Production of

75TPD of Ethanol
By Molasses
Final Year Project (Group-10)
Amir Nauman But 13073123-052
Farrukh Javaid 13073123-053
Supervisor: Dr. Ghulam Abbas
Contents

• Ethanol and Molasses Introduction

• Ethanol Production by Molasses in Pakistan
• Ethanol as Fuel
• Capacity Selection Factors
• Production Methods and Selection
• Process Flow Diagram
• Process Description
• Material Balance
• Energy balance
• Designing
Ethanol

• Ethanol is a volatile, flammable, colorless liquid with a slight chemical odor.

• The molecule is a simple one, being an ethyl group linked to a hydroxyl group.
• Its structural formula, CH3CH2OH, is often abbreviated as C2H5OH,
C2H6O or EtOH.
Molasses

• Molasses is a viscous by-product of refining process of sugarcane or sugar

beets into sugar.
• Molasses varies by amount of sugar, method of extraction, and age of plant.
• Molasses is primarily used for sweetening and flavoring foods.
• Blackstrap Molasses is shown in the fig.
Ethanol Production by Molasses in Pakistan

• Total 9 distillery units are operating to accomplish this process.

• These units are operating in following districts of Pakistan:
• Karachi
• Lahore
• Sargodha
• Only 3000 ton/month production of ethanol from molasses is
done in Pakistan checked in 2011.
• 2.5 million MT of molasses is being converted to 0.2 million
ton of ethanol.
Ethanol Production by Molasses in
Pakistan

• Ethanol produced in Pakistan is not only used in Pakistan but

exported to other countries too.
• Pakistan exported 50% of its total production.
• Pakistan export ethanol to Europe, Japan, Korea, Taiwan,
Philippines, Dubai and KSA.
• In 2013, 273 ktons of ethanol were exported from Pakistan.
Ethanol Production by Molasses in Pakistan

Year Molasses Production Ethanol Exported

2008-2009 2.048 million MT 61710 MT

2009-2010 2.122 million MT 99711 MT

2010-2011 1.497 million MT 122104 MT

2011-2012 1.438 million MT 169233 MT

2012-2013 1.911 million MT 273079 MT

2013-2014 2.650 million MT 315846 MT

Ethanol Production by Molasses in Pakistan

Country Production Rate(MT/Yr.)

U.S. 8-10 million

Brazil 12-14 million (Maximum)

China 3.6 million

Pakistan 4 million
Ethanol Production by Molasses in Pakistan

Total Installed Alcohol Production in 400000 MT Per Year

Pakistan
Local Consumption 2000 MT Per Year

Export 80000 MT Per Year in 2014

Balance 318000 MT Per Year

Ethanol as Fuel

• Ethyl Alcohol is also used as fuel in automobiles.

• It was 1st introduced in Brazil in 1978.
• Nowadays, cars are able to run using 100% ethanol fuel or a mix of ethanol and
gasoline.
• Fuel ethanol or anhydrous alcohol is produced by dehydration of rectified spirit.
• Ethanol could be blended in various proportions in petrol.
Ethanol as Fuel

• Use of ethanol in place of tetraethyl lead which acts as anti-knocking agents will
prevent dangerous and poisonous emissions containing lead from petrol.
• Engines of cars do not need any change to use petrol with up to 24 % ethanol in
it.
• Gasoline with ethanol as anti-knocking agent will not cause any damage to the
engine.
Ethanol as Fuel

• The functions of fuel ethanol is Octane enhancement or

anti-knocking agent.
• Ethanol is also added to diesel. Usually, 3% by volume is
added. Tests have been conducted satisfactorily with up to
10% by volume addition.
Capacity Selection Factors

• Following factors are indirectly related with our production capacity.

• Facilities
• Product and Service Factors
• Process Factors
• Human Factors
• Policy Factors
Capacity Selection Factors

• Operational Factors
• Supply Chain Factors
• External Factors
Production of Ethanol

• Major processes utilized when ethanol is being produced from corn are
following:
• Wet Milling Process
• Dry Milling Process
• Corn’s components are Starch (61%), Corn oil (4 %), Protein (8%) and Fiber (11%)
and approximately 16% of the corn kernel’s weight is moisture.
Production of Ethanol

• Wet Milling Process‘ key products are:

• Corn Oil
• Germ Meal
• Corn Gluten Meal
• Protein Feed
• Starch
•The wet milling process is of higher operating costs and results in slightly lower
ethanol yields.
Production of Ethanol

• Dry Milling Process’ key products are:

• Ethanol
• Dried Distillers Grains
• Low value animal feed Product
•Dry Milling Process is less costly and highly yield process.
•In Wet Milling Process corn is 1st soaked in aqueous solution of Sulphur dioxide.
•In Dry Milling Process corn is 1st grounded to medium-to-fine particles in a
hammer mill.
Production Methods & Selection

• Industrial ethyl alcohol can be produced by three methods.

• Synthetically from ethylene.
• As a by-product of certain industrial operations.
• By the fermentation of sugar molasses.
Production Methods & Selection

• Synthetically from Ethylene

• Indirect Hydration of Ethylene
• Direct Hydration of Ethylene
• Hydrolysis of Ethyl Halides
• Oxidation Of Ethene
• Hydrolysis of ethyl Ester
• Hydrogenation of Acetaldehyde
 Process Description

• Synthetically From Ethylene:

• Indirect Hydration process
• Direct Hydration process
Indirect Hydration Process
• Developed in 1930 by Union Carbide Corporation.
• Also called strong Sulfuric acid ethylene Process
Steps Involved
1> Absorption of ethylene in concentrated sulfuric acid to form
mono and Di-ethyl sulfate
CH2 = CH2 + H2SO4 -> CH3CH2OSO3H
Ethyl hydrogen sulfate
2CH2=CH2 + H2SO4 -> 2(CH3CH2O)2 SO2
Di-ethyl sulfate
Indirect Hydration Process

• 2) Hydrolysis of ethyl sulfates to ethanol

CH3CH2OSO3H+H2O -> CH3CH2OH + H2SO4
(CH3CH2O)2 SO2 + 2H2O -> 2CH3CH2OH + H2SO4
(CH3CH20)2 SO2 + CH3CH2OH -> CH3CH2OSO3H + (CH3CH2)2
Di-ethyl ether
Indirect Hydration Process

• Re- concentration of the dilute sulfuric acid:

The hydrocarbon feed stock contains 35-95% ethylene; the remaining gases
are methane and ethane. Certain unsaturated hydrocarbons are undesirable as
their presence leads to the formation of secondary alcohol.
• Process
• Absorption of Ethylene into sulfuric acid
• Separation
• Washing Of Distillate with water or Sodium hydroxide
• Distillation
Limitations Of Process

• The re-concentration of dilute (50-60%) sulfuric acid is one of the

more costly operations in the manufacturing of ethanol by this
process

• The buildup of carbonaceous material in the sulfuric acid

presents one of the most serious problems; of acid
concentration. Certain unsaturated hydrocarbons are undesirable
as their presence leads to the formation of secondary alcohol.

• Acid concentration also presents corrosion problems.

Limitations Of Process

• Diethyl ether is the principal by-product of ethyl alcohol with diethyl sulfate. The
diethyl sulfate not only causes an increase in ether formation but is also more
difficult to hydrolyze to alcohol than is ethyl hydrogen sulfate.
• Costly equipment must by used to concentrate the sulfuric acid and over come
the corrosion problems. Such as mild steel lined with brick or lead, pipe lines are
generally of lead; and for concentration absorption column are used.
Direct Hydration Process

• Developed in 1970
• Designed to eliminate the use of Sulfuric Acid
• There are two main processes for the direct hydration of
ethylene to ethanol.
• Vapor-phase contacts a solid a liquid catalyst with
gaseous reactants.
• Mixed - phase processes contact a solid or liquid catalyst
with liquid and gaseous reactants.
Limitations Of Process

• Higher hydrocarbons are formed by the polymerization of ethylene. Any higher

unsaturated hydrocarbons present are converted to the corresponding alcohol by
hydration.

• Corrosion problem take place. Copper is widely used for lining the reactors. Some
heat exchangers are made of phosphor bronze.
PFD EQUIPMENTS

• T-101 (molasses tank)

• T-102 (Diluter)
• M-101 (Mixer-Settler)
• T-103 (Sulphuric acid tank)
• P-101 (centrifugal pump)
• S-101 (sterilizer)
• M-102 (mixer)
• Y-101 (yeast culture vessel)
PFD EQUIPMENTS

• T-108 (Yeast)
• Y-102 (pre-fermenter)
• F-201 (fermenter)
• A-201 (absorber)
• T-201 (storage tank)
• H-302 (Preheater)
• H-301 (Heat exchanger)
• D-301 (Distillation column-I)
PFD EQUIPMENTS

• D-302 (Distillation column-II)

• E-301 (separator)
• D-303 (Distillation Column-III)
• T-301 (Aldehyde)
• T-302 (Fusel Oil)
• T-303 (Ethanol tank)
Material Balance

Basis: 75 TPD
Quality of alcohol: 95.4%
• 75000 kg/day
• 93388.12 L/day
• 24670.61 gallons/day
• Molasses usage: 2.5 gallons/gallon of alcohol
• Sulphuric Acid required: 0.17 lb/gallon of alcohol
• Ammonium Sulphate Required: 0.015 lb/gallon of alcohol
Material Balance

• Total Sulphuric Acid required: 9.238 TPD

• Total Ammonium Sulphate required: 0.815 TPD
• Total Molasses required: 325.56 TPD
• Yeast Required: 3 kg/1000 L of molasses
• Total Yeast Required: 0.6662 TPD
• Fusel Oil Produced: 2114026 L/Day
• Carbon dioxide Produced: 52.0896 TPD (45.67 m3/Day)
Material Balance Equipments

• Storage Drum
• Distillation Column-III
• Separator
• Surge drum
• Distillation column-II
• Distillation column-I
• Mash Storage Tank
• Scrubber
• Fermenter
Material Balance Equipments

• Yeast Culture Vessel

• Yeast Propagator
• Mixer
• Sterilizer
• Mixer-Settler
• Diluter
Material Balance

• Storage tank

M33

• M33 = Product Stream of Plant= 75 TPD

Material Balance

• Distillation Column-I M33

M27

M29

M32
Material Balance

• Inlet= Outlet
• M27+M29= M33+M32
• Distillation Column-III
• M27= Product from Distillation Column-II=99.615 TPD
• M29= Alcohol Water mixture from separator= 61.822 TPD
• M32= Bottom product from rectifying column= 86.437 TPD
• M33= Product Stream = 75 TPD
Material Balance

• Separator

M34

M28
M 29

M30
Material Balance

• Inlet=Outlet
• M28+M34=M29+M30
• M28= Bottom Product from Column-II= 32.322 TPD
• M29= Alcohol water mixture = 61.822 TPD
• M30= Fusel Oil from separator= 0.5 TPD
• M34= Water added to separator= 30 TPD
Material Balance

• Surge Drum

M25

M26

M31
Material Balance

• Inlet=outlet
• M25=M26+M31
• M25=Top Product from column-II= 0.5 TPD
• M26= recycle stream= 0.25 TPD
• M31= Aldehyde to storage = 0.25 TPD
Material Balance

• Distillation Column-II M25

M26
M27

M23
M28

M24
Material Balance

• Inlet=outlet
• M23+M26=M24+M25+M27+M28
• M26= recycled stream= 0.25 TPD
• M23= product from column-I= 242.68 TPD
• M24= Bottom Product from Rectification column=110.492 TPD
• M25=Top Product from Rectification column=0.5 TPD
• M27= Middle Product from Rectification Column=99.615 TPD
• M28=Product from Rectification Column to Separator=32.322 TPD
Material Balance

• Distillation Column-I
M23

M21

M22
Material Balance

• inlet=outlet
• M21=M22+M23
• M21= from mash storage tank= 1213.4 TPD
• M22= bottom stream od column= 960.72 TPD
• M23= Top product of the column= 242.68 TPD
 Material Balance

• Mash Storage Tank

M20 M21
Material Balance

• Inlet=outlet
• M20=M21
• M20= From fermenter= 1213.4 TPD
• M21= M20= 1213.4 TPD
Material Balance

M19
• Scrubber

M18
M17

M16
Material balance

• Inlet=outlet
• M18=M16+M17+M19
• M16= Carbon dioxide from fermenter= 61.28 TPD
• M17= water from scrubber to diluter= 27.192 TPD
• M18= Water added to scrubber= 18 TPD
• M19= Carbon dioxide from scrubber= 52.0896 TPD
Material Balance

• Yeast Culture Vessel

M11

M10 M12
Material Balance

• Inlet=Outlet
• M10+M11=M12
• M10= molasses from mixer= 65.8338 TPD
• M11= yeast added to vessel = 0.6662 TPD
• M12= feed to pre-fementer = 66.5 TPD
Material Balance

• Yeast Propagator

M12

M14

M13
Material Balance

• Inlet=outlet
• M12+M13=M14
• M12= feed to prefementer= 66.5 TPD

• M13= Dilute Molasses= 150 TPD

• M14= Yeast culture to fermenter= 216.5 TPD

Material Balance

• Fermenter
M16

M14

M20
M15
 Material Balance

• Inlet=outlet
• M14+M15=M16+M20
• M14= yeast culture from prefementer= 216.5 TPD
• M15= molasses from mixer-settler = 1048.9896 TPD
• M16= Carbon dioxide produced in fermenter= 52.0896 TPD
• M20= From fermenter to mash storage tank = 1213.4 TPD
Material Balance

• Mixer

M7

M8
M10

M9
 Material Balance

• Inlet=Outlet
• M7+M8+M9=M10
• M7 = Sulphuric acid added= 4.619 TPD
• M8 = Molasses from sterilizer= 60.3998 TPD
• M9 = Nutrients added= 0.815 TPD
• M10 = molasses from mixer to yeast= 65.8338 TPD
Material Balance

• Sterilizer

M5 M8
Material Balance

• Inlet=Outlet
• M5=M8
• M5 = from mixer settler to sterilizer= 60.3998 TPD
• M8 = M5 = 60.3998 TPD
 Material Balance

• Mixer- Settler
M4

M6
M3
 Material Balance

• Inlet=outlet
• M3+M4=M6
• M3 = from diluter to mixer settler= 1254.7704 TPD
• M4 = sulphuric acid to mixer-settler= 4.619 TPD
• M6 = feed from mixer-settler= 1259.3894 TPD
 Material Balance

• Diluter

M1

M2 M3

M17
 Material Balance

• Inlet=outlet
• M1+M2+M17=M3
• M1 = Molasses to diluter= 325.56 TPD
• M2 = water added to diluter= 902.0184 TPD
• M3 = from diluter to mixer-settler= 1254.7704 TPD
• M17 = water from scrubber= 27.192
Material Balance

• Overall material balance

Inlet streams Outlet streams

M1 M19
M2 M22
M4 M24
M7 M30
M9 M31
M11 , M18 , M34 M32
M33
Material Balance

• Total material entering

• 325.56+902.0184+4.619+0.815+0.6662+18+30
• 1286.2976 TPD (i)
• Total material exiting
• 52.0896+960.72+110.492+0.5+0.25+86.437+75
• 1285.4886 TPD (ii)
Energy balance
Energy Balance

Here are the Six equipment on which Energy balance is

Applied. These are:
• Preheater
• Heat Exchanger
• Distillation Column I
• Sterilizer
• Fermenter
• Distillation Column II
Energy Balance around Preheater

21(b)
21(a) Preheater
 Energy Balance
• Basis: Room Temperature 25 0C
• Heat in the inlet stream Q 21(A) = m Cp ΔT
Cp for Ethanol=0.6211(Perry’s Chemical Engineering hand Book
m21=1213.4Tons/day
1213.4T 1000kg 1day
m21=
day1T 24 hour
m21=50558.33kg/hr
• Q21=mCpΔT
• Q21=50558.33kg 0.6211kcal 35k
hr kg-k
Energy Balance

Q21=10999062.32kcal/hr
And required Preheat is 98C so,
Q 21(A) = m Cp ΔT
=50558.33kg 0.6211kcal 73k
hr kg-k
Q 21(A) =2292329.85kcal/hr
Heat Required = 2292329.85-1099062.32
= 1193267.53kcal/hr
Energy Balance around Heat
exchanger

Cold fluid

21 21(a)

22(b) Heat Exchanger 22(a)

Hot Fluid
Energy Balance

Q 21(a) = m21 Cp ΔT
ΔT=32-25 =70C 0r 7k
Q21=50558.33kg 0.6211kcal 7k
hr kg-k

Q21=219812.45kcal/hr
Q22(a) =m22 Cp ΔT
M22 =970.72 tons/day
M22 =40446.67 kg/hr
Cp= 0.6211kcal/kg-k
Energy Balance

ΔT=100-25
ΔT=75
Q22(a) = 40446.67kg 0.6221kcal 75k
hr kg-k

Q22(a) = 1884106.85kcal/hr
Q21(a) = 1099062.32 kcal/hr (calculated in Preheater)
Heat gained by cold fluid= Q21(a) – Q21
= 1099062.32 – 219812.45
Q22(b) =879249.87kcal/hr
Energy Balance

Q22(b)= m22CpΔT

So temperature outlet of hot fluid would b reduced and is

calculated below

Q22(b) = m22CpΔT

879249.87 = 40446.67* 0.6221* (100-T)

T=650C
Energy Balance around Fermenter

16

14

20
15
Energy Balance

Cp of Molasses =3.198 kcal / kg-oC

Heat of Reaction=?
(zymase)
C6H12O6 → 2C2H5OH +2CO2
Heat of formation of alcohol = -277kj/gmol
= -277kJ kg.mol 1000g.mol
g.mol 46.048kg 1kg.mol
= 6015.4 kj/kg
=6015.4kj 1cal 1000J 1kcal
kg 4.18J 1KJ 1000cal
Energy Balance

Heat of formation of Alcohol= -1439.105772

Heat of formation of CO2 = -393 KJ/kg
= -393kJ kg.mol 1000g.mol 1cal 1000J 1kcal
g.mol 44kg kg.mol 4.18J 1kg 1000cal

Heat of formation of CO2 =-2136.798608kcal/kg

Total Heat = -3575.90438kcal/kg
Heat of Reaction = 325560* (-3575.90438)
= -1164171430 kcal /hr
Energy Balance

Inlet streams:
Q15=heat flow through M15= m15CpΔT
T=260C (T=ΔT)
Cp=3.198 kJ/Kg.0C
m15=1048.9896tons/day
= 43707.9 kg/ hr
Q15= 3634224.469KJ/hr
Heat flow through M14= m14CpΔT
T=270C
Energy Balance

Cp=2.6Jg-1k-1
(This is the Heat capacity of Saccharomyces Serevisiae) by Edwin
H.Battely, Robert L.Putnam Juliana Boerio-Goates

m14=216.5tons/day
=9020.833kg/hr
Cp = 2.6 KJ/Kg.0C
Q14= m14CpΔT
= 9020.833*2.6*27
Q14= 633262.5KJ/hr
Energy Balance

Total Input= 633262.5+3634224.469

= 4267486.969kJ/hr
Outlet streams:
Q16 =m16CpΔT
T =33oC = 306k
Cp =0.96kJ/kg.0C
m16=52.0896tons/day
=2170.4kg/hr
So,
Q16=68758.272KJ/hr
Energy Balance

Q20 =m20CpΔT
Cp=0.34KJ/Kg.oC
T=400C
Q20=687593.33KJ/hr
Total output=756351.60KJ/hr
Heat to b removed = 3511135.364kJ/hr
Energy Balance around Sterilizer

5 8

Sterilizer
Energy Balance

Q5=m5CpΔT
m5=60.3998 Tons/day
= 2516.65833kg/hr
ΔT=32-25= 7k
Cp=0.472kcal/ Kg.k
Q5= 8315.039122kcal/hr
Q8=m8CpΔT
m8= 60.3998tons/day
=2516.658kg/hr
Cp=0.472kcal/hr
Energy Balance

ΔT= 75k
Q8=89089.705kcal/hr

Heat Q supplied= Q8-Q5

= 80774.66588kcal/hr
Energy Balance around Ditillation Column I
25

27
26

23
28

24
Energy Balance

Q23=m23CpΔT
m23=10111.667kg/hr
Cp=0.8819kcal/kg.k
ΔT=92-25=67k
Q23=597471.1015kcal/hr
Q24=m24CpΔT
m24=110.492tons/day
4603.833kg/hr
Cp=1kcal/kg.k
ΔT=100-25= 75 k
Energy Balance

Q24=4603.833*1*75
= 345287.4975kcal/hr
Q25=m25CpΔT
m25=0.5tons/day
=20.83kg/hr
Cp=0.739kacl/kg.k
T1=25
T2=82
ΔT=57k
Energy Balance

ƛ=2.61*10-5kcal/kg
Q25=(20.83*.739*57) + (20.83*2.61*10 -5)
Q25=877.4226kcal/hr
Q28=m28CpΔT
= 1346.75*0.65028489*75
Q28=65682.83817kcal/hr
Q27=m27CpΔT+mƛ
Cp=0.739kcal/kg
m27=99.615tons/day
=4150.625kg/hr
Energy Balance

ΔT=82-25=57k
ƛ=2.61*10-5kcal/kg
By Putting values,
Q27=190173.4446kcal/hr

Q26=m26CpΔT
m26=0.25tons/day
ΔT=78-25=53k
Cp=0.739kcal/kg
Q26=407.9896kcal/hr
Energy Balance

Heat Out=Q24+Q25+Q27+Q28
= 345287.4975+877.4226+190173.446+65682.83817
= 602021.2029kcal/hr
Heat In= Q23+Q26
= 597471.1015+407.9896
= 597879.0911kcal/hr
Heat provided by steam to Reboiler = Qout – Qin
=602021.2029 – 597879.0911
= 4142.1118 kcal/hr
Energy Balance around Distillation Column
II
23

27

32
Energy Balance
Q27=190173.4446kcal/hr
Q33=m33CpΔT
M33=75tons/day
=3125kg/hr
Cp=0.6211kcal/kg.k
ΔT=78-25=53k
Q33=m33CpΔT
Q33=3125*0.6211*53
Q33=102869.6875kcal/hr
Energy Balance

Q32=m32CpΔT
m32=86.437tons/day
=3601.541667kg/hr
ΔT=100-25=75k
Cp = 1kcal/kg.k
Q32=3601.541667*1*75
=270115.625kcal/hr
Energy Balance

Q29 = m29CpΔT
m29= 61.822tons/day
=2575.916667kg/hr
Cp= 0.65028489kcal/kg.k
ΔT= 90-25=65k
Q29 =2527.916667*1*65
Q29 =108880.1796kcal/hr
Energy Balance

Heat In = Q27 + Q29

=190173.4446 + 108880.1796
=299053.6242kcal/hr
Heat out= Q32 + Q33
=270115.625 + 102869.6875
=372985.3125kcal/hr
Heat supplied by Reboiler = Qout – Qin
=372985.3125 – 299053.6242
=73931.6883 kcal/ hr
Designing
Designing Equipments

Four major Equipments are designed . These are as follows

Fermenter
Heat exchanger
Distillation column
Fermenter Design

• Reactor Selection
• Process Design
• Mechanical Design
• Heat Calculation
• Specification Sheet
Fermenter Design

• Fermenter modeled as a batch reactor.

C6H12O6→2C2H5OH +2CO2

• Batch reactor consists of an agitator and a jacket around it for

cooling purposes.

• Reactants are filled in and allowed to react for a certain period of

time without them exiting.

• Jacket consists of agitation nozzles for providing higher

turbulence and hence better heat transfer.
Fermenter Design
 Fermenter Design
The yeast being used is Saccharomyces cerevisiae. According to
an experimental research paper, for a conversion of 70%, the
time taken for the batch reaction is 48 hrs. The following
equation was then used to calculate the entire batch time.

Where;
tF’ = Time needed for filling.
tR = Time taken for reaction.
tC’ = Time taken to cool.
tE’ = Time taken for emptying and cleaning.
tB = Time taken for the entire batch operation.
 Fermenter Design

Time required for the entire batch operation:

 Charging time (tF’ ): 2 hrs.
 Cooling time (tC’) : 1.5 hrs.
 Reaction time (tR): 48 hrs.
 Emptying and cleaning time (tE’) : 0.5 hrs.

Total time for batch (tB): 2 + 1.5 + 48 + 0.5 = 52 hrs.

 Fermenter Design
Volume of Fermenter :

Conversion = 70%.
Reaction Time = 48 hrs.
Batch Time (tB) = 52 hrs.
No. of Fermenters used =4
Working Pressure of Vessel (P) = 180 kPa
Temperature of Reaction = 32 oC.
pH = 4.8
Mass flow rate in (ml’) = 6700 Kg/hr.
Density of Material in Fermenter (ρ’) = 1200 Kg/m3.
 Volume of Fermenter
Now;
tB = 52 hrs.
Density of Feed (ρ’) = 1200kg/m3

Now;
ml’ =8788.12Kg/hr
Therefore;
Vr = 8788.12 x 52
1200
Vr = 380m3.
 Volume of Fermenter
Now;
We allow 30% of volume of fluid as the free space in the
fermenter.
Hence;
With 30% allowance;
VT = 1.30 x Vr
= 1.30 x 380
= 495 m3.
 Dimensions
L/D = 1.5
VT = Π x (D2/4) x L
= Π x (D2/4) x 1.5D
= (3/8)Π x (D3)
VT = 495 m3.
Hence, putting in above equation;
D = 7.5m.
L = 1.5*7.5= 11.24 m
 Fermenter Design
Now;
Height of Dished Bottom =1m
( From Literature)
Therefore;

Total Height = 11.24+ 1 = 12.2 m.

MECHANICAL DESIGN
 Wall Thickness
Static Pressure (Ps) = ρ’ x g x H
= (1200 x 9.81 x 11.24)/1000
=132kpa
Operating pressure of fermenter(P) = 180Kpa
Total Pressure at base = Ps + P
= (132 + 180) kPa.
=312Kpa
For safety purpose 33% excess is allowed (1+0.33) = 1.33
Maximum allowable pressure = 1.33 (312)
= 414.96 kPa = 60 Psi
Wall thickness = P x ri + Cc
SEj – 0.6P
Material = Carbon Steel.
Working Stress of Carbon Steel,S = 94500 KN/m2.
Joint Efficiency, Ej = 0.85
Internal Radius, ri = 7.5/2=3.75m
Corrosion allowance=Cc = 2mm.
Therefore wall thickness = 0.01943+ Cc
= 0.01943 + 0.002
= 0.0214 m
Therefore outside diameter= Di + 2t = 7.5*2(0.0214)=7.543 m.
 Reactor Head
There are three types of heads:

•Ellipsoidal Head.

•Torispherical Head.

•Hemispherical Head.

Ellipsoidal head is used for pressure greater than 150 psi and for
less than that pressure we use Torispherical head. That is why we
have selected a Torispherical head.
Torispherical Head

= 0.019 + 0.002 = 0.021 m = 21

mm.
 AGITATOR DESIGN

Agitator Dimensions are:

Impeller Diameter Da= Dt/3=7.5/3 = 2.5 m
Impeller Height above Vessel floor E = Da = 2.5 m
Length of Impeller Blade L = Da /4=2.5/4 = 0.625 m
Width of Impeller Blade W= Da /5=2.5/5 = 0.5 m
Width of Baffle J = Dt/10=7.5/10 = 0.75 m
No. of Impellers =3
No. of Impeller blades =6
Distance between 2 consecutive impellers = 2.5 m
Tip Velocity = 3 – 6 m/sec
Tip Velocity = 5 m/sec
Tip Velocity = π x Da x N
Speed of Impeller = N = [5/( π x 2.5)] x 60 = 43RPM
Power Requirement
Power no (Np )= = 6

Shaft RPM (N)= 43 RPM = 0.716 rev/sec

Power = (Np x N3 x Da5 x ρ) = 50 hp.

Now,

Assuming the impeller is 85 % efficient:

Actual Power required = 50/0.85 = 58.82hp=60hp

 Baffle Design

No. of baffles =6

Width of one baffle = Dt / 10 = 0.75m.

Height of baffle = 10 m.
VISUAL DISPLAY OF AGITATOR WITH DIMENSIONS

regg
0.75

0.625

0.5m
2.25m

7.5m
VISUAL DISPLAY OF FERMENTER WITH DIMENSIONS

7.5m

FRONT VIEW
VISUAL DISPLAY OF FERMENTER WITH DIMENSIONS

Cooling Jacket Agitator

0.68
0.75mm Width of Baffle
2.2 m
2.25m

6.80
7.5mm

TOP VIEW
 Heat transfer Calculation
Cooling fluid used = Cooling Water.
Cooling Jacket area available (A) = 17 m2
This area is obtained from Table 7.3 in
“ Chemical Process Engineering Design and Economics by
Harry Silla”

CW inlet temp = 20 oC
CW outlet temp = 28 oC

Approaches;
• ΔT1= 32 – 20 = 12 0C
• ΔT2= 32 – 28 = 4 0C
LMTD = ΔT1 – ΔT2 = 12-4
ln (ΔT1 / ΔT2 ) ln (12/4)
LMTD = 7.28

Heat of Reaction;
Q = ∆Hr = 1.1 x 106 kJ/hr
Design Overall Coefficient=U D=(Ho* Hio)/(Hio+Ho)
=(0.67*60.54)/(0.67+60.54)
=0.662Btu/hr.ft2.0F=170W/m2.0K
Now; Heat Removable by Jacket;
Qj = UD x A x LMTD
= 27938 W
 Heat transfer Calculation

Since the heat of reaction (1.1 x 106 kJ/hr) < heat removable
by jacket (2 x 106kJ/hr )
Our design for a cooling jacket is justified in comparison with
a cooling coil.
Now Cooling water Flow rate can be calculated as:
Heat to be removed from reactor = 1.1 x 106 kJ/hr
 Identification
Item Fermenter
Item Name R-101
No. Required 4
Function Production of Industrial Alcohol by Fermentation
Operation Batch
Type Jacketed, Stirred Tank Reactor
Volume 495m3
Height 12.24 m
Diameter 7.5m
Temperature 32oC
Working Pressure 1.8 atm
Batch Time 52 hrs
Height to Diameter Ratio 1.5
Type of Head Torispherical
Depth of Dished Bottom 1m
Wall Thickness 0.0214 m
Head Thickness 0.021 m
No. of Baffles 6
Width of Baffle 0.75m
Height of Baffle 10 m
Material of Construction of Fermenter Carbon Steel
Identification
Item Agitator
Type Three 6-bladed Flat Turbine
Number of Blades 6
Impeller Diameter 2.25m
Length of Blade 0.625 m
Width of Blade 0.5 m
Impeller Above Vessel Floor 2.2 m
Speed of Impeller 38 RPM
Power Required 60 hp

Identification
Item Cooling Jacket
Fluid Handled Cooling Water
Inlet Temperature 20oC
Outlet Temperature 28oC
Heat Transfer Area 17 m2
UD 0.662Btu/hr.ft2.0F
Designing of Distillation
Column
Distillation Column Design

Feed Inlet = 99.615tons/day

=4150.625 kg/hr
Moles of alcohol= 2150.02/46.048 * (kg.mol/hr)
=46.69kgmol/hr
Moles of water = 2000.60125/18 * (kgmol/hr)
=111.1445139kgmol/hr
Mole fraction of Alcohol =X AF= 0.29
Mole fraction of water = XBF =0.69
Distillation Column Design

Top product stream = 75TPD

=3125kg/hr
Alcohol in stream= (3125*0.9154)
= 2981.25kg/hr
Moles of Alcohol = 64.7422kgmol/hr
Amount of water=3125-2981.25
= 143.75kg/hr
Moles of water =7.986kgmol/hr
Mole fraction of Alcohol= XDA=0.89
Mole fraction of water = XDB = 0.11
Distillation column Design

Bottom Product stream = 86.437TPD

= 3601.541667kg/hr
Alcohol amount= 0.42%
= (3601.541667* 0.0042)
= 15.1264kg/hr
Moles of Alcohol = 0.32849 kgmol/hr
Amount of water = 3586.415192 kg/hr
Moles of water = 199.2453kgmol/hr
Mole fraction Alcohol= 0.00164
Mole fraction of water = 0.998
Distillation Column design

Pressure = 1atm = 101.325kpa

Top temperature = 820C = 355 k
Bottom temperature = 1000C = 373k
Now , using Antoin Equation for Pvap. Of Alcohol
Pvap. = 117.099kpa
K = Pvap/ P = 117.099/101.325
Kalch. = 1.1557
Now , using Antoin Equation for P vap. Of Water,
Pvap.=101.3227393kpa
Kwat. = Pvap./P= 0.9999
Light = Alcohol , Heavy = Water
Distillation Column Design

Relative volatility of Alcohol= ɑA= 1.1557/0.9999 =1.16

Relative volatility of Water= ɑB= 0.9999/0.9999 =1

Maximum Reflux ratio= (underwood

Eq.)

(1.16*0.29)/(1.16 - ɵ) + (0.69*1)/(1 - ɵ) =0
So ,

ɵ =1.1076
Distillation Column Design

Minimum Reflux ratio =

(1.16*0.89)/(1.16-1.1076) + (1*.11)/(1-1.16) = R m +1
Rm = 18.015
Optimum Reflux Ratio :
From Book “Rules of Thumb for Chemical Engineers)
R = 1.2 – 1.5 of Rm
So we select multiple 1.2
R = 1.2 Rm
R = 21618
Distillation Column Design

Calculation of Number of stages :

Using Fenske’s Equation
Nmin + 1 = ln[(xA/xB)D/(xB /xA)S]
ln (αAB) average
Nmin + 1 = ln[(0.89/0.11)D/(0.998 /0.00164)S]
ln (1.08) average
Nmin = 11.2
Nmin = 12 stages
Distillation Column Design

Number of Theoratical plates :

Using Gilliland equation

(N-12)/ (N + 1) = 0.75[1- {(21.618-18.015)/(21.08+1)}0.566]

(N-12)/(N+1) = 0.48484
N = 24
Distillation Column Design

Column Efficiency :

uavg = 0.58 Cp
ɑavg = 1.08
E0 = 51 – 32.5 [ log (0.58*1.08)]
Eo = 67.5 %
Actual number of plates = 24/0.675 = 36 plates
Distillation Column Design

Location of Feed plate : (Kirkbride equation)

ND/NB = [ (86.437/75)(0.69/0.29)(0.00164/0.11)2]0.200
ND/NB = 0.7
ND= 0.7 NB
ND +NB = 36
NB= 36/1.7 = 21
so feed is entering at 21st plate.
Distillation Column Design

Material Balance :
Calculations at Top
Ln = D*Rmin
Ln = 3125*18.015
Ln = 56296.875kg/hr
Vn = L n + D
Vn = 56296.875 + 3125
Vn = 59421.875 kg /hr
Dv = 1.57kg/m3
DL = 803 kg /m3
Distillation Column Design

Calculation on Bottom:
Lm = Ln + F
Lm= 56296.875 + 4150.625
Lm = 60447.5 kg /hr
Vm = Lm – B
Vm = 60447.5 – 3601.541667
Vm = 56845. 95833 kg/hr
Distillation Column Design

ρv = 1.57kg/ m3 (v= 10.06m3/sec)

ρL = 803 kg/m3 ( L= 1.9 * 10-2m3sec-1)
For values of Csb ( Tray flooding velocity) ,
(L/V)*(ρv / ρL )0.5 = (1.9*10-2/10.6) * (1.57/803)0.5
= 8*10-2
Let tray spacing = 0.61m
Csb = 7.8 * 10-2
=0.078m/sec(From graph plant designing Fig15.5 by Timer
Haus)
Distillation Column Design

Net vapor velocity at flooding;

ɑ= surface tension
= 21.5
Vn,f = (0.078)[21.5/20]0.2[(803-1.57)/1.57]0.5
Vn,f = 1.79m/sec
For 75% flooding , Actual vapor velocity
Vn = (0.75) (0.79)
Vn = 1.34 m/sec
Distillation Column Design

An = mv/Vn = 10.06/1.34
An= 7.9m2
So for75% flooding, Actual area
Ac = An/ 0.75
Ac = 7.9/ 0.75
Ac = 10.75 m2
So Diameter = D =
D = [( 4* 10.5)/3.1416)]1/2
D= 3.66m
Distillation Column Design

Height of Column:
Hc= (Nact-1) Hs+ ∆H
Hc= (36-1) *(0.61) + 2m
Hc = 23.4
It should b less then 30 m.
Pressure Drop:
H=23.4m
ρL=803kg/m3 , g=9.81m/sec2
Pt = ρgH = 803 * 9.81 * 23.4
Pt = 184pa = 0.124 psi per tray
Designing of Heat
Exchanger
Heat Exchanger Design
For Cold stream:
m21 =50558.33kg/hr
Temperature in = 320C= 305 k
Temperature out = 600C = 333k
pressure = 44.1psi
Cp = 4.605 kJ/kg.k
For Hot stream:
m22 = 40446.67kg/hr
Temperature in = 1000C= 373 k
Temperature out = 680C = 341k
pressure = 120psi
Cp = 4.034 kJ/kg.k
Heat Exchanger Design
Heat load =Q = m21 Cp ΔT
Q = 50558.33*4.605*(60-32)
Q = 6518991.07 kJ/hr

LMTD

LMTD=(341-305) – (373-333)
ln[(341-305)/373-333]
LMTD=37.965K
Heat Exchanger Design
R = (Th, in - Th, out)/ ( Tc, out - Tc, in)
R= (373-341)/(333-305)
R= 1.143
P = (Tc, out - Tc,in)/ ( Th,in - Tc,in)
P = (333-305)/(373-341)
P =0.875
Ft=0.86
True temperature difference
ΔTo.m = LMTD * Ft
ΔTo.m =32.64990C
Heat Exchanger Design
Assumed that
Ud = 500 W/m2.k
Heat transfer Area = Q/(Ud * LMTD)
A = 6518991.07/(500*305.6499)
A= 42.657m2

Number of Tubes = N = A/ 3.14doLe

= 42.657/(3.14*0.019*49)
= 146 tubes
Heat Exchanger Design
Outer Dia = ¾ inch = 0.019
Length = 4.9 m
BWG = 16
Inner Dia = 0.620in = 0.01575 m
Flow Area = Π/4 * (I.D)2 * N
= Π/4 * (0.01575)2*146
= 0.02844m2
Surface area per unit length = 0.0597m 2/m
Actual Number of Tubes = n t =A/(As*Lt)
=42.657/(0.597*4.9)= 146
Heat Exchanger Design
Actual Number of Tube passes = np = 4
Pitch for Square = 1 inch
pt = 1 inch = 0.0833ft
= 0.0254 m
Tube clearance = Pt – D0
= 0.0254 – 0.019
= 0.0064m
Shell internal Dia = 0.4236 m ( for 146 tubes from literature )
Baffle Spacing = B= 0.66 Ds
= 0.66 ( 0.4236) = 0.2796m
Heat Exchanger Design
Number of passes = 1
Number of baffles = length of tube / baffle spacing
= 4.9/ 0.2796
= 18
Tube spacing = 0.00635
References
1. Richerdson and Coulson’s Chemical Engineering Vol. II
2. Process heat Transfer by Kern
3. Plant Design and Economics for Chemical Engineering by
Timmerhaus
4. Unit Operations of Chemical Engineering by Warren McCabe,
Julian Smith, Peter Harriott emeritus
5. Chemical Process Engineering Design and Economics by Silla
Thank you….