The document describes the design basis for a 1000 ton per year riboflavin (vitamin B2) crystal production plant to be set up in Bangladesh. It provides details on the geological and climatic conditions of the site, as well as design specifications for utilities. The process will use Candida famata fermentation to produce riboflavin crystals from glucose, vegetable oils and nutrients. Major equipment will include fermenters, crystallizers, centrifuges and rotary dryers. An economic analysis estimates total direct costs to be $6.64 million and total indirect costs to be $1.12 million.

1. PROCESS DESIGN
SESSIONAL
CHE 408
FEBRUARY 2017
1000 TONS PER YEAR RIBOFLAVIN (VITAMIN B2) CRYSTAL
PRODUCTION PLANT
Department of Chemical Engineering
Bangladesh University of Engineering & Technology

2. PROJECT TITLE
1000 TONS PER YEAR RIBOFLAVIN (VITAMIN B2) CRYSTAL PRODUCTION PLANT

3. PROJECT DEFINITION
A Riboflavin crystal (Vitamin B2) production plant is to be set-up at Tongi ,
Gazipur in Bangladesh, having capacity 3 tons per day, corresponding to 1000
tons of Riboflavin Crystal per year including all offsite auxiliaries, utilities and
support facilities. Glucose, vegetable oils and nutrients will be used as
feedstock. Candida famata fermentation process will be applied.

4. DESIGN BASIS
GEOLOGICAL DATA
SITE CHARACTERSTICS
❑ Nearest River – Turag
❑Minimum Water Level – 7-10 Meters
❑Maximum Water Level – 65-70 Meters
❑ Average Depth Of Wells – 30-35 Meters
❑Water Level Record During Flood – 10 Ft (Above Ground Level)

5. DESIGN BASIS
GEOLOGICAL DATA
SOIL CHARACTERSTICS
❑ Deposits Of The Pleistocence Age .
❑ Surface Clays – 12-15 Meters Thick Underlain By Slits And Fine Sands (Followed By 35
Meters Coarse Materials)
❑Arsenic Content Is Below WHO Limit .
SEISMIC CONDITION
❑Maximum Earth Quake – 6 In Richter Scale
❑Seismic Zone – 3 Seismic Zones In Bangladesh & The Site Is In Zone II
❑Seismic Coefficient – 0.15 G

6. DESIGN BASIS
CLIMATIC CONDITIONS
❑Rainy Season - Hot And Humid (Having About 90 Percent Of The Annual Rainfall) .
❑Winter - Cool And Dry.
❑Summer - Hot And Dry (Interrupted By Occasional Heavy Rainfall) .
❑Annual Average Temperature - Maximum 36 °C & Minimum Temperature Is About 12.70 °C
❑Annual Rainfall - Approximately 2,376 Mm.
❑Soil Condition - Soil Is Fertile (Not Used For Any Major Economical Activities) .
❑Corrosion Tendency - Iron And Arsenic Are The Major Water Quality Concern For Drinking
Purposes

7. DESIGN BASIS
CLIMATIC CONDITIONS
❖EQUIPMENTS
❑Maximum Dry Bulb Temperature – 38-40 ° C (Summer)
❑Minimum Dry Bulb Temperature – 4-7 °C (Winter)
❖HVAC
❑Maximum Dry Bulb Temperature – 25° C (Summer)
❑Minimum Dry Bulb Temperature – 20°C (Winter)
❑Relative Humidity (Maximum) – 90% (Summer)
❑Relative Humidity (Minimum) – 45 % (Summer)

8. DESIGN BASIS
CLIMATIC CONDITIONS
METEOROLOGICAL CONDITIONS
Ambient
Temperature
Humidity Rainfall Barometric Pressure Wind Direction
Maximum : 38-40°C
Minimum : 8-10°C
Average : 30°C
Average
RH :
75-78%
Average Annual : 1555 mm
Maximum monthly : 335 mm
Minimum (monthly) :1.5 mm
Maximum Daily : 450 m
Maximum intensity : 0.5mm/min
Minimum Pressure :
740 mm (Hg)
Design Barometric
Pressure :
760 mm (Hg)
Summer : South to
North
Winter : North to
South
Design wind velocity
: 3.5-4.5 m/sec

9. DESIGN BASIS
UTILITY CONDITIONS
Steam Water Electric power Air
Saturated
Steam
150°C
Ground Water (25°C)
Potable Water (WHO ,ECR-97)
Waste Water Treatment
❑ Raw Water
pH : 5-6.5
COD < 1500 mg/L
BOD < 900 mg/L
DO < 4
❑ Discharge Water
pH : 6.5-8
COD < 200 mg/L
BOD < 50 mg/L
DO > 4
440V : 3 phase, 50 cycle
230V :1 phase, 50 cycle for motors <0.4
kW
120V : 1 phase, 50 cycle for
instrumentations and control
❖ Instrument air :
❑ Pressure : 715 kPa
❑ Temperature : 25°C
❑ Dew Point : 4°C
❖ Plant Air :
Pressure : 250kPa
Temperature : 30°C

10. DESIGN BASIS
RAW MATERIALS
❑ Glucose Syrup
❑ Water
❑ Dl-methoinine
❑ Malt Extract
❑ Yeast Extract
❑ Peptone
❑ Sunflower Oil
❑ Manganese Sulfate
❑ Potassium Biphosphate
❑ Candida famata (Yeast)

11. Specification sheet
of Rotary Dryer
1. CUSTOMER Job no.
Reference no.
Address : Proposal no.
Plant location: Date
Service of Unit: Item no.
Size: 2m x 13.1m
2. CAPACITY DETAILS 3. FEED DETAILS
Operation Continuous Nature of feed Solid + Suspension
Feed rate 0.6039 ton/hr Moisture of feed 0.35
Evaporation Rate: 167.7 kg/hr Density 80lb/ft3
Efficiency(moisture removed) 70% Viscosity Not required
Volume of dryer 4.118 m3 pH Not required
Full Capacity 5.284 ton
4. DRY PRODUCT DETAILS 5. MODE OF AIR HEATING Steam
Moisture content 0.10 (Dry
basis)
6. POWER REQUIREMENTS
Desired particle size Not required Power of the Blower 2.47 KW
Heat sensitivity Upto 280 ̊C Power of the Exhaust Fan 2.69 KW
Solvent recovery Not Required Power Required to Drive
the Dryer
30.5KW
7. DESIGN DATA 8. ANY OTHER SPECIFICATION
Operating pressure 1 atm Dia of the Feed pipe 10 inches
Design Pressure 1.5 atm Dia of the air inlet pipe 12 inches
Operating Temperature Max 170 ̊C Dia of the air Outlet pipe 13 inches
Design Temperature 130 ̊C Rotation of the Dryer 10 rpm
Shell Material AISI SS317 Inner Dia of the dryer 2 m
Support Saddle
Support
Outer Dia of the dryer 2.18m
Shell type Cylindrical Number of Flights 20
Lining: Asbestos Radial Height of the flights 9.84 inches
Internal corrosion allowance 25 mm The Volumetric Heat
transfer Coefficient of
dryer
4.2213
Btu/ft3.h. ºF
Insulation 80 mm
Thickness 10 mm

12. SIDE VIEW OF ROTARY DRYER

13. CROSS SECTION OF ROTARY DRYER

14. P & I DIAGRAM OF ROTARY DRYER

15. SELECTION OF PROCESS AND PROCESS DESCRIPTION
❑Candida famata Fermentation
Process .
❑The Product Is Obtained As Dry
Crystal .
❑Fermentation Is Operated Batch-wise
❑Equipment AISI SS 317

16. SELECTION OF PROCESS AND PROCESS DESCRIPTION
Upstream Processing Fermentation Downstream Processing
❑ Preparation
❑ Sterilization
❑ Carbon and Nitrogen
Source (Raw Materials)
❑ Main Fermentation
(Fermentation Tank)
❖ Broth Harvest
❑ Crystallize
❑ Centrifuge (Decanter)
Oil and Aqueous fraction
❑ Dryer (Rotary Dryer)
❖ Dry Crystal (Product)

17. PROCESS BLOCK DIAGRAM
Nutrient Tank
T1
Glucose Syrup Tank
T2
Fermenter
F1
HS1
HS2
Air Filter
AF1
Air
Compressor
AC1
Air
Glucose
Syrup
Nutrients
Water
Harvest Tank
T3
Crystallizer
C1
Storage Tank
T4
Decanter
D1
Storage Tank
T5
Rotary Dryer
RD1
HE1
Exhaust Gas
Oil
Fraction
Aqueous
Fraction
Dry
Air
Exhaust Gas
Product

18. PROCESS FLOW DIAGRAM
1
7
2
6
3
54
11
12
14
15
16
17
18
19
20
21
8 9
22
23
24
32
30
31
25
26
27
T1T2
T3
T4
T5
F1
P1
P2
P3
P4 P5
P6
P7
P8
HS1
HS2
C1
D1
RD1
HE1
AC1
AF1
13
10
28
29
B1
B2

19. LIST OF PROCESS LICENSORS
❖Production Of Riboflavin By Fermentation Process
❑Merck & Co Inc , New Jersey , USA ; US2595499
❑Hoffmann La Roche , Basel , Switzerland ; US2493274
❖A Fermentation Process For Riboflavin-producing Organisms
❑Zeagen, Inc. Wo1992001060
❖Method For The Preparation Of Riboflavin
❑Dai Nippon Sugar Mfg Co Ltd , Japan ; US3433707

20. LIST OF MAJOR EQUIPMENTS AND LIST OF VENDORS
No. Equipment Vendor
1 Fermenter Zhenjiang East Biotech Equipment and Technology Co., Ltd. ,
China
2 Crystallizer Zhenjiang Mingchen Machinery Technology Co., Ltd. , China
3 Decanter Centrifuge Jiangsu Huada Centrifuge Co., Ltd. , China
4 Rotary Dryer Jiangsu Zhenxing Drying Equipment Co., Ltd. , China

21. Identification: Item: Fermenter Date: 15/02/2017
By: ChE,BUET
Function: To produce Riboflavin from Candida famata
Operation: Batch
Type: Batch reactor ( jacketed and cylindrical )
Material Handled: Inlet Outlet
Quantity (kg) 18784904 kg 222950 kg ( Liquid)
18561954 kg (Exhaust Gas)
Pressure (atm) 1 1
Temperature (ºC) 40 50
Design Data:
Tank Turbine
Height 5.0 m Impeller diameter 0.833 m
Diameter 2.50 m Impeller length 0.208 m
Shell thickness 6 mm Impeller width 0.167 m
Capacity safety factor 25% Impeller type Six-blade turbine
Capacity 20 m
3
Speed 25 rpm
Operating pressure 180 kPa Shaft diameter 1.64 cm
Operating Temperature 35 - 50 ºC Power required 0.22 hp
Material of construction: SS 317
Code AISI3
Utilities:
Cooling Jacket Thickness = 1.5 mm , Area available (A) = 17 m
2
Tolerance: Rules of thumb and heuristics
Skirt: 3 mm thick and 2.5 m height (AISI SS317)
SPECIFICATION SHEET
OF
FERMENTER

22. FRONT VIEW OF FERMENTER
2.5 m
5 m
1.67 m
0.167 m
1.64 cm
2.5 m
2.6 m
cm5
Feed 1 Feed 2
Product
Compressed
Air
2 cm

23. TOP VIEW OF FERMENTER
0.237 m
0.208 m
2.5 m
0.833 m

24. P & I DIAGRAM OF FERMENTER
AT
TTTC
FC
PT FC

25. SIZING OF STORAGE TANKS
Position of
tank
Volume
(m3)
Teui mm Agitator
speed
Power KW
T1 28.6 3314.6 39.83 3.16
T2 160 5884.1 22.40 7.76
T3 204 6380.4 20.69 9.13
T4 245 6782.0 14.67 8.57
T5 125 5419.3 24.36 7.03
Sizing of Centrifugal Pumps
Position of
the pump
Volumetric
flow rate
m3
Required
head m
Power Hp Other
Properti
es
P1 0.003 8.89 0.08 Pressur
e ratio
(P2/P1)
= 2
Pdrop =
12KPa
P2 0.004 9.75 0.97
P3 0.003 10.77 0.67
P4 0.003 10.38 0.08
P5 0.003 8.61 0.07
P6 0.003 10.36 0.08
P7 0.003 8.27 0.28
P8 0.003 8.27 0.28

26. OTHERS
Equipment name Properties
Air Compressor Pressure ratio, P2/P1 = 2
Power Requirement = 15
Hp
Heat exchanger Heat duty = 7.7x 105 KJ/hr
Surface area = 6.5 m2
Blowers Pressure (assumption) = 20
cm water column
Power requirement = 2 Hp

27. PLOT PLAN

28. EQUIPMENT LAYOUT

29. FRONT VIEW OF DECANTER

30. TOP VIEW OF DECANTER

31. P & I DIAGRAM OF DECANTER

32. SPECIFICATION
SHEET OF DECANTER
Identification Item: Centrifuge Date: 11/02/2017
Function
To remove oil and aqueous fraction from
solution media
Operation: Batch
Material
Parameters Inlet Outlet
Quantity (kg) 1114.7 kh/hr 1114.7 kh/hrHandled
Temperature(ºC) 30 35
Height 3 m Design pressure 10.7 atm
Design Centrifuge Diameter 0.70m
Operating 30-35 ºC
TemperatureData
Shell
33 mm
Capacity safety
10%
thickness factor
Motor
Speed
1200
Power required 10.5 hp
rpm
Material of Stainless Steel
construction
Code AISI SS 317
Utilities Not required
Tolerance 10% of load
Insulation Noise cancelling

33. FRONT VIEW OF
CRYSTALLIZER

34. TOP VIEW OF CRYSTALLIZER

35. P & I
DIAGRAM OF
CRYSTALLIZER

36. SPECIFICATION
OF
CRYSTALLIZER
Identification: Item: Crystallizer Date: 15/02/2017
Function: To produce Riboflavin Crystal
Operation: Batch
Type: Agitated jacketed cooling crystallizer
Material Handled: Inlet Outlet
Quantity (kg) 2787 kg 824 kg Riboflavin Crystal
355 kg Riboflavin (in suspensio
1609 kg water and others
Pressure (atm) 1 1
Temperature (ºC) 45 25
Design Data:
Tank Turbine
Height 3.0 m Impeller diameter 0.66 m
Diameter 2 m Impeller length 0.165 m
Shell thickness 14 mm Impeller width 0.137 m
Capacity safety factor 25% Impeller type Six-blade turbine
Capacity 4.5 𝒎 𝟑 Speed 100 rpm
Operating pressure 250kPa Shaft diameter 4 cm
Operating Temperature 20 ºC -50 ºC Power required 3 hp
Material of construction: SS 317
Code AISI3

37. ECONOMIC ANALYSIS
TOTAL EQUIPMENT
COST
Storage tank for glucose 19500
Storage tank for Nutrient 30300
Storage tank before
Crystallizer 33300
Storage tank before
decanter 32100
Storage tank before dryer 28800
Fermenter 940200
crystallizer 127842
Rotary Dryer
269400
Centrifuge 182400
Air Blower 10044
Total equipment cost 1711266
Item Price ($)
Glucose supply Pump 3060
Nutrient supply Pump 3300
Harvest pump 3360
Pump Before crystallizer 3060
Pump after crystallizer 3060
Pump before decanter 3060
Pump after decanter 3240
Pump before dryer 3240
Air compressor 4500
Heat Exchanger 7500

38. DIRECT COST
TOTAL DIRECT COST = 6639712.08 USD
Item % of equipment cost Cost (USD)
Purchased equipment 100 622504
Land 8 49800
Piping 45 217876
Installation 30 124500
Service facilities 30 186751
Instrumentation 20 62250
Electrical system 30 62250
Building 50 124500
Yard improvement 5 31125

39. TOTAL INDIRECT COST = 1112322 USD
Indirect cost
Item
% of equipment
cost
Cost (USD)
Engineering 15 256690
Construction
expense
15 256690
Contractors fee
10
171126
Contingency
25
427816
Fixed Capital
Investment 7752035 USD
Working
Capital
Investment
(20% of total
capital
investment)
1938009 USD
Total capital
investment
9690044 USD

40. TOTAL PRODUCTION COST
Manufacturing cost
Type Percentage USD
Direct cost
Raw material 40% of Total
Production cost 9496243
Operating cost 10% of Total
Production cost 2374061
Utilities 10% of Total
Production cost 2374061
Maintenance &
repairs
10% of Fixed
Capital
investment
775203.
5
Fixed charges 10% of Total
Production cost
2374066
1
Plant overhead 10% of Total
Production cost
2374066
1
General Expenses
Administrative cost 6% of Total
Production cost 14244396
Distribution and selling 5% of Total
Production cost 11870330
Research and developing 5% of Total
Production cost 11870330
Financing 2% of Total
capital
investment
193800
Total production cost
23740507

41. ECONOMIC ANALYSIS
• ANNUAL REVENUE
SALES PRICE $30/KG RIBOFLAVIN CRYSTAL(90% PURE)
SO TOTAL REVENUE $27215550/YR
• TOTAL PROFIT/YR = $27215550- $ 23740607
=$ 3474943/YR
SALVAGE VALUE = 10% OF (PURCHASED EQUIPMENT + LAND +
BUILDING) =$ 304605

42. ECONOMIC ANALYSIS
• % RATE OF RETURN
• TAX RETURN = 15%
• NET PROFIT AFTER TAX =
$ 2948984
RATE OF RETURN = NET
PROFIT AFTER TAX/TOTAL
INVESTMENT COST
= 30.1%
Depreciation calculation
Minimum attractive rate of return (MARR) =
15%
Plant useful life = 15 years
Depreciation = FCI (A/P, 15 %, 15) – Salvage
(A/F, 15%, 15)
= $1238476.51- $6402
= $1232074

43. CASH FLOW DIAGRAM AND IRR
-10000000
0
10000000
20000000
30000000
40000000
0.00 0.20 0.40 0.60 0.80 1.00 1.20
IRR Analysis
By PW method,
PW = -Total capital investment + Annual Income (P/A,
i%, 15) + Salvage Value (P/F, i%,15)
=0 , IRR is 29%

44. ECONOMIC ANALYSIS
ERR is 19.4% here
Project is feasible
Payback period
End of year Net Cash Flow Cumulative PW
without interest
Present Worth
of cash flow
with interest
( i=15%/yr)
Cumulative PW
with interest
(i=15%/yr)
0 -9690044 -9690044 -9690044 -9690044
1 2948984 -6741065 2564333.913 -7125715.087
2 2948984 -3792081 2229855.577 -4895859.51
3 2948984 -843097 1939004.849 -2956854.661
4 2948984 +2105887 1686091.173 -1270763.488
5 2948984 5054871 1466166.238 +195402.7496

45. THANK YOU