Ministry Of Higher Education and Scientific Research

Al-Qadissiya University
College Of Engineering
Chemical Engineering Department
2018-2019

(Production of bioethanol from sweet potatoes)

A Project Submitted To The College Of Engineering Al-Qadissiya University

In Partial Fulfillment Of The Requirement For The Degree Of Bachelor of
Science In Chemical Engineering.

Done by:
Alaa Hakem & Hassan Alaa & Ghofran Riadh

Under the supervision of:

Dr. Salih A. Rushdi

1
 ‫ربما ال تتاح الفرصة دائما لي ألقول لكم شكرا وربما ال املك دائما جرأة التعبير عن االمتنان‬
‫والعرفان إلى شمعة الحياة التي تنير عتمة الليل بكل حب وتواضع إلى عنوان الصفاء في‬
‫حياتي إلى من سهر الليل خوفا علي إلى من بذال كل شي من اجلنا ‪...‬‬
‫أبي و أمي‬
‫الى المحبة التي ال تنضب‪ ..‬والخير البلى حدود إلى من شاركتهم كل حياتي الى جوهرتي‬
‫الثمينة وكنزي الغالي‪...‬‬
‫أخوتي ورفاق دربي‪....‬‬
‫الى من سهروا الليالي في طلب العلم وكافحوا لتثقيفي وتعليمي الى الشموع التي تحترق من‬
‫اجل انارة طريقنا الى كل من ساهم في تعليمي ولو حرفا واحدا من أساتذتي في مسيرتي‬
‫وبالخصوص من عمل معنا على إتمام هذا المشروع أستاذنا الفاضل الدكتور صالح‬
‫و الى كلية الهندسة قسم الهندسة الكيمياوية‬

‫وأخيرا الى شرفاء هذه أالمه رجالها ونسائها الرائعين الذين يعبرون كل شيء بأقدارهم دون‬
‫انحناء‪ 00‬الى التفاصيل الجميلة في هذه الحياة ‪00‬‬

‫‪2‬‬
 Chapter one

3
 (1-1) Introduction

Bioethanol: Fuel produced by the process of fermentation and most of the carbohydrates

produced from sugar and starch such as potatoes, sugar cane and corn are done with the help of

enzymes.

Figure 1:1
The first use of ethanol was the engine in 1826 and in 1876, Nicholas Otto, the inventor of

modern four-cycle internal combustion engine. Use ethanol to run an early engine. Ethanol was

else used as fuel for lighting in the 1850, but its used limited when taxes were levied cumin to

help pay for the civil war. Ethanol continued to be used as fuel after tax was abolished and the

Henry ford model was supplies in 1908 .

In the past, many countries have faced problems with non-renewable energy sources and have

been forced to seek new sources that are environmentally friendly and have no negative impact

on the environment. At present, many countries are looking for renewable and environmentally

friendly sources of energy. These sources are treated as a way to reduce the total cost of energy

and reduce reliance on imported energy sources. Ethanol has been found to be the most

appropriate solution because it can be a substitute for gasoline because it has similar properties to

gasoline and can be mixed with benzene giving a product that has a lower carbon dioxide
mission rate when burning less.

4
 Sweet potato:
is one of the renewable resources that can enter as raw material in the production of bioethanol.

It is available and can be grown in different regions. Sweet potatoes have a higher carbohydrate

content than corn and wheat. Many countries rely on bioethanol as an alternative source of

energy such as Brazil, America and Indonesia.

Figure 1:2

Amylase enzyme:
is an enzyme that is secreted in humans and in other living organisms such as plants ,

Figure 1:3

5
 Types of Amylase Enzyme:
The enzyme is divided into several types :

Alpha amylase: is the main enzyme for digestion starch and carbohydrates in animals and

humans, and this enzyme works on any part of carbohydrates or starch, so this enzyme is

relatively fast, and product when the breakdown of complex carbohydrates Glucose and dextrin

and maltose, which are simple sugars

Beta amylase: This enzyme is found in plants, bacteria and fungi. This type is associated with

only a certain portion of starches, so it is considered slow compared to other species. Its main

function is the conversion of carbohydrates from maltose .sugar, which gives the sweet taste

when the fruit is leveled

here are

uses of the enzyme amylase:

1- is secreted when you eat starches in the mouth of the salivary glands and pancreas
and issued to the small intestine is destroyed and digested into simple molecules .
2- used in the manufacture of bread: so that the use of fungi to digest carbohydrates
complex to produce materials help in the maturity of the dough, which is used in the
manufacture of chemical compounds used in washing and cleaning materials to
remove the outstanding fats and dirt.
3- purposes of medical examinations

6
 Table (1-1) : properties of bioethanol

Table 1:1

7
 Structure and chemical formula of ethanol

Chemical formula:
is C2H6O . This can also be written as CH3CH2OH or C2H5OH it is made of nine atoms that
include two carbon (c) atoms , six hydrogen(h)atoms, and one oxygen (O) atoms

Chemical structure :
There are methyl group (which is the CH3) and ethylene group (which is the CH2) in the
chemical structure

Figure 1:4

8
 Physicaland chemical properties

1- Colorless liquid is volatile

2- The melting point of bioethanol 117.3 C
3- The boiling point of bioethanol 78.5 C
4- Mixable with water in all proportions
5- Ethanol burns in the air with a blue flame and produces combustion of carbon dioxide
and water
6- Its interaction with active metals results in ethylene oxide and hydrogen
7- Reacts with some acids to form the ester
8- The ethanol has a high viscosity
9- Has the coefficient of refraction equal to 589.3
10- A density quality 816

Uses:
1- Used as a solvent in the manufacture of varnish and perfume coating
2- preservative material for vital samples
3- Used as fuel for cars
4- Used in personal care products such as mouthwash and barber creams
5- Enter into the pharmaceutical industry as a basic drug holder found in
medicine
6- is used as a solvent for the manufacture of antibiotics and medicine pills
7- Used in cleaning products
8- is used as raw material in the production of vinegar and yeast
9- Used in food products such as flavorings, extracts, polishing and coating
10- Source of energy in some animal feed products dedicated to animals

9
 general look at the future of ethanol

Ethanol has a great future, since dependence on oil sources and its use as fuel can be carried out

at any time and have a significant impact on the pollution of the environment and the residues

from the burning of fossil fuels cause great pollution in the environment. Ethanol is a friend of

the environment and does not leave harmful chemical violations. In the future, ethanol will be

the most common and used fuel. The United States and the EU are also seeking to increase the

use of ethanol by 20% because it is a clean and friendly fuel for the environment. Global ethano

l production is on the rise. Ethanol production is currently 1.87 million barrels Daily.

There has been a general trend in America and other countries to increase reliance on renewable

energy sources and support research aimed at finding them and reducing dependence on fossil

fuels

In order to develop ethanol production and increase production volume in order to replace
gasoline, we must work to find things, including:

 Reduce the cost of conversion of agricultural products to bioethanol

 Increase crop diversity used in bioethanol production
 Look for new microbes and enzymes that can easily convert starch into sugar

10
 Global production of bioethanol

amount of bio-ethanol Countries

produced billion gallons
/ year
4.8 United States of America

4.4 Brazil

1.0 China

0.5 India

0.25 France

Table 1:2 (global production of bioethanol)

Cons of bioethanol
Bioethanol has no significant impact on the environment in terms of abundance

Because of the lucrative prices of bioethanol, some roads may be food crops for biofuel

production as well as non-diversification and cultivation of crops

Calcium oxygen reproduction of carbon oxides

Bioethanol or gas free of gases banned from energy by 70% of the fuel and the engines

can be made to work on bioethanol used for gasoline or diesel

Phosphorus and nitrogen are used in the production of bioethanol and have a negative

effect on the environmentThe bioethanol is hygroscopic, ie, it absorbs water from the air

and therefore has a high aggressive to corrosion and therefore can only be transported by

rail and motor

11
 Chapter two

12
 Method of production bioethanol
Due to the importance of bioethanol and its good qualities and the low impact on the

environment has become a great interest and made some interested in it and increased

research to find many ways and appropriate for the production of these methods is the

method of production by sweet potatoes

One of the most important reasons why scientists are interested in the production of

bioethanol sweet potato because it contains high production of ethanol, where the

proportion of production of ethanol between 46710 - 8595 liters / ha and sweet potatoes

contain a high percentage of carbohydrates and available in many areas where It is the

sixth most cultivated crop in the world. Its global production in 2016 is 105 million tons.

Also, the characteristics of sweet potatoes are a permanent crop that is more adaptive to

the environmental conditions, grows easily, has high drought resistance and is easily

harvested.

Bioethanol is produced from the potato where the source of energy is starch. The process

of converting starch into bioethanol is carried out in three main steps: hydrolysis (acidic

or enzymatic), fermentation and distillation

Where the process of hydrolysis of the total detection of the particles of amylose, which

is converted and converted to dexttins and then to glucose

In the fermentation phase, the simple sugars are converted to ethanol. After the

fermentation process, distillation occurs. In the distillation process, the bioethanol

13
 produced from the wet deposits is separated to obtain the final bioethanol product. This

step is responsible for the highest energy consumption in the bioethanol production

process. But there is a difference in the use of yeast used in the production process, where

there are many yeast used in production, including yeast

1- Pichia
2- Stipites
3-S.cerevisiae
4- Trichoderma.sp

There is also a common way to produce bioethanol between yeast

(S.cerevisiae and Trichoderma.sp)

In this paper we will study the production of bioethanol from sweet potatoes using s.cerevisiae

yeast and also the method of its production by common yeast (S.cerevisiae and Trichoderma.sp

The steps in these methods are not very different, but there is a difference in terms of

temperature, operational conditions and PH value of the process

14
 The production of bioethanol by sweet potatoes using S.cerevisiae

The production of bioethanol in this way is more common and its materials are readily available

and can be obtained by

hydrolysis, fermentation and distillation.

Primary materials used in this process:

1 - Sweet potatoes

2 - Enzyme Almelyz

3. Yeast s.cerevisiae

4- water

Operating conditions:
The temperature of the hydrolysis is 30 ° C and its duration is 90 minutes

The fermentation temperature is 70 ° C for 20 hours

The distillation temperature is 80 ° C and takes 1.5 hours

Concentration of alpha-amylase enzyme 700 ml / t

Yeast concentration of s.cerevisiae 3.3

Productivity:
The productivity is based on the actual productivity of the potato and this method is a common

and more widely used method because of the availability of raw materials easily and the highest

productivity of bioethanol in this method (16 L/ h) and the value of PH for this process 4.5

15
 Method of producing bioethanol by sweet potato using the common yeast
method (s.cerevisiae and trichoderma.sp)

The method of production in this way was to study the improvement of the common culture of

the ratio of (1: 4) on the yeast s.cerevisiae and trichoderma.sp for the production of ethanol and

that this method is also done by hydrolysis, fermentation and distillation

Raw materials used in this process

1-Sweet potatoes

2- Common yeast

3 - Water

4 - Alpha Amylaes enzyme

5. NH4CL

6. Nitrogen sources

Operating conditions
The temperature of the hydrolysis is 70 ° C

The fermentation temperature is 30 ° C for 72 hours

Concentration (NH4) 2SO4 is 0.2%

Productivity
The production of bioethanol from potato flour through the process of co-fermentation has
increased with the fermentation time and biomass of the yeast. In this process, 78% of the sugar
consumed has been converted to ethanol and the amount of production by this process is 65%
higher than the quantity of production by yeast S The rate of bioethanol production was 172g /
kg. The pH value of this process was 5 to 6

16
 Method of production bioethanol from dates
Bioethanol can be produced from dates because it is rich in single and bilateral sugars,
salts and vitamins. These elements are important for the growth of microorganisms .
Especially yeasts used in ethanol product.

The raw materials

Dates juice prepared from a thyme with a concentration of 70% and other concentrations
such as (50 - 100 - 200 - 300) g / l.
Yeasts involved in this process are two types:
. Saccharomyces s.cerevisiae
Candida Utilis.

Circumstances
The operation was performed under non-aerobic conditions and at 30 ° C for 48 hours.
The cells were collected by centrifugation at 4500 rpm and for 15 min

The Productivity
The yield of S.cerevisiae was more efficient with sugar consumption and converted to
ethanol in both ways with a production of 8.4% ethanol within 36 hours compared to
C.utilis yeast which gave 6.8%.
The highest productivity was in PH = 4.5

17
 Production of bioethanol remnants of
agricultural crops

In the state of Kansas, one of the world's largest bioethanol plants has been launched
from agricultural waste. The leaves, husks, corn stalks and other plant wastes, such as
wood and grass, have been used to produce ethanol, which is mixed with diesel to fuel
engines. This type of fuel is called cellulosic ethanol or second-generation biofuels

raw materials
Corn leaves, scales and stalks
Or plant wastes such as wood and grass
Enzymes are used to break down solid biological polymers
Yeast is also used

Productivity
Ethanol production in this way is very expensive because this fuel from agricultural
waste faces funding problems. The high cost of cellulosic ethanol is due mainly to the
multiplication of the chemical processes of raw materials and the nature of the enzymes
used in the production process

18
 Production of Production of Production of
bioethanol from ethanol from sweet ethanol from sweet
dates potatoes using potatoes
s.cerevisiae using(trichoderma.sp
and s.cerevisiae)

raw materials Dates juice of the sweet potato sweet potato

class Zuhdi Alpha - enzyme Common
concentration of 70% Yeast s.cerevisiae Yeasttrichoderma.sp
Water and s.cerevisiae
Water
Alpha amylase
NH4cl
Nitrogen sources
Temperature 300 C 30 C 30 C

Yield 280 L 60 g/kg 172g/kg

Conversion 65% 90% 78%

Enzymes -------- Alpha-amylase Alpha amylase

Type of yeast s.Cerevisiae s.Cerevisiae s.Cerevisiae and

canditautilis trichoderma.sp
PH 4.5 4.5 – 4 6–7

Process time 36 Hour 20 Hour 72 Hour

Table 2:1 (comparison of methods of producing bioethanol)

19
 Method of work followed
Method of producing bioethanol by sweet potatoes and yeast ()

The reason for choosing this method is that the raw materials of this process are available and
easy to obtain. This method is the most common and yeast is the most widely used in the
production of industrial bioethanol because it tolerates a wide degree of acidity, making the
process less susceptible.

They are available and their cost is low

20
 Chapter three

Material balance

21
 Figure PFD of production bioethanol from sweet potato

22
 Work methods in the laboratory :
We add 50 ml of ethanol to the beakar containing 50 ml of distilled water and then the
mixture point with the distillation raising the temperature to 80 C . as the temperature
rises we see the evaporation of ethanol which collects from the top of the distillation
system in another flask found that the amount of ethanol distilled 48 ml

23
 Yield =100000

Conversion = 90%

300 day
ℎ𝑜𝑢𝑟
300 × 24 = 7200 𝑦𝑒𝑎𝑟

7200 𝐵𝑎𝑡𝑐ℎ
𝑁𝑜. 𝑜𝑓 𝑏𝑎𝑡𝑐ℎ = = 84
86 𝑦𝑒𝑎𝑟

100000 𝑙𝑖𝑡𝑒𝑟 𝑘𝑔
𝑡𝑜𝑡𝑎𝑙 𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑒𝑡ℎ𝑎𝑛𝑜𝑙 = = 1200 = 960
84 𝐵𝑎𝑡𝑐ℎ 𝑏𝑎𝑡𝑐ℎ

Compound Molecular formula Molecular weight

𝒌𝒈
( )
𝒌𝒎𝒐𝒍𝒆
Cellulose 𝐶6𝐻10𝑂5 162
Water 𝐻2𝑂 18
Glucose 𝐶6𝐻12𝑂6 180
Carbon dioxide 𝐶𝑂2 44
Ethanol 𝐶2𝐻5𝑂𝐻 46

Table 3:1 (Molecular formula & weight for compound)

24
 Reactor

𝛼−𝑎𝑚𝑎𝑙𝑦𝑠
𝑐𝑒𝑙𝑙𝑢𝑙𝑜𝑠𝑒 → 𝑔𝑙𝑜𝑢𝑐𝑜𝑢𝑠𝑒

𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑔𝑙𝑜𝑢𝑐𝑜𝑢𝑠𝑒 = 2343.67

2343.67
𝑚𝑜𝑙𝑒 𝑜𝑓 𝑔𝑙𝑜𝑢𝑐𝑜𝑢𝑠𝑒 = = 13 𝑚𝑜𝑙𝑒
180
13
𝑚𝑜𝑙𝑒 𝑜𝑓 𝑐𝑒𝑙𝑙𝑢𝑙𝑜𝑠𝑒(𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛) = = 14.45
1 × (0.9)

𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑐𝑒𝑙𝑙𝑢𝑙𝑜𝑠𝑒 (𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛) = 2343.58

𝑡𝑜𝑡𝑎𝑙 𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑐𝑒𝑙𝑙𝑢𝑙𝑜𝑠𝑒 = (1 + 0.1) × 2343.58 = 2577.938

𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑟𝑒𝑠𝑖𝑑𝑢𝑎𝑙 𝑐𝑒𝑙𝑙𝑢𝑙𝑜𝑠𝑒 = 2577.938 − 2343.58 = 234.35

Component In put Out Put

Mass(kg) Mass (kg)
C6H10O5 2577.938 234.35
H2O 999.2 999.2
α − 𝑎𝑚𝑎𝑙𝑦𝑠𝑒 3.3 3.3
C6H12O6 _____ 2343.67
Total 3580.43 3580.52

Table 3:2 (Material balance for Reactor-101)

25
 Filter

𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑔𝑙𝑜𝑢𝑐𝑜𝑢𝑠𝑒 = 2297 𝑘𝑔

𝐹 =𝑇+𝑃

𝑇 = 0.02 𝐹

𝐹 = 0.02 𝐹 + 2297

𝐹 = 2343.67 𝑘𝑔 (𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝐶6𝐻12𝑂6)𝑓𝑒𝑒𝑑

𝑇 = 46.67 𝑘𝑔 (𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑠𝑜𝑙𝑖𝑑 𝑤𝑎𝑠𝑡𝑒)

Component In put Out put mass (kg)

mass(kg) 1 2
C6H12O6 2343.67 2297 ------
Solid waste ------ ------ 46.67
Total 2343.67 2343.67

Table 3:3 (Material balance for Filter -101)

26
 Reactor

𝐶6𝐻12𝑂6 → 2𝐶2𝐻5𝑂𝐻 + 2𝐶𝑂2

960.8
𝑚𝑜𝑙𝑒 𝑜𝑓 𝑒𝑡ℎ𝑎𝑛𝑜𝑙 = = 20.8
46
𝑚𝑜𝑙𝑒 𝑜𝑓 𝐶𝑂2 = 𝑚𝑜𝑙𝑒 𝑜𝑓 𝑒𝑡ℎ𝑎𝑛𝑜𝑙 = 20.8

𝑚𝑜𝑙𝑒 𝑜𝑓 𝑒𝑡ℎ𝑎𝑛𝑜𝑙
𝑚𝑜𝑙𝑒 𝑜𝑓 𝐶6𝐻12𝑂6 (𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡) = = 11.55 𝑚𝑜𝑙𝑒
2 × 𝑐𝑜𝑛𝑣𝑒𝑟𝑠𝑖𝑜𝑛
𝑡𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒 𝑜𝑓 𝐶6𝐻12𝑂6 = (1 + 0.1) × 11.55 = 12.74 𝑚𝑜𝑙𝑒

𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝐶6𝐻12𝑂6 (𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡) = 2087 𝑘𝑔

𝑡𝑜𝑡𝑎𝑙 𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝐶6𝐻12𝑂6 = 2297 𝑘𝑔

𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝐶6𝐻12𝑂6 𝑟𝑒𝑠𝑖𝑑𝑢𝑎𝑙 = 2297 − 2087 = 210 𝑘𝑔

Component In put mass(kg) Out put mass (kg)

Ethanol ------- 960.8
C6H12O6 2087 210
CO2 ------ 915.2
H2O 999.2 999.2
Yeast 2.667 2.667
Total 3088 3088
Table 3:4 (Material balance for reactor-102)

27
 Distillation

𝐷 = 960 𝑘𝑔

𝐷(𝑒𝑡ℎ𝑎𝑛𝑜𝑙) = 960 × 0.98 = 940.8 𝑘𝑔

𝐷 (𝐻2𝑂) = 960 − 940.8 = 19.2 𝑘𝑔

𝑤 = 1000𝑘𝑔

𝑊 (𝐸𝑡ℎ) = 1000 × 0.02 = 20 𝑘𝑔

𝑊 (𝐻2𝑂) = 1000 − 20 = 980 𝑘𝑔

𝐹 = 𝐷 (𝐸𝑡ℎ) + 𝑊 (𝐸𝑡ℎ) = 940.8 +20=960.8 kg

𝐹 (𝐻2𝑂) = 𝐷 (𝐻2𝑂) + W (H20) = 19.2 + 980 = 999.2 kg

Component In put mass (kg) Output mass(kg)

D W
Ethanol 960.8 940.8 20
H2O 999.2 19.2 980
Total 1960 1960
Table 3:5 (Material balance for Distillation)

28
 Chapter four

Energy balance

29
 Energy balance
The general energy balance equation is :

∆𝐾𝐸 + ∆𝑃𝐸 + ∆𝐻 = 𝑄 − 𝑊

In this project we don't have velocity or height or movement parts, so :

∆𝐾𝐸 = ∆𝑃𝐸 = 𝑊 = 0

So that the general equation will be

𝑄=𝑊

∆𝐻 = 𝐻2 − 𝐻1
𝑇

𝑚 ∫ 𝑐𝑝(𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛) × ∆𝑇
𝑇𝑟𝑒𝑓

Q = 𝑚 × 𝑐𝑝(𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛) × (T − Tref)

Compound Molecular Molecular Heat capacity 𝑯𝒇°

formula weight
(𝒌𝒈⁄𝒌𝒎𝒐𝒍𝒆)
𝒌𝒋
Cellulose 𝐶6𝐻10𝑂5 162 1300 𝑘𝑗⁄𝑘𝑔. 𝑘 -963 𝐤𝐠
𝒌𝒋
Water 𝐻2𝑂 18 4.18 𝑘𝑗⁄𝑘𝑔. 𝑘 -285.8
𝐤𝐠
𝒌𝒋
Glucose 𝐶6𝐻12𝑂6 180 218.6 𝑗⁄𝑘. 𝑚𝑜𝑙 -1271𝐤𝐠
𝒌𝒋
Carbon 𝐶𝑂2 44 0.82 𝑘𝑗⁄𝑘𝑔 . 𝑘 -393.5 𝐤𝐠
dioxide
𝐤𝐣
Ethanol 𝐶2𝐻5𝑂𝐻 46 2.44 𝑘𝑗⁄𝑘𝑔 . 𝑘 -277.𝐤𝐠

Table 4:1 (properties of compounds)

30
 Reactor

𝑇(𝐾) = 25 + 273 = 298𝐾

𝑇(𝐾) = 30 + 273 = 303𝐾

𝑄 = ∆𝐻

∆𝐻 = 𝑚 𝑐𝑝 ∆𝑇

∆𝐻 = 𝑚 𝑐𝑝 (𝑇 − 𝑇𝑟𝑒𝑓)

∆𝐻1 = 𝑚 𝑐𝑝 (298 − 298) = 0

∆𝐻2 = 0

2343.67 218.6
∆𝐻3 = 𝑚 𝑐𝑝 ∆𝑇 = × 103 × × (303 − 298)
180 103
∆𝐻3 = 14231.28 𝑘𝑗

𝑄 = ∆𝐻𝑜𝑢𝑡 − ∆𝐻𝑖𝑛 = ∆𝐻3 − (∆𝐻1 + ∆𝐻2)

𝑄 = 14231.28 − (0) = 14231.28 𝐾𝐽

∆𝐻𝑟𝑒𝑐 = ∆𝐻𝑓°(𝑝) − ∆𝐻𝑓°(𝑟)

𝑘𝑗
∆𝐻𝑟𝑒𝑎𝑐 = 1 × −1271 − (1 × −963) + (1 × −285.8) = −22.2
𝑘𝑔

𝑘𝑗
𝑄 = 14231.28 − 22.2 = 14209.08
𝑘𝑔

31
 Heat exchanger

𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 (𝐶6𝐻12𝑂6) = 2343.67𝑘𝑔

𝑇(𝑘) = 30 + 273 = 303𝑘

𝑇(𝑘) = 50 + 273 = 323𝑘

∆𝐻𝑖𝑛 = 14231.28 𝑘𝑗
2343.67 218.6
∆𝐻𝑜𝑢𝑡 = 𝑚 𝑐𝑝 ∆𝑇 = × 103 × × (323 − 298)
180 103
∆𝐻𝑜𝑢𝑡 = 71156.42 𝑘𝐽

𝑄 = ∆𝐻

𝑄 = ∆𝐻𝑜𝑢𝑡 − ∆𝐻𝑖𝑛 = 71156.42 − 14231.28 = 56925.14 𝑘𝐽

32
 Reactor 2

𝑇(𝑘) = 323𝑘

𝑇(𝑘) = 343𝑘

𝐻1 = 71156.42 𝑘𝐽

𝐻2 = 𝑚 𝑐𝑝 ∆𝑇 = 960.8 × 2.44 × (343 − 298)

𝐻2 = 105495.84 𝑘𝐽

𝐻3 = 𝑚 𝑐𝑝 ∆𝑇 = 915.2 × 0.82 × (343 − 298)

𝐻3 = 33770.88 𝑘𝐽

∆𝐻 = 𝐻3 + 𝐻2 − 𝐻1 = (33770.88 + 105495.84) − 71156.42

∆𝐻 = 68110.3 𝑘𝐽

∆𝐻𝑟𝑒𝑎𝑐 = ∆𝐻𝑓°(𝑝) − ∆𝐻𝑓°(𝑟𝑒𝑎𝑐)

∆𝐻𝑟𝑒𝑎𝑐 = 2 × 𝐻𝑓°(𝐶2𝐻5𝑂𝐻) + 2 × 𝐻𝑓°(𝐶𝑂2) − 1 × 𝐻𝑓°(C6H12O6)

∆𝐻𝑟𝑒𝑎𝑐 = 2 × −277.6 + (2 × −393.5) − 1 × −1271

𝑘𝑗
∆𝐻𝑟𝑒𝑎𝑐 = −71.2
𝑘𝑔

33
 𝑄 = ∆𝐻 + ∆𝐻𝑟𝑒𝑎𝑐 = 68110.3 − 71.2

𝑘𝑗
𝑄 = 68039.1
𝑘𝑔

𝑘𝑗
∆𝐻 𝑎𝑡 120 𝑐° = 2706
𝑘𝑔

∆𝐻 𝑎𝑡 105𝑐° = 2683.4 𝑘𝑗⁄𝑘𝑔

𝑄 = 𝑚. ∆𝐻

68039.1 = 𝑚(2706 − 2683.4)

𝑚 = 3010.5 kg steam required for fermentation

34
 Distillation

𝑇(𝑘) = 70 + 273 = 343𝑘

𝑇(𝑘) = 80 + 273 = 353𝑘

𝐻(𝐹) = 105495.84 𝑘𝐽

𝐻(𝐷) = 𝑚 𝑐𝑝 ∆𝑇

𝑚(𝐷) = 960.8 𝑘𝑔

𝑐𝑝𝑚𝑖𝑛 = 𝑋𝐶2𝐻5𝑂𝐻 × 𝑐𝑝𝐶2𝐻5𝑂𝐻 + 𝑋𝐻2𝑂 × 𝑐𝑝𝐻2𝑂

= 0.979 × 2.44 + 0.019 × 4.18

𝑘𝐽
= 2.46
𝑘𝑔. 𝑘

𝐻𝐷 = 960.8 × 2.46 × (353 − 298)

𝐻𝐷 = 129996.24 𝑘𝐽

𝐻𝑊 = 𝑚 𝑐𝑝 ∆𝑇

𝑚𝑊 = 1000𝑘𝑔

𝑐𝑝𝑚𝑖𝑛 = 𝑋𝐶2𝐻5𝑂𝐻 × 𝑐𝑝𝐶2𝐻5𝑂𝐻 + 𝑋𝐻2𝑂 × 𝑐𝑝𝐻2𝑂

35
 = 0.02 × 2.44 + 0.98 × 4.18
𝑘𝑗
𝑐𝑝𝑚𝑖𝑛 = 4.14
𝑘𝑔. 𝑘

𝐻𝑊 = 1000 × 4.14 × (303 − 298)

𝐻𝑊 = 20700𝑘𝐽

𝐻ℎ𝑒𝑎𝑡 = 𝐻𝑊 − 𝐻𝑟𝑒𝑏𝑜𝑖𝑙𝑒𝑟

𝐻𝑟𝑒𝑏𝑜𝑖𝑙𝑒𝑟 = 𝑚 𝑐𝑝 ∆𝑇

= 20 × 2.44 × (353 − 303)

𝐻𝑟𝑒𝑏𝑜𝑖𝑙𝑒𝑟 = 2440 𝑘𝐽

𝐻ℎ𝑒𝑎𝑡 = 20700 − 2440

𝐻ℎ𝑒𝑎𝑡 = 18260 𝑘𝐽

𝐻𝐹 + 𝐻ℎ𝑒𝑎𝑡 = 𝐻𝐷 + 𝐻𝑊 + 𝐻𝑐𝑜𝑜𝑙

𝐻𝑐𝑜𝑜𝑙 = (105495.84 + 18260) − (129996.24 + 20700)

𝐻𝑐𝑜𝑜𝑙 = −26940.4 𝑘𝐽

𝑸 = ∆𝑯𝒊𝒏 𝑸 = ∆𝑯𝒐𝒖𝒕
105495.84 129996.24
18260 20700
--------- -26940.4
Total = 123755.84 123755.84

Table 4:2 (Energy balance)

36
 Chapter five

37
 Design of Equipment's:

A bioreactor may refer to any manufactured or engineered device or system that supports a
biologically active environment .
In one case , a bioreactor is a vessel in which a chemical process is carried out which involves
organisms or
biochemically active substances derived from such organisms. This process can either be aerobic
or anaerobic. These bioreactors are commonly cylindrical, ranging in size from liters to cubic
meters , and are often made of stainless steel.
A bioreactor may also refer to a device or system meant to grow cells or tissues in the context of
cell culture.
These devices are being developed for use in tissue engineering or biochemical engineering.

5-1) Design of Hydrolysis:

38
 5.1.1) Chemical design:

-Volume hydrolysis:
Conversion=90%
Batch time =84 hrs.
Working pressure of vessel (P)=1.1bar
Temperature of reaction =25 C◦
Mass flow rate =2577.938 kg/batch
Density of material =Σxi*p
p (average)=(xp)C6H10O5+(xp)H20+(xp)C8H12O6
=(0.22*1500)+(0.9*1000)+(0.18*1540)
=1507.2 kg/m3
Vr=(mass flow rate*time of batch)/p(ave)
Vr=(2577.938*1)/1507.2
=1.71 m3
we allow 75% volume of fluid as the free space in the
hydrolysis .Hence with 75% allowance
Vt=(Vr)/0.75
Vt=1.71/0.75
=2.28 m3

39
 -Dimensions:
𝐻
=2
𝐷
Vt=π/4 *(D2)*(H)
2.28=π/4*(D2)*(2D)
D=0.58m
H=1.2m
Height of dished bottom =1m
Total height=1.2+1
=2.2

5.1.2) Mechanical Design:

Static pressure
Ps=pmax*g*H
1507.2 ×9.81× 2.2 × 1000

Ps=32.5 bar
Pt=Ps+P
=32.5+1
=33.5 bar
Maximum allowable pressure=0.75*33.5

Pt=25 bar

40
 -Cylindrical Section:
Design temperature=100C (F)
Design pressure=10 bar
Design pressure take 10% above operating pressure
Design pressure
P=1 bar
S=13.3*103 Ps = 92N/mm2
Ej= 1
Corrosion allowance = 2mm
Material = Stainless steel (316)

Pi. Di
t=
2SEj − 1.2Pi
=3mm

t= 3+2 = 5mm

-Domed head:
1-Hemisperical head
Pi. Di
t=
4SEj − 0.4Pi

t = 1.6 mm

2-Torisperical head
Pi. Di
t=
2SEj − 0.2Pi
t= 3 mm

41
 3-

Re=d=Di=0.58
Knuckle=6%Rc=0.06*0.58
=0.0348
0.885Pi. Rc
t=
SEj − 0.1Pi
t = 5mm

Weight load:

For a steel vessel, we use the equation

Wv=240*Cw*Dm*(Hv+0.8*Dm)*t

Cw=1.15
t=5mm
Dm=(Di+t)*10-3
=0.58+5*10-3
=0.585mm

Wv=240*1.2*0.585(1.2+0.8*0.585)
=1.346 KN=1346N

-Weight plate:
Plate area = π/4*(D2)
=π/4*(0.5852)
=0.268m2
Weight of plate= 1.2*0.268
=0.3216KN=321.6N
2Plates=2*321.6
=643.2N

42
 -Weight of insulation:
Mineral wool density= 130 kg/m3
Height between tangent lines = 1.2
Teff = 70 mm

Approximate volume of insulation=π*Di*h*teff

=π*0.585*0.07*1.2
=0.1543m3

Weight=g*0.1543*mineral density
=9.81*0.1543*130
=196.8N

WD=2*196.8
=393.7N

Total weight=1346+643.2+393.7
=2383.9

Table(4.1.1):weight of hydrolysis

Total weight of hydrolysis N

Weight of shall 1346
Weight of plate 643.2
Weight of insulation 393.7
Total 2382.9

43
 5-2 Reacter 102

𝑚
𝜌= 𝑣

𝐴+𝐵 →𝐶+𝐷
Chemical design
Con=90%
Batch time=84
P=1.1bar
T=70+273=343K
Mass flow rate=2087

44
 density=(𝑥𝑖. 𝜌)ℎ2𝑜 + (𝑥𝑖 𝜌)𝑒𝑡ℎ + (𝑥𝑖 𝜌)𝑐𝑙𝑜𝑐 + (𝑥𝑖 𝜌)𝑐𝑜2
= (0.8× 1000) + (0.5 × 0.789) + (0.2 × 1540) + (0.5 × 770)
=1108.77𝑘𝑔⁄𝑚3
𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 × 𝑡𝑖𝑚𝑒 𝑜𝑓 𝑏𝑎𝑡𝑐ℎ
𝑣𝑟 =
𝜌𝑎𝑣𝑟
2087×1
= = 1.88𝑚3
1108.77

We allow 75% of volume of fluid as the free space in the

fermenterhence
With 75% allowance
𝑣𝑟
𝑣𝑡 =
0.75
1.88
𝑣𝑡 = =2.5𝑚3
0.75

45
 Dimensions :
𝐻
=2
𝐷
𝜋
𝑣𝑡 = 𝐷2 𝐻
4
𝜋
2.5= 𝐷2 .(2D)
4

D=0.57
H=1.15
Height of dished bottom=1m
Total height=1.15+1=2.15

Mechanical design :
Static pressure
𝑝𝑠 = 𝜌𝑚𝑎𝑥 .g.h
1108.77×9.8×2.15
=
1000

=23.4
𝑝𝑡 =𝑝𝑠 + 𝑝
=23.4+1=24.4
Maximum allowable pressure =0.75×24.4
=18.3

46
 Cylindrical section :
Design tempareture =100℃(212℉)
Design pressure =10 bar
Design pressure take 10% abore operating pressure
Design pressure
P =1bar
From table (14.2) maximum allowable stress

S =13.3× 103 ps=92𝑁⁄

𝑚𝑚2
From table (13.3)(vol.6) joint efficiency
Ej=1
Corrosion =2mm
Material =staninless steel(316)
𝑝𝑖×𝐷𝐼
T=
2𝑆.𝐸𝑗−1.2𝑝𝑖

4.56×1.28×1000
t=
2×92×1−1.2×4.56

t=3mm
t=3+2=5mm

47
 domed head
1- Hemispherical head
𝑝𝑖×𝐷𝐼
t=
4𝑆.𝐸−0.4𝑃𝐼
4.56×1.28×1000
=
4×92×1−0.4×4.56
=2mm
2- Tori spherical head
𝑝𝑖×𝐷𝐼
T=
2𝑠.𝐸−0.2𝑃𝐼

4.56×1.28×1000
=
2×92×1−0.2×1.28

=3mm

3-
𝑅𝑒 =di =0.57
𝑘𝑛𝑢𝑐𝑘𝑙𝑒 = 6%𝑅𝐶
=0.06× 0.57
=0.0342
0.885.𝑝𝑖.𝑅𝑐
t=
𝑆𝐸−0.1𝑃𝐼

0.855×1.28×1000
t=
92×1−0.1×1

t=5mm

48
 design offlatends :
𝐶.𝑃𝑖
t=𝐷𝐶 . √
𝑆𝐸

0.25×4.56
=1.28× 1000 × √
92×1

=403mm
-weight load
For a steel vessel we use the equation
Wv=240.Cw.Dm.(Hv+0.8Dm).t
Cw=1.15
t=5
Dm=(Di+t)× 10−3

=(0.57+5)× 10−3
=0.575
Hv=1.15
t=0.005
Wv=240.Cw.Dm.(Hv+0.8Dm).t
Wv=1.28KN=1280N
Weight plate
𝜋
Plate area= . (𝐷𝑖)2
4

=0.26𝑚2

49
 Weight of plate =1.2.Area
=1.2× 0.26
=0.312KN =312N
2plates =2× 31 = 624𝑁
Weight of insulation :
𝑘𝑔
Mineral wool density =130
𝑚3

Height between tangent lines =1.92

Teff =70mm
Approximate volume of insulation =𝜋. 𝐷𝑖. ℎ. 𝑡𝑒𝑓𝑓
=𝜋 × 0.57 × 1.15 × 0.07 = 0.1442𝑚3
Weight =0.1445. g. Mineral wool density
=0.54×9.8× 130
=183.6N
Double this to allow for fitting Wdi
Wd =2× 183.6=367.3
Total weight =128+624+367.3
=1119.3
Total weight of fermenter N
Weight of shell 128
Weight of plate 624
Weight of insulation 367.3
Total 1119.3

50
51
52
 D – 101

Number of stage :-
XHik XHK
log{ { }d×{ KHI }w
XHK
Nm =
log( ∝Lk)

𝑝. 𝑜 𝑐𝑜𝑚𝑝
∝ (𝑅𝑒𝑙𝑝𝑡𝑖𝑣𝑒 𝑣𝑜𝑙𝑒𝑡𝑖𝑙𝑖𝑡𝑦 ) =
𝑝 𝑜𝑟𝑒𝑎𝑣𝑦𝑘𝑒𝑦
Tbo=70 + 273 = 343 k

Tbottom=80 + 273 = 353 k

Ethanol is a light key

Water Is the heavy key

Table the vapor pressure and volatility of component

53
 Comp Po top ∝ 𝒕𝒐𝒑 P° 𝒃𝒐𝒕𝒕𝒐𝒎 ∝ 𝒃𝒐𝒕𝒕𝒐𝒎 ∝ 𝑨𝒗𝒆
.Ethanol 931 4.01 11 23.7 3.94 3.97
water 232 1 285 1 1

0.9𝑔 0.9921
log( )×( )
20 𝑔 0.0079
𝑁𝑚 = =6
log(3.975)
R=4

𝑅 4
= = 0.8
𝑅+1 4+1

Rm = 3
𝑅𝑚 3
= = 0.75
𝑅𝑚 + 1 3 + 1
From figure (4.1) AppendixA

Nm/N = 0.5
6
N= = 12 ideal stage
0.5

Estimate base pressure , assume column efficiency of 60 percent take

reboiler as equivalent tone stage
12−1
Number of stages = = 18 stages
0.6

54
 Column diameter

At bottom T=353k

From table (4.1) Appendix B

Peth = 741.6 kg/m3

PH2o = 982.5 kg/m3

Pliq bottom = 𝜀 𝑥𝑖 × 𝑝𝑖

= 𝜀 00.0079 × 7416 + 0.9921 × 982.5

= 980.5 kg/m3

At top
T = 343
Peth = 739.8 kg/m3
pH2o =981.4 kg/m3
Pliq – top = 𝜀 𝑥𝑖 × 𝑝𝑖
= 𝜀 0.949 × 739.8 + 0.05 × 381.4
= 751 kg/m3

𝑝 𝑚.𝑤𝑡
Pgas =
𝑅𝑡

At.Top
M.wtmix =𝜀M. wtixi
= 46 × 0.949 + 18 × 0.05

55
 =44.5 kg/m3
𝒌𝒈
𝝆𝒈𝒂𝒔 = 𝟏. 𝟓𝟖
𝒎𝟑
At bottom
M.wtmax =𝜀M. wt xi
= 46 × 0.079 + 18 × 0.9921
= 18.22 kg/m3
Assume ( 100 mm ) of the liquid drop per plate

Column prusser drop =𝜌𝑎𝑣. 𝑔. ℎ. 𝑁𝑎𝑐𝑡

= 934.8 × 9.81 × 100 × 10−3 × 18

=12975.098 pa = 12.98 k pa

Pbottom= p top + drop pressure

= 101.3 + 12.98

= 114.28 k pa
114.28 ×18.22
𝜌𝑔𝑎𝑠 = = 0.79 𝑘𝑔/𝑚3
0.314 ×353

From table ( 4 -2 ) Appendix B

𝐴𝑡 − 𝑇𝑜𝑝 𝜎 = 0.0177𝑁/𝑚
𝑎𝑡 − 𝑏𝑜𝑡𝑡𝑜𝑚 𝜎 = 0.00203𝑁/𝑚

56
 At Top

Vapor flow rate = 960 kmole / hr

Liquid flow rate = 1000 kmole / hr

at bottom

the feed to the columns liquid

vapor flow rate vm = vn = 960 kmole / hr

liquid flow rate Lm = vm + w

= 960 + 20

= 980 kmole / hr

𝐿𝑤 𝑝𝑟
Ftr Top = = √
𝑣𝑤 𝑝𝐿

1000 1.58
= √ = 0.047
960 751

𝐿𝑤 𝑝𝑟
Ftr bottom = = √
𝑣𝑤 𝑝𝐿

980 0.709
= √ = 0.027
960 980.5

Take plate spacing as ( 0.75m )

57
 From figure (4-2) Appendix A

Bottom k1 = 0.3 , Top k1 = 0.12

Estimating flooding vapor velocity (uf)

𝜎 0.2 𝑝1−𝑝𝑣
Uf=K1×(
0.02
) √ 𝑝𝑣

at bottom
0.020 980.5−0.709
uf = 0.13 ( 0.02 )0.2 √ 0.709

= 4.84 m / sec

at Top

0.0177 0.2 751−1.58

vf = 0.12 ( 0.02
) √
1.58
= 2.55 𝑚/𝑠𝑒𝑐

Design for (85%) flooding at mixture flow rates

bottom

uv = 4.84 × 0.85 = 4.11

Top

uv = 2.55 × 0.85 = 2.16

58
 volume trice flow rate :
𝐿𝑤 𝑀.𝑊𝑇 980×18.22
bottom = = = 6.99 𝑚/𝑠𝑒𝑐
𝑃𝑉 0.709×3600
𝐿𝑤 𝑀.𝑊𝑇 1000×44.5
Top = = = 7.82 𝑚/𝑠𝑒𝑐
𝑃𝑉 1.58×3600

𝑀𝑎𝑥 𝑏𝑜𝑡𝑡𝑜𝑚 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 6.99

An ( bottom ) = = = 1.7 𝑚2
𝑢𝑉 4.11
7.28
An ( Top ) = = 3.62 𝑚2
2.16

Take trial down comer area (Ad ) as ( 12%) of total column area ( Ac)

An = 0.88 Ac
1.7
Ac bottom = = 1.93
0.88
3.62
Ac Top = = 4.11
0.88

Column diameter
𝜋
A= 𝐷2
4

1.93 ×4
D bottom = √ = 1.56 𝑚
𝜋

4,11 ×4
D bottom = √ = 2.3 𝑚
𝜋

59
 Use same diameter a bore and below feed reducing the perforated are a for
plates below the feed

De = 1.56 m

Provisiouel plate design

Column diameter De =1.56 m

Column Area :
𝜋 𝜋
Ac = 𝐷𝑐 2 = (1.56 ).2 = 1.91 𝑚2
4 4

Down comer area

Ad = 0.12 Ac = 0.12 X 1.91 = 0.23 m2

Net Area (An) = Ac – Ad

= 1.91 – 0.23 = 1.68

Active area ( Aa ) = Ac – 2 Ad = 1.45 m2

Hole area ( An) = 0.14 Aa = 0.14 X 1.45 =0.203 m2

𝐴𝑑 0.12 𝐴𝑐
= = 0.12 𝑋 100 = 12
𝐴𝑐 𝐴𝑐

𝑓𝑟𝑜𝑚 𝑓𝑖𝑔𝑢𝑟𝑒 ( 4 − 3)𝐴𝑝𝑝𝑒𝑛𝑑𝑖𝑥 𝐴 𝑙𝑤⁄𝑑𝑒 = 0.77

𝑙𝑤
= 0.77
1.56
:- weir length ( Lw ) = 1.56 X 0.77 = 1.2m

Weir height : hw = 60 mm

Hole diameter dn = 6mm

Plate thickness = 6mm

Check weeping :-

60
 1000×44.5
Max Liquid rate = Lw X M.wt = = 12.36 𝑘𝑔/𝑠𝑒𝑐
3600

𝑙𝑤 2⁄
Weir crest Liquid rate wo = 750 × ( ) 3
𝑝𝑡 𝐿𝑤

12.36 2⁄
= 750 × ( ) 3 =73.26
751𝑋0.539

Hw + ow = 60 + 73.26 = 133.26 mm

From figure ( 4-4 ) Appendix A , k2 = 30.1

30.1−0.9(25.4−6)
un = = 10.05 𝑚/𝑠𝑒𝑐
√1.58

𝑣𝑎𝑝𝑜𝑟 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒

uact ( un ) =
𝐴ℎ
7.82
= = 38.5 𝑚/𝑠𝑒𝑐
0.203

uact> un

... No weeping will happened

Entrainment checking :-
𝑣𝑎𝑝𝑜𝑟 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒/𝐴𝑛
Percentage flooding =
𝑢𝑓

7.82/1.68
= = 1.82%
2.55

FLv (Top ) = 0.047

From figure ( 4-5 ) Appendix A

𝜔 = 0.0052 < 0.1

No entrainment will happened

61
 Plate pressure drop :-
𝑝𝑙𝑎𝑡𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 6
= =1
ℎ𝑜𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 6
𝐴ℎ 𝐴ℎ 0.203
= = = 0.12 = 12%
𝐴𝑝 ℎ𝑎 1.82
From figure ( 4-6) Appendix A

Co = 0.87
𝑢𝑛 2 𝑝𝑣
d = 51 ( ) ( )
𝑐𝑜 𝑝𝐿

38.5 2 1.58
= 51 ( ) ×( ) = 3.91 𝑚𝑚
0.87 751

12.5 ×1000
r= = 16.6 𝑚𝑚
751

t = hd + hw + how + hr

= 3.91 + 60 + 73.26 + 16.6 = 153.7 mm

Total drop pressure = pghn

= 751 X 9.81 X 18 X 10-3 = 2038.3 pa = 23.38 kpa

Bottom pressure = 101.3 +20.38 = 121.68 kpa

Down comer liquid backup

hap = hw -10 = 60 – 10 = 50 mm

arc under a porn , Aap = hap X Lw = 50 X 10-3 X 0.539 = 0.027 m2

Ad = 0.23 m2

Aap< Ad so take AapTouse in calculation of hde

62
 𝐿𝑤
Dc = 166 ( )2
𝑝𝑙 𝐴𝑎𝑝

1.25
= 166 ( )2 = 0.63 𝑚𝑚
751 𝑋 0.027

Backup down comer

hb = ht + hw+ how+hde

= 148.63 + 60 + 15.9 + 0.63 = 225.16mm = 0.225 m

0.5 ( lt + hw ) = 0.5 ( 0.75 + 0.6 ) = 0.67 m

hb< 0.5 ( Lt + hw )

so plate spacing is accept table

check residence time :-

𝐴𝑑 ℎ𝑝 𝑝𝐿 0.23 𝑋 0.225 𝑋 75
tr = = = 4 𝑠𝑒𝑐
𝐿𝑤 1.25

tr = 4 sec > 3 sec

Trial layout :-

63
 Use cartridge type construction allow ( 50 mm ) un perforated strip
round plate edge ( 50 mm ) wide calming zone .

Lw / Dc = 0.77

From figure ( 4-7) Appendix A

∅ 𝑒 = 99°
Angles untended by the edge of the plate = 180 – 90 = 81°

Mean length un perforated edge strips ( The Two area )

= ( 0.7 – 50 X 10-3 ) X 81 X 2 X 𝜋/360 = 0.92 m

Area of un perforated edge straight strips = 50 X 10-3 X 0.92 = 0.0463

Approx = weir length – width fun perforated strips

= 0.539 – ( 50 X 10-3 ) = 0.489 m

Area of calming zone = 2X ( 0.489 X 50 X 10-3 ) = 0.048m2

Total area of un perforated Ap = Aa – un perforated

= 0.29 – 0.048

= 0.242 m2

A / Ap = ( 0.04 / 0.242 ) = 0.165

From figure ( 4-8 ) Append ix A

Lp / d = 2.4

Hole pitch Lp = 2.4X6 = 14.4 mm

Number of holes :-

64
 𝜋
Area one hole = (0.006)2 = 2.8 X 10-5 m2
4
𝐴𝑛
No of holes = 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑜𝑛𝑒 ℎ𝑜𝑙𝑒𝑠

0.04
= = 1428.5 ℎ𝑜𝑙𝑒𝑠
2.8𝑋10−5
High of column :-

H = ( N+1) Z

Z = tray spacing

N = actual no . of stage

H= ( 18 + 1 ) X 0.75 = 14. 25 m

Position of feed point :-

𝑁𝑟 𝐵 𝑥𝑓−𝐻𝑘 𝑥𝑣−𝐿𝑘 2
Log { } = 0.206 log{ ( ) ( )( }
𝑁𝑠 𝐷 𝑥𝑓−𝐿𝑘 𝑥𝑑−𝐻𝑘

54.83 0.0079 2
= 0.206 log{ ( ) (0.27) ( }
21.1 0.05

𝑁𝑟
= 0.697
𝑁𝑠

For N = 18

Nr + Ns = 18

Nr = 0.967 X Ns

65
 0.697 X Ns + Nr = 18

Ns = 10.6 = 11 STAGE

The feed will enter the distillation column at the stage (21).

66
 Chpter six

Cost estimation :

67
 Table (6-1) :

Cost of plan at index at Cost of plan at index at

2014 2014 2017 2017
1250000$ 576.1 1231340$ 567.5

Estimation of total investment cost:

direct cost :

a- Purchase equipment cost

(15-40%) of F.C.i
=0.25*1231340$
=344775$
b-Installation cost
=0.40*344775$
=137910$
c- Instrument and control installed (0.18%)
=0.18*344775
=62059$
d- Piping instillation cost (0.45%)

68
 =0.45*344775$
=155148.75$
e- Electric installation (0.25%)
=0.25*344775
=86193$
F-Building Process
=0.40*344775
=137910$
g-Service Facilities (0.65%)
=0.65*344775
=41373$
h-Yard Improvement (0.12%)
=0.12*344775
=41373%
i= Land (0.04%)
=0.04*344775
=13791$
Cost of direct cost=10015691$

69
 :Indirect cost-2
a-Engineering and Supervision (5-30% of D.C) assume 0.18
=0.18*1001569
=180282$
b-Construction Expenses
=1001569*0.01
=100157$
c-Construction Fee (0.05)
=0.05*1001569$
=50078$
d-Contingency (0.18)
=0.18*1001569
=180282$
Cost of I.D =510799
F.c.i = D.I + D =1512368$
Total capital investment
Total product cost
:Fixed charges
=0.10*1512368$
=151237$ depreciation
:Local Taxes
=0.03*1512368
=45371$

70
 :Insurance
0.007*1512368
=10586$
:Rent
0.10*1512368
=151236$
Total Fixed Charge= 358430$
F.c.i= 0.20 T.p.c
T.p.c=3584390.20
=1792150$

71
 :Direct Product-2
a-Raw Material (0.40)
=0.40*1792150
=716860$
b-Operating Labor (0.15)
=0.15*1792150
=268822$
c-Direct Supervisory and Electrical labor
=0.20*268822
=53764$
d-Utilities
=0.15*1792150
=268822$
e-Maintenance Assume (0.07)
=0.07*1512368
=105866$
f-Operating Supplies (OS) :( 0.015 0f maintenance)
OS=0.15*105866
=15880$

72
 g-Laboratory Charges (0.15 of OL)
=0.15*268822
=40323$
h-Patent and royalties: (assumed 0.04)
0.04*1792150
=71686$
i-Patent overhead cost:
=0.60*(268822+15880+105866)
=234340$

73
 :General Expenses-3
a-Administration cost:
=0.5*268822$
134411$
b-Distribution and selling price
=0.25*1792150
=448037$
c-Research and development cost
=0.03*1792150
=53765$
Total Sum G.E= 636213$
Manufacturing cost= product cost + Fixed charges+ Plant overhead
MC=1792150$+358430$+234340$
=2384920$
Total product cost = M.C + G.M
=2384920+646213
=302133$

74
 Gross earnings and rate of return:
Making days =32 days
Total income
= product day rate * days of year * price for unit
=2521 g/days *320*40 $/1kg
=80640 kg/s* 40
Gross profit =80640*40-1792150
=1433450$
Tax=0.25
=0.25*1433450
=358363
Net profit= 1433450-358363
=1075087$
Rate of return= 1075 net profit/total capital investment
Rate of return=1075087/17921508
=0.59

75
 Reference:
1- Bazjinfectdis . 2012;" Antibiotics produced by ethanol"
2- IOPconf. Series: earth and environment alscience (2017)
3- https://en.wikipedia.org/wiki/bioethanol
4- H.A. El-Enshasy a,*, N.A. Mohamed b, M.A. Farid b, A.I. El-Diwan Bioresource
Technology 99 (2008) 4263–4268 Improvement of erythromycin
5- H.A. El-Enshasy a,*, N.A. Mohamed b, M.A. Farid b, A.I. El-Diwan Bioresource
Technology 99 (2008) 4263–4268 Improvement of erythromycin

76