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Decanters are used to separate liquids where there is a sufficient difference in density between
the liquids for the droplets to settle readily. Decanters are essentially tanks which give sufficient
residence time for the droplets of the dispersed phase to rise (or settle) to the interface between
the phases and coalesce. In an operating decanter, there will be three distinct zones or bands:
clear heavy liquid; separating dispersed liquid (the dispersion zone); and clear light liquid. The
decanter in this design will separate the glucose and xylose (heavy phase) from the mixture (light
phase). The sizing and costing summary for decanter is shown in Table 7.3.
In the design, three pumps are used to increase the pressure of streams 18, 22 and 40 to desired
pressure conditions. Pump, P-101 basically is used to pump liquid solvent from 1 bar to 1.2 bar
before entering flash drum, FD-101. Pump, P-102 is used to pump liquid solvent from 1 bar to
1.3 bar before entering splitter, S-101. Pump, P-103 is used to pump liquid solvent from 1.1 bar
to 18 bar before entering reactor, R-101.The sizing and costing summary for pumps are shown in
Table 7.4.
In the design, continuous filter, F-101 is used to separate lignin, unreacted hemicellulose and
cellulose from water, xylose and sulfuric acid. In filter, F-102 the unreacted cellulose and lignin
are removed. Filter, F-103 and F-104 are used to filter out calcium sulfate from reactor PR-103
and PR-104. The sizing and costing summary for filters are shown in Table 7.5.
Crusher, CR-101 is used to reduce the size of shredded empty fruit bunch (EFB) from mill to 1-
3mm so that it can be fed into the reactor for pre-treatment process. The sizing and costing
summary for crusher is shown in Table 7.6.
In equilibrium flash process, a feed stream is separated into liquid and vapor streams. Flash
drum, FD-101 is to reduce the water content in sugar solution which is stream 20 and similarly
flash drum, FD-102 is used to reduce water content of the stream before it enters new vessel so
that the size of the vessel can be smaller. The sizing and costing summary for flash drums is
shown in Table 7.7.
Mixer is used to combine two streams from different equipment to the next equipment. In this
plant, mixer is used to mix between the butanol, water, hydrochloric acid, xylose and glucose.
The sizing and costing summary for mixer is shown in Table 7.8.
Splitter, is a type of equipment which splits one chemical stream into two streams in a chemical
plant. In this plant, splitters are used to split water with equal composition. The sizing and
costing summary for splitter is shown in Table 7.9.
Storage tank is used to store the chemicals supply as well as the products before delivering to the
market. In this design, it is required to install storage tanks for Furfural, Levulinic Acid and
DMF product. The sizing and costing summary for storage tank is shown in Table 7.10.
Reactor is the heart of a chemical plant where the reactions take place to convert the raw
materials to the desired products. Several parameters shall be taken into account while designing
a reactor, including the reactor type, temperature, pressure and reactor size. The sizing and
costing summary for storage tank is shown in Table 7.11.
Function
Operating Condition
Temperature (°C) 70 70
Pressure (bar) 1 1
Residence Time,𝜏 (hr) 1 1
Specifications
Design Type Vertical Cylindrical Tank Vertical Cylindrical Tank
Material of Construction Carbon Steel Carbon Steel
Vessel
Diameter (m) 2.034 2.07
Height (m) 4.069 4.13
Volume (m3) 13.23 13.88
Thickness (mm) 0.625 0.625
Equipment Cost RM 969,595.03 RM 989,295.22
Item no Biphasic Reactor, R-101 Trickle Bed Reactor, R-102
Function
Operating Condition
Temperature (°C) 120 60
Pressure (bar) 18 1.4
Residence Time,𝜏 (hr) 6 6
Specifications
Design Type Vertical Cylindrical Tank Vertical Cylindrical Tank
Material of Construction Stainless Steel 316 Stainless Steel 316
Vessel
Diameter (m) 6.11 1.28
Height (m) 12.22 2.55
Volume (m3) 357.95 3.27
Thickness (mm) 3.25 0.5
Equipment Cost RM 25,141,120.45 RM 944,985.66
Item no Tubular Reactor, R-103
Function
Operating Condition
Temperature (°C) 105.945
Pressure (bar) 1.7
Residence Time,𝜏 (hr) 1
Specifications
Design Type Vertical Cylindrical Tank
Material of Construction Stainless Steel 316
Vessel
Diameter (m) 12.13
Height (m) 24.27
Volume (m3) 2806.28
Thickness (mm) 0.875
Equipment Cost RM 27,541,004.67
Total Estimated Equipment Cost = RM 172,881,629.10