W theo 194.29 Watt
W act 242.86 Watt
Head 21.53 m
Type Rotary
P atm 101,325 Pa
P vap 17,750 Pa
NPSHa 29.363243 m
NPSHr 29.31998413 m
Name PM-103
P in 101,325 Pa
P out 201,325 Pa
ΔP 100,000 Pa
Δh 0 m
Ρ 880 kg/m3
G 9.8 m/s2
L pipe 5 m
F 2.571 m2/s2
ṁ 0.0453 kg/s
Flow 5.1452E-05 m3/s
Η 0.5
W theo 5.26 Watt
W act 10.52 Watt
Head 11.86 m
Type Rotary
P atm 101,325 Pa
P vap 40,000 Pa
NPSHa 7.111074 m
NPSHr 7.110969388 m
Name PM-104
P in 109,700 Pa
P out 300,000 Pa
204
ΔP 190,300 Pa
Δh 0 m
ρ 956 kg/m3
g 9.8 m/s2
L pipe 3 m
F 1.419 m2/s2
ṁ 0.4606 kg/s
Flow 0.0004817 m3/s
η 0.7
W theo 92.32 Watt
W act 131.89 Watt
Head 20.45 m
Type Rotary
P atm 101,325 Pa
P vap 70,160 Pa
NPSHa 4.230332 m
NPSHr 4.21950834 m
3.16.2.1. Wastewater Treatment
Table below will be shown the specification of pump for wastewater treatment.
Name P-204
P in 80,645 Pa
P out 300,645 Pa
ΔP 220,000 Pa
Δh 0 m
ρ 1,003 kg/m3
g 9.8 m/s2
L pipe 12 m
F 5.412 m2/s2
ṁ 0.3927 kg/s
Flow 0.00039144 m3/s
7
η 0.65
W 88.24 Watt
theo
W act 135.76 Watt
Head 22.93 m
Type Rotary
P atm 101,325 Pa
P vap 4,685 Pa
205
NPSH 7.734164 m
a
NPSHr 7.72629626 m
Name P-205
P in 50,645 Pa
P out 150,645 Pa
ΔP 100,000 Pa
Δh 0 m
ρ 1,000 kg/m3
g 9.8 m/s2
L pipe 3 m
F 1.357 m2/s2
ṁ 0.1109 kg/s
0.00011089
Flow 7 m3/s
η 0.6
W
theo 11.24 Watt
W act 18.73 Watt
Head 10.34 m
Type Rotary
P atm 101,325 Pa
P vap 4,632 Pa
NPSH
a 4.695691 m
NPSH
r 4.69506323 m
Name P-206
P in 150,645 Pa
P out 230,645 Pa
ΔP 80,000 Pa
Δh 0 m
ρ 1,001 kg/m3
g 9.8 m/s2
L pipe 3 m
F 1.356 m2/s2
206
ṁ 0.1287 kg/s
Flow 0.000128613 m3/s
η 0.6
W theo 10.46 Watt
W act 17.44 Watt
Head 8.30 m
Type Rotary
P atm 101,325 Pa
P vap 4,632 Pa
NPSHa 14.890006 m
NPSHr 14.88916108 m
3.16.2.2. Water Utility
Table below will be shown the specification of pump for water utility.
Name P-202
P in 101,325 Pa
P out 300,000 Pa
ΔP 198,675 Pa
Δh 0 M
ρ 992 kg/m3
g 9.8 m/s2
L pipe 3 M
F 1.368 m2/s2
ṁ 48.9493 kg/s
Flow 0.04932565 m3/s
5
η 0.75
W 9,866.72 Watt
theo
W act 13,155.63 Watt
Head 20.57 M
Type Centrifugal
P atm 101,325 Pa
P vap 4,685 Pa
NPSH 132.183675 M
a
NPSHr 9.93704413 M
7
207
Name P-203
P in 101,325 Pa
P out 400,000 Pa
ΔP 298,675 Pa
Δh 0 m
ρ 992 kg/m3
g 9.8 m/s2
L pipe 7 m
F 3.191 m2/s2
ṁ 47.8810 kg/s
Flow 0.048253031 m3/s
η 0.8
W theo 14,564.79 Watt
W act 18,205.98 Watt
Head 31.04 m
Type Centrifugal
P atm 101,325 Pa
P vap 4,685 Pa
NPSHa 126.906731 m
NPSHr 9.937845277 m
Name P-204
P in 101,325 Pa
P out 1,000,000 Pa
ΔP 898,675 Pa
Δh 0 m
ρ 992 kg/m3
g 9.8 m/s2
L pipe 3 m
F 1.368 m2/s2
ṁ 0.5409 kg/s
0.0005451
Flow 7 m3/s
η 0.8
W theo 490.67 Watt
W act 613.34 Watt
Head 92.57 m
Type Rotary
P atm 101,325 Pa
P vap 4,685 Pa
NPSHa 9.954075 m
NPSHr 9.9391474 m
208
209
APPENDIX H
MECHANICAL DRAWING
9261 mm
1057 mm
MECHANICAL DRAWING BOILER
CHEMICAL ENGINEERING PRODUCTION OF VITAMIN B12 FROM MOLASSES

ENGINEERING FACULTY
SIZE FSCM NO DWG NO REV
PLANT DESIGN COURSE
SG-101
GROUP TK - 06 SCALE N/A SHEET 1 OF 1
Figure H.1. Mechanical Drawing of Boiler
210
Figure H.2. Mechanical Drawing of Seed Medium Blending
211
2.47 m
7.15 m
35 mm
MECHANICAL DRAWING FREEZE DRYING
CHEMICAL ENGINEERING
ENGINEERING FACULTY PRODUCTION OF VITAMIN B12 FROM MOLASSES
SIZE FSCM NO DWG NO REV

PLANT DESIGN COURSE
FDR-101
2.79 m GROUP TK - 06
SCALE N/A SHEET 1 OF 1
Figure H.3. Mechanical Drawing of Freeze Dryer
Figure H.4. Mechanical Drawing of Clarifier
212
Figure H.5. Mechanical Drawing of Ion Exchange Chromatography
213
Figure H.6. Mechanical Drawing of Pre-Seed Fermenter
214
Figure H.7. Mechanical Drawing of Seed Fermenter
215
Figure H.8. Mechanical Drawing of Main Fermenter
216
Figure H.9. Mechanical Drawing of Aeration Tank
Figure H.10. Mechanical Drawing of Centrifuge
217
Figure H.11. Mechanical Drawing of Sterilizer
Figure H.12. Mechanical Drawing of Centrifuge Extractor
APPENDIX I
HAZID & HAZOP ANALYSIS
Table I.1. HAZID Analysis
Potential
Unit/Equipment/Location Description Causes Consequences Frequency Prevention
Hazard
To shaking
Regularly check and
suspension cell,
Cell Culture Flask Leakage Over capacity Insignificant Unlikely control the storage
aerobic bacteria, and
capacity
microorganism
Regularly check and
control the inlet and
Leakage Overflow Moderate Possible
outlet flow. Check
Mixing sucrose, the mixing rate
Seed Medium Blending water, and other Maintain flow rate
nutrients and temperature by
Pressure above
Implode Catastrophic Very likely controlling steam
the limit
and cooling water
flow rate
Table I.1. HAZID Analysis (cont’d)

219
Fermentation Medium Mixing molasses, Leakage Overflow Moderate Possible Regularly check and
Blending water, and other control the inlet and
nutrients outlet flow. Check
the mixing rate
Implode Pressure above Catastrophic Very likely Maintain flow rate
the limit and temperature by
controlling steam
and cooling water
flow rate
Blending Storage Storage tank after Leakage Overflow Moderate Possible Regularly check and
fermentation control the inlet and
outlet flow. Check
the mixing rate

the limit and temperature
Semi-Continuous To adequately heat Leakage, Corrosion of Major Possible Monitoring and

Sterilizer large amounts of process tube maintenance
medium under a disruption frequently
short amount of
220
time
Batch Sterilizer To prepare Leakage, Corrosion of Major Possible Monitoring and
inoculation of agar process tube maintenance
slants containing the disruption frequently
microorganism into
the fermenter
Pre-Seed Fermenter First step Leakage Overflow Moderate Possible Regularly check
fermentation and control the
inlet and outlet
flow, check the
mixing rate, make
sure to handle
spill carefully
221

by controlling
steam and cooling
water flow rate
Seed Fermenter Second step Leakage Overflow Moderate Possible Regularly check
inlet and outlet
flow, check the
mixing rate

by controlling
steam and cooling
water flow rate
Main Fermenter Second step Leakage Overflow Moderate Possible Regularly check
inlet and outlet
flow, check the
mixing rate, make
sure to handle
spill carefully
222

by controlling
steam and cooling
water flow rate
Centrifuge To separate solid Leakage Overflow Minor Possible Regularly check
particle (cell mass) and control the
from broth Clogging Blockage Moderate Possible inlet and each
outlet flows
Centrifuge Extraction To separate liquid Leakage Overflow Minor Possible Regularly check
waste and product and control the
inlet and each
outlet flows
Process Corrosion of Major Possible Change bearing
disruption tube or bearing periodically
223
Ion Exchanged To purify vitamin Mechanical High ion Major Unlikely Inspecting
Chromatography B12 by adsorbing it damage exchanged pressure and
with a negatively flammable chromatography temperature
charged resin pressure control regularly
Freeze Dryer To remove a solvent Heating and Extreme Major Unlikely Regularly check
usually water from cooling temperature and control
dissolved or system transition temperature inside
dispersed solids damage freeze dryer,
control exhaust
gas outlet flow
Belt Conveyor To load solid that Belt damage Excessive Minor Possible Install impact
has been crushed impact idlers or cradles in
through a belt the loading zone
Cyanocobalamin Storage Tank for Leakage Over capacity Major Possible Regularly check
Tank cyanocobalamin and control the
storage capacity
Compressors To supply gas that Sound Operation Nose Minor Possible Installing silencer
are needed for pollution on equipment
fermentation which emit noise,
224
processes using earplugs

Air Filtration To sterilize remove Membrane Overflow and Moderate Possible Maintain flow rate
contaminants filter damage high pressure and temperature
by controlling
steam and cooling
water flow rate,
regularly check
the membrane
condition
Leakage Overflow Minor Possible Maintain flow rate

and temperature
by controlling
steam and cooling
water flow rate,
regularly check
the membrane
condition
Water Utility To manage and treat Hotspot Heat release of Minor Very likely Using PPE
water from all water
process
Damage and Corrosion Minor Possible Using robust

leakage material that can
225
withstand
corrosion,
frequent
maintenance
Wastewater Utility To manage and treat Surrounding Overflow or Major Possible Maintain regular
wastewater from all contamination wastewater that schedule for
process store too long wastewater
treatment o the
flow will be in
safe range
Chemical Wastewater Major Unlikely Employee that
exposure or characteristic will handle
contact (BOD, COD, wastewater should
and TSS) above be equipped with
allowed level proper PPE and
safe distance
Steam Utility To manage and treat Fire and Fuel used in Major Unlikely Periodic
steam from all explosion boiler, high inspection and
process temperature, maintenance
high pressure
226
Noise Loud operation Minor Very likely Wear earplugs

pollution equipment
Damage Leaked steam Minor Unlikely Periodic

from fuel inspection and
storage tank maintenance
Pump To transport fluids Noise High decibel Moderate Very likely Using silencer,
between pollution operation insulation, or
equipment/unit provide
employees with
ear plugs
Implode Pressure above Catastrophic Very likely Regularly control,
the limit check, and
maintain fluid
pressure and flow
within safe range
227
Component High Major Possible Shut down pump

damage temperature when it is not
condition being operated,
regularly maintain
pump condition
228
Table I.2. HAZOP Analysis
Unit/Equipment Parameter Deviatio Possible Cause Effect Action Required Control

n
Cell Culture Level Low level Lack of supply Process units do not Install level indicator Schedule
Flask of feed have sufficient supply control and
of feed level
High Valve in inlet Tank overflow which Scheduled inspection indicator
level failed to be causes flooding and maintenance and
opened install level indicator
Medium Flow High Medium valve Unbalance amount of Regularly maintain and Flow
Blending is too wide medium for check controller Control
P.Denitrificans (FC)
Water rate is Different final product Adjust conveyor rate to

too fast specification its optimum
Low Medium valve Unbalance amount of Regularly maintain and
is too small medium for check controller
P.Denitrificans
Water rate is Different final product Adjust conveyor rate to
too slow specification its optimum
Table I.2. HAZOP Analysis (cont’d)
None Pipe clogged Process flow is stopped

Clean up clog within
pipe
Temperature High Steam flowrate Nutrient within Decrease steam Temperature
is too high medium will not affect flowrate Control
the growth of (TC)
229
P.Denitrificans
Cooling water Temperature for Increase cooling water
flowrate is too cooling down medium flowrate
low process is not achieved
Semi-Continuous Temperature More Hot water flow Sterilizer unit operation Hot water flow to be Temperature
Sterilizer rate is too high will not go well decreased Control
(TC)
Batch Sterilizer Temperature Less Hot water flow Sterilizer unit operation Hot water flow to be Temperature
rate is too low will not go well increased Control
(TC)
Fermenter Flow High P.Denitrificans Not optimum condition Regularly maintain and Flow
flow is too high and balance cultivation check controller Control
Medium valve (FC)
is too wide
Low P.Denitrificans
flow is too low
Medium valve
is too small
None Pipe clogged Process flow is stopped Clean up clog within
pipe
Pressure High Accumulation Implodes Open more emission Pressure
230
of gas and valve Control

components (PC)
within
fermenter
Centrifuge Flow High Separated liquid Product from Regularly maintain and Flow
valve is too centrifuge is not fulfill check controller Control
wide qualification (FC)
Liquid waste Adjust conveyor rate to
conveyor rate is its optimum
too fast
Low Separated liquid Regularly maintain and
valve is too check controller
small
Liquid waste Adjust conveyor rate to
too slow
Temperature High Hot air flowrate Unstable temperature Decrease hot water Temperature
is too high for maintain vitamin flowrate Control
Low Hot air flowrate B12 condition Increase hot water (TC)
is too low flowrate

231
Centrifuge Flow High Separated liquid Product from Regularly maintain and Flow
Extraction valve is too centrifuge extraction is check controller Control
wide not fulfill qualification (FC)
Low Separated liquid
valve is too
small
Ion Exchanged Level No level Total pump Lost of product Install a level control Level
Chromatograph failure, open and do periodic Control
y drainage and maintenance of the (LC)
the valve is pump and valve
closed
Low level The valve is Longer time needed to
partially open fill up the tank, which
lower than increases the retention
specified time of the production
High Valve fails to Reactant overflow in

level close the ion exchanged
chromatography, which
can cause equipment
damage
232
Flow No flow Total pump Absorption cannot Flow

failure, open occur, which decreases Control
drainage and the production capacity (FC)
the valve is
closed
Low flow The valve is Longer time needed to
partially open fill up the tank, which
lower than increases the retention
specified time of the production
High flow Valve fails to Reactant overflow in

close the ion exchanged
chromatography, which
can cause equipment
damage and
turbulences forming in
the tank that causes
foaming
Mixing No Agitator does The reactants are not Motor and RPM RPM
mixing not operate properly mixed leading monitoring system Control
to lower product yield should be provided
Poor Agitator does
233
mixing not work at

desired RPM
High Incorrect set The reactants are
mixing point of the mixed with a higher-
RPM than-specified RPM,
which disrupts
Pressure Low Leakage in the The pressure drops Install a pressure Pressure
pressure ion exchanged because of leakage, control and do periodic Control
chromatograph which decreases maintenance (PC)
y product yield
High Valve failure The gas inside the ion
pressure exchanged
chromatography builds
up, which increase the
pressure that can cause
explosion
Freeze Dryer Pressure High Emission flow Implodes Open emission valve Pressure
valve is to small more Control
(PC)
Low Emission flow Unstable emission flow Close emission valve
valve is to high more
Flow High Dry vitamin Water content in dry Regularly maintain and Flow
B12 flowrate is vitamin B12 product is check controller Control
too high not meet requirement (FC)
Table J.2. HAZOP Analysis (cont’d)
234
Low Dry vitamin

B12 flowrate is
too low
Temperature High Time for Unstable temperature Adjust timing for Temperature
freezing and for final dry vitamin freezing and drying of Control
drying are too B12 product vitamin B12 (TC)
long
Low Time for
freezing and
drying are too
slow
Belt Conveyor Temperature High Heat radiation Process disruption Monitoring and Temperature
maintenance frequently Control
(TC)
Cyanocobalamin Level Low level Lack of supply Process units do not Install level indicator Schedule
Storage Tank of feed have sufficient supply control and
of feed level
indicator
High Valve in inlet Tank overflow which Scheduled inspection
level failed to be causes flooding and maintenance and
opened install level indicator
235
Compressors Pressure Low The efficiency The pressure is Install a pressure Pressure
pressure of the different from the set control and do periodic Indicator
compressor pressure, which causes maintenance
drops the next operation to
not work as specified,
reducing product yield
More The set
point is
inaccurate
Air Filtration Pressure High Driving force Trigger heat and Open outlet flow valve Pressure
from pump is possibly fire in more Control
too high filtration process (PC)
Low Clogged in Product do not meet Clean up filter

filter by specification after
particulate filtration
Flow High Filtrated valve Product from air filter Regularly maintain and Flow
is too wide is not fulfill check controller Control
Solid waste qualification Adjust conveyor rate to (FC)
too fast
Low Filtrated valve
is too small
Solid waste
236
conveyor rate is
too slow
Temperature High Hot air flowrate Unstable temperature Decrease hot air Temperature
is too high for maintain vitamin flowrate Control
Low Hot air flowrate B12 condition Increase hot air (TC)
is too low flowrate
Pump Pressure No Blocked inlet Does not produce Install auto-vent on the Pressure
pressure and outlet of the permeate water line and periodical Indicator
pump inspection and
Low Pipe or vessel Low water pressure to maintenance to clean
pressure rupture and the next unit and the pump
plugging possibility of cavitation
Flow Low flow Failure in pump Low water pressure to Install a control valve Flow
section the next unit and and periodical Control
possibility of cavitation inspection and (FC)
maintenance to clean
the pump
High flow Mechanical High water supply to Install a control valve
failure in flange the next unit, which and periodical
causes the pump to run inspection and
out of fluids, causing maintenance to clean
the pump to be the pump
overheated
APPENDIX J
MATERIAL SAFETY DATA SHEET
SUB-APPENDIX A
Ammonium Phosphate
237
238
239
240
241
242
SUB-APPENDIX B
Ammonium Sulfate
243
244
245
246
247
248
SUB-APPENDIX C
Betaine
249
250
251
252
253
254
255
SUB-APPENDIX D
Cobalt Chloride
256
257
258
259
260
261
262
263
SUB-APPENDIX E
KH2PO4
264
265
266
SUB-APPENDIX F
Magnesium Sulfate Hydrate
267
268
269
270
271
272
273
274
SUB-APPENDIX G
Manganese Sulfate Hydrate
275
276
277
278
279
280
SUB-APPENDIX H
Sodium Hydroxide
281
282
283
284
285
286
287
SUB-APPENDIX I
Sulfur
288
289
290
291
292
293
294
SUB-APPENDIX J
Zinc Sulphate 7-Hydrate
295
296
297
298
299
300
301
302
SUB-APPENDIX K
Cresol
303
304
305
306
307
308
309
SUB-APPENDIX L
Sodium Cyanide
310
311
312
313
314
315
316
317
SUB-APPENDIX M
Sodium Nitrite
318
319
320
321
322
323
324
325
SUB-APPENDIX N
Sodium Chloride
326
327
328
329
330
331
332
333
SUB-APPENDIX O
Hydrogen Chloride
334
335
336
337
338
339
340
341
342
SUB-APPENDIX P
Ammonia
343
344
345
346
347
348
349
350
SUB-APPENDIX Q
Sucrose
351
352
353
354
355
356
357
358
359
SUB-APPENDIX R
Glucose
360
361
362
363
364
365
366
SUB-APPENDIX S
Fructose
367
368
369
370
371
372
373
374
APPENDIX K
PLANT CASHFLOW
Table K.1. Cashflow
Year % Capacity Revenue OPEX Maintenance Cost Depreciation Cash Expenses All Ex
0 2021 0 0 0 0 0 0
1 2022 70% 6,565,020 3,092,214 1,037,889 1,370,499 4,130,102
2 2023 90% 8,440,740 3,743,010 1,037,889 1,234,891 4,780,899
3 2024 100% 9,378,600 3,954,093 1,037,889 1,112,801 4,991,981
4 2025 100% 9,378,600 3,749,285 1,037,889 1,002,878 4,787,173
5 2026 100% 9,378,600 3,544,477 1,037,889 903,906 4,582,365
6 2027 100% 9,378,600 3,134,861 1,037,889 814,792 4,172,750
7 2028 100% 9,378,600 2,930,053 1,037,889 734,552 3,967,942
8 2029 100% 9,378,600 2,725,246 1,037,889 662,298 3,763,134
9 2030 100% 9,378,600 2,520,438 1,037,889 597,233 3,558,326
0 2031 100% 9,378,600 2,315,630 1,037,889 538,640 3,353,518
1 2032 100% 9,378,600 2,315,630 1,037,889 485,873 3,353,518
2 2033 100% 9,378,600 2,315,630 1,037,889 438,349 3,353,518
3 2034 100% 9,378,600 2,315,630 1,037,889 395,545 3,353,518
4 2035 100% 9,378,600 2,315,630 1,037,889 356,992 3,353,518
5 2036 100% 9,378,600 2,315,630 1,037,889 322,263 3,353,518
6 2037 100% 9,378,600 2,315,630 1,037,889 290,978 3,353,518
7 2038 100% 9,378,600 2,315,630 1,037,889 262,794 3,353,518
8 2039 100% 9,378,600 2,315,630 1,037,889 237,400 3,353,518
9 2040 90% 8,440,740 2,084,067 1,037,889 214,519 3,121,955
0 2041 70% 6,565,020 1,620,941 1,037,889 193,901 2,658,829
Table K.1. Cashflow (cont’d)
Cummulat
Year Before Tax Cash Flow Net Profit Before Tax Income Tax Net Profit After Tax After Tax Cash Flow Flow
2021 -25,129,796 -25,129,796 0 -25,129,796 -25,129,796 -2
2022 2,434,918 1,064,419 266,105 798,314 2,168,813 -2
2023 3,659,841 2,424,950 606,238 1,818,713 3,053,604 -1
2024 4,386,619 3,273,818 818,455 2,455,364 3,568,164 -1
2025 4,591,427 3,588,549 897,137 2,691,412 3,694,290 -1
2026 4,796,235 3,892,328 973,082 2,919,246 3,823,153 -
2027 5,205,850 4,391,058 1,097,764 3,293,293 4,108,086 -
2028 5,410,658 4,676,107 1,169,027 3,507,080 4,241,631
2029 5,615,466 4,953,168 1,238,292 3,714,876 4,377,174
2030 5,820,274 5,223,041 1,305,760 3,917,280 4,514,514
2031 6,025,082 5,486,441 1,371,610 4,114,831 4,653,471 1
2032 6,025,082 5,539,209 1,384,802 4,154,407 4,640,279 1
2033 6,025,082 5,586,733 1,396,683 4,190,050 4,628,398 2
2034 6,025,082 5,629,536 1,407,384 4,222,152 4,617,698 2
2035 6,025,082 5,668,090 1,417,023 4,251,068 4,608,059 3
2036 6,025,082 5,702,819 1,425,705 4,277,114 4,599,377 3
2037 6,025,082 5,734,103 1,433,526 4,300,578 4,591,556 4
2038 6,025,082 5,762,288 1,440,572 4,321,716 4,584,510 4
375
2039 6,025,082 5,787,681 1,446,920 4,340,761 4,578,161 4

2040 5,318,785 5,104,265 1,276,066 3,828,199 4,042,718 5
2041 3,906,191 3,712,290 928,072 2,784,217 3,801,435 5
376
APPENDIX L
CONTROL TABULATION
Table L.1. Control Tabulation Fermentation Section
Unit Contr Manip

Contr
N Oper olled Sens ulated Contr Actu Mecha
Nam I oller
o. ation Varia or Variab oller ator nism
e D Tag
ble le
The
magnet
ic float
transmi
ts data
with an
electric
signal
into the
level
controll
er;
which
Maint compar
aning es the
Seed V mediu variabl
Water Glob e and
Medi - m Mag
feed LC- e the set
1 um 1 level Level netic PID
flowrat 101 Valv point;
Blen 0 to not float which
e e
ding 1 cause then
overfl sends
ow an
electric
signal
into the
globe
valve
(on/off)
to
adjust
the
water
feed
flowrat
e.
Table L.1. Control Tabulation Fermentation Section (cont’d)
Unit Contr Manipu

Contr
N Opera olled Sen lated Contr Actu Mecha
Na I oller
o. tion Varia sor Variabl oller ator nism
me D Tag
ble e
377
The
digital
pH
meter
transmi
ts data
with an
electric
signal
into the
pH
meter
control
ler;
which
compar
Mainta
es the
ning
variabl
pH at pH NaOH Glob
pHIC- e and
an pH met feed PID e
101 the set
optima er flowrate Valve
point;
l level
which
for
then
sends
an
electric
signal
into the
globe
valve
(on/off
) to
adjust
the
NaOH
feed
flowrat
e.
Unit Contr Manip

Cont
N Oper olled Sens ulated Cont Actu Mech
I roller
o. Name ation Varia or Variab roller ator anism
D Tag
ble le
Ferme V Maint Water Glob The
Mag
ntation - aning feed LC- e magne
2 Level netic PID
Mediu 1 mediu flowrat 104 Valv tic
float
m 0 m e e float
378
transm
its
data
with
an
electri
c
signal
into
the
level
contro
ller;
which
compa
res the
variabl
level e and
to not the set
Blendi
2 cause point;
ng
overfl which
ow then
sends
an
electri
c
signal
into
the
globe
valve
(on/off
) to
adjust
the
water
feed
flowra
te.
Unit Contr Manipu

Contr
N Opera olled Sen lated Contr Actu Mecha
Na I oller
o. tion Varia sor Variabl oller ator nism
me D Tag
ble e
Mainta pH NaOH pHIC- Glob The
pH PID
ning met feed 102 e digital
379
pH
meter
transmi
ts data
with an
electric
signal
into the
pH
meter
control
ler;
which
compar
es the
variabl
pH at
e and
an
the set
optima er flowrate Valve
point;
l level
which
for
then
sends
an
electric
signal
into the
globe
valve
(on/off
) to
adjust
the
NaOH
feed
flowrat
e.
Unit Contr Manip

Cont
N Oper olled ulated Cont Actu Mecha
Na I Sensor roller
o. ation Varia Varia roller ator nism
me D Tag
ble ble
S Maint TC- The
T aning 101 Diap thermo
Temp Therm Steam
Steri - heatin TC- hrag couple
3 eratur ocoupl flowrat PI
lizer 1 g 103 m transm
e e e
0 tempe TC- Valve its data
1 rature 107 with an
380
electric
signal
into
the
temper
ature
control
ler;
which
compa
S res the
T variabl
- e and
1 the set
0 point;
for
2 which
sterili
S then
zation
T sends
- an
1 electric
0 signal
4 into
the
diaphr
agm
valve
to
adjust
the
steam
flowrat
e.
Unit Contr Manip

Cont
N Oper olled Sens ulated Cont Actu Mech
Nam roller
o. ID ation Varia or Variab roller ator anism
e Tag
ble le
E Maint The
X aning flat
Expa C- pressu PIC- diaphr
Vacuu
nsion 10 re to 101 agm
Flat m Diaph
Vess 1 separa Press PIC- transm
4 diaph Steam PI ragm
el E te ure 102 its
ragm flowrat Valve
Cha X steam PIC- data
e
mber C- from 105 with
10 sterili an
2 zed electri
381
c
signal
into
the
pressu
re
indicat
or
contro
ller;
which
compa
res the
variabl
e and
the set
E point;
mediu
X which
m via
C- then
flashi
10 sends
ng
3 an
electri
c
signal
into
the
diaphr
agm
valve
to
adjust
the
vacuu
m
steam
flowra
te.
Unit Contr Manip Cont

Cont
N Oper olled ulated rolle Actu Mech
Nam Sensor rolle
o. ID ation Varia Varia r ator anism
e r
ble ble Tag
H Maint The
TC-
E aning Chille Diap thermo
102
Heat X- cooli Temp Therm d hrag couple
TC-
5 Exch 10 ng eratur ocoupl Water PI m transm
104
anger 2 tempe e e flowra Valv its data
TC-
H rature te e with
108
E for an
382
electri
c
signal
into
the
temper
ature
control
ler;
which
compa
res the
variabl
e and
X-
the set
10
point;
4 sterili
which
H zed
then
E medi
sends
X- um
an
10
electri
6
c
signal
into
the
diaphr
agm
valve
to
adjust
the
chilled
water
flowra
te.
Unit Mani
Contr Cont
pulate Cont
N Operat olled rolle Actu Mech
Nam I Sensor d rolle
o. ion Varia r ator anism
e D Varia r
ble Tag
ble
Mainta The
Pre- S Chille Diap
ning thermo
Seed F Temp Therm d hrag
cooling TC- couple
6 Fer R- eratur ocoupl Water PI m
temper 105 transm
ment 10 e e flowra Valv
ature its
er 1 te e
for data
383
with
an
electri
c
signal
into
the
temper
ature
control
ler;
which
compa
res the
variabl
e and
microo
the set
rganis
point;
m
which
culture
then
to grow
sends
optimal
an
electri
c
signal
into
the
diaphr
agm
valve
to
adjust
the
chilled
water
flowra
te.
Unit Contr Manip

Contr
N Opera olled Sens ulated Contr Actua Mecha
Na I oller
o. tion Varia or Variabl oller tor nism
me D Tag
ble e
Maint Steriliz The
aning Mag ed Diaph magnet
LC-
mediu Level netic medium PID ragm ic float
102
m float flowrat Valve transm
level e its data
384
with an
electric
signal
into
the
level
control
ler;
which
compa
res the
variabl
e and
the set
point;
which
to not
then
cause
sends
overfl
an
ow
electric
signal
into
the
diaphr
agm
valve
to
adjust
the
steriliz
ed
mediu
m
flowrat
e.
Unit Contr Manip

Contr
N Operati olled Sen ulated Contr Actu Mecha
Na I oller
o. on Varia sor Variabl oller ator nism
me D Tag
ble e
The
Maintani
orifice
ng
plate
optimal Orif Butte
Air transm
aeration Flowr ice FC- rfly
flowrat PI its data
for ate plat 105 Valv
e with an
microor e e
electric
ganism
signal
growth
into
385
the
flowrat
e
control
ler;
which
compar
es the
variabl
e and
the set
point;
which
then
sends
an
electric
signal
into
the
butterfl
y valve
to
adjust
the air
flowrat
e.

Cont
N Operat olled ulated rolle Actu Mech
Nam I Sensor rolle
o. ion Varia Varia r ator anism
e D r
ble ble Tag
The
Mainta
thermo
ning couple
cooling transm
temper its data
S Chille Diap
ature with
Seed F Temp Therm d hrag
for TC- an
7 Ferm R- eratur ocoupl Water PI m
microo 106 electri
enter 10 e e flowra Valv c
rganis
2 te e signal
m
culture into
the
to grow
temper
optimal ature
386
control
ler;
which
compa
res the
variabl
e and
the set
point;
which
then
sends
an
electri
c
signal
into
the
diaphr
agm
valve
to
adjust
the
chilled
water
flowra
te.
Unit Contr Manip

Contr
Na I oller
me D Tag
ble e
The
magneti
c float
Maint transmit
aning s data
mediu Steriliz with an
m Mag ed Diaph electric
LC-
level Level netic medium PID ragm signal
103 into the
to not float flowrat Valve
cause e level
overfl controll
ow er;
which
compar
es the
387
variable
and the
set
point;
which
then
sends
an
electric
signal
into the
diaphra
gm
valve to
adjust
the
sterilize
d
medium
flowrat
e.
Unit Contr Manip

Contr
Na I oller
me D Tag
ble e
The
orifice
plate
transm
its data
with an
Maintani
electric
ng
signal
optimal Orif Butte
Air into
aeration Flowr ice FC- rfly
flowrat PI the
for ate plat 106 Valv
e flowrat
microor e e
e
ganism
control
growth
ler;
which
compar
es the
variabl
e and
388
the set
point;
which
then
sends
an
electric
signal
into
the
butterfl
y valve
to
adjust
the air
flowrat
e.

Cont
N Operat olled ulated rolle Actu Mech
Nam I Sensor rolle
o. ion Varia Varia r ator anism
e D r
ble ble Tag
The
thermo
F couple
R transm
- its data
1 Mainta with
0 ning an
1 cooling electri
F temper TC- c
Chille Diap
R ature 109 signal
Main Temp Therm d hrag
- for TC- into
8 Ferm eratur ocoupl Water PI m
1 microo 110 the
enter e e flowra Valv
0 rganis TC- temper
te e
2 m 111 ature
F culture control
R to grow ler;
- optimal which
1 compa
0 res the
3 variabl
e and
the set
389
point;
which
then
sends
an
electri
c
signal
into
the
diaphr
agm
valve
to
adjust
the
chilled
water
flowra
te.
Unit Contr Manip

Contr
Na I oller
me D Tag
ble e
The
magnet
ic float
transm
its data
with an
electric
Maint
signal
aning
LC- into
mediu Steriliz
104 the
m Mag ed Diaph
LC- level
level Level netic medium PID ragm
105 control
to not float flowrat Valve
LC- ler;
cause e
106 which
overfl
compa
ow
res the
variabl
e and
the set
point;
which
then
390
sends
an
electric
signal
into
the
diaphr
agm
valve
to
adjust
the
steriliz
ed
mediu
m
flowrat
e.
Unit Contr Manip

Contr
Na I oller
me D Tag
ble e
The
orifice
plate
transm
its data
with an
electric
signal
into
Maintani the
ng FC- flowrat
optimal Orif 107 Butte e
Air
aeration Flowr ice FC- rfly control
flowrat PI
for ate plat 108 Valv ler;
e
microor e FC- e which
ganism 109 compar
growth es the
variabl
e and
the set
point;
which
then
sends
an
electric
391
signal
into
the
butterfl
y valve
to
adjust
the air
flowrat
e.
Unit Contr Manip

Contr
N Oper olled Sen ulated Contr Actu Mecha
I oller
o. Name ation Varia sor Variab oller ator nism
D Tag
ble le
The
orifice
plate
transm
its data
with
an
electri
c
Maint signal
aning into
total the
G requir flowrat
Orif Butte
- ed air Air e
Compr Flowr ice FC- rfly
9 1 flow flowrat PI control
essor ate plat 104 Valv
0 for e ler;
e e
1 ferme which
nter compa
aerati res the
on variabl
e and
the set
point;
which
then
sends
an
electri
c
392
signal
into
the
butterf
ly
valve
to
adjust
the air
flowrat
e.
Unit Contr Manip

Contr
N Operat olled Sen ulated Contr Actua Mecha
Na I oller
o. ion Varia sor Variab oller tor nism
me D Tag
ble le
The
orifice
plate
transm
its data
with
an
P
electric
-
signal
1 Mainta
into
0 ning
the
1 mediu
FC- flowrat
P m
Orif Mediu 101 e
Pu - flowrat Diaph
1 Flowr ice m FC- control
mp 1 e to PI ragm
0 ate plat flowrat 102 ler;
s 0 meet Valve
e e FC- which
2 follow-
103 compa
P up unit
res the
- specific
variabl
1 ations
e and
0
the set
3
point;
which
then
sends
an
electric
signal
393
into
the
diaphr
agm
valve
to
adjust
the
mediu
m
flowrat
e.
Table L.2. Control Tabulation Separation Section
EQUIPMENT CONTROLLED SENSOR MANIPULATED CONTROLLER CONTROLLER A

VARIABLE VARIABLE TAG
BLENDING Level Point Discharge flowrate Level LIT-3 D

STORAGE Level controller va
V-103 Sensor (PI)
(optical)
Flowrate Orifice Valve opening in Flowrate FIC-2 G

plate stream 2 controller
(PI)
Table L.2. Control Tabulation Separation Section (cont’d)

Flowrate Orifice Valve opening in Flowrate FIC-1 G

plate stream 1 controller
(PI)
CENTRIFUGE Flowrate Orifice Input flowrate Flowrate FIC-3 G
394
DC-101 meter (cyanocobalamin controller

with impurities) (PI)

CENTRIFUGA Flowrate Orifice Solvent input Flowrate FIC-6 D

L EXTRACTOR meter flowrate controller va
CX-101 (PI)
CENTRIFUGA Flowrate Orifice Solvent discharge Flowrate FIC-7 D

L EXTRACTOR meter flowrate controller va
CX-101 (PI)
EQUIP CONTR SEN MANIPU CONTR CONTR ACTU CONTR

MENT OLLED SOR LATED OLLER OLLER ATOR OL
VARIAB VARIAB TAG PROCE
LE LE DURES
ION Flowrate Orific Valve Flowrate FIC-8 Diaphra The flow
EXCHA e opening in controller gm transmitte
NGE meter stream 8 (PI) valve r will
INX-101 send an
electric
signal to
the flow
controller
; which
compares
the
395
measured
flow rate
with its
setpoint
and sends
pneumati
c signal
the
control
valve
Flowrate Orific Valve Flowrate FIC-9 Diaphra The flow
e opening in controller gm transmitte
meter stream 10 (PI) valve r will
send an
electric
signal to
the flow
controller
; which
compares
the
measured
flow rate
with its
setpoint
and sends
pneumati
c signal
the
control
valve
EQUIPMENT CONTROLLED SENSOR MANIPULATE CONTROLLER CONTROLLER A

VARIABLE D VARIABLE TAG
Flowrate Orifice meter Valve opening in Flowrate FIC-10 D
stream 11 controller v
(PI)
396
FREEZE Temperature Thermocouple Nitrogen Flowrate Flowrate TIC-16 N

DRIER Controller
(PI)

Final Report - TK06

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Final Report - TK06

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UNIVERSITAS INDONESIA

PRODUCTION OF VITAMIN B12 FROM MOLASSES

CHEMICAL ENGINEERING DEPARTMENT

1. Name : Athalia Limbong

2. Name : Achmad Rayhan

3. Name : Christopher Reynaldo

4. Name : Merinda Innayah Fawwazita

5. Name : Muhammad Nabil Hifzhan

6. Name : Nur Elistiani Eksadita

Depok, December 2020

iii Universitas Indonesia

Department of Chemical Engineering, Faculty of Engineering, Universitas

Cyanocobalamin, often referred to as vitamin B12 is a dietary supplement

Keywords: Cyanocobalamin, Molasses, Pseudomonas Denitrificans,

To calculate whether this plant is profitable or not, an economic analysis is

The weighted average cost of capital or WACC is calculated to determine

LIST OF GROUP MEMBERS.............................................................................ii

1.2. Literature Review....................................................................................2

1.2.1. Vitamin B12........................................................................................2

1.2.2. Fermentation Process..........................................................................6

1.2.3. Bacteria for Fermentation Process......................................................7

1.3. Market and Capacity Analysis.............................................................10

CHAPTER 2 PROCESS DESCRIPTION.........................................................13

2.1. Process Alternatives..................................................................................13

2.1.1. Fermentation Section........................................................................13

2.1.2. Separation and Purification...............................................................16

2.2. Process Selection........................................................................................17

2.2.1. Process Material................................................................................17

2.3. Selected Process Description.................................................................25

viii Universitas Indonesia

2.3.2. Medium Mixing................................................................................25

2.3.4. Seed Fermentation............................................................................26

2.3.5. Product Fermentation........................................................................26

2.3.8. Ion Exchanged Chromatography......................................................28

2.3.9. Freeze Drying...................................................................................29

2.1. Block Flow & Process Flow Diagram..................................................29

2.2. Mass Balance..........................................................................................29

2.3. Energy Balance......................................................................................30

2.4. Plant Efficiency......................................................................................30

2.8.1. Water Utility.....................................................................................31

2.8.2. Air Utility..........................................................................................32

2.8.3. Electricity Utility..............................................................................33

2.8.4. Fuel Utility........................................................................................35

2.8.5. Wastewater Treatment......................................................................36

CHAPTER 3 EQUIPMENT DESIGN...............................................................38

3.1. Cell Culture Flask..................................................................................38

3.2. Medium Blender....................................................................................38

3.2.1. Seed Medium Blending....................................................................38

3.2.2. Fermentation Medium Blending.......................................................39

3.2.3. Blending Storage..............................................................................40

3.3.2. Batch Sterilizer.................................................................................45

3.4.1. Pre-Seed Fermenter..........................................................................46

3.4.2. Seed Fermenter.................................................................................47

3.4.3. Main Fermenter................................................................................49

3.6. Centrifugal Extractors..........................................................................51

3.7. Ion Exchange Chromatography...........................................................51

3.8. Freeze Dryer...........................................................................................52

3.9. Belt Conveyor.........................................................................................53

3.10. Cyanocobalamin Storage Tank............................................................53

3.12. Air Filtration..........................................................................................54

3.13. Water Utility...........................................................................................55

3.14. Wastewater Utility.................................................................................55

3.15. Steam Utility...........................................................................................55