Chapter 6-Equipment Design (Production of Lactic Acid From Sugarcane Bagasse)

I.
INTRODUCTION
Several factors are considered in properly designing an efficient and economical
production plant. Equipment design and its importance are significant in the industrial
manufacturing plants that is at par with the production of cost-effective and high quality products.
With the reference with the previous chapters, an ideal process flow diagram was produced
that determine the plant capacity and detailed computation of the mass and energy balances of the
equipment. Equipment will be subject to determine their capability while being subjected to
different parameters such as temperature, pressure and the likes. This manuscript will be providing
an optimum design for the Fermentor, Rotary Drum Filter, Carbon adsorber and Evaporator.
The importance of appropriate materials of construction must also be recognized. Products
desired cannot be manufactured without considering the selection of appropriate and optimum
materials of construction. This will be used to consider the container safe, economical for
manufacturing and maintaining of the product quality. The materials to be selected must resist
corrosion and sufficient strength to prevent breakdown caused by external parameters and
processing of the product. Operating conditions are also one of the major considerations for the
design of equipment. The design must be capable of producing the desired condition and must
withstand any stresses and extreme conditions of the operation.
Designing involves in the preparation of individual equipment specification sheet that is
derived from the fabrication of different kinds of units with the help of available brochures.
Modernization and development of new processes requires the use of chemical engineering
principles and theories that is blended with actual limits with concern on the environmental and
safety standards.
279
II. SPECIFICATION SHEETS
A. Specification Sheet for Fermenter
SPECIFICATION SHEET
IDENTIFICATION
Name of Equipment Fermenter
Equipment Code R2
Equipment Type Stirred-Type Bioreactor
Operation Batch Operation
Number required 2 units
BASIC DESIGN DATA
Function To ferment glucose into lactic acid
Operating Temperature 24 - 37C
Operating Pressure 1.20 atm
Material Handled C6H12O6 (glucose), H2O, Na2SO4, Yeast Extract, CaCO3
VESSEL DESIGN
Vessel Capacity 6 m3
Height 5.50 m
Diameter 3.00 m
Material of Construction SS304
Shell Thickness 3.00 mm
Head Thickness 3.00 mm
Welding Type Double Welded Butt Joints (fully radiographed)
IMPELLER DESIGN
Impeller Type 4-Pitched No. of Impeller 3
Blade
Rotational Speed 150 rpm Impeller Diameter 1m
No. of Baffles 4 Impeller Width 0.2 m
Baffle Width 0.25 m Impeller Length 0.25 m
Impeller Clearance at the Bottom 1m Distance between Impeller 1.25 m
POWER REQUIREMENT
Motor Size 5 hp
COOLING SYSTEM DESIGN
Jacket Area 3.25 m2
Jacket Diameter 11.00 m
Distance of Outer Shell to Jacket 4.50 m
Thickness of Jacket 2.00 mm
Material of Construction SS304
Cooling Medium Water
Cooling Temperature 25C
280
Stirrer Shaft
Seal
Inoculation Pipe Vent
Working
level
Impeller
HT
HL
Baffle
Sampling Da
point
Drain Point
281
W
La
282
ASSUMPTIONS
1. The fermentation will be conducted in a batch reactor.
2. 1 units of fermenter will be used per batch.
3. An allowance of 5-6 hours for the cleaning and start-up of the fermenter will be
allocated.
4. The material of construction of the fermenter will be SS304 for corrosion resistance.
5. ASME-UPV vessel design code will be used for the vessel design.
6. The impellers to be used will be Four-Pitched Blade turbines.
7. Motor efficiency of the agitator is 80 %.
8. The cooling system of the fermenter will be a jacketed type.
Design Equations:
Residence Time of Fermentation
From Bioprocess Engineering (2nd Edition) by Doran, P. M.:
1 max
tb = ln [1 + (p p0 )]
max x0 q p f
q p = YP () + ms
S
where:
max maximum specific growth rate
x0 initial cell density
qp specific rate of product formation
pf/0 final(f) / initial (0) product concentration
283
tb batch culture time
ms - maintenance coefficient
Vessel Design
(Ref: Principles of Fermentation Technology by Stanbury, P.F. et al:Table 7.2. Details of
Geometrical Ratios of Fermenters with Three Multi-bladed impellers)
Height of the Liquid (L):
DT 2
VFeed = HL
4
Internal Pressure (P):
g
P = Patm + Hliquid g c
Shell Thickness:
For Cylindrical shell
(Ref: Plant Design and Economics by Peters and Timmerhaus, Table 4 p.537)
Pri
ts = + Cc
SEJ 0.6P
284
Head Thickness:
For Ellipsoidal head
(Ref: Plant Design and Economics by Peters and Timmerhaus, Table 4 p.537)
PDa
th = + Cc
2SEJ 0.2P
Impeller Design
(Ref: Principles of Fermentation Technology by Stanbury, P.F. et al:Table 7.2)
Impeller Diameter:
1
=
3
Impeller distance from Vessel floor:
1
=
3
Length of Impeller Blade:
1
=
4
Width of Impeller Blades:
1
=
5
Baffle Width:
1
=
12
285
Distance between Impellers:
= 1.3
(Ref: Plant Design and Economics by Peters and Timmerhaus, page 241)
Power Requirement:
For NRe>10,000
(Ref: Unit Operations of Chemical Engineering by McCabe and Smith, 5th Edition)
KT n3 D5a
P= gc
Da v
NRe =
Da impeller diameter
Viscosity of Fermentation Broth:
(Ref: Chemical Engineering Design Principles, Practice, and Economics of Plant and
Process Design by G. Towler, et al. p. 440 Eq. 8-11.)
1 x
= i
Ave i
286
Cooling System (Jacket) Design
(Ref: Ch.E. Handbook 8th Edition, p. Eq. 5-31)
Surface Area of Jacket (Heating Area):
Q
AJ =
UTLM
Log Mean Temperature Difference:

(Ref: Ch.E. Handbook 8th Edition, p. 5-7 Eq. 11-5a)
(t1 t "2 ) (t 2 t1" )

TLM =
(t1 t "2 )
ln [ ]
(t 2 t1" )
Where 1- inlet condition, 2- outlet condition
-hot fluid , -cold fluid
Diameter of Vessel with Jacket

Vwater (Djacketedvessel )2 (DT + 2t s )2
Area of Jacket = =
HL 4 4
Outer Shell to Jacket Distance

Jacketed Vessel Diameter Outer Shell Diameter of Tank
dsj =
2
Thickness of Jacket
Pri
ts = + Cc
SEJ 0.6P
287
NOMENCLATURE
Aj Jacket Area, m2
c Corrosion allowance, in
Da Impeller Diameter, m
DT Inside Diameter of Tank, m
E Distance of impeller from the bottom of the vessel
g Gravitational constant, m/s2
HT Height of tank, m
J Baffle width, m
L Blade Length of Impeller, m
mS maintenance coefficient, h-1
P Internal pressure, psi
Q Heat released during reaction, W
qp specific rate of product formation, h-1
Sw Working Stress, psi
tB Batch time, h
tH Head thickness, mm
tR Reaction time, h
tS Shell thickness, mm
Vliquid Volume of liquid, m3
VT Volume of tank, m3
W Impeller width, m
XA Conversion
Xo initial cell density, g/L
Y Impeller distance, m
- Viscosity of fermented broth, Pa-s
max maximum specific growth rate, h-1
density of fermented broth, kg/m3
288
Design Calculations:
6 12 6 + 0.0171.61 0.56 0.16 = 0.0141.8 0.50.2 + 0.0032 + 0.0012 +
23 6 3
Residence Time of Fermentation
1 max
tb = ln [1 + (p p0 )]
max x0 q p f
From Optimization and modeling of Lactic acid production by Rasfid Roslina
mass of lactic acid

pf = volume of fermented broth
1000g
476.28 kg
kg
pf = 1000L
5.8535 m3
1 m3
pf = 81.3667 g/L
p0 = 0, no product at the beginning of fermentation
Yp/s= 0.8248 kg Lactic acid per kg glucose, ms=0.098/h
q p = (0.09033 h-1) (0.8248) + 0.098
q p = 0.1725 h-1
x0 = 9.26565 g/L
max = 0.09033/h.
289
0.09033
1
tb = ln [1 + (81.3667 0)]
0.09033 9.26565 0.1725
( )( )

= 42.62 hours (1.77days)
Total batch time:
= + + + +
(Ref: Chemical Process Engineering, Design and Economics by Silla, Table 7.10 p. 397)
Assuming that it takes the maximum time for all variables, therefore:
tf = 2.38 h
tc = 2.0 h
te = 1.0 h
tb = 42.62 h + 2.38 h + 2.0 h + 1.0 h
tb = 48 h (2 days)
290
unit 1 batch harvested
Number of Units Required = 1 batch 2 days
day
Number of Units = 2 units
Vessel Design
In Fermented Broth:
Component Mass (kg) Density(kg/m3) Volume(m3)
Calcium Lactate 576.83 1,490 0.3871
Calcium Carbonate 7.44 2,710 0.0027
Calcium Sulfate 7.89 2,320 0.003
97.55 1,540 0.063

Glucose
Water 5,395.31 1,000 5.395
Sodium Carbonate 6.14 2,540 0.0024
Total 6,094.39 5.8535
Total Volume of Feed = 5.8535 m3/batch
Total Mass = 6,094.39 kg/batch
Total Mass
Average Density: ave = Total Volume
6,094.39 kg
ave =
5.8535 m3
= 1,041.14 kg/m3
291
Volume of Feed per unit of Fermenter:
Total Volume
VFeed = Number of Units
5.8535 m3 /batch
VFeed =
1 unit/batch
=5.8535 m3/unit
From Brochure Mobius Bioreactors Specification Sheet, and upscaling the rated capacity of the
bioreactor to 6000L:
D = 2.52 m = 99.21 in (R=49.60 in)
H = 5.05 m
VFeed
Height of Liquid: HLiquid =
D 2
4 T
5.8535 m3
HLiquid =
(2.5255)2
4
= 1.1685 m
g
Internal Pressure: P = Patm + Hliquid g c
kg m
P = 101,325 Pa + (1,041.14 m3 ) (1.1685 m) ( 9.81 s2 )
= 113,259.57 Pa = 16.431 psi
292
Shell Thickness:
For Cylindrical shell:
Pri
ts = + Cc
SEJ 0.6P
For Fully Radiographed Double-butt Welded: EJ = 1.00. For SS304, working stress (SW
= 123 MPa = 17,844.56 psi)
(Ref: ChE Handbook, 8th ed., Table 25-11, p. 25-36)
(16.431 psi)(49.6 in)

t s = (17,844.56)(1)(0.6)(16.431)
t s = 0.0457 in, < 0.25 in
1
t s = 0.0457 in + in
16
= 0.1081 in 2.748 mm (3mm)
Head Thickness:
For Ellipsoidal head:
PDa
th = + Cc
2SEJ 0.2P
For Fully Radiographed Double-butt Welded: EJ = 1.00. For SS304, working stress (SW =
123 MPa = 17,844.56 psi)
(16.431 psi)( 99.21 in)

t h = 2(17,844.56)(1)(0.2)(16.431)
293
t h = 0.0457 in, <0.25 in
1
t h = 0.0457 in + in
16
= 0.1081 2.747 mm (3mm)
Impeller Design
From brochure Mobius Bioreactors Specification Sheet, the impeller used is 4-Pitched Blades.
Impeller Diameter:
1
=
3

= (. ) = .

Impeller distance from Vessel floor:
1
=
3

= (. ) = .

Length of Impeller Blade:
1
=
4

= (. ) = .

294
Width of Impeller Blades:
1
=
5

= (. ) = .

Baffle Width:
1
=
12

= (. ) = .

Distance between Impellers:
= 1.3
= . (. ) = .
Power Requirement
For NRe>10,000
KT n3 D5a
P= gc
Dv
NRe =
Viscosity of Fermentation Broth:
1 x
= i
Ave i
295
xi
Component Mass (kg) Mass Fraction Viscosity
i
Calcium Lactate 576.83 0.0946 - -
Calcium -
7.44 0.0012 -
Carbonate
Calcium Sulfate 7.89 0.0013 - -
97.55 0.016 0.00555 2.883

Glucose
Water 5,395.31 0.8853 0.000864 1,024.653
Sodium 1.212
6.14 0.001 0.000825
Carbonate
Total 6,094.39 1.00 1,028.748
1 x
= i
Ave i
1
= 1,028.748
Ave
= 9.72E-04 Pa-s
Computation of the Reynolds Number:
Da v
NRe =

296
From the brochure Mobius Bioreactors Specification Sheet, the type of impeller used is a 4-pitched
blade turbine. The fermenter will be agitated at 150rpm.
1 min kg
(0.842 m)(150rpm )(1,041.14 3 )
60 s m
NRe = 9.72E-04 Pas
= 2,254,732 > 10,000
Power Requirement
K T n3 D5a
=
gc
For Four-Pitched Blade turbine, KT = 1.27.
(Ref: Unit Operations and Processes in Environmental Engineering 2nd Edition by Reynolds and
Richards, Table 8.2 p. 236)
K T n3 D5a
=
gc
1 kg
(1.27)(150 )3 (0.842 m)5 (1,041.14 3 )
60 m
PTheo = 1
PTheo = 2,783.33 W 3.73 hp
297
Approximate Efficiency of an Electric Motor varies between sizes. In this equipment, a
less than 5 kW turbine have a motor efficiency = 80%
(Ref: Chemical Engineering Design by Sinnott R.K., Table 3.1 p. 93)
.
= = = 4.66 hp 5 hp
.
From, the nearest standard size electric motor is 5 hp.
(Ref: Chemical Process Engineering, Design and Economics by Silla, Table 5.10 p. 240)
Cooling System (Jacket) Design
Surface Area (Heating Area):
Q
AJ =
UTLM
298
kJ 1000J 1 batch 1 unit 1h
Qunit = 4,173,629.01 batch 3600s
kJ 1 unit 72 h
= 16,101.96 W/unit
Log Mean Temperature Difference:
Fermentation Broth Cooling Water

Inlet Temperature Outlet Temperature Inlet Temperature Outlet Temperature
(C) (C) (C) (C)
50 37 25 35
(t1 t "2 ) (t 2 t1" )
TLM =
(t1 t "2 )
ln [ ]
(t 2 t1" )
(50 35) (37 25)
TLM =
(50 35)
ln [ ]
(37 25)
= 13.44 K
The cooling water will flow counter-current to the feed:
Counter-current Flow
60
50
Temperature, C
40
30
20
Feed Cooling Water
299
From Chemical Process Engineering Design and Economics Table 7.6; for stirred tank (jacketed)
using cooling water with organic solution. U = 50 80 Btu/h-ft2-F. For an average value of U =
65 Btu/h-ft2-F (369.07 W/m2-K):
(Ref: Chemical Process Engineering, Design and Economics by Harry Silla. 2003, Table 7.6 p.
386)
16,101.96 W/unit
AJ =
W
(369.07 2 ) (13.44 K)
m K
= 3.246 m2 3.25 m2
300
Diameter of Vessel with Jacket: Cooling water flowrate is at 99,800 kg/day for Fermenter.
Vwater (Djacketedvessel )2 (DT + 2t s )2

Area of Jacket = =
HL 4 4
kg 1 batch
99,800
batch 1 unit
Vwater = kg
1000 3
m
Vwater = 99.8 m3/unit
m3
99.80 unit (Djacketedvessel )2 (2.5255 + 2(3103 m)2
=
1.1685 m 4 4
= 10.548 m 10.75 m
Outer Shell to Jacket Distance:
Jacketed Vessel Diameter Outer Shell Diameter of Tank

dsj =
2
10.548 ( 2.5255 +3103 )
dsj = 2
= 4.01 m 4.25 m
301
Thickness of Jacket:
For SS304, the working stress (SW) = 17,844.56 psi
Pri
ts = + Cc
SEJ 0.6P
kg m
P = (1000 m3 )(9.81 s2 )(1.852 m)
P = 18,168.12 Pa = 2.636 psi
(2.636 psi)(49.6 in)

t s = (17,844.56)(1)(0.6)(2.636)
t s = 0.0073 in, < 0.25 in
1
t s = 0.0073 in + in
16
= 0.0698 in 1.774 mm (2mm)
302
B. Specification Sheet for Microfilter
SPECIFICATION SHEET
IDENTIFICATION
Name of Equipment Microfilter
Equipment Code F-3
Number of Elements 2
Number of tubes per element 100
Function To separate the cell mass and other solids
from the fermented medium
Operation Continuous
Type Tubular Microfiltration Membrane
Materials Handled Calcium Lactate, Cell Mass, Calcium
Carbonate, Sodium Carbonate, Calcium
Sulfate, Residual sugars and Water
Number Required 1 unit
BASIC DESIGN DATA
Pressure 1.5 bar
Pressure Drop 1.9738 atm 2 bar
Temperature 25 30 C
Filtrate Flow 0.2438 m3/h
Permeate Flux 18.7402 L/m2-hr
Permeability 329.3533 L/ m2-hr-atm
Rate of Filtration 13.7 m3/hr
Filtration Time 0.4276 hours
Membrane Permeability 329.3533 L/m2-hr-atm
Power Requirement 0.2438 hp
Total Filtering Time 0.7276 hours/day
Shell Thickness 2.0199 x 10-3 m
MEMBRANE DESIGN
Filter Membrane Used Polyether sulfone (PES)
Total element Area 9.3 m2
No. of tubes 100
Area of membrane/per module 0.093 m2
Pore Size 0.1 micron
Membrane Diameter 1.55 x 10-3 m
Length 1.022 m
Operating Mode Crossflow Filtration
HOUSING DESIGN
Type 2-port style
Materials of Construction Stainless steel AISI 316/316L
Module Length 1.044 m
PUMP DESIGN
Pump Type Centrifugal Pump
303
DIAGRAM FOR MICROFILTER (F-3):
D0 = 160.6 mm
L0= 1022 mm
L0 = 1040 mm
I0 = 125 mm
304
ASSUMPTIONS:
1. The Microfiltration is operated at constant pressure filtration.

2. Material of Construction Stainless steel AISI 316/316L
- Pentair X-Flow R-100 Microfiltration Membrane Brochure
3. Type of Microfiltration Membrane: Tubular Membrane

- Membrane Filtration Handbook, pg.16
4. Operating Pressure: <2 bar; 1.5 bar
5. Pressure Drop: 1.9738 atm

- Table 14 from Membrane Filtration Handbook
6. Membrane Material: Polyether sulfone (PES)
7. Theoretical Internal Diameter of permeate tube: 1 in = 0.0254 m
- Table 8 Types and Variables of Tubular Membranes, Membrane Filtration
Handbook, p.18
8. For Shell Thickness:
- Hesse and Rushton Equipment Design
- Fm = 1.0, for high tensile strength steel
- Fs = 0.25, steel factor
- Fa = 1.0, radiographing factor
- Fr = 1.0, steel relieving factor
- Su = 248 MPa, Table 28-11, p.28-39, Chemical Engineering Handbook 7th
Edition
- e = 0.7, for V and U single butt joint
9. Length of module: 1040 mm
10. Viscosity () of the filtrate, since it is composed mostly of water has a value of = 0.85
cP or 8.5x10-4 Pa-s
- Unit Operation, of Chemical Engineering Appendix
11. The velocity is assumed to be 5 m/s that gives a turbulent flow and good mass transfer, -
pg.1036, Unit Operations of Chemical Engineering, 7th Edition
12. Size range of calcium lactate: 0.000394 0.0015 microns
- Molecular Recipes: Calcium Chloride, Calcium Lactate and Calcium Lactate

Gluconate
305
Size range of cell mass: 0.5 0.8 microns
- JGI Genome Portal
13. Length of tube: 1.022 m

DESIGN EQUATIONS
1. Unit Operations of Chemical Engineering by McCabe and Smith 7th Edition, Equation
29.48, p.1040

= kc ln 2
1 2
Where:
= permeate flux (L/m2-h)
Kc = Mass Transfer Coefficient
Cs = cell mass and CaSO4 concentration in the retentate (kg/m3)
C1 = cell mass and CaSO4 concentration in the feed (slurry) (kg/m3)
C2 = maltose, dextrin and insoluble solid concentration in (kg/m3)
30.55, p.1041
7.32 1016
Dv=

Where:
Dv = diffusivity (cm2/s)
T= operating temperature (K)
ro = radius of particles (cm)
= (cP)
3.10, p.53

NRe =

Where:
D = diameter of tube (cm)
D= 1 in 2.54 cm
V= velocity of fluid (cm/s)
= average density of the feed (g/cm3)
= viscosity of major component in solution fed as assumed (g/cm-s)
4. Unit Operations of Chemical Engineering by McCabe and Smith 7th Edition, p.539

NSc =

Where:
306
= viscosity of major component in solution fed as assumed (cP)
= average density of feed (g/cm3) = Xi = 1060.256 kg/m3 = 1.060256 g/cm3
Dv = diffusivity (cm2 /s)
5. Unit Operations of Chemical Engineering by McCabe and Smith 7th Edition, p.552
NSh = 0.0096 NRe0.913 NSc 0.346
Where:
NSh= Sherwood Number
NSc= Schmidt Number
NRe = Reynolds Number
17.50 p.545

kc =

Where:
NSh = Sherwood Number

7. =
8. Hesse and Rushton Process Equipment Design, Equation 4-3, p.87

ts = 2 +
Where:
ts= minimum shell thickness

C = corrosion allowance usually taken as 1/6 inch
D = inside diameter
P = maximum internal pressure
S = working or allowable tensile stress
e = efficiency of the welded joints
9. Chemical Engineering Handbook 7th Edition, Equation 10-50, pg.10-23

P=
3.559 10^6
Where:
H = total dynamic head (Pa)
Q = capacity = 13.7 m3/hr
307
DETAILED DESIGN COMPUTATION
MEMBRANE PROCESS SELECTION
According to Table 2 from Membrane Filtration Handbook, among the four membrane
processes: reverse osmosis, nanofiltration, ultrafiltration and microfiltration; it is best to use
microfiltration since its primary purpose in the process is to separate the cell mass and other solids
from the fermented medium. Thickness should be in range of 10-150 m. The pore size will be
ranging between 4 - 0.02 m with membrane module allowed are tubular and hollow fiber.
Membrane materials allowed are ceramic PP, PSO (polysulfone) and PVDF
(polyvinylidenedifluoride). The operating pressure should be <2 bar (Wagner, 2001).
308
MEMBRANE MATERIAL SELECTION
Means high resistance

Means low resistance
Means either that the information is based on theory of that practical results have
proved to be dubious
According to Table 4 in Membrane Filtration Handbook as shown, it is suitable to use
Polyether sulfone (PES) because of its high resistance with most of the organic and inorganic
compounds. It is suitable even at high operating temperatures and has high resistance in a wide
range of pH.
309
From Material Balance:
Table 1: Input/Feed to the Microfilter

Component Mass Mass Density Volume Xi
(kg/day) Fraction (kg/m3) (m3/day)
(Xi)
Calcium Lactate 576.83 0.0946 1,490.00 0.3871 140.954
Water 5,395.31 0.8853 1,000.00 5.3953 885.300
CaCO3 7.44 0.0012 2,710.00 0.0027 3.252
Na2CO3 6.14 0.0011 2,540.00 0.0024 2.794
Cell Mass 3.2329 0.0005 600.00 0.0037 0.300
CaSO4 7.88 0.0013 2,320.00 0.0033 3.016
Glucose 97.55 0.0160 1,540.00 0.0633 24.640
Total 6,094.38 5.8578 1060.256
Table 2: Filtrate/Permeate
(Xi)
Calcium Lactate 576.74 0.0948 1,490.00 0.3871 141.252
Water 5,394.48 0.8870 1,000.00 5.3945 887.000
Na2CO3 6.14 0.0010 2,540.00 0.0024 2.540
CaCO3 6.84 0.0011 2,710.00 0.0027 2.981
Glucose 97.54 0.0161 1,540.00 0.0633 24.794
Total 6,081.74 5.8500 1058.567
Table 3: Residue/Retentate
(Xi)
Calcium Lactate 0.08 0.006329 1,490.00 0.0000537 9.43021
Water 0.82 0.064873 1,000.00 0.00080 64.87300
Cell Mass 3.23 0.255538 600.00 0.0054 153.32280
CaSO4 7.88 0.623418 2,320.00 0.0034 1446.32976
Glucose 0.01 0.000791 1,540.00 0.0000065 1.21814
CaCO3 0.59 0.046677 2,710.00 0.00022 126.49467
Total 12.64 0.00988 1801.66858
310
MEMBRANE AREA CALCULATION
Diffusivity (Dv):
From Unit Operations of Chemical Engineering by McCabe and Smith, 7th Edition, page 538
7.32 1016
Dv=

Where:
T= operating temperature (K)
ro = radius of particles (cm)
= viscosity (cP)
Size range of calcium lactate: 0.000394 0.0015 microns (Molecular Recipes: Calcium
Chloride, Calcium Lactate and Calcium Lactate Gluconate)
Size range of cell mass: 0.5 0.8 microns (JGI Genome Portal)
0.000394+0.0015 106 100

Dave of calcium lactate = = 9.47 x 10-8 cm
2 1 1
0.5+0.8 106 100

Dave of cell mass = = 6.5 x 10-5 cm
2 1 1
9.47 108 +6.5 105

Dave = = 3.2547 x 10-5 cm
2
3.2547 105
r0 ave = = 1.6274 105 cm
2
= viscosity (cP)
Assume that the bulk concentration comprises major component of the solution which is
composed of water with viscosity of 0.85 cP or 8.5x10-4 Pa-s.
7.32 1016 (30+273.15)
Dv =
(1.6274 105 ) (0.85 )
= 1.6042 x 10-8 cm2 /s
Schmidts Number (NSc):

From Unit Operations of Chemical Engineering by McCabe and Smith, 7th Edition, p. 539

NSc =

311
Where:
= viscosity of major component in solution fed as assumed (cP)
= average density of feed (g/cm3) = Xi = 1060.256 kg/m3 = 1.060256 g/cm3
Dv = diffusivity (cm2 /s)

0.085
NSc =
(1.060256 /3) (1.6042 x 108 cm2 /s)
= 4997399.827
Reynolds Number (NRe):
From Unit Operations of Chemical Engineering by McCabe and Smith, 7th Edition, p.53

NRe =

Where:
D= 1 in 2.54 cm
V= velocity of fluid (cm/s)
= average density of the feed (g/cm3)
= viscosity of major component in solution fed as assumed (g/cm-s)
Table 8 p.18 Types and Variables of Tubular Membranes, Membrane Filtration Handbook
Assume V=5m/s that gives turbulent flow and good mass transfer ( pg. 1036 of Unit Operations
of Chemical Engineering, McCabe Smith, 5th Edition)

2.54 (500 )
NRe =
0.085
= 14,941.1765
312
Sherwood Number NSh (for high Schmidt Number):
NSh = 0.0096 NRe0.913 NSc 0.346
Where:
NSh= Sherwood Number
NSc= Schmidt Number
= 0.0096 (14,941.1765)0.913 (4997399.8270)0.346
= 12,919.6280
Mass Transfer Coefficient (Kc):

Unit Operations of Chemical Engineering by McCabe and Smith 7th Edition, Equation
17.50, p.545

kc =

Where:
NSh = Sherwood Number
(12,919.6280)(1.6042 x 108 cm2 /s)

kc = = 8.1597 x 10-5 cm/s
2.54
Permeate flux ():

From Unit Operations of Chemical Engineering by McCabe and Smith, 7th Edition, p. 1042

= kc ln 2
1 2
Where:
= permeate flux (L/m2-h)
Kc = Mass Transfer Coefficient
313
C2 = maltose, dextrin and insoluble solid concentration in (kg/m3)
According to Overall Material balance sheet, since there will be no component of cell mass and
CaSO4 in filtrate/permeate, C2 = 0.
Permeate flux equation will be:

= kc ln 1
For Cs and C1 calculation:

Based on Overall Material Balance Data Sheet:
( + )
Cs = 4
(3.23+7.88)/
=
0.009883 /
= 1124.4939 kg/m3
( +4 )
C1 =

(7.88+3.2329)/
=
5.8578 3 /
= 1.8971 kg/m3

Since C2 = 0, = kc ln 1
-5
1124.4939 /3
= (8.1597 x 10 cm/s) ln
1.8971 /3
= 5.2098 x 10-4 cm/s = 5.2098 x 10-6 m/s
From Table 30.4 Conversion Factors for Permeate Flux in Unit Operations of Chemical
Engineering by McCabe Smith
314
1 2.78 107
=
2
1
2
= 5.2098 x 10-6 m/s x 2.78107

= 18.7402 L/m2- h
According to the Membrane Filtration Handbook by Wagner, p. 94, there is no general rule for
the permeate flux of Microfiltration, and,if in doubt, a low flux value should be used, given that
there is also no given permeate flux from the brochures used, thus, this value of permeate flux is
acceptable.
Permeability (Qm):

Qm =
()
Where:
= permeate flux
Qm = membrane permeability
P = pressure drop
= osmotic pressure difference
= average viscosity of water as assumed major component in feed
water = viscosity of water (0.85cP)
Osmotic Pressure Difference ():

= (Cs -C1)

Where:
R= 0.08206 L-atm/mol-K
MWave = average molecular weight of cell mass and CaSO4
315
(29000+136.14)/
MWave = = 14568.07 g/mol
2
Cs = 1124.4939 kg/m3 = 1124.4939 g/L
C1 = 1.8971 kg/m3 = 1.8971 g/L

(0.08206 )(30+273.15)
= (1124.4939-1.8971) g/L
14568.0700 /
= 1.9169 atm
Pressure Drop (P):

For Microfiltration (Process Liquid) from Table 15 of Membrane Filtration Handbook, p.24
Typical Number of Elements = 2 (Table 15 from Membrane Filtration Handbook, p. 23)

Maximum allowed pressure drop = 1.0 bar per element (Table 14 from Membrane Filtration
Handbook)
1
P= 1 bar (2 elements) = 2 bar ( ) = 1.9738 atm
1.01325
P = 1.9738 atm = 200 kPa
Permeability (Qm):
()
Qm=
()

.
2
(0.85 )
=
(1.97381.9169 )(0.85)
Qm = 329.3533 L/m2-hr-atm
316
From Membrane Filtration Handbook, Table 37 Necessary Steps for Designing a System, p.117:
Actual Area of Membrane:

( )
=

( )
2
Where:
A= area of membrane (m2)

v = Permeate flux ( )
2
Number of tubes per element required:

No. of ultrafilter unit =
/

= ( ) ( )
But since there is a given 9.3 m2 of total membrane area and 100 number of tubes in the Pentair
X-Flow R-100 Microfiltration Membrane Brochure, the total membrane area and no. of tubes
were not computed.
9.3 2
Ratio of total membrane area / no. of tubes = = 0.093 m2 (Filter Area)
100
To solve for total time of filtration:

From the Pentair X-Flow R-100 Microfiltration Brochure, the flowrate is 13.7 m3/hr
Time of Filtration:
5.8578 3
3
= .
13.7
Backwash Frequency: once every 15 minutes

Backwash Frequency for 1 hour:
60
1 = 60 15 = 4
1
Backwash Duration: 5 minutes (average) range is 1 10 minutes
Total Filtering Time (t):
Total time of filtration breakdown:
Time of Filtration = 0.4276 hours
317
Time of Washing = 0.3 hours
_______________________________________
Total Time = 0.7276 hours/day
FILTER MEDIA
The appropriate material for the filter membrane with respect to the feed and pressure applied is
a Polyether sulfone (PES) according to the Pentair X-Flow R-100 Microfiltration Membrane
Brochure.
POWER REQUIREMENT
From Chemical Engineering Handbook 7th Edition, pg.10-23 Equation 10-50

P=
3.559 10^6
Where:
H = total dynamic head (Pa)
H = 1.4804 atm = 150000 Pa 101325 Pa = 48675 Pa
Q = capacity = 13.7 m3/hr
Assume: 1 day = 24 hour-operation
3
48675 13.7

= = 0.1853 kW = 0.2438 hp
3.599106
0.1853
Pactual = = = 0.2647 kW
0.70
TYPE OF PUMP USED: CENTRIFUGAL PUMP
From Perrys Chemical Engineers Handbook 7th Edition, pg. 10-24
Centrifugal pump is used due to its capacity ranging from 0.5 m3/h to 2 x 104 m3/h (2
gal/min to 105 gal/min (2 gal/min to 105 gal/min, this type of pump is widely used in the
chemical industry for transferring liquids of all types.
SHELL THICKNESS (ts):

ts = 2 + ( , . 4 3, . 87)
318
Where:
ts= minimum shell thickness
C = corrosion allowance usually taken as 1/6 inch
D = inside diameter
P = maximum internal pressure
S = working or allowable tensile stress
e = efficiency of the welded joints
S = Su * Fs * Fm * Fr * Fa
Su = ultimate or yield strength of material (ChE Handbook 8th edition, Table 25-8, p.25-36)
Fm = material factor = 1.0 for high tensile strength carbon steel
Fs = steel factor = 0.25
Fa = radiographing factor = 1.12 if mandatory and 1,0 if not mandatory
Fr = stress relieving factor
Su = ultimate yield strength of material (Chemical Engineering Handbook 7th Ed., p.28-39)
Where:
Fm = 1.0
Fs = 0.25
Fr = 1.0
Fa = 1.0
e = 0.7 for V of U double butt joint
Su = 248 x 106 Pa = 2447.5799 atm
S = (2447.5799 atm)(1)(1)(0.25)(1)= 611.8950 atm
Operating Pressure = 1.4804 atm

ts = 2 +
(1.4804 )(0.254)
ts = (2)(611.8950)(0.7)1.4804 + 1.58103 = 2.0199103
ts = 2.0199 mm
319
C. Specification Sheet for Carbon Adsorber
SPECIFICATION SHEET
IDENTIFICATION
Name of Equipment Carbon Adsorption Tank
ProtectTM LM-72 Modular Liquid Adsorber
Equipment Model
(Calgon Carbon Corporation)
Equipment Code T-4
Equipment Type Fixed-bed down flow adsorber
BASIC DESIGN DATA
Function To purify and adsorb the residual sugar
Temperature 25-30 OC
Pressure 107.5 kPa
Hydraulic Loading 0.74 m3 feed/(m2 bed hr)
Flow Rate 0.665 m3/hr.
Glucose (C6H12O6), Lactic Acid (C3H6O3)
Materials Handled
, Water (H2O)
ADSORBER DESIGN
Carbon Type Norit SX-plus
Carbon Bed Length 23 in.
Contact Time 46.24 mins.
Carbon Replacement 60 days
Carbon Weight 308.4 kg
Pressure Drop 0.24 Pa.
Succession of two metal screens
Carbon Support
with sizes 14 and 80 mesh
VESSEL DESIGN
Height 48 in.
Diameter 42 in.
Material of Construction UNS K03005 Carbon Steel
320
Wall Lining Vinyl ester
Wall Lining Thickness 30 mils
Shell Thickness 1 in.
Head Thickness 1 in.
double-welded butt joints
Welding Type
(spot-examined)
321
DT = 42 in.
Influent
Carbon Charge 30 mils

ts = 1 in.
HL = 11 in.
HT =48 in.
Carbon Bed Surface
Hb= 23 in.
Carbon Discharge
Metal Screen
Effluent
Fixed-Bed Carbon Adsorber
322
List of Assumptions
1. Norit SX-plus will be used as an adsorbent in the process.

2. 1 unit of carbon adsorber will be used.
3. Maximum usable time of adsorbent is 60 days.
4. Carbon Steel (UNS K03005) with vinyl ester lining is used as material of construction in vessel desig
adsorption vessel for better abrasion resistance to withstand movement of the hard carbon particles.
5. ASME-UPV vessel design code will be used for the design of vessel.
6. The allowance for vapor space is around 20% of the height of liquid available
Summary of design Equations:

Adsorber Design
Carbon Usage Rate
(Ref: Adsorption Design Guide by U.S. Army Corps of Engineers, page 3-4)
(Co Ce )V
CUR =
Wsat
Where;
CUR = Carbon usage rate
Co = Initial concentration of adsorbate in feed
Ce = Desired concentration of adsorbate in effluent
= Equilibrium or saturation value of adsorbent
Volume of Activated Carbon

CUR t
Vcarbon =
carbon (bulk)
Where;
t = Maximum usable time of adsorbent (Change Out Period)
323
Bed Depth
= ( )
Mass of Carbon Needed
2

= ( ) ( )
4
Linear Flow Velocity / Hydraulic Loading,

(Ref: Unit Operations of Chemical Engineering by McCabe et.al, eq. 25.3, p. 847)
( )
=

Where:
= Maximum usable time of adsorbent, hr
= Length/Height of adsorber bed, m
= True density of the bed, kg/m3
= Equilibrium or saturation value of adsorbent, g adsorbate/g carbon
= Initial value of adsorbate in the adsorbent, g adsorbate/g carbon
= Linear flow velocity, m/hr
= Initial concentration of adsorbate in feed, kg/m3
Volumetric Flow Rate of Feed

2
=
4
Contact Time (Residence Time)

(Ref: Adsorption Design Guide by U.S. Army Corps of Engineers, p .3-3)

=

Pressure Drop
324
2
150 (1 )2 1.75 1
= + ,
2 2 3 3
Where:
= Pressure differential
= Bed length
= Linear flow velocity
= Viscosity
= Particle diameter
= Porosity of adsorbent
= Sphericity of carbon adsorbent
= Average density of feed
Vessel Design
Height of Liquid

=
2
Since vapor space is around 20%
= (1 0.20)
Maximum Allowable Internal Pressure

= + +

Maximum Allowable Working Stress

=

Shell Thickness
ASME vessel design for cylindrical shell
325

= +
0.6
Head Thickness
ASME vessel design for ellipsoidal head

= +
2 0.2
Adsorber Design
From Material Balance

Mass, m Density, Volume
Component
(kg/day) (kg/m3) (m3/day)
Lactic Acid 470.03 1209.00 0.3889
Water 393.47 995.03 0.395
Glucose 0.46 1540.00 0.0003
Total 863.96 0.7846
Technical Specification of Activated Carbon

(Ref: Cabot Norit Activated Carbon Specification)
Carbon Type : Norit SX-plus
Apparent Density : 608.7 kg/m3
Mean Diameter : 1.3 mm
Porosity : 0.95
Carbon Usage Rate

(Co Ce )V
CUR =
Wsat
326
Where;
CUR = Carbon usage rate
Co = Initial concentration of adsorbate in feed
Ce = Desired concentration of adsorbate in effluent
= Equilibrium or saturation value of adsorbent
Initial glucose concentration in feed

0.46 1000 1 3
Co = 3
= 0.59
0.7846 1 1000
1 1000
Co = 0.59 = 3.25
180.16 1
Equilibrium or saturation value of adsorbent:

(Ref: Glucose and Cellobiose Adsorption onto Activated Carbon by Yu Sun)
From the graph above;

At glucose concentration of 0.59 g/L; = 0.09
Desired concentration of glucose in the effluent
327
= 0 ; Since all glucose component of the feed was adsorb
Therefore:
m3 1000 L
(0.59 0) (0.7846 )
day 1 m3
CUR =
0.09

= . . /

Volume of Activated Carbon

CUR t
Vcarbon =
carbon (bulk)
Where; t = Maximum usable time of adsorbent (Change Out Period)
Then:
Maximum usable time of adsorbent per unit is 60 days
Change out Period / Carbon Replacement in Unit, t = 60 days
(Ref: Chemical Process Equipment Selection and Design by Walas)
Therefore:
kg
5.14 (60 days)
day
Vcarbon =

608.7 3

= .
Mass of Carbon Needed:

= Vcarbon
kg
= 0.51 3 (608.7 )
m3
= . ( )
Adsorber Diameter and Bed Depth

Based on the available diameter of the carbon adsorber with a carbon capacity of around 1000 lbs, then:
328
Dadsorber = 42 1.07 . 36
(Ref: Modular Liquid Adsorber Protect LM Series by Calgon Carbon Corporation)

Then:
= ( )
2

= ( ) ( )
4
1.072
0.51 3 = ( ) ( )
4
= = . (. )( . )
Linear Flow Velocity / Hydraulic Loading,

( ) ( )
= ; =

Where:
= Maximum usable time of adsorbent, hr
= Length/Height of adsorber bed, m
= True density of the bed, kg/m3 /(1 )
= Equilibrium or saturation value of adsorbent, g adsorbate/g carbon
= Initial value of adsorbate in the adsorbent, g adsorbate/g carbon
= Linear flow velocity, m/hr
= Initial concentration of adsorbate in feed, kg/m3
329
Then:
Initial value of adsorbate in the adsorbent
= 0 ; since fresh carbon is introduced into the unit
Therefore:
( )
=

kg
(608.7 )
m3
(0.57 m)(0.09 0)
= 1 0.95
0.46 24
( 3 ) (60 )
0.7846 1

= . (. /)

Volumetric flow rate of feed

, =

(1.07)2 2
= 0.74 [ ]
4

= .

330
Contact Time (Residence Time)
(Ref: Adsorption Design Guide by U.S. Army Corps of Engineers, p .3-3)

=

Then:
(1.07 )2
(0.57 ) [ ]
4
=
0.665 3 /
= . .
Pressure Drop
2
150 (1 )2 1.75 1
= + ,
2 2 3 3
Where:
= Pressure differential
= 1.86 , Bed length

= 0.74 6.74104 , Linear flow velocity

= 4.12 cp 0.00277 , viscosity

(Ref: Viscositv and Densitv of Aqueous L.A. Solutions, p. 1145)

= 1.3 mm 0.00427 ft, Particle diameter
= 0.95, Porosity of adsorbent
= 0.73, Sphericity of carbon adsorbent
(McCabe & Smith, T. 7.1, p.164)
= average density of feed
863.96
= = 3
= 1,101.15 3 (68.74 3 )
0.7846
331

150 (6.74104 ) (0.00277 )
(1 0.95)2
= 1.86
0.953
(32.2 2 ) (0.73)2 (0.00427 ft)2
[
2
lb 4
1.75 (68.74 ) (6.7410 )
ft 3 (1 0.95)
+
0.953
(32.2 2 ) (0.73)(0.00427 ft)
]
lbf 1 ft 2
= (0.0049 ) ( )
ft 2 12 in
= . .
Other Design Data

Internal Lining : Vinyl ester (30 mils); for better abrasion resistance
Carbon Support : The bed is supported at the bottom by two metal screens placed in succession with
and 80 mesh supported by steel grid and support bars
(Ref: Chemical Process Equipment Selection and Design by Walas, p. 510)
Inlet Distributor: Inlet flow distributor will be used for equal distribution of feed in the activated carb
332
Vessel Design
Total Height of Adsorber

Based on the available height of the carbon adsorber with a carbon capacity of around 1000 lbs, then:
= . . 36
(Ref: Modular Liquid Adsorber / ProtectTM LM Series by Calgon Carbon Corporation)
Height of Liquid
Since the carbon bed was positioned in the middle of the adsorption tank, the available height for liquid is the

=
2
1.22 0.57
=
2
= 0.325 (13 . )
Assuming that the allowance for vapor space is around 20% of the height of liquid available, then the height
level that must be maintained on the top of the bed is,
= (1 0.20)
= 0.325 (1 0.20)
= 0.26 11 .
Maximum Allowable Internal Pressure

= + +

333
1 2 308.49.8 14.7
= 14.7 + 68.74 3 (0.85 ) ( ) (1) + ( )
12 (1.07)2 101325
4
= . (. )
Material of Construction
Carbon Steel UNS K03005 with 30 mils vinyl ester lining
(Ref: Adsorption Design Guide by U.S. Army Corps of Engineers)
Tensile Strength: 415 Mpa (60,207.25 psi)
Factor of Safety: 5
Maximum Allowable Working Stress

=

415 MPa
= = 83.00 (12,041.45 )
5
Shell Thickness
ASME vessel design for cylindrical shell

= +
0.6
Where;
= 0.85, double-welded butt joints (spot-examined)
= 2 = 1.07 2 = 0.535 (21.06 )
= 1/16 in., Corrosion allowance

(15.59 ) (21.06 ) 1
2
= +
16
(12,041.45 2 ) (0.85) (0.6) (15.59 2 )

= . (. ) .
334
Head/Bottom Thickness
ASME vessel design for ellipsoidal head

= +
2 0.2
Where;
= 1.0, welding efficiency (seamless)
= 1/16 in., Corrosion allowance
1 12
(15.59 ) (1.07 0.3048 ) 1
2 1
= +
16
2 (12,041.45 2 ) (1.0) 0.2 (15.59 2 )

= . (. ) .
To have a uniform thickness adsorber, the head and bottom thickness of the adsorber would
be the same as the shell which is 1 in.
335
D. Specification Sheet for Evaporator
Specification Sheet
IDENTIFICATION
Name of Equipment Evaporator
Equipment Code H-2
Feed Capacity 0.4785 m3/hr
Evaporation Capacity 0.2888 m3/hr
Function To concentrate Lactic Acid Solution
Operation Continuous
Type Tubular Evaporator
Materials Handled Lactic Acid Solution
DESIGN DATA
Operating Pressure 0.477 MPa
Temperature 125 oC
Density 1102.77 kg/m3
Steam Economy 0.84
Initial Concentration of Lactic Acid 55 percent by weight
Final Concentration of Lactic Acid 85 percent by weight
Rate of Water Removal 189.77 kg/hr
EVAPORATOR VESSEL DESIGN
Design Pressure 30.40 kPa
Material of Construction SS-316 L
Vessel Volume 1 m3
Diameter 1.5 m
Height 2.5 m
DISTILLATE TANK DESIGN
Design Pressure 30.40 kPa
Material of Construction SS-316 L
Vessel Volume 1 m3
Diameter 1.0 m
Height 2.0 m
HEATING SYSTEM DESIGN
1-2 Shell and Tube Heat Exchanger
Tube Design Shell Design
Lactic Acid
Fluid Handled Fluid Handled Saturated Steam
Solution
Mass Flow Rate 527.70 kg/hr Mass Flow Rate 224.69 kg/hr
Temperature In 95 C Temperature In 150 oC
Temperature Out 125 C Temperature Out 150 oC
Number of Tubes per pass 9 Shell Diameter 211 mm
336
Number of Passes 2 Baffle Diameter 208 mm
Length 7.0 m Baffle Spacing 85 mm
Outside Diameter 25.5 mm Shell Thickness 2 .0 mm
Inside Diameter 20 mm
Pitch 32 mm
Clearance 6.5 mm
PUMP DESIGN
Pump Type Centrifugal
Power Requirement 5 hp
337
`
1.5 m
2.5 m
2.0 m
1.0 m
source: PF10 impianti industriali
338
Assumptions and Design Equations:
1. BWG no. 12 with 1 inch Outside Diameter is used in tube design.
2. For the Heat Exchanger the One shell, two tube passes and Square Pitch tube
arrangement is used.
3. For the design of vessel, API-ASME vessel design code is used.
4. For the flash tank, SS316 L will be the material of construction to be used.
5. Allowance for safety is 20% of the total volume of the feed.
6. 30% of the conical vessel volume for the extension of the conical vessel in the form of a
cylinder will be used for the vapor space.
7. Pump efficiency is 70%.
RESIDENCE TIME CALCULATION

(ref.: Equation 2, page 28; APV Evaporator Handbook)
3 1
m=( )3
L (L v )
Where: m=film thickness
=liquid wetting rate
=liquid viscosity
=gravitational constant (9.81m/s)
l =liquid density
v =vapor density

4
RL =

339
Where: RL = liquid volume fraction
m=film thickness
d=diameter
RL AL
t=
qL
Where: t = residence time

A = cross sectional area
L = tube length
qL = liquid rate
HEAT EXCHANGER DESIGN EQUATION
(Ref: Unit Operations of Chemical Engineering by McCabe & Smith, p. 306-307)
Q = UAFtTLM (for 1-shell & 2-tube passes)
(, , ) (, , )
=
(, , )

(, , )
Tube Side of Heat Exchanger
Number of Tubes
A A
NT = A T = dTL For Square Pitch Tube Arrangement,
O o
Pitch = 1.25 Do
Clearance = 0.25 Do
(Ref: Eqn. 12.3b of Coulson and Richardson, p. 648)

Bundle diameter, Db (mm)
1

= ( ) 1
1
Shell Side of Heat Exchanger
340
Baffle Diameter = Ds 4.88 mm

Baffle Spacing =
5
Shell Thickness

= +
2
FLASH TANK DESIGN EQUATION
Vessel Diameter and Height
Using H=1.5D
For Conical Vessel,

= 0.2306693
Hydraulic Pressure (P)
P = Vapor Pressure of Water @ 105C + gH
Maximum Stress (S)

(Ref: Eq. 4-1 of Process Equipment Design by Hesse and Rushton)
= . + + + +
Shell Thickness (ts)

(Ref: Eq. 4-7 of Process Equipment Design by Hesse and Rushton)
1
= +
2 ( ) 16
where A = 30
+
= +
2
Head Thickness
(Ref: Equation 4-10 of Process Equipment Design by Hesse and Rushton, p8.)
297
Using Ellipsoidal Head,

= +
2
ACTUAL POWER CALCULATION

(Ref: Chemical Engineering Handbook 8th Ed., p. 10-27)
HQ
Power =
3.670105 n
Where: H = total dynamic head (Pa)

Q = capacity (m3/hr)
=liquid density (kg/m)3
n= pump efficiency
Pressure Head
(Ref:p. 10-27 Perrys Chemical Engineering Handbook 8th Ed. By Perry et.al)
Ps
H=

Pressure Drop
(Ref: Equation 12.18 p.666 Chemical Engineering Vol. 6, 4th Edition by Coulson and
Richardson)
L u2s
Ps = 8jf ( )
Do 2
298
DETAILED DESIGN COMPUTATION
Amount Fed to the Evaporator:

Mass Rate Volumetric Rate Boiling Pt.
Component Density (kg/m3)
(kg/day) (m3 /day) (C at 1 atm)
Lactic Acid 466.33 1206 0.3867 227.6
Water 386.54 1000 0.3865 100
TOTAL 854.87 0.7732
RESIDENCE TIME CALCULATION

3 1
m=( )3
L (L v )
Where: m=film thickness
=liquid wetting rate
=liquid viscosity
=gravitational constant (9.81m/s)
l =liquid density
v =vapor density

4
RL =

Where: RL = liquid volume fraction
m=film thickness
d=diameter

RL AL
t= qL
Where: t = residence time

A = cross sectional area
L = tube length
299
qL = liquid rate
Liquid volume fraction, y

From H-2
Vapor 307.42 kg
Liquid (distillate) 547.45 kg
TOTAL 854.87 kg
307.42 kg
= = 0.3596
854.87kg
Vapor density, V
From H-2
Components Mass rate, kg/day Density, kg/m3 Vol. flow rate, m3/day
Water 307.42 1000 0.3074
TOTAL 307.42 0.3074
307.42
V = = 1000 kg/m3
0.3074
Liquid density, L
From H-2
Components Mass rate, kg/day Density, kg/m3 Vol. flow rate, m3/day
Lactic Acid 466.33 1206 0.3867
Water 81.12 1000 0.0811
TOTAL 547.45 0.4678
547.45
L = = 1170.29 kg/m3
0.4678
3(0.0228)(1.04210^ 3) 1
m=( )3 = 3.314710^ 4
9.81(1170.29)(1170.29 1000)
From Perrys ChE Handbook 8th edition, Table 11-12;

300
Using BWG #12 with 1 OD
Tube OD = 1 in. = 0.0254 m
For heat exchanger, preferred length of tubes is 20 ft = 6.096 m
4(3.314710^ 4)
RL = = 0.0522
0.0254
(0.0522)(3.95)(6.096)
t= = 1.62 hr.
0.7752
Design Operation:
Evaporating Time: 1.62 hr./day
3 1 day 3
= (0.7752 )( ) = 0.4785
1.62 hr
3 1 day 3
= (0.4678 )( ) = 0.2888
1.62 hr
1 day
= (307.42 )( ) = 189.77
1.62 hr
DESIGN CALCULATIONS FOR HEAT EXCHANGER
Heat Transfer Equation: =

Q =767,517.49 kJ/day (from energy balance)
BTU
U = 250ft2hr (from engineeringtoolbox.com)
(, , ) (, , ) (150 125) (150 95)

TLM = =
(, , ) (150 125)

(, , ) (150 95)
TLM = 38.05
From figure 15.6(a) Unit Operations by McCabe & Smith 6th ed., p438
Z
Ft =
NH
301
TH
where; Z= TC
Tactual
NH =
Tmax
Since there is no TH, Ft = 1.0
Heat Transfer Area
kJ 1,000J 1 day 1hr
Q (767,517.49 )( )( )( )
day kJ 1 hr 3600 s
A= =
UFtTLM W
BTU m 2K
(250 2 ) (5.6783 BTU ) (1)(38.05)
ft hr
ft 2 hr
A = 3.95 m2
Tube Side Design
Fluid Handled : Lactic Acid Solution

kg 1 day
Mass Flow Rate (kg/s) = 854.87 = 527.70 kg/hr
day 1.62 hr
Volumetric Flow Rate (GPM)

m3 1 day 1 hr 1000L 264.17 gal
= 0.7752
day 1.62 hr 60 min 1 m3 1000 L
= 2106.84 gpm
854.87 /
Density (kg/m3) = 0.7752 3 / = . /
Number of Heating Tubes (NT)

AT AT
NT = =
AO do L
From Perrys ChE Handbook 8th edition, Table 11-12;

Using BWG #12 with 1 OD
Tube OD = 1 in. = 0.0254 m
302
Tube ID = 0.782 in. = 0.01986 m
For heat exchanger, preferred length of tubes is 20 ft = 6.096 m = 7m
3.95 m2
NT = = 9 x 2 =
()(0.0254 m)(6.096 )
For Square Pitch Tube Arrangement

Tube Pitch, pt = 1.25 Do = 1.25 (25.4 mm) = 31.75 mm= 32 mm
Clearance = 0.25 Do = 0.25 (25.4 mm) = 6.35 mm = 6.5 mm
Shell Side Design
Fluid Handled : Steam
kg 1
Mass Flow Rate ( ) = 364 = 224.69 /
hr 1.62 hr
(Ref: Steam Tables by engineeringtoolbox.com)
Specific Volume of steam @ 150C: 0.3934 m3/kg
0.3934 3
Volume of Steam (3/hr) = 224.69 = 88.39 3 /

Bundle diameter, Db (mm)

1

= ( ) 1 Eqn. 12.3b, Coulson and Richardson, p. 648
1
Where,
do = tube outside diameter, mm
Nt = number of tubes
From Table 12.4, Coulson and Richardson, p. 649
K1 = 0.156
n1 = 2.296
303
1
18 2.296
= (25.4) ( ) = . =
0.156
For fixed tube sheet type:
From Figure 12.10 (Coulson & Richardson, p. 646),
Bundle diametrical clearance = 10 mm
Shell diameter, DS = 200.90 + 10 = 210.90 mm = 211 mm 8.30 in.
Baffle Diameter
(Ref: Chemical Engineering Volume 6, 4th Edition by Coulson and Richardson, Table
12-5 p. 651)
Baffle Diameter = Ds 4.88 mm
Baffle Diameter = 210.90 mm 3.2 mm = 207.70 mm = 208 mm
Baffle Spacing
(Ref: Chemical Engineering Volume 6, 4th Edition by Coulson and Richardson, Table
12-5 p. 595)
Baffle Spacing = 0.4(210.90) = . = 85 mm
Number of Baffles
Tube Length (Ltube )
NB + 1 = Baffle Spacing (PB )
6.096 x1000 mm
NB + 1 =
84.36 mm
NB = 71.26 = 72
Shell thickness Calculation:

Internal Pressure
P = Pressure of Steam @ 150C
P = 476.25 kPa 69.09
304
Working Stress
(Ref Chemical Engineering Handbook, 8th Ed., Table 25-15, p.25-39)
For SS-316 L Grade of Steel;
Tensile Strength: 552 mPa 80,082.90 psi
(Ref: Process Equipment Design by Hesse and Rushton, p.81)

Sw = SUlt. Fs Fm Fa Fr
Where;
Fs = 0.25; for temperatures up to 650oC
Fm =1; for grade A or high tensile strength carbon steels
Fa = 1.0; for non-radiograph vessels
Fr = 1.0; for plate thickness of the shell/head at any welded joints do not exceed 5/4 in.
Sw = 80,082.900.251.01.01.0
Sw = 20,020.73 psi
(Equation 4-10,p8; Process Equipment Design by Hesse and Rushton)

= +
2
Where;
C = 1/16 in
p= 69.09 in; pressure of steam @ 150C
e= 0.80; for double welded V-butt
S=20,020.73 psi; working stress
D= Ds= 151.12 mm 5.94 in
69.09 5.94 1
= +
(2)(20,020.73 )(0.8) 16
= . = .
305
DESIGN CALCULATIONS FOR EVAPORATION TANK
Vessel Capacity
VFEED = 0.7752 m3
From Mass & Energy Balance;
mVAPOR = 307.42 kg/day
1
Mass Flow Rate (kg/hr) = 307.42 = 189.77 /
1.62 hr
water vapor@ 125C = 52.13 mol/dm3 (from table 2-305 Ch.E Handbook 8th ed.)
g
189.77 kg 1000
kg
VVAPOR = = 0.20223
mol dm3 g
52.13 3 1000 3 18
dm m mol
VFLASH TANK = VFEED + VVAPOR = 0.7752 3 + 0.2022 m3 = 0.9774 m3
VFLASH TANK = 0.9774 m3
Using 20% allowance for safety factor,

VFLASH TANK = (1.20) (0.9774) = 1.17 m3

For Conical Vessel;
= 1.5 (from Chemical Engineering Resources.com)
h= height of conical bottom, 2 tan(60 )
1 2 2
= + = + [ ] = 0.2306693
3 4 4
= 0.2306693 = 1.17m3
3 1.17 3
=
0.230669
= 1.17 3.84 .
= 1.5(1.17) = 1.76 5.76
306
For the extension of the conical vessel in the form of a cylinder for vapor space;
Using 30% of the conical vessel volume:
VVessel Extension = 0.3(1.17 ) = 0.351 m3
For Cylindrical Vessel

Dcylinder = Dcone = DV = 1.17 m = 1.5 m
D2 H (1.17m)2 H
V= = = 0.351 m3
4 4
HExtension = 0.3265 m
Total Height = HV + HExtension

HT = 1.76 + 0.33 = 2.09 m (6.86 ft) = 2.5 m
Material Specification for Vessel thickness Calculation:

Material of Construction : SS316 L
Top Head : Ellipsoidal Head
Welding Type : Double Welded V-Butt
Efficiency : 0.8
Corrosion Allowance : 1/16 inch
Hydraulic Pressure
Psolution at 125C = xA PA0 + xB PB
xA = 0.19 PA = 10.44 mmHg (Lactic acid)
xB = 0.81 PB = 1733.55 mmHg (H2O)
Psolution at 125C = xA PA0 + xB PB
Psolution at 1250 C = 0.81(1733.55) + 0.19(10.44)
Psolution at 125C = 1406.16 mmHg 1.85 atm 27.20 psi
307
Head Thickness (th)

= +
2
Where;
C = 1/16 in
p= 27.20 psi; internal pressure of vessel
S= 20,020.73 psi; working stress
D=Dv=1.10 m 43.31 in
27.20 43.31 1
= +
(2)(20,020.73 )(0.8) 16
= . = . . .
Vessel Thickness
(Ref: Eq. 4-7 of PED by Hesse and Rushton, API-ASME code)
API-ASME CODE:
M = Dv = 1.76 m 69.27 in
60
A = of included cone angle = = 30
2

= + 1/16
2()
27.20 psi (43.31 )
= + 1/16
2(cos(30))(20,020.73)(0.8)
= . = . . .
308
DESIGN CALCULATIONS FOR DISTILLATE TANK
Vessel Capacity
VFEED = 0.4678m3
Using 20% allowance for safety factor,

VFLASH TANK = (1.20) (0.4678) = 0.5614 m3

For Conical Vessel;
= 1.5 (from Chemical Engineering Resources.com)
h= height of conical bottom, 2 tan(60 )
1 2 2
= + = + [ ] = 0.2306693
3 4 4
= 0.2306693 = 0.5614 m3
3 0.5614 3
=
0.230669
= 0.9184
= 1.5(0.9184) = 1.38 1.5
For the extension of the conical vessel in the form of a cylinder for vapor space;
Using 30% of the conical vessel volume:
VVesselExtension = 0.3(0.4678) = 0.1403 m3
For Cylindrical Vessel
Dcylinder = Dcone = DV = 0.9184 m = 1 m
D2 H (0.9184 m)2 H
V= = = 0.1403 m3
4 4
HExtension = 0.2118 m
Total Height = HV + HExtension

HT = 1.38 + 0.2118 = 1.5918 m (5.22 ft) = 2.0 m
309
Material Specification for Vessel thickness Calculation:
Material of Construction : SS316 L
Top Head : Ellipsoidal Head
Welding Type : Double Welded V-Butt
Efficiency : 0.8
Corrosion Allowance : 1/16 inch
Hydraulic Pressure
Psolution at 125C = 1406.16 mmHg 1.85 atm 27.20 psi
Head Thickness (th)


= +
2
Where;
C = 1/16 in
p= 27.20 psi; internal pressure of vessel
S= 20,020.73 psi; working stress
D=Dv=0.9184 m 36.16in
27.20 36.16 1
= +
(2)(20,020.73 )(0.8) 16
= . = . . .
Vessel Thickness
(Ref: Eq. 4-7 of PED by Hesse and Rushton, API-ASME code)
API-ASME CODE:
M = Dv = 0.9184 m 36.16 in
60
A = of included cone angle = = 30
2
310

= + 1/16
2()
27.20psi (36.16 )
= + 1/16
2(cos(30))(20,020.73)(0.8)
= . = . . .
Steam Economy
mass of vapor 307.42

E= = = .
mass of steam used 364
Pump Design
Capacity
m3 1 day m3
Capacity = 0.7752 = 0.4785
day 1.62 hr hr
Pressure Drop
(Ref: Equation 12.18 p.666 Chemical Engineering Vol. 6, 4th Edition by Coulson and
Richardson)
L u2s
Ps = 8jf ( )
Do 2
Where:
Jf = friction factor = density
L = length of tubes us = tube side velocity
Do = outer diameter of tubes
(Ref: Pubchem.ncbi/compound/lacticacid)
Viscosity of Lactic acid = 1.042 mPa-s
(Ref:Unit Operations by McCabe & Smith, 6th ed., p478)

Velocity of liquids at film evaporator using centrifugal pump;
v = 3 m/s
311
m kg
Do v (0.0254 m) (3 ) (1102.77 3 )
s m
NRe = =
(1,042 Pa s)
NRe = 0.0806
From Fig. 12.24 p. 668 of Chemical Engineering Vol. 6 4th Ed. By Coulson and
Richardson
= 0.13
Therefore:
kg m 2
6.096 1102.77 m3 (3 s )
= 8 (0.13) ( ) = 1,226,169
0.0254 2
Pressure Head
(Ref: p. 10-27 Perrys Chemical Engineering Handbook 8th Ed. By Perry et.al)
Ps 1,226,169 Nm
H= = = 1111.90
kg kg
1102.77 3
m
HQ
Power = 3.670105 n
Nm m3 kg
1111.90 0.7752 1102.77 3
kg hr m
Power = 5
= 3.7 kW
(3.67010 )0.7
= . .
312

Chapter 6-Equipment Design (Production of Lactic Acid From Sugarcane Bagasse)

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Chapter 6-Equipment Design (Production of Lactic Acid From Sugarcane Bagasse)

Загружено:

Авторское право:

Доступные форматы

I.

Several factors are considered in properly designing an efficient and economical

The importance of appropriate materials of construction must also be recognized. Products

withstand any stresses and extreme conditions of the operation.

Designing involves in the preparation of individual equipment specification sheet that is

1. The fermentation will be conducted in a batch reactor.

2. 1 units of fermenter will be used per batch.

6. The impellers to be used will be Four-Pitched Blade turbines.

7. Motor efficiency of the agitator is 80 %.

8. The cooling system of the fermenter will be a jacketed type.

Residence Time of Fermentation

From Bioprocess Engineering (2nd Edition) by Doran, P. M.:

max maximum specific growth rate

x0 initial cell density

qp specific rate of product formation

pf/0 final(f) / initial (0) product concentration

(Ref: Principles of Fermentation Technology by Stanbury, P.F. et al:Table 7.2. Details of

Geometrical Ratios of Fermenters with Three Multi-bladed impellers)

Height of the Liquid (L):

Internal Pressure (P):

For Cylindrical shell

For Ellipsoidal head

(Ref: Principles of Fermentation Technology by Stanbury, P.F. et al:Table 7.2)

Impeller distance from Vessel floor:

Length of Impeller Blade:

Width of Impeller Blades:

Viscosity of Fermentation Broth:

Process Design by G. Towler, et al. p. 440 Eq. 8-11.)

(Ref: Ch.E. Handbook 8th Edition, p. Eq. 5-31)

Surface Area of Jacket (Heating Area):

Log Mean Temperature Difference:

(t1 t "2 ) (t 2 t1" )

Diameter of Vessel with Jacket

Outer Shell to Jacket Distance

6 12 6 + 0.0171.61 0.56 0.16 = 0.0141.8 0.50.2 + 0.0032 + 0.0012 +

Residence Time of Fermentation

From Optimization and modeling of Lactic acid production by Rasfid Roslina

mass of lactic acid

p0 = 0, no product at the beginning of fermentation

Yp/s= 0.8248 kg Lactic acid per kg glucose, ms=0.098/h

q p = (0.09033 h-1) (0.8248) + 0.098

= 42.62 hours (1.77days)

Total batch time:

tb = 42.62 h + 2.38 h + 2.0 h + 1.0 h

Number of Units = 2 units

Component Mass (kg) Density(kg/m3) Volume(m3)

Calcium Lactate 576.83 1,490 0.3871

Calcium Carbonate 7.44 2,710 0.0027

Calcium Sulfate 7.89 2,320 0.003

97.55 1,540 0.063

Sodium Carbonate 6.14 2,540 0.0024

Total 6,094.39 5.8535

Total Volume of Feed = 5.8535 m3/batch

Total Mass = 6,094.39 kg/batch

D = 2.52 m = 99.21 in (R=49.60 in)

= 113,259.57 Pa = 16.431 psi

For Cylindrical shell:

= 123 MPa = 17,844.56 psi)

(Ref: ChE Handbook, 8th ed., Table 25-11, p. 25-36)

(16.431 psi)(49.6 in)

t s = 0.0457 in, < 0.25 in

= 0.1081 in 2.748 mm (3mm)

For Ellipsoidal head: