What are the advantages and disadvantages of membrane structures.pptx
Design-ppt_SAmodified.pptx
1. 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
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
▰ 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
6. 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
7. 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).
8. 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
9. 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
11. 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
15. 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. 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. 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
20. 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. 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
26. 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. 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. 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. 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
34. 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. 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. 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
41. 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. 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
43. 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
50. 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
52. 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)
53. 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
54. 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. 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
