Basic concepts and opportunities for application of process engineering techniques to local industry applications (appropriate technology)

1. Career & Capacity Building
Process Engineering for Appropriate
Technology
With Engr. Akachidike Kanu
Webinar Lecture presented to:
FUTY (Fed Univ ofTechYola Nigeria) Alumni Group

2. Industrialization
• Industrialization: the development of
industries in a country or region on a
wide scale – Oxford Dictionary
• Industry: large-scale business activity
or a type of productive manufacture or
trade
Process enablers
1. Industrialize an agricultural region
(policy)
2. Produce/supply processed agro
products on a large scale (business)
3. Study, design and operate fertilizer
plant (engineer)

3. Industrial Process Engineering
• Process Engineering: processes and equipment for
turning raw materials (feed) into product. Essential
part of many industries – manufacturing, utilities,
energy, mining, supply chain, healthcare, etc.
• Chemical Engineering: …emphasis on change of state
and composition of matter in a controlled process
• Manufacturing engineering: …emphasis on
machining/ assembling (screws, bolts, welds, glues,
rivets) individual pieces into a distinct product
• Industrial Engineering: …optimizing integrated
systems of people, money, knowledge, information,
equipment, energy and materials.

4. Technical Systems Framework
Economic
Driver
Scientific Principle Engineering Method
Batch -
Continuous
Processing
Flow processes – steady &
transient
Flow conditions (PVT)
Fluidization, EOS, Stokes’
Law, Simulation
Scale-Up Rate laws, Unit Operations, Mass,
energy & momentum transfer
Mass & Energy balances,
Process modeling, etc
Safety Process control &
instrumentation, time transient
processing
HAZOP, SIL, ALARP, statics,
etc.
Efficiency &
Economics
Profitability, Synergies,
Economies of scale
DCF, Cost functions, MEFS,
Cost-Benefit Analysis, Pinch
Quality Integration, Loss prevention Poka-Yoke, Agile
Operational
Excellence
Optimization, Loss Prevention Lean, Operations research

5. Assets Lifecycle
Original (modified) data from Kristina Eisen, et al, Current and future
requirements to industrial analytical infrastructure
Upstream - Midstream
Downstream – intermediates and end-
products manufacturing
Build
Operate
Decomm

6. Potent industries
• Grain and root crop processing (Garri, yam,
plantain, processing)
• Extracts and concentrates (Fruit and vegetable
juices, nutritional supplements, etc)
• Ingredients processing (Egusi shelling, ukwa, etc)
Case Study: Food Processing – Massive opportunity area
• High demand for food produce and products
• Alarming high cost of food in Nigeria
• Low productivity in produce value chains

7. Case Study: Food Processing – Process System Approach
Size reduction Filtration Clarification Drying Packaging
Extraction
“Poundo yam” processing plant in Ibadan (1998)
• Size reduction (Cutter) and dryer
• Packaging
Garri processing plant in Ibadan (1998) (Proposal)
• Size reduction (grinding)
• Filter, dryer, furnace
• Packaging

8. Case Study: Food processing - Antidote to high cost of produce
Nigeria India
Bread
1 loaf
$0.86
₦299.16
$0.41
₹26.44
-52.4%
Local cheese (500 grams) $2.08
₦723.16
$2.47
₹158.97
+18.3%
Milk (1 liter) $1.84
₦639.80
$0.63
₹40.36
-66.0%
Eggs
1 dozen
$1.31
₦454.10
$0.87
₹55.92
-33.7%
Boneless chicken breast (1 kg) $4.11
₦1,424.55
$3.00
₹193.30
-27.0%
Apples (1 kg) $3.84
₦1,333.92
$1.76
₹113.48
-54.2%
Bananas (1 kg) $1.88
₦651.00
$0.69
₹44.72
-63.0%
Oranges (1 kg) $1.94
₦671.85
$0.95
₹60.95
-51.2%
Tomatoes (1 kg) $1.90
₦660.87
$0.45
₹29.14
-76.3%
Potatoes (1 kg) $1.82
₦631.78
$0.34
₹21.62
-81.6%
Onions (1 kg) $1.02
₦354.13
$0.45
₹28.86
-56.1%
Average -49.4%

9. Cases Study: Energy, Fuels & Chemicals – National Imperative
• Record flares
• Foreign dominated
upstream -
midstream
development and
operations
• Biofuels and biomass
fuels processing
• Gas processing &
petrochemical
• Agro Chemicals
(herbicides)
Gas to Methanol Plant (2016)
Production of Methanol from
natural gas
Challenging monetization options
Strong market demand
Prod CuH2SO4.5H2O (2000)
• Strong market demand
• Challenging scale-up
• Scrap copper + dilute H2SO4
(catalyzed)
• Filtration
• Crystallization
• Packaging

10. Case Study: Gas-Methanol – Opportunity Identification

11. Case Study: Gas-Methanol - Concept Selection

12. MeOH Offgas
CH3OH 0.997 0.01
CO2 0.06
CO 0.21
C1 0.003 0.04
H2 0.51
H2O 0.00
Other 0.17
Total 1.000 1.00
MeOH Offgas Sygas
Mass flow (ton/day) 4,800.00 1,524.98 6,324.98
Product
CO2 0.01
N2 0.06
C1 0.80
C2 0.07
C3 0.03
iC4 0.01
nC4 0.01
iC5 0.00
nC5 0.00
Total 1.00
Feed Gas
Syngas
Crude
MeOH
Case Study: Plant Design - Concept Definition

13. Feedstock Qty Ref
HHV (MBTU/Mscf) 1,102 DAT
Feedstock (MMBtu/t) 28.00 MMSA
Process Net Fuel (MMBtu/t) 5.50 MMSA
Direct Cost Structure Qty $/ton Reference
Variable OPEX
Boiler Feedwater Makeup (m3/t) 0.75 0.50 MMSA
Cooling Water Makeup (m3/t) 8.05 0.10 MMSA
Catalyst per ton 1.75 1.80 MMSA
Electricity (kWh/t) 134.62 MMSA, NTNU
Power generator heat rate (BTU/kWh) 10,408 EIA
Fixed OPEX
Labour ($/t) 4.00 MMSA, Turton
Plant Inspection, Maintenace and SGA ($/t) 12.00 MMSA
Freight to Market ($/t/km) 0.003 MMSA
Marine Facilities Maintenance (M$/yr) 0.70 Questor
CAPEX
Plant ISBL Direct CAPEX (M$/ton/day) 0.27 DAT
Indirect Cost Coeficients (DAT)
Owner´s Cost
Facilities Abandonment
Insurance (OPEX)
Contingency
Plant Specifications
Plant capacity (ton/day) 5,170
Reformer type Combined
Onstream days/year 350
Feed gas plateau year 2023
Distance to Market (coast to coast) (km) 7,200
Case Study: Plant Design - Proof of Commerciality

14. Textile Manufacture
• Pre colonial weaving industry (Akwete)
• Post colonial products importation
from Holland and Asia
• The Asian industries boom
• Where are we now?
Case Study: Local Crafts & Tech
Distilleries
• World famous champagne market
• Local gin market
• Ogogoro, Kaikai & brukutu brews and
distilleries
• What’s lacking….?
• ….Process Engineering !!

15. Thank You!
Discussions and Q &A!