Scribd Logo
Upload

Welcome to Scribd!

  • 39 views

    Department of Chemical Engineering Complex Engineering Problems Assignment Date:16th September 2020

    Uploaded by

    FzUsman
    This document summarizes a design project for producing ethanol through fermentation of sugars. It outlines the objectives, introduction, methodology, technical details, costs, and feasibility analysis of a batch fermentation process. Key aspects of the proposed design include fermenting molasses in large batch fermentors, recovering ethanol through distillation, and producing ethanol as the final product. An economic analysis estimates the total product cost to be approximately $53.04 per liter of ethanol produced.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Department of Chemical Engineering Complex Engineering Problems Assignment Date:16th September 2020

    Uploaded by

    FzUsman
    39 views9 pages
    This document summarizes a design project for producing ethanol through fermentation of sugars. It outlines the objectives, introduction, methodology, technical details, costs, and feasibility analysis of a batch fermentation process. Key aspects of the proposed design include fermenting molasses in large batch fermentors, recovering ethanol through distillation, and producing ethanol as the final product. An economic analysis estimates the total product cost to be approximately $53.04 per liter of ethanol produced.

    Original Title

    Group 9.pdf

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    This document summarizes a design project for producing ethanol through fermentation of sugars. It outlines the objectives, introduction, methodology, technical details, costs, and feasibility analysis of a batch fermentation process. Key aspects of the proposed design include fermenting molasses in large batch fermentors, recovering ethanol through distillation, and producing ethanol as the final product. An economic analysis estimates the total product cost to be approximately $53.04 per liter of ethanol produced.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    39 views9 pages

    Department of Chemical Engineering Complex Engineering Problems Assignment Date:16th September 2020

    Uploaded by

    FzUsman
    This document summarizes a design project for producing ethanol through fermentation of sugars. It outlines the objectives, introduction, methodology, technical details, costs, and feasibility analysis of a batch fermentation process. Key aspects of the proposed design include fermenting molasses in large batch fermentors, recovering ethanol through distillation, and producing ethanol as the final product. An economic analysis estimates the total product cost to be approximately $53.04 per liter of ethanol produced.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 9

    DEPARTMENT OF CHEMICAL ENGINEERING

    COMPLEX ENGINEERING PROBLEMS


    Assignment
    Date:16th September 2020

    Group Members & Seat No:

    Muhammad Faizan (B1333043)


    Fasih Asif (B1333020)
    M. Hammad Khalid (B1333044)
    Umair Haider (B1433052)
    Syed Ateeb Ali (B1433043)
    Objective
    Design production unit of ethanol through the fermentation of reducing sugar.

    Introduction
    Alcoholic fermentation is a biological process in which sugars such
    as glucose, fructose, and sucrose are converted into cellular energy and thereby
    produce ethanol and carbon dioxide as metabolic waste products.
    Alcoholic fermentation is considered and anaerobic process. Sugarcane is rich in
    sucrose and thus it is used as a feedstock to produce the biofuel ethanol. Ethanol
    is generally available as a byproduct of fermentation. It can be used as
    a biofuel alternative to gasoline.
    The fermentation process design is central to the overall plant economic
    comparison. The fermentation equipment for a conventional 2,000,000,000 L/yr
    facility is described. Fermentation has a large direct effect on overall plant costs.

    FLOW DIAGRAM WITH P&ID:

    Methodology
    Two general arrangements of process flows and equipment can be used to
    describe all of the designs considered. First simple continuous processes, by
    staggering harvest times for batch fermentors to provide a continuous product
    flow, Other can also describe a batch production facility. We are selecting batch
    fermentation process.
    Molasses and added nutrients are taken from storage and mixed with water to
    the desired feed concentration and sterilized by direct steam injection in a
    continuous sterilizer. Feed from the mixer is then send to the fermenter.
    Filtered air is spared into the fomenters to maintain the optimum oxygen
    concentration. An absorber is used to recover ethanol from the fermenter vent
    gas.
    For selective ethanol removal processes, the fermenting beer is cycled through a
    selective ethanol recovery device such as membrane separator, extractor or flash
    vessel. A portion of the dilute beer is then centrifuged and sent to stripper. The
    bottom product of fermentor is mixed with the yeast cream feed to the rotary
    dryer as a further nutrient supplement. The rotary steam tube dryer is operated
    at high temperature using 600 psig steam to reduce the drying area. The ethanol-
    water vapors evaporated from the yeast is then condensed. the condensed
    stream in introduced in distillation column.
    The distillation system consists of an atmospheric pressure stripper followed by a
    vacuum distillation column to produce 95 wt 70% azeotropic alcohol. Vapor reuse
    methods are used to achieve a high energy efficiency. The fermentation plant is
    designed assuming 330 days/ yr and 24 h/day operation.

    Technical & Economical Feasibility

    Raw Material Materials. utility, and labor costs Cost in dollars

    Molasses 50 wt '70 sugar, 95% utilizable 8S/ton


    1.11/ethanol
    Nutrients
    product
    Process water 50.4/1000 gal
    Utilities
    600 psig steam 4.41/1000 Ib
    50 psig steam 3.15/1000 Ib
    1 atm steam exhaust 0.76/1000 Ih
    Electricity 8.82/kw h
    Cooling water 22.6/1000 gal
    Labour
    Operator man
    10/man h
    hours

    Batch fermentation purchased


    equipment summary
    Storage
    Molasses 7860000 L, carbon steel 268,000
    Ethanol 4240000 L, carbon steel 167,000
    Yeast 323000 L, carbon steel, 5 units 247,000
    Screw conveyor 0.40 hp, 100 ft long 8,000
    690,000

    Fermentation

    127000 L, stainless steel, 8 units,


    Batch fermentor 591,000
    residence time = 6.54 h
    Fermentor agitator 84 hp, stainless steel, 8 units 433,000
    Fermentor cooler stainless steel, 8 units 28,900
    Seed tank 12700 L, stainlcss steel, 8 units 166,000
    Seed tank agitator 8.4 hp, stainless steel, 8 units 97,100
    Air filter glass fiber, 1200 kg/h air 400
    42 hp, 30 psig, stainless steel, 1200 kg/h
    Air compressor 46,600
    air
    insulated stainless steel pipes plus heat
    Feed-water sterilizer 86,100
    exchangers, 113000
    Feed mixing tank 9,450 L. stainless steel 17,600
    Feed mixer agitator 12.5 hp. stainless steel 15,700
    Centrifuge 217 hp, 117000 L/h feed 319,000
    Total 1,801,000
    Ethanol recovery
    Absorber 1 in. Raschig rings, gas rate = 10500 kg/h 67,500
    Absorber-water
    3500 kg/h water 13,100
    sterilizer

    Stillage evaporator 37300 ft2, effects 1,590,000

    7140 ft ', 27.4 hp, 11600 kg/h water


    Rotary dryer 1,374,000
    removed, 3 units
    115000 kg/h feed, feed EtOH wt % = 8.0,
    Distillation 341,000
    stripper followed by dirtillation column
    Total 3,380,000

    Batch fermentation
    production cost summary

    Raw material Cost $/L Product


    Nutrient solution 1.11
    Water 7.4 kg/L 0.099
    Molasses 3.7 kg/L 34.7
    Raw materials subtotal 35.909
    UTITLITES
    Power 6710000 kW h/yr 0.592
    Cooling water 6S°F, 43.4 kg/L 0.26
    Steam 50 psig, 2.38 kg/L 1.654
    Steam 600 psig, 0.92 kg/L 0.896
    Operating labor $10/nian h 1.348
    Operating supervision 15% operating labor 0.202
    Maintenance 6% fixed capital 1.46
    Operating supplies 15% maintenance 0.22
    Laboratory charges 15% operating labor 0.202
    Direct production cost 42.743
    Depreciation linear, 18 yr, zero salvage 1.348
    Property taxes 3% fixed capital 0.73
    Insurance 0.7% fixed capital 0.17

    Fixed cost 2.248

    60% (operating labor + operating


    Plant overhead cost 1 ,806
    supervision + maintenance)
    (direct production + fixed costs +
    Manufacturing cost 46.797
    plant overhead)
    Administrative
    15% operating labor 0.202
    expenses
    Distribution and
    5% total production cost 2.474
    marketing
    Total general expenses 2.676
    After-tax profit (15% return on investment) 4.311
    Income tax 4.31 1
    Yeast credit ($O.l14/kg 50 wt %)yeast product 4.782
    Steam credit (75.6C/1000 Ib) 0.268
    Total product cost 53.04
    SWOT Analysis :
    Large experiences in the production of bioethanol from sugar are available
    (especially in Brazil). -- A very broad range of feedstock can be used for ethanol
    production

    Strengths
    Ethanol has a high octane number which is good for combustion properties (the
    anti knocking number is enhanced). Ethanol contains 35% oxygen which reduces
    particulate and NOx emissions from combustion when compared to the
    combustion of petrol. Combustion of ethanol results in low CO emissions.
    Bioethanol can be blended with gasoline at any ratio. Ethanol contains no sulfur,
    causing no emissions of sulfur oxides. Small amounts of bioethanol are neither
    toxic to humans nor to the environment. In Europe the production of ethanol
    mainly depends on a single feedstock source: sugar beets. The feedstock costs for
    starchy crops are high. Ethanol processing from cellulose is relatively cost
    intensive. The feedstock costs for sugar crops are high. -- Ethanol processing from
    cellulose is relatively energy intensive. For feedstock cultivation fertilizers and
    pesticides are required. There are no experiences for large-scale production of
    ethanol from cellulose. Ethanol is characterized by high vapor pressures.

    Weaknesses
    Weaknesses Blending gasoline with ethanol increases emissions of volatile
    organic compounds. Energy input for ethanol processing from sugar is lower than
    ethanol processing from starch and cellulose. Energy input for ethanol processing
    from starch is lower than ethanol processing from cellulose. Research is carried
    out to optimize ethanol processing from cellulose.

    Opportunities
    Research is carried out to optimize ethanol processing fromstarch.Energy input
    for ethanol processing from starch is higher than ethanol processing from sugar.
    Energy input for ethanol processing from cellulose is higher than ethanol
    processing from sugar or starch. Sugar beets are food crops (competition of
    ethanol with food products). Most starchy crops are food crops (competition of
    ethanol with food products). Production costs for ethanol from cellulose are
    relatively high.

    Threats
    In most European countries the use of bioethanol is not yet established and thus
    limited infrastructure for ethanol distribution exists.

    CONCLUSION
    Although current industrial fermentation for fuel ethanol production employs two
    types of feed stocks such as free fermentable sugars and starch, free sugars
    containing juice is more economic than starch feed stocks as the former can
    directly be used in fermentation without any prior treatment. However, better
    yield also depends somewhat on the selection of microorganisms and
    fermentation mode and techniques as well as the influence of several
    factors.Selective ethanol removal fermentation processes offer
    even greater savings as more concentrated feeds and products can be handled,
    further reducing the cost of auxiliary equipment.Very expensive separation
    devices can be justified and research should be continued in this area. It should
    be noted, however,that much of this savings could also be achieved by employing
    s tillage recycle in combination with conventional fermentation processes.
    REFERENCE:
    1. Renshaw, S. F. Sapakie, and M. C. Hanson, Chem. Eng.
    2. H. H. Topiwala and B. Khosrovi, Biotechrtol. Bioeng., 20, 73
    3. E. J. Del Rosario, K. J. Lee, and P. L. Rogers, Biotechnol. Bioeng.,
    Prog., 78(5), 33 (1982).
    (1978).
    4. B. L. Maiorella, “Vacuum Ethanol Distillation Technology,” in
    The Ethanol Separation Handbook, L. Douglas, Ed. (Solar Energy
    Research Institute, Golden, CO, 1984).
    5. S. P. Prescott and C. G. Dunn, Industrial Microbiologv, 2nd ed.,
    (McGraw-Hill, New York, 1949).
    6. R. Katzen, “Grain Motor Fuel Alcohol Technical and Economic
    Assessment Study,” U.S. National Technical Information Service,

    You might also like