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Design-ppt_SAmodified.pptx

The document provides details of a design project for a 20 ton per day plant to process plastic waste into acetic acid and bioethanol. It includes a process flow diagram and descriptions of key equipment such as a shell and tube heat exchanger, distillation column, fixed bed gasifier, and secondary bioreactor. Equipment are designed according to relevant codes and include specifications for materials, dimensions, pressures, temperatures and other process parameters.

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CHE 408: Process Design Sessional Presented by Afia Subhani (1602001) Anika Bushra (1602006) K. M. Nazmus Sakib (1602026) Ishmamul Hoque Sadab (1602031) Design of a 20 Ton/Day Combined Thermochemical and Biological Plastic Waste Processing Plant for The Production of Acetic Acid and Bio-ethanol Supervised by Dr. Shoeb Ahmed Professor Department of Chemical Engineering BUET Presentation on Department of Chemical Engineering BUET
1. Project Definition 2 ▰ A plant is to be set up at Zinjira, Keraniganj in Bangladesh having a capacity to process 20 ton/day of segregated plastic waste to produce 9600 L/day acetic acid and 14400 L/day ethanol corresponding to a yearly production of 3.2×106 L of acetic acid and 4.8×106 L of ethanol on processing 6600-ton plastic waste, including all offsites, auxiliaries, utilities, and supporting facilities. ▰ The process involves converting plastic wastes into syngas through gasification followed by fermentation of syngas to produce acetic acid and ethanol with the help of bacteria Clostridium ljungdahlii.
Raw Materials ▰ Clostridium ljungdahlii culture ▰ Air ▰ Segregated Plastic Waste ▰ Bacterial growth nutrient medium 3 Products ▰ 99 % Acetic Acid (V/V) ▰ 90 % Ethanol (V/V) ▰ Tar Component Quantity per L of medium 2 gm FeCl2.4H2O 10 mL 85% H3P04 0.05 mL MPFN Trace Metals 20 mL (NH4)2HPO4 0.6 g NH4Cl 2 g NaCl 0.2 g KCl 0.15 g MgCl2.6H2O 0.5 g CaCl2.2 H2O 0.2 g Cysteine HCl.H2O 0.25 g Vitamin solution 0.7-0.8 /0.1-0.2* mL Table 1:Table for the composition of nutrient
Design Basis 4 2
5 Plant Location
Geographical Data Site Characteristics  Nearest River: Buriganga  Maximum water level: 1.54-2.1 meters  Average Depth of wells: 10-15 meters  Water level record during flood: 4m above plant ground level Soil Characteristics  The project area is dominated by organic clay and peats.  The cluster lies on the Madhupur Clay with its average thickness of about 10 meters consists of over-consolidated clayey slit and is underlain by the Pleistocene Dupi Tila formation.  Arsenic content is below WHO limit. 6
Seismic Condition ▰ Maximum earthquake – 7 on Richter scale ▰ Seismic Zone – 3 seismic zones in Bangladesh & the site is in Zone II ▰ Seismic Coefficient – 0.15 g 7 Al-Hussaini, T., Hossain, T., & Al-Noman, M. (2012). Proposed Changes to the Geotechnical Earthquake Engineering Provisions of the Bangladesh National Building Code. Geotechnical Engineering Journal Of The SEAGS & AGSSEA, 43(2).
Meteorological Data ▰ Climate 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). ▰ Temperature Maximum 36°C Minimum 12.7°C ▰ Rainfall Average yearly 1329 mm 8 ▰ Humidity Average annual relative humidity 59.8% Highest 79% (Summer) Lowest 45% (Winter) ▰ Wind • Wind direction: Summer: South to North Winter: North to South • Design wind velocity: 60-65 m/s
Utilities 9  Process Steam Temperature and Pressure: 527 0C, 1 atm Source: Groundwater, river water (after treatment)  Cooling water Temperature and Pressure: 25 0C, 1 atm Source: Ground water, river water (after treatment) Plant air Temperature and Pressure:25 0C, 7.5 atm Source: Atmospheric air  Instrument air Pressure: 3−20 psig Source: Atmospheric air  Inert gas (N2) Temperature and Pressure: 25 0C, 8 atm Source: Atmospheric air  Electric power Source: National Grid
Process Selection 10 3
11  Processing a broad range of syngas component ratios  No need for an external gas shift operation  High tolerance to contaminants  Higher selectivity of biological catalysts leading to higher yields  Inexpensive biological catalyst, low cost growth media  Simplified downstream processing, less undesired by-products  Greater fuel yield and energy efficiency  Lower carbon dioxide emissions  Higher rate of carbon conversion to fuel
Process Flow Diagram 12 4
13
List & sizing of Equipment 14 5
15 Name of Equipment Identification No. No. of Items Size Water Storage Tank T-100 1 Volume: 79 m3 Shredder S-100 1 Capacity: 0.23 kg/s Elevator E-100 1 Length: 2.31m Diameter: 0.23 m Power of drive: 0.045 KW Washer W-100 1 Volume: 3.168 m3 Screw Conveyor SC-100 1 Length: 10.5 m Diameter: 0.23 m Power of drive: 0.21 KW Rotary Dryer DR-100 1 Peripheral surface area= 3.02 m2 Heat Exchanger HE-100 1 Surface area: 1.82 m2 Heat duty: 33.3 KW Gasifier G-100 1 Volume: 64.05 m3 Cyclone Separator C-100 1 Body diameter: 1.052 m Ceramic (Candle) Filter CF-100 1 tube filter area: 1.48 m2 No. of cells: 6 Tubes per cell: 78 Pressure Swing Adsorber (PSA) PA-100 1 Diameter: 1.1 m Height: 3.23 m Air Compressor CM-100 1 Power: 172 KW Economizer EC-100 1 Surface area: 0.92 m2 Heat duty: 42.84 KW Superheater SH-100 1 Surface area: 29.94 m2 Heat duty: 615.76 KW Table 5a: List of equipment and sizing
16 Name of Equipment Identification Code No. of Items Size Syngas Cooler CO-103 1 Surface area: 53.73 m2 Heat duty: 270.26 KW Syngas Storage Tank ST-100 1 Volume: 1171 m3 Primary Bioreactor M-100 1 Volume: 0.25 m3 Syngas Compressor CM-101 1 Power: 843.6 KW Secondary Bioreactor M-101 to M-110 10 Volume of each: 64.29 m3 Liquid Storage Tank ST-101 1 Diameter: 2.68 m Height: 5.36 m Cell Separator CS-100 to CS-109 10 Diameter of each: 1.7 m Length of each: 1.55 m Pumps P-100 9 Power: 837.2 W P-101 Power: 394.5 W P-102 Power: 191.3 W P-103 Power: 794.1 W P-104 Power: 211.9 W P-105 Power: 536.6 W P-106 Power: 635.0 W P-107 Power: 3530.6 W P-108 Power: 865.5 W Table 5b: List of equipment and sizing
17 Name of Equipment Identification Code No. of Items Size Distillation Column D-100 2 Height: 14.7 m Diameter: 0.9 m D-101 Height: 6.6 m Diameter: 1.5 m Reboiler H-100 2 Surface area: 4.46 m2 Heat duty: 304.17 KW H-101 Surface area: 16.83 m2 Heat duty: 1144.44 KW Condenser CO-100 2 Surface area: 10.55 m2 Heat duty: 239.72 KW CO-101 Surface area: 31.14 m2 Heat duty: 1041.67 KW Ethyl Acetate Storage Tank T-101 1 Volume: 0.94 m3 Acetic Acid Storage Tank ST-102 1 Volume: 33 m3 Ethanol Storage Tank ST-103 1 Volume: 49 m3 Table 5c: List of equipment and sizing
Individual Design 18 6
Individual Equipment Shell & Tube Heat Exchanger (HE-100) 19
20 Thermal Design of Heat Exchanger Heat Balance: Q = 113628 Btu/hr LMTD=922.37 oF FT = 0.99 Corrected LMTD, ΔT = 913.15 oF Tube side: (Assume) Tube OD, do= 0.75 inch BWG= 18 Tube ID, di = 0.652 inch Length of tube, L= 5 ft No. of tubes, Nt = 20 Square pitch, PT =1 inch Heat transfer coefficient, hio=91.97 Btu/hr. ft2 oF Shell side: (Assume) Shell ID, Di = 30 inch ⸫ Baffle space, B= Di×0.2 = 6 inch Clearance, C =0.25 inch Heat transfer coefficient, ho = 15.79 Btu/hr. ft2 oF Clean overall coefficient, Uc= 13.47 Btu/hr. ft2 oF Dirty overall coefficient, UD= 6.34 Btu/hr. ft2 oF Dirt factor, Rd(calculated) = Uc−UD UcUD = 0.08354 Rd(required) =0.00938 Pressure drop calculation: Tube side, ΔPT = 0.05 <10 psi Shell side, ΔPs= 0.00029 psi <10 psi
21 Mechanical Design of Heat exchanger Code: ASME code section VIII division 1 Materials: Stainless Steel (Grade 304) Corrosion allowance, C = 3mm =0.11811 inch For SS-304, maximum allowable pressure, F = 9781 psi Tube thickness: 0.12 inch= 3.02mm Shell thickness: 0.35 inch= 8.89mm Nozzle Diameter: 7.981 inch Thickness: 0.17inch=4.33mm Head Type: Torispherical Thickness: 0.46inch= 11.80mm Height= 7.44inch Baffle Shape: Segmental Cut: 25% No. of baffles: 9 Insulation Material: Mineral wool Critical thickness: 30.33mm ⸫Thickness= 32mm Support Type: Saddle A B C D E F G H 27.2inch 23.0inch 3.9inch 5.1inch 9.5inch 11.7inch 5.9inch 3.9inch
22 Figure: Cross-sectional view of 1-2 shell and tube heat exchanger (U- bend Type) Mechanical Drawing
23 Figure: Cross-sectional view of tube bundle arrangement
24 Figure: P & ID of shell and tube heat exchanger Piping & Instrumentation Diagram
Individual Equipment 25 Atmospheric Distillation Column (D-100)
Design Parameters for Atmospheric Distillation Column 26 Temperature 100˚C Pressure 101.3 kPa Material of construction Carbon steel Column height 14.7 m Column diameter 0.9 m Column thickness 5 mm Tray type Sieve tray No. of trays 23 Feed stage 12th stage
27 Tray spacing 0.61 m Tray thickness 2.86 mm Hole diameter 4.76 mm Pitch type Equilateral triangular Pitch length 15 mm Weir length 0.4 m Weir height 25.4 mm Downcomer area 0.026 m2 Downcomer width 49 mm Insulation material Fiber glass Insulation thickness 100 mm
28 Insulation area 51.23 m2 Column weight 2791.7 kg Head type ASME Tori-spherical Inside depth of dish 0.378 m Head thickness 5 mm Support type Skirt support Skirt height 1.84 m Skirt thickness 3 mm Reboiler duty 304.2 kW Reboiler area 4.46 m2 Condenser duty 239.7 kW Condenser area 7.16 m2
29 Purpose No. of Nozzles Location Feed inlet 1 12th stage Top vapor outlet 1 1st stage Reflux nozzle 1 1st stage Boil-up nozzle 1 23rd stage Bottom liquid outlet 1 23rd stage Level controller 1 23rd stage Gauge glass 1 23rd stage Temperature indicator 15 Several stages Manhole 5 4,8,12,16 and 20th stages Liquid sampling point 3 5,15,20th stages Pressure gauge 2 1 and 23rd stages
30 Figure: Mechanical drawing of D-100
31 Figure: Mechanical drawing of top view of sieve tray
32 Figure: P&ID of D-100
Individual Equipment Fixed Bed Gasifier (G-100) 33
34 Design Parameters Highest bed temperature 0C 800 0C Operating pressure 1 bar Gasifier type Fixed bed, updraft Solid residence time 1 hr Inner diameter of the gasifier vessel 2.75 m Height of gasifier vessel 8.81 m Total height including bunker, throat and ash throat 11.59 m
35 Mechanical Design • Code: ASME Section VII, Division 01 • Dimensions of Vessel Height: 11.59 m Diameter = 2.75 m Dead weight= 13031 kg • Shell Materials: SS 309 Wall thickness: 9.71 mm • Head Type: ASME Semi-Ellipsoidal Head Materials: SS 309 Wall thickness: 4.5 mm • Pressure Design pressure = 2.026 atm Working pressure = 1 bar • Insulation Material: Mineral wool blocks Thickness: 1.69 mm Weight: 27 kg • Jacket Jacket thickness: 54 mm Wall thickness: 5.18 m Jacket nozzle diameter: 81 mm • Gas inlet Nozzle Diameter: 0.30 m Thickness: 0.63 mm • Gas outlet Nozzle Diameter: 0.43 m Thickness: 0.9 mm
36 Mechanical Design • Support Type: Skirt Material: ASME SA 387 GRADE 22 Thickness: 19.3 mm • Rotating Grate Diameter: 2.20 m No. of openings: 810 Diameter of dome: 0.73 m Height of dome: 0.24 m Rotating speed: 20 rpm
37 Mechanical Drawing
38 Mechanical Drawing Front sectional view of the rotating grate Top view of rotating grate
39 P&ID
Individual Equipment Secondary Bioreactor (M-101/…/M- 110) 40
41 • Code: ASME Section VII, Division 01 • Process: Fed-Batch; Gas Residence Time: 150 s; Liquid Retention Time: 20 hrs. • Shell Materials: SS304 steel Thickness: 18 mm (corrosion allowance in accordance to ASME UG-16) • Head Type: ASME Semi-Ellipsoidal Head Materials: SS304 steel Thickness: 15 mm (corrosion allowance in accordance to ASME UG-16) • Dimensions of Vessel Height: 8.72 m Diameter = 2.91 m Weight= 2093.04 kg • Sparger Type: Sintered Metal Sparger by Mott Corp. Model: Type A Hex Nipple Sparger of Media Grade-40(2240-A16-10-A00-XX-AB) Diameter=2.5’’ Length=40’’=1.1016 m Number of sparger = 1 Mechanical Design
42 Mechanical Design • Column Support Type: Skirt Material: Structural Steel Length:100cm Diameter: 2.943 mm Thickness 1.5 mm • Agitator Type: Impeller Power: 8.69 hp Bracket support for drive system = 1.744 m • Shaft Material: SS304 steel Shaft diameter: 12 cm Coupling diameter: 24 cm • Pressure Design pressure = 8.5 atm Working pressure = 6 atm • Insulation Material: Polyurethane Foam Thickness: 13 cm Weight: 29.0374 • Jacket Length: 7.412 m Internal diameter: 3.197 m • Base plate Type: annular, ID = 285 cm, OD = 315 cm, Thickness = 2 cm Number of bolts = 12
Agitator type: Rushton disk turbine, Impeller type: Flat blade, No of agitator = 3, No. of blades = 6, No. of baffles = 4, Blade thickness = 5 mm, Angle of blade = 45º Impeller diameter = 96.89 cm Blade length = 24.22 cm, width = 19.378 cm Turbine revolutions = 60 rpm Distance between two impellers = 121.11 cm Support to mount drive: L shaped bracket support Length of bracket support = 174.604 cm Mechanical Design
44 Mechanical Drawing
45 P&ID
Plot Plan and Equipment Layout 46 7
47
48 EQUIPMENT LAYOUT
Economic Analysis 49 8
Economic Analysis 50 Steps Followed  Purchased equipment cost estimation incorporating cost indices  Estimation of total capital investment  Estimation of total production cost  Profitability analysis  Feasibility analysis
Economic Analysis 51 Equipment Name Identification No. Quantity Cost (US $) Water Storage Tank WT-100 1 20000 Shredder S-100 1 8000 Elevator E-100 1 5500 washer W-100 1 7000 Screw Conveyor SC-100 1 11500 Rotary dryer DR-100 1 40000 Heat Exchanger HE-100 1 3000 Gasifier G-100 1 209437.46 Cyclone separator C-100 1 9094 candle filter CF-100 1 126000 Pressure swing adsorption PA-100 1 8400 Air compressor CM-100 1 101365 Economizer EC-100 1 2100 Superheater SH-100 1 10000 Purchased Equipment Cost
Economic Analysis 52 Purchased Equipment Cost (cont’d) Equipment Name ID No. Quantity Cost (US $) Syngas cooler CO-103 1 8200 Syngas storage tank ST-100 1 400000 Syngas compressor CM-101 1 295952 Primary Bioreactor M-100 1 3500 Secondary Bioreactor M-101 to M-110 10 1000000 Liquid storage tank ST-101 1 54000 Cell separator CS-100 to 109 10 2900000 Pump P-100 to P-108 9 10447 Distillation Column D-100 to D-101 2 126126 Reboiler H-100 to H-101 2 7370 Condenser CO-100 to CO-101 2 13571 Ethyl acetate tank T-101 1 6200 Acetic acid storage tank ST-102 1 40000 Ethanol storage tank ST-103 1 50000 CEPCI in 2002 and 2022 is 395.6 and 785.9 respectively Total purchased equipment cost (TPEC) at 2022 = $10.88M Delivered equipment cost = $11.97 M ( delivery/shipment cost is 10% of TPEC)
Economic Analysis 53 Cost items Percentage of delivered equipment cost Purchased equipment delivered 100 Purchased equipment installation 39 Instrumentation and Control(installed) 26 Piping (installed) 31 Electrical system (installed) 10 Building, auxiliaries (including Services) 29 Yard Improvements 12 Service Facilities (installed) 55 Land - Estimation of Capital Investment Cost items Percentage of delivered equipment cost Engineering and supervision 32 Construction Expenses 34 Legal expenses 4 Contractor’s Fee 19 Contingency 37 Components of direct cost Components of indirect cost Direct cost $37.43 M Indirect cost $15.08 M Fixed Capital Investment $52.50 M Working Capital Investment $9.27 M Total Capital Investment $61.77 M
Economic Analysis 54 Raw Material Cost and Annual Sales Annual sales Raw material Yearly amount Unit price Cost (US $) Plastic waste 6660 ton $ 144/ton 959040.00 Nutrient broth 1372188.343 L $ 2.38/L 3264436.07 Ethyl acetate 1649.33 L $ 8.42/L 13887.39 Total raw material cost 4237363.45 4.24 M Raw material cost Product Yearly production Unit price Cost (US $) Ethanol 4795999.2 L $6.00/L 28775995.20 Acetic acid 3203992.8 L $5.88/L 18839477.66 Tar 126.56331 ton $585.00/ton 74039.54 Total 47689512.40 47.69M
55 Net cash flow and Cash Flow Diagram Annual sales = $47.69M Total production cost, (TPC) = $35.91M Depreciation cost (10% FCI) = $5.25M Profit before taxes = $(47.69-35.91-5.25) M = $6.53M Annual tax rate = 35% Income tax = $(0.35×6.53) M = $2.28M Profit after tax= $(6.53-2.28) M = $4.24M Net cash flow = Profit after tax + Depreciation = $(4.24+5.25) M = $9.49 M Here, MARR=10% Plant life= 20 years Salvage value = 10% of Total capital investment =$6.18 M
56 Feasibility Analysis PW (10%) = $19.98 M >0 IRR = 14.44% ERR = 11.55% -60000000 -40000000 -20000000 0 20000000 40000000 60000000 80000000 100000000 120000000 140000000 0 10 20 30 40 50 PW i, % PW vs Interest rate Graph for IRR determination
57 Payback Period End of year (k) Net cash flow (M USD) Cumulative PW at i=0%/yr through year k (M USD) PW of cash flow at i= 10%/yr (M USD) Cumulative PW at i=10%/yr through year k (M USD) 0 -61.77 -61.77 -61.77 -61.77 1 9.49 -52.28 8.63 -53.14 2 9.49 -42.78 7.85 -45.29 3 9.49 -33.29 7.13 -38.16 4 9.49 -23.79 6.48 -31.68 5 9.49 -14.30 5.89 -25.78 6 9.49 -4.81 5.36 -20.42 7 9.49 4.69 4.87 -15.55 8 9.49 14.18 4.43 -11.12 9 9.49 23.68 4.03 -7.09 10 9.49 33.17 3.66 -3.43 11 9.49 42.66 3.33 -0.11 12 9.49 52.16 3.03 2.92 Simple payback period 7 yrs Discounted payback period 12 yrs
THANK YOU!

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Design-ppt_SAmodified.pptx

  • 1.
    CHE 408: ProcessDesign Sessional Presented by Afia Subhani (1602001) Anika Bushra (1602006) K. M. Nazmus Sakib (1602026) Ishmamul Hoque Sadab (1602031) Design of a 20 Ton/Day Combined Thermochemical and Biological Plastic Waste Processing Plant for The Production of Acetic Acid and Bio-ethanol Supervised by Dr. Shoeb Ahmed Professor Department of Chemical Engineering BUET Presentation on Department of Chemical Engineering BUET
  • 2.
    1. Project Definition 2 ▰A plant is to be set up at Zinjira, Keraniganj in Bangladesh having a capacity to process 20 ton/day of segregated plastic waste to produce 9600 L/day acetic acid and 14400 L/day ethanol corresponding to a yearly production of 3.2×106 L of acetic acid and 4.8×106 L of ethanol on processing 6600-ton plastic waste, including all offsites, auxiliaries, utilities, and supporting facilities. ▰ The process involves converting plastic wastes into syngas through gasification followed by fermentation of syngas to produce acetic acid and ethanol with the help of bacteria Clostridium ljungdahlii.
  • 3.
    Raw Materials ▰ Clostridiumljungdahlii culture ▰ Air ▰ Segregated Plastic Waste ▰ Bacterial growth nutrient medium 3 Products ▰ 99 % Acetic Acid (V/V) ▰ 90 % Ethanol (V/V) ▰ Tar Component Quantity per L of medium 2 gm FeCl2.4H2O 10 mL 85% H3P04 0.05 mL MPFN Trace Metals 20 mL (NH4)2HPO4 0.6 g NH4Cl 2 g NaCl 0.2 g KCl 0.15 g MgCl2.6H2O 0.5 g CaCl2.2 H2O 0.2 g Cysteine HCl.H2O 0.25 g Vitamin solution 0.7-0.8 /0.1-0.2* mL Table 1:Table for the composition of nutrient
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    Geographical Data Site Characteristics Nearest River: Buriganga  Maximum water level: 1.54-2.1 meters  Average Depth of wells: 10-15 meters  Water level record during flood: 4m above plant ground level Soil Characteristics  The project area is dominated by organic clay and peats.  The cluster lies on the Madhupur Clay with its average thickness of about 10 meters consists of over-consolidated clayey slit and is underlain by the Pleistocene Dupi Tila formation.  Arsenic content is below WHO limit. 6
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    Seismic Condition ▰ Maximumearthquake – 7 on Richter scale ▰ Seismic Zone – 3 seismic zones in Bangladesh & the site is in Zone II ▰ Seismic Coefficient – 0.15 g 7 Al-Hussaini, T., Hossain, T., & Al-Noman, M. (2012). Proposed Changes to the Geotechnical Earthquake Engineering Provisions of the Bangladesh National Building Code. Geotechnical Engineering Journal Of The SEAGS & AGSSEA, 43(2).
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    Meteorological Data ▰ Climateconditions • 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). ▰ Temperature Maximum 36°C Minimum 12.7°C ▰ Rainfall Average yearly 1329 mm 8 ▰ Humidity Average annual relative humidity 59.8% Highest 79% (Summer) Lowest 45% (Winter) ▰ Wind • Wind direction: Summer: South to North Winter: North to South • Design wind velocity: 60-65 m/s
  • 9.
    Utilities 9  Process Steam Temperatureand Pressure: 527 0C, 1 atm Source: Groundwater, river water (after treatment)  Cooling water Temperature and Pressure: 25 0C, 1 atm Source: Ground water, river water (after treatment) Plant air Temperature and Pressure:25 0C, 7.5 atm Source: Atmospheric air  Instrument air Pressure: 3−20 psig Source: Atmospheric air  Inert gas (N2) Temperature and Pressure: 25 0C, 8 atm Source: Atmospheric air  Electric power Source: National Grid
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    11  Processing abroad range of syngas component ratios  No need for an external gas shift operation  High tolerance to contaminants  Higher selectivity of biological catalysts leading to higher yields  Inexpensive biological catalyst, low cost growth media  Simplified downstream processing, less undesired by-products  Greater fuel yield and energy efficiency  Lower carbon dioxide emissions  Higher rate of carbon conversion to fuel
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    List & sizingof Equipment 14 5
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    15 Name of EquipmentIdentification No. No. of Items Size Water Storage Tank T-100 1 Volume: 79 m3 Shredder S-100 1 Capacity: 0.23 kg/s Elevator E-100 1 Length: 2.31m Diameter: 0.23 m Power of drive: 0.045 KW Washer W-100 1 Volume: 3.168 m3 Screw Conveyor SC-100 1 Length: 10.5 m Diameter: 0.23 m Power of drive: 0.21 KW Rotary Dryer DR-100 1 Peripheral surface area= 3.02 m2 Heat Exchanger HE-100 1 Surface area: 1.82 m2 Heat duty: 33.3 KW Gasifier G-100 1 Volume: 64.05 m3 Cyclone Separator C-100 1 Body diameter: 1.052 m Ceramic (Candle) Filter CF-100 1 tube filter area: 1.48 m2 No. of cells: 6 Tubes per cell: 78 Pressure Swing Adsorber (PSA) PA-100 1 Diameter: 1.1 m Height: 3.23 m Air Compressor CM-100 1 Power: 172 KW Economizer EC-100 1 Surface area: 0.92 m2 Heat duty: 42.84 KW Superheater SH-100 1 Surface area: 29.94 m2 Heat duty: 615.76 KW Table 5a: List of equipment and sizing
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    16 Name of EquipmentIdentification Code No. of Items Size Syngas Cooler CO-103 1 Surface area: 53.73 m2 Heat duty: 270.26 KW Syngas Storage Tank ST-100 1 Volume: 1171 m3 Primary Bioreactor M-100 1 Volume: 0.25 m3 Syngas Compressor CM-101 1 Power: 843.6 KW Secondary Bioreactor M-101 to M-110 10 Volume of each: 64.29 m3 Liquid Storage Tank ST-101 1 Diameter: 2.68 m Height: 5.36 m Cell Separator CS-100 to CS-109 10 Diameter of each: 1.7 m Length of each: 1.55 m Pumps P-100 9 Power: 837.2 W P-101 Power: 394.5 W P-102 Power: 191.3 W P-103 Power: 794.1 W P-104 Power: 211.9 W P-105 Power: 536.6 W P-106 Power: 635.0 W P-107 Power: 3530.6 W P-108 Power: 865.5 W Table 5b: List of equipment and sizing
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    17 Name of EquipmentIdentification Code No. of Items Size Distillation Column D-100 2 Height: 14.7 m Diameter: 0.9 m D-101 Height: 6.6 m Diameter: 1.5 m Reboiler H-100 2 Surface area: 4.46 m2 Heat duty: 304.17 KW H-101 Surface area: 16.83 m2 Heat duty: 1144.44 KW Condenser CO-100 2 Surface area: 10.55 m2 Heat duty: 239.72 KW CO-101 Surface area: 31.14 m2 Heat duty: 1041.67 KW Ethyl Acetate Storage Tank T-101 1 Volume: 0.94 m3 Acetic Acid Storage Tank ST-102 1 Volume: 33 m3 Ethanol Storage Tank ST-103 1 Volume: 49 m3 Table 5c: List of equipment and sizing
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    Individual Equipment Shell &Tube Heat Exchanger (HE-100) 19
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    20 Thermal Design ofHeat Exchanger Heat Balance: Q = 113628 Btu/hr LMTD=922.37 oF FT = 0.99 Corrected LMTD, ΔT = 913.15 oF Tube side: (Assume) Tube OD, do= 0.75 inch BWG= 18 Tube ID, di = 0.652 inch Length of tube, L= 5 ft No. of tubes, Nt = 20 Square pitch, PT =1 inch Heat transfer coefficient, hio=91.97 Btu/hr. ft2 oF Shell side: (Assume) Shell ID, Di = 30 inch ⸫ Baffle space, B= Di×0.2 = 6 inch Clearance, C =0.25 inch Heat transfer coefficient, ho = 15.79 Btu/hr. ft2 oF Clean overall coefficient, Uc= 13.47 Btu/hr. ft2 oF Dirty overall coefficient, UD= 6.34 Btu/hr. ft2 oF Dirt factor, Rd(calculated) = Uc−UD UcUD = 0.08354 Rd(required) =0.00938 Pressure drop calculation: Tube side, ΔPT = 0.05 <10 psi Shell side, ΔPs= 0.00029 psi <10 psi
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    21 Mechanical Design ofHeat exchanger Code: ASME code section VIII division 1 Materials: Stainless Steel (Grade 304) Corrosion allowance, C = 3mm =0.11811 inch For SS-304, maximum allowable pressure, F = 9781 psi Tube thickness: 0.12 inch= 3.02mm Shell thickness: 0.35 inch= 8.89mm Nozzle Diameter: 7.981 inch Thickness: 0.17inch=4.33mm Head Type: Torispherical Thickness: 0.46inch= 11.80mm Height= 7.44inch Baffle Shape: Segmental Cut: 25% No. of baffles: 9 Insulation Material: Mineral wool Critical thickness: 30.33mm ⸫Thickness= 32mm Support Type: Saddle A B C D E F G H 27.2inch 23.0inch 3.9inch 5.1inch 9.5inch 11.7inch 5.9inch 3.9inch
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    22 Figure: Cross-sectional viewof 1-2 shell and tube heat exchanger (U- bend Type) Mechanical Drawing
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    23 Figure: Cross-sectional viewof tube bundle arrangement
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    24 Figure: P &ID of shell and tube heat exchanger Piping & Instrumentation Diagram
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    Design Parameters forAtmospheric Distillation Column 26 Temperature 100˚C Pressure 101.3 kPa Material of construction Carbon steel Column height 14.7 m Column diameter 0.9 m Column thickness 5 mm Tray type Sieve tray No. of trays 23 Feed stage 12th stage
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    27 Tray spacing 0.61m Tray thickness 2.86 mm Hole diameter 4.76 mm Pitch type Equilateral triangular Pitch length 15 mm Weir length 0.4 m Weir height 25.4 mm Downcomer area 0.026 m2 Downcomer width 49 mm Insulation material Fiber glass Insulation thickness 100 mm
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    28 Insulation area 51.23m2 Column weight 2791.7 kg Head type ASME Tori-spherical Inside depth of dish 0.378 m Head thickness 5 mm Support type Skirt support Skirt height 1.84 m Skirt thickness 3 mm Reboiler duty 304.2 kW Reboiler area 4.46 m2 Condenser duty 239.7 kW Condenser area 7.16 m2
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    29 Purpose No. ofNozzles Location Feed inlet 1 12th stage Top vapor outlet 1 1st stage Reflux nozzle 1 1st stage Boil-up nozzle 1 23rd stage Bottom liquid outlet 1 23rd stage Level controller 1 23rd stage Gauge glass 1 23rd stage Temperature indicator 15 Several stages Manhole 5 4,8,12,16 and 20th stages Liquid sampling point 3 5,15,20th stages Pressure gauge 2 1 and 23rd stages
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    31 Figure: Mechanical drawingof top view of sieve tray
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    Individual Equipment Fixed BedGasifier (G-100) 33
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    34 Design Parameters Highest bedtemperature 0C 800 0C Operating pressure 1 bar Gasifier type Fixed bed, updraft Solid residence time 1 hr Inner diameter of the gasifier vessel 2.75 m Height of gasifier vessel 8.81 m Total height including bunker, throat and ash throat 11.59 m
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    35 Mechanical Design • Code:ASME Section VII, Division 01 • Dimensions of Vessel Height: 11.59 m Diameter = 2.75 m Dead weight= 13031 kg • Shell Materials: SS 309 Wall thickness: 9.71 mm • Head Type: ASME Semi-Ellipsoidal Head Materials: SS 309 Wall thickness: 4.5 mm • Pressure Design pressure = 2.026 atm Working pressure = 1 bar • Insulation Material: Mineral wool blocks Thickness: 1.69 mm Weight: 27 kg • Jacket Jacket thickness: 54 mm Wall thickness: 5.18 m Jacket nozzle diameter: 81 mm • Gas inlet Nozzle Diameter: 0.30 m Thickness: 0.63 mm • Gas outlet Nozzle Diameter: 0.43 m Thickness: 0.9 mm
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    36 Mechanical Design • Support Type:Skirt Material: ASME SA 387 GRADE 22 Thickness: 19.3 mm • Rotating Grate Diameter: 2.20 m No. of openings: 810 Diameter of dome: 0.73 m Height of dome: 0.24 m Rotating speed: 20 rpm
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    38 Mechanical Drawing Front sectionalview of the rotating grate Top view of rotating grate
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    41 • Code: ASMESection VII, Division 01 • Process: Fed-Batch; Gas Residence Time: 150 s; Liquid Retention Time: 20 hrs. • Shell Materials: SS304 steel Thickness: 18 mm (corrosion allowance in accordance to ASME UG-16) • Head Type: ASME Semi-Ellipsoidal Head Materials: SS304 steel Thickness: 15 mm (corrosion allowance in accordance to ASME UG-16) • Dimensions of Vessel Height: 8.72 m Diameter = 2.91 m Weight= 2093.04 kg • Sparger Type: Sintered Metal Sparger by Mott Corp. Model: Type A Hex Nipple Sparger of Media Grade-40(2240-A16-10-A00-XX-AB) Diameter=2.5’’ Length=40’’=1.1016 m Number of sparger = 1 Mechanical Design
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    42 Mechanical Design • ColumnSupport Type: Skirt Material: Structural Steel Length:100cm Diameter: 2.943 mm Thickness 1.5 mm • Agitator Type: Impeller Power: 8.69 hp Bracket support for drive system = 1.744 m • Shaft Material: SS304 steel Shaft diameter: 12 cm Coupling diameter: 24 cm • Pressure Design pressure = 8.5 atm Working pressure = 6 atm • Insulation Material: Polyurethane Foam Thickness: 13 cm Weight: 29.0374 • Jacket Length: 7.412 m Internal diameter: 3.197 m • Base plate Type: annular, ID = 285 cm, OD = 315 cm, Thickness = 2 cm Number of bolts = 12
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    Agitator type: Rushtondisk turbine, Impeller type: Flat blade, No of agitator = 3, No. of blades = 6, No. of baffles = 4, Blade thickness = 5 mm, Angle of blade = 45º Impeller diameter = 96.89 cm Blade length = 24.22 cm, width = 19.378 cm Turbine revolutions = 60 rpm Distance between two impellers = 121.11 cm Support to mount drive: L shaped bracket support Length of bracket support = 174.604 cm Mechanical Design
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    Economic Analysis 50 Steps Followed Purchased equipment cost estimation incorporating cost indices  Estimation of total capital investment  Estimation of total production cost  Profitability analysis  Feasibility analysis
  • 51.
    Economic Analysis 51 Equipment NameIdentification No. Quantity Cost (US $) Water Storage Tank WT-100 1 20000 Shredder S-100 1 8000 Elevator E-100 1 5500 washer W-100 1 7000 Screw Conveyor SC-100 1 11500 Rotary dryer DR-100 1 40000 Heat Exchanger HE-100 1 3000 Gasifier G-100 1 209437.46 Cyclone separator C-100 1 9094 candle filter CF-100 1 126000 Pressure swing adsorption PA-100 1 8400 Air compressor CM-100 1 101365 Economizer EC-100 1 2100 Superheater SH-100 1 10000 Purchased Equipment Cost
  • 52.
    Economic Analysis 52 Purchased EquipmentCost (cont’d) Equipment Name ID No. Quantity Cost (US $) Syngas cooler CO-103 1 8200 Syngas storage tank ST-100 1 400000 Syngas compressor CM-101 1 295952 Primary Bioreactor M-100 1 3500 Secondary Bioreactor M-101 to M-110 10 1000000 Liquid storage tank ST-101 1 54000 Cell separator CS-100 to 109 10 2900000 Pump P-100 to P-108 9 10447 Distillation Column D-100 to D-101 2 126126 Reboiler H-100 to H-101 2 7370 Condenser CO-100 to CO-101 2 13571 Ethyl acetate tank T-101 1 6200 Acetic acid storage tank ST-102 1 40000 Ethanol storage tank ST-103 1 50000 CEPCI in 2002 and 2022 is 395.6 and 785.9 respectively Total purchased equipment cost (TPEC) at 2022 = $10.88M Delivered equipment cost = $11.97 M ( delivery/shipment cost is 10% of TPEC)
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    Economic Analysis 53 Cost items Percentageof delivered equipment cost Purchased equipment delivered 100 Purchased equipment installation 39 Instrumentation and Control(installed) 26 Piping (installed) 31 Electrical system (installed) 10 Building, auxiliaries (including Services) 29 Yard Improvements 12 Service Facilities (installed) 55 Land - Estimation of Capital Investment Cost items Percentage of delivered equipment cost Engineering and supervision 32 Construction Expenses 34 Legal expenses 4 Contractor’s Fee 19 Contingency 37 Components of direct cost Components of indirect cost Direct cost $37.43 M Indirect cost $15.08 M Fixed Capital Investment $52.50 M Working Capital Investment $9.27 M Total Capital Investment $61.77 M
  • 54.
    Economic Analysis 54 Raw MaterialCost and Annual Sales Annual sales Raw material Yearly amount Unit price Cost (US $) Plastic waste 6660 ton $ 144/ton 959040.00 Nutrient broth 1372188.343 L $ 2.38/L 3264436.07 Ethyl acetate 1649.33 L $ 8.42/L 13887.39 Total raw material cost 4237363.45 4.24 M Raw material cost Product Yearly production Unit price Cost (US $) Ethanol 4795999.2 L $6.00/L 28775995.20 Acetic acid 3203992.8 L $5.88/L 18839477.66 Tar 126.56331 ton $585.00/ton 74039.54 Total 47689512.40 47.69M
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    55 Net cash flowand Cash Flow Diagram Annual sales = $47.69M Total production cost, (TPC) = $35.91M Depreciation cost (10% FCI) = $5.25M Profit before taxes = $(47.69-35.91-5.25) M = $6.53M Annual tax rate = 35% Income tax = $(0.35×6.53) M = $2.28M Profit after tax= $(6.53-2.28) M = $4.24M Net cash flow = Profit after tax + Depreciation = $(4.24+5.25) M = $9.49 M Here, MARR=10% Plant life= 20 years Salvage value = 10% of Total capital investment =$6.18 M
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    56 Feasibility Analysis PW (10%)= $19.98 M >0 IRR = 14.44% ERR = 11.55% -60000000 -40000000 -20000000 0 20000000 40000000 60000000 80000000 100000000 120000000 140000000 0 10 20 30 40 50 PW i, % PW vs Interest rate Graph for IRR determination
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    57 Payback Period End ofyear (k) Net cash flow (M USD) Cumulative PW at i=0%/yr through year k (M USD) PW of cash flow at i= 10%/yr (M USD) Cumulative PW at i=10%/yr through year k (M USD) 0 -61.77 -61.77 -61.77 -61.77 1 9.49 -52.28 8.63 -53.14 2 9.49 -42.78 7.85 -45.29 3 9.49 -33.29 7.13 -38.16 4 9.49 -23.79 6.48 -31.68 5 9.49 -14.30 5.89 -25.78 6 9.49 -4.81 5.36 -20.42 7 9.49 4.69 4.87 -15.55 8 9.49 14.18 4.43 -11.12 9 9.49 23.68 4.03 -7.09 10 9.49 33.17 3.66 -3.43 11 9.49 42.66 3.33 -0.11 12 9.49 52.16 3.03 2.92 Simple payback period 7 yrs Discounted payback period 12 yrs
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