Professional Documents
Culture Documents
Brief Background
The mango industry, which is one of the Philippines aid in sustaining the
country’s economy, produces about 685 thousand metric tons of mango from January
2018 up to September 2018 (Philippine Statistics Authority, 2018). Around 41% of the
total mango production is then used for the mango processing industry (BAS, 2004)
which accumulated to roughly around 281 thousand metric tons of processed mango
products such as dried mango, mango puree and mango concentrates. Majority of the
processing plants for the production of dehydrated candied and puree mangoes are
located in Cebu. Profood, which is one of the main exporter of processed mango, have an
operating capacity of 1140 metric tons of mango per day (Galolo, 2017) along with nine
more mango processing plants based in Cebu making Cebu as a top producer and
Along with banana, pineapple and other agricultural products, processed mango
products has played an important role in the foreign trade market. Philippines, being
ranked seventh amongst the exporters of fresh and dried mangoes, exports around 4%
share of the global market and 98% of the total production is used for domestic
Processing of mango come into life for the purpose of extending the mangoes
shelf life since ripe mangoes tend to degrade faster causing for a loss in profit and also,
accumulation of wastes in the landfill. In the said processing of mangoes, only the flesh
part of the mango is used and is then processed to produced dried mango, puree, candies,
2
and juice concentrates as its end products leaving 50% by-products or wastes such as
mango seeds and peels. Around 40%, by average, is the percent waste accumulated by
According to Istiana et.al (2017), using Luff Schoorl testing method, Mangifera
Indica L. species of mango seeds has a glucose content of 15.29% which can be therefore
be used to produce a bioethanol through converting the glucose content into alcohol using
the fermentation process and distillation process for purification. Mango seeds are
normally dried and is used as fuel for the reboiler. However, due to large amounts of
mango being processed every day, generation of mango seeds and its storage is becoming
a problem for the processing plants. As a raw material being this abundant, as well as the
need of its proper disposal and high market gap of bioethanol in the country, mango seed
Bioethanol, on the other hand, is a fuel that contains energy from geologically
recent carbon fixation, produced from living organisms, such as plants and algae. Fuels
are made by biomass conversion. The biomass can be converted into liquid fuel. Biofuels
have increased in popularity because of rising oil prices and the need for energy security
(Jacques et.al, 2015). Bioethanol is also used as an additive for gasoline because of its
property that oxygenates the fuel mixture so that it burns completely and can therefore
reduce greenhouse gases emission. Greenhouse gases are the one to blame for the rapid
alternative source of energy aside from the use of fossil fuels. At present time, the most
common blend is 90% gasoline and 10% ethanol which the blend is called E10 (Pirolini,
3
2015) but the Department of Energy wants to pursue the E20 or 20% ethanol blend in
gasoline by the year 2020 (USDA, 2017). The only thing that hinders the E20 blend is the
lack of renewable sources of raw material and lack of bioethanol plant operating in the
country.
Therefore, this driven the researchers to come up with a plant design for the
production of bioethanol using mango seeds. The name of the plant will be MaKernel
The main objective of this study is to come up with a plant design for the
1. To generate a process that will be able to produce bioethanol from mango seeds
2. Conduct a market study which includes the evaluation of the local market
production of bioethanol
4
3. Select a plant location that provides proximity to the source of raw material,
4. To provide the necessary design of all the equipment needed for the production of
bioethanol and the treatment of the waste produced based on the material balances
attained.
5. Prepare financial statements for the first five years of operation of the plant
The study of the production of bioethanol using mango seeds kernel as the raw
material is objectively chosen based on market, technical, financial and social aspects of
business. Mango seeds waste will be the main raw material that will be used in this plant
design which will be supplied by the mango processing industries in Cebu. The proposed
plant will be located near to the source of raw material and water. All designs made are
purely theoretical and are based for the ideal operation of the plant. The proposed
duration of the construction of the plant will be roughly around two years and a financial
study covering the first five years of the plant operation will be provided. Estimates for
the costs of goods, equipment, buildings, facilities, labor and services were taken from
The study of the Production of Bioethanol from Mango Seeds Kernel will be of
Biofuel Industry.
mango seeds kernel will be of great benefit to the biofuel industry in the Philippines
especially now that the target ethanol blend for gasoline is E20. As the demand of the
Environment.
and accumulation of toxic pollutants and compound in the atmosphere increases which
are harmful to the environment. Therefore, the use of bioethanol mixed in the gasoline is
helpful to the environment because it reduces greenhouse gases, it is carbon neutral and it
can be easily diluted to non-toxic concentrations or can be easily degraded in case of fuel
based fuels.
Community.
From the construction up to the operation of the plant, many will be given
jobs which results to the increase in employment rate of the people in the community that
would somehow help them in providing their needs. Increase in the economic growth of
the city is also one of the great opportunities that the community can benefit for the
problem of storage and contributes to the pollution in the processing plants due to its
6
material for the production of bioethanol can help reduce the problem of the dried mango
Chapter 1
Market Study
Product Description
contain a hydroxyl group, –OH, bonded to a carbon atom. Ethanol is a natural byproduct
of plant fermentation. Since ethanol is produced from plants that harness the power of the
On the other hand, Bioethanol is a good source of renewable fuel. Its expanding
use is helping to reduce harmful pollutants in our air. Bioethanol is produced through
processing biological matter, either waste products or crops grown specifically for the
purpose of creating Ethanol. In Philippines, gasoline and petroleum diesel is blended with
10% v/v bioethanol and used in motor vehicles to improve vehicle emissions and power.
The raw material used to produce bioethanol product is Mango seed kernel which
considered waste by the Mango processing industries. The mango seeds were known to
contain sugar make it a potential feedstock for bioethanol production and this will be
bioethanol.
Product Demand
Within the span of seven years, local bioethanol supply increased approximately
12 times, ranging from 23 million liters (ML) in 2009 to 274 ML in 2017, resulting to the
With the expected entry of three more bioethanol distilleries by 2018 with a combined
capacity of 149M L, local bioethanol supply can cover about 72% of the current
utilization rate of 100%. However, increase in the bioethanol blending to E20 by 2020
projected 860M L in 2020 using E20. Assuming a 100% local bioethanol distillery
utilization rate, the realistic local bioethanol capacity in 2020 is only about 386M L, or
The following table shows the ethanol blend targets and implementation dates
since inception. As an aspirational goal, the DOE wants to make available an 85 percent
Table 1
2009 5
2011 10
2015 10
2020 20
2025 20/85*
Product Supply
Table 2 shows the ten accredited bioethanol producers here in the Philippines
while Table 3 shows the additional bioethanol plant constructed for the sole purpose of
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decreasing the importation of bioethanol and utilizing the feedstock available in the
country.
Table 2.
Capacity (Million
liters/ year)
Incorporated
Corp.
Corporation Oriental
10
Inc.
Inc.
Total 282.12
Table 3.
Capacity (Million
liters/ year)
Producers, Inc.
Corp.
Total 149
Based from Table 2 and Table 3, as given by the Department of Energy, there are
gradually increases every year but is still short of the annual demand of 174.12 million
liters. Insufficient feedstock availability and high domestic ethanol price are the two main
challenges identified to bridge the bioethanol supply gap and accelerate local bioethanol
investment. At present time, Philippines uses only molasses and sugarcane for bioethanol
production. However, available molasses in the country cannot cater the demand for an
E20 blend. Additionally, sugarcane is used in the production for bioethanol and as well as
for the production of sugar which is a common necessity in the country. Higher price of
local ethanol than gasoline is also a factor that threatens the stability of the Philippines
The Philippines was the first country in Southeast Asia to enact biofuels
legislation. The blend mandate was gradually increased in accordance with the Biofuels
Act of 2007, ending with a 10 percent ethanol requirement in August 2011, which
remains the current mandate. However, meeting this target with domestically produced
ethanol has been a challenge due to the inadequate capacity of existing sugarcane
distilleries, low productivity and high production costs (Foreign Agricultural Service,
2016).
demand in the Philippines for the next several years even though domestic production
capacity is catching up. Fuel use is predicted to increase as the population and economy
population and continued expansion of the Philippine economy, all translate to increased
12
fuel consumption in the next 3 - 5 years. According to GAIN report, as of year 2018 the
fuel consumption is 605 ML which is composed of the fuel production and fuel imports
of 280 ML and 325 ML, respectively. The present distilleries can supply 431.12 ML of
The plant will produce 17.4 ML of bioethanol per year contributing to about 10%
of the market gap. It will therefore cut down the market gap to about 156.49 ML in the
year 2019. Moreover, the capacity is based on the growing demand and consumption and
Price Study
for 2nd half of the crop year 2017 – 2018 is at Php 50 per Liter however on July 2018 the
reference price increase to Php 58.08 compared to Php 42.42 per liter. Prices are seen
moving when the 4th quarter comes because of the start of milling season where molasses
Mango seeds has an average market value of Php 725 per ton and it is available
all year round. Compared to the molasses that is Php 8,216 per ton. Using the mango seed
as a feedstock for bioethanol productions will help the energy sector in finding a new
Marketing Program
The marketing program for bioethanol from mango seed wastes will be as focused
on the following:
5. Focus for local Filipino distributors as key target for the market; and
Chapter 2
Technical Study
Raw Material
900 thousand metric tons of mango produced annually in the country. This is due to the
country’s location which fits the conditions needed to grow a mango bearing tree.
According to Philippine Statistics Authority in the year 2018, the country still has an
existing production area of 185,194 hectares with 9,460,132 number of bearing trees.
Base on export volume and value, mango industry is one of the aid for Philippines
industry economic standing. Peak season for harvesting mangoes is between April to
June, however, Central Visayas and Mindanao produce mango fruits during off season to
According to K&R United (2016), production of mango fruit in the country is all
year round compared to other countries such as Indonesia, USA, Malaysia and Thailand
which harvest time for mango are only around 2 months, 4 months, 4 months and 8
Around 90% of the total production of mango in the country is used for local
consumption while the remaining 10% are the only ones exported. Processed mango
products such as dried mangoes, purees, or concentrated juices takes the 41% of the
mango supply left for local consumption (AgriBusiness, 2016). There are several mango
accumulation of mango wastes that is not utilized well and ended up being a pollution.
15
From this mango consumption, the part of the fruit which always becomes waste
and is discarded are its seed. Since mango seed is a large industrial waste available due to
expanding mango processing plants, and lack of bioethanol supply in the country, a
research about the possibility of converting the mango seeds kernel as a renewable source
the total weight is the weight of the mango seed in the entire fruit and around 60% of the
total weight of the mango seed is composed of the kernel (Archimede et.al, 2015).
soluble sugars. Additionally, Table 1 shows the chemical composition of mango seed
kernel (MSK) using the values taken from the research study of Chime et.al, (2017).
These includes the cellulose, hemicellulose, and lignin content which can be further
Table 4.
Ash 3.88
Lignin 15.0
Hemicelluloses 34.06
Cellulose 25.2
Using all the data gathered, this proves that utilizing the mango seed waste
is the best suitable raw material to be used in the process to produce bioethanol.
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Manufacturing Process
Schematic Diagram.
Mango
Seeds
Breaking
Rolls
Water Drying
Acid-sugar-solution
Distillation Slops
Dehydration Ethanol
Process Involved.
Mango seeds will be collected from wastes produced from various mango
processing plants which are located in Cebu and other places in the Philippines.
Breaking Rolls.
Mango seed contains, by average, around 60% kernel and the remaining
40% for the outer shell. The material needed for the process is the kernel so the mango
seeds undergo the crusher to free the kernel inside of the mango seeds.
Sieving.
Since the outer shell and the MSK are mixed, a sieving machine which is
used to separate the two. The outer shell is then used for the boiler while the MSK
Drying.
The MSK which contains 44.4% moisture will be dried to achieve a 12%
moisture. Co-current rotary drier will be used to the process for the purpose of reducing
Milling.
After the MSK have been dried, it further undergoes milling to reduce its
Acid Hydrolysis.
convert the lignocellulosic materials into fermentable sugars. Arkenol process will be
hemicelluloses,15% lignin, 15.29% soluble sugar and the remaining is made up of solids,
will be subjected to a dilute sulfuric acid pre-treatment for 20 minutes for the purpose of
achieving high reaction rates and improving the hydrolysis of cellulose. Sulfuric acid
(70% v/v) with a ratio of 1 g biomass per 1.25 g of acid will be used for the breaking
down of complex structures such as cellulose, hemicellulose and lignin which is then
converted into fermentable sugars. The working temperature will be 50oC. A mass of
17,231 kg per hour of sulphuric acid will be used. According to Arkenol Technology, the
acid hydrolysis process converts 90% of cellulose, hemicellulose and lignin into
fermentable sugars.
For the 2nd stage of acid hydrolysis, biomass produced from the previous
hydrolysis process will react with 30% sulphuric acid with a ratio similar to that in the 1st
stage acid hydrolysis. With a working temperature of 100oC, the mixture will be
thoroughly mixed with a retention time of 30 minutes per batch. A biomass having a flow
rate of 4,702 kg per hour will be used. The acid-sugar solution will be further processed
Electrodialysis.
stages of acid hydrolysis enters the electrodialysis tank, where an assumption is made that
95% of the H2SO4 will be recovered and will be returned back to the two-stage acid
hydrolysis while the remaining sugar solution with 5% remaining H2SO4 will be
19
Neutralization.
neutralized with Ca(OH)2 to the pH conditions (4.4-4.6) which is the best suitable pH
solution for fermentation. Sulfuric acid neutralized using Ca(OH)2 produces a byproduct
which is gypsum. Gypsum is then allowed to settle down in the neutralization tank which
is then further filtered. Gypsum can be sold which can be an additional profit for the
company.
Ethanol Fermentation.
The obtained sugar solution with a brix of 19, which is ideal for
bioethanol by using yeast, or the Saccharomyces cerevisiae. The sugar solution will be
further supplemented with other nutritional components of fermentation such as urea and
DAP which are needed by the yeasts to achieve higher activity rate from the yeasts. The
pH will then be maintained within the range of 4.0-4.2. This process will start by feeding
a small amount of fermentable sugar solution in the culture vessel containing yeasts for
propagation (Piriya et.al,2012). There will be three culture vessels for the growth of
yeasts cells, which will then be transferred in the three pre-fermenter tank for its
propagation and growth. Fermentation will occur by fed-batch method. The fermentable
Filter.
The beer produced from the fermentation process will undergo filtering to
remove the residue which are the yeast, DAP, urea and solids that were not filtered.
Distillation.
The clarified beer which contains 6.64% (v/v) enters the distillation and is
then heated up to 78.5oC which is its operating temperature which is determined using the
low boiling components are concentrated in the vapour phase, and the vapour is then
ethanol production, and efficient distillation tower is used to separate the water and
ethanol. Water, having the high boiling point stays in the bottom while the ethanol is
obtained from the top of the tower (Onuki, 2008). A good distillation obtains 95% (v/v)
Dehydration.
An extra process is required before the final blending of the pure ethanol
with gasoline because the required purity of ethanol to be used for blend with the fuel is
99.99%. Since distillation only achieved 95% purity, the distillate will undergo further
separation of water and ethanol with the use of molecular sieve dehydrator. In ensuring
the level of dryness in final ethanol product but not compromising the energy
consumption of the plant, zeolite has been proven to be ideal. The dehydration process
will be using Zeolite 3A as the adsorbent of the Pressure Swing Adsorption process.
21
manufacturing plant, are considered as source of the raw material with the basis of 50
tons per day per manufacturing plant, of waste generated during off season and is
expected to increase during peak season (Profood Corp., 2016). As of present time, a total
of 46 manufacturing plants for the production of dried mango and mango juices exists in
the country.
The desired production per year is the 10% of the present market gap of
the bioethanol industry here in the Philippines for the year 2018 which is 17.4 Million
Profood, which is one of the main exporter of processed mango, with an operating
capacity of 1140 metric tons of mango per day (Galolo, 2017) along with nine more
day to provide the required 58,000 L of ethanol have a small discrepancy due to other
processes added and the loss per process undergone by the raw material compared to the
study of Cristina et al. which causes some variations in the yield of the bioethanol.
Figure 2 shows the mass flow rate diagram of the entire operation. It is the
material balance in every process which indicates the mass of the material that goes in
operation involved in a bioethanol plant. Figure 3 shows the block flow diagram of the
each processes the raw material undergoes before it produce the main product, the
bioethanol.
Figure 4 shows the production flow diagram which shows the equipment
Acid
Outer
Water
Shell
2nd Stage
Acid Acid
Hydrolysis
Yeast,
DAP, Urea Ca(OH)2
Undissolve Gypsum
CO2
d yeast and
suspended
solids
95%
Alcohol
Distillation Dehydration At least 99.99%
Beer alcohol
Biodigester
Slops
Figure 3. Block Flow Diagram
25
Two-thirds of the energy fueling the process is wasted as unused heat after high pressure,
high temperature steam does its work. When the typical efficiency of electrical
generation is added to the typical efficiency of a boiler system providing process heat to
an ethanol plant, the combined efficiency is roughly 49 percent. Bringing the power
generation to the ethanol plant and making use of the electrical generation's waste heat in
a combined heat and power (CHP) system, boosts that efficiency to 75 percent.
Increasing the efficiency of power and steam generation, in turn, reduces carbon
emissions (Schill, 2009). Instead of separately purchasing electricity from the local grid
and a gas boiler for onsite heating, the plant will use power co-generation technology for
methane, which are recovered from the process, will be used in the co-generation plant as
boiler fuel. Through conveying system that connects biomass shed and biomass-fired
boiler, the biomass will be fed to the furnace. Demineralized water from water treatment
plant will be used in the boiler to avoid scaling in the boiler and pipes. This water will be
converted to steam through heating in the furnace. The steam from the boiler will pass
through super heaters, to be heated above its saturation temperature, which will convert it
from saturated steam or wet steam to superheated steam or dry steam (Vallourec, 2017).
And then transformation of thermal energy to mechanical energy takes place where the
high-pressured steam will pass through a series of rotor blades of the non-condensing
turbine (Thermal Engineering, 2011). The turbine will be connected to a generator where
27
mechanical energy will be converted to electrical energy that will supply power to the
entire bioethanol plant. The steam from the turbine will then be used for the production of
The exhaust stream from the production will be liquefy in a condenser and
will be cooled down through the cooling tower. The cooled water will undergo recovery
in the water treatment plant and will supply the demineralized water that will recirculate
in the power plant. Before heating in the economizer and feeding it to the boiler, the
demineralized water will be introduced in the deaerator. The deaerator has significant
importance in remove the trapped air in the water molecules which can affect the boiler
The flue gas coming from the boiler can be further utilized through the use
of economizer, part of the heat will be extracted to heat the feed water to the boiler. The
rest of the flue gas will be introduced in the gas scrubber before releasing it to the
atmosphere. The use of economizer reduces the fuel consumption thus, increasing the
boiler efficiency (Sethi, 2016). Figure 5 shows the Power Plant Diagram of the
bioethanol plant.
28
The process will be carried out in anaerobic digester. The slops will then
be fed into the reactor where anaerobic bacterial culture will be maintained in suspension.
Inlet temperature of the slops will be assumed to be at 40oC. According to Metcalf and
Eddy (1991), an average period of 10 days as a residence time for anaerobic digestion at
40oC is the recommended time for the slops to be retained in the reactor. Produced gas
such as methane gas and carbon dioxide gas due to the decomposition of organic matter
present in the wastewater are then fed into the degasser for the separation of two gases.
Methane gas will then be fired to the boiler meanwhile the carbon dioxide will be
produced will be stored to sell it out for usage in carbonated drinks. The remaining
wastewater after the anaerobic digestion process will flow to the clarifier for further
treatment before it will be completely disposed to the lagoon. Important parameters such
as BOD, COD and pH of the wastewater will be monitored and reduced in order to meet
the effluent standards set by the DENR. Figure 6 shows the waste water treatment plant
Utilizing the ground water sources the location site provides, the
bioethanol plant will provide its own water supply through deep well injection. The
groundwater will be extracted from the source using pumps and the raw water tank will
store the water pumped from the deep well. For the primary treatment, a sedimentation
process will be done that will cause the suspended solids to form slurry which will then
be moved to the center of the tank which is then collected in a trough (Fein and Kaplan,
2014). Therefore, the raw water from the tank will be fed to the clarifier to remove any
suspended solids. The clarified water tank will store the collected overflow from the
clarifier.
The clarified water will then pass through the Activated Carbon Filter tank
where through using activated carbon, organic matter from the feed water will be
For the softening of water, or the removal of iron and manganese, the
water will pass through the ion exchange unit. This involves a chemical process where
water is filtered through an exchange media such as NaCl. As the water flows through the
unit, the resin releases its sodium ions and trades them for calcium and magnesium ions
osmosis, the softened water will travel through semi-permeable membrane using
pressurized pumps to filter out minerals and other contaminants. The water that will be
collected after the process will be the demineralized water. The demineralized water will
32
go into the cooling tower to be fed to condenser and boiler. The rest of the demineralized
The processed water tank will store the water from the activated carbon
filter which will be used for the heat exchanger, fermentation and utilities.
The softened water tank will store the water from the softening unit which
For the water supply needed in the power plant, the demineralized water
from the reverse osmosis process will be used which is then further stored in a
Using the cooling water, the used water from the distillation process and
power plant will be cooled down and recover it again in the water treatment plant for
further use.
33
Production Schedule
The plant will be designed to operate 24 hours a day, 7 days a week. A total of
300 days a year will the plant be operating while allocating the remaining 65 days for
facilities are done during maintenance. For the production and engineering department,
the daily 24 hour work schedule will be divided into 3 shifts (8 AM-4 PM, 4PM-12 AM,
12 AM-8 AM) where in each shift, there will be at least 2 on duty operators on each
division and 1 supervisor. The initiation of shifts will start after steady-state condition of
the plant is reached which is expected 2 months after the start-up of the plant. For the
administrative department, they will have 8 hours (8 AM-5 PM) of duty per day with 1
hour of lunch period from 12 NOON to 1 PM, 6 days a week. The employees will
continue on working on regular days, non-working holidays and will be entitled to leaves.
Incentives will be provided for those who will work on holidays, both for all the
departments.
The plant has the capacity to process 38,685 kg of mango seeds per hour to
produce 1,882 kg of bioethanol per hour. The maximum annual bioethanol production of
the plant is 17.4 million liter which can help in boosting the country’s bioethanol supply
and can cater the country’s increasing demand for bioethanol. Table 2.3.1 and 2.3.4
Table 5.
Table 6.
Dimensions:
Length: 2670 mm
Width: 3740 mm
Height: 1990 mm
Dimensions:
Length: 4.5 m
Width: 3.4 m
Height: 2.4 m
37
Function: To reduce the seed moisture content from 44.4% to 12% moisture to
Dimensions:
Length: 25.5 m
Diameter: 2.88 m
Dimensions:
Length: 2.4384 m
Width: 1.524 m
Height: 2.5908 m
38
Hydrolysis.
No. of Units: 1
Operation: Batch
Dimension:
Diameter: 2.585 m
Height: 3.8775 m
No. of Impellers: 2
No. of Units: 1
Operation: Batch
Dimension:
Diameter: 1.8 m
Height: 2.7 m
No. of Impellers: 2
Function: Provision for recovery of sulphuric acid from the two-stage hydrolysis
process.
Dimensions:
No. of Units: 5
Operation: Batch
Dimension:
Diameter: 7.83 m
Height: 15.66 m
No. of Impellers: 2
Length of Blade:0.6525 m
Pre-fermenter.
Function: For the preparation of yeast before it enters the main fermenter
No. of Units: 3
Dimension:
Diameter: 3.64 m
Height: 7.28 m
No. of Impellers: 2
Culture Vessel.
No. of Units: 1
No. of Units: 1
H= 2(1.69) = 3.38 m
Function: To separate the dead yeasts cells and suspended solids present in the
fermented solution.
No. of Units: 1
Bowl Volume: 66 L
Sludge Space: 17 L
Neutralization.
No of Units: 1
Dimension:
44
Operating Temperature: 30 oC
No. of spirals: 15
Pitch: 0.5938 m
Distillation.
Capacity:
45
No. of Units: 1
Condenser.
No. of units: 1
Dimensions:
Area: 128.55 m2
Length of tubes: 8m
Diameter of tubes:
7
Outside diameter: 8 𝑖𝑛 =22.23mm
Reboiler.
Function: To generate vapors in the bottoms which are returned to the column.
No. of Units: 1
Dimensions:
Area: 21.56 m2
Number of U tubes: 46
Outside Diameter: 50 mm
Inside diameter 45 mm
Freeboard: 0.14 m
distillate
No. of Units: 1
Height of Vessel: 3 m
Diameter of Vessel: 1 m
Pore Size: 3Ǻ
Storage Tanks.
No. of units: 2
Function: Serves as a container for the 99.99% ethanol from the molecular sieve
dehydration section for the whole day production. The product will be
Number of units: 3
Function: To store the hydrolysate produced from the acid hydrolysis process
Volume: 118.36 m3
Diameter: 4.49 m
Height: 7.48 m
Function: To store the 70% blend of sulphuric acid which will be used in the 1st
stage hydrolysis
Number of units: 1
Capacity: 477.035 m3
Function: To store the 30% blend of sulphuric acid which will be used in the 2nd
stage hydrolysis
Number of units: 1
Capacity: 162.71 m3
Number of Units: 1
Capacity: 363.6 m3
Anaerobic Digester.
organic materials into methane (CH4) and carbon dioxide. This is accomplished in
50
the absence of oxygen therefore the anaerobic digester tank is capped to prevent
oxygen from coming in and to capture the methane and carbon dioxide produced.
The produced methane will be fed in the boiler for fuel consumption while the
Number of Units: 3
Capacity: 390 m3
No. of Impellers: 2
Function: To store the groundwater from the source that will be used in the process
Number of units: 1
Function: To stock the demineralized water after the reverse osmosis process
Number of units:1
Capacity: 95m3
Clarifier.
Operating Conditions
Turbidity<25 NTU
Basis: 1 hour
Diameter: 4 m
Number of units: 2
52
Efficiency: 95%
Degasser.
Number of units: 2
Number of channels: 4
Lagoon.
Function: Receive, hold and treat wastewater for a period of time before disposal.
Number of Units: 3
Dimensions: 30 x 20 x 5 m
53
Cooling Tower.
Function: To cool the water from the condenser and boiler and return it back to
the process.
Number of Units: 1
Length: 18 m
Height: 9 m
Width: 6 m
Motor output: 1 kW
Reverse Osmosis.
Thickness of membrane: 1 mm
Operating Conditions
54
Turbidity< 5 NTU
Diameter = 4 m
Softening Unit.
Operating Conditions
Diameter = 5 m
Power Plant.
Turbine.
Function: Produces Mechanical Energy using steam produced from the boiler
Number of Units:
Power Generation
55
Operating Parameters:
𝑘𝑔
Steam Requirement: 29,376.06 ℎ𝑟
Boiler.
Number of units: 1
𝑘𝑔
Fuel Steam Capacity:29,376.06 ℎ𝑟
𝑘𝑔
Amount of fuel: 36,969.77 ℎ𝑟
56
Plant Location
The plant will be located in Brgy. Carmen, Toledo City, Cebu. The land that will
be bought will be 200219.38 square meters of land area. The plant area will occupy 75%
of land that which will include the administrative building, production facilities,
laboratory, wastewater treatment facility, water treatment facility, storage facilities and
other facilities essential for operation. While the remaining 25% of the land around will
The plant is enclosed by four points which is specifically located at the following
points:
Latitude: Longitude:
The main raw material for the proposed plant is mango seed. There are
three leading mango processing industry: Profood, M’Lhuillier Food Products, and FPD
Food International that generate tons of mango seed waste from their manufacturing of
dried mangoes and other products that operates on Cebu city, the supply of raw materials
to expand. This means that the proposed bioethanol plant will supply the local market
specifically the Central Visayas area. The plant is one and seventeen hours away to the
Cebu international port and less than one hour away to the Toledo port in which the
Water Supply.
The plant will have its own water supply through deep well injection that
Power Supply.
The plant will generate its own electricity by steam powered turbine. The
boiler will use a combination of methane gas, which is generated by the plant through
anaerobic digestion and biomass as fuels. In case of emergency situations, the plant will
Community.
accessible to hospitals, church, shopping districts and basic needs. The company will give
priority to workers from the community to work inside the plant. The workers will have
Plant Layout
Figure 8 shows the plant layout of the proposed plant. The plant was arranged and
designed with high regard to the efficiency of the production and overall safety of the
personnel. The production will start near the receiving area of the plant where raw
materials are received and prepared for milling. The center of the plant will be designated
as the main area operation where fermentation and distillation facilities and control room
will be located. The supporting facilities such as the warehouse will be located on the
right side of the plant, the water treatment house will be near the power plant station and
the laboratory will be located near the control room. The fire house and clinic will be
situated near the production are in case of accidents or emergencies. The administration
building will be located near the entrance making it accessible for visitors. The
wastewater treatment plant will be situated on the lower right side of the plant.
Scheduling of deliveries for raw material and other materials needed for
Administrative Building.
This will be the office for the Plant Manager, Human Resource Staffs and
Finance Personnel of the plant. The building will be located near the canteen for an easy
access of the employees of the plant. Per OSH requirements, each floor should be at least
2.7 meters from floor to ceiling with maximum number of persons employed in a
workroom area shall not exceed one person per 11.5 cubic meters. This is to avoid
environment for the workers. Exposed sides of a Stairway floor opening should be
It will be found near the administrative building. It will also near the
distillery plant since it will be commonly used in this area and also in case of a power
shut down, personnel in the distillery plant can have and easy access to the power
generator operators to minimize production loss. Control room for this equipment will be
found near the area. Where mechanical handling equipment is used, safe clearance is
required to avoid contact of the worker to the rotating equipment. Power boiler should be
equipped by at least one safety valve if the heating surface is 500 square feet and two
safety valves for more than 500 square feet. Suitable manholes or other openings for
frequent inspection, examination and cleaning should not be less than 70 mm x 90 mm.
Canteen.
The area for the employees to have their lunch breaks and snacks. It will
be located besides the administrative building for an easy access to the employees. Under
62
the Occupational Health and Safety Act of 2004, employers are required to provide
hygienic facilities for preparing and eating meals while at work. It is a must that the
canteen and even the one’s preparing the foods are checked from time to time to avoid
contamination of foods which may result to large number of employees being sick.
Clinic.
The clinic shall have a licensed nurse and a physician throughout the plant
operation. The office will be equipped with the first aid kits, oxygen tanks, transport
materials, beds and other equipment that would be beneficial in case of emergency. It will
be found inside the control room. An addition of personal ambulance to transport patients
which cannot be healed by mainly first aid kits is also used as a safety precaution.
Distillation Plant.
dehydrator and heat exchangers will be found in this region. It will be located near the
fermentation plant for an easy access transport of material that will be distilled. Interlocks
all over the distillation area are provided so that when the sensors read differently from
the required values, it will automatically inform the DCS or at worst case scenario, shut
Fermentation Plant.
The area will be located near the distillation plant. Mango seeds kernel
powder storage tank, vats, and heat exchangers are found in this area. The control room
for this area is the one used in the distillery plant since both process are co-located to
each other. Plenty of safety signs are also required for each tanks defining the hazards it
may present.
63
Parking Lot.
The parking lot must have a standby ambulance and fire trucks for
emergency purposes. This area will be located on the upper side of the plant.
A building set for scientific research where all the tests for quality analysis
of raw materials and product, chemicals used and other materials that need quality
assurance. This will be located between near the control room. The laboratory will have
its own ventilation and exhaust equipment to provide continual inflow of fresh air to keep
the concentration of contaminants within safe limits. Hazardous processes shall also be
carried out in a separate rooms, and shall be carried out in an air-tight enclosure to
prevent personal contact with harmful substances and the escape of dusts, fibers, fumes
gases and mists into the air on the room which the person works. Labelled containers and
organization also play a big role to avoid confusion of chemicals in the quality control
laboratory. Personal disposal facility for laboratories are provided since disposed
Storage Room.
Final product will be stored in this area using vats. The storage room will
be located near the distillation plant for an easy transport. The tanks should be supported
so that leakage from any part of the tank will be noticeable. An addition of bund walls to
hold overflows during maximum operations. Tanks used for storing corrosive or caustic
liquids should have a permanent open wet pipe not less than 5 cm, in diameter at highest
point of the tank and a drain connection at the lowest point in the tank discharging in a
Warehouse.
The warehouse will be located near the ancillary process of the plant for
an easy transfer of materials that will be bought by the company and for an easy checking
of inventories. Roadways for automobiles, trucks and other vehicles shall be constructed
water storage, raw water storage, and aeration tanks. It will be situated near the disposal
area of the treated water. Interlocks all over the effluent area are used to avoid disposal of
below standard values wastewater effluent which may be toxic to the environment.
Values for BOD, COD, pH and temperature are monitored to ensure that the effluent
Raw Material.
new phenomenon that is experiencing rapid growth. Over the past ten years, trade in
mango products has tripled; in 2005 the total exports were just US$ 696 million, while in
2015 it had increased to almost US$ 2.1 million. Mango products include fresh mango
and processed ones such as dried, frozen, puree and juice. The mango export market is
quite concentrated and dominated by developing countries located in the Tropics. The
Philippine holds a relatively significant position in the mango GVC (Global Value
Chain), and in 2015, the country ranked seventh amongst exporters of fresh and dried
65
mango, with US$ 91 million in exports and a 4% share of the global market
(UNComtrade, 2016).
For the third quarter of 2018, mango production was 4.3 percent higher
compared to the production in the same period of previous year, from 55.44 thousand MT
to 57.85 thousand MT. Central Visayas, with 19.10 thousand MT share, was the highest
producer of mango during the period, sharing 33.0 percent to national production.
Northern Mindanao ranked next with 20.1 percent share and third was Caraga with 12.0
percent share. Carabao variety reached 46.46 thousand MT during the period,
2018).
Waste Disposal
methane (CH4) gas to be used as an additional fuel and the liquid that is left behind will
Sludge.
It is advisable to dewater the sludge. The same with the slops it will also
by the farmers
Biomass.
Biomass from the 2nd stage acid hydrolysis will be collected. It will not
undergo anymore anaerobic digester but will be given together with the slops to the
farmers.
Flue gases are the by-products of the combustion of the biomass and
methane gas in the boiler. These air pollutants should be treat first before discharging
because of its great threats to the environment. To remove harmful particles and gases
Labor Requirement
The plant requires a range of labor in order to function efficiently. The following
are the labor needed to ensure the quality and quantity of product produced. All the cited
labors, except for the administrative section, are required to use or be in their Personal
Protective Equipment before going out into the field. Some PPE’s needed are the hard
hats for any debris that may fall, goggles for eye protection against particulate matters,
something that may cause wounds, and respirators, to avoid inhaling particulate matter
Chemical Engineers.
and supervising the processes involved in the production to ensure efficient manufacture
Civil Engineers.
Civil engineers are responsible in constructing the plant and its facilities.
They plan, design and oversee construction and maintenance of building structures and
infrastructure.
Electrical Engineers.
Mechanical Engineers.
equipment of the plant. They plan and design tools, engines, machines, and other
Environmental Engineers.
produced in the plant to ensure that the standards set by the Department of Environmental
and Natural Resources will be met. They are involved in efforts to improve recycling,
waste disposal, public health, and water and air pollution control.
68
Plant Manager.
plant. He is responsible in managing the workforce in the plant. They will oversee all
daily operations of the plant from production and manufacturing to ensuring policies and
procedures are followed. They develop processes that will maximize stewardship, safety,
Plant Operators.
Plant operators are responsible in manning all the equipment in the plant.
They monitor reactors, turbines, generators, and cooling systems, adjusting controls as
necessary. Operators also start and stop equipment and record the data.
Office Personnel.
Office personnel are responsible for the inspection of products for quality
Maintenance Personnel.
Organizational Structure
Figure 9 shows the organizational chart which summarizes the hierarchy of the
company
69
Owner
(Corporation)
General
Manager
(1)
Plant Administrative
Manager (1) Head (1)
Physician (1)
Safety Quality Production Maintenance Power Plant
Officer (1) Control Supervisor Staff (6) Supervisor
Human Sales and
Officer (1) (3) (3) Accounting Logistics
Resource Marketing Staff (4)
Nurse (3) Staff (3)
Staff (2)
Staff (2)
Quality Production Power Plant
Control Operators Operators
Analyst (6) (27) (6) Security
Guards
(12)
Samplers Helpers
(6) (14)
Chapter 3
Financial Study
Increase of bioethanol production is one of the most important issue that the
uses E10 as its fuels drive the demand of the bioethanol the highest in the past years.
Department of Energy also has set to implement the E20 or the 20% ethanol blend of
fuels used by the year 2020. For this purpose, Biofuels Act of 2006 was made to cater the
tool which is the financial study analysis. This consists of the evaluation of the financial
condition and operating performance of the investment as well as forecasting its future
condition and performance. Expected return and expected risk are the two specific factors
in order to come up with the financial decision, which financial feasibility analysis can be
of used to examine those two factors (Fabozzi and Peterson, 2003). This chapter will
The total capital investment for the implementation of MaKernel Bioethanol Plant
Table 7.
Fixed Capital Investment = Total Direct Cost + Total Indirect Cost + Office and
Transportation Equipment
Financing Scheme
To finance the proposed project and operation of the plant, the researchers will
borrow 40% of the total project cost needed from the land bank of the Philippines
years. The purchased land title along with the buildings and equipment, will be the
72
collateral for the loan. The remaining amount of 488011350.3 will come from the
shareholder’s venture.
Major Assumptions
4. Company will have a land of 20 hectares. The cost of land will 120 per square
meter.
5. Construction period will be (2) years and production starts on the third year.
price
10. Engineering Costs, which includes home office cost or contractor charges,
engineering services required to carry out the project, will be 20% of the purchase
equipment cost.
21. Product sales will increase 4% annually for first five years
23. Sales for CO2 shall remain constant at Php 6,000,000 per month, regardless of
25. Money loaned from the bank is 40% of the total project cost.
26. Bank Loans Payable Php 381,773,086.68 paid at the end of the 3rd year or 1st year
27. Interest in the loan during Pre-operational Phase will be paid immediately in those
years.
28. An increase of 3% annually of the initial salary in the employees’ salary for the
30. The contribution table for PhilHealth is based on the PhilHealth. Premium
Contribution Table.
31. The contribution table for SSS is based on the SSS 2018 schedule of contribution.
32. Employee’s Healthcare is Php 8,000/employee per year and will remain the same
33. Accident Insurance of employee is Php 250 per employees per year and will
36. Depreciation starts at the first year of operation. Salvage value is 10% of the fixed
cost.
39. Sales are paid 95% cash upon delivery and the 5% is paid the following year
supply, and equipment and machineries and services facilities are 30, 10, 15 and
10 years respectively.
42. Purchase of indirect materials is paid 70% cash upon purchased and the remaining
43. Advertising and marketing are Php 500,000.00 in the first year of operations and
will decrease 5% every year for the next four years of operations.
45. The surplus cash shall be invested in money market and with an option to pay off
loans.
Financial Statements
provides information about the company’s financial activities and performance that are
The financial statements are made of Income Statement, Cash Flow and the
Balance Sheet. These statements are made from year 2021 – 2025 and are based on the
Table 8.
Income Statement
Operation
1st Year 2nd Year 3rd Year 4th Year 5th Year
Table 9.
Balance Sheet (Assets)
Pre – Operational Operational
Year 1 Year 2 1st Year 2nd Year 3rd Year 4th Year 5th Year
Current Assets
50,090,862.1 354,640,151.5 881,709,648.9 1,172,193,729.7 1,470,601,605.6
Cash 431,721,556.28 614,791,333.46
2 7 0 6 6
Accounts
- - 40,291,125.00 41,902,770.00 43,578,880.80 45,322,036.03 47,134,917.47
Receivable
50,090,862.1 394,931,276.5 925,288,529.7 1,217,515,765.7 1,517,736,523.1
Current Assets 431,721,556.28 656,694,103.46
2 7 0 9 3
Non – Current Assets
Property, Plant and Equipment (Schedule 13)
Land 24,026,325.60 24,026,325.60 24,026,325.60 24,026,325.60 24,026,325.60 24,026,325.60 24,026,325.60
Buildings,
Structures and
141,724,970.07 141,724,970.07 141,724,970.07 141,724,970.07 141,724,970.07 141,724,970.07 141,724,970.07
Land
Improvement
Office and
Transportation 4,842,036.00 4,842,036.00 4,842,036.00 4,842,036.00 4,842,036.00 4,842,036.00 4,842,036.00
Equipment
Total Cost of
Factory
541,131,703.89 541,131,703.89 541,131,703.89 541,131,703.89 541,131,703.89 541,131,703.89 541,131,703.89
Equipment &
Machineries
Service
51,536,352.75 51,536,352.75 51,536,352.75 51,536,352.75 51,536,352.75 51,536,352.75 51,536,352.75
Facilities
Less:
Accumulated - - (41,793,705.95) (83,587,412.67) (125,381,118.59) (167,174,825.11) (208,968,531.23)
Depreciation
78
Non-Current
763,261,388.31 763,261,388.31 721,467,682.36 679,673,975.64 637,880,269.72 596,086,563.20 554,292,857.08
Assets
Table 10.
(Liabilities and Shareholders’ Equity)
Pre – Operational Operational
nd
Year 1 Year 2 1st Year 2 Year 3rd Year 4th Year 5th Year
Liabilities
Current Liability:
Account Payable 381,630,694.16 - 99,525,120.3 102,510,873.9 105,586,200.1 108,753,786.1 112,016,399.7
Non-Current Liability
Loans Payable 325,340,900.2 325,340,900.2 302,882,468.5 278,627,653.1 252,432,452.5 224,141,694.3 193,587,675.5
Total Liabilities 706,971,594.36 325,340,900.2 402,407,588.80 381,138,527.00 358,018,652.60 332,895,480.40 305,604,075.20
Shareholders’ Equity
Ordinary Capital 488,011,350.
488,011,350.3 488,011,350.3 488,011,350.3 488,011,350.3 488,011,350.3 488,011,350.3
3
Retained Earnings:
Beginning
- - - 225,980,019.83 467,218,201.80 717,138,796.52 992,695,498.29
Balance
Net Income
- - 237,873,705.08 253,934,928.39 263,074,310.24 290,059,686.07 300,756,269.91
Table 11.
Statement of Cash Flow
Pre-Operation Operational
Year 1 Year 2 1st Year 2nd Year 3rd Year 4th Year 5th Year
1. Cash Flow from Plant Operation Activities
Net Income - - 237,873,705.08 253,934,928.39 263,074,310.24 290,059,686.07 300,756,269.91
Increase/Decrea
se in Accounts - - (40,291,125.00) (1,611,645.00) (1,676,110.80) (1,743,155.23) (1,812,881.44)
Receivable
Increase/Decrea
se in
- - 41,793,706.32 41,793,706.32 41,793,706.32 41,793,706.32 41,793,706.32
Depreciation
(Table …)
Increase/Decrea
se in Accounts - - 99,525,120.3 2,985,753.6 3,075,326.2 3,167,586 3,262,613.6
Payable
Net Cash
provided by
- - 338,901,406.70 297,102,743.31 306,267,231.96 333,277,823.16 343,999,708.39
Operating
Activities
2. Cash Flow from Investing Activities
Purchase of
Land (Schedule (12,013,162.8) (12,013,162.8) - - - - -
14)
Purchase of
Buildings,
Structures and
(70,862,485) (70,862,485) - - - - -
Land
Improvements
(Schedule 14)
81
Purchase of
Factory
Equipment & (270,565,852) (270,565,852) - - - - -
Machineries
(Schedule 14)
Purchase of
Office and
(2,421,018) (2,421,018) - - - - -
Transportation
Equipment
Purchase of
Service (25,768,176.4) (25,768,176.4) - - - - -
Facilities
Net Cash
provided by
(381,630,694) (381,630,694) - - - - -
Investing
Activities
3. Cash Flow from Financing Activities
Proceeds of 10
Year Bank 325,340,900.2 - - - - - -
Loan
Issuance of
488,011,350.3 - - - - - -
Capital
Payment of
Loan - - (22,458,432) (24,254,815) (26,195,201) (28,290,758) (30,554,019)
(Schedule 17)
Payment of
- - (11,893,685.25) (12,696,746.42) (13,153,715.51) (14,502,984.30) (15,037,813.50)
Dividends
Net Cash
provided by
813,352,250.43 - (34,352,117.25) (36,951,561.42) (39,348,916.51) (42,793,742.30) (45,591,832.50)
Financing
Activities
82
Increase in
431,721,556.28 (381,630,694) 304,549,289.45 260,151,181.89 266,918,315.45 290,484,080.86 298,407,875.89
Cash
Cash Balance,
- 431,721,556.28 50,090,862.12 354,640,151.57 614,791,333.46 881,709,648.90 1,172,193,729.76
Beginning
Cash Balance,
431,721,556.28 50,090,862.12 354,640,151.57 614,791,333.46 881,709,648.90 1,172,193,729.76 1,470,601,605.66
End
83
Financial Ratios
The following ratios shown are computed from the figures in the financial
statement:
Test of Liquidity.
Current Assets
Current Ratio=
Current Liabilities
Year 1 3.97
Year 2 6.41
Year 3 8.76
Year 4 11.20
Year 5 13.55
position since the ratios calculated are better than 1:1 ratio, thus can pay their short-term
obligations.
84
Gross Profit
Gross Profit Margin =
Sales
Year 1 0.52
Year 2 0.53
Year 3 0.53
Year 4 0.54
Year 5 0.55
Year 1 0.42
Year 2 0.43
Year 3 0.43
Year 4 0.46
Year 5 0.46
85
Year 1 0.30
Year 2 0.27
Year 3 0.24
Year 4 0.23
Year 5 0.21
Year 1 0.70
Year 2 0.74
Year 3 0.77
Year 4 0.85
Year 5 0.88
86
Sales
Sales to Assets =
Total Assets
Year 1 0.73
Year 2 0.63
Year 3 0.55
Year 4 0.49
Year 5 0.44
Payback Period.
0 Year
(813,352,250.43) (813,352,250.43)
Pre - Operation
1st Year
(381,630,694.16) (1,194,982,944.59)
Pre – Operation
0 Year
304,549,289.45 (890,433,655.14)
Operation
1st Year
260,151,181.89 (630,282,473.25)
Operation
2nd Year
266,918,315.45 (363,364,157.80)
Operation
3rd Year
290,484,080.86 (72,880,076.94)
Operation
4th Year
298,407,875.89 225,527,798.95
Operation
87
The payback period for the total project cost of Php 813,352,250.43 is
Breakeven Analysis.
Total Fixed Cost
Breakeven Point (BEP) in Volume =
(Selling Price per L-Variable Cost per L)
Breakeven Point of Bioethanol, which is the main product, must be sold in order for the
company to start earning profit. The effect of tax is not includes in this analysis.
Financial Analysis
The financial study gives emphasis on the feasibility of the plant which will
produce 17,400,000 liters of bioethanol annually. It is expected that the cost for the
project is high but factors like the current demand of bioethanol in the market, the selling
88
of by-products and the generation of own power for the production affects the financial
ratios which indicates the company’s financial liquidity, profitability and insolvency.
Using the current ratio it is determined the liquidity of the company. From the values
calculated above, the current ratio increases annually and has high values therefore, the
company is will be able to meet its short term obligations and will be able to pay for its
liabilities.
The profitability of the company on the other hand, is determined by the Gross
Profit Margin, Pre – Tax Profit Margin, Return on Assets (ROA), Sales to Assets (STA)
and Return on Equity (ROE). From the values calculated above, the current ratio is
increasing for the first five years of operation due to the increasing current assets. For the
gross profit margin, the ratios for the three year of operation are increasing and on its
fourth year the ratio decreases due to the decrease in total gross profit. This only shows
that the company was not able to use its assets to efficiently generate profit. Return on
Equity (ROE) increases also because on the increasing sales during the period and that is
because there is an increase in profit before tax every year but on the fourth year it
decreases.
The payback period for the company is approximately 3 years and 3 months
which indicates the length of time when the business can recover its investment. The
company’s short payback period indicates that the investments are recovered sooner and
Summary
The main objective of this feasibility study is to come up with a plant design for
6. To generate a process that will be able to produce bioethanol from mango seeds
7. Conduct a market study which includes the evaluation of the local market
production of bioethanol
8. Select a plant location that provides proximity to the source of raw material,
9. To provide the necessary design of all the equipment needed for the production of
bioethanol and the treatment of the waste produced based on the material balances
attained.
10. Prepare financial statements for the first five years of operation of the plant.
The plant will be situated at Brgy. Carmen, Toledo City, Cebu. The land that will
be bought will be 200219.38 square meters of land area. The main raw material for the
proposed plant is mango seed. There are three leading mango processing industry:
Profood, M’Lhuillier Food Products, and FPD Food International that generate tons of
mango seed waste from their manufacturing of dried mangoes and other products that
operates on Cebu city, the supply of raw materials is ensured for production. This fact
supports the decision to put up the plant at the previously mentioned location.
90
As stated in the product and demand analysis, increasing motor vehicle sales,
Philippine economy, all translate to increased fuel consumption in the next 3 - 5 years.
According to GAIN report, as of year 2018 the fuel consumption is 605 ML which is
composed of the fuel production and fuel imports of 280 ML and 325 ML, respectively.
The present distilleries can supply 431.12 ML of bioethanol leaving a 173.88 ML market
gap.
The plant will supply 17.4 ML of bioethanol per year contributing to about 10%
of the market gap. It will therefore cut down the market gap to about 156.49 ML in the
Equipment design and specification have been calculated based on literatures such
Equipment – Design and Selection by Walas. The cost of equipment and assumptions
used in the financial study on direct costs, indirect costs and other costs were based on
the Plant Design and Economics for Chemical Engineers by Peters and Timmerhaus.
91
The proposed bioethanol plant has an annual production of 17.4 ML liters by using
mango seed kernel as raw material. The proposed project shows that it can meet the
bioethanol demand of the country and can compete with other bioethanol plant available
locally. The plant site gives an advantage on the economic sustainability of the plant due
to its high availability of the raw materials, its accessibility of water supply and
distribution or marketing finished products. The plant location was strategically located
The financial study shows that the proposed plant’s projected performance will be
stable based on the projected liquidity, profitability and project leverages which gave
The plant layout was designed to the plant’s efficiency and 30% safety factor. The
plant layout includes all the equipment, buildings and facilities arranged and designed to
The following are the recommendations offered by the researchers for the
2. Improve the financial assumption on the prices of goods, equipment, services and
materials purchased to avoid too much deviation from actual financial values;
alcohol; and
92
4. The by-product CO2 can be captured and sold as liquid CO2 as food grade for
Appendix A
Material Balance
manufacturing plant, are considered as source of the raw material with the basis of 50
tons per day per manufacturing plant, of waste generated during off season and is
expected to increase during peak season (Profood Corp., 2016). As of present time, a total
of 46 manufacturing plants for the production of dried mango and mango juices exists in
the country.
The desired production per year is the 10% of the present market gap of the
bioethanol industry here in the Philippines for the year 2018 which is 17.4 Million Liter.
which is one of the main exporter of processed mango which contributes to around 85%
of the total mango processed products produced in Cebu, with an operating capacity of
1140 metric tons of mango per day (Galolo, 2017) along with nine more mango
mango seeds kernel yields around 0.1041 L of ethanol for every 1 kg of mango seeds
kernel used, while mango seed kernel is on average, 60% of the whole seed.
However, the presumptive amount of mango seeds calculated needed per day to
provide the required 58,000 L of ethanol have a small discrepancy due to other processes
added and the loss per process undergone by the raw material compared to the study of
Cristina et. al which causes some variations in the yield of the bioethanol.
Breaking Rolls
The breaking of the mango seeds into mango kernel and its outer shell.
Sieving
The separation of the Mango Kernel and Outer Shell with the use of sieving. By average,
60% of the entire mango seed is the kernel.
Mango Seed Kernel = 0.6 (928,431) = 557,058.99 kg/day
Mango Seed (Outer Shell)= 557,058.99-928,431= 371,372.7 kg/day
Outer Shells
371.3727 Ton
Drying
Mango seed kernel contains approximately 44.4% moisture. The initial 44.4% moisture
content will be reduced to 12% moisture content.
95
205.09899 Ton
Milling
Based on the assumption that 6% of the mango seeds are losses during milling.
Loss= 351,960(0.06)
= 21,117.6 kg/day
MSK Pwder after milling = 351,960 - 21,117.6 = 330,842.4 kg/day
413.55 Ton
70% H2SO4
631.55 Ton
Sugar-Acid-H2O
Solution
141.01 Ton
30% H2SO4
162.86 Ton
Sugar-Acid-H2O
Solution
Electrodialysis
Assuming 95% of the sulfuric acid was recovered
C= 0.95 (331,804.1) = 315,213.9 kg/day
OMB: F= C + D
Solving for D (Sugar Solution)
794,406.24 = 315,213.9 + D
D= 479,192.34 kg/day
Sugar-Acid-H2O
794.41 Ton Solution
315.2 Ton
Recycle H2SO4
99
Neutralization
Ca(OH)2 will be used to neutralize the sulfuric acid.
The neutralization reaction between Ca(OH)2 and H2SO4 is
=12,527.3 kg/day
Mgypsum =
1 𝑘𝑚𝑜𝑙 Ca(OH)2 1 1 𝑘𝑚𝑜𝑙 CaSO4 ● 2H2O 172 𝑘𝑔 CaSO4 ● 2H2O
12,527.3 kg Ca(OH)2 ( 74 𝑘𝑔 Ca(OH)2 ) ( ) (1 𝑘𝑚𝑜𝑙 CaSO4 ● 2H2O)
1 𝑘𝑚𝑜𝑙Ca(OH)2
12.53 Ton
Ca(OH)2
Sugar-Acid-H2O
Solution Gypsum
462.6 Ton
Sugar-Acid-H2O
Solution
Fermentation
239,796.79 𝑘𝑔
Brix= ( 462,602.14+X ) = 0.19
1 𝑘𝑔 𝑘𝑔 𝐿
Urea =(16.67 𝑔/𝐿) (1000 𝑔) (799,486.23 + 462,602.14 ) (1 𝑘𝑔) =
𝑑𝑎𝑦
21,039.01313 kg/day
Yeast + Urea + DAP = 77,471.5 kg/day
Yeast + Urea +
DAP
799.5 Ton
77.5 Ton
Water
44.6 Ton
CO2
Centrifugation
After fermentation, suspended solids which include nutrients and dead yeasts are
separated using the centrifuge.
77.5 Ton
Suspended Solids
101
Distillation
Feed Condition: 6.64% (v/v) ethanol @ T= 320C
From Perry’s Chemical Engineers’ Handbook 8th Edition, Table 2-32:
Density of ethanol: 16.9224 mol/L = 779.5811 g/L
Density of water: 55.4454 mol/L = 998.8489 g/L
Based from Baya et.al (2018) assumptions, a good distillation produces 95% (v/v)
ethanol and bottoms containing 2% (v/v) ethanol
1𝑘mol 18.189 kg
B=64.3181 x 106 mol/day (1000 mol) ( ) = 1.1699 x 106 kg/day
1kmol
F = 1.2175 x
106 kg/day
XF = 0.0212
XB= 0.0062
LM
103
Dehydration
MW of the Distillate = 41.88 kg/kmol
kg 1000 mol mol
D=48580.8 ( ) = 1.16 × 106
day 41.88 kg day
Ethanol in D=(0.8529)(1.16×106 )
=991.38×103 mol
Water in D=(1.16×106 ) − (991.38 × 103 )
= 170,987.3 mol
1 − 0.9999
Water in product = (981.45 × 103 mol)
0.9999
mol 18 𝑔 1 kg
= 98.15 ( )( )
day 1 mol 1000 g
= 1.7667 kg/day
kg kg
45, 146.7 1.7667
day day
Ethanol production rate = +
kg kg
0.7796 L 0.99885 L
L Kg
= 𝟓𝟖𝟎𝟎𝟎 (0.7787 )
day L
= 𝟒𝟓𝟏𝟔𝟒. 𝟔 𝐤𝐠/𝐝𝐚𝐲
104
Product=
58,000 L/day
= 45,164.6
kg/day
105
Appendix B
Energy Balance
Dryer
𝑇𝑣 = 100 °C
2.) Sensible heat to raise temperature of solid from initial (30°C) to vaporization
temperature (100°C)
𝑘𝐽
𝑞1 = 1,279,765.66
ℎ
3.) Sensible heat to raise temperature if water from initial (30°C) to vaporization
temperature (100°C)
𝑘𝐽
𝑞2 = 1,006,581.456
ℎ
𝑞3 = 𝑉𝜆v
𝑘𝐽
𝜆v=2260
𝑘𝑔
𝑘𝐽
𝑞3 = 2848.60 × 2260 = 6,442,244.789
ℎ
5.) Sensible heat to raise temperature of the bone dry solid from vaporization
𝑘𝐽
𝑞4 = −914,118.3287
ℎ
6.) Sensible heat to raise temperature of water remaining in the material from
𝑘𝐽
𝑞5 = −122,775.3794
ℎ
𝑞𝑡𝑜𝑡𝑎𝑙 = 𝑞1 + 𝑞2 + 𝑞3 + 𝑞4 + 𝑞5
− 122,775.3794
107
𝒌𝑱
𝒒𝒕𝒐𝒕𝒂𝒍 = 𝟕, 𝟔𝟗𝟏, 𝟔𝟗𝟖. 𝟏𝟗𝟕
𝒉
Fermentation
44.42 x106
( )
18
xH2O = ( 44.42 x106 1,322,204.39 ) = 0.99
( )+( )
18 180
Q= -85,133,381.6 kJ/day
Dehydration
TD= 78.5oC
D= 48.3333 kmol/hr
Qs = D[CpΔTλ]
@ T= 78.5oC
109
With water entering at 25oC and assuming tht condensation of ethanol is completed at
50oC
Qc = P(CpΔT + λ)
λ= 38,872 kJ/kmol.K
Qc = 40,506,210.24 kJ/day
110
𝑘𝑚𝑜𝑙
XF = 0.0212 %EtOH = 6.7% F = 65.4781 x 106 𝑑𝑎𝑦
𝑘𝑚𝑜𝑙
xD = 0.8529 %EtOH = 95% D = 1.16𝑥106 𝑑𝑎𝑦
𝑘𝑚𝑜𝑙
xB = 0.0062 %EtOH = 2% B = 64.3181 x 106 𝑑𝑎𝑦
TF = 80 deg C
Ropt = 2.02
HLn = HD
111
KJ/Kg KJ/Kg
418.9 2675 0
207 1064 1
(0.067)(779.58)
XF = (0.067)(779.58)+(1−0.067)(998.8489) = 0.053
(0.95)(779.58)
XD = (0.95)(779.58)+(1−0.95)(998.8489) = 0.937
(0.02)(779.58)
XB = (0.02)(779.58)+(1−0.02)(998.8489) = 0.016
𝑘𝐽
HF = 396.72
𝑘𝑔
𝑘𝐽
HV = 2649.72 𝑘𝑔
112
𝑘𝐽
HB = 215.87 𝑘𝑔
𝑘𝐽
HLn = HD = 391.87 𝑘𝑔
𝑚𝑜𝑙
At reflux ratio (R) = 3.02, D = 1.16𝑥106 𝑑𝑎𝑦
𝑚𝑜𝑙
L = 3.02 (1.16𝑥106 )
𝑑𝑎𝑦
L = 3.50x106 mol/day
mol 𝑘𝑔 𝑘𝐽 1𝑘𝑔
(4.66x106 day ) (41.88 𝑘𝑚𝑜𝑙 ) (2649.72 ) (1000𝑔) =
𝑘𝑔
𝑘𝐽 41.88𝑘𝑔 1𝑘𝑔
)( ) (1000𝑔) + 𝑞𝑟
𝑘𝑔 𝑘𝑚𝑜𝑙
KJ 𝒌𝑱
Reboiler duty: 𝑞𝑟 = 4.49x108 day = 𝟏. 𝟖𝟕𝒙𝟏𝟎𝟔 𝒉𝒓
𝑘𝑔 𝑘𝑔 𝑘𝑔
(𝑓𝑒𝑒𝑑)𝑀𝑊𝑎𝑣𝑒 = (0.0212 × 46 ) + ((1 − 0.0212) × 18 ) = 18.59
𝑘𝑚𝑜𝑙 𝑘𝑚𝑜𝑙 𝑘𝑚𝑜𝑙
𝑘𝑔 𝑘𝑔
(𝑏𝑜𝑡𝑡𝑜𝑚𝑠)𝑀𝑊𝑎𝑣𝑒 = (0.0062 × 46 ) + ((1 − 0.0062) × 18 )
𝑘𝑚𝑜𝑙 𝑘𝑚𝑜𝑙
𝑘𝑔
= 18.17
𝑘𝑚𝑜𝑙
𝑚𝑜𝑙 𝑘𝑔 𝑘𝐽 1𝑘𝑔
(65.4781 x 106 ) ( 18.59 𝑘𝑚𝑜𝑙) ( 396.72 ( )) +
𝑑𝑎𝑦 𝑘𝑔 1000𝑔
mol 1𝑘𝑔 kg 𝑘𝐽 KJ
(64.3181 x 106 day )(1000𝑔)(18.17 kmol)( 215.87 ) + 4.49x1011 day
𝑘𝑔
𝑘𝐽 𝒌𝑱
Condenser duty: 𝑞𝑐 = 2.37𝑥108 𝑑𝑎𝑦 = 𝟗. 𝟖𝟗𝒙𝟏𝟎𝟔 𝒉𝒓
cooling jacket must be installed to regulate the exothermic reaction in the tank.
Calculation for the amount of water needed to regulate the temperature of the
Substituting Values
𝑘𝐶𝑎𝑙 𝑐𝑎𝑙
∆𝐻𝑅 = −50.06 = −50,060.00
𝑚𝑜𝑙 𝑚𝑜𝑙
λs = ∆𝐻𝑉 − ∆𝐻𝐿
kJ
ΔHL = 419.04
kg
kJ kJ 1kg 18.0154g
λs = (2676.1 kg − 419.04 kg) (1000g) ( )
1mol
kJ Cal
λs = 40.66 mol = 539,168.1644 kg
The values obtained shows that ΔHf is greater than λs, the cooling water in the cooling
jacket will undergo phase change with a maximum temperature of 120 deg C. Assuming
75+30
𝑇𝑚𝑒𝑎𝑛 = = 52.5℃
2
Where:
Cal
𝐶𝑝𝐻2 𝑆𝑂4 = 794.3 kg ℃
Cal
𝐶𝑝𝑙𝑖𝑚𝑒 = 794.3 kg ℃
Cal
𝐶𝑝𝑔𝑦𝑝𝑠𝑢𝑚 = 0.259 kg ℃
Cal
𝐶𝑝𝑔𝑙𝑢𝑐𝑜𝑠𝑒 = 334.0055 kg ℃
Cal
𝐶𝑝𝑤𝑎𝑡𝑒𝑟 = 997.77 kg ℃
12,527.30 29,117.5
𝑋𝑙𝑖𝑚𝑒 = 925,388.56 = 0.0135 𝑋𝑔𝑦𝑝𝑠𝑢𝑚 = 925,388.56 = 0.1675 𝑋𝑤𝑎𝑡𝑒𝑟 =
222805.55
= 0.2408
925,388.56
16,590.20 242,218.98
𝑋𝐻2 𝑆𝑂4 = 925,388.56 = 0.0179 𝑋𝑔𝑙𝑢𝑐𝑜𝑠𝑒 = = 0.2617
925,388.56
116
Cal
Cpm = 352.6567 kg ℃
The reference temperature for water would be the mean temperature of the initial and
final temperature of the water before it vaporizes, which is 25 deg C and 100 deg C
respectively.
25+100
Tmean = = 62.5 ℃
2
𝑐𝑎𝑙
𝐶𝑝𝐻2 𝑂 = 998.99
𝑘𝑔 ℃
The reference temperature for steam would be the mean temperature of the initial and
final temperature of the water after it vaporizes, which is 100 deg C and 120 deg C
respectively.
120+100
Tmean = = 110℃
2
𝑐𝑎𝑙
𝐶𝑝H2O = 1011.4120
kg ℃
Substituting Value
cal
(1011.4120 kg ℃ (120 − 100)℃)
mwater = 546.92kg/hr
117
Neutralization
3.9 ℎ𝑝
Power per unit volume = 1000 𝑔𝑎𝑙
3.9 ℎ𝑝 1 𝑔𝑎𝑙 𝑘𝑤
Power = 1000 𝑔𝑎𝑙 (3.78 𝑥10−3 𝑚3 )(0.746 ℎ𝑝 )( 555.2331𝑚3 )
Power = 427.35 kW
Pumps
Pump 1 (From 70% H2SO4 Storage Tank to 1st Stage Acid Hydrolysis Reactor)
Data:
4.786 m3
Volumetric flow rate: = 4.247 x 10-3
1127 s
g∆z
W= + ∑F
gc
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( s ) and ρ= m3
0.45
Di =0.363(4.247 x 10-3 ) (1127)0.13
Di = 0.0775 m
118
4.247 x 10-3 m
v= π = 0.9
( 4 )(0.0775)2 s
∑ F= ∑ Flength + ∑ Ffittings
2fLv2
∑ Flength =
Dgc
Dvρ (0.0775)(0.9)(1127)
NRe = = = 22,985 ≈ Turbulent flow
μ 3.42 x 10 − 3
ε 0.0457×10-3
= = 5.897x10-4
D 0.0775
f = 0.0068
2(0.0068)(8)(0.9)2
∑ Flength = = 0.142 J/kg
0.0775
v2
∑ Ffittings = ∑ Kf ( )
2gc
[2(0.75)+0.17)](0.9)2
∑ Ffittings = =0.676 J/kg
2
g∆z 9.8(5)
W= + ∑ F= + 0.818 = 49.818 J/kg
gc 1
119
W = 238.43 Watts
238.43
Wactual = = 340.61 Watts
0.70
Pump 2 (From 1st Stage Acid Hydrolysis Reactor to @nd Stage Acid Hydrolysis)
Data:
1.31 m3
Volumetric flow rate: = 1.32 x 10-3
990 s
g∆z
W= + ∑F
gc
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( s ) and ρ= m3
0.45
Di =0.363(1.32 x 10-3 ) (990)0.13
Di = 0.12 m
120
1.32 x 10-3 m
v= π = 0.12
( 4 )(0.12)2 s
∑ F= ∑ Flength + ∑ Ffittings
2fLv2
∑ Flength =
Dgc
Dvρ (0.12)(0.12)(990)
NRe = = = 50,733 ≈ Turbulent flow
μ 2.81 x 10−4
ε 0.0457×10-3
= = 3.81x10-4
D 0.12
f = 0.0055
2(0.0055)(8)(0.12)2
∑ Flength = = 0.011 J/kg
0.12
v2
∑ Ffittings = ∑ Kf ( )
2gc
[2(0.75)+0.17)](0.12)2
∑ Ffittings = =0.01 J/kg
2
g∆z 9.8(5)
W= + ∑ F= + 0.023 = 49.023 J/kg
gc 1
121
W = 64.22 Watts
64.22
Wactual = = 91.74 Watts
0.70
Pump 3 (From 30% H2SO4 Storage Tank to 2nd Stage Acid Hydrolysis Reactor)
Data:
1.6326 m3
Volumetric flow rate: 1221.2 =1.337 x 10-3 s
g∆z
W= + ∑F
gc
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( s ) and ρ= m3
0.45
Di =0.363(1.337 x 10−3 ) (1221.2)0.13
Di = 0.0466 m
122
1.337 x 10-3 m
v= π = 0.7839
( 4 )(0.0466)2 s
∑ F= ∑ Flength + ∑ Ffittings
2fLv2
∑ Flength =
Dgc
Dvρ (0.0466)(0.7839)(1221.2)
NRe = = = 23,479 ≈ Turbulent flow
μ 1.9 𝑥 10−3
ε 0.0457×10-3
= = 9.807x10-4
D 0.0466
f = 0.0069
2(0.0069)(8)(0.7839)2
∑ Flength = = 1.456 J/kg
0.0466
v2
∑ Ffittings = ∑ Kf ( )
2gc
[2(0.75)+0.17)](0.7839)2
∑ Ffittings = =0.513 J/kg
2
g∆z 9.8(5)
W= + ∑ F= + 1.969 = 50.969 J/kg
gc 1
123
W = 83.21 Watts
83.21
Wactual = = 118.87 Watts
0.70
Data:
9.19 m3
Volumetric flow rate: 1000 = 9.19 x 10-3 s
g∆z
W= + ∑F
gc
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( s ) and ρ= m3
0.45
Di =0.363(9.19 x 10-3 ) (1265)0.13
Di = 0.11 m
124
9.19 x 10-3 m
v= π = 0.97
( 4 )(0.11)2 s
∑ F= ∑ Flength + ∑ Ffittings
2fLv2
∑ Flength =
Dgc
Dvρ (0.11)(0.97)(1265)
NRe = = = 2454.1≈ Turbulent flow
μ 0.055
ε 0.0457×10-3
= = 4.15x10-4
D 0.11
f = 0.0086
2(0.013)(5)(0.97)2
∑ Flength = = 0.38 J/kg
0.11
v2
∑ Ffittings = ∑ Kf ( )
2gc
[2(0.75)+0.17)](0.97)2
∑ Ffittings = = 0.79 J/kg
2
g∆z 9.8(5)
W= + ∑ F= + 1.17 = 50.17 J/kg
gc 1
125
W = 461.06 Watts
461.06
Wactual = = 658.66 Watts
0.70
Data:
5.35 m3
Volumetric flow rate: 1063.6 = 5.03 x 10-3 s
g∆z
W= + ∑F
gc
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( s ) and ρ= m3
0.45
Di =0.363(5.03 x 10-3 ) (1296.8)0.13
Di = 0.085 m
126
5.03 x 10-3 m
v= π = 0.89
( 4 )(0.085)2 s
∑ F= ∑ Flength + ∑ Ffittings
2fLv2
∑ Flength =
Dgc
Dvρ (0.085)(0.89)(1296.8)
NRe = = = 1486.41 ≈ Laminar flow
μ 0.066
f = 16/Re
f=16/(1486.41)
f=0.011
2(0.011)(5)(0.89)2
∑ Flength = = 1.02 J/kg
0.085
v2
∑ Ffittings = ∑ Kf ( )
2gc
[2(0.75)+0.17)](0.89)2
∑ Ffittings = = 0.66 J/kg
2
g∆z 9.8(3)
W= + ∑ F= + 1.68 = 31.08 J/kg
gc 1
W = 166.28 Watts
166.38
Wactual = = 237.54 Watts
0.70
Data:
5.35 m3
Volumetric flow rate: 1063.6 = 5.03 x 10-3 s
g∆z
W= + ∑F
gc
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( s ) and ρ= m3
0.45
Di =0.363(5.03 x 10-3 ) (1296.8)0.13
Di = 0.085 m
5.03 x 10-3 m
v= π = 0.89
( 4 )(0.085)2 s
∑ F= ∑ Flength + ∑ Ffittings
2fLv2
∑ Flength =
Dgc
128
Dvρ (0.085)(0.89)(1296.8)
NRe = = = 1486.41 ≈ Laminar flow
μ 0.066
f = 16/Re
f=16/(1486.41)
f=0.011
2(0.011)(5)(0.89)2
∑ Flength = = 1.02 J/kg
0.085
v2
∑ Ffittings = ∑ Kf ( )
2gc
[2(0.75)+0.17)](0.89)2
∑ Ffittings = = 0.66 J/kg
2
g∆z 9.8(3)
W= + ∑ F= + 1.68 = 31.08 J/kg
gc 1
W = 166.28 Watts
166.38
Wactual = = 237.54 Watts
0.70
Data:
15 m3
Volumetric flow rate: 1037.2 = 0.014 s
g∆z
W= + ∑F
gc
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( s ) and ρ= m3
Di =0.363(0.014)0.45 (1037.2)0.13
Di = 0.13 m
0.014 m
v= π = 1.05
( 4 )(0.13)2 s
∑ F= ∑ Flength + ∑ Ffittings
2fLv2
∑ Flength =
Dgc
Dvρ (0.13)(1.05)(1037.2)
NRe = = = 68,727 ≈ Turbulent flow
μ 2.06x10−3
ε 0.0457×10-3
= = 3.51x10-4
D 0.13
130
f = 0.005
2(0.005)(9)(1.05)2
∑ Flength = = 0.82 J/kg
0.13
v2
∑ Ffittings = ∑ Kf ( )
2gc
[2(0.75)+0.17)](1.05)2
∑ Ffittings = = 0.92 J/kg
2
g∆z 9.8(6)
W= + ∑ F= + 1.34 = 60.14 J/kg
gc 1
W = 902.1 W
902.1
Wactual = = 1288 Watts
0.70
Data:
15 m3
Volumetric flow rate: 1037.2 = 0.014 s
g∆z
W= + ∑F
gc
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( s ) and ρ= m3
Di =0.363(0.014)0.45 (1037.2)0.13
Di = 0.13 m
0.014 m
v= π = 1.05
( 4 )(0.13)2 s
∑ F= ∑ Flength + ∑ Ffittings
2fLv2
∑ Flength =
Dgc
Dvρ (0.13)(1.05)(1037.2)
NRe = = = 68,727 ≈ Turbulent flow
μ 2.06x10−3
ε 0.0457×10-3
= = 3.51x10-4
D 0.13
ϵ
@NRe = 68,727 and D = 3.54x10-4
f = 0.005
2(0.005)(5)(1.05)2
∑ Flength = = 0.42 J/kg
0.13
v2
∑ Ffittings = ∑ Kf ( )
2gc
[2(0.75)+0.17)](1.05)2
∑ Ffittings = = 0.92 J/kg
2
g∆z 9.8(11)
W= + ∑ F= + 1.34 = 109.14 J/kg
gc 1
W = 1637.1 W
1637.1
Wactual = = 2,338 Watts
0.70
Data:
15 m3
Volumetric flow rate: 1037.2 = 0.014 s
g∆z
W= + ∑F
gc
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( s ) and ρ= m3
Di =0.363(0.014)0.45 (1037.2)0.13
Di = 0.13 m
0.014 m
v= π = 1.05
( 4 )(0.13)2 s
∑ F= ∑ Flength + ∑ Ffittings
2fLv2
∑ Flength =
Dgc
Dvρ (0.13)(1.05)(1037.2)
NRe = = = 68,727 ≈ Turbulent flow
μ 2.06x10−3
ε 0.0457×10-3
= = 3.51x10-4
D 0.13
f = 0.005
2(0.005)(5)(1.05)2
∑ Flength = = 0.42 J/kg
0.13
v2
∑ Ffittings = ∑ Kf ( )
2g c
[2(0.75)+0.17)](1.05)2
∑ Ffittings = = 0.92 J/kg
2
g∆z 9.8(8)
W= + ∑ F= + 1.34 = 79.74 J/kg
gc 1
W = 1196.1 W
1196.1
Wactual = = 1708 Watts
0.70
Data:
14.09 m3
Volumetric flow rate: 985.25 = 0.014 s
135
g∆z
W= + ∑F
gc
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( s ) and ρ= m3
Di =0.363(0.014)0.45 (989.25)0.13
Di = 0.13 m
0.014 m
v= π = 1.05
( 4 )(0.13)2 s
∑ F= ∑ Flength + ∑ Ffittings
2fLv2
∑ Flength =
Dgc
Dvρ (0.13)(1.05)(989.25)
NRe = = = 135,032 ≈ Turbulent flow
μ 1x10−3
ε 0.0457×10-3
= = 3.51x10-4
D 0.13
f = 0.005
136
2(0.005)(9)(1.05)2
∑ Flength = = 0.76 J/kg
0.13
v2
∑ Ffittings = ∑ Kf ( )
2gc
[2(0.75)+0.17)](1.05)2
∑ Ffittings = = 0.92 J/kg
2
g∆z 9.8(8)
W= + ∑ F= + 1.68 = 80.08 J/kg
gc 1
W = 1126.72 W
1126.72
Wactual = = 1609.61 Watts
0.70
Data:
0.56 𝑚3
Volumetric flow rate: 807.05 = 6.94𝑥10−4 𝑠
g∆z
W= + ∑F
gc
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( s ) and ρ= m3
0.45
Di =0.363(6.94𝑥10−4 ) (807.05)0.13
Di = 0.03 m
6.94x10−4 m
v= π = 0.98
( 4 )(0.03)2 s
∑ F= ∑ Flength + ∑ Ffittings
2fLv2
∑ Flength =
Dgc
Dvρ (0.03)(0.98)(807.05)
NRe = = = 23,036 ≈ Turbulent flow
μ 1.07 x 10 − 3
ε 0.0457×10-3
= = 1.52x10-3
D 0.03
f = 0.007
2(0.007)(9)(0.98)2
∑ Flength = = 4.03 J/kg
0.03
138
v2
∑ Ffittings = ∑ Kf ( )
2gc
[2(0.75)+0.17)](0.98)2
∑ Ffittings = = 0.80 J/kg
2
g∆z 9.8(8)
W= + ∑ F= + 4.83 = 83.23 J/kg
gc 1
W = 46.6256
46.6256
Wactual = = 66.61 Watts
0.70
Data:
0.52 𝑚3
Volumetric flow rate: = 6.66𝑥10−4
781 𝑠
g∆z
W= + ∑F
gc
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( ) and ρ=
s m3
0.45
Di =0.363(6.66𝑥10−4 ) (781)0.13
Di = 0.03 m
6.66x10−4 m
v= π = 0.94
( 4 )(0.03)2 s
∑ F= ∑ Flength + ∑ Ffittings
2fLv2
∑ Flength =
Dgc
Dvρ (0.03)(0.94)(781)
NRe = = = 22,451 ≈ Turbulent flow
μ 9.81 x 10 − 4
ε 0.0457×10-3
= = 1.52x10-3
D 0.03
f = 0.007
2(0.007)(10)(0.94)2
∑ Flength = = 3.71 J/kg
0.03
v2
∑ Ffittings = ∑ Kf ( )
2gc
[2(0.75)+0.17)](0.94)2
∑ Ffittings = = 0.73 J/kg
2
g∆z 9.8(8)
W= + ∑ F= + 4.44 = 82.84 J/kg
gc 1
W = 46.39 Watts
46.39
Wactual = = 66.27 Watts
0.70
Data:
3.65 𝑚3
Volumetric flow rate: 1840 = 1.98𝑥10−3 𝑠
g∆z
W= + ∑F
gc
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( s ) and ρ= m3
0.45
Di =0.363(1.98𝑥10−3 ) (1840)0.13
Di = 0.06 m
1.98𝑥10−3 m
v= π =0.70
( 4 )(0.06)2 s
∑ F= ∑ Flength + ∑ Ffittings
2fLv2
∑ Flength =
Dgc
Dvρ (0.06)(0.70)(1840)
NRe = = = 3,864 ≈ Laminar flow
μ 20x 10 − 3
f=16/Re
f=16/(3864)
f = 0.0041
2(0.0041)(10)(0.70)2
∑ Flength = = 0.67 J/kg
0.06
v2
∑ Ffittings = ∑ Kf ( )
2gc
142
[2(0.75)+0.17)](0.70)2
∑ Ffittings = = 0.41 J/kg
2
g∆z 9.8(5)
W= + ∑ F= + 1.08 = 50.08 J/kg
gc 1
W = 182.79 W
182.79
Wactual = = 261.13 Watts
0.70
Data:
0.145 m3
Volumetric flow rate: = 6.47 x 10-5
2240 s
g∆z
W= + ∑F
gc
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( s ) and ρ= m3
143
0.45
Di =0.363(6.47 x 10-5 ) (2240)0.13
Di = 0.0129 m
6.47 x 10-5 m
v= π = 0.495
( 4 )(0.0129) 2 s
∑ F= ∑ Flength + ∑ Ffittings
2fLv2
∑ Flength =
Dgc
Dvρ (0.0129)(0.495)(2240)
NRe = = = 13,886 ≈ Turbulent flow
μ 1.03 𝑥 10−3
ε 0.0457×10-3
= = 3.54x10-3
D 0.0129
f = 0.0095
2(0.0095)(8)(0.495)2
∑ Flength = = 2.89 J/kg
0.0129
v2
∑ Ffittings = ∑ Kf ( )
2gc
[2(0.75)+0.17)](0.495)2
∑ Ffittings = = 0.20 J/kg
2
144
g∆z 9.8(5)
W= + ∑ F= + 23.009 = 72.01 J/kg
gc 1
W = 10.44 Watts
10.44
Wactual = = 14.92 Watts
0.70
Data:
𝑘𝑔
Mass flow rate: 94,505 ℎ𝑟 = 26.25 kg/s
26.25 𝑚3
Volumetric flow rate: = 0.03
1000 𝑠
g∆z
W= + ∑F
gc
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( s ) and ρ= m3
Di =0.363(0.03)0.45 (1000)0.13
145
Di = 0.18
0.03 m
v= π = 1.18
( 4 )(0.18)2 s
∑ F= ∑ Flength + ∑ Ffittings
2fLv2
∑ Flength =
Dgc
Dvρ (0.18)(1.18)(1000)
NRe = = = 212,400 ≈ Turbulent flow
μ 1x 10 − 3
ε 0.0457×10-3
= = 2.54x10-4
D 0.18
f = 0.004
2(0.004)(10)(1.18)2
∑ Flength = = 0.62 J/kg
0.18
v2
∑ Ffittings = ∑ Kf ( )
2g c
[2(0.75)+0.17)](1.18)2
∑ Ffittings = = 1.16 J/kg
2
g∆z 9.8(5)
W= + ∑ F= + 1.78 = 50.78 J/kg
gc 1
W = 1282.70 W
1282.70
Wactual = = 1832.43 Watts
0.70
Data:
16.19 m3
Volumetric flow rate: = 0.02
1000 s
g∆z
W= + ∑F
gc
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( s ) and ρ= m3
Di =0.363(0.02)0.45 (1000)0.13
147
Di = 0.15 m
0.02 m
v= π = 1.13
( 4 )(0.15)2 s
∑ F= ∑ Flength + ∑ Ffittings
2fLv2
∑ Flength =
Dgc
Dvρ (0.15)(1.13)(1000)
NRe = = = 169500 ≈ Turbulent flow
μ 1x 10 − 3
ε 0.0457×10-3
= = 1.99x10-4
D 0.15
f = 0.0045
2(0.0045)(6)(1.13)2
∑ Flength = = 0.08 J/kg
0.15
v2
∑ Ffittings = ∑ Kf ( )
2g c
[2(0.75)+0.17)](1.13)2
∑ Ffittings = =1.07 J/kg
2
g∆z 9.8(5)
W= + ∑ F= + 1..50 = 50.50 J/kg
gc 1
W = 817.60 Watts
817.60
Wactual = = 1168 Watts
0.70
Data:
50.84 m3
Volumetric flow rate: = 0.05|
1000 s
g∆z
W= + ∑F
gc
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( ) and ρ=
s m3
Di =0.363(0.05)0.45 (1000)0.13
Di = 0.23 m
149
0.05 m
v= π = 1.20
( 4 )(0.23)2 s
∑ F= ∑ Flength + ∑ Ffittings e
2fLv2
∑ Flength =
Dgc
Dvρ (0.23)(1.20)(1000)
NRe = = = 276000 ≈ Turbulent flow
μ 1 x 10 − 3
ε 0.0457×10-3
= = 1.99x10-4
D 0.23
f = 0.004
2(0.004)(8)(1.20)2
∑ Flength = = 0.40 J/kg
0.23
v2
∑ Ffittings = ∑ Kf ( )
2g c
[2(0.75)+0.17)](1.12)2
∑ Ffittings = =1.05 J/kg
2
g∆z 9.8(5)
W= + ∑ F= + 1.45= 50.45 J/kg
gc 1
150
W = 2564.88 Watts
2564.88
Wactual = = 3664.11 Watts
0.70
Data:
5.56 m3
Volumetric flow rate: 1000 = 5.56x10^-3 s
g∆z
W= gc
+ ∑F
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( s ) and ρ= m3
Di = 0.086m
5.56𝑥10 − 3 m
v= π = 0.96
( 4 )(0.086)2 s
151
∑ F= ∑ Flength + ∑ Ffittings e
2fLv2
∑ Flength =
Dgc
Dvρ (0.086)(0.96)(1000)
NRe = = = 82560 ≈ Turbulent flow
μ 1x 10 − 3
ε 0.0457×10-3
= = 5.31x10^-4
D 0.086
f = 0.005
2(0.005)(8)(0.96)2
∑ Flength = = 0.86 J/kg
0.086
v2
∑ Ffittings = ∑ Kf ( )
2gc
[2(0.75)+0.17)](0.96)2
∑ Ffittings = = 0.77 J/kg
2
g∆z 9.8(5)
W= + ∑ F= + 1.63 = 50.63 J/kg
gc 1
W = 281.50 Watts
281.50
Wactual = = 402.14 Watts
0.70
Data:
0.23 m3
Volumetric flow rate: 1000 = 2.3x10-4 s
g∆z
W= + ∑F
gc
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( s ) and ρ= m3
Di =0.363(2.3x10^-4)0.45 (1000)0.13
Di = 0.02 m
2.3𝑥10−4 m
v= π = 0.73
( 4 )(0.02)2 s
∑ F= ∑ Flength + ∑ Ffittings e
2fLv2
∑ Flength =
Dgc
153
Dvρ (0.02)(0.73)(1000)
NRe = = = 14,600 ≈ Turbulent flow
μ 1 x 10 − 3
ε 0.0457×10-3
= = 5.897x10-4
D 0.02
f = 0.008
2(0.008)(8)(0.73)2
∑ Flength = = 0.88 J/kg
0.0775
v2
∑ Ffittings = ∑ Kf ( )
2gc
[2(0.75)+0.17)](0.72)2
∑ Ffittings = = 0.43 J/kg
2
g∆z 9.8(5)
W= + ∑ F= + 1.31 = 50.31 J/kg
gc 1
W = 11.57 Watts
11.57
Wactual = = 16.53Watts
0.70
154
Data:
34.41 m3
Volumetric flow rate: = 0.03
1000 s
g∆z
W= + ∑F
gc
From Plant Design and Economics for Chemical Engineers by Max S. Peters et al.,
m3 kg
Di =0.363 m0.45
v ρ
0.13
where mv ( s ) and ρ= m3
Di =0.363(0.03)0.45 (1000)0.13
Di = 0.18 m
0.03 m
v= π = 1.18
( 4 )(0.18)2 s
∑ F= ∑ Flength + ∑ Ffittings e
2fLv2
∑ Flength =
Dgc
Dvρ (0.18)(1.18)(1000)
NRe = = = 212400 ≈ Turbulent flow
μ 1 x 10 − 3
ε 0.0457×10-3
= = 2.54x10-4
D 0.18
f = 0.004
2(0.004)(8)(1.18)2
∑ Flength = = 0.50 J/kg
0.18
v2
∑ Ffittings = ∑ Kf ( )
2g c
[2(0.75)+0.17)](1.18)2
∑ Ffittings = =1.16 J/kg
2
g∆z 9.8(5)
W= + ∑ F= + 1.66 = 50.66 J/kg
gc 1
W = 1743.21 Watts
1743.21
Wactual = = 2490.3 Watts
0.70
P=7741.08 W
156
Conveyors
Length = 6 m = 19.68 ft
Velocity = 90 m/hr
𝐿 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦
𝑃ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 = 0.4 + ( )( )
300 100
19.68 50.28
𝑃ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 = 0.4 + ( )( )
300 100
𝑃ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 = 0.43 ℎ𝑝
𝑃𝑉𝑒𝑟𝑡𝑖𝑐𝑎𝑙 = 0.001(𝐻)(𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦)
𝑃𝑉𝑒𝑟𝑡𝑖𝑐𝑎𝑙 = 0.001(4.92)(50.28)
𝑃𝑉𝑒𝑟𝑡𝑖𝑐𝑎𝑙 = 0 ℎ𝑝
𝑃𝐸𝑚𝑝𝑡𝑦 = 0.4ℎ𝑝
𝑃𝑇𝑜𝑡𝑎𝑙 = 0.83 ℎ𝑝 = 𝟎. 𝟔𝟐 𝒌𝑾
𝑇𝑜𝑛𝑠
Capacity = 20.12 ℎ𝑟
Approximately:
Length = 5 m = 16.40 ft
Velocity = 90 m/hr
𝐿 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦
𝑃ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 = 0.4 + ( )( )
300 100
16.40 20.12
𝑃ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 = 0.4 + ( )( )
300 100
𝑃ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 = 0.41 ℎ𝑝
𝑃𝑉𝑒𝑟𝑡𝑖𝑐𝑎𝑙 = 0.001(𝐻)(𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦)
𝑃𝑉𝑒𝑟𝑡𝑖𝑐𝑎𝑙 = 0.001(4.92)(20.12)
𝑃𝑉𝑒𝑟𝑡𝑖𝑐𝑎𝑙 = 0.10 ℎ𝑝
𝑃𝐸𝑚𝑝𝑡𝑦 = 0.4ℎ𝑝
Length = 4 m = 13.21 ft
158
Velocity = 90 m/hr
𝐿 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦
𝑃ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 = 0.4 + ( )( )
300 100
13.21 30.17
𝑃ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 = 0.4 + ( )( )
300 100
𝑃ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 = 0.41 ℎ𝑝
𝑃𝑉𝑒𝑟𝑡𝑖𝑐𝑎𝑙 = 0 hp
𝑃𝐸𝑚𝑝𝑡𝑦 = 0.4ℎ𝑝
𝑃𝑇𝑜𝑡𝑎𝑙 = 0.81 ℎ𝑝 = 𝟎. 𝟔𝟎 𝒌𝑾
Length = 5 m = 16.4 ft
Velocity = 90 m/hr
𝐿 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦
𝑃ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 = 0.4 + ( )( )
300 100
16.4 17.92
𝑃ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 = 0.4 + ( )( )
300 100
𝑃ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 = 0.41 ℎ𝑝
159
𝑃𝑉𝑒𝑟𝑡𝑖𝑐𝑎𝑙 = 0 hp
𝑃𝐸𝑚𝑝𝑡𝑦 = 0.4ℎ𝑝
Appendix C
Conveyors
Tons 𝑇𝑜𝑛𝑠
Capacity: 928.43 = 38.64
day ℎ𝑟
Tons 𝑇𝑜𝑛𝑠
Capacity = 38.68 (1.30) = 50.28
hr ℎ𝑟
@ 0o Inclination (horizontal)
(in) (Tons/hr
16 38.70
? 50.28
18 51
Approximately:
Length = 6 m = 19.68 ft
Velocity = 90 m/hr
Tons 𝑇𝑜𝑛𝑠
Capacity: 371.37 = 15.47
day ℎ𝑟
161
Tons 𝑇𝑜𝑛𝑠
Capacity = 15.47 (1.30) = 20.12
hr ℎ𝑟
@ 20o Inclination
(in) (Tons/hr
? 20.12
14 38.40
16 52.50
Approximately:
Length = 5 m = 16.40 ft
Velocity = 90 m/hr
Tons 𝑇𝑜𝑛𝑠
Capacity: 557.06 = 23.21
day ℎ𝑟
Tons 𝑇𝑜𝑛𝑠
Capacity = 23.21 (1.30) = 30.17
hr ℎ𝑟
@ 0o Inclination (horizontal)
162
(in) (Tons/hr
14 27.99
? 30.17
16 38.70
Approximately:
Length = 4 m = 13.21 ft
Velocity = 90 m/hr
Tons 𝑇𝑜𝑛𝑠
Capacity: 330.84 = 13.78
day ℎ𝑟
Tons 𝑇𝑜𝑛𝑠
Capacity = 13.78 (1.30) = 17.92
hr ℎ𝑟
@ 0o Inclination (horizontal)
(in) (Tons/hr
? 17.92
14 27.99
16 38.70
163
Approximately:
Length = 5 m = 16.4 ft
Velocity = 90 m/hr
𝑃 50 33000
T= = = 0.0612ℎ𝑝 × = 2020.04 𝑙𝑏 𝑓𝑡
2𝜋𝑁 2𝜋(130) 1
Where:
P= 50 hp
N= 130 rpm
𝑇 2020.04𝑙𝑏 𝑓𝑡
𝐹= = = 1539.28 𝑙𝑏 = 6 845.81 N
𝑟 1.31234 𝑓𝑡
Process Conditions
Feed Air
Outlet Temperature 50 °C 50 °C
164
1 𝑑𝑎𝑦 1000 𝑘𝑔
557.05899 𝑡/𝑑𝑎𝑦 ( ) ( 1 𝑡𝑜𝑛 ) 𝑘𝑔
24 ℎ𝑟𝑠
Feed = = 7,736.93
3 𝑢𝑛𝑖𝑡𝑠 ℎ𝑟
2019)
Handbook)
of Perry’s Handbook: Humidity = 0.0213 kg of water per kg of dry air Taking the humid
heat of Air:
165
𝑘𝐽
𝐶𝑠 = 1.045
𝑘𝑔 𝐾
Allotting an allowance of 10%, for the possible heat losses and due to startup,
𝑀𝑎 = (1.10)(133,821.22)
𝑘𝑔
𝑀𝑎 = 147,203.34
ℎ𝑟
The allowable mass velocity of the air ranges from 2000 kg/hr-m2 up to 25,000 kg/hr-m2
(McCabe, Harriot, & Smith, 1993). Assuming that the mass velocity of air =24,000
𝑀𝑎 147,203.34
𝐴= = = 6.13 𝑚2
𝑀𝑎𝑠𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑎𝑖𝑟 24,000
𝜋
5.2 = (𝐷)2
4
𝐷 = 2.80 𝑚
Drying diameter ranges from 1 to 3 m (McCabe, Harriot, & Smith, 1993), thus the
The following empirical equation is used to calculate for the overall heat transfer
coefficient from Perry’s Handbook with the index n = 0.67 (McCormick, 1962). The k
value falls in the range 3.75 ≤ k ≤ 5.25 as suggested by AICHE for SI unit (van’t Land,
𝑘𝐺 𝑛
𝑈𝑎 =
𝐷
4.75(24,000)0.67
𝑈𝑎 =
2.80
𝑘𝐽
𝑈𝑎 = 1385.63
ℎ𝑟 − 𝑚3 − 𝐾
For the calculation of wet bulb temperature, the most economical operation of rotary
dryer can be achieved for Nt is in general between 1.5 and 2.5 (Mujumdar, 2014).
378.15 − 𝑇𝑤𝑏
1.5 = ln ( )
323.15 − 𝑇𝑤𝑏
𝑇𝑤𝑏 = 307.35 𝐾
∆𝑇 = 36.67 𝐾
𝑄 = 𝑈𝑎 𝐴𝐿(∆𝑇)𝑙𝑚
𝑄 7,691,698.197
𝐿= = = 24.68 𝑚
𝑈𝑎 𝐴(∆𝑇)𝑙𝑚 1,385.65 (6.13)(36.67)
𝐿 24.68
= = 8.814
𝐷 2.8
L/D ratio is most efficient between 4 and 10 for industrial dryers (Mujumdar, 2014),
Speed values ranges 0.1 to 0.5 m/s (van’t Land, 2012). Assuming the peripheral speed of
The revolution of a drier varies between 2-5 rpm. Therefore, the above value can be
accepted.
Flight Design:
3.28 𝑓𝑡
𝑁𝑜. 𝑜𝑓 𝑓𝑙𝑖𝑔ℎ𝑡𝑠 = 3 (2.8𝑚 × ) = 27.5 ≈ 28
1𝑚
Flight Depth:
𝐷 2.8 𝑚
𝐹𝑑 = = = 0.35 𝑚
8 8
Using the following empirical equation for the residence time (in minutes) in dryer as
Figure: Conventional hot air drying of mango kernels (D denotes drying temperature in
°C)
169
𝑀𝑠 4ℎ𝑟𝑠
=
𝐴𝑅𝑐 (0.545 − 0.34 + (0.34 − 0.02) ln 0.34 − 0.02 )
0.075 − 0.02
𝑀𝑠
= 5.205
𝐴𝑅𝑐
𝑀𝑠 𝑑𝑥
𝑅=
𝐴 𝑑𝜃𝑡
𝑅 = 𝑅𝑐
𝜃𝑐
𝑀𝑠
𝑅 ∫ 𝑑𝜃 = − (𝑋𝑐 − 𝑋𝑖)
0 𝐴𝑅𝑐
𝜃 = −5.205(0.12 − 0.444)
𝜃𝑡 = 1.69 ℎ𝑟𝑠
πD2i (1.5Di )
V=
4
H(height)
=1.5
Di (inside diameter)
170
πD2i (1.5Di )
20.3541=
4
Di = 2.585 m
H = 3.8775 m
ρgH
Static Pressure, Ps =
1000
990.53×9.81×3.8775
Ps = = 37.678 kPa
1000
Pt = 175.573 kPa
Using data from Plant Design and Economics for Chemical Engineers by McGraw-Hill.
Assume to have a joit efficiency, εf = 0.85 and corrosion allowance equals to 0.002
P (ri )
Thickness, tw = + Cc
Sεf-0.6P
171
2.585
(233.512) (
tw = 2 ) + 0.002
(94,458.175×0.85)-(0.6×233.512)
tw = 5.7656x10-3 m
Agitator Design
From Unit Operations of Chemical Engineering by McCabe, Smith and Harriot (7th ed.),
page 247
Dt 2.585
Da = = = 0.862 m
3 3
Ha = Da ; Ha =0.862 m
Da 0.862
L= = = 0.2155 m
4 4
Da 0.862
W= = =0.1724 m
5 5
Dt 2.585
J= = = 0.2154 m
12 12
From Chemical Process Equipment Selection and Design by Stanley Walas, page 288,
having a maximum level H/Dt approximately equal to 1.6, the number of impellers is
equal to 2.
πD2i (1.5Di )
V=
4
H(height)
=1.5
Di (inside diameter)
πD2i (1.5Di )
6.876 =
4
Di = 1.8 m
H = 2.7 m
ρgH
Static Pressure, Ps =
1000
1000×9.81×2.7
Ps = = 26.487 kPa
1000
Using data from Plant Design and Economics for Chemical Engineers by McGraw-Hill.
Assume to have a joit efficiency, εf = 0.85 and corrosion allowance equals to 0.002
P (ri )
Thickness, tw = + Cc
Sεf-0.6P
1.8
(218.628) (
tw = 2) + 0.002
(94,458.175×0.85)-(0.6×218.628)
tw = 4.4547x10-3 m
Agitator Design
From Unit Operations of Chemical Engineering by McCabe, Smith and Harriot (7th ed.),
page 247
Dt 1.8
Da = = = 0.6 m
3 3
Ha = Da ; Ha =0.6 m
Da 0.6
L= = = 0.15 m
4 4
Da 0.6
W= = =0.12 m
5 5
174
Dt 1.8
J= = = 0.15 m
12 12
From Chemical Process Equipment Selection and Design by Stanley Walas, page 288,
having a maximum level H/Dt approximately equal to 1.6, the number of impellers is
equal to 2.
Nomenclature
Di = inside diameter
Ps = static pressure
Pt = total pressure
tw = thickness
Dt = outside diameter
Da = impeller diameter
J = width of baffle
175
Neutralization
H = height of tank
𝜋𝐷 2 𝐻
V= H=D
4
𝜋𝐷 2 𝐻
555.2331m3 = 4
D = 8.9083m
H = 8.9083m
From the Unit process in Chemical Engineering by McCabe, Smith and Hariott
Da = Impeller Diameter
Ha = Da = 2.9694 m
𝐷𝑡 8.9083 𝑚
L= = = 2.2271 m
4 4
𝐷𝑡 8.9083 𝑚
W= = = 1.7817 m
5 5
𝐷 8.9083 𝑚
J = 12𝑡 = = 0.7424 m
12
176
Inlet temperature of the cooling water is assumed to be 20 C and the outlet temperature is
28 C.
∆𝑇1 − ∆𝑇2
∆𝑇𝑚 =
∆𝑇
ln ∆𝑇1
2
∆𝑇1 = 30 − 10 = 10℃
∆𝑇2 = 30 − 28 = 2℃
10 − 2
∆𝑇𝑚 = = 4.97 𝐾
10
ln
2
Pitch = 2Dp
𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑗𝑎𝑐𝑘𝑒𝑡
No. of Spiral = 𝑃𝑖𝑡𝑐ℎ
8.9083 𝑚
No. of Spiral = 0.5938 𝑚 = 14.90 approx 15
Spacing between jacket vessel wall for large vessel is equal to 0.3m
Fermenter
Density of the feed is assumed to be the density of the water at 32OC, from Perry’s
𝑘𝑔 1 𝑑𝑎𝑦
= 77,471.5 𝑑𝑎𝑦 ( 24 ℎ𝑟 ) = 3,227.98 kg/hr
Since the working volume is too large, it will be divided into five fermenters
2905.72 m3
( ) = 581.14 m3
5
From Chemical Process Engineering Design and Economics by Harry Silla, a safety
factor 30% will be used, 30% of the volume as the free space in the fermenter
= 755.49 m3
From Chemical Process Equipment Selection and Design by Stanley Walas, the
𝑉 = 𝜋(𝐷2 /4)(𝐻)
But, H/D = 2
𝑉 = 𝜋(𝐷2 /4)(2𝐷)
D= 7.83 m
H= 2(7.83) = 15.66 m
Mechanical Design:
= 333.45 kPa
= 443.49 kPa
= 0.0217 + 0.002
= 0.0237 m
Therefore,
For reactor head, torispherical will be used since operating pressure of the vessel
1.104𝑃𝐷
th= (2Ɛ𝑆−0.2𝑃) + 𝐶
1.104(443.49)(7.83)
= (2(0.85)(94408)−0.2(443.49)) + 0.002 m
= 0.0259 m
Agitator Design:
𝐷𝑡 7.83
Impeller Diameter, Da= ( 3 ) = ( ) = 2.61 m
3
Da 2.063
Length of Impeller Blade, L = ( )= ( ) = 0.6525 m
4 4
Da 2.063
Width of Impeller Blade, W= ( )= ( ) = 0.522 m
5 5
𝐷𝑡 7.83
Width of Baffles, J= ( 12 ) = ( ) = 0.6525 m
12
1.4 1 H/3
0.8 1 H/3
𝐻 16.66
( )=( ) = 2.13
𝐷𝑡 7.83
Impeller clearance:
𝐷𝑡 7.83
Lower: ( 3 ) = ( ) = 2.61 m
3
2 2
Upper: (3 𝐻) = (3 𝑥16.66) = 11.11 m
No. of Baffles = 4
Pre fermenters
V(pre-fermenter) = 0.1V(fermenter)
= 0.1(755.49)
= 75.55 m3
But, H/D = 2
D= 3.64 m
H= 2(3.64) = 7.28 m
3.64
443.49( )
2
tw= (94,408(0.85)−0.6(443.49)) + 0.002 𝑚
= 0.0121 m
Agitator Design:
𝐷𝑡 3.64
Impeller Diameter, Da= ( 3 ) = ( ) = 1.213 m
3
Da 1.213
Length of Impeller Blade, L = ( )= ( ) = 0.3033 m
4 4
Da 1.213
Width of Impeller Blade, W= ( )= ( ) = 0.2426 m
5 5
𝐷𝑡 3.64
Width of Baffles, J= ( 12 ) = ( ) = 0.3033 m
12
𝐻 8.28
( )=( ) = 2.27
𝐷𝑡 3.64
Number of impellers = 2
Impeller clearance:
𝐷𝑡 3.64
Lower: ( ) = ( ) = 1.2133 m
3 3
2 2
Upper: (3 𝐻) = (3 𝑥8.28) = 5.52 m
No. of Baffles = 4
Culture Vessels
3rd
Vcv3=Vpf =75.55 m3
But, H/D=2
D=3.64 m
182
H= 2(3.64) = 7.28 m
D= 1.69 m
Distillation
kg
MWF =18.5936 kmol
𝑘𝑔
MWD =41.88 𝑘𝑚𝑜𝑙
kg
MWB = 18.189 kmol
kg 𝑘𝑚𝑜𝑙
𝐹 = 1.2175 x 106 day = 65.4781 x 106 xF = 0.0212
𝑑𝑎𝑦
kg 𝑘𝑚𝑜𝑙
𝐷 = 48, 580.8 day = 1.16x 106 xD = 0.8529
𝑑𝑎𝑦
kg 𝑘𝑚𝑜𝑙
𝐵 = 1.1699 x 106 day = 64.3181 x 106 xB = 0.0062
𝑑𝑎𝑦
@ T=78 °C = 351.15 K
𝑐𝑎𝑙 𝐽
Cp = 1.014 𝑔 𝐾 =195.446 𝑚𝑜𝑙 𝐾
183
q-line:
𝑞 𝐹𝑥
𝑦= 𝑥 − 𝑞−1
𝑞−1
Cp(𝑇𝐵 −𝑇𝐹 )
q = 1+ 𝜆𝐹
TB = Boiling Temperature of F
TF = Temperature of F
@ x = 0.0212
TB = 94.98°C =368.13K
TF = 80°C
Cp(𝑇𝐵 −𝑇𝐹 )
q = 1+ 𝜆𝐹
Hv = Heat of Vaporization
From Table 2-141 and 2-150 of perry’s chemical engineering Handbook (PCEH) 8th ed
Water Ethanol
Tc 647.096 K 514 K
𝐽
𝜆F = 38,974.30 𝑚𝑜𝑙
Solving for q:
𝐽
195.446 (94.98−80)K
𝑚𝑜𝑙 𝐾
q = 1+ 𝐽 = 1.0751
38,974.30
𝑚𝑜𝑙
𝑞 1.0751
𝑚= = = 14.31
𝑞−1 0.0751
𝐹 𝑥 0.0212
Y intercept = 𝑞−1 = 0.0751 = 0.28
By graphing :
By graphing :
𝑅𝑚 𝑥𝐷 −𝑦𝑝 0.8529−0.31
=𝑥 =0.8529−0.04
𝑅𝑚+1 𝐷 −𝑥𝑝
Rm = 2.01
By Frenske Equation
𝑥𝐷 1−𝑥𝐵
ln( )
1−𝑥𝐷 𝑥𝐵
𝑁𝑚𝑖𝑛 = 𝑙𝑛∝
185
𝑃𝐸𝑡ℎ𝑎𝑛𝑜𝑙
∝=
𝑃𝑊𝑎𝑡𝑒𝑟
@T=78.5 C
A B C
765.74
∝= = 2.30
333.50
𝑁𝑅 1−𝑥𝐹 𝑥 𝐵 0.206
=( (1−𝑥𝐵 ) 𝐷)
𝑁𝑠 𝑥𝐹 𝐷
186
𝑚𝑜𝑙 0.206
𝑁𝑅 1−0.0212 0.0062 2.68×106
ℎ𝑟
=( (1−0.8529) 𝑚𝑜𝑙 )
𝑁𝑠 0.0212 48,333.33
ℎ𝑟
𝑁𝑅
= 2.62 (Eq. 1)
𝑁𝑠
𝑁𝑅 + 𝑁𝑠 = 13 (Eq. 2)
Solving Simultaneously:
𝑁𝑅 = 9.40
𝑁𝑠 = 3.59
Feed entry:
@ TDistillation=78.5°C
𝑚𝑜𝑙 𝑚𝑜𝑙
𝜌𝑉 𝐸𝑡ℎ𝑎𝑛𝑜𝑙 = 15.960 𝜌𝐿 𝐸𝑡ℎ𝑎𝑛𝑜𝑙 = 0.04223
𝐿 𝐿
𝑚𝑜𝑙 𝑚𝑜𝑙
𝜌𝑉 𝑤𝑎𝑡𝑒𝑟 = 55.359 𝜌𝐿 𝑤𝑎𝑡𝑒𝑟 = 0.01771
𝐿 𝐿
Average MW of D:
𝑘𝑔
𝑀𝑊𝑎𝑣𝑒 𝐷 = (0.8529) (46.068 𝑘𝑚𝑜𝑙) + (1 − 0.8529)(18.015)
𝑘𝑔
𝑀𝑊𝑎𝑣𝑒 𝐷 = 41.935 𝑘𝑚𝑜𝑙
𝑚𝑜𝑙
𝜌𝐿 = [(0.95) (15.960 )+
𝐿
𝑘𝑔
𝜌𝐿 = 749.71 𝑚3
𝑚𝑜𝑙
𝜌𝑉 = [(0.95) (0.04223 )+
𝐿
𝑘𝑔
𝜌𝐿 = 1.7221 𝑚3
749.71−1.7221 0.5
𝑢̂𝑣 = [−0.17(0.5𝑚)2 + 0.27(0.5𝑚) − 0.047]( )
1.7221
𝑚
𝑢̂𝑣 = 0.915 𝑠
̂
4𝑉
Dc = √𝜋𝜌 𝑤𝑢̂
𝑉 𝑣
𝐿
= 2.02
𝐷
𝑘𝑔
𝑉̂𝑤 = 𝐿 + 1 = 2.02 + 1 = 3.02 𝑠 (𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑎𝑝𝑜𝑟 𝑟𝑎𝑡𝑒)
𝑘𝑔
4(3.02 )
𝑠
Dc = √ 𝑘𝑔 𝑚 = 1.56 𝑚
𝜋(1.7221 3 )(0.915 )
𝑚 𝑠
Dc = (1.2)(1.56m)
Dc = 1.87 m
𝐻 = 𝐷15 = 1.87(15𝑚)
𝑯 = 𝟐𝟖. 𝟎𝟓 𝒎
188
Condenser:
q = mwCp∆T
Assuming ∆T = 25°C
𝑘𝐽 kJ
9.89𝑥106 ℎ𝑟 = 𝑚𝑤 (4.186 kg K)(25K)
𝒌𝒈
𝒎𝒘 = 𝟗𝟒, 𝟓𝟎𝟓 𝒉𝒓
For Condensers:
𝑊
𝑈 = 1000
𝑚2 °𝐶
Temperature ratio,
𝑇 −𝑇
R = 𝑡1−𝑡2
2 1
78.5−50
R= 50−25
R = 1.14
(78.5−50)−(50−25)
∆𝑇m = [ 78.5−50 ] 0.8
𝑙𝑛
50−25
∆𝑇m = 21.37°C
𝑞
A = 𝑈∆𝑇
𝑚
𝑘𝐽 1000𝐽 1ℎ𝑟
9.89𝑥106 ( )( )
ℎ𝑟 𝑘𝐽 3600𝑠
A= 𝑊
1000 2 (21.37°C)
𝑚 𝐾
189
A = 128.55 m2
ID = 0.652 in = 16.56mm
Using L = 8m,
128.55 m2
# of tubes = 0.5587 𝑚2 = 230.08 ≈ 𝟐𝟑𝟎 𝑻𝒖𝒃𝒆𝒔
Pt = 1.25(22.23mm)
Pt = 27.79 mm
Using 2 Passes:
K1 = 0.156
n1= 2.291
1
230 2.291
Db = 22.23 (0.156)
Db = 537.04 mm
𝐷𝑏 537.04 𝑚𝑚
NT = =
𝑃𝑡 27.79 𝑚𝑚
190
NT = 19.32
NT ≅ 19
𝑘𝐽
qr= 1.87 × 106 ℎ
Ts in = 120 deg C
Ts out = 90 deg C
qs=ms(Cp∆𝑇+𝜆)
For Steam:
KJ
Cp = 1.88 kg K
𝜆 = 2202 kJ / kg
qr = qs
𝑘𝐽 𝑘𝐽 𝑘𝐽
1.87 × 106 ℎ𝑟 = ms ((1.88 𝑘𝑔 𝐾)(120-90)K + (2202𝑘𝑔))
𝒌𝒈
ms =828.02 𝒉𝒓
qr= UA∆𝑇m
𝑘𝐽 1000𝐽 1ℎ𝑟 𝑊
1.87 × 106 ℎ𝑟 ( )(3600𝑠)= 1000𝑚2 °𝐶(A)(24.09°𝐶)
1𝑘𝐽
A =21.56 m2
21.56 m2
# of U – Tubes = 50
(𝜋)(3)
1000
Pitch = 1.25Do
Bundle Diameter:
1
𝑁 𝑛1
Db = do((𝐾1 )
1
K1=0.158
N1=2(U-tubes)
n1= 2.263
1
2(46) 2.617
Db = 50mm (0.158)
Db = 569.60 mm = 0.57m
𝑘𝑔
ms= 828.02 ℎ𝑟
𝑘𝐽
C p=1.8837 𝑘𝑔 𝐾
𝑘𝑔 1ℎ𝑟 𝑘𝐽
Power Requirement = 828.02 ℎ𝑟 (3600 𝑠) (1.8837 ) (24.99𝐾)
𝑘𝑔 𝐾
Dehydration
The fermented solution undergoes distillation process to remove the water present
on it but water removal of the distillation process has a limit which requires the use of an
additional process before it blends with pure ethanol with gasoline due to the ethanol-
25 0.249 0.317
40 0.238 0.153
193
50 0.220 0.090
60 0.200 0.052
The Arrhenius equation explains the variation of Langmuir equation isotherm constant
∆𝐻 1
ln|K| = (𝑅𝑇 ) (𝑇) + 𝑙𝑛 |𝐾𝐿 | (eq.1)
Where:
y= ln|K|
∆𝐻
m= (𝑅𝑇 )
1
x= (𝑇)
b= 𝑙𝑛 |𝐾𝐿 |
-1
-1.5
-2
-2.5
-3
-3.5
∆𝐻
m= (𝑅𝑇 ) = 5204.5867
b= 𝑙𝑛 |𝐾𝐿 | = −18.5592
𝐾𝐿 = 8.7064x 10-9
m= -0.001
b= 0.670
(𝑄)(𝐾)(𝐶∗)
q*= + Kc*
1
(0.317)(0.0218)(𝐶∗)
q*= + 0.0218c*
1
195
adsorbed on the surface are in equilibrium with those in the gas phase is:
6.9106x10−3𝑃
q*= + 0.0218P
1
Concentration of the adsorbed phase can be calculated using zeolite 3A to purify 95mol%
ethanol to 99.99mol% in a two bed pressure swing adsorption process with feed gas and
off gas at 25 atm and 2 atm, respectively. Adsorption time is 300 seconds and beds are
In feed:
(3.852x10−3)(3.67)
Molecules of A adsorbed on the surface = 1+(0.02189𝑥3.67)
𝑔 𝑤𝑎𝑡𝑒𝑟
= 0.0131 𝑔 𝑎𝑑𝑠𝑜𝑟𝑏𝑒𝑛𝑡
Off-gas:
(3.852x10−3)(1.9)
Molecules of A adsorbed on the surface = 1+(0.02189𝑥1.9)
𝑔 𝑤𝑎𝑡𝑒𝑟
= 0.00703 𝑔 𝑎𝑑𝑠𝑜𝑟𝑏𝑒𝑛𝑡
300
[(48.3333x0.1471)-( 48.3333x0.0001)](18.015)( (3600) = (0.0131 − 0.00703)Ma(0.85)
Ma=2067.33 kg
2067.33
Volume of adsorbent bed= (779.5811) = 2.65 m3
(1.2)(2.65) = 3.182 m3
molecular sieve units”, L/D ratio of the vessel should not be below 2. Therefore, an
L/D=4
D= 1.00 m
H= 4.00 m
Final H= 4.00-1=3.00 m
Number of units: 3
L 7 days
Capacity of each tank=58,000 ( ) =406,000 L/wk
day 1 week
1 m3 1.30
V=406,000 L ( )( ) =175.933 m3 /unit
1000 L 3
πD2 H
V= (1)
4
197
2H = 5D
5
πD2 ( 2 D)
175.933 =
4
D = 4.47 m
H = 11.175 m
No of units: 1
1 𝑚3
Capacity = 91,045.61 kg/day (1000 𝑘𝑔)
= 91.05 m3
V= 91.05(1.3) = 118.36 m3
𝑉 = 𝜋(𝐷2 /4)(𝐻)
But, 3H=5D
D= 4.49 m
H= 7.48 m
Number of Units: 1
= 366.9503 m3/day
198
𝑉 = 𝜋(𝐷2 /4)(𝐻)
D= 7.14 m
H= 11.9 m
Number of Units: 1
= 125.1611 m3/day
𝑉 = 𝜋(𝐷2 /4)(𝐻)
D= 4.99 m
H= 8.32 m
No. of Units: 1
199
1 𝑚3
Capacity = 315,213.9 kg/day ((1127 𝑘𝑔) = 279.69 m3/day
V = 279.69(1.3) = 363.6 m3
𝑉 = 𝜋(𝐷2 /4)(𝐻)
But, 3H=5D
D= 6.52 m
H= 10.87 m
Anaerobic Digester
Number of Units: 5
V= 1500 m3
1.3
V= 1500 (5 𝑢𝑛𝑖𝑡𝑠) = 390 m3
𝑉 = 𝜋(𝐷2 /4)(𝐻)
But 3D=2H,
𝜋(𝐷 2 ) 3
390 = [(2) 𝐷]
4
D= 6.92 m
H= 10.38 m
Agitator Design
From Unit Process in Chemical Engineering by Mccabe, Smith and Hanott (7th ed) p.247
𝐷𝑡 6.92
Impeller Diameter, Da= ( 3 ) = ( ) = 2.31 m
3
200
Da 2.31
Length of Impeller Blade, L = ( )= ( ) = 0.5775 m
4 4
Da 2.31
Width of Impeller Blade, W= ( )= ( ) = 0.462 m
5 5
𝐷𝑡 6.92
Width of Baffles, J= ( 12 ) = ( ) = 0.58 m
12
1.4 1 H/3
0.8 1 H/3
𝐻 10.38
( )=( ) = 1.5
𝐷𝑡 6.92
Impeller clearance:
𝐷𝑡 6.92
Lower: ( 3 ) = ( ) = 2.31 m
3
2 2
Upper: (3 𝐻) = (3 𝑥10.38) = 6.92 m
Requirements
From Raw Water Tank and Processed Water Tank to utilities: 20,000 kg/h
Basis: 1 hr
Volume: 190 m3
H=2D
𝑉 = 𝜋(𝐷2 /4)(𝐻)
D= 5.26 m
H= 10.51 m
Basis: 1 hr
Volume: 55 m3
V= 55 (1.2) = 66 m3
𝑉 = 𝜋(𝐷2 /4)(𝐻)
But, H=2D
202
66 = 𝜋(𝐷2 /4)(2𝐷)
D=3.48 m
H= 6.95 m
Basis: 1 hr
Volume: 45 m3
V=45(1.2) = 54 m3
But, H=2D
𝑉 = 𝜋(𝐷2 /4)(𝐻)
54 = 𝜋(𝐷2 /4)(2𝐷)
D=3.25 m
H= 6.5 m
Basis: 1 hour
Volume: 95 m3
V= 95(1.2) = 114 m3
But, H=2D
95 = 𝜋(𝐷2 /4)(2𝐷)
203
D= 3.93 m
H= 7.85 m
204
Appendix D
Power Requirement
Pumps
PTotal=340.61+91.74+118.87+658.66+237.54+237.54+1288+2338+1708+1609.6
1+66.61+261.13+14.92+1832.43+66.27+1168+3664.11+402.14+16.53+24.903
PT=16,145.61 W = 16.15 kW
Conveyor
Conveyor 1=0.62
Conveyor 2=0.62
Conveyor 3=0.68
Conveyor 4=0.60
Conveyor 5=0.60
Ptotal= 3.12 kW
Roll Crusher
0.746kW
𝑃 = 7.1hp ( )
hp
𝑷 = 𝟓. 𝟑𝟎𝐤𝐖
Sieving
0.746kW
𝑃 = 60.35hp ( )
hp
205
𝑷 = 𝟒𝟓. 𝟎𝟐𝐤𝐖
Dryer
𝑘𝐽 1ℎ𝑟
𝑃 = 7,691,698.197 ( )
ℎ𝑟 3600𝑠
𝑷 = 𝟐𝟏𝟑𝟔. 𝟓𝟖𝐤𝐖
Mill
0.746kW
𝑃 = 300hp ( )
hp
𝑷 = 𝟐𝟐𝟑. 𝟖𝐤𝐖
Electrodialysis:
𝑷 = 𝟐𝟒𝐤𝐖
ft
D = 3.246 m (3.28 1m) = 10.65 ft
𝑃 3.8ℎ𝑝
=
𝑉 1000𝑔𝑎𝑙
𝑷 = 𝟐𝟑. 𝟐𝟔𝒌𝑾
ft
D = 2.48 m (3.28 1m) = 8.13 ft
206
𝑃 4.7ℎ𝑝
= 1000𝑔𝑎𝑙
𝑉
𝑷 = 𝟏𝟐. 𝟖𝟐𝒌𝑾
Main Fermenter
ft
D = 7.83 m (3.28 1m) = 25.68 ft
𝑃 1.7ℎ𝑝
=
𝑉 1000𝑔𝑎𝑙
𝑷 = 𝟏𝟐𝟔𝟕. 𝟑𝟒𝒌𝑾
Pre-Fermenter
ft
D = 3.64 m (3.28 1m) = 11.94 ft
𝑃 3.8ℎ𝑝
= 1000𝑔𝑎𝑙
𝑉
𝑷 = 𝟏𝟔𝟗. 𝟗𝟖𝒌𝑾
Neutralization
ft
D = 8.91 m (3.28 1m) = 29.22 ft
𝑃 1.3ℎ𝑝
= 1000𝑔𝑎𝑙
𝑉
𝑷 = 𝟏𝟒𝟐. 𝟒𝟓𝒌𝑾
Centrifuge
𝑷 = 𝟔𝟎𝐤𝐖
Cooling Tower
P=35.16 kW
Reboiler
𝑘𝐽 1ℎ𝑟
𝑃 = 1.87 × 106 (3600𝑠)
ℎ
𝑷 = 𝟓𝟏𝟗. 𝟒𝟒𝐤𝐖
Total Power Requirement = 16.15 + 3.12+ 5.30 + 45.02 +2136.58 + 223.80 + 24+ 23.26
Appendix E
Bund Area
H = 11.175 m
𝜋
AB = 4 𝐷2
𝜋
AB = 4 (7.14)2 = 40.04 m2
30% H2SO4:
V= 162.71 m3
H= 8.32 m
D= 4.99 m
Net Capacity of the Bund = 162.71 m3 x 1.33 = 216.40 m3
Bund area:
𝜋
AB = 4 𝐷2
𝜋
AB = 4 (4.99)2 = 19.56 m2
AE=2(19.56)= 39.12 m2
Total area = Tank Area + Operational Allowances
= 39.12 + 2
Total Area = 41.12 m2
Height of the Bund area = Bund Capacity / Total Area
= 157.42 / 41.12 = 3.83 m
Appendix F
Decanter
1.00 990,000.00 198,000.00 1,188,000.00
Centrifuge
Rotary Vacuum
1.00 1,300,000.00 260,000.00 1,560,000.00
Centrifuge
Subtotal: 219,377,532.82
Storage Tank
Ethanol Storage
3.00 3,390,065.00 678,013.00 12,204,234.00
Tank
Sulfuric Acid
1.00 3,026,133.50 605,226.70 3,631,360.20
Recovery Tank
70% Sulfuric
Acid Storage 1.00 3,222,296.00 644,459.20 3,866,755.20
Tank
30% Sulfuric
Acid Storage 1.00 2,829,971.00 565,994.20 3,395,965.20
Tank
Lime Storage
1.00 3,800,130.00 760,026.00 4,560,156.00
Tank
Subtotal: 27,658,470.60
Power Plant
Furnace 1.00 501,000.00 100,200.00 601,200.00
Turbine 1.00 2,025,600.13 405,120.03 2,430,720.16
Boiler 1.00 1,690,000.00 338,000.00 2,028,000.00
Subtotal: 5,059,920.16
Water Treatment Plant
Raw Water
1.00 609,802.44 121,960.49 731,762.93
Tank
Processed
1.00 400,135.00 80,027.00 480,162.00
Water Tank
Softened Water
1.00 360,200.30 72,040.06 432,240.36
Tank
Demineralized
1.00 280,220.00 56,044.00 336,264.00
Water Tank
Clarified Water
1.00 388,700.00 77,740.00 466,440.00
Tank
Clarifier 1.00 350,200.00 70,040.00 420,240.00
Degasser 2.00 208,716.90 41,743.38 500,920.56
Activated
1.00 350,089.00 70,017.80 420,106.80
Carbon Filter
Dual Media
1.00 350,089.00 70,017.80 420,106.80
Filter
Reverse
1.00 239,777.00 47,955.40 287,732.40
Osmosis
Softening Unit 1.00 280,500.28 56,100.06 336,600.34
217
Subtotal: 4,832,576.18
PhilHealth
Contribution 18,604.08 19,162.2 19,720.32 20,278.45 20,836.57
(Table 9)
Health Insurance
96,000 98,880 101,760 104,640 107,520
(Schedule 10)
Accident
Insurance 3,000 3,090 3,180 3,270 3,360
(Schedule 11)
13th Month Pay
112,752 116,134.6 119,517.1 122,899.7 126,282.2
(Schedule 12)
Repair and
5,153,635 5,308,244 5,462,853 5,617,462 5,772,072
Maintenance
Depreciation of
8,890,020.85 9,156,721 9,423,422 9,690,123 9,956,823
Equipment
Total
Manufacturing 374,440,804 384,865,118 395,588,008 406,618,431 417,965,613
Overhead
TOTAL COST
383,838,101 394,544,334 405,549,143 416,861,485 428,490,585
OF SALES
222
Administrative
1 30,000 1 089 13 068
Head
Human
1 25,000 907.5 10 890
Resource Head
Administration Human
1 9,396.00 341.07 4 092.9
Resource Staff
Physician 1 20,000 726 8 712
Nurse 3 9,396.00 1 023.22 12 278.7
Accounting
and Finance 1 25,000 907.5 10890
Head
Accounting and Accounting
Finance and Finance 2 9,396.00 341.0748 8185.795
Staff
Sales and
Marketing 1 25,000 907.5 10890
Head
Sales and Sales and
Marketing Marketing 1 9,396.00 341.0748 4092.898
Staff
Logistics and
Purchasing 1 25,000 907.5 10890
Logistics and Head
Purchasing Logistics and
Purchasing 3 9,396.00 341.0748 12278.69
Staff
Engineering
1 46,224.00 1677.931 20135.17
Head
Engineering
Powerplant
3 25,000 907.5 32670
Supervisor
Maintenance
1 46,224.00 1677.931 20135.17
Head
Maintenance
Maintenance
3 25,000 907.5 32670
Supervisor
Quality
1 25,000 907.5 10890
Control Officer
Quality
Control 6 9,396.00 341.0748 24557.39
Analysts
Quality Control
Laboratory
6 9,396.00 341.0748 24557.39
Sampler
Production
1 46,224.00 1677.931 20135.17
Head
Production Production
3 25,000 907.5 32670
Supervisors
Electrical Supervisor 3 25,000 907.5 32670
226
Administration Human
1 9,396.00 129.195 1550.34
Resource Staff
Physician 1 20,000 275 3300
Nurse 3 9,396.00 387.585 4651.02
Accounting and
1 25,000 343.75 4125
Finance Head
Accounting and Accounting and
2 9,396.00 258.39 3100.68
Finance Finance Staff
Sales and
1 25,000 343.75 4125
Marketing Head
Sales and Sales and
1 9,396.00 129.195 1550.34
Marketing Marketing Staff
Logistics and
Purchasing 1 25,000 343.75 4125
Logistics and
Head
Purchasing
Logistics and
3 9,396.00 387.585 4651.02
Purchasing Staff
Engineering
1 46,224.00 635.58 7626.96
Head
Engineering
Powerplant
3 25,000 1031.25 12375
Supervisor
Maintenance
1 46,224.00 635.58 7626.96
Head
Maintenance
Maintenance
3 25,000 1031.25 12375
Supervisor
Quality Control
1 25,000 343.75 4125
Officer
Quality Control
6 9,396.00 775.17 9302.04
Analysts
Quality Control Laboratory
6 9,396.00 775.17 9302.04
Sampler
Production
1 46,224.00 635.58 7626.96
Head
Production Production
3 25,000 1031.25 12375
Supervisors
Electrical Supervisor 3 25,000 687.5 8250
Instrumentation Supervisor 3 25,000 412.5 4950
Pollution
Pollution 1 15,000 343.75 4125
Control Officer
Control/ Safety
Safety Officer 1 15,000 129.195 1550.34
Subtotal: 50 131238.4
TOTAL 129 253 715.28
228
Accounting
and Finance 1 8,000 8000
Head
Accounting and Accounting
Finance and Finance 2 8,000 8000
Staff
Sales and
Marketing 1 8,000 24000
Head
Sales and Sales and
Marketing Marketing 1 8,000 8000
Staff
Logistics and
Purchasing 1 8,000 24000
Logistics and Head
Purchasing Logistics and
Purchasing 3 8,000 8000
Staff
Engineering
1 8,000 24000
Head
Engineering
Powerplant
3 8,000 8000
Supervisor
Maintenance
1 8,000 48000
Head
Maintenance
Maintenance
3 8,000 48000
Supervisor
Quality
Control 1 8,000 8000
Officer
Quality
Control 6 8,000 24000
Quality Control Analysts
Laboratory
6 8,000 24000
Sampler
Production
1 8,000 24000
Head
Production Production
3 8,000 8000
Supervisors
Electrical Supervisor 3 8,000 8000
Instrumentation Supervisor 3 8,000 24000
Pollution
Pollution Control 1 8,000 8000
Control/ Safety Officer
Safety Officer 1 8,000 16000
Subtotal: 50 384000
TOTAL: 129 1 016 000
230
Logistics and
Purchasing 3 250 750
Staff
Engineering
1 250 250
Head
Engineering
Powerplant
3 250 750
Supervisor
Maintenance
1 250 250
Head
Maintenance
Maintenance
3 250 750
Supervisor
Quality
1 250 250
Control Officer
Quality
Control 6 250 1500
Analysts
Quality Control
Laboratory
6 250 1500
Sampler
Production
1 250 250
Head
Production Production
3 250 750
Supervisors
Electrical Supervisor 3 250 750
Instrumentation Supervisor 3 250 750
Pollution
Pollution 1 250 250
Control Officer
Control/ Safety
Safety Officer 1 250 250
Subtotal: 50 12000
TOTAL 129 31 750
Powerplant
6 9,396.00 56 376
Operator
Maintenance
6 9,396.00 56 376
Staff
Subtotal: 12 112 752
Administration
Plant Manager 1 50,000 50000
Administrative
1 30,000 30000
Head
Human
1 25,000 25000
Administration Resource Head
Human
1 9,396.00 9396
Resource Staff
Physician 1 20,000 20000
Nurse 3 9,396.00 28188
Accounting
and Finance 1 25,000 25000
Accounting and Head
Finance Accounting
and Finance 2 9,396.00 18792
Staff
Sales and
Marketing 1 25,000 25000
Sales and Head
Marketing Sales and
Marketing 1 9,396.00 9396
Staff
Logistics and
Purchasing 1 25,000 25000
Logistics and Head
Purchasing Logistics and
Purchasing 3 9,396.00 28188
Staff
Engineering
1 46,224.00 46224
Head
Engineering
Powerplant
3 25,000 75000
Supervisor
Maintenance
1 46,224.00 46224
Head
Maintenance
Maintenance
3 25,000 75000
Supervisor
Quality
1 25,000 25000
Control Officer
Quality Control Quality
Control 6 9,396.00 56376
Analysts
233
Laboratory
6 9,396.00 56376
Sampler
Production
1 46,224.00 46224
Head
Production
Production
3 25,000 75000
Supervisors
Electrical Supervisor 3 25,000 75000
Instrumentation Supervisor 3 25,000 75000
Pollution
Pollution 1 15,000 15000
Control Officer
Control/ Safety
Safety Officer 1 15,000 15000
Subtotal: 50 975384
TOTAL 129 1 717 668
Year 2021 Year 2022 Year 2023 Year 2024 Year 2025
Sulfuric
Acid 35,904 Ton 4900 175,929,600.00 181,207,488.00 186,643,712.64 192,243,024.02 198,010,314.74
P-S
Depreciation=
n
P = Actual Cost; S = Salvage Value; n = # of years
236
Buildings,
Structures, and 4,251,749.10 4,251,749.10 4,251,749.10 4,251,749.10 4,251,749.10 4,251,749.10 4,251,749.10
Land Improvement
Office &
Transportation - - 435,783.24 435,783.24 435,783.24 435,783.24 435,783.24
Equipment
Purchased Factory
Equipment and - - 32,467,902.23 32,467,902.23 32,467,902.23 32,467,902.23 32,467,902.23
Machineries
Buildings,
Structures, and 4,251,749.10 8,503,498.20 12,755,247.31 17,006,996.41 21,258,745.51 25,510,494.61 29,762,243.71
Land Improvement
Office &
Transportation - - 435,783.24 871,566.48 1,307,349.72 1,743,132.96 2,178,916.20
Equipment
Purchased Factory
Equipment and - - 32,467,902.23 64,935,804.47 97,403,706.70 129,871,608.93 162,339,511.17
Machineries
TOTAL
8,890,020.85 17,780,041.70 (41,793,705.95) (83,587,412.67) (125,381,118.59) (167,174,825.11) (208,968,531.23)
DEPRECIATION:
238
i(1+i)n
Annuity=P (
(1+i)n -1
P = Money loaned from the bank at t = 0
i = interest
n = # of years to pay the loan
241
Appendix G
Financial Ratios
Test of Liquidity
Current Assets
Current Ratio=
Current Liabilities
394,931,276.57
Current Ratioyear 1 = = 3.97
99,525,120.3
656,694,103.46
Current Ratioyear 2 = = 6.41
102,510,873.9
925,288,529.7
Current Ratioyear 3 = = 8.76
105,586,200.1
1,217,515,765.79
Current Ratioyear 4 = = 11.20
108,753,786.1
1,517,736,523.13
Current Ratioyear 5 = = 13.55
112,016,399.7
Test of Profitability
Gross Profit
Gross Profit Margin =
Sales
421,984,399
Gross Profit Marginyear 1 = = 0.52
805,822,500
443,511,066
Gross Profit Marginyear 2 = = 0.53
838,055,400
466,028,473
Gross Profit Marginyear 3 = = 0.53
871,577,616
242
489,579,235.64
Gross Profit Marginyear 4 = = 0.54
906,440,720.64
514,207,764.47
Gross Profit Marginyear 5 = = 0.55
942,698,349.47
Sales
Sales to Assets =
Total Assets
805,822,500
STAyear 1 = = 0.73
1,096,515,780.26
838,055,400
STAyear 2 = = 0.63
1,330,006,657.04
871,577,616
STAyear 3 = = 0.55
1,572,662,412.25
906,440,720.64
STAyear 4 = = 0.49
1, 840,023,498.98
942,698,349.47
STAyear 5 = = 0.44
2,125,609,678.4
Payback Period
72,880,076.94
Payback Period = 3 + = 3.24 (operation phase only)
298,407,875.89
244
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