MAPÚA UNIVERSITY

School of Chemical, Biological and

Materials Engineering and Sciences

Piping and Instrumentation Diagram of Calaca Batangas Algal

Biofuel Plant

Prepared by:

Correia, Feliciana Maria

Evidente, Ralph Carlo T.
Legarde, Jasmine Marjorie C.
Pereira Soares, Gretha Elizabeth Otipaga
Sese, Louisse Naomi N.
Ocado, Patricia Andrea C.

Submitted to:

Engr. Rommel Galvan

A Final Design Project Report Submitted in Partial Fulfillment of the Requirements for the
Degree of Bachelor of Science in Chemical Engineering

December 2017
 NOTES:
01. CE – Centrifugal Extractor
02. CP – Cultivation Pond
03. D – Dryer
FIC FIC FT FIC FT
04. HX – Heat Exchanger
FT
FIC
101
FT
101
TIA
101
LIC
101
LT
101
LIC
102
LT
102
104
PIA
104 105
PIA
104
105 106 106
05. M – Mixing Tank
PIA
101 PI
103
TIA
102
06. P – Pump
101
FV-104 07. R – Reactor
[7]
DV 102 [13] FV-105
08. T – Tank
[10]
[11] V-102 PIA 09. V – Closed Vessel
[4] [5] V-101
105
From Cultivation
Pond D-101 P-101 [15]
FV-101 FV-102 FV-103
CE-101 [12]
V 103 [14]
LT Valves and Instruments
106
R-101
[6] LP Steam
PI
102
HP Steam
pHI
R-102
[20]
01. FV – Flow Valve
CO 2
FIC
102
FT
102
102
FV-106
LIC
106
02. V – Valve
[5a] H2O FV-104
03. FT – Flow Transmitter
pHI
101
[8]
PIA H2SO4
[18] [19] V 110
04. FIC – Flow Indicator and
102
FIC V 104
[16]
FV-107
M-101 Controller
For
P-401
[9] 103 P-102
05. LT – Level Transmitter
Transesterification T-101
FT P-303
R-201 06. LIC – Level Indicator and
103
V 105 Controller
06. pHI – pH Indicator
07. PI – Pressure Indicator
08. PIA – Pressure Indicator and
Alarm
09. TT – Temperature Transmitter
10. TIC – Temp Indicator &
Controller
11. TIA - Temp Indicator and
Alarm

Calaca,
Batangas
Biofuel
Plant

Piping and Instrumentation

Diagram

Drawing No. D-G01-205 Rev. No. 0

Sheet 1 of 7
 NOTES:

01. FDb – Flash Drum Vessel

02. FR – Fermentation Reactor
TIC TIC
03. HX – Heat Exchanger
DV 204 TIC
203 202
201 FV 201
04. M – Mixing Tank
TT
FT FIC TT
FT FIC
202
TIA
201 [24]
LT
201
LIC
201 05. P – Pump
Ammonia
06. R – Reactor
203 202
203 203 202
TT
Inoculum feed and 201 [23]
nutrients
[30] [26]
PI
202 V 202
V 201
Water 07. SR – Saccharification Reactor
[34]
V 206
FR-201 [27]
FV 203 Valves and Instruments
PIA
[32] [22] P-201 01. FV – Flow Valve
M-201
02. V – Valve
203
V-48 [31] FV-205 HX-202 [25] FV 202 From R-102
S-3
HX-203 P-202 [21]
03. FT – Flow Transmitter
PhI
SR-201 R-201
203
[28]
HX-201
V-207 [29] [24a]
Waste Water
FT
201
FIC
201 PhI V 203 PIA 04. FIC – Flow Indicator and
201 201
[35] PIA PhI
V 204 PI
201 Controller
LIC
104
LT
104
SSF Flash drum
202 202
Enzyme (NH4)2SO4 05. LT – Level Transmitter
Vapor
06. LIC – Level Indicator and
[38]
To GT-301 Controller
PIA
07. PhI – pH Indicator
FV-205 FDb-201
204
08. PI – Pressure Indicator
TIA
202
[39]
To M-301
09. PIA – Pressure Indicator and
Alarm
SSF Flash drum
Liquid 10. TT – Temperature Transmitter
11. TIC – Temp Indicator and
Controller
12. TIA - Temperature Indicator and
Alarm

Calaca,
Batangas
Biofuel
Plant

Piping and Instrumentation

Diagram

Drawing No. D-G01-205 Rev. No. 0

Sheet 2 of 7
 NOTES:
TIC
FV 302 301
01. DT – Distillation Column
LT
302
02. FD – Flash Drum
LIC
301
LT
301
LIC
TT
301 CO 2 recycle to 03. GT – Gas Tank
[43] ponds
TIA PIA
302
V 301 04. HX – Heat Exchanger
301 301
05. M – Mixing Tank
06. P – Pump
07. VS – Vent Scrubber
PIA
Vapors from FD-201 [40] [41] Valves and Instruments
VS-301 302
FV-301 [38] GT-301
PI FV-303 [42] 01. FV – Flow Valve
[50] HX-301
301
V 302
02. V – Valve
FV-304 Water 03. FT – Flow Transmitter
V 304
[44] 04. FIC – Flow Indicator and
Controller
P-301 05. LT – Level Transmitter
FV-306
FT
301
FIC
301
PIA
303
06. LIC – Level Indicator and
TIC
[45] 302 Controller
07. PI – Pressure Indicator
08. TT – Temperature Transmitter
PI
302 TT
HX-302 302

FV-305 [49] 09. TIC – Temp Indicatior and

[48] To DT-302
[46]
DT-301 Controller
M-301
V 305
10. TIA – Temp Indicator and Alarm
[47]
P-302
V 303
[51]
[39]
FV-307
LIC LT HX-303
Liquids from FD-201 303 303

TT TIC
[52] 303
303

Calaca,
To water
recycle pool Batangas
Biofuel
Plant

Piping and Instrumentation

Diagram

Drawing No. D-G01-205 Rev. No. 0

Sheet 3 of 7
 NOTES:

01. D - Decanter
02. DT – Distillation Tower
03. HX – Heat Exchanger
04. M - Mixer
05. P – Pump
06. R – Reactor
02. T – Tank
TIC
Valves and Instruments
305 01. FV – Flow Valve
TIC
306 FV-315 02. V – Valve
PI
304 TT
LIC
305
LT
305
03. FT – Flow Transmitter
305
TT 04. FIC – Flow Indicator and
[60] HX-306
306
[59]
Controller
FV-314 [58] FV-316 05. LT – Level Transmitter
HX-305
LIC
304
LT
304
FV-311
TIC
06. LIC – Level Indicator and
P-304 304 Controller
[61]
[54] TIC
07. PI – Pressure Indicator
[55] TT
307 08. PIA – Pressure Indicator and
304 Alarm
HX-307 FV-312 PIA
305 TT 09. TT – Temperature Transmitter
307
10. TIC – Temp Indicator and
PIA FV-309 MS-301
From DT-301 304 V 306 Controller
DT-302 TIC PIA
FV-308 [49] 303
[62] 306
PI
303 [63]
[56] HX-308
TT
303 [17]
M-101

[57]
HX-304 P-303 To Pretreatment Area

FIC Calaca,
302
FT
302
Ethanol Batangas
Biofuel
ST-301
Plant

Piping and Instrumentation

Diagram

Drawing No. D-G01-205 Rev. No. 0

Sheet 4 of 7
 NOTES:

01. D - Decanter
PI FV-502 02. DT – Distillation Tower
Methanol [69]
401 03. HX – Heat Exchanger
V 401 04. M - Mixer
FV-501 05. P – Pump
[68] 06. R – Reactor
NaOH [71] HX-502 01. T – Tank
V 402 [70] Valves and Instruments
P-403 A/B FIC
M-401 501
01. FV – Flow Valve
TIC
FV-504 501 02. V – Valve
FIC FT
FT
501
03. FT – Flow Transmitter
502 502
TT 04. FIC – Flow Indicator and
PI 501
402 Controller
PI 05. LT – Level Transmitter
[72] 502

S-9
06. LIC – Level Indicator and
[64] Controller
[66]
From T-101 [65]
FV-503 P1A
501 [77]
[78]
07. PI – Pressure Indicator
HX-501
FV-505
TIC
502
08. PIA – Pressure Indicator and
P-402 A/B R-501 Alarm
PI
501 P-502 A/B 09. TT – Temperature Transmitter

202
FV-506

FC
TT
502
10. TIC – Temp Indicator and
Controller
[74] [75]
[80]
D-501
HX-503 [76]
P-501 A/B

202
FT
FV-508
TIC LT LIC
504 FV-510 501 501
PI
503
HX-504
PI
FV-511
505 TT [82]
504 [81]

[86]
[84] Calaca,
Batangas

503
503

TIC
[83] FV-509

TT
To DT-602 LIC HX-505
[85] P-503 A/B
502 To DT-601 Biofuel
D-502 R-502
Plant
LT
502
P-505 A/B
PIA
PI 402
504

[89]
Piping and Instrumentation
[88]
To DT-601 Diagram

P-504 A/B Drawing No. D-G01-205 Rev. No. 0

Sheet 5 of 7
 NOTES:

01. D – Decanter
02. DT – Distillation Tower
03. HX – Heat Exchanger
04. KR – Kettle Reboiler
05. ST – Storage Tank
FV-603
TIC
603
TT
603
06. TC – Total Condenser
PIA
602 Valves and Instruments
01. FV – Flow Valve
02. V – Valve
03. FT – Flow Transmitter
[92]
[93] 04. FIC – Flow Indicator and
FV-601
TIC
601
ST-701 Controller
05. LT – Level Transmitter
HX-603
06. LIC – Level Indicator and
TC-601 Controller
PIA
601 [91] FAME 07. PI – Pressure Indicator
From D-501
08. PIA – Pressure Indicator and
HX-601 Alarm
S-10 09. TT – Temperature Transmitter
[79]
10. TIC – Temp Indicator and
TT LT Controller
602 601
DT-601
LIC
TIC 601
FV-602 602 TIC TT
[90] FV-605 604 604
PIA
603

[89]
From D-502 KR-601 FV-604
HX-602 Calaca,
Batangas
[94] ST-703
Biofuel
Plant
HX-604 [95]

Glycerol
Piping and Instrumentation
Diagram

Drawing No. D-G01-205 Rev. No. 0

Sheet 6 of 7
 FV-607
TT TIC
FV-606
NOTES:
605 605

01. D – Decanter
[97] [96]
TIC 02. DT – Distillation Tower
606
03. HX – Heat Exchanger
HX-606 TC-602
PIA
604 04. KR – Kettle Reboiler
LT [87] [86] 05. P – Pump
302 06. ST – Storage Tank
DT-602 From D-502
[98] FV-609 07. TC – Total Condenser
TT LIC HX-605
606 PIA 302 Valves and Instruments
605 01. FV – Flow Valve
[99] [KR2] 02. V – Valve
PI
601 03. FT – Flow Transmitter
FV-610 04. FIC – Flow Indicator and
HX-607 FV-608
ST-702 KR-602 Controller
[100]
TIC
608
05. LT – Level Transmitter
[105] 06. LIC – Level Indicator and
` Controller
Methanol Water
[106] 07. PI – Pressure Indicator
HX-608 P-601 A/B 08. PIA – Pressure Indicator and
Hydrochloric
TT Alarm
PIA
acid
608
606 09. TT – Temperature Transmitter
[101] 10. TIC – Temp Indicator and
Controller
[109] ST-704
D-601 D-602
TIC TT
607 607 [107]
[102]
[103] Biodiesel
Calaca,
Batangas
To Wastewater [104] Biofuel
Treatment Facility [108] Plant

Piping and Instrumentation

Diagram

Drawing No. D-G01-205 Rev. No. 0

Sheet 7 of 7
Process Description for Area 100

Raw Material Preparation, Pretreatment and conditioning

This section includes the cultivation process for algae. Water, raw microalgae, nitrogen and
phosphorus source are added to the cultivation pond (CP-101), which operates at 30 ℃ and 101.325 kPa,
and the mixture will then be redirected to photobioreactor (R-101). At R-101, the biological growth of the
algae is promoted through controlling the environmental parameters. After the algae is harvested, it is then
redirected to the drying bed (D-101), which operates at 80 ℃, such that cell concentration is increased, and
the moisture content is reduced. At the centrifugal extractor (CE-101), the incoming algal biomass is then
split into extracted oil, which proceed to T-101 and is redirected for biodiesel production, and residual
biomass, which will be pumped to the closed vessel with low-pressure steam at V-101. The exiting residual
biomass from V-101 proceeds to the closed vessel V-102, with a high-pressure steam. Some of the algal
biomass from the exit stream of V-101 will be converted at V-102 into to the following products: cellulose,
hemicellulose, and lignin. The processes from V-101, and V-102 serve as pretreatment. The products
obtained from V-102, together with the remaining residual biomass will then proceed at R-102 for thermal
acid hydrolysis. Concentrated sulfuric acid and water is mixed at M-101, and the resulting diluted sulfuric
acid will proceed at R-102 and will serve as a catalyst for the hydrolysis reaction. Hydrolysis enables the
conversion of carbohydrates in the feedstock to soluble sugars.

Process Description for Area 200

Fermentation

The slurry received from the pretreatment section passes through a heat exchanger (HX-201) to
reach the 30℃ which is a temperature for saccharification and fermentation. Prior to sending the slurry to
SSF reactors, slurry goes to (R-201) for ammonia conditioning reaction to neutralize its pH. Then, the slurry
goes to mixing tank (M-201) and are mixed with enzymes for saccharification. Then, the slurry goes to
saccharification reactors (SR-201) in which the added enzymes will break down the complex sugars into
glucose. The saccharification products goes to fermentation reactor (FR-201) where bacteria Z. mobilis and
nutrients was added. In the fermentation process, sugars are converted into ethanol and CO2. The
fermentation products from (FR-201) goes to a flash drum (FDb-201). The overhead vapors contain little
amounts of ethanol and are sent to gas tank (GT-301). Bottom liquids are sent to recovery section for ethanol
purification (M-301).
Process Description for Area 300

Purification Process (Part 1)

This section separates the fermentation broth into water, anhydrous ethanol and solids. Distillation
and molecular sieve adsorption are used to recover ethanol from the raw fermentation liquid and produce
80% ethanol. Distillation is accomplished in two columns. The first column, which can be seen in DT-301,
is called Water Remover Column. It removes the dissolved CO2, most of the water, and the dissolved solids.
The overhead stream from this column is fed to Vent Scrubber along with the vent vapors from (containing
mostly CO2, ethanol vapor, and oxygen). This is to recover nearly all the ethanol. The effluent is fed back
to DT-301.

Purification Process (Part 2)

The product quantity of ethanol has been projected according to the market share analysis and the
plant capacity. In the storage tank, there will be 80% ethanol 5% H2O.

Inside the molecular sieve (MS-301), the undesirable byproducts that cannot be removed by normal
distillation, will be removed. A molecular sieve adsorbeer is used to remove water from ethanol by
adsorbing the water into the beads and allowing ethanol to pass freely to the next stream, once the beads
are full of water, the temperature and pressure can be manipulated allowing water to be released from it.
The product from Molecular sieve 95% will go to storage tank by passing through a heat exchanger (HX-
308) for a temperature control and the other 5 % will be send again to the distillation column upon
heating/cooled in heat exhangers(HX-306). Heat exchanger has a main duty as wash preheater, or to cooled
down the ethanol solution when it is heated too much and a main heat exchanger which exploits the waste
heat rejected from the power plant.

Next will consist of equipment such as heat exhangers (HX-305, HX-306, HX-307), pump(P-304),
and distillation (DT-302) column. Heat exchanger has a main duty as wash preheater, or to cooled down
the ethanol solution when it is heated too much and a main heat exchanger which exploits the waste heat
rejected from the power plant. Pump was used in order to transfer the solution from one stream to another
since the solution has more volatile properties. Distillation column is used to separate different fractions of
hydrocarbons based on their volatility where the upper product will go to the molecular sieve (MS-301)
and the bottom product will go to a mixing tank(M-101) for pre-treatment again (recovery). The total
quantity for stream 58 = stream 59 = stream 60 = stream 61, and stream 55 are known from previous material
balance. Since there is no reactor in this section, there will be no material balance based on reaction to get
each composition in stream 49 however, ratio and proportion can be applied. The existing pilot plant data
can be used as heuristic to do the ratio and proportion for the compositions.

Process Description for Area 400-700

Pretreatment of Algal Biomass for Biodiesel Production

This section includes preparation of raw materials needed for algal oil. The algal oil will be pumped
to the first transesterification reactor (R-501). Methanol and sodium hydroxide will then be mixed in mixer
(M-401) and will be pumped to the first transesterification reactor (R-501).

Transesterification Process

The raw materials (algal oil, methanol and sodium hydroxide) will be pumped to the first
transesterification reactor (R-501) and will be maintained at 60 ℃ using heat exchangers (HX-501 and HX-
502). The feed to the reactor should be 6:1 methanol to algal oil ratio. Sodium hydroxide entering the reactor
should have a concentration of 1.0 wt % of the feed algal oil. The purity of the algal oil is assumed to be
99.5 % and the remainder will be for the free fatty acid (FFA). In this reaction, the assumption is that the
conversion of algal oil to product is 97.7 %. The product of R-501 will be transferred to decanter (D-501)
to separate the glycerol from the product and some unreacted triglycerides. Decanter is being maintained at
33.3℃. The glycerol will then be transferred to distillation unit (DT-601) for further purification. The main
product will then be sent to second transesterification reactor (R-502) to furthermore react the unreacted
triglyceride to increase the conversion. Again, the reactor should be maintained at 60℃ as an optimum
temperature for the transesterification reaction. The product from R-502 will be sent to another decanter
(D-502) to separate the glycerol from residual biodiesel. Glycerol will be pumped to DT-601 along with
the glycerol product from the R-501. The residual biodiesel will then be sent to another distillation unit
(DT-602) for further purification.

Biorefinery

Glycerol from the reactors are being transferred and purified in DT-601, operating at 60 ℃ with
kettle reboiler (KR-601) and total condenser (TC-601) operating at 97.2 ℃and 16.7 ℃, respectively. The
residual fatty acid methyl esters (FAME) is assumed to be the overhead product and glycerol is the bottom
product. The second distillation unit (DT-602) is operating at 60 ℃ and has a kettle reboiler (KR-602) and
total condenser (TC-602) operating at 43.9 ℃ and 16.7 ℃, respectively. Methanol and other impurities are
being separated from FAME, where methanol is the overhead product and FAME is the bottom product.
FAME is being sent to a decanter (D-601) for alkali removal. D-601 is maintained at 25 ℃. Excess sodium
hydroxide is being neutralized with hydrogen chloride. Hydrogen chloride is also used to split the soap that
may form during the reverse saponification reaction. The neutralization is also being done so as to reduce
the water usage in the water washing process for the purification of FAME, and to minimize the emulsion
formation. Again, the FAME is being purified in another decanter (D-602) wherein in the residual catalyst,
salts, methanol, free glycerol and triglycerides are being removed using warm water to achieve a 99.65 wt
% purity of biodiesel to meet the ASTM D 6751 biodiesel specification.

Product Storage

The glycerol, residual FAME, methanol and algal biodiesel will be stored in different storage tanks
(ST-701; ST-702; ST-703; ST-704). Residual FAME will be stored in ST-701, the recovered methanol will
be stored in ST-702, the purified glycerol will be stored in ST-703 and the biodiesel will be stored in ST-
704. Glycerol, the residual FAME and biodiesel can be readily used commercially while the recovered
methanol can be recycled back to the Raw Materials Preparation section.