Abhishek Final

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PRODUCTION OF BIO-BUTANOL

SUBMITTED BY

Abhishek Singh-(091401)

Dhyananand Yadaw-(091409)

UNDER THE GUIDANCE OF

Prof. N.N.Dutta

Submitted in partial fulfillment of the Degree of

Bachelor of Technology

DEPARTMENT OF CHEMICAL ENGINEERING

JAYPEE UNIVERSITY OF ENGINEERING & TECHNOLOGY

A-B ROAD, RAGHOGARH, GUNA 473226, M.P., INDIA


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CERTIFICATE

This is to certify that work titled Production of Bio-Butanol submitted by AbhishekSingh&Dhyananand Yadaw in partial fulfillment for the award of B. TECH of Jaypee University of

Engineering & Technology, Guna has carried out under my supervision. This work has not been

submitted partially or wholly to any other University or Institute for the award of this or any other degree

or diploma.

Signature of Supervisor..

Name of Supervisor ....

Designation ..

Date .


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ACKNOWLEDGEMENTS

Wewish to express deep sense of gratitude and sincere thanks to our project supervisor Prof.N.N.Dutta Professor, Department of Chemical Engineering & Chemical Technology for hisvaluable guidance,encouragement, suggestions, and moral support throughout the period of this project work.

We express our thanks to Professor N. J. Rao Vice Chancellor of Jaypee University for hisvaluablesuggestions. We would like to thank Professor K. K. Tiwari, who is associated with JUET afterhisretirement from ICT Mumbai for his guidance and suggestions during this project work. We wouldlike tothank Dr. G. K.Agarwal for his suggestions during this work. Our special thanks to Dr.

HariMahalingam Head of Chemical Engineering Department for providing all the necessary facilities tocomplete this work.We would like to thank all other faculty members of Chemical Engineering Department for their

supportduring this work.Finally we would like to thank our batch mates and family for the motivation and support they

haveprovided us.

Signature of students ......... ...............................Name of StudentsAbhishek Singh Dhyananand Yadaw

Date


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Table Of Content

Title Page . i

Certificate ..... ii

Acknowledgement .. iii

1. Introduction

1.1 Historical profile 1

1.2 Introduction .. 1

1.3 Manufacture.. 11.4 Current market share for n-butanol.. 2

1.5 Industrial applications...21.6 Current application...31.7 Various grades and specification of the Biobutanol.4

2 Economic scenario

2.1 Demand and supply:62.2 Indian scenario .. .9

3 Properties

3.1 Physical and chemical properties ...10

3.2 Chemical Product Identification...11

3.3 Hazards Identification...11

3.4 First Aid Measures....11

3.5 Fire and Explosion Data12

3.6 Accidental Release Measures12

3.7 Handling and Storage 12

3.8 Exposure Controls/Personal Protection..13

3.9 Stability and Reactivity Data..13

3.10 Toxicological Information..13

3.11Transport Information..13

3.12Environmental Effects..14

3.13Health effects... 14

4 An introduction to the manufacturing of Biobutanol strategies

4.1 Brief description of pyrolysis.16

4.2 Brief description of fermentation16

4.2.1 Methods for removal of butanol from the broth..17

4.3 Comparison of gasification, fermentation and pyrolysis..20

5 Production of Bio-Butanol by ABE Fermentation

5.1 ABE Fermentation 22


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6 Material balance

6.1 Material balance across pretreatment of wheat straw..25

6.2 Across fermenter.. ...25

6.3 Across Gas Stripper..26

6.4 Across Phase Separator.27

6.5 Across Purge Recycle....28

6.6 Across Splitter29

6.7 Across Phase separator (Down).30

6.8 Across Decanter.. 31

6.9 Across molecular sieve (MS)..32

6.10 Across Distillation Column (1).33

6.11 Across Distillation Column (2).34

7 Energy Balance

7.1 Energy Balance across the fermenter35

7.2 Heat Balance across Condenser.36

7.3 Energy Balance across Gas Stripper...37

7.4 Across Distillation Column (1)..37

7.5 Across Distillation Column (2)...38

8 Detailed Design of Equipment

8.1 Fermenter Design.39

8.2 Storage tank design...39

8.3 Heat Exchanger Design.42

8.4 Distillation Column Design...51

9 Cost Estimation and Economics

9.1 Purchased Equipment Cost...60

9.2 Estimation of Capital Investment Cost..62

9.3 Manufacturing Cost...63

9.4 Profitability analysis..65

10 Plant Layout..66


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11 Control Strategy

11.1 Brief Introduction to Distillation Control67

11.2 Temperature Control68

11.3 Condenser and Pressure Control..69

11.4 Cooling Medium Flow Variation.70

11.5 Reboiler Control...70

11.6 Feed Preheat Control71

11.7 Distillation Column Control.72

12 HAZOP Study Applied To the Exothermic Fermenter Reactor73


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1 INTRODUCTION1.1Historical profile: Biobutanol production via anaerobic bacteria fermentation has been observed since 1861,

when it was witnessed by Pasteur. By the beginning of the 20th century, interest in butanol had risen

sharply. This was due to butanols involvement in the solution to a material shortage. Between 1912 and 1914,

Chaim Weizmann, a chemist, performed one of the first microorganism screenings to study microbiology inhopes to better understand the fermentation process. One species he isolated, Clostridium acetobutylicum, was

able to yield more acetone and butanol. The next advancement occurred during World War 1, when the British

army needed to produce smokeless gun powder.

When Weizmanns patent expired in 1936, a flood of anaerobic fermentation plants were opened. Molassesfermentation processes grew in popularity as new microorganisms were isolated. Every company had its own

unique patented microorganism, which was able to produce acetone and butanol in great amounts from the

molasses.

The next spike in fermentation utility occurred during WW2, when acetone was again needed for munitions

production. Acetone production from molasses was set to the highest sustainable rates and above in some

places. Great Britain actually had to import its molasses and the U.S. eventually reverted to corn mash. Othercompanies involved in acetone production included India, Australia, South Africa, and Japan. Fermentation

processes finally began to experience a decline after the end of WW2 and by the 1960s, came to a screechinghalt in the U.S. This was the time that petrochemical production of solvents became much easier and cheaper

and also when farmer interests in molasses caused molasses prices to increase dramatically. The combination of

these events made fermentative production of acetone and butanol inefficient and not economical.

1.2Introduction: Rising petroleum prices and finite petroleum reserves have caused interest in alternativemeans of fuel production for decades now.Biomass is utilized as raw material to produce biofuel and the

emitted CO during the consumption of this biofuel, is recycled in synthesizing biomass. Therefore, utilization

of the biofuel acts as a counterbalance leading to reduction in atmospheric greenhouse gas emissions. Butanol

has been identified as a possible fuel from renewable resources. Compared to ethanol, butanol offers several

advantages as a biofuel such as higher energy content lower vapor pressure and lower hygroscopy. With thedepletion of fossil fuel ABE fermentation becomes interesting again.

1.3Manufacture:Company name Feed stock / specification Process used

Sovert spoiled and waste food from domestic and commercial sources Fermentation

Butamax Corn Fermentation

Gevo corn, sugar, and beets Fermentation

Cathay Industrial

Biotech

Corn Fermentation

Cobalt Technologies wood pulp and sugar beets Fermentation


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1.4Current market share for n-butanol:

1.5Industrial applications:ABE fermentation was largely used to synthesize acetone that was solvent for preparation of smokeless

nitrocellulose explosive (cordite). Butanol was increasingly being used as a solvent in rubber production and quick-

drying lacquer to render a good finish on car bodies. Butanol was also used as precursor for production of acryl

esters, glycol ethers, butyl acetate, butyl amines, and amino resins. Some other applications are listed below:

Solvent for dyes, e.g. in printing, inks.

Feedstock for the production of flotation aids, e.g. butyl xanthate.

Extractant in the production of drugs and natural substrates such as antibiotic, hormones, vitamins,

alkaloids and camphor.

Additive in polishes and cleaners, e.g. floor cleaners and stain removers.

Solubilizer in the textile industry, e.g. additive in de-icing fluids.

Gasoline additive (anti-icing).

Mobile phase in paper and thin layer chromatography.

Humectants for cellulose nitrate.


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1.6Current applicationCurrent use of butanol in vehicles: Currently no production vehicle is known to be approved by the

manufacturer for use with 100% butanol. As of early 2009, only few vehicles are approved for even using E85 fuel

(i.e. 85% ethanol + 15% gasoline) in the USA. However, in Brazil all vehicle manufacturers (Fiat, Ford, VW, GM,

Toyota, Honda, Peugeot, Citroen and others) produce flex fuel vehicles that can run on 100% ethanol or any mix of

ethanol and gasoline. These flex fuel cars represent 90% of the sales of personal vehicles in Brazil, in 2009. BP and

DuPont, engaged in a joint venture to produce and promote butanol fuel, claimthat "Biobutanol can be blended up to

10%v/v in European gasoline and 11.5%v/v in US gasoline".

Some other applications:


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1.7Various grades and specification of the Biobutanol: normal(n)-butanol

iso(i)-butanol

sec-butanol

tert-butanol

N-Butanol:

Clear, colorless liquid that is flammable. Characteristic banana-like odor

Global market of 3M ton/year (market value over US$4 billion)

Applications

Solventfor paints, coatings, varnishes

Plasticizersto improve how a plastic material processes

Coatingsas a solvent for a variety of applications,

Chemical intermediate or raw materialfor other chemicals and plastics,

Textilesas a swelling agent from coated fabric

Cosmeticsmakeup, nail care products, shaving products

Drugs and antibiotics, hormones, and vitamins

Gasoline (as an additive) and brake fluid (formulation component)

Isobutanol:

Colorless liquid with a sweet musty odor. Miscible with all common organic solvents (only slightly soluble

in water)

Current market value of about US$560 M/year

Uses:

Direct solvent for surface coatings and adhesives

Chemical intermediate

Dispersing agent cleaning preparations and floor polishes

Processing (extraction) solvent flavor and fragrance manufacture, pharmaceutical, pesticide

Additive in gasoline and deicing fluids


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Sec-Butanol

Flammable, colorless liquid that is slightly soluble in water and completely miscible with polar organic

solvent.

Uses:

Although some 2-butanol is used as a solvent, it is mainly converted to butanone ("MEK -methyl

ethyl ketone), important industrial solvent and found in many domestic cleaning agents and paint

removers.

Volatile esters of 2-butanol have pleasant aromas and are used in small amounts as perfumes or in

artificial flavors.

tert-Butanol

Clear liquid with a camphor-like odor. It is very soluble in water and miscible with ethanol and diethyl

ether.

Tends to be a solid at room temperature (melting point slightly above 25 XC)

Uses:

Solvent

Denaturant for ethanol,

Ingredient in paint removers,

Gasoline additive (octane booster; as an oxygenate)

Intermediate in the synthesis of other chemical commodities such as MTBE, ETBE, TBHP, other flavors

and perfumes.


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2 Economic scenario:2.1 Demand and supply:The worldwide market for n-butanol is around 3 million tonnes per year (circa $5 billion), growing at a rate of 3.2 %

per year through 2025. Demand is concentrated in North America (28%), Western Europe (23%) and North East

Asia (35%). The majority of the worlds n-butanol is manufactured in North America and Western Europe bymultinational chemical companies including Dow, Celanese, BASF and Eastman. Chinas current productioncapacity is around 15% of world supply comprising a mixture of petrochemical and renewable assets. The current

supply of butanol to the chemical market is dominated by a few very large petrochemical companies.

"Our intention initially is to supply demand on the Latin American market, currently estimated at 80,000

tones/year," said Pedrosa. "Butanol demand is forecasted to reach around 200,000 tones in 2015.

Several economic studies have been performed on the production of butanol (traditional ABE fermentation)

from corn, whey permeate, and molasses

Is not economical when compared with butanol derived from the current petrochemical route

New developments in process technology for butanol production could allow for a significant reduction inthe price of butanol.

Petrochemical industries gave capacity to reduce the price of butanol.

Table 2-1 Global top 10 manufacturers of Biobutanol kmt/y


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The economics of current and future biofuels:

Corn to ethanol: US$ 1.53/gal (0.40/L)

Corn to butanol: US$ 1.96/gal (0.52/L)

Sugarcane to ethanol (Brazil): US$ 1.29/gal (0.34/L)

In 2010, the product of n-butyl alcohol in China is516kmt, net import is 620kmt, apparent consumption is

1,139kmt and the degree of self-sufficiency is 45% [6]. During2000~2010, the average annual growth rate

of product is 7.09%and that of apparent consumption is 11.93%.

China OXO market will change from supply falls short of demand now to both supply and demand arebasically balanced


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OXO Supply and demand in China during 20082015 kmt/yr, kmt

2.2Indian scenario:Uttar Pradesh ranks first in area (36.58% of India) and production (36.27% of India) of wheat in the country. There

has been impressive increase in wheat production from 42 lakh tones in 1961 -62 to 259.76 lakh tones in 1999-00

(51.8% increase). Most of the production comes from the areas of the Ganga-Yamuna Doab and the Rohilkhand

plains. Out of 100 leading wheat producing districts (each with more than lakh tones of production), 43 belong to

Uttar Pradesh and 19 to the western part of the state. Aligarh district is the leading producer contributing 1.3% of the

total production of the country and 4 percent of Uttar Pradesh. Five leading producers of Aligarh, Bulandshahr,

Meerut, Moradabad and Gorakhpur together supply 18.5 per cent of the state's wheat output. Other important

districts include Muzaffarnagar, Mathura, Saharanpur, Deoria, Kanpur, Budaun, Agra and Etawah which have

significant share in the wheat production of the state. In fact wheat is a popular crop in the entire area located west

of Allahabad, Here canal and tube well irrigation, greater use of HYV seeds, fertilizers and new farm techniques

have greatly favored the cultivation of wheat and sugarcane amongst the farmers.


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3 Properties3.1Physical and chemical properties:CAS Number: 71-36-3

Physical state and appearance: Liquid. (Z)

Odor: Vinous. (Slight.)

Taste: Not available

Formula: CH3(CH2)3OH

Molecular Weight: 74.12g/mole

Color: Colorless.

Boiling Point: 117.7C (243.9F)

Melting Point: -89.5C (-129.1F)

Specific Gravity: 0.81(Water = 1)

Vapor Pressure: 0.6kPa (@ 20C)

Vapor Density: 2.55 (Air = 1)

Volatility: Not available.

Odor Threshold: 1.2 ppm

Dispersion Properties: See solubility in water, methanol, diethyl ether, n-octanol.

Solubility: Easily soluble in methanol, diethyl ether. Partially soluble in cold water, hot water, n-octanol.

Auto ignition Temperature: 343C

Flash point: 26-29 C

Stability: Stable at ordinary condition.

NFPA Ratings: Health: 1; Flammability: 3; Reactivity: 0

Toxicity: Oral rat LD50: 2460 mg/kg

Acidity: 0.002 max ( KOH mg/kg)


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3.2Chemical Product Identification:Product Name: 1-Butanol

Catalog Codes: SLB3157, SLB1489

CAS#: 71-36-3

RTECS: EO1400000

TSCA: TSCA 8(b) inventory: 1-Butanol

Synonym: Propylcarbinol

Chemical Name: N-Butyl alcohol

Chemical Formula: CH(CH)CHOH

3.3Hazards Identification:Potential Acute Health Effects: Very hazardous in case of skin contact (irritant, permeator), of eye contact

(irritant), of ingestion, of inhalation. Slightly hazardous in case of skin contact (sensitizer). Inflammation of the eye

is characterized by redness, watering, and itching. Skin inflammation is characterized by itching, scaling, reddening,

or, occasionally, blistering.

Potential Chronic Health Effects:

CARCINOGENIC EFFECTS: Not available. MUTAGENIC EFFECTS: Not available. TERATOGENIC

EFFECTS: Not available.

DEVELOPMENTAL TOXICITY: Not available. Repeated or prolonged exposure is not known to aggravate

medical condition.

3.4First Aid Measures:Eye Contact: Check for and remove any contact lenses. Immediately flush eyes with running water for at least 15

minutes, keeping eyelidsopen. Cold water may be used. Get medical attention immediately.

Skin Contact: In case of contact, immediately flush skin with plenty of water for at least 15 minutes while

removing contaminated clothingand shoes. Cover the irritated skin with an emollient. Cold water may be used

Wash clothing before reuse. Thoroughly cleanshoes before reuse. Get medical attention immediately.

Serious Skin Contact: Wash with a disinfectant soap and cover the contaminated skin with an anti-bacterial cream.Seek immediate medicalattention.

Inhalation: If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give

oxygen. Get medicalattention if symptoms appear.


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Serious Inhalation: Evacuate the victim to a safe area as soon as possible. Loosen tight clothing such as a collar,

tie, belt or waistband. Ifbreathing is difficult, administer oxygen. If the victim is not breathing, perform mouth-to-

mouth resuscitation. Seek medicalattention.

Ingestion: Do NOT induce vomiting unless directed to do so by medical personnel. Never give anything by mouth

to an unconsciousperson. If large quantities of this material are swallowed, call a physician immediately. Loosen

tight clothing such as a collar,tie, belt or waistband.

3.5Fire and Explosion Data:Flammability of the Product: Flammable.

Auto-Ignition Temperature: 343C (649.4F)

Flash Points: CLOSED CUP: 28.9C (84F). OPEN CUP: 36.1C (97F) (Cleveland).

Flammable Limits: LOWER: 1.4% UPPER: 11.2%

Products of Combustion: These products are carbon oxides (CO, CO2).

Fire Hazards in Presence of Various Substances: Highly flammable in presence of open flames and sparks.

Flammable in presence of heat, of oxidizing materials, of reducingmaterials, of combustible materials.

Explosion Hazards in Presence of Various Substances: Risks of explosion of the product in presence of

mechanical impact: Not available. Risks of explosion of the product inpresence of static discharge: Not available.

Fire Fighting Media and Instructions: Flammable liquid, soluble or dispersed in water. SMALL FIRE: Use DRY

chemical powder. LARGE FIRE: Use alcohol foam,water spray or fog. Cool containing vessels with water jet in

order to prevent pressure build-up, auto ignition or explosion.

Special Remarks on Fire Hazards: May form explosive mixtures with air. CAUTION: MAY BURN WITH

NEAR INVISIBLE FLAME

3.6Accidental Release Measures:Small Spill: Dilute with water and mop up, or absorb with an inert dry material and place in an appropriate waste

disposal container.

Large Spill: Flammable liquid. Keep away from heat. Keep away from sources of ignition. Stop leak if without risk.

Absorb with DRY earth,sand or other non-combustible material. Do not touch spilled material. Prevent entry into

sewers, basements or confinedareas; dike if needed. Be careful that the product is not present at a concentration

level above TLV. Check TLV on the MSDSand with local authorities.

3.7Handling and Storage:

Precautions: Keep away from heat. Keep away from sources of ignition. Ground all equipment containing material.

Do not ingest. Donot breathe gas/fumes/ vapor/spray. In case of insufficient ventilation, wear suitable respiratory

equipment. If ingested,seek medical advice immediately and show the container or the label. Avoid contact with

skin and eyes. Keep away fromincompatibles such as oxidizing agents, reducing agents.


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Storage: Store in a segregated and approved area. Keep container in a cool, well-ventilated area. Keep container

tightly closed andsealed until ready for use. Avoid all possible sources of ignition (spark or flame).

3.8Exposure Controls/Personal Protection:Engineering Controls: Provide exhaust ventilation or other engineering controls to keep the airborne

concentrations of vapors below their respectivethreshold limit value. Ensure that eyewash stations and safety

showers are proximal to the work-station location.

Personal Protection: Splash goggles. Lab coat. Vapor respirator. Be sure to use an approved/certified respirator or

equivalent. Gloves.

Personal Protection in Case of a Large Spill: Splash goggles. Full suit. Vapor respirator. Boots. Gloves. A self

contained breathing apparatus should be used to avoidinhalation of the product. Suggested protective clothing might

not be sufficient; consult a specialist BEFORE handling thisproduct.

Exposure Limits: CEIL: 152 (mg/m3) Consult local authorities for acceptable exposure limits.

3.9Stability and Reactivity Data:Stability: The product is stable.

Incompatibility with various substances: Highly reactive with oxidizing agents, reducing agents. Slightly reactive

with organic materials, acids, alkalis.

Corrosivity:Non-corrosive in presence of glass.

Polymerization: Will not occur.

3.10 Toxicological Information:Routes of Entry: Dermal contact, Eye contact, Inhalation, Ingestion.

Toxicity to Animals: WARNING: THE LC50 VALUES HEREUNDER ARE ESTIMATED ON THE BASIS OF

A 4-HOUR EXPOSURE. Acute oraltoxicity (LD50): 790 mg/kg [Rat.]. Acute dermal toxicity (LD50): 3400 mg/kg

[Rabbit.]. Acute toxicity of the vapor (LC50): 80004 hours [Rat.].

Other Toxic Effects on Humans: Very hazardous in case of skin contact (irritant, permeator), of ingestion, of

inhalation. Slightly hazardous in case of skincontact (sensitizer).

Special Remarks on Chronic Effects on Humans: Can cause gastrointestinal disturbances.

Special Remarks on other Toxic Effects on Humans: Exposure can cause nausea, headache and vomiting.

3.11 Transport Information:DOT Classification: CLASS 3: Flammable liquid.

Identification: Butanol UNNA: UN1120 PG: III


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3.12 Environmental Effects:1-Butanol is not expected to be toxic to aquatic or terrestrial organisms at levels normally found in the environment.

A. Toxicity to Aquatic Organisms: 1-Butanol has low acute toxicity to aquatic organisms; toxicity values aregreater than 100 mg/L. Ninety-six hour LC50 values for Pimephales promelas (fathead minnow), tested in static

bioassays, are 1,910 mg/L in Lake Superior water and 1,940 mg/L in reconstituted water (Verschueren 1983). Other

96-hour LC50 values were 1510-1940 mg/L for fathead minnows, 2100 mg/L for copepods, and 2250-2400 mg/L

for bleaks (U.S. EPA 1989). Toxicity threshold values for thecell multiplication inhibition test were 650 mg/L for

Pseudomonas putida (bacteria), 875 mg/L for Scenedesmus quadricauda (green algae) (Verschueren 1983).

B. Toxicity to Terrestrial Organisms: Mallard duck eggs immersed for 30 seconds in 100% 1-butanol failed to

produce viable chicks by day 18 of incubation (U.S. EPA 1989). No information was found in the available

literature for terrestrial mammals. The oral LD50 in the rat, 0.79 to 4.36 g/kg and the results of chronic studies in

laboratory animals (section C) (U.S. EPA 1989), suggest that the chemical would not be acutely toxic to terrestrial

animals unless present in very high concentrations.

C. Abiotic Effects: Most 1-butanol in the atmosphere is removed by reaction with hydroxyl radicals (U.S. EPA

1989). According to the definition provided in the Federal Register (1992), 1-butanol is a volatile organic

compound (VOC) substance. As a VOC, 1-butanol can contribute to the formation of photochemical smog in the

presence of other VOCs.

3.13 Health effects:Metabolism: 1-Butanol appears to follow the same metabolic pathway as do other alcohols: oxidation to the

aldehyde, then to the acid, and ultimately to carbon dioxide and water (U.S. EPA 1989). In one study in rats, orally

administered 1-butanol was metabolized rapidly and nearly completely to carbon dioxide (~80% of the administered

dose was eliminated as 14CO2 in expired air;


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4 An introduction to the manufacturing of Biobutanol strategies:PastBio-butanol (19101950)

ABE fermentation from molasses and starch

PresentPetro-butanol

After 1950

Future -Bio-butanol

Biochemical routes

New ABE fermentation

Other fermentative processes

Thermochemical routes

Gasification of biomass


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4.1 Brief description of pyrolysisThe most common industrial process to produce butanol involves a few steps. First, synthesis gas is produced.

Synthesis gas is a very important raw material. It is composed of hydrogen and carbon monoxide, and is produced

by burning a feed at a high temperature while limiting the oxygen available for the reaction. The feed material for

producing synthesis gas can be natural gas, fuel oil, coal, or even biomass. Once synthesis gas is produced, it can be

used to make a wide variety of chemicals, including diesel (via the Fischer-Tropsch reaction), methanol, ethanol,

propanol, or butanol.

If the desired end product is butanol, the synthesis gas is reacted under pressure with propylene to first produce

butyraldehyde, and then this is reacted with hydrogen under pressure to produce butanol. The crude product contains

butanol, Isobutanol, and water, and must be distilled to obtain specification butanol, which has a wide variety of end

uses.

The energy return on investment (EROI) for producing butanol in this way is certainly less than 1. I have never

bothered to calculate it, but there are a number of energy intensive steps involved in butanol production. However,

given the end uses for butanol, the EROI was never a major concern. Sure, saving energy during the production of

butanol was always a priority, but since it typically is not used as a fuel, there was no requirement that the EROI be

greater than 1 in order to have a viable process.

4.2Brief description of fermentationProduction of butanol by the anaerobic fermentation is one of the oldest industrial method for obtaining this organic

solvent. Butanol can be obtained using several chemical technologies. It is also possible to produce butanol in the

process of fermentation by means of bacteria of the genus Clostridium. This process occurs under anaerobic

conditions, and butanol as one of the products - called Biobutanol.

The most popular bacteria species used for fermentation is Clostridium acetobutylicum. Such fermentation is so

called ABE (acetone-butanol-ethanol), due to the names of the main products of this process, the typical ratio of

these compounds being 3:6:1. The final concentration of butanol is about 3%

In the course of industrial production of Biobutanol, using a fermentation process one must take into account three

factors, evaluation of the process profitability: the cost of raw material and its pretreatment, a relatively small

amount of product obtained its significant toxicity, cost of product recovery from fermentation broth.Clostridium

acetobutylicum belongs to the amylolytic bacteria; therefore a good substrate for production of butanol for these

bacteria is starch. Nevertheless, the use for the fermentation crop products is not very economical, primarily

because of too high price due to demand for these products from food industries. Therefore, for the production of

butanol there are commonly used agricultural wastes for example: straw, leaves, grass, spoiled grain and fruits etc

which are much more profitable from an economic point of view. One looks for other sources of plant biomass,

which production does not require a lot of work and costs (e.g. algae culture)

Modern research on the production process of Biobutanol focuses on finding the best kind of substrate for

fermentation process and for efficient strain of bacteria. Potentially, one can use all the waste containingmonosaccharide, and polysaccharides and waste glycerol. Analogously, the biomass of algae is one example of such

a substrate. Algae culture does not require intensive labor and high costs. Some of the micro-algae contain relatively

high percentage of sugars in dry matter, such as Chlorellacontains about 30-40% of sugars, which greatly increases

their usefulness in the production of Biobutanol. There is also carried out research on the genetic modification the

bacteria Clostridium acetobutylicum and Clostridium beijerinckiiin order to increase the resistance of bacteria to the

concentration of butanol in the fermentation broth.


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4.2.1 Methods for removal of butanol from the broth:The method eliminates the toxic effect of butanol on bacterial cells is a systematic removal of this compound from

the fermentation broth. The traditional method of product recovery is distillation. As butanol has a higher boiling

point than water, therefore, this process consumes much energy, and therefore it increases the cost of the whole

process, especially at low concentration of butanol in the broth. Distillation is a process energetically and

economically unfeasible, as the boiling point of water is lower than the maximum concentration of butanol and

butanol fermentation broth is 3% by weight. This leads to low productivity and high costs of separation and

purification of butanol. Therefore, currently other methods are used such as adsorption, membrane pertraction,

extraction, pervaporation, reverse osmosis or "gas stripping". Particularly, much attention is paid to the method of

pervaporation, which is potentially promising way to recover butanol from fermentation broth, as it allows

separation and concentration of the product during a single process.

1) Butanol recovery by adsorption: Adsorption is investigated in the butanol separation from fermentationbroth but the capacity of adsorbent is very low and cannot be used on industrial or semi - industrial plant. A

variety of materials can be used as adsorbents for butanol recovery, but silicalite is the one used most often.

Silicalite, a form of silica with a zeolite-like structure and hydrophobic properties, can selectively adsorb

small organic molecule like C1C5 alcohols from dilute aqueous solutions. Removal of butanol fromfermentation broth by adsorption from the liquid phase can be used only in laboratory scale. This follows

from the small-capacity of adsorbents for butanol. For this reason, the separation process is not suitable on

an industrial or semi-technical scale.

2) Butanol recovery by membrane reactor: One of options of butanol removal is to use methods ofimmobilization of microorganisms in the membrane or the use of membrane reactors. For example, in the

capillary membranes (hollow fiber) the increase in efficiency from 0.39 g/dm3/h to 15.8 g/dm3/h was

attained. On industrial scale cell immobilized technique gives more disadvantages like poor mechanical

strength and increase mass transfer resistance. Also, leakage of cells from the matrices is a frequent

problem.

3) Butanol recovery by gas stripping: Among various recovery techniques, gas stripping is a promisingtechnique that can be applied to butanol recovery during ABE fermentation. Separation of volatile

compounds can be obtained by lowering the pressure, heat or the use of inert gas. In many practical

applications, a combination of these techniques is applied. By introducing the solution into the column in

countercurrent to the gas (inert) one achieves the separation of specific components. In this case they are

butanol, ethanol and acetone.


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18

4) Butanol recovery by pervaporation: Pervaporation is one of the promising techniques for the removal

of toxic substances for Clostridium acetobutylicum such as butanol, ethanol and acetone. This method

involves the selective transport by diffusion of some components through a membrane. A vacuum applied

to the side of permeate. The permeated vapors should be condensed on low pressure side. Membrane in this

case ought to be a hydrophobic polymer since transportation of organic components from the fermentation

broth is preferred. Polydimethylsiloxane membranes and silicon rubber sheets are generally used for the

pervaporation process. The drawback of the method can be high costs to produce low pressure at low

pressure side of the membrane. Selection of a suitable polymer forming the active part of the membrane is a

crucial issue in this case.

5) Application of ionic liquids: Release of butanol from fermentation broth is a very difficult technicalproblem. The extraction process using conventional solvents may be useful, but requires the use of solvents

which are often volatile, toxic and dangerous. In recent years one may observe a growing interest in ionic

liquids, IL as non-volatile, environmentally friendly solvents for various chemical processes. Ionic liquids

can provide a solution in the case of butanol extraction from fermentation broth. Ionic liquids are organic

salts present in the liquid state at room conditions, have very low vapor pressure and low solubility in

water. Hence, IL is valuable solvent in the extraction process from aqueous solutions. The following

combinations of cations and anions constituting the IL are shown in Table. They are promising, due to the

properties as a liquid extraction, in the system water- butanol - IL. Combinations of cations and anions give

16 different IL. In addition, the substitution of the corresponding radical in the structure of cations allows

obtaining several times more IL that can be taken into account in designing a suitable ionic liquid to test the

extraction process. Studies on the properties of ionic liquids and in particular their possible extraction is

currently undertaken and the results of experiments are reported in the literature. The use of ionic liquids

for the extraction of butanol (to remove from the environment fermentation) can be realized through direct

application of the liquid in the bioreactor, and the separation of butanol outside the bioreactor. The diagram

of such a solution is shown in Figure.Fermentation broth with the addition of the ionic liquid is introduced

into the bioreactor. Selected IL should be verified if it is not toxic to the bacterium Clostridium

acetobutylicum. As a result of contact of the IL with broth the extraction of Biobutanol take place

simultaneously with other metabolic products such as ethanol and acetone. Due to the extremely low

solubility of IL in water the fraction of the extract constitutes a separate phase, which must be derived fromthe environment of bioconversion and enter evaporator where the ingredients are extracted and will be

distilled. Regenerated ionic liquid after a suitable cooling is recycled to the fermentation tank. Removal of

bioconversion products makes further progress towards the transformation of raw materials into

Biobutanol.


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19

Another option is the use of ionic liquids removal of fermentation broth outside the bioreactor and the

separation of butanol in the membrane contractor.


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20

4.3Comparison of gasification, fermentation and pyrolysis:Advantages of pyrolysis:

Low capital (~$2.00 per annual gal).

Any tree or crop species.

Simple preparation of raw material.

Hi yield (~170 gpt, and low operating cost).

Disadvantages of pyrolysis:

Unstable as reactions slowly continue; shelf life issues.

Low BTU content as it contains ~15% water.

Very acidic, cannot be used in all boilers.

Therefore, lower selling price (~50% of gasoline).

Advantages of gasification:

Feedstock diversity.

SMSW feedstock operating cost can be as low as $0.24/gal.

Lower capital cost claimed by those using fermentation .

Yield (80 gpt to claims of 111 gpt).

Smaller units can be self-financed.

Disadvantages of gasification:

Some approaches lack extended pilot line runs.

Pilot lines are propriety, not always available.

Sierra Biofuels will be a pilot/demo site.

Plasma arc gasifiers are difficult to operate.

Some syngas conversion technology unproven.

Product selling price ~70% of wholesale gasoline (BTU basis).

Many plants are stand alone and appear under-optimized for heat recovery.


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21

Advantages of fermentation:

Have operating demo plants with good scale to commercial.

Have strong partners.

Moderate capital cost.

Disadvantages of fermentation: Must accumulate and store crop feedstock for long periods.

Moderate yield, reported at 80 gpt.

Enzyme cost typically high.

Selling price ~ 70% gasolines.


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22

5 PRODUCTION OF BIO-BUTANOL BY ABE FERMENTATION5.1ABE FermentationProduction of butanol by the anaerobic fermentation is one of the oldest industrial method for obtaining this organic

solvent. Butanol can be obtained using several chemical technologies. It is also possible to produce butanol in the

process of fermentation by means of bacteria of the genus Clostridium. This process occurs under anaerobic

conditions, and butanol as one of the products - called Biobutanol.

The most popular bacteria species used for fermentation is Clostridium acetobutylicum. Such fermentation is so

called ABE (acetone-butanol-ethanol), due to the names of the main products of this process, the typical ratio of

these compounds being 3:6:1. The final concentration of butanol is about 3%

In the course of industrial production of Biobutanol, using a fermentation process one must take into account three

factors, evaluation of the process profitability: the cost of raw material and its pretreatment, a relatively small

amount of product obtained its significant toxicity, cost of product recovery from fermentation broth. Clostridium

acetobutylicum belongs to the amylolytic bacteria; therefore a good substrate for production of butanol for these

bacteria is starch. Nevertheless, the use for the fermentation crop products is not very economical, primarily

because of too high price due to demand for these products from food industries. Therefore, for the production ofbutanol there are commonly used agricultural wastes for example: straw, leaves, grass, spoiled grain and fruits etc

which are much more profitable from an economic point of view. One looks for other sources of plant biomass,

which production does not require a lot of work and costs (e.g. algae culture)

Modern research on the production process of Biobutanol focuses on finding the best kind of substrate for

fermentation process and for efficient strain of bacteria. Potentially, one can use all the waste containing

monosaccharide, and polysaccharides and waste glycerol. Analogously, the biomass of algae is one example of such

a substrate. Algae culture does not require intensive labor and high costs. Some of the micro-algae contain relatively

high percentage of sugars in dry matter, such as Chlorella contains about 30-40% of sugars, which greatly increases

their usefulness in the production of Biobutanol. There is also carried out research on the genetic modification the

bacteria Clostridium acetobutylicum and Clostridium beijerinckii in order to increase the resistance of bacteria to the

concentration of butanol in the fermentation broth.

Block diagram


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23

Process Flow Diagram:


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24

Process Description:

The process is divided into two major sections: the fermentation section, where the pretreated glucose is converted

to acetone, butanol, and ethanol by a novel strain of Clostridium and the separation section, where acetone, butanol,

and ethanol are separated to streams of the purity needed for sale. Fermenter has a heat exchanger that removes the

heat generated in the reaction at transfers it to cooling water. The cells are used in fermentation batch and then they

are dried to 9% moisture and sold as fertilizer, keeping the time each cell is used under the 500 hours successfully

used by Ezeji, Qureshi, and Blaschek (2005). To avoid contamination, all of the incoming feed is sterilized in a

pasteurizer consisting of two heat exchangers. First, the fresh feed is contacted with the recently sterilized feed, to

cool the outgoing feed and pre-heat the incoming feed. The fresh feed is then heated to 212F with low-pressure

steam and held for five minutes before being considered sterile, when it is then contacted with fresh, cool incoming

feed. In addition to sterilizing the feed, the process also has regular built-in cleaning time for the fermentation

section, when the fermentation vessels are cleaned with caustic. Estimation for the amount of caustic required for

this process is obtained by scaling up an estimate for the ethanol process by McAloon et al. (2000). With these

procedures in place, according to the problem statement, the plant still suffers from, on average, one contaminated

batch in fermenter every 11 days. For this reason, a scale-up produces 36 enough cells to seed the growth phasetanks every 11 days.

The liquid fermentation products are pumped from the fermenters into a holding tank so that the fermentation

section can be run in batch mode but the separation can be run continuously. The products are first fed into a gas

stripper, in which N2 is fed into the bottom and strips the organics from the water. The bottoms water stream is then

divided into two streams, one that is recycled back to the fermenters and the other that is sold back to the mill to

keep the process zero-discharge. Since any water sold back to the mill must have less than 10 ppm organics, the

water is first sent through a steam heat exchanger and a phase separator to concentrate the water stream. This phase

separator produces an ethanol impurity stream that is fed into a decanter with the stripper condensate, consisting

mostly of acetone, butanol, water, and ethanol. The decanter produces two liquid streams, one butanol-rich stream

containing most of the acetone and ethanol and a water-rich stream containing small concentrations of organics. This

water-rich stream is recycled back to the fermentation section to avoid the loss of product. The organic streamcontaining most of the products are sent to molecular sieves, which dehydrate the stream, eliminating the butanol-

water and ethanol-water azeotrope and greatly simplifying the distillation sequence. The water stream is also

recycled back to the fermenters and the organic stream is fed into two distillation columns, one that takes butanol off

in the bottoms, at 99.9% purity, and one that separates acetone at 99.5% purity and ethanol at 99.5% purity. These

are the necessary purity specifications for sale. The ethanol is denatured with 5% gasoline to prevent human

consumption.


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6 Material balance95CHO 60CHOH +30CHCOCH +10CHOH +220CO +120H +30HOA:B:E= 3:6:1

Capacity: 6000 TPA

Working Days per Year: 300

Time required for one batch: 264 (11days)

Total batches run per year: 27.2727

6.1Material balance across pretreatment of wheat straw:32 gm. Of glucose = 100 gm. Of WS

1kg. of glucose = (.1/.032) kg. Of WS

78453.439 kg. of glucose = 201162.66 kg. Wheat straw (for one batch)

Total wheat straw required = 5,486,254.364 kg.

6.2Across fermenter:

95CHO 60CHOH +30CHCOCH +10CHOH +220CO +120H + 30HO95 180=17100kg. 60 74= 4440kg. 30 58=1740kg. 10 46=460kg. 220 44=9680kg. 120 2=240kg.

30 18=540kg.

FermenterGlucose

Micro organism

Water

CO H

Acetone

Butanol

Ethanol Water

Glucose

Microbes


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S. No. Component Inlet (kg.) Outlet (kg.)

1 Glucose 78453.439 7845.344

2 Water 235360.32 237590.05

3 Microbes 7845.34 7845.34

4 Acetone 0 7184.68

5 Butanol 0 18333.33

6 Ethanol 0 1899.399

7 CO 0 39969.96

8 H 0 990.99

Input = 321659.099 kg. Output = 321659.093 kg.

6.3Across Gas Stripper:

Unknown stream: 7M , 3M , 4M , 11M , Known stream: 1M =1188.61Kg

hr

Acetone Balance: 1188.61 0.008+ 7M 0.02= 11M 8 7

10

+ 4M 0.04

Water Balance: 1188.61 0.97+0.003 7M = 11M 0.99+ 4M 0.02

Butanol Balance: 1188.61 0.016+ 7M 0.001= 11M 8 7

10

+ 4M 0.04

Nitrogen balance: 3M = 4M 0.88 + 7M 0.96

Gas Stripper7

3


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27

Stream No. 1 3 7 4 11

Flow rateKg

hr

1188.61 4773.52 500.46 4879 1067.54

Comp. Composition

Acetone 0.008 0.000 0.02 0.04 8 7

10

Butanol 0.016 0.000 0.001 0.04 8 7

10

Ethanol 0.003 0.000 0.002 0.008 6 5

10

Water 0.970 0.000 0.003 0.02 0.99

Nitrogen 0.000 1.000 0.96 0.88 0.000

CO 0.00003 0.000 0.006 0.005 0.000

H 0.000 0.000 2 6

10

2 6

10

0.000

Glucose 0.003 0.000 0.000 0.000 0.003

6.4Across Phase Separator:

Unknown Streams: 6M , 9M Known stream: 5M

Acetone Balance: 5M 0.04= 6M 0.025+ 9M 0.236

Butanol Balance: 5M 0.04= 6M 0.001+ 9M 0.475

6M = 4007.49Kg

hr 9M =402

Kg

hr

Phase Separator59

6


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6.5Across Purge Recycle:

Unknown Stream: 8M Known Stream: 6M , 7M

8M = 6M 7M

8M = 4007.49500.46

8M = 3507.03

Kg

hr

Stream No. 6 8 9 5

Flow rateKg

hr

4007.49 3507.03 402 4879

Comp. Composition

Acetone 0.025 0.024 0.236 0.04

Butanol 0.001 0.001 0.475 0.04

Ethanol 0.002 0.002 0.077 0.008

Water 0.003 0.003 0.206 0.02

N 0.963 0.96 0.006 0.88

CO 0.006 0.006 4 4

10

0.005

H 2 6

10

0 0 2 6

10

Glucose 0.000 0.000 0 0.000

6

7 8


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6.6Across Splitter:

11M 6

510

=13

M 6 5

10

+13

M 6 5

10

12M = 533.77

Kg

hr

13M = 533.77

Kg

hr

Stream No. 12 13 11

Flow rateKg

hr

533.77 533.77 1067.54

Comp. Composition

Acetone 0 0 8 7

10

Butanol 0 0 8 7

10

Ethanol6

5

10

6 5

10

6 5

10

Water 0.99 0.99 0.99

N 0 0 0.000

CO 0 0 0.000

H 0 0 0.000

Glucose 0.003 0.003 0.003

11

13


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6.7Across Phase separator (Down):

M12 = M14

Ethanol Balance:5

14 6 10M = 315 2.6 10M

+ 516 1 10M

Water Balance: M14 0.99 =M15 0.99 + M16 0.99

M15= 10.30Kg

hr

M16= 523.46Kg

hr

Stream No. 14 15 16

Flow rateKg

hr

533.77 10.30 523.46

Comp. Composition

Acetone 0 0 0

Butanol 0 0 0

Ethanol 6510 1 510 1 510

Water 0.99 0.99 0.99

N 0 0 0

CO 0 0 0

H 0 0 0

Glucose 0.003 3.4310 3.4 310

Phase

Separator

14

16

15


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6.8 Across Decanter:

Known: M17, M19 Unknown: M20, M21

Acetone Balance: M19 0 + M17 0.236 = M21 0.284 +5

20 8 10M

Butanol Balance: M19 0 + M17 0.475 = M21 0.571 +5

20 8 10M

M21 = 334.76Kg

hr M20= 77.54

Kg

hr

Stream No. 20 21 17 19

Flow rateKg

hr

77.54 334.76 402 10.30

Comp. Composition

Acetone 8510 0.284 0.236 0

Butanol 8510 0.571 0.475 0

Ethanol 1.6310 0.093 0.077 1 510

Water 0.99 0.046 0.206 0.99

N 0 6.7310 0.006 0

CO 0 4.6 410 4 410 0

H 0 0 0 0

Glucose 0 0 0 3.4310

Decanter17

19

20

21


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32

6.9Across molecular sieve (MS):

M23 = M21 0.5 = 167.38Kg

hr

Acetone Balance:

23 25 270.281 0.296 0.047M M M

Butanol Balance:

23 25 270.571 0.602 0.095M M M

M25=136.59

Kg

hr M27=140.44

Kg

hr

Stream No. 27 25 23

Flow rateKg

hr

140.44 136.59 167.38

Comp. Composition

Acetone 0.047 0.299 0.281

Butanol 0.095 0.602 0.571

Ethanol 0.015 0.098 0.093

Water 0.753 1.23410 0.046

N 0.083 1.78310 6.7 310

CO 0.007 0 4.6410

H 0 0 0

Glucose 0 0 0

Molecular

Sieve

23

2725


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33

6.10 Across Distillation Column:

Acetone Balance:4

28 29 30 310.299 0.753 0.31 1.5 10M M M M

Butanol Balance:4

28 29 30 310.602 5.4 10 0.00 0.99M M M M

Ethanol Balance:4

28 29 30 310.098 0.246 0.036 6.1 10M M M M

29M = 108.40

Kg

hr

30M = 0.0804

Kg

hr

31M =164.56

Kg

hr

Stream No.

Kg

hr

28 29 30 31

Flow rate 273.18 108.40 0.0804 164.56

Comp. Composition

Acetone 0.299 0.753 0.31 1.5410

Butanol 0.602 5.4410 0 0.999

Ethanol 0.098 0.246 0.036 6.1410

Water 1.2410 2.3 410 0 0

N 1.7310 3.8 410 0.646 0

CO 0 0 0 0

H 0 0 0 0

Glucose 0 0 0 0

Distillation

Column

28

30 29

31


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34

6.11 Across Distillation Column (2):

Acetone Balance:3

29 32 33 340.753 0.995 0.454 2.5 10M M M M

Butanol Balance:4 3

29 32 33 345.4 10 0.00 0.00 2.23 10M M M M

Ethanol Balance:3

29 32 33 340.246 4.2 10 0.00 0.995M M M M

32M = 130.55

Kg

hr

33M = 0.05

Kg

hr

34M = 26.24

Kg

hr

Stream No. 32 33 34 29

Flow rateKg

hr

130.55 0.0005 26.24 108.40

Comp. Composition

Acetone 0.995 0.454 2.55 310 0.753

Butanol 0 0 2.23310 5.4 410

Ethanol 4.2310 0 0.995 0.246

Water 3.09410 0 0 2.3 410

N 5.15410 0.636 0 3.8 410

CO 0 0 0 0

H 0 0 0 0

Glucose 0 0 0 0

Distillation Column

(2)29

33 32

34


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7 ENERGY BALANCE

Std. enthalpy of formation = -1271 KJmol

= H

H(Acetone) = -248.2 (l)KJ

mol

H(Ethanol) = -277.63 (l)KJ

mol

H(Butanol) = -328 (l)KJ

mol

H(CO) = -248.2 (g)KJ

mol

H(H) = 0 (g)KJ

mol

H(HO) = -285.8 (l)KJ

mol

Heat of the reaction:

95CHO 60CHOH +30CHCOCH +10CHOH +220CO +120H +30HO

H = -248.2 30 - 328 60 - 277.63 10393.5 220 + 1271 95

H = -4301.3KJ

mol

7.1Energy Balance across the fermenter:435 H = m 4.2 (37-30)

m = 63641.68Kg

hr


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Temperature dependency of specific heat of component:

Cp (N) (g) = 0.2911 10 + 0.0861 10 T + 1.7016 10 T +0.001 10 T + 909.79 T

Cp (CO) (g) = 0.2937 10 + 0.345 10 T + 1.428 10 T + 0.264 10 T + 588 T

Cp (H) (g) = 0.2762 10 + 0.0956 10 T + 2.466 10 T + 0.0376 10 T + 567.6 T

Cp (acetone) (g) = 0.5704 10 + 1.632 10 T + 1.607 10 T + 0.968 10 T + 731.5 T

Cp (butanol) (g) = 0.7454 10 + 2.590 10 T + 1.6073 10 T + 1.732 10 T + 712.4 T

Cp (water) (g) = 0.3336 10 + 0.2679 10 T + 2.6105 10 T + 0.089 10 T + 1169 T

Cp (ethanol) (g) = 0.492 10 + 1.4577 10 T + 1.6628 10 T + 0.939 10 T + 744.7 T

Cp (acetone) (L) = 1.3560 10 - 1.77 10 T + 0.2837 T + 6.89 10 T

Cp (butanol) (L) = 1.912 10 - 7.304 10 T + 2.2998

Cp (water) (L) = 2.7637 10 - 2.0901 10 T + 8.125 T - 1.4116 10 T + 9.3701 10 T

Cp (ethanol) (L) = 1.0264 10 - 1.3963 10 T3.0341 10 T + 2.0386 10 T

7.2Heat Balance across Condenser: Reference Temperature 5C

S.No. Component Fraction Enthalpy (J/Kg) Fraction Enthalpy (J/Kg)

1 Acetone 0.04 1552752.69 0.04 0

2 Butanol 0.04 1925826.66 0.04 0

3 Ethanol 0.008 1747645.00 0.008 0

4 Water 0.02 859044.14 0.02 0

5 Nitrogen 0.88 195876.43 0.88 0

6 CO 0.005 444317.00 0.005 0

7 H 62 10 2981320.00 62 10 0

Input Output

Condenser4 5

33.3 C 5C


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37

= 2

1

T

iT

y Cpdt = 344904 J/kg

Q = = 4870 344904 = 1682786727.00 J/hr

This amount of utility is required.

7.3 Energy Balance across Gas Stripper: Reference 0 C

Input:

Stream3. Q=844714609 J/hr

Stream1. Q=9710469478 J/hr

Output:

Stream4. Q=7.6472729231010 J/hr

Stream11. Q=7266398110 J/hr

7.4Across Distillation Column: Reference Temperature 32.2C

Input:

Stream28. Q=4030589.032 J/hr

Output:

Stream31. Q=5376190.73 J/hr

Gas Stripper

(1),33.9C

7 ,0C

(3),61.1C

(4),33.3C

(11),27.8C

Distillation

Column(28),76.1C

(29),32.2C

31 ,135C


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38

Difference in Q = 1345601.69 J/hr

So, this much amount of energy supplied by reboiler.

7.5Across Distillation Column (2): Reference Temperature 32.2C

Output:

Stream34. Q=374904.25 J/hr

So, this much amount of heat supplied by reboiler.

(29),32.2C

(32),32.2 C

(34),94.4 C


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8 Detailed Design of Equipment8.1Fermenter Reactor:

6L

D (By assumption)

Volume of the reactor =2

4Ld

So, the volume of the reactor is9

189 10 lt., this much volume cant be achieved. So, we divided thisin 9 fermenters.

50,000 =3

46 d

d= 22 m. (Dia. of the reactor)

8.2Storage tank design:Usually we must design the storage tank which has volume more than the reactor.

So for our purpose we use50,000+50,000/9 = volume of vessel

Volume of vessel = 55,555lt.

2L

D (For the storage tank or holding tank)

55,555 =3

2d

d = 34m.

P1 = 1atm, t=33C, L = 68m., d = 34m.Sp. gravity of liquid = 1

Conical roof:Slope permissible = 1 in 5

Superimposed load = 12502

N m Material = CS (structural) IS-2062

Permissible stress = 1422

N mm

Density = 10003

kg m Modulus of elasticity = 52 10

2N mm

This design is based on the Indian std. design.

IS-803

Corrosion allowance (c) = 0.7mm.


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Shell design:

Internal pressure: 2( 0.3) 10p H

p2

kg cm , Hm. ,3

kg cm

p = 0.6772

N mm

Thickness of the shell at bottom:

3( )2

10p d

t cf j

J = 85%

t = 96mm.

Butt joints are provided for welding the vertical joints between plates to form the lowest layer of the shell. An

allowance of 2mm. is made between two adjacent plate to facilitate welding and total circumference is welded with

16 plates. So,

= ( 34) - 3( )16 2 10

=106.7m.

Length of the each plate = 106.8/.16

= 6.67m.

Size of the plate selected from IS-1730 is 6700mm. (length) 2000mm. (width).

To determine the number of the layers to be used with 16mm thick plate it is necessary to determine the height of up

to which a plate of lesser thickness on be used.

Assuming thickness of 75 mm

So,

3

0.001 ( 0.3) 10 34 1075

2 142 0.85

H

H = 53.55

H = 53.55 + c

= 54

Since the width of the plate selected is 2000mm it is necessary to use 96mm thick plate to form the two lower most.

This will cover a height of (2 2) i.e. 4m


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41

The remaining height of the tank = 68-4 = 64m

And third layer will be of 75mm thickness.

So, remaining height of the tank = 64-2 = 62m

Assuming: - thickness 50mm3

0.001 ( 0.3) 10 34 1050

2 142 0.85

H

H = 35.8m

The remaining four layers will be of 50mm thickness

Height of four layers = 4 2= 8m

So, remaining height of the tank = 62-8 = 54m

Remaining height 54m is also covered by 50mm thickness plate.

So, No. of layers = 27+4+3 = 34 layers

Bottom: -

Bottom diameter (bD ) = 3

2 9634

10

= 34.192m

Tank area = 34m

Thickness of shell = 96mm

Thickness of plates to be used to form the bottom

Annular plates = 75mm

Other plates = 50mm

The bottom will be lap (fillet) welded. The overlap between the sketch plates and annular plates is 65mm and

between the sketch plates i.e. 30mm. the joints between plates will be staggered so that no more than three plates are

overlapped within 30cm of each other or of the shell.

Circumference of bottom =bD

= 107.36m


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8.3Heat Exchanger DesignDesign: - Shell and Tube type heat exchanger

Design pressure: - By additional of 5% to the maximum working pressure.

Design temperature: - 10C higher than the maximum temperature.

ABEoABEABE pQ m c T

ABEQ = 98.93 J/hr

1T = 97 C

2T = 51 C

1 2

1

2

ln

T TLMTD

T

T

LMTD = 12.015 C

Water flow rate (wm ) = 10.30 kg/hr

ABE, 10atm

5C, 402 kg/hr

ABE, 10atm

39C, 402 kg/hr

Water, 1atm

102C, 10.3 kg/hr Water, 1atm

90C, 10.3 kg/hr

Shell & Tube Type

Heat exchanger


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43

Mean difference temperature:

102 90

39 5R

= 0.353

39 5102 5

S

= 0.351

From fig. 6.1 by book Introduction to Process Engineering and Designthe value of tF as per the condition

tF = 0.95

mT = tF lmT

mT = 11.414 C

By table 6.7, page-163 (by book)

As per the design guidelines as given in the table assume: -

oU = 400 w/m2C

Pr

98.93 1000

400 11.414oA

= 21.66 m2

Let us consider the length of the tube (L) = 1.82m

According to length do=15.875mm

No. of tubes (Nt): -

APro= Nt do L

Nt = 238

For 1st trial: -

No. of tube passage Np = 4

For triangular arrangement: - db (tube bundle diameter)

Db= do(Nt/k1)1/h1

K1 and h1 are constant

Pt/do = 1.25, for this arrangement

K1=0.175, h1=2.285


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Db =373.31mm

Di = Db+C = 390mm

C= 10-20mm for U-tube heat exchanger

Check for Reynolds No.: -

e

dR

and

t

t

mG

a

i t

e

d GR

2

4t

t i

p

Na d

N

2

i otd d (Thickness (t) =1.22mm)

ta=0.53

tG = 147.14, =10cp

So, Re=800

Value of Re is less than 2000. So we use Sidder-Boltas equation:

0.140.33

1.86 Re Pri i i

f w

h d dNu

Lk

w

=1

Prp

k

c k=0.13

Pr = 180

So, hi=904.61 = 90.461 w/m2-k

So, this is our heat transfer coefficient for flow of water in tube side and ABE mixture flow in the shell side.


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Calculation for shell side pressure drop: -

0.142

82

ss s

s fse

L

w

DjPd B

According to figure: - (by book)

fj 7.7

2

10

214 sin 60

2 4

2

ot

e

o

p dd

d

e

d=11.446mm

Bs= Baffle spacing= Ds/5 = 78

So, Ps=156 kpa

As a thumb rule: - Fluid which provide poor Reynolds No. must be allocated to shell side to get high transfercoefficient.

Mechanical Design: -

Shell:

Material: Carbon Steel

Corrosion allowance: 3mm

Number of shell: 1

Number of passage: 4

Fluid: ABE mixture

Working pressure: 0.33 N/mm2

Design pressure: o.5 N/mm2

Temperature inlet: 5 C

Temperature outlet: 39 C

Segmental baffles (25% cut) with tie rods and spacers.


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Head:

Crown Radius: 400mm

Knuckle Radius: 40mm

Shell flange: female facing

Gasket: Flat metal jacketed asbestos filled

Bolts: 5% Cr Mo steel

Nozzles:

Inlet and Outlet: 75mm

Vent: 25mm

Drain: 25mm

Opening for relief valve: 50mm

Permissible stress for CS: 95 N/mm2

Permissible stress for bolt material: 140.6 N/mm2

Tube Side: -

Tube and tube sheet material: Stainless Steel

Working pressure: 19 N/mm2

Design pressure: 21.5 N/mm

2

Inlet temperature: 102 C

Outlet temperature: 90 C

Permissible stress: 100.6 N/mm2

Pitch of tube: 25mm

Channel and Channel cover: -

Material: Carbon Steel

Permissible stress: 95 N/mm2


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Shell side: - Triangular pitch of tubes

a = 0.8662

ts

= 5.4 cm2

an= 1 238 5.4 = 1285.2 cm2

2

1606.54 0.8

n

s

aDA

D = 45cm = 450mm

Shell thickness: -

2sP D

f j Pt

j = 85%

ts = 1.38mm

By book (Mahajani): -

Table4 gives a minimum thickness of 6.3mm including corrosion allowance. So we use 8mm thickness.

Nozzle thickness: -

2n

P D

f j Pt

= 4mm

Head thickness: -

2

c

h

P w

f j

Rt

(Torrispherical)

Rc= 95% of internal diameter = .95 450 = 427.5mm

13

4

c

I

w R

R

= 3.67mm

th= 7.127mm 8mm


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Baffles: -

Segment cut: 20%-25%

Spacing between baffles: -

B.S.=Ds/5 = 90mm

Maximum length of baffle = 12m

So, half =6m

No. of baffles = 6000/90 = 66.666 67 (theoretical)

But actually = 67-2 = 65

Tie rods: -

No. of tie rods = 4 (minimum use)

Minimum diameter of tie rods = 10mm

Flange design: -Assume the shell I.D. as the I.D. of gasket

( 1)

o a

ai

m

m

d Y Pd Y P

From table: - steel or soft iron Ya=52.05 N/mm2, m = 3.75

o

i

d

d= 1.01

do = 1.01 450 = 454.5mm

do - di = 4.5mm and (do - di)/2 = 2.25mm (width)

2.25mm is very less so we take minimum thickness as 10mm.

Outer diameter of gasket = 450+10+10 = 470mm

Basic gasket seating width (bo) = (width of gasket)/2

bo= 10/2 = 5mm

bo


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Ag= gasket area = b G

Load on the bolt under atmospheric condition: -

W1 = b G Ya

= 375905.1 N

Load on bolt under operating condition: -

W2= 2b G m P + ( /4) G2 P

= 100118 N

So, W1> W2, we take W1 to calculate bolt area

Total bolt area = W1/(f of bolt MOC)

= 375905.1/140.6 = 2673.57 mm2

Number of bolts = (Mean gasket dia.)/2.5 = 45/2.5 = 18

Area of a bolt = (Total bolt area)/(No. of bolts) = 2673.57/18 = 148.53 mm2

Flange design: -

Thickness: -

Pt G C

k f

1

1.50.3

m g

k

H G

w h

2

4H PG

20.5

4460

= 65979.25 N

2gB G

h

550 460

2

= 45

K=0.92

t = 39mm


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For tube: -

2

oP

f j P

Dt

21.5 (450 2 8)

2 100.6 1 21.5

= 41.89 42mm

No corrosion allowance because tubes are of stainless steel.

Channel and channel cover: -

Thickness

c

k pt

fG

, k=0.3 for ring type gasket

0.3 21.5

46095

t

= 119mm

Nozzles: -

2nP D

f j Pt

21.5 75

2 95 1 21.5nt

= 9.6mm

nt = 9.6 + C.A. = 12.6mm

So, thickness of nozzle is 14mm.


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8.4Distillation Column Design

For stripping:1

m

m wmm m

WLy x xV V

For rectifying:1

n

n dnn n

DL

y x xV V

Bubble point calculation: - Step 1: - calculate average molecular weight

M1 = 58.08, M2 = 74.12, M3 = 46

M=0.299 58.08 + 0.602 74.12 + 0.098 46 = 66.49

This is close to molecular weight of butanol so it is taken as reference component.

Step 2: - bubble point of reference component

3367.12ln(760) 17.62995188.7

, =117.49 C or 390 K

Take 1st approximation of the bubble point calculate of other component at 117.49 C

A=0.753,

B=5.4*10^-4,

E=0.246,32C, 1atm

B=0.99,

A=1.5*10^-4,E=6.1*10^-4,

105C, 1atm

A=0.299,

B=0.602,

E=0.098,

76.1C, 8atm


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2787.516.39112

229.67 117.49

4279.88

lnacetone

v

acetonemmHG

p

p

3667.7018.68233226.1 117.49

3003.96

ln ethanolv

ethanolmmHG

p

p

Since solution is ideal so,

4279.885.63

760

3003.963.95

760

AB

EB

Now use equation:

3

1

1r iB i

ik x

1r AB A BB B EB E k x x x

rk =1.00,v

B

r

pk

p

v

Bp =760 mmHg

So, k values

kb = kr=1

k1 = kA = 4279.88/760 = 5.63

k2 = kE = 3003.96/760 = 3.95

3

11

1i

ik x

Tbp=117.49 C

Dew point calculation: -4

0.753 58 5.4 74.12 46 0.24610avM


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avM =55 ,

Acetone: 2787.5ln(760) 16.39112229.67

, = 55.99 C

Vapor pressure of: -

Butanol: 3367.12ln( ) 17.62995

188.7 55.99

v

Bp

,v

Bp = 47.90 mmHg

Ethanol: 3367.70ln( ) 18.68233

226.1 55.99

v

Ep

,v

Ep = 293.08 mmHg

Relative volatilities:

47.90 0.063760BA

, 293.08 0.385760EA

From equation:

3

11i

iA

y

k

4

3

5.41 0.753 0.2461

1 0.063 0.385

10k

k3=1.4

3

v

A

p

pk ,

v

Ap = 1064 mmHg

2787.5ln(1064) 16.39112

229.67

, = 66.201 C

Step 3: Take new T=66.201 C and calculate vapor pressure of component.

3367.12ln( ) 17.62995

188.7 66.201

67.356

v

B

v

B

p

mmHgp

3367.70ln( ) 18.68233

226.1 66.201

387.83

v

E

v

E

p

mmHgp


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K-values:-

KB=0.088, KE=0.51, KA=1.4

1.00i

i

y

k

, So, our Tdp = 62.201 C

0.5

(0.063 0.385 5.63 3.95)av

av =3.16

Minimum No. of theoretical stages required usingFrenskeys method:-

log

logd b

m

av

LK HK

HK LK

X X

X XN

log4 4

13.936

0.753 0.99

5.4 10 1.5 10

log 3.16d b

mN

Under woods method:

1i if

i

qx

(For feed)

Assume feed is standard liquid so q=0

1i idm

i

xR

(For distillate)

5.63 0.299 3.95 0.098 1 0.6020

5.63 3.95 1

=1.65

For distillate:1 0.753 0.246 0.385

11 1.65 0.385 1.65 mR

mR = 3.49

Gillilands co-relation:


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0.5

1 54.4 1( ) 1 exp

11 117.21mf N

N NN

1mR R

R

, mR k R put k = 1.1, 1.2, 1.3, 1.4

R = 3.839, 4.188, 4.537, 4.886

= 0.072, 0.135, 0.189, 0.237

f(N) = 0.5831, 0.5192, 0.4699, 0.4290..

R = 4.36, N = 29.31

Or13.936

0.5004

1

N

N

N = 29

FUG method does not give information about feed tray location. Feed tray location can be determined by using

following equation: - (Kirkbride equation)

2

log 0.206 logr

sf

w HK bLK

DLK

dHK

X XNN X X

Where Nr= Number of stages above the feed plate

Ns = Number of stages below the feed

24

164.56log 0.206 log

4108.40

0.602 6.1 10

0.098 5.4 10

r

sf

NN

r

s

NN

=1.67, So, Nr+Ns=29

Ns=10.87 11, Nr= 18.168 18

Hence 11th stage from the bottom will be feed stage.

Mav = 66.49 kg/kmol

F = 273.18 kg/hr or 4.108 kmol/hr


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D = 108.40 kg/hr or 1.985 kmol/hr

B = 164.56 kg/hr or 2.220 kmol/hr

Now, molar flow rate of vapor and liquid in top section: -

L = R

D = 4.36

1.985 = 8.654 kmol/hr

V = (R+1) D = 5.36 1.98 = 10.639 kmol/hr

Now, molar flow rate of vapor and liquid in bottom section: -

L = L + F q = 8.654 + 4.108 1 = 12.762 kmol/hr

V = F(q-1)+V = 4.108(1-1)+V = 10.639 kmol/hr

Calculation of tower diameter: -

At top: - operating pressure = 1atm

V = 10.639 kmol/hr

L = 8.654 kmol/hr

Here total condenser we used: -

Hence, 0.813w

w

L

V

LV

Density of vapor: -

354.59 2731.98 /

62.201 273 22.414

av

vkg

R T

Mm

Density of liquid at top: -

3

4

1 1822 /

5.40.753 0.246

0.821 1.261 1.028

10L

i

i

kg mw

Liquid vapor flow rate at top: -0.5

0.5

0.813 0.03981.98

822.30w

LV

w

V

L

LF

V

Assumed tray spacing = 0.3m


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Corresponding Cf = 0.06m

From book Introduction to process Engineering and design by S.B. Thakre & B.I. Bhatt Page-468.

Now flooding velocity: -

0.50.2

0.02f p

L V

V

c

f = flooding velocity, = surface tension of fluid

3

10.2 10i ix

0.2 0.53

0.635 1.129 /10.2 822 1.9810

0.02 1.98f

m s

Actual vapor velocity through tower is v = 0.85f = 0.959 m/s

Volumetric flow rate of liquid at top: -

310.639 54.59

293.321.98

av

V

Qhr

M m

= 0.082 m3/sec

Net area required at top: -20.082

0.10.959nQ

v mA

Let downcomer area Ad = 0.12 Ac

Ac = Internal cross sectional area of tower

An= AcAd, Ac = 0.114m2

Inside diameter of the column required at top: -

4 4 0.1140.381c

imAD

Tower diameter required at bottom: -

Operating pressure at bottom of the column = operating pressure at top +tP

tP = Total pressure drop in sieve tray low


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fh = 120 mm LC

tP = Actual no. of trays fwg h

Assuming tray efficiency = 0.5

Actual no. of trays Na = N/0.5 = 29/0.5 = 58

tP = 56.124 kpa

Operating pressure at bottom: -

Pt = Pt + tP

= 157.449 kpa

Temperature at bottom: - 117.49 C , V=10.639 kmol/hr , L= 12.762 kmol/hr

So, L/V =1.199

Density of vaporv

= 2.529 kg/m3 avR T

M

Density of liquid at bottom: -1

822L

i

i

w

kg/m3

Liquid vapor flow factor at bottom: -

0.5

0.102wLV

w

V

L

LF

V

Actual tray spacing = 0.3m

Cf=0.0616

Flooding velocity: -

0.50.2

0.02f f

L V

V

C

= 0.96 m/s

Actual vapor velocity = 0.85 f = 0.82 m/s

Volumetric flow rate of liquid at bottom: -


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Q = 0.056 m3/sec

Net area required at bottom: - An = Q/v = 0.105 m2

Let downcomer area = Ad

Ad = 0.12

Ac ,

An = Ac - Ad

Ac = 0.13 m2

40.41 .c

imAD

Di = 0.41m


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9 COST ESTIMATION AND ECONOMICSCAPITAL COST ESTIMATION:

The estimation of capital investment items is based on delivered equipment cost and delivered equipment cost is

calculated on the basis of purchase equipment. The various percent of delivered equipment are taken on the basis of

the type of chemical plant for ex. whether it is solid processing or solid fluid processing etc.

For the cost estimation we first calculate cost of equipment. The cost of various items is calculated using the tables

in plant design and economics for chemical engineer .The data given of year 1998 which has been converted to 2013

using present index factor.

Using equation for finding purchased equipment cost

LogCp= K1+K2*LogA1+K3*LogA2

To get the value at present time we use the formula C2=C1*(I2/I1)

Where,

C2= Present cost

C1= Cost of reference year

I1= Price index of reference year

I2= Price index of present year

To calculate the cost of equipment of required size

C2=C1 (Q2/Q1)n

Q=attribute

n=cost exponent

9.1Purchased Equipment Cost:Cost Index in 1998 = 389.5

Cost Index in 2012 = 585.3

Cost Index Factor (CIF) = (cost index 2012) / (cost index 1998) = 1.5

The cost of storage tanks used in the process, as based on correlations, is as fallows.

Compounds Storage capacity m Cost in 1998 (US $) Cost in 2012 (US $)

Holding Tank 100.53 27778.5 41667.75

Acetone Tank 30 14307.8 21461.70

Butanol Tank 60 19759.39 29639.08

Ethanol Tank 10 7401.164 11101.75


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The cost of process equipment are estimated using correlations in Process Equipment CostFinal Report by H.P.Loh, U.S. Department of Energy and other sources from internet.

Cost of heat exchanger:

Equipment Heat Transfer area (m2) Cost in 1998 (US $) Cost in 2012 (US $)

Heat Exchanger-4 0.29 1000 1500

Heat Exchanger-10 5.41 9000 13500

Heat Exchanger-12 2.13 7500 11250

Cost of flash drum:

Equipment Volume (m ) Cost in 1998 (US $) Cost in 2012 (US $)

Flash Drum-5 2.49 10500 15750

Flash Drum-14 3.29 12410.44 18615.66

Cost of Distillation Column:

Equipment Number of trays Dia. of thecolumn

Cost in 1998 (US $) Cost in 2012 (US $)

Distillation column-28 29 0.91 65000 97500

Distillation column-29 21 0.68 45000 67500

Cost of pump = $ 27,000

Cost of reactor = $ 200,000 X 9 = 1,800,000

Cost of compressor (3 MW capacity) = $ 500,000

Thus, Total purchased Equipment cost = $ 2,656,485.94

For exchange rate 1 $ = 54.28

Purchased equipment cost = Rs 144,114,362.20


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9.2ESTIMATION OF CAPITAL INVESTMENT COST:1) DIRECT COST:

Expenses which are directly involved of actual installation of complete facility. Direct cost includes purchasedequipment cost at manufacturers site, piping, insulation, instrumentation, electrical and labor associated withinstalling the equipment.

Purchased equipment cost (PEC):= Rs 144,114,362.20

1.1.Installation Including insulation and painting:

Installation cost= 20% of PEC = Rs 28,822,872.44

1.2.Instrumentation and control, Installed (ICC):

ICC= 10% of PEC = Rs 14,411,436.22

1.3.Piping cost (PC):

Piping cost= 25 % of PEC = Rs 36,028,590.55

1.4.Electricals cost (EC):

Electricals cost= 2 % of PEC = Rs 2,882,287.24

1.5.Building, Process And auxiliary cost (BPC):

BPC= 6% PEC= Rs 8,646,861.73

1.6.Insulation cost (IC):

IC=8 % of PEC= Rs 11,529,148.98

1.7.Land cost (LC):

LC=6% of PEC= Rs 86,468,617.312

TOTAL DIRECT COST= Rs 188,969,814.40

2) INDIREST COST (IC):Expenses which are not directly involved of actual installation of complete facility. It includes transportation cost,

all insurance on items shipped, labor burden and salaries.

2.1Engineering and Supervision (E&SC):E&SC= 6% of direct cost = Rs 6,191,153.00

2.2Construction Expense and Contractors Fee (CE&CC):CE&CC = 5 % of direct cost = Rs 5,159,294.16


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2.3Contingency (CC): It covers unforeseen circumstances. It includes loss of time due to stormand strike, small change in design and unpredicted price increase.

CC = 8% of direct cost = Rs 8,254,870.66

Total indirect cost= Rs 19,605,317.82

Fixed capital investment (FCI):

FCI = Direct cost + Indirect cost

= Rs. 208,575,132.30

Fixed capital investment (FCI) = 80% of total capital investment (TCI)

Total capital investment (TCI) = Rs 260,718,915.3

Working Capital (WC):

WC= 20 % of fixed capital investment(FCI)= Rs 41,715,026.46

9.3Manufacturing Cost:1. Direct cost

Direct cost include the factors that vary with rate of production

1.1.Raw material cost (RMC):Manufacturing cost is the sum of cost of chemical feed stocks required by process.

Component Rs/ton Total consumption

ton/Yr.

Rs./Yr.

Wheat straw 3000 149,624.97 448,874,907.90

Total raw material cost = Rs 448,874,907.90

Let total manufacturing cost be Rs Y per year

1.2.Operating labour cost (OLC):OLC = 10 % oftotal manufacturing cost = 0.1Y Rs/yr.

1.3.Direct supervisory and clerical labour (DS&CLC):DS&CLC=1% of total manufacturing cost= 0.01Y Rs/yr.

1.4.Utilities (UC):UC= 10 % of total manufacturing cost = 0.1Y Rs/yr.

1.5.Maintenance and Repair (M &RC): let average life is 10 yearsM &RC= 20 % of (FCI/average life = 2,306,698.56 Rs/yr.

1.6.Laboratory charges (LCC):LCC = 1% of total manufacturing cost = 0.01Y Rs/yr.


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1.7.Patent and Royalties (P&RC):P&RC= 3% of total manufacturing cost = 0.03Y Rs/yr.

Thus total direct manufacturing cost = 451,181,606.50 + 0.25Y

2) Fixed charges (FC):2.1 Depreciation cost (DC)

Range=depend on life period, salvage value and method of calculation- about 5-10% of FCI for machinery &equipment, 2-3% for building.DC = 10% of fixed capital investment for machinery & equipment and 2.5% for buildings.DC = 20,857,513.23

2.2 Local Taxes (LT):2 % of FCI = 4,171,502.65

2.3 Insurance (Inc.):Inc. = 0.6% of FCI = Rs 1,251,450.79

Thus total fixed charge= Rs 26,280,466.67

3 General expanses (GE):3.1 Administrative cost

2% of total manufacturing cost = 0.02 Y Rs/yr.

3.2 Distribution and selling cost

5% of total manufacturing cost=0.05 Y Rs/yr.

3.3 Research and development Cost (R&D):

R&D = 5.2% of manufacturing cost = 0.052 Y Rs/yr.

Thus,

Total Manufacturing cost = Direct manufacturing cost + Fixed Charges+ general expanses

So we get Y = 751,636,803.60

Gross earning/Income:

Market selling price of butanol per ton = 1500 $ /ton

Production of acetone per year = 6000 ton/yr.

Market selling price of ethanol per ton = 700 $ /ton

Production of ethanol per year = 3000 ton/yr.

Market selling price of acetone per ton = 3700 $ /ton


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Production of acetone per year = 1000 ton/yr.

Total income = selling price* quantity of product manufacture = Rs 803,344,000

Gross income (GI) = total income- total manufacturing cost = Rs 51,707,196.40

9.4Profitability analysis:Tax rate=35%

Tax= Rs 18,097,518.74

Net profit= Rs 33,609,677.66

Payback period = [fixed capital investment (FCI) / (profit + depreciation)]

= 115334928.10/ (33,609,677.66+1061951.19)

= 4.33 yr.


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10Plant Layout:


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11CONTROL STRATEGY

11.1 Brief Introduction to Distillation Control:All distillation columns have to be carefully operated in order to achieve the required production rates and productquality. The 3 main objectives of column control can be stated as:

To set stable conditions for column operation.

To regulate conditions in the column so that the product(s) always meet the required specifications.

To achieve the above objective most efficiently, e.g. by maximizing product yield, minimizing energyconsumption, etc.

Process variables like temperatures, pressures, flow rates, levels and compositions must be monitored and controlled

in all distillation processes. These process variables within a distillation system affect one another, whereby a

change in one process variable will result in changes in other process variables. Thus, in column control one should

be looking at the whole column and not focusing on any particular sections only.

Each column has a control system that consists of several control loops. The loops adjust process variables as

needed to compensate for changes due to disturbances during plant operation.

Each of the process variables has its own control loop, which typically consists of a sensor and transmitter,

controller and control valve. See the Figurebelow. Each control loop keeps track of the associated process variable.

An adjustment is made to a process variable by varying the opening of its control valve. The stream flow rate is

therefore adjusted and a desirable variable is being controlled.

The sensor measures the process variable from the plant (i.e. Plant data) and the transmitter sends the information to

the DCS (Distributed Control System) controller located in the control room.

The controller checks if the process variable agrees with the set point. If not, it will send corrective signal to the

control valve that will make adjustment in the plant so as to match the process variable to the set point. This goes on

continuously, essentially in a loop - hence the term "control loop".
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Pressure is often considered the prime distillation control variable, as it affects temperature, condensation,

vaporization, compositions, volatilities and almost any process that takes place inside the column. Column pressure

control is frequently integrated with the condenser control system.

Reboiler and condensers are integral part of a distillation system. They regulate the energy inflow and outflow in a

distillation column.

Distillation Control Philosophy:

Column pressure normally controlled at a constant value.

Feed flow rate often set by the level controller on a preceding column.

Feed temperature usually controlled by varying the reflux.

Bottom temp. Controlled by varying the steam to reboiler.

The composition controlled by regulating the reflux flow and boiled-up (reboiler vapor).

Pressure is often considered the prime distillation control variable, as it affects temperature, condensation,vaporization, compositions, volatilities and almost any process that takes place inside the column. Column pressurecontrol is frequently integrated with the condenser control system.

Reboiler and condensers are integral part of a distillation system. They regulate the energy inflow and outflow in adistillation column.

11.2 Temperature Control:Column temperature control is perhaps the most popular way of controlling product compositions. In this case, thecontrol temperature is used as a substitute to product composition analysis.

Ideally, both top and bottom compositions should be controlled to maintain each within its specifications. Seethe Figurebelow.

In practice, simultaneous composition control of both products suffer from serious "coupling" (interaction) betweenthe 2 controllers, resulting in column instability. In the system shown, suppose that there are concentration changes
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