THE DESIGN OF A 50,000 METRIC TONNES PER ANNUM (TPA) MODIFIED FAT

PRODUCTION PLANT USING RAPESEED OIL FROM PORTHARCOURT, RIVERS

DONE BY:

GROUP 7

SUBMITTED TO:

THE DEPARTMENT OF CHEMICAL ENGINEERING

SCHOOLOF ENGINEERING AND ENGINEERING TECHNOLOGY

FEDERAL UNIVERSITY OF TECHNOLOGY, OWERRI

IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE AWARD OF THE

NOVEMBER, 2018.

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 CERTIFICATION

This is to certify that the design work was carried out by the members of Chemical Engineering
design group 11 for the 2017/2018 academic session.

S/N STUDENT’S NAME REGISTRATION NUMBER

…………………………………….. ……………………………………

Engr. Dr Oga Date

………………………………….. ……………………………………

Engr. Dr. M.S. Nwakaudu Date

…………………………………. …………………………………..

Engr. Dr. F. Kamen Date

…………………………………. ……………………………………

Engr. Prof. Nwadikom Date

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 DEDICATION

We dedicate this work to the Almighty God for His support and guidance through the course of
this project.

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 ACKNOWLEDGEMENT

We wish to express our utmost gratitude to God almighty, our supervisor Engr. Dr. Orga, for his
wonderful encouragement, dedication and advice throughout the period of our design work. We
also acknowledge our lecturers Prof. K.O. Okpala, Prof K.B. Oyo, Prof. O.C. Ndukwe, Dr.
Effiong, Dr. M.S Nwakaudu, Dr. Orga, Dr. I.S Ike, Mr. E.C. Okwara, Engr. S.O. Olubiyi, Engr.
Osoka and the host of others for the way they have impacted us with knowledge. We will forever
remain grateful to you all.

Thanks to every member of the group whose active cooperation enabled this project to see the light
of the day and come to fruition.

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 EXECUTIVE SUMMARY

The report contains a detailed engineering design work of a plant that produces 50,000 metric
tonnes per annum (TPA) of FAT, using rapeseed from Porthacourt in Nigeria; which is aimed at
meeting about 50% of the demand for oil in Nigeria. It is envisaged that the plant is to be located
at Porthacourt in Rivers State, due to its proximity to raw materials as one of the major city in
the state and nearness to market. The plant flow sheeting was done with a steady state assumption
using Microsoft excel spreadsheet, applying the law of conservation of mass and energy, the
material balance across the whole plant was computed and the energy balance computed around
temperature dependent units ( flaker and heat exchangers etc.). The selected process route for fat
production is the Hydrogenation, because hydrogenated oil has a longer shelf life unlike other
process route. The rapeseed are destonned, dehulled and conditioned at 60OC. The oil is flaked
into grits and cooked in a rotary cooker at a temperature of 105OC and at a pressure of 6-10 bar.
The cooked seed is sent into a screw press of 92% efficiency, where the cake is separated from the
oil before refining process. At the refining stage, the oil is dugummed to remove basically the
phospholipids present in the oil and other gums which are not needed in the oil. It is futher bleached
to remove certain percentage of free fatty acids, tocopherols, carotene etc.

After refining of the oil it is futher sent to the hydrogenation chamber which makes up dearaetion
unit, heat recovery unit, hydrogenating reactor, drop tank, filter tank etc. The hydrogenation
reactions occur at Nickel surface. As the temperature increases, the less H2 is available at the
catalyst surface for reaction and as the pressure increases the more H2 is available at the catalyst
surface for reaction. However, the main objective of hydrogenation is to improve flavor stability,
adjust melting characteristics and to saturate organic compounds. The hydrogenated product is
deodorized via vacuum distillation. At first, the oil is heated up in the regenerative heat exchanger,
and subsequently, it is injected into the vacuum distillation column where the unwanted chemical
are distilled away, the oil comes out neutral, without any taste or smell remaining from the source
plant.

With the aid of Autodesk AutoCAD, the plant layout, Piping and instrumentation diagrams and
plant equipment schematics were carefully drafted and 3-Dimensional diagram of the plant was
represented using AutoCAD 3D and INVENTOR. The expected operating days of plant is 335
days, while 720 hours is used for plant maintenance. The plant is commissioned and starts

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operating at a safe mode and shut down after detailed awareness and proper line flushing. The
safety of the plant is paramount as Hazard operability (HAZOP) is carried out with respect to
temperature and flow as property word and risk assessment studies were carried out on areas such
as destonning, dehulling, conditioning unit, refining and hydrogenation unit etc.

In our economic analysis, the purchase equipment cost was estimated using the chemical
engineering purchase cost index (CEPCI) of 2006, proposed by Gavin and Sinnott, which was
scaled up to 2018 CEPCI.

In our economic analysis, the purchase equipment cost was estimated using the chemical
engineering purchase cost index (CEPCI) of 2006, proposed by Gavin and Sinnott, which was
scaled up to 2018 CEPCI. The Oil plant total capital investment is $68,604,092.95 with a total
annual revenue of $75,000,000 an annual net profit of $14,069,386.97, a payback period of 8.5
years with a break even volume of 398,267.886 tonnes and a oil price of $1,148.36/ ton.

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 TABLE OF CONTENTS

INTRODUCTION……………………………………………………………………………………..1

1.1 BACKGROUND STUDY.............................................................................................................1

1.2 PROBLEM STATEMENT............................................................................................................2

1.3 DESIGN OBJECTIVES ................................................................................................................2

1.4 SCOPE OF THE DESIGN ............................................................................................................2

1.5 DESIGN LIMITATIONS ..............................................................................................................3

1.6 JUSTIFICATION OF DESIGN.....................................................................................................3

1.7 PROCESS ROUTES......................................................................................................................3

1.7.1 Process Routes For Rapeseed Oil Extraction .........................................................................3

1.7.2 Extraction of oil from Rapeseed .............................................................................................3

1.8 JUSTIFICATION OF THE PROCESS .........................................................................................6

1.9 Refining Of Rapeseed oil...............................................................................................................7

1.9.1 Refining Methods ...................................................................................................................7

1.10 MODIFICATION OF RAPESEED OIL .....................................................................................9

1.10.1 HYDROGENATION............................................................................................................9

1.10.2 INTERESTIFICATION (IE). .............................................................................................10

1.10.3 CHEMICAL INTERESTERIFICATION...........................................................................11

1.10.4 ENZYMATIC INTERESTERIFICATION ........................................................................11

1.10.4 FRACTIONATION ............................................................................................................12

1.11 JUSTIFICATION OF THE PROCESS .....................................................................................13

1.12 PROCESS RAW MATERIAL FOR PRODUCTION OF MODIFIED FAT ...........................13

1.13 PROCESS EQUIPMENT LISTING .........................................................................................14

1.14 DESIGN BASIS ........................................................................................................................14

1.15 PLANT CAPACITY..................................................................................................................14

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 1.16 PLANT OPERATING TIME ....................................................................................................14

1.17 PLANT LOCATION .................................................................................................................14

1.17.1 IDEAL PLANT LOCATION .............................................................................................15

1.17.2 LOCAL ANALYSIS ..........................................................................................................15

1.17.3 SELECTION CRITERIA ...................................................................................................15

1.17.4 SELECTION OF LOCATION FOR THE FAT MODIFICATION PLANT.....................16

LITERATURE REVIEW .............................................21

2.1 RAPESEED OIL..........................................................................................................................21

2.2 VEGETABLE OIL ...................................................................................................................22

2.2.1 GENERAL PROPERTIES ...................................................................................................22

2.2.2 CHEMICAL PROPERTIES .................................................................................................23

2.3 OIL PRODUCTION AND PROCESSING.................................................................................24

2.3.1 OIL SEEDS AND OIL-RICH FRUITS USED IN PRODUCTION OF EDIBLE OILS.....24

2.3.4 Preparation and pressing of rapeseed (canola) .....................................................................26

2.4 OIL MODIFICATION PROCESS ..............................................................................................32

MATERIAL AND ENERGY BALANCE .............................................41

3.1 MATERIAL BALANCE.............................................................................................................41

3.1.1 METHODS OF SOLUTIONS TO MATERIAL BALANCE..............................................42

3.1.2 USES OF MATERIAL BALANCE .....................................................................................42

3.1.3 ASSUMPTION FOR THE PROCESS (FAT MODIFICATION) .......................................42

3.1.4 THE CONCEPT OF STOICHIOMETRY............................................................................42

3.1.5 SUMMARY OF MATERIAL BALANCE UNIT................................................................44

3.2 ENERGY BALANCE .................................................................................................................58

3.2.1 CONSERVATION OF ENERGY ........................................................................................59

3.2.2 ENERGY TERMS TO CONSIDER IN BALANCE ...........................................................61

3.2.3 CALCULATION OF SPECIFIC ENTHALPY....................................................................61

3.2.4 ASSUMPTION FOR THE PROCESS .................................................................................62

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 3.2.5 THE SUMMARY OF ENERGY BALANCE OF UNITS ...................................................62

PLANT PROCESS CONTROL, P&ID AND ENGINEERING DRAWINGS………… ..............73

4.1 Plant Layout.................................................................................................................................73

4.1.1 Factors considered in plant layout ........................................................................................73

4.2.1 Design of piping system .......................................................................................................75

4.3.1 Instruments............................................................................................................................75

4.3.2 Instrumentation and Control objectives ................................................................................75

4.4 Control scheme ............................................................................................................................76

4.4.1 Level control .........................................................................................................................76

4.4.2 Alarms, Safety Trips and Interlocks .....................................................................................76

4.4.3 Interlocks ..............................................................................................................................76

4.5 THE P AND I DIAGRAM ..........................................................................................................77

4.5.1 Symbols and Layout .............................................................................................................77

4.5.2 Basic Symbols.......................................................................................................................77

4.5.3 Type of Instrument................................................................................................................78

PROCESS EQUIPMENT DESIGN, SPECIFICATIONS AND MATERIAL SELECTION ......81

5.1. Process Equipment Design and Specification ............................................................................81

5.2 Design Specification Sheet ..........................................................................................................81

5.2.1 DESTONNER (DE-01) ........................................................................................................81

5.2.2 DEHULLER ( D-01) ............................................................................................................82

5.2.3 FLAKER..............................................................................................................................83

5.2.4 ROTARY COOKER (R-01) .................................................................................................83

5.2.5 SCREW PRESS....................................................................................................................84

5.2.6 HEAT EXCHANGER ..........................................................................................................85

5.2.7 HYDROGENATION REACTOR ........................................................................................85

5.2.8 BLEACHING TANK ...........................................................................................................86

5.3 Material Selection ........................................................................................................................87

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 5.3.1 The equipment materials for construction. ...........................................................................87

5.3.2 Mechanical Properties...........................................................................................................87

5.4 Corrosion Resistance ...................................................................................................................90

5.4.1 Material selection for corrosion resistance. ..........................................................................90

SAFETY, LOSS MANAGEMENT AND POLLUTION CONTROL ............................................92

6.1 plant safety...................................................................................................................................92

6.1.1 AREAS OF SAFETY TRAINING REQUIRED AT THE PLANT.....................................93

6.1.2 PROCESSES AND HAZARDS INVOLVED .....................................................................98

6.2 Loss Management ......................................................................................................................100

6.2.1 Factors Contributing To High Plant Losses in Degrading and Variations .........................100

6.3 POLLUTION (EMISSION) CONTROL...................................................................................103

6.3.1 Spill Containment ...............................................................................................................104

6.3.2 Wastewater Treatment ........................................................................................................104

6.3.3 Solid Waste Disposal ..........................................................................................................107

6.3.4 Air Pollution Control ..........................................................................................................107

6.3.5 Noise Pollution ...................................................................................................................109

ECONOMIC ANALYSIS………………………………………………... ......................................111

7.1 Background................................................................................................................................111

7.2 Cost Estimate of Plant Equipment .............................................................................................111

7.3 Capital Investment .....................................................................................................................112

7.4 Fixed Capital Investment ...........................................................................................................112

7.5 Working Capital.........................................................................................................................112

7.6 Costing Method..........................................................................................................................112

7.7 Rapid Capital Cost Estimation Methods....................................................................................113

7.8 Estimation of Purchase Equipment Cost ...................................................................................113

7.9 Profitability Analysis .................................................................................................................113

7.10 Estimation of Revenue.............................................................................................................114

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 7.11 Rate of Return ..........................................................................................................................114

7.12 Payback Period ........................................................................................................................114

7.13 Net Return................................................................................................................................115

7.14 Discounted Cash Flow .............................................................................................................115

7.15 Result Of Cost Analysis...........................................................................................................115

PLANT STARTUP/ SHUTDOWN AND OPERATING PROCEDURES...................................118

8.1 General Principles......................................................................................................................118

8.1.1 Pre-commissioning .............................................................................................................119

8.1.2 Commissioning & startup ...................................................................................................119

8.1.3 Typical difficulties & problems in commissioning ............................................................120

8.1.4 Startup & post-commissioning ...........................................................................................123

8.2 Maintenance...............................................................................................................................124

8.3 Installation and startup...............................................................................................................124

8.4 Operations..................................................................................................................................125

8.5 Lubrication.................................................................................................................................125

8.6 Spare parts..................................................................................................................................126

8.7 Maintenance personnel. .............................................................................................................126

8.8 Preventive maintenance. ............................................................................................................127

REFERENCES……………………………………………………………………………………….131

APPENDIX I…………………………………………………………………………………………132

MASS AND COMPONENT BALANCE ABOUT EACH UNIT. .............................................133

UNIT 2: DEHULLER D-01 ............................................................................................................133

APPENDIX III………………………………………………………….............................................150

PLATE HEAT EXCHANGER........................................................................................................150

HYDROGENATION REACTOR ...................................................................................................150

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 LIST OF TABLES

Table 1.1 Comparison between Traditional, Mechanical and Chemical Process 6

Table 1.2: Comparison between the three process routes 13

Table 2.1 Typical reaction times for hydrogenation pressures up to 6 barg

(dead-end reactor, INTERMIG agitator). 39

Table 2.2 Typical process parameter variation for different hydrogenated products

(from rapeseed oil). 39

Table 3.1 Flow composition in the destonner 45

Table 3.2 Flow composition in the dehuller 46

Table 3.3 Flow composition in the steam conditioner 47

Table 3.4 Flow composition in the flaker 48

Table 3.5 Flow composition in the rotary cooker 49

Table 3.6 Flow composition in the screw press 50

Table 3.7 Flow composition in the centrifuge 51

Table 3.7 Flow composition in the degummer 53

Table 3.8 Flow composition in the bleaching tank 55

Table 3.9 Flow composition in the centrifuge 57

Table 3.10 Flow composition in the hydrogenation tank 58

Table 3.11 Flow composition in the deodorizer. 59

Table 3.12 Energy Balance in the Destonner 64

Table 3.13 Energy Properties For Destonner 64

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Table 3.14 Energy Balance in The Dehuller 64

Table 3.15 Energy Properties For Dehuller 65

Table 3.16 Energy Balance in The Steam Conditioner 65

Table 3.17 Energy Properties For Steam Conditioner 66

Table 3.18 Energy Balance in the Flaker 66

Table 3.19 Energy Properties For Flaker 66

Table 3.20 Energy Balance in The Rotary Cooker 67

Table 3.21 Energy Properties for Rotary Cooker 67

Table 3.22 Energy Balance in The Screw Press 68

Table 3.23 Energy Properties for Screw Press 68

Table 3.24 Energy Balance in the Centrifuge 69

Table 3.25 Energy Properties for Centrifuge 69

Table 3.26 Energy balance about the degummer unit 70

Table 3.27 Energy balance about the Bleaching Tank 71

Table 3.28 Energy properties for Bleaching Tank 71

Table 3.29 Energy balance about the Filter 72

Table 3.30 Energy properties for filter 72

Table 3.31 Energy balance about the bleaching tank 73

Table 3.32 Energy properties for Hydrogenation 73

Table 4.1: Typical allowable velocity and pressure drops in pipes 76

Table 4.2 Letter Code for Instrument Symbols 80

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Table 5.1 Experiment Design and Specification Sheet for the Destonner. 82

Table 5.2 Experiment Design and Specification Sheet for the Dehuller. 83

Table 5.3 Experiment Design and Specification Sheet for the flaker. 84

Table 5.4 Experiment Design and Specification Sheet for Rotary cooker. 84

Table 5.5 Experiment Design and Specification Sheet for screw press. 85

Table 5.6 Experiment Design and Specification Sheet for Heat Exchanger. 86

Table 5.7 Experiment Design and Specification Sheet for Hydrogenation reactor. 86

Table 5.8 Experiment Design and Specification Sheet for Bleaching Tank. 87

Table 5.9 Properties of selected materials 89

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 LIST OF FIGURES

Fig 1.1: Chemical reaction of preparation of fats and oils. 12

Fig 1.2 Map showing site area for port Harcourt 17

Fig 1.3 Map showing location area for Ibadan 18

Fig 1.4 map showing location area for Ikeja 19

Fig 1.5 Map showing area for Ara-Ijero location 20

Fig 2.1 Rotary cooker. 29

Fig 2.2 Elements of a typical press (opened cage). 29

Fig 2.3 Typical worm assembly, showing worms, distance pieces, knife bars

and a mixing device. 30

Fig 2.4 Oil flowing between cage bars. 31

Fig 2.5 Pressed cake at outlet. 32

Fig 2.6 Schematic Process of Hydrogenation 41

Fig 3.1 Process flowsheet of the whole process 44

Fig 3.2 Destonner 45

Fig 3.3 Dehuller 46

Fig 3.4 Steam Conditioner 47

Fig 3.5 Flaker 48

Fig 3.6 Rotary cooker 49

Fig 3.6 Screw Press 50

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Fig 3.7 Centrifuge 51

Fig 3.8 Degummer 52

Fig 3.9 Bleaching Tank 54

Fig 3.10 Centrifuge 56

Fig 3.11 Hydrogenation 57

Fig 3.12 Deodorizer 58

Fig 3.13: Energy balance over a system 60

Fig 3.14 Destonner Flow diagram 63

Fig 3.15 Dehuller Flow diagram 64

Fig 3.16 Steam Conditioner Flow diagram 65

Fig 3.17 Flaker flow diagram ` 66

Fig 3.18 Steam Conditioner Flow diagram 67

Fig 3.19 Screw Press Flow diagram 68

Fig 3.20 Centrifuge flow diagram 69

Fig 3.21 Centrifuge flow diagram 70

Fig 3.22 Bleaching tank flow diagram 71

Fig 3.23 Filter flow diagram 72

Fig 3.24 Hydrogenation tank flow diagram 73

Fig 4.1 Control Valves 78

Fig 4.2 Actuators 78

Fig 4.3 Oil plant piping and instrumentation diagram 81

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Fig 6.1 Component for lockout and tagout 98

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 LIST OF SYMBOLS

ΔH = Change in Enthalpy

Qin = Heat duty in

Qout = Heat duty out

Hf = Heat of Formation

Cp = Specific Heat Capacity

ΔT = Change in Heat Capacity

m = Mass

T = Temperature

Tref = Reference Temperature

v = Velocity

d = diameter

ῤ = Density

V = Volumetric flow rate

t = thickness

L = Length of Kiln

F = Fouling Factor

t = time (minutes)

T = retention time

a = ratio of raw meal fed per product

b = average bulk density of material

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Tlm = Log mean temperature

U = Overall Coefficient

A = Area

N= Number of turns

M = Mass flow rate

Pd = Pressure drop

P = absolute pressure = 1 bar

ῤg = Gas density

LB = Belt Length

Ce = Purchase Cost

S = Size Parameter

n = exponent for the type of equipment

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