CHAPTER 6

6.1 EQUIPMENT SIZING

6.1.1 IP CLARIFICATION

Clarifier size:

ton 1 batch 1 day

POME out = 6144.915 batch 20 days 16.67 hours

= 1.843 ton/hour

f
Volume calculation, V =2( )

ton
1.843 X 2hr
=2 ( hr
3
)
0.876 ton/m

= 8.416m3

Area, height and diameter:

3
D
Assume V = 4

D3
8.416 m3=
4

D= 2.204 m

Based on assumption , L/D=1/4

L = 4D

= 4(2.204m)

= 8.818m

Area = D D

= 2.204m 2.204m

= 4.858 m2
6.1.2 MIXING TANK

Tank size:

kg 1batch 1day
POME out = 6144915.475 batch x 20 days x 16.67 h

kg
= 18431.05879 h

Blending Time: 6h

Density of pome: 876 kg/m

f
Volume calculation, V =2( )

kg
18431.06 X 6 hr
hr
=2 ( )
kg
876.0 3
m

= 252.48026 m

252.48026 m
4 multiple unit = 4

=63.12 m

Area, height and diameter:

Assume V=(D)/4

63.12 m=(D)/4
 D= 4.32m
Based on assumption, L/D=1/4
L = 3D
= 3(4.32m)
= 12.96m
Area =2rh+2r
= 2 (2.16 m )(12.96m) +2(2.16m)
=189.46m
6.1.3 ANAEROBIC DIGESTER (FERMENTER)

Size digester: (Biogas Technology GmbH; page

12)
m
POME in = 129.0432 day x 20 days

= 2580.8645 m3 => 2600 m3

2600 m
= =1300 m
2
*10% upper tank is empty for gas accumulation:
10
= 1300 m3 x (1+ 100 )

= 1430 m3 => 1500 m3.

16.67 hour
Volumetric flow rate (Q) = 2580.8645 m3/(20days x 1 day )

= 7.74 m3/hr.

Volume equation: F = dV/dt

Area, height and diameter: (Biogas Technology GmbH; page 12)

(H/D) = 3:1 *Assume the vessel is cylinder:V = ( 4 )D2H

3 3
H = 3D => 4 3D = 1500 m
D = 8.60 m.

1500 m3 = 4 (8.60 m)2H

H = 25.82 m.
Area (A) = 2r2 + rh
= 2(5.359 m)2 + (5.359 m)(32.149 m)
A = 464.97 m2.
6.1.4 CONDENSER

Based on the Tata McGraw- Hill, the heat flux can be find using the formula:

Btu
Range x GPM x 500 = Q ( hr )

Range = 308 K 277 K

= 31 K

GPM = Gal per min

kg 1 batch 1 day 1 hr 1 gal

GMP = 2339878.88 batch 20 days 16.67 hr 60 min 3.7854 kg

= 30.9004 GPM

Hence,

Q = 31 K x 30.9004 x 500

0.29307107W
btu
= 478956.2 x Btu
hr 1( )
hr

= 140368.206 W

From the book of Heat and Mass transfer, McGraw-Hill education, the overall heat transfer
coefficient can be determined at table 11-1. In this table, it given the representative values of
the overall heat transfer coefficients in heat exchanger where the type of heat exchanger is
steam condenser. This is since the condenser is used to condense the vapor or moisture that
present in the biogas. Hence, the overall heat transfer coefficient for steam condenser heat
exchanger 1000 W/m2. K.

Q = U A (Tlm)

140368.206 W = (1000 W/m2. K) A ( 11.726 K)

A= 9.8504 m2
6.1.5 GAS ENGINE

Size of turbine: *(Systematic Methods of Chemical Process Design)

Assumption: ideal behavior, isentropic, adiabatic

P1 = 2.0 atm P2 = 1.0 atm
T1 = 35.0 C T2 = ?

P 2 ( 1 )/
T2 = T1 P1 )
( (page 125)
1.41
1.0 atm
= 35.0 C ( 2.0 atm ) 1.4

= 28.7 C

Substitutes into theoretical power for ideal system: (page 126)

2
P
( 1)
P
W = (/(-1))RT1 ( 1)
[ 1]

[( ]
1.41
g . mol 1.4 J 1.0 atm
W = 4489.6449 s 1.41 (
8.314 )(
gmolK
( 308.15 K ))2.0 atm ) 1.4
1

= 33025.06 kJ/s

Efficiency, T = 0.8 (page 126)

m = 0.8
Wb = 1.562 W
6.1.6 CLARIFICATION

Clarifier size:
kg 1 batch 1 day 1 m
POME in = 3805036.628 batch x 20 day x 16.67 hours x 876 kg
m
= 217.182 hour

Volume calculation,

Detention time x flow

24 hour
V =

Assuming detention time= 2.25 h

m
217.182 X 2.25 hr
hr
= 24 hours

=20.36 m3
Area, height and diameter:

D3
Assume volume batch, V=
4

3 D3
84.1 m =
4

D= 2.96m
Based on assumption, L/D=1/4
L = 4D
= 4(4.750m)
= 11.84m
Area = 2rh + 2 r
= 2 ( 1.48m)(11.84m) + 2 (1.48m)
= 123.864 m
6.2 EQUIPMENT COSTING
6.2.1 IP CLARIFICATION

The bare cost for the clarification tank can be calculated based on Biegler et al, (1999)
systematic method of chemical process design
Cost Vertical vessel
L D
Bare cost = c ( L )( D ) (Table 4.11;

page 134) 1000 $ (8.818 m 1.2192m)0.81 (2.204 m 0.9144 m)1.05

= 12,509.354 $ USD 4.40 MYR /1 $ USD (*Currency on 20th April 2017, 1 USD =

4.40 MYR)

55,041.157 MYR

Module factor, MF 2=4.23 (Table 4.11; page 134 )

Stainless steel, solid MPF=F m F p (Table 4.2; page 113)
= 3.67 1.0 = 3.67
CEPCI 2017
Updating factor, UF= CEPCI 2015

558.4927

566.6
= 0.986
Updated bare module cost = UF ( BC )( MPF+ MF 1)
0.986(55,041.157 $ USD)(3.67+ 4.231)
374,467.012 $ USD x 4.40 MYR/1 $ USD
1,647,654.851 MYR
6.2.2 MIXING TANK

The bare cost for the mixing tank can be calculated based on Biegler et al, (1999) systematic
method of chemical process design
Cost Vertical vessel
L D
Bare cost = c ( L )( D ) (*Table 4.11; page 134)

0.81 1.05
42.42 7.09
= 1000 $ ( 4 ) ( ) 3

= 16,705.71$ USD x 4.40 MYR/1$USD (*Currency on 20th April 2017, 1 USD =

4.40 MYR)

= 73, 505.11 MYR

= 73, 505.11 MYR x 4 multiple unit
= 294, 020.45 MYR

Module factor, MF2 = 4.23 (Table 4.11; page 134)

Stainless steel, solid MPF = FmFp (Table 4.2; page 113)
= 3.67 x 1.0 = 3.67
CEPCI 2017
Updating factor, UF = CEPCI 2015

558.4927
= 566.6

= 0.986
Updated bare module cost = UF(BC)(MPF+MF-1)

= 0.986(66,822$ USD )(3.67+4.23-1)

= 451,856.04 $ USD x 4.40 MYR/ 1$ USD
= 1, 988, 166. 6 MYR
6.2.3 ANAEROBIC DIGESTER (FERMENTER)

The bare cost for the fermenter can be calculated based on Biegler et al, (1999) systematic
method of chemical process design.
Cost: Vertical vessel
L D
Bare cost = c ( L )( D ) (Table 4.11; page

134) = 1000$ (105.48 ft/ 4.0 ft)0.81 x (35.16 ft/ 3.0 ft)1.05
= 187703.86$ x 4.40MYR/1$ (*Currency on 20 th April 2017, 1 USD = 4.40
MYR)
= 825, 896.98 MYR.

Module factor, MF2 = 4.23 (Table 4.11; page 134)

Stainless steel, solid MPF = FmFp (Table 4.2; page 113)

= 2.25 x 3.67 = 8.2575
CEPCI 2017
Updating factor, UF=
CEPCI 2015
= 558.4927/115.0
= 4.86
Updated bare module cost = UF(BC)(MPF+MF-1) (page 135)
= 4.86(187703.86$)(8.2575+4.23-1)
= 10479365.73$ x 4.40 MYR/ 1$

= 46,109,209.19 MYR
6.2.4 CONDENSER

The bare cost for the condenser can be calculated based on Biegler et al, (1999) systematic
method of chemical process design. By using the Guthrie material and pressure factor the
formula use :

S
BC = C ( S )

The base cost for the equipment can be get from the table 4.12 where the area for the
condenser converted to ft2

10.769 ft 2
A = 11.970 m 2 2
1m

= 128.8515 ft2

As the S is in the range of 100 104 ft2 . hence,

128.8515
BC = $5000 ( 400 )0.65

= $ 2394.358
= MYR 10 535.18 (*Currency on 20th April 2017, 1 USD = 4.40 MYR)

Since the condenser use is 3 multiple units hence the bare cost, MYR 31 605.52

Module factor, MF2 = 3.29

For stainless steel solid, Fm = 3.10 and Fp = 0.0 and Fd = 1.0

Material and Pressure Correctio method, MPF = Fm ( Fp + Fd )

= 3.10

CEPCI 2017 558.4927

Updating factor, UF = =
CEPCI 2015 566.6

= 0.985

Bare Module Cost, BMC = UF (MPF + MF 1) (BC)

= 0.985 ( 3.10 + 3.29 1) ( MYR 31 605.52)

= 167,798.45 MYR
6.2.5 GAS TURBINE
The bare cost for the gas turbine can be calculated based on Biegler et al, (1999) systematic
method of chemical process design. By using the Guthrie material and pressure factor the
formula use :

S
BC = C ( S )

*(Table 4.12; page 134)

3 0.77
= (23x10 ) x (1.562/100)
= 935.11$ x 4.40 MYR
= 4,114.48 MYR

Module factor, MF2 = 3.11 (Table 4.12; page 134)

Stainless steel, solid MPF = FmFp (Table 4.2; page 113)

= 2.25 x 3.67
= 8.2575
Bare modul cost = BC x MF (page 135)
= 935.11 x 3.11
= 2,908.19$

CEPCI 2017
Updating factor, UF= CEPCI 2015

= 558.4927/115.0
= 4.86

Updated bare modul cost = UF(BC)(MPF+MF-1) (page 135)

= 4.86 x (935.11)(8.2575+3.11-1)
= 47116.50$ x 4.40 MYR
= 207,312.60 MYR
6.2.6 CLARIFICATION
The bare cost for the clarification tank can be calculated based on Biegler et al, (1999)
systematic method of chemical process design
Cost, Vertical vessel
L D
Bare cost = c ( L )( Do ) (Table 4.11; page

134)
0.81 1.05
38.84 9.7111
= 1000 $ ( 4 ) ( 3 )
= 21,642.23$ USD x 4.40 MYR/1$USD (*Currency on 20th April 2017, 1 USD =
4.40 MYR)
= 95,225. 83 MYR
Module factor, MF2 = 4.23 (Table 4.11; page 134)
Stainless steel, solid MPF = FmFp (Table 4.2; page 113)
= 3.67 x 1.0 = 3.67
CEPCI 2017
Updating factor, UF = CEPCI 2015

558.4927
= 566.6

= 0.986
Updated bare module cost = UF(BC)(MPF+MF-1)
= 0.986(21,642.23$ USD )(3.67+4.23-1)
= 147,240.75 $ USD x 4.40 MYR/ 1$ USD
= 647,859.29 MYR
6.3 TOTAL EQUIPMENT COST

EQUIPMENT VOLUME/ CAPACITY COST

IP Clarifier 8.416m3 1,647,654.851 MYR

Mixing Tank 63.12 m x 4 1, 988, 166. 6 MYR

Anaerobic digester (Fermenter) 1500 m3 x 2 46,109,209.19 MYR

Condenser 140368.206 W x 3 167,798.45 MYR

Gas Engine 1.562 W 207,312.60 MYR

Clarifier 20.36 m3 647,859.29 MYR

TOTAL 50,768,000.98 MYR

REFERENCES
Ananthanarayanan.P.N, (2013). Basic Refrigeratio and Air Conditioning. Tata McGraw-Hill
Education. Fourth edition.

Biegler.L.T, Grossmann.I.E and Westerberg.A.W, (1999). Systematic methods of chemical

Process design. Prentice-Hall.

Cengel.Y.A and Ghajar A.J, (2015). Heat and Mass Transfer. McGraw-Hill Education. Fifth
edition.

Task Force of the Water Environment Federation. (2015). Clarifier Design. Aging (Vol. 7).
https://doi.org/10.1073/pnas.0703993104

Schulz, S. (n.d.). Biogas Technology GmbH, 133.