KKKB 4844 BIOPROCESS PLANT DESIGN PROJECT II Lim Kah Huay A132816 Low Bee Chan A132764 Sonia Dilip Patel A/P Dilip Kumar A133115 Fatin Atikah Binti Kassim A132739 Jamilah Binti Ahmad A133159 Muhammad Khairil Azim bin Abdullah A133275 PRODUCTION OF BIOETHANOL FROM GLYCEROL USING Enterobacter aerogenes TISTR1468 Group KB4
Bioethanol production . slides comprises of mechanical drawings, control, waste treatment, safety..
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KKKB 4844BIOPROCESS PLANT DESIGN PROJECT II
Lim Kah HuayA132816Low Bee Chan A132764Sonia Dilip Patel A/P Dilip Kumar A133115Fatin Atikah Binti Kassim A132739Jamilah Binti Ahmad A133159Muhammad Khairil Azim bin Abdullah A133275
PRODUCTION OF BIOETHANOL FROM GLYCEROL USING Enterobacter aerogenes TISTR1468
Group KB4
2
CONTENT
1. Introduction2. Summary of Production3. List of improvement work4. Heat integration5. PFD after heat integration6. Piping and Instrumentation7. P&ID after HAZOP8. Detailed Unit & Mechanical Design9. Waste Management10. Process Hazard Analysis11. Plant Layout12. Conclusion
SUMMARY OF PRODUCTIONSpecifications Description
Product Bioethanol
Microorganism used Enterobacter aerogenes TSITR 1468
Height of impeller above vessel floor, C 0.65 m 1.17 mImpeller width, W 0.20 m 0.13 mLength of impeller width, L 0.25 m 0.26 mDiameter of impeller base, Dd 0.65 m 0.70 mBaffle width, J 0.16 m 0.29 m
Power number, Np 0.3 1.6
Flow number, Nq 0.55 0.85
Impeller speed 0.10 rps 0.01 rps
Power, P 0.3057 W 0.0008 W
Sparger ring diameter, Ds 1.08 m 1.15 m
Sparger location above vessel floor, S 0.49 m 0.53 m
Mixing time, tT 6.67 s 2041.06 s
Circulation rate, Q 0.05 m3/s 0.29 m3/s
…Continue
Detailed Design Fermenters
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MECHANICAL DESIGNSEED FERMENTER, F-101
Process Description Microaerobic continuous fermentation with an aeration rate of 0.5
vvm, medium consistently mixed by agitator. Glycerol and ammonium phosphate serve as raw material of carbon
and nitrogen source respectively Fermentation output consists of bioethanol and carbon dioxide
Material of Construction Carbon Steel SA 537
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Design Specifications Details
Operating Pressure 1 atm (15 psia)
Operating Temperature 37°C (310 K)
Corrosion Allowance 2 mm
Vessel Layout Vertical
H/D ratio 3:1
Volume 16.35
Torispherical Head (Top and Bottom Design)
Crown radius, R (m) 1.81
Knuckle radius, a (m) 0.19
Distance from the center of the torus to the center of the torus tube, c (m)
0.76
Height from the base of the dome to the top, h (m) 0.38
Cylindrical Shell (Shell Design)
Height, (m) 4.96
Effective Length, L (m) 5.21
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Vessel Parts Dimensions (mm)
Torispherical Top 5.72
Cylindrical Shell 8.89
Torispherical Bottom 5.72
Overall 11
Minimum Wall Thickness
Design of Cooling JacketDesign Parameters Details
Type Type 1 (confined entirely to the cylindrical shell)
Closure Type (b-2)
Material of Construction Carbon Steel SA537
Jacket Space 50 mm
Required minimum thickness of closure member as determined ()
Detailed Design of Flash Drum C-104KHAIRIL AZIM (A133275)
Inlet (S41)
Vapour Outlet (S42)
Liquid Outlet (S43)
h=1.219m
Dv=0.366
Flash drum C-104 is used to separate the vapour and liquid. For design calculations it is normally assumed that the vapour and liquid are in equilibrium and the vessel is adiabatic
Condition Value
Temperature 100 oC
Pressure 1 atm
Density of Water 958.4 kg/m3
Vapour Density 1.422 kg/m3
From the calculation,•The diameter must be large enough•The high of vessel outlet above the gas inlet should be sufficient for liquid drops.•Liquid level will depend on hold up time necessary for smooth operations and control
hv=0.283 m3
The conclusion from the calculation,Minimum vessel diameter,Dv = 0.366 mLiquid depth required,hv = 0.238 m3Height of the tank,H = 1.219 m
Mechanical Design of Flash Drum C-104KHAIRIL AZIM (A133275)
Parts Value/Description
Main Part:•Height•Diameter•Thickness•MAWPvessel
1.219 m0.366 m3.5 mm1.714 kPa
Support•Type•Material•Height•Thickness
Conical skirtPlain Carbon Steel0.25 m3.5 mm
Flanges•Feed•Liquid•Vapour
Welding neckWelding neckWelding neck
Design Summary of C-104
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Properties Value
Cooling water flow rate (kg/h) 105458
Water inlet temperature (°C)
37
Water outlet temperature (°C)
28
Ambient wet bulb temperature (°C)
23.9
Tower characteristic, KaL/V
1.5
Minimum tower area (m2)
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Height of cooling tower (m)
10.4Source : HarrisonCooling Tower 2002
DETAIL DESIGN OF COOLING TOWERFATIN ATIKAH (A132739)
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DETAIL DESIGN OF HEAT EXCHANGERNumber of tube 43
Length tube 4 m
Shell-Side Pressure Drop 78.94 kPa
Tube-Side Pressure Drop 1.84 kPa
Shell-side coefficient 63.94 W/m2oC
Tube-side coefficient 661 W/m2oC
Overall heat transfer cofficient, Uo
549.47 W/m2oC
Shell and Tube Exchanger
FATIN ATIKAH (A132739)
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MECHANICAL DESIGN FOR HEAT EXCHANGER (E-103) Parts Value/Description
Main Part:•Vessel length•Height vessel•Inner diameter•Outer diameter
4.0 m0.267 m0.016 m0.02 m
Support•Type•Material•Height•Thickness
Saddle support Carbon Steel 0.8 m0.15 m
Flanges Welding neck
Shell and Tube Exchanger
Saddle support Welding neck flanges
FATIN ATIKAH (A132739)
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Faculty of Engineering and Built Environment
Department of Chemical and Biochemical Engineering
Project Title:
Production of Bioethanol from Enterobacter aerogenes
Set of organized and systematic assessments of the potential hazards associated with an industrial process. A PHA provides information intended to assist managers and employees in making decisions for improving safety and reducing the consequences of unwanted or unplanned releases of hazardous chemicals.
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FMEA method- Systematic process to identify potential failures to fulfill the intended function, to identify possible failure and locate the failure impacts- Example of the method is shown in Seed Fermenter F-101
Component Failure mode Failure effects Symptom Safeguard ActionLevel control valve
Valve fails openValve fails closed
Fluid will exceed the level of storage tank causing overflow and rupture the tank
Liquid overflow None Schedule inspection and maintenance required
Pure glycerol valve
Valve fails open No glycerol in the tank. Product produce does not meet the specification.
The reaction is not complete
None Daily check
Temperature control valve
Valve fails open High temperature in the tank. It will effect product reaction
Condenser(Cooler) Power failure Unable to cool the
outlet stream
Very high
temperature is
flowing out
None Back-up power
supply generator
Level control valve Valve fails open
Valve fails closed
Fluid will exceed
the level of storage
tank causing
overflow and
rupture the tank
Liquid overflow None Schedule
inspection and
maintenance
required
- FMEA analysis for Distillation Column C-101
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PROCESS HAZARD ANALYSIS
HAZOP Analysis
• HAZOP Analysis is to identify how a process deviation can be prevented or mitigate to minimize the potential hazard. Example of the analysis is in the distillation column.
Project name : Process Plant Design
Process : Bio ethanol production
Part : Distillation Column
Study node Process parameterDeviations
(guide words)Possible causes Possible consequence Action required
Stream 28 Flow NO Pipe broken or plugging
Loss of feed into column/not achieve into desired output.
Level decrease in distillation column.Off specification product.
1. Schedule inspection and maintene.an
LOW 1. Pipe partial plugged or leakage.
1. Level decrease in distillation column.
2. Off specification product.3. Back flow of material.
Install check valve.
HIGH 1. High pressure from source
1. Flooding in distillation column. 1. Install bypass line with manual valve.
Distillation column Level HIGH 1. Output pipe blockage.
Overpressure of reflux drum.Condensed liquid flow back to
distillation.
1. Install high level alarm2. Scheduling inspection
LOW Pipe partial clogged & leakage. Level decrease in the vessel The valve closed.Back flow of material.
1. Scheduling inspection2. Install valve.
Temperature HIGH 1. Low incoming flow from H-101 cause overheating.
Off specification product.
Install temperature sensor.
LOW 1. H-101 malfunction.2. High incoming flow through H-
1. Scheduling inspection2. Install temperature sensor.
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CONCLUSION
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A high yield and potential for ethanol as fuel from Enterobacter aerogenes. Pengerang has been the best location judging from the coming development as Asia’s largest storage terminal.
Production rate of 3276 kg/hr and high demand in 2018 (projection) will leave a very stable economic growth for ethanol.
65% saving of energy through pinch and heat exchanger installation will further bloom the net profit.
Mechanical calculations and drawings for main utilities provide a clearer insight of the sizing and supports.
Safety has been of top consideration through FMEA and HAZOP performed. Layers of control aspect will further enhance the safety and continuous operation of ethanol plant.
Waste management has been of top priority and calculations from waste treatment plant designed is able to lower down pollutants to allowable limits.