Tk13 Revised Assignment3

UNIVERSITAS INDONESIA
BIO-ETHANOL PRODUCTION THROUGH

BIOSACCHARIFICAITON AND FERMENTATION WITH
EFB AS FEEDSTOCK
Revised Assignment 3
GROUP 13
GROUP PERSONNEL:
Jessica Farah (1506673302)
Nabilla Larasati Karlinda (1506673435)
Nur Alfin Hidayati (1506673340)
Wahidin (1506673536)
Wildan Raafi Utomo (1506673246)
CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
UNIVERSITAS INDONESIA
NOVEMBER 2018
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EXECUTIVE SUMMARY
This Bio-ethanol production plant consist in many stages of process.
Beginning from pre-treatment of raw material until the process in the utility. In
order to produce this Bio-ethanol product, this plant need some equipment to use
such as reactor, column, mixer, clarifier, centrifuge, heat exchanger, HCL cooler,
ethanol heater, reboiler, condenser, furnace, mixing tank, piping, storage tank,
pump, washing machine, compressor, dryer, conveyor, filter, and ion exchanger.
In the pre-treatment area, the EFB from storage tank was handling with
conveyor to washing machine for washing the EFB with liquid detergent which is
transported using a pump. After that the clean EFB entered into rotary dryer then
grinder to get EFB with small and smooth structure. After that, EFB entered into
reactor to hydrolysis the EFB with dilute HCL which is transported using a pump
from storage tank. Hydrolysis or delignification reactor is a CSTR reactor which
acts as both delignification process and hydrolysis of cellulose and hemicellulose
into glucose and xylose, for the fermentation purpose. The total volume of reactor
hydrolysis is 576.732 L with diameter of reactor is 0.702 m and height of reactor is
1.579 m.
In the simultaneous saccharification and fermentation area, there are 3
storage tank to put yeast, Ca(OH)2, and enzyme, 2 pump and 3 belt conveyor to
transported the material, 3 mixer tank, ammonia compressor, clarifier, separator and
2 reactor. The reactor in this area consists of a seed fermentor reactor and SSF
reactor. Seed fermenter is categorized as bioreactor that acts like batch reactor, but
in this process, to optimize the process and time duration, the process will continue
as continuous process, but the bioreactor will be more than one to emulate the batch
process. The total volume of seed fermentor reactor is 43.473 L with diameter of
reactor is 2.964 m and height of reactor is 6.669 m. SSF reactor is a bioreactor where
both saccharification and fermentation process happen. It uses bacteria culture from
seed fermenter along with additional yeast and nitrogen to ferment the glucose and
xylose to ethanol. Also, it uses enzyme to saccharify the remaining cellulose and
hemicellulose into glucose and xylose. The total volume of SSF reactor is 392.421
L with diameter of reactor is 5.978 m and height of reactor is 13.451 m.
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In ethanol purification process area, there are ethanol heater, mixing tank,
condenser, reboiler, and 3 column. The column in this area consist of distillation
column, extractive column, and EG recovery column. Distillation column use to
separate ethanol from water with feed mass flow rate is 3.64E+04 kg/h, reflux ratio
10, column pressure 101.33 kPa, number of actual tray 15 with type sieve tray,
temperature condenser 78.08 oC, temperature reboiler 100 oC, stage efficiency
64.08%, material stainless steal, column height 9 m, and column OD 2.184 m.
Extractive Distillation column use to purify ethanol until 99.5% by mass with feed
mass flow rate is 5.14E+03 kg/h, reflux ratio 1.5, column pressure 101.33 kPa,
number of actual tray 20 with type sieve tray, temperature condenser 78.14 oC,
temperature reboiler 85.98oC, stage efficiency 57.38%, material stainless steal,
column height 12 m, and column OD 0.9144 m. EG recovery column use to
regenerate used EG with feed mass flow rate is 7.86E+03 kg/h, reflux ratio 1.3,
column pressure 101.33 kPa, number of actual tray 4 with type sieve tray,
temperature condenser 78.33oC, temperature reboiler 191.9oC, stage efficiency
70.24%, material stainless steal, column height 1.8 m, and column OD 1.524 m.
In order to make easier, efficient and safe plant, piping and instrumentation
diagram is also play an important role needed to put controls of some variable in
plant production such as temperature, pressure, flow rate, pH and level. on the other
hand, this instrumentation also makes this plant safely to work with high pressure
operating condition. The instrumentation in this plant divided into controller,
transmitter and analyser which works together in controlling plant.
The consideration when determining control for process are including safety
factor, environmental protection factor, equipment protection factor, smooth
operation and production rate factor, product quality factor, profit and monitoring
diagnosis. First thing to consider is safety factor such as pressure in vessels which
is controlled using pressure safety valve. Environmental factor is also considered in
controlling temperature and quality of waste water from the plant. Equipment
protection is also important for example protection for pumps using level controller
to ensure that only liquid which entering the pumps. Flow controller is also used to
ensure smooth operation and production rate. Product quality is controlled using
analyszer in ethanol product.
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LIST OF CONTENT
EXECUTIVE SUMMARY .................................................................................. II
LIST OF CONTENT .......................................................................................... IV
CHAPTER 1 MAIN SIZING AND SPECIFICATION......................................1
1.1. Reactor .........................................................................................................1
1.1.1. Hydrolysis/Delignification Reactor .......................................................1
1.1.2. Neutralizing Reactor ..............................................................................3
1.1.3. Seed Fermenter ......................................................................................5
1.1.4. SSF Reactor ...........................................................................................7
1.2. Distillation Column .....................................................................................9
1.2.1. Main Distillation Column ....................................................................13
1.2.2. Extractive Distillation Column ............................................................14
1.2.3. Recovery Distillation Column .............................................................16
1.4. Clarifier ......................................................................................................17
1.5. Centrifuge ..................................................................................................19
1.5.1 Centrifuge in Main Process .................................................................19
1.5.2 Centrifuge in Water Treatment Process ..............................................20
1.6. Heat Exchanger .........................................................................................22
1.6.1. Ethanol-Ethylene Glycol Heat Exchanger ...........................................22
1.6.2. Reboiler................................................................................................27
1.6.4. Condenser ............................................................................................36
1.6.5. Furnace.................................................................................................39
1.9. Piping..........................................................................................................44
1.9.1 Piping Pre-Treatment ...........................................................................44
1.9.2 Piping SSF Process ...............................................................................46
1.9.3 Pipe of Purification ...............................................................................48
1.9.4 Pipi of Utility ........................................................................................49
1.10. Storage Tank .............................................................................................51
1.11 EFB Warehouse .........................................................................................57
CHAPTER 2 ADDITIONAL SIZING AND SPECIFICATION .....................58
2.1. Pump ..........................................................................................................58
2.1.1. Pump in Main Process ...........................................................................58
2.1.2. Pump in Water Treatment Process ........................................................62
2.2. Washing Machine .......................................................................................65
2.3. Compressor .................................................................................................67
2.4. Fan ...............................................................................................................69
2.5. Dryer............................................................................................................71
2.6. Grinder ........................................................................................................73
2.7. Belt Conveyor .............................................................................................73
2.8. Filter ............................................................................................................74
2.8.1 Sand Filter (Y-401) ..............................................................................74
2.8.2 Plate Filter Press ..................................................................................74
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2.9. Ion Exchanger ............................................................................................75
CHAPTER 3 PIPING AND INSTRUMENTATION DIAGRAM ..................76
3.1. Piping and Instrumentation Design ..........................................................76
3.2. Plant Control Tabulation ..........................................................................76
CHAPTER 4 .........................................................................................................85
CONCLUSION.....................................................................................................85
REFERENCE .......................................................................................................86
CONTENT OF TABLE
Table 1.1. Hydrolysis/Delignification Reactor Specification .............................1
Table 1.2. Neutralizing Reactor Specification ....................................................3
Table 1.3. Seed Fermenter Reactor Specification ..............................................5
Table 1.4. SSF Reactor Specification ..................................................................7
Tabel 1.5 Main Distillation Column Specifications.........................................13
Table 1.6 Extractive Distillation Column Specifications ................................14
Table 1.7 EG Recovery Column Specifications ...............................................16
Tabel 1.8. Specification of Clarifier ...................................................................17
Table 1.9 Spesification Centrifuge ....................................................................19
Table 1.10 Specification centrifuge in WTP ......................................................20
Table 1.11 Ethanol-Ethylene Glycol Heat Exchanger Specification ...............22
Table 1.12 Main Distillation Reboiler Specification .........................................27
Table 1.13 Extractive Distillation Reboiler Specification .................................30
Table 1.14 Ethylene Glycol Recovery Reboiler Specification ..........................33
Table 1.15 Main Distillation Condenser Specification .....................................36
Table 1.16 Extractive Distillation Condenser Specification .............................37
Table 1.18 Specification of furnace for steam generation ................................39
Table 1.19 Specification of furnace for biogas ..................................................41
Table 1.20 Spesification pipe of liquid detergent ..............................................44
Table 1.21 Spesification pipe of EFB fibers .......................................................44
Table 1.22 Spesification pipe of EFB to Delignification ...................................45
Table 1.23 Spesification pipe of S-101 ................................................................45
Table 1.24 Spesification pipe to SSF...................................................................46
Table 1.25 Spesification pipe of water ................................................................46
Table 1.26 Spesification pipe of sugar water .....................................................46
Table 1.27 Spesification pipe of sludge...............................................................47
Table 1.28 Spesification pipe to SSF reactor .....................................................47
Table 1.29 Spesification pipe to purification .....................................................48
Table 1.30 Spesification pipe of stream 30 .........................................................48
Table 1.33 Spesification pipe of steam ...............................................................49
Table 1.34 Spesification pipe of process water ..................................................50
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Table 1.35 Spesification pipe for cooling water .................................................50
Table 1.36 Spesification pipe for sanitation .......................................................51
Table 1.37 Spesification pipe to WTP ................................................................51
Table 1.38 Storage Tank Specification ...............................................................52
Table 1.44 Warehouse Specification...................................................................57
Table 2.1 Specification pump ............................................................................58
Table 2.11 Washing Machine Specifications .....................................................66
Table 2.12 Compressor Specification .................................................................67
Table 2.15 Fan Specification ...............................................................................69
Table 2.19 Rotary Dryer Specification ...............................................................72
Table 2.20 Rotary Dryer Total Specification .....................................................72
Table 2.21 Specification of grinder .....................................................................73
Table 2.22 Specification of belt conveyor...........................................................74
Table 2.23 Ion Exchanger Specification .............................................................75
Table 3.1 The P&ID Tabulation Table .............................................................80
CONTENT OF FIGURE
Figure 1.1. Mechanical Drawing of Hydrolysis/Delignification Reactor ..........2

Figure 1.2. Mechanical Drawing of Neutralizing Reactor .................................4
Figure 1.3. Mechanical Drawing of Seed Fermenter Bioreactor .......................6
Figure 1.4. Mechanical Drawing of SSF Bioreactor ...........................................8
Figure 1.5 Mechanical drawing of clarifier ......................................................18
Figure 1.6 Mechanical drawing of centrifuge ...................................................21
Figure 1.7. Tube Layout of the Ethanol-Ethylene Glycol Heat Exchanger ....24
Figure 1.8. Exchanger Drawing of the Ethanol-Ethylene Glycol Heat
Exchanger .............................................................................................................25
Figure 1.9. Setting Plan of the Ethanol-Ethylene Glycol Heat Exchanger .....26
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Figure 1.10 Picture of Boiler ...............................................................................29
Figure 1.13 Drawing of Furnace .........................................................................43
Figure 1.14 Storage tank flat bottom and with legs ..........................................56
Figure 2.1. Washing Machine Specifications .....................................................66
Figure 2.2 Direct Heat Type Rotary Dryer Available Specification ...............72
Figure 2.2. Sand Water Filter Specification ......................................................74
Figure 3.1. Pretreatment P&ID ..........................................................................77
Figure 3.2. SSF P&ID ..........................................................................................78
Figure 3.3. Ethanol Purification P&ID ..............................................................79
Figure A.1. Choosing Type of HE .......................................................................87
Figure A.2. Fill in Necessary Properties ............................................................88
Figure A.3. Fill in Fluid Properties.....................................................................88
Figure A.4. Run Case ...........................................................................................89
Figure A.5. Process Iteration ..............................................................................89
Figure A.6. Process Result ...................................................................................90
Figure B.1 Trough Conveyor Belt .....................................................................90
Figure B.2 Capacity of Belt Conveyor ..............................................................91
Figure B.3 Belt Speed of Conveyor....................................................................91
Figure B.4 The Empy Power of Belt Conveyor ................................................92
Figure D.1 General Range of Application for Compressor.............................93
Figure F.1 Lower Limit of Furnace ...................................................................96
Figure F.2 Upper Limit of Furnace ...................................................................96
Figure G.1 Nominal Size of Pipe, Schedule 40 (in mm) ....................................98
Figure G.2 Nominal Size of Pipe, many schedule (in inch) ..............................98
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CHAPTER 1
MAIN SIZING AND SPECIFICATION
1.1. Reactor
1.1.1. Hydrolysis/Delignification Reactor
Hydrolysis or delignification reactor is a CSTR reactor which acts as both
delignification process and hydrolysis of cellulose and hemicellulose into glucose
and xylose, for the fermentation purpose. To prevent the acid from hydrolyzing the
EFB completely, the residence time is decreased, so the process can also be
continuous. The specification of the reactor is shown at table 1.1.
Table 1.1. Hydrolysis/Delignification Reactor Specification
Hydrolysis/Delignification Kinetic CSTR Reactor R-101
Parameters Value Unit
X 0.287 %
K 0.402 1/s
Vo 5.787 L/s
V 5.787 L/s
V 524.302 L
Total volume with safety 576.732 L
Diameter of Reactor 0.702 M
Height of Fluid 1.435 M
Height of Reactor 1.579 M
Shell Thickness 1.120 Cm
Diameter of Impeller 0.246 M
Diameter of Baffle 0.070 M
Width of Blade Impeller 0.0819 M
Length of Blade Impeller 0.0614 M
Position of Impeller from Bottom 0.234 M
Spesific Power for Agitation 2.000 kW/m3
Residence Time 90.600 S
The mechanical drawing of hydrolysis/delignification reactor is as below:
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UNLESS OTHERWISE HYDROLYSIS/DELIGNIFICATION
SPECIFIED, UNITS CSTR REACTOR
ARE IN METERS
DRAWN BY: TK13 SIZE: A4 DATE: 03 NOVEMBER 2018
Figure 1.1. Mechanical Drawing of Hydrolysis/Delignification Reactor
3
1.1.2. Neutralizing Reactor

Neutralizing reactor is a CSTR reactor in which neutralization of
remaining HCl in the sugar sludge occurs. Ca(OH)2 will simultaneously act as a
neutralizer for HCl and lime feedstock, so the sugar sludge will further be purified
from its impurities and detritus. The specification of the reactor is shown at table
1.2.
Table 1.2. Neutralizing Reactor Specification
Neutralizing CSTR Reactor R-201

Parameter Value Unit
X 0.965 %
K 94.464 1/s
Vo 25.934 L/s
V 7.569 L/s
V 27249.880 L
Diameter of Reactor 2.618 M
Height of Fluid 5.355 M
Height of Reactor 5.891 M
Shell Thickness 1.306 Cm
Diameter of Impeller 0.916 M
Diameter of Baffle 0.262 M
Width of Blade Impeller 0.30543333 M
Length of Blade Impeller 0.229075 M
Position of Impeller from Bottom 0.873 M
Residence Time 1200.000 S
The mechanical drawing of neutralizing reactor is as below:
UNLESS OTHERWISE
SPECIFIED, UNITS NEUTRALIZING CSTR REACTOR
ARE IN METERS
Figure 1.2. Mechanical Drawing of Neutralizing Reactor
5
1.1.3. Seed Fermenter

Seed fermenter is categorized as bioreactor that acts like batch reactor, but
in this process, to optimize the process and time duration, the process will continue
as continuous process, but the bioreactor will be more than one to emulate the batch
process. The specification of the reactor is shown at table 1.3.
Table 1.3. Seed Fermenter Reactor Specification
Seed Fermenter Bioreactor R-202
Component Glucose & Xylose
X 0.326 %
µ 0.084 1/h
t 4.700 h
V 39.521 m3
Total volume with safety 43.473 m3
Simplified Michaelis Menten
Kinetics Model
(First Order)
Diameter of Reactor 2.964 m
Height of Fluid 6.063 m
Height of Reactor 6.669 m
Shell Thickness 1.351 cm
Diameter of Impeller 1.037 m
Diameter of Baffle 0.296 m
Width of Blade Impeller 0.346 m
Length of Blade Impeller 0.259 m
Position of Impeller from Bottom 0.988 m
The mechanical drawing of the bioreactor fermenter is shown below:
UNLESS OTHERWISE
SPECIFIED, UNITS SEED FERMENTER BIOREACTOR
ARE IN METERS
Figure 1.3. Mechanical Drawing of Seed Fermenter Bioreactor
7
1.1.4. SSF Reactor

SSF reactor is a bioreactor where both saccharification and fermentation
process happen. It uses bacteria culture from seed fermenter along with additional
yeast and nitrogen to ferment the glucose and xylose to ethanol. Also, it uses
enzyme to saccharify the remaining cellulose and hemicellulose into glucose and
xylose. The specification of the SSF reactor is shown at table 1.4.
Table 1.4. SSF Reactor Specification
Main Fermenter Bioreactor R-203
Batch Reactor
Glucose &
Component Unit
Xylose
X 0.930 %
µ 0.133 1/h
t 20.000 h
V 356.746 m3
Total volume with safety 392.421 m3
Simplified Michaelis Menten
Kinetics Model
(First Order)
The mechanical drawing of the SSF bioreactor is shown below:
UNLESS OTHERWISE
SPECIFIED, UNITS ARE SSF BIOREACTOR
IN METERS
Figure 1.4. Mechanical Drawing of SSF Bioreactor
9
1.1.5 Coagulation Reactor

Coagulation reactor is where the coagulation process happens. The reactor
is a continuous CSTR reactor, and colloids will stabilize and react with impurities
so the coagulation process can occur. Coagulant used in this process is aluminium
sulphate (Al2SO4)3. The reactor specification is shown below:
Table 1.5. Coagulation Reactor Specification
Coagulation Reactor D-402

X 0.990 %
k 11103.653 1/s
vo 776.560 L/s
V 6.924 L/s
V 24925.669 L
Residence Time 1200.000 s
The mechanical drawing of the coagulation reactor is shown below:
UNLESS OTHERWISE COAGULATION REACTOR
SPECIFIED, UNITS ARE IN
METERS
Figure 1.5. Mechanical Drawing of Coagulation Reactor
11
1.1.6 Flocculation and Neutralization Reactor

Flocculation and neutralization reactor is a CSTR reactor in which the
water is simultaneously neutralized and cleaned from its impurities. Ca(OH)2 will
act as a neutralizer and as a flocculant, so the slow mixing process in which particles
that have had their charge neutralized (coagulation) are encouraged to clump
together with other particles, creating larger masses that will settle more rapidly.
The specification of this reactor is shown at table below:
Table 1.6. Flocculation and Neutralization Reactor Specification
Flocculation and Neutralization Reactor D-403
X 0.950 %
k 1493.148 1/s
vo 543.657 L/s
V 6.918 L/s
V 24904.519 L
Residence Time 1200.000 s
The mechanical drawing of the coagulation reactor is shown below:
12
UNLESS OTHERWISE FLOCCULATION AND NEUTRALIZATION

SPECIFIED, UNITS ARE IN REACTOR
METERS
Figure 1.6. Mechanical Drawing of Flocculation and Neutralization Reactor
13
1.2. Distillation Column

The tables that are shown below, shows the specifications of the main
distillation column, EG dehydration column, and EG recovery column. The number
of actual tray is the number of trays without condenser and reboiler.
1.2.1. Main Distillation Column

Tabel 1.5 Main Distillation Column Specifications
Equipment Specification
Equipment Name Distillation Column
Equipment Code T-301
To separate ethanol from
Function
water
Operation Data
Feed Mass Flow Rate
3.46E+04
(kg/h)
Reflux Ratio 10
Column Pressure (kPa) 101.3250
Number of Actual Tray 15
Condenser Temperature
78.08
(oC)
Reboiler Temperature (oC) 100
Stage Efficiency (%) 64,08
Construction Data
Material Stainless Steal
Column Height (m) 9,00
Column Diameter (m) 2.184
Plate Type Sieve Tray
Material SS-316
Shell Thickness (in) 0.026213
Head Type Torispherical
Head Thickness (in) 0.004699
14
1.2.2. Extractive Distillation Column
Table 1.6 Extractive Distillation Column Specifications

Extractive Distillation
Equipment Name
Column
To purify ethanol until 99.5%
Function
by mass fraction
Operation Data
Feed Mass Flow Rate
5.14E+03
(kg/h)
Reflux Ratio 1.5
78.17
(oC)
Reboiler Temperature (oC) 85.98
Stage Efficiency (%) 57.38
Construction Data
Material Stainless Steel
Column Height (m) 12
Material SS-316
Figure 1.7. Distillation Column
16
1.2.3. Recovery Distillation Column
Table 1.7 EG Recovery Column Specifications

Extractive Distillation
Equipment Name
Column
Function To regenerate used EG
Operation Data
Feed Mass Flow Rate
7.86E+03
(kg/h)
Reflux Ratio 1.3
78.33
(oC)
Reboiler Temperature (oC) 191.9
Stage Efficiency (%) 70.24
Construction Data
Material Stainless Steel
Column Height (m) 1.8
Material SS-316
17
1.4. Clarifier
Clarifier is used to separate solid product because of previous process
produces CaCO3. It must be separated because it is the reason of plugging and
fouling in a pipeline. The specification of the Clarifier is shown at table 1.8.
Tabel 1.8. Specification of Clarifier
Mass flow rate for 1
75.64 ton/h
clarifier
Volumetric flow rate 76.3030 m3/h
Clarifier volume 83.9333 m3
Clarifier height 5 M
D2/D1 0.4997 m/m
y 4.9948 M
y/(y+h) 0.4997 m/m
D1 6.5403 M
D2 3.2685 M
Amount of clarifier unit 1 Unit
The mechanical drawing of the clarifier is shown below:
UNLESS OTHERWISE
SPECIFIED, UNITS CIRCULAR CLARIFIER
ARE IN METERS
Figure 1.5 Mechanical drawing of clarifier
19
1.5. Centrifuge
The centrifuge serves to rotate the sample at high speed, forcing heavier
particles to collect to the bottom of the centrifuge tube. The specification of the
centrifuge is below.
1.5.1 Centrifuge in Main Process
Table 1.9 Spesification Centrifuge
Identification
Item Centrifuge
Item Number
Equipment Name CF-201
Number of Unit 1
To separate product with waste by
Function
density differences
Operating Condition
Time (h) 0.53247362
Flowrate (kg/h) 34,591
Capacity (m3) 502.91
Temperature (oC) 25
Specification Design
Type Vertical tank with Torispherical head
Material Carbon Steel A285 Grade A
Tank Diameter (m) 6.130682067
Tank Height (m) 4.291477447
Shell Thickness
0.008
(m)
Head Thickness
0.006657882
(m)
Straight Flange (m) 3.729619123
20
1.5.2 Centrifuge in Water Treatment Process

Centrifuge is also used in waste water treatment process, in which the
function is to separate remaining impurities in water before water treatment process,
such as COD, BOD, ash, lignin, etc. The specification of the centrifuge is as below:
Table 1.10 Specification centrifuge in WTP
Identification
Item Centrifuge
Item Number
Equipment Name CF-202
Number of Unit 1
To separate product with waste by
Function
density differences
Operating Condition
Time (h) 0.53247362
Flowrate (L/h) 53,352
Capacity (m3) 532.352
Temperature (oC) 35.76
Specification Design
Type Vertical tank with Torispherical head
Material Carbon Steel A285 Grade A
Tank Diameter (m) 6.48959229
Tank Height (m) 4.54620954
Shell Thickness
0.008
(m)
Head Thickness
0.006489592
(m)
Straight Flange (m) 3.729619123
The mechanical drawing of the centrifuge is shown below:
D = 6.131
H = 4.291
UNLESS OTHERWISE
SPECIFIED, UNITS DISK STACK CENTRIFUGE
ARE IN METERS
Figure 1.6 Mechanical drawing of centrifuge
22
1.6. Heat Exchanger

1.6.1. Ethanol-Ethylene Glycol Heat Exchanger
The heat exchanger is used to exchange heat between ethanol and ethylene
glycol, so the temperature of the ethanol will increase, and the temperature of
ethylene glycol will decrease. The specification and the sketch of the heat
exchanger will be calculated using HTRI Xchanger Suite software. The
specification is shown below:
Table 1.11. Ethanol-Ethylene Glycol Heat Exchanger Specification
Equipment Specification Design Construction

Parameter Unit Parameter Unit Shell Tube
side side
Equipment Code E-301 Maximum kPa 1.1 1.1
Design
Pressure
Material Carbon Steel (Shell Maximum °C 45 195
and Tube) Design
Temperature
Type Shell and Tube M Passes per 1 6
(AEM) (Fixed Tube) Shell
Surface per Unit m2 81.036 Corrosion mm 5 5
Allowance
Performance of One Unit and Liquid Properties Shell Construction Information
Parameter Unit Shell Tube Parameter Unit
Fluid Ethyl Ethylene ID mm 257.455
Alcohol Glycol
Total Vapor Flowrate In kg/h 0 0 Heat m2 13.506
Transfer
Area
Total Vapor Flowrate kg/h 0 0
Tube Construction Information
Out
Total Liquid Flowrate In kg/h 34591.424 3778 OD mm 25.4
23
Performance of One Unit and Liquid Properties Tube Construction Information

Total Liquid Flowrate kg/h 34591.424 3778 ID mm 20.4
Out
Temperature In °C 40.200 44.850 Pitch mm 31
Temperature Out °C 191.500 140.000 Length mm 6096
Viscosity In cP 0.721 0.399 Tube Triangular
Arrangement
Viscosity Out cP 0.666 0.846 Baffle Information
Specific Heat In kJ/kg°C 4.110 3.566 Baffles 13
Number
Specific Heat Out kJ/kg°C 4.111 3.240 Central mm 465.011
Spacing
Pressure kPa 101.3 101.3 Baffle mm 6.350
Pressure Drop kPa 0 0 Thickness
Fouling Factor m2°K/W 0.0000 0.0000
Heat Duty MW 0.1755
Overall Coefficient W/m2K 106.76/214.48/214.48
(Required/Clean/Actual)
Effective LMTD °C 121.74
The drawings of the heat exchanger is shown below:
Figure 1.7. Tube Layout of the Ethanol-Ethylene Glycol Heat Exchanger
(Source: HTRI Xchanger)
Figure 1.8. Exchanger Drawing of the Ethanol-Ethylene Glycol Heat Exchanger
Figure 1.9. Setting Plan of the Ethanol-Ethylene Glycol Heat Exchanger
27
1.6.2. Reboiler
Reboiler is designed using HTRI program. Reboiler design calculation is
using TEMA as references. The TEMA type of all reboilers is AKU, which means
K for kettle type reboiler and U for U type tubes inside the shell. The specification
of three reboiler for three distillation column is shown from Table below;
Table 1.12 Main Distillation Reboiler Specification
Equipment Name Heat Exchanger
Equipment Code E-303
Type Shell and Tube
Operating Condition
Tube
Data Shell Side
Side
To
Fluid Stream Inlet LPS in
Reboiler.1
Fluid Stream Outlet 34 LPS out
Fluid Flow (kg/h) 4.61E+04 4.58E+04
Temperature in (oC) 25 99.9
Temperature out (oC) 70 100
Operating pressure
101.33 101.33
(kPa)
No. of passes 1 2
Fouling factor (m2
o
0.000205
C/W)
Heat Duty (MW) 29.053
∆T LMTD (oC) 50.62
Overall U (W/m2 oC) 1,180.99
28
Design Specification
Type of unit Fixed tube
Material SS-316 or SA-240
Heat Transfer Area
717.67
(m2)
Tube OD (mm) 25.4
Tube Length (m) 6.096
Shell ID (m) 1.524
Tube Pitch (mm) 31.75
Tube Thickness (mm) 1.651
Number of tubes 1,382
Tube arrangement Triangular
The drawings of the reboiler is shown below:
Figure 1.10 Picture of Boiler
30
Table 1.13 Extractive Distillation Reboiler Specification

Type Shell and Tube
Operating Condition
Tube
Data Shell Side
Side
To
Fluid Stream Inlet SHS in
Reboiler.2
Fluid Stream Outlet 34 SHS out
Temperature in (oC) 83.01 120.4
Temperature out (oC) 83.49 99.9
Operating pressure
101.33 101.33
(kPa)
No. of passes 1 2
Fouling factor (m2
o
0.000205 0.000205
C/W)
∆T LMTD (oC) 25.61
Overall U (W/m2 oC) 415.9
Material SS-316
Heat Transfer Area
682.36
(m2)
Tube OD (mm) 25.4
Shell ID (m) 1.524
31
33
Table 1.14 Ethylene Glycol Recovery Reboiler Specification

Type Shell and Tube
Operating Condition
Tube
Data Shell Side
Side
To
Fluid Stream Inlet HPS in
Reboiler.3
Fluid Stream Outlet 38 HPS out
Temperature in (oC) 156.9 215
Temperature out (oC) 191.9 211.5
Operating pressure
101.33 20,000
(kPa)
No. of passes 1 2
Fouling factor (m2
o
0.000205
C/W)
∆T LMTD (oC) 36.62
Overall U (W/m2 oC) 861.5
Material SS-316
Heat Transfer Area
332.036
(m2)
Tube OD (mm) 19.05
Shell ID (m) 1.422
34
36
1.6.4. Condenser
Condensers in bioethanol production plant for three distillation columns
specification are shown from Table in below. Condenser design calculation is
Kern’s Method and TEMA as reference.
Table 1.15 Main Distillation Condenser Specification
Type Shell and Tube
Operating Condition
Shell Tube
Data
Side Side
To
Fluid Stream Inlet 1
Cond.1
Fluid Stream Outlet 2 5
Temperature in (oC) 25 78
Operating pressure
101.33 101.33
(kPa)
No. of passes 1 2
Fouling factor (m2
o
0.000205 0.000205
C/W)
∆T LMTD (oC) 23.661
Material SS-316 or SA-240
Heat Transfer Area
167.828
(m2)
Tube OD (mm) 19.050
37
Shell ID (m) 0.540
Tube Pitch (mm) 24
Number of tubes 575
Table 1.16 Extractive Distillation Condenser Specification

Type Shell and Tube
Operating Condition
Shell Tube
Data
Side Side
To
Cond.2
Operating pressure
101.33 101.33
(kPa)
No. of passes 1 2
Fouling factor (m2
o
0.000205
C/W)
∆T LMTD (oC) 23.609
38
Material SS-316
Heat Transfer Area
20.081
(m2)
Tube OD (mm) 19.050
Shell ID (m) 0.540
Tube Pitch (mm) 24
Number of tubes 69
Table 1.17 Ethylene Glycol Recovery Condenser Specification

Equipment Code E107
Type Shell and Tube
Operating Condition
Shell Tube
Data
Side Side
To
Cond.3
Operating pressure
101 101.325
(kPa)
No. of passes 1 2
39
Operating Condition
Fouling factor (m2
o
0.000205 0.000205
C/W)
∆T LMTD (oC) 24.417
Material SS-316 atau SA-240
Heat Transfer Area
47.181
(m2)
Tube OD (mm) 19.050
Shell ID (m) 0.540
Tube Pitch (mm) 24
Number of tubes 162
1.6.5. Furnace
The furnace in this plant functions for steam generators and for biogas.
The specification is shown below:
Table 1.18 Specification of furnace for steam generation
Equipment Name Furnace
Equipment Code F-601
Type NC
Heat Release Rate per Unit Volume
ṁc (kg/h) 5400.000
1.500
LHV (kJ/kg) 20829.600
40

qv (kW/m3) 350.000
V (m3) 89.270
Heat Release Rate per Unit Cross Sectional
Area
Flow (kg/h) 34755.000
34.755
qa (kW/m3) 2130.000
A (m2) 14.669
Heat Release Rate per Unit Wall Area of
Burner
qb (kW/m3) 2320.000
(a+b) Hb (m2) 134.674
b (m) 3.000
Hb (m) 5.000
a (m) 23.935
Type of Burner
Power produced
27012.406
(kW)
Boiler type NC
Determination of Furnace Size
α 30.000
β 45.000
γ 50.000
E (m) 0.800
d (m) 0.750
Furnace Material
Inner case
SS-304
material
Furnace wall Fire brick
41
Table 1.19 Specification of furnace for biogas

Equipment Name Furnace
Equipment Code F-602
Type NC
ṁc (kg/h) 1990.242
0.553
LHV (kJ/kg) 28387.310
qv (kW/m3) 350.000
V (m3) 44.839
Heat Release Rate per Unit Cross Sectional Area
Flow (kg/h) 17966.750
17.967
qa (kW/m3) 2130.000
A (m2) 7.368
Heat Release Rate per Unit Wall Area of Burner
qb (kW/m3) 2320.000
(a+b) Hb (m2) 67.646
b (m) 3.000
Hb (m) 5.000
a (m) 10.529
Type of Burner
Power produced (kW) 13964.143
Boiler type NC
Determination of Furnace Size
α 30.000
β 45.000
γ 50.000
E (m) 0.800
d (m) 0.750
42
Furnace Material
Inner case material SS-304
Furnace wall Fire brick
The drawings of the furnace is shown below:
UNLESS OTHERWISE
SPECIFIED, UNITS FURNACE
ARE IN METERS
Figure 1.13 Drawing of Furnace
44
1.9. Piping
Pipe is an important element in a plant because it is connecting one equipment
with another. Not only in main process unit, sizing pipe in water process utility is
an important thing to do. Plant layout is needed to sizing the whole pipe, this pipe
sizing is just preferred to the pipeline through the pump.
1.9.1 Piping Pre-Treatment
Table 1.20 Spesification pipe of liquid detergent
Liquid
Name
Detergent Unit
ṁ 1.1580 kg/s
ρ 1065.13 kg/m3
Flow 0.001087191 m3/s
Fluid Non Water
v 1 m/s
A 0.001087191 m2
ID 0.037 M
ID 37.215 Mm
Nominal 1.25 "
Schedule 40
Table 1.21 Spesification pipe of EFB fibers
Name EFB Fibers Unit

ṁ 6.7610 kg/s
Ρ 1241.86 kg/m3
Flow 0.005444253 m3/s
Fluid Non Water
V 1 m/s
A 0.005444253 m2
ID 0.083 M
ID 83.279 Mm
Nominal 3 "
Schedule 40
45
Table 1.22 Spesification pipe of EFB to Delignification

EFB to
Name
Delignification Unit
ṁ 6.7610 kg/s
Ρ 1241.86 kg/m3
Flow 0.005444253 m3/s
Fluid Non Water
V 1 m/s
A 0.005444253 m2
ID 0.083 m
ID 83.279 mm
Nominal 3 "
Schedule 40
Table 1.23 Spesification pipe of S-101

Name S-101 Unit
ṁ 7.0980 kg/s
ρ 1222.39 kg/m3
Flow 0.005806657 m3/s
Fluid Non Water
v 1 m/s
A 0.005806657 m2
ID 0.086 M
ID 86.006 Mm
Nominal 3 "
Schedule 40
46
Table 1.24 Spesification pipe to SSF

Name To SSF Unit
ṁ 5.0310 kg/s
Ρ 1117.27 kg/m3
Flow 0.00450294 m3/s
Fluid Non Water
V 1 m/s
A 0.00450294 m2
ID 0.076 M
ID 75.738 Mm
Nominal 2.5 "
Schedule 40
1.9.2 Piping SSF Process

Table 1.25 Spesification pipe of water
Name Water Unit
ṁ 15.9100 kg/s
ρ 1000 kg/m3
Flow 0.01591 m3/s
Fluid Water
v 3 m/s
A 0.005303333 m2
ID 0.082 M
ID 82.194 mm
Nominal 3 "
Schedule 40
Table 1.26 Spesification pipe of sugar water
Name Sugar Water Unit

ṁ 20.9420 kg/s
ρ 1025.94 kg/m3
Flow 0.0204125 m3/s
47
Fluid Non Water

v 1 m/s
A 0.0204125 m2
ID 0.161 M
ID 161.255 mm
Nominal 6 "
Schedule 40
Table 1.27 Spesification pipe of sludge

Name Sludge2 Unit
ṁ 21.0100 kg/s
ρ 1007.41 kg/m3
Flow 0.020855461 m3/s
Fluid Non Water
v 1 m/s
A 0.020855461 m2
ID 0.163 m
ID 162.995 mm
Nominal 6 "
Schedule 40
Table 1.28 Spesification pipe to SSF reactor
Name To SSF Unit

ṁ 16.2000 kg/s
ρ 1027.52 kg/m3
Flow 0.015766116 m3/s
Fluid Non Water
v 1 m/s
A 0.015766116 m2
ID 0.142 M
ID 141.719 mm
Nominal 5 "
48
Schedule 40
Table 1.29 Spesification pipe to purification

Name To Purification Unit
ṁ 9.6090 kg/s
Ρ 953.59 kg/m3
Flow 0.010076658 m3/s
Fluid Non Water
v 1 m/s
A 0.010076658 m2
ID 0.113 M
ID 113.298 Mm
Nominal 4 "
Schedule 40
1.9.3 Pipe of Purification

Table 1.30 Spesification pipe of stream 30
Name 32 Unit
ṁ 9.6120 kg/s
ρ 974.2 kg/m3
Flow 0.009866557 m3/s
Fluid Non Water
v 1 m/s
A 0.009866557 m2
ID 0.112 M
ID 112.111 Mm
Nominal 4 "
Schedule 40
Name 34 Unit
ṁ 8.1856 kg/s
49
ρ 947.9 kg/m3
Flow 0.00863551 m3/s
Fluid Non Water
v 1 m/s
A 0.00863551 m2
ID 0.105 m
ID 104.884 mm
Nominal 4 "
Schedule 40
Name 36 Unit
ṁ 2.1825 kg/s
ρ 892.6 kg/m3
Flow 0.002445104 m3/s
Fluid Non Water
v 1 m/s
A 0.002445104 m2
ID 0.056 m
ID 55.810 mm
Nominal 2.5 "
Schedule 40
1.9.4 Pipe of Utility

Table 1.33 Spesification pipe of steam
Name Steam Unit
ṁ 14.6450 kg/s
ρ 967.37 kg/m3
Flow 0.015138985 m3/s
Fluid Non Water
v 1 m/s
A 0.015138985 m2
50
ID 0.139 M
ID 138.872 mm
Nominal 5 "
Schedule 40
Table 1.34 Spesification pipe of process water

Name Process water Unit
ṁ 2.4280 kg/s
Ρ 1017 kg/m3
Flow 0.002387414 m3/s
Fluid Water
V 3 m/s
A 0.000795805 m2
ID 0.032 m
ID 31.840 mm
Nominal 2 "
Schedule 40
Table 1.35 Spesification pipe for cooling water
Name For Coling Water Unit

ṁ 2.9690 kg/s
ρ 1020.94 kg/m3
Flow 0.002908104 m3/s
Fluid Water
v 3 m/s
A 0.000969368 m2
ID 0.035 M
ID 35.141 Mm
Nominal 2 "
Schedule 40
51
Table 1.36 Spesification pipe for sanitation

Name For sanitation Unit
ṁ 5.9650 kg/s
ρ 1000 kg/m3
Flow 0.005965 m3/s
Fluid Water
v 3 m/s
A 0.001988333 m2
ID 0.050 M
ID 50.328 Mm
Nominal 2.5 "
Schedule 40
Table 1.37 Spesification pipe to WTP

Name To WTP Unit
ṁ 6.6880 kg/s
ρ 1061.75 kg/m3
Flow 0.006299035 m3/s
Fluid Water
v 3 m/s
A 0.002099678 m2
ID 0.052 M
ID 51.718 Mm
Nominal 2.5 "
Schedule 40
1.10. Storage Tank

Every vessel has the different specification and design. The detail
specification of each vessel can be shown as table below.
52
Table 1.38. Storage Tank Specification

Type V-101
Type of fluida Liquid detergent
Mass flow (kg/h) 4167
Density (kg/m3) 1100
Volume (m3/h) 3.788
Volume (m3/week) 636.415
Volume (m3) 700.056
Horizontal/vertical Vertical with Concrete Foundation
Temperature (°C) 25
Pressure (kPa) 101.300
L/D 0.8
D (m) 10.129
L (m) 8.103
Thickness (mm) > 12
Open/close vessel Close
Material type Carbon steel SA283
Vessel Head type Dished Head

Type V-102
Type of fluida HCl
Mass flow (kg/h) 1212.465
Density (kg/m3) 1180
Volume (m3/h) 1.028
Volume (m3) 189.884
Horizontal/vertical horizontal Concrete Supports
Temperature (°C) 25
L/D 0.8
53
D (m) 6.585
L (m) 5.268
Thickness (mm) 10

Type Tk-301
Type of fluida Ethanol
Density (kg/m3) 776.700
Volume (m3/h) 4.112
Volume (m3) 759.876
Horizontal/vertical Vertical with Concrete Foundation
Temperature (°C) 78.330
L/D 0.800
D (m) 10.407
L (m) 8.325
Thickness (mm) > 12

Type Tk-203
Type of fluida Enzyme
54
Volume (m3/h) 1.621

Volume (m3) 299.487
Horizontal/vertical Vertical Concrete Foundation
L/D 0.800
D (m) 7.654
L (m) 6.123
Thickness (mm) >12
Material type Stainless steel 316

Type Tk-201
Type of fluida Yeast
Volume (m3/h) 0.008
Volume (m3) 1.441
Horizontal/vertical Vertical with legs
L/D 3.000
D (m) 0.850
L (m) 2.551
Thickness (mm) 5
Material type Stainless steel 316
55

Type TK-202
Type of fluida Kalsium Hidroksida
Volume (m3/h) 0.090
Volume (m3) 16.704
Horizontal/vertical vertical with legs
L/D 3.000
D (m) 1.909
L (m) 5.727
Thickness (mm) 5
Material type Stainless Stell 316
The drawings of the furnace is shown below:
56
Figure 1.14 Storage tank flat bottom and with legs
57
1.11 EFB Warehouse

The warehouse is used to stocking the raw materials (Empty Fruit
Bunches). The raw materials are stocked every day from the supplier. The
warehouse is a rectangle building with a triangular prism roofs.
Table 1.44. Warehouse Specification
Equipment Name Empty Fruit Bunches Warehouse
Equipment Code W-101
Storage for Empty Fruit Bunches (Raw
Function
Material)
Number of Unit 1
Material Concrete
Rectangle building with a triangular
Type
prism roofs
Operation Data
Temperature (°C) 30°C
Bulk Density (kg/m3) 1,150
Dimension
Capacity (ton) 661.392
Length (m) 15.04
Width (m) 11.28
Height (m) 3.76
58
CHAPTER 2
ADDITIONAL SIZING AND SPECIFICATION
2.1. Pump
The pump is used to drain fluid at this plant, found in the main process and
utilities. The detail specification of each vessel can be shown as table below
2.1.1. Pump in Main Process
Table 2.1 Specification pump
Liquid Detergent Pump
Name P-101
P in 101,325 Pa
P out 201,325 Pa
ΔP 100,000 Pa
Δh 0 m
ρ 1065 kg/m3
g 9.8 m/s2
L pipe 5 m
F 2.124 m2/s2
ṁ 1.1580 kg/s
Flow 0.001087201 m3/s
η 0.75
W theo 111.18 Watt
W act 148.24 Watt
Head 9.80 m
Type Centrfugal
P atm 101325 Pa
P vap 6.56E+03 Pa
NPSHa 8.861638 M
59
Acid Pump
Name P-102
P in 101,325 Pa
P out 201,325 Pa
ΔP 100,000 Pa
Δh 0 M
ρ 982 kg/m3
g 9.8 m/s2
L pipe 5 M
F 2.302 m2/s2
ṁ 0.3370 kg/s
Flow 0.00034301 m3/s
η 0.75
W theo 35.08 Watt
W act 46.77 Watt
Head 10.62 M
Type Centrifugal
P atm 101325 Pa
P vap 6.56E+03 Pa
NPSHa 9.607023 M
Water Pump
Name P-202
P in 101,325 Pa
P out 201,325 Pa
ΔP 100,000 Pa
60
Δh 0 m
ρ 1000 kg/m3
g 9.8 m/s2
L pipe 5 m
F 2.262 m2/s2
ṁ 15.9100 kg/s
Flow 0.01591 m3/s
η 0.75
W theo 1626.99 Watt
W act 2169.32 Watt
Head 10.43 m
Type Centrifugal
P atm 101325 Pa
P vap 4.27E+03 Pa
NPSHa 9.673125 m
SSF Feed Pump
Name P-201
P in 101,325 Pa
P out 201,325 Pa
ΔP 100,000 Pa
Δh 0 M
ρ 1117 kg/m3
g 9.8 m/s2
L pipe 7 M
F 2.834 m2/s2
ṁ 5.0310 kg/s
Flow 0.00450294 m3/s
η 0.75
61
W theo 464.55 Watt

W act 619.41 Watt
Head 9.42 M
Type Centrifugal
P atm 101325 Pa
P vap 6.56E+03 Pa
NPSHa 8.365372 M
Diluted Enzyme Pump
Name P-203
P in 101,325 Pa
P out 201,325 Pa
ΔP 100,000 Pa
Δh 0 m
ρ 995 kg/m3
g 9.8 m/s2
L pipe 5 m
F 2.274 m2/s2
ṁ 0.4480 kg/s
Flow 0.000450387 m3/s
η 0.75
W theo 46.06 Watt
W act 61.41 Watt
Head 10.49 m
Type Centrifugal
P atm 101325 Pa
P vap 6.56E+03 Pa
NPSHa 9.489000 m
62
Ca(OH)2 Pump
Name P-204
P in 101,325 Pa
P out 201,325 Pa
ΔP 100,000 Pa
Δh 0 m
ρ 2330 kg/m3
g 9.8 m/s2
L pipe 5 m
F 0.971 m2/s2
ṁ 0.0580 kg/s
Flow 2.4898E-05 m3/s
η 0.75
W theo 2.55 Watt
W act 3.39 Watt
Head 4.48 m
Type Centrifugal
P atm 101325 Pa
P vap 6.56E+03 Pa
NPSHa 4.051817 M
2.1.2. Pump in Water Treatment Process

Waste Water Pump

Equipment Name Pump
Equipment Code P-501
Type Centrifugal Pump
Operation Data
63
Temperature (K) 328.15

Pressure Inlet (Pa) 101325.00
Vapor Pressure
15697.50
(Pa)
Pressure Outlet
201325.00
(Pa)
Flow Rate (m3/s) 0.01401
Friction Loss
4.02
(m2/s2)
Efficiency (%) 0.7
Fluid Water
Power (kW) 2.09
Head (m) 13.53
NPSHa (m) 8.35
NPSHr (m) 7.76
Slurry Pump
Equipment Name Pump
Operation Data
Vapor Pressure (Pa) 5607.14
Pressure Outlet (Pa) 201325.00
64
Friction Loss (m2/s2) 1.94

Efficiency (%) 0.7
Fluid Slurry
Power (kW) 1.90
Head (m) 12.78
NPSHa (m) 9.18
NPSHr (m) 8.38
To WTP Pump
Equipment Name Pump
Operation Data
Efficiency (%) 0.7
Fluid Water
Power (kW) 1.17
Head (m) 14.29
NPSHa (m) 11.19
NPSHr (m) 8.15
65
To Recycle Pump
Equipment Name Pump
Operation Data
Efficiency (%) 0.7
Fluid Water
Power (kW) 1.77
Head (m) 13.96
NPSHa (m) 11.35
NPSHr (m) 8.12
2.2. Washing Machine

Washing machine is used to wash and rinse the EFB from its debris and
impurities. The washing machine types that will be used is spray belt washer, in
which the available specifications in the market, are as below:
66
Figure 2.1. Washing Machine Specifications

(Source: Aquapruf catalogue, n.d.)
With its maximum load of 453 kg and belt speeds for about 78.6 m/min
and lengths for about 25.3 m. The maximum capacity for the belt per hour is about:
𝑚
78.6 𝑚𝑖𝑛
𝑇𝑖𝑚𝑒𝑠 𝑝𝑒𝑟 𝑏𝑎𝑡𝑐ℎ = = 3.106 𝑏𝑎𝑡𝑐ℎ𝑒𝑠 𝑝𝑒𝑟 𝑚𝑖𝑛𝑢𝑡𝑒
25.3 𝑚
𝑘𝑔
𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑝𝑒𝑟 𝑚𝑖𝑛𝑢𝑡𝑒 = 453 𝑘𝑔 × 3 𝑏𝑎𝑡𝑐ℎ𝑒𝑠 𝑝𝑒𝑟 𝑚𝑖𝑛𝑢𝑡𝑒 = 1359
𝑚𝑖𝑛
𝑘𝑔
= 81540
ℎ𝑜𝑢𝑟
With the maximum load is about 81540 kg/hour, the washing machine
needed will be only just one, with its specifications as below:
Table 2.11. Washing Machine Specifications
Equipment Name WSH-101
Types Spray Belt Washer
Wash-in Stream Diluted Detergent
Capacity (kg/h) 25000
Belt Speeds (m/min) 78.6
Lengths (m) 25.3
Belt Widths (m) 6.1
Materials Stainless Steel
RPM from Gearmotor 258
Drive/Driven Pulley 30
67
2.3. Compressor
Compressor is an equipment to increase gas pressure. The specification of
compressors in our plant is show in tabel below.
Table 2.12. Compressor Specification

Equipment Name Compressor
Equipment Code K-101
Fluid Dry Steam
Type Centrifugal Compressor
Operation Data
Power (kW) 51.790
Head (m) 14831.518
Fluid Air
Operation Data
Power (kW) 1732.686
Head (m) 6287.045
68
Fluid Methane
Operation Data
Power (kW) 91.708
Head (m) 11754.433
Fluid Air
Operation Data
Power (kW) 706.620
Head (m) 6287.045
69
2.4. Fan
Forced draft fans are used for supplying the combustion air into the furnace
of a boiler in reactor. Fans are use when the pressure rises is not to far. The vendor
of this fan come from Oriental Motor, USA. And the specification of fans in our
plant is show in tabel below.
Table 2.15. Fan Specification

Fan Reactor in WTP
Item Letter Specifications
Installation Conditions - Factory Floor
W 0,48 m
Size H 1,44 m
D 0,36 m
Cabinet Surface Areas S 2,4192 m2
Material - Steel
Overall Heat Transfer Coefficient U 5 W/(m2/K)
Target Temperature Rise Delta T 5 C

Total Heat Generation Q 433 W
Safety Factor St 2
Voltage V 3,1204 VAC
Current I 1 A
Frequency F 60 Hz
Required Air Flow 120 CFM
Model Type - MRS18-BTM

Fan Reactor in SSF Process
W 0,48 m
Cabinet Size
H 1,44 m
70
D 0,36 m
Surface Areas S 2,4192 m2
Material - Steel

Safety Factor St 2
Voltage V 115 VAC
Current I 0,4 A
Frequency F 60 Hz

Fan Reactor in Seed Fermentor
W 0,48 m
Size H 1,44 m
D 0,36 m
Material - Steel

Safety Factor St 2
Voltage V 115 VAC
Current I 0,4 A
Frequency F 60 Hz
71

Model Type - MRS20-BM

Fan Reactor in SSF Reactor
W 0,48 m
Size H 1,44 m
D 0,36 m
Material - Steel

Safety Factor St 2
Voltage V 115 VAC
Current I 1 A
Frequency F 60 Hz
2.5. Dryer
Rotary dryer is used to dry the washed EFB from the remaining water
content, be it from the washing process or the natural moisture content inside the
EFB. The dryer will also elevate the temperature of EFB to temper the reaction
temperature in delignification process.
Based from available specification designs of direct heat rotary dryer,
which is shown below:
72
Figure 2.2 Direct Heat Type Rotary Dryer Available Specification

(Source: 911metallurgist, n.d.)
The maximum achievable capacity for rotary dryer is 200 tons per 24
hours, or about 8333.333 kg/hour, therefore to accommodate the EFB feedstock’s
rate of 24465 kg/hour, 3 rotary dryers will be needed, with each machine capacity
is about 8155 kg/hour. Manual dimensions are set to the SuperPro simulator to
determine the remaining sizing details of the dryer, which is shown below:
Table 2.19 Rotary Dryer Specification
Equipment Name RD-101
Number of Units 3
Drum Diameter (m) 1.219
Drum Length (m) 12.192
L/D 10
Drying Capacity (kg/h) 8155
Drum Area (m2) 46.698
Drum Volume (L) 14233.600
Remaining measurement data, can be counted manually with the overall

sizing as below:
Table 2.20 Rotary Dryer Total Specification
Equipment Name RD-101

Number of Units 3
Drum Diameter (m) 1.219
Drum Length (m) 12.192
73
L/D 10
Drying Capacity (kg/h) 8155
Drum Area (m2) 46.698
Drum Volume (L) 14233.600
Number of Flights (m) 3.657
Radial Height (m) 0.152375
Materials of Dryer Mild Steel
Thickness of Dryer (mm) 15
Diameter of Feed Pipe (m) 0.232729
BHP of Blower (hp) 11.95052
Diameter of Inlet Pipe (m) 0.525
Diameter of Outlet Pipe (m) 0.463
According to several brochures of existing rotary dryer products, one can

order dryer with either pre-set or custom dimensions to meet the process
requirements, with different cost of each methods.
2.6. Grinder
Grinder is useful for destroying raw materials so that they are obtained as desired,
the specification below,
Table 2.21 Specification of grinder

Equipment Name Grinder
Equipment Code TZ-30
Power 30 kW
Weight 6000 kg
Dimensions (m) 3 x 4 x 2.5
Mill Roller (mm) 318*408
Linear speed (m/mm) 8.98-11.98
Pressure (mPa) 12-15
2.7. Belt Conveyor

Conveyor is aim to load solid that has been crushed through a belt.
74
Table 2.22 Specification of belt conveyor

Type Flat &Roll
Inclination degree 30º
Width (inches) 16
Length (ft) 100
Power (hp) 1.9
Maximum velocity (ft/min) 85.73
Maximum Capacity
(ton/hr) 29.16
Materialof Belt Polymer or Plastic
2.8. Filter
2.8.1 Sand Filter (Y-401)
Sand water filter (Y-401) is used to filters the micro solid particle. The
vendor of this filter come from Watts. The specification of sand water filter from
Watts can be determined based on water flowrate.
Figure 2.2. Sand Water Filter Specification

(Source: Watts, Water Filter Specification)
Based on the flowrate, 14.07 gpm, we need water filter with
PWM10111C10 model number. The technology that Watts used is micro filter from
zeolit, sand, anhtracite, and garnet. We need 1” pipe. The space required for this
filter is 13” x 14” x 65” with 173 lbs.
2.8.2 Plate Filter Press
75
We need plate filter press (Y-101) to filter solid particles (ash and lignin) to
produce SSF feed. The vendor of this filter come from M.W.Watermark. The
specification of sand water filter from M.W.Watermark can be determined based
on capacity.
Figure 2.3. Plate Filter Press Specification

(Source: M.W.Watermark, Filter Press)
Based on the capacity, 27 ft3, we need filter press with 1000 mm model
number. The plate dimension is 1000 mm x 1000 mm and the shifting can be
operated manual, semi automatic or automatic. We need 3” feed x 3” discharge as
standard piping.
2.9. Ion Exchanger
Table 2.23. Ion Exchanger Specification
Name Ion Exchanger

Code CE-401
To remove soluble anion and cation and
Function
water hardness
Operation Semi-continuous
Material Carbon Steel SA-283 Grade C
Type Vertical with head torispherical
Pressure Design (psi) 17.772
Amount (coloumn) 2
3
Resin Volume (m ) 111.712
3
Flowrate (m /h) 193.731
Tank diameter (m) 3.552
Tank height (m) 1.023
Shell thickness (mm) 5
Head thickness (mm) 5
CHAPTER 3
PIPING AND INSTRUMENTATION DIAGRAM
3.1. Piping and Instrumentation Design
P&ID stands for Piping and Instrumentation Diagram or Drawing.
Alternatively, it could also be called Process and Instrumentation Diagram or
simply P&I diagram or drawing. A P&ID is a working document that is used by
every discipline involved in the design, engineering and construction of process
plants. It is used as a Process Plant Layout and Piping Design reference for checking
engineering and design documents and drawings associated with a project.
Figure 3.1. Pretreatment P&ID
Figure 3.2. SSF P&ID
Figure 3.3. Ethanol Purification P&ID
3.2 Plant Control Tabulation
Table 3.1. The P&ID Tabulation Table
Operation Controlled Manipulated
Controller Function Control Procedure
Equipment Variable Variable
When the flow transmitter give electric signal
Washing Washing Control the washing agent to FIC, FIC will send pneumatic signal to
EFB Flow
Machine (WT- agent flow FIC liquid flow rate to a certain increase/decrease the control valve opening
Rate
101) rate ratio with EFB flow rate until washing agent liquid has the desired flow
rate
Control the steam flow rate so When the TT give electric signal to TIC, TIC
Hydrolysis
Reactor Steam Flow that the reaction can undergo will give pneumatic signal to increase/decrease
Reactor (R- TIC
Temperature Rate and produced the desire the control valve opening that affect the steam
101)
amount of product flow rate
To control the amount of
Hydrolysis Amount of The PSV will be automatically opened when
Reactor emitted gas from the reaction
Reactor (R- gas emitted PSV pressure in the reactor exceeds normal
Pressure occurred, so that the gas will
101) from reaction condition
not over pressure the reactor
When the TT give electric signal to TIC, TIC
Seed Cooling To prevent temperature run
Reactor will give pneumatic signal to increase/decrease
Fermentor (R- water flow TIC out due to fermentation
Temperature the control valve opening that affect the steam
201) rate reaction
flow rate
Seed Amount of The PSV will be automatically opened when
Fermentor (R- gas emitted PSV pressure in the reactor exceeds normal
When the TT give electric signal to TIC, TIC
Cooling To prevent temperature run
SSF Reactor Reactor will give pneumatic signal to increase/decrease
water flow TIC out due to fermentation
(R-202) Temperature the control valve opening that affect the steam
rate reaction
flow rate
Seed Amount of The PSV will be automatically opened when
Fermentor (R- gas emitted PSV pressure in the reactor exceeds normal
When the temperature transmitter give an
Control inlet steam flow rate
Column Inlet steam electric signal to the TIC, TIC will then send
so the column bottom
Bottom flow rate in TIC pneumatic signal that will open the control
Main temperature doesn't exceed the
Temperature reboiler valve to release some steam to control the heat
Distillation necessary
supplied.
Column (T-
Amount of
301) To control the amount of blow The PSV will be automatically opened when
Column Top vapor
PSV up vapor so that the vapor will pressure in the column exceeds normal
Pressure emitted from
not over pressure the reactor condition
reaction
When the temperature transmitter give an

Column Inlet steam electric signal to the TIC, TIC will then send
Bottom flow rate in TIC pneumatic signal that will open the control
temperature doesn't exceed the
Temperature reboiler valve to release some steam to control the heat
necessary
supplied.
Extractive
Amount of
Distillation To control the amount of blow The PSV will be automatically opened when
Column Top vapor
Column (T- PSV up vapor so that the vapor will pressure in the column exceeds normal
302) not over pressure the reactor condition
reaction
When the amount of ethanol composition is
To control the desired
Top Product Make up EG less than the desired number, the AT will give
AIC composition of produced
Composition flow rate electric signal to AIC to increase/decrease the
ethanol
control valve opening
EG Recovery Column Inlet steam When the temperature transmitter give an
Column (T- Bottom flow rate in TIC electric signal to the TIC, TIC will then send
303) Temperature reboiler pneumatic signal that will open the control
temperature doesn't exceed the valve to release some steam to control the heat
necessary supplied.
Amount of
To control the amount of blow The PSV will be automatically opened when
Column Top vapor
PSV up vapor so that the vapor will pressure in the column exceeds normal
not over pressure the reactor condition
reaction
CHAPTER 4
CONCLUSION
Based on this assignment, we can conclude several important things:

1. Specification of equipment including dimensions, materials, operating
conditions, and other necessary conditions
2. The controlled parameter for off-grid plant is temperature, flow rate,
pressure and level.
3. The types of main equipment are reactor, distillation column, clarifier,
centrifuge, heat exchanger, and storage tank.
4. In frementation process needs two, the are seed fermenter and one main
fermenter to make the process continuous.
REFERENCE
Hammad M.A., Alsaad M.A., 1999, The Use Of Hydrocarbon Mixtures As

Refrigerants In Domestic Refrigerator, Appl. Thermal Eng. 19: 1181–1189.
He. J. et al. (2008). Research on ethanol synthesis from syngas. Journal of

Zhenjiang University Science A. 2008 9(5):714-719
Seider W.D., Seader J.D., Lewin D.R., 2004, Product and Process Design
Principles. Synthesis, Analysis and Evaluation, Wiley and Sons Inc.
Sinnott RK, 2005, Chemical Engineering Design, Coulson and Richardson’s

Chemical Engineering Vol 6, 4th ed., Elsevier
Sunggyu. L.. Speight. J. G.. Loyalka. S. K. (2007). Handbook of Alternative Fuel

Technology. Boca Raton: CRC Press
Walas, Stanley M. 1990, Chemical Process Equipment : Selection and Design,

Buther Worth
APPENDIX
A. Step by Step Designing Heat Exchanger by Using HTRI
Here are step by step of designing heat exchanger by utilizing HTRI
Xchanger software to achieve both sizing and mechanical drawing of heat
exchanger.
1. Open the software and choose new and choose the heat exchanger type
Figure A.1. Choosing Type of HE

(Source: Adapted from HTRI Xchanger)
2. Fill in the red highlighted box (which means that it’s compulsory to be
filled) with the data from the simulation, such as the temperature, the
flowrate, the assumed pitch, etc
88
Figure A.2. Fill in Necessary Properties

3. Fill in the hot and cold fluid required properties so the iteration can be done.
Figure A.3. Fill in Fluid Properties

89
4. Press run case to start iteration, and wait for the result.
Figure A.4. Run Case

Figure A.5. Process Iteration

90
5. The result then can be viewed.
Figure A.6. Process Result

B. Belt Conveyor
According to mass and energy balance before, we have to sizing the belt
conveyor. In our plant, we have two belt conveyors. According the capacity, speed
and power table for belt conveyor on Wallas, 1988. We can calculate the equipment
size for belt conveyor.
Figure B. 1 Trough Conveyor Belt

(Source : Peer Consultatns, 1991)
91
We use trough belt conveyor because this type of conveyor can decreased
the spilled material from process.
Figure B. 2 Capacity of Belt Conveyor

(Source: Walas, Stanley, M. Chemical Process Equipment. 1988)
According the table above, we can estimate the belt width with maximum
inclination degree is 20O, and maximum capacity the conveyor can handle is 214.8
ton/hour.
Figure B.3 Belt Speed of Conveyor

According to table above, we can estimate that the belt conveyor maximum
speed with fugure below,
92
Figure B.4 The Empy Power of Belt Conveyor

C. Pump
There are several steps to sizing pump.
1. Find out physical properties of the stream which will go into the pump and
other information needed in the calculation (mass flow, pressure inlet,
pressure output, vapor pressure, temperature, density, static head, pipe
length after pump).
2. By using these formula below, we get the information of Power, Head, and
NPSHa of each pump:
dWao dWpompa P V2 P1( Atm) V2 2 F PVapor
  (  gz  ) F NPSHa =  ( z2  z1 )   
dm dm  2 g 2g g g
3. Assumptions :
 No velocity difference due to its small number
 Pump efficiency 75%
D. Compressor
There are several steps to sizing compressor.

1. Find out physical properties of the stream which will go into the pump and
other information needed in the calculation (pressure inlet, temperature
inlet, compression ratio, flow rate, molecular weight and tip speed)
2. Determine the type of the compressor
93
To accomplish this step, we use the “general range of application of

compressor” graph as shown below.
Figure D.1. General Range of Application for Compressor

(Source: Kern, 2010)
3. Calculate the specific gravity and isentropic heat capacity ratio

MWgas   1.3  0.31SG  0.55
SG= MWair
4. Calculate the compressor speed

T Z R  P2 
 1

h   11 a    1
  MW   P1  

5. Input data ( Flow rate, Tip speed, Conversion factor, Efficiency polytropic,
Polytropic heat capacity ratio)
6. Calculate efficiency isentropic
 1
Eisen 
 
P2
P1 1
 
n 1
P2
P1
n 1
7. Calculate the actual flowrate
8. Calculate compression power (kW/stage)
9. Calculate diameter of impeller and compressor speed
94
10. Determine Loss Factor
11. Calculate Mechanical Losses
12. Calculate total power

Total Power = Kw/stage + Mechanical Losses
E. Storage Tank
1. Vol rate to the tank

2. Volume Tank
Based on literature if volume above 3,8 m3 volume of each tank only filled
90%. The headspace is 10% thus the working volume which calculated before is
90%.
3. Diameter and height of tank
Comparison of high tank with tank diameter (Hs: D) = 0.5. The volume will
be represented by using roof dome shape, the diameter and height of tank could be
calculated.
1 2 1
𝑉𝑠 = 𝜋𝐷 𝐻𝑠 = 𝜋𝐷3
4 8
Cover and pedestal tank of roof dome shape with major to minor axis ratio of
1
2:1, so high head is𝐻ℎ = 𝐷 (Walas, 1990). Therefore, the volume of heads (cover and
6
pedestal) :
1 1 1 1
𝑉ℎ 𝑟𝑜𝑜𝑓 𝑑𝑜𝑚𝑒 = 𝜋𝐷2 . 𝐻ℎ . 2 = 𝜋𝐷2 𝐷. 2 = 𝜋𝐷3
4 4 6 24
Tank volume :
1 1 4
𝑉𝑡 = 𝑉𝑠 + 𝑉ℎ = 𝜋𝐷3 + 𝜋𝐷3 = 𝜋𝐷3
8 24 24
95
Then, diameter :
3 24𝑉
𝑡
𝐷=√
4𝜋
Height of cylinder : Hs = 0.5D

1
Height of roof dome : 𝐻ℎ = 6 𝐷
Height of tank : Ht = Hs + Hh
4. Thickness of wall and head
Calculation of storage tanks wall thickness is based on circumferential stress
(longitudinal joint). We can use the following formula (Towler, 1990) :
𝑃. 𝑅
𝑡𝑤 = + (𝐶. 𝐴)
𝑆𝐸 − 0.6𝑃
While storage tanks’ head thickness can be calculated with the following formula
(Towler, 1990):
𝑃. 𝐷𝑖. 𝐾
𝑡ℎ = + (𝐶. 𝐴)
2𝑆𝐸 − 0.2𝑃
F. Furnace
There are several steps to sizing furnace such as:

1. Calculate volume (V) of burning contact from heat release rate per unit
volume (𝑞𝑣 ).
𝑚̇𝑐 𝐿𝐻𝑉
𝑞𝑉 = (𝑘𝑊/𝑚3 )
𝑉
Where, 𝑚̇𝑐 = Design fuel consumption rate, kg/s.
V = Furnace volume, 𝑚3 .
LHV = Lower heating value of fuel kJ/kg.
96
Figure F.1 Lower Limit of Furnace
2. Calculate area (A) of burning contact from heat release rate per unit cross
sectional area (𝑞𝐴 ). The maximum value for those variable can be shown
in the table below.
𝑞𝐴 = (𝑘𝑊/𝑚2 )
𝐴𝑔𝑟𝑎𝑡𝑒
Figure F.2. Upper Limit of Furnace
3. Calculate a and b are width and depth of furnace, and Hb is the height of
burner region from heat release rate per unit cross sectional area (𝑞𝑏 ).
𝑞𝑏 = (𝑘𝑊/𝑚2 )
2(𝑎 + 𝑏)𝐻𝑏
97
Figure F.3. Recommended values of buerrner region heat release rate
4. Determine the minimum value of the unknown variables based on these rule
of thumb.
G. Pipe
To calculate the size of the pipe, we need to volumetric rate of fluid which
goes through it and also the velocity of the fluid. We assume that the velocity of
water is 3 m/s and non-water is 1 m/s.
𝑚̇
𝑄=
𝜌
𝑄
𝐴=
𝑣
4𝐴
𝐼𝐷 = √
𝜋
After getting know the minimum internal diameter, we look at the tables
below to find the appropriate pipe size from vendor. We use Pipe Schedule 40.
98
Figure G.1 Nominal Size of Pipe, Schedule 40 (in mm)
Figure G.2. Nominal Size of Pipe, many schedule (in inch)
We also calculate the length needed from a unit to other unit by considering
the safety. We use GAPS Guidelines about Oil and Chemical Plant Layout and
Spacing. It tells the minimum safety distance between some unit operations.
99
Figure G.3. Minimum Safety Distance between Unit Operation in Chemical Plant, GAPS
Guidelines (in feet)
Figure G.4. Minimum Safety Distance between Houses in Chemical Plant,

GAPS Guidelines (in feet)
H. Extractive Distillation Column

1. In UniSim Design Program, open utilities
100
2. In utilities dialog tab, choose Tray Sizing then click add utility
3. Rename as T-302 and then select column that is about to be calculated
101
4. Click OK, then select tray type as sieve tray, click add section and activate
sizing calculation
5. Finally, click performance Tab and see the result
102
I. EFB Warehouse
The warehouse is used to stocking the raw materials (Empty Fruit Bunches). The
raw materials are stocked every day from the supplier. The warehouse is a rectangle
building with a triangular prism roofs. Some specifications that should be known
are :
 Bulk density for nickel ore is 1150 kg/m3
 The processs will be done with feed flow rate is 661.392 tons/day or 27.558
tons/h
Basic Planning
Construction materials : Concrete
Materials Store = 1150 kg/m3
Raw Material Volume
661,392 kg
Raw material volume = = 575.12 m3
kg
1150 m3
To ensure that the warehouse is safe and not overloaded, off-grid plant decided to
make the ware house is 90% full. So the ware house volume is
Volume warehouse = 575.12 m3 : 0.9 = 639.02 m3
Volume of warehouse = length x width x height = 4 : 3: 1
Length = 4 x 3.76 = 15.04 m
Width = 3 x 3.76 = 11.28 m
Height = 1 x 3.76 = 3.76 m
J. Reactor
1. Hydrolysis/Delignification Reactor
Hydrolysis or delignification reactor is a CSTR reactor which acts as both
delignification process and hydrolysis of cellulose and hemicellulose into glucose
and xylose, for the fermentation purpose The reaction is assumed as first order. So,
CSTR design equation for calculating volume, is,
- Volume of Fluid
𝑉 = 𝑉𝑜𝑋/𝑘(1 − 𝑋)
𝑉 = 5.787 × 0.287/0.402(1 − 0.287)
103
V = 524.302 L
- Volume of Reactor = 1.1 x 524.302 = 576.732 m3
- Diameter of hydrolysis reactor
𝐷 = 0.702 𝑚
- Height of Reactor
Hr=Hs+Hc = 2D+d = 1.579 m
- Height of Fluid in Reactor
Hf= (volume of liquid in reactor x high of reactor)/reactor volume
Hf= 1.435 m
- Diameter of impeller
Di = 0.35 x D = 0.35 x 0.702 = 0.246 meter
- Diameter of Baffle
Db = 0.1 x D = 0.1 x 0.702 = 0.070
- Width of Blade Impeller
Wbi = 1/3 x Di = 1/3 x 0.246 = 0.0819
- Length of Blade Impeller = 0.25 x Di = 0.25 x 0.246 = 0.0614 meter
- Shell Thickness
𝑑𝑠 = [(𝑃𝑥𝑅)/(𝑆. 𝐸 − 0.6𝑃)] + (𝐶𝑥𝐴)
ds = 0.43 inch = 1.12 cm
- Position of impeller from bottom
H = 1/3 x D = 0.234 m
- Specific power for agitation
Power= 2 kW/m3
2. Neutralization Reactor
Neutralizing reactor is a CSTR reactor in which neutralization of remaining HCl
in the sugar sludge occurs. So, CSTR design equation for calculating volume, is,
- Volume of Fluid
𝑉 = 𝑉𝑜𝑋/𝑘(1 − 𝑋)
104
𝑉 = 7.569 × 0.965/94.464(1 − 0.965)

V = 27249.880 L
- Volume of Reactor = 1.1 x 27249.880 L = 29974.868 L
𝐷 = 2.618 𝑚
- Height of Reactor
Hr=Hs+Hc = 2D+d = 5.891 m
Hf= 5.355 m
Di = 0.35 x D = 0.35 x 2.618 = 0.916 m
Db = 0.1 x D = 0.1 x 2.618 = 0.262 m
Wbi = 1/3 x Di = 1/3 x 0.916 = 0.305 m
- Shell Thickness
𝑑𝑠 = [(𝑃𝑥𝑅)/(𝑆. 𝐸 − 0.6𝑃)] + (𝐶𝑥𝐴)
ds = 1.306 cm
H = 1/3 x D = 0.873 m
Power = 1 kW/m3
3. Seed Fermenter
Seed fermenter is a batch bioreactor. The volume of seed fermenter is obtained
by production capacity. The design equation of batch reactor and first order
reaction, is,
𝒕 = 𝑰𝒏(𝟏/𝟏 − 𝑿)/µ
105
𝑡 = 𝐼𝑛(1/1 − 0.326)/0.084
𝑡 = 4.7 ℎ𝑜𝑢𝑟
- Volume of Fluid
Volume of fluid in batch reactor is obtained by production capacity, which in this
seed fermenter, V, is 39.521 m3
- Diameter of seed fermenter
𝐷 = 2.964 𝑚
- Height of Reactor
Hr=Hs+Hc = 2D+d = 6.669 m
Hf= 6.063 m
Di = 0.35 x D = 0.35 x 2.964 = 1.037 m
Db = 0.1 x D = 0.1 x 2.964 = 0.296 m
Wbi = 1/3 x Di = 1/3 x 1.037 = 0.346 m
- Shell Thickness
𝑑𝑠 = [(𝑃𝑥𝑅)/(𝑆. 𝐸 − 0.6𝑃)] + (𝐶𝑥𝐴)
ds = 1.351 cm
H = 1/3 x D = 0.988 m
Power = 3 kW/m3
106
4. SSF Reactor
SSF reactor is a bioreactor where both saccharification and fermentation process
happen. It uses bacteria culture from seed fermenter along with additional yeast and
nitrogen to ferment the glucose and xylose to ethanol. The volume of main
fermenter is obtained by production capacity. The design equation of batch reactor
and first order reaction is,
𝒕 = 𝑰𝒏(𝟏/𝟏 − 𝑿)/µ
𝑡 = 𝐼𝑛(1/1 − 0.93)/0.133
𝑡 = 20 ℎ𝑜𝑢𝑟
- Volume of Fluid
Volume of fluid in batch reactor is obtained by production capacity, which in
this seed fermenter, V, is 356.746 m3
- Diameter of main fermenter
𝐷 = 5.978 𝑚𝑒𝑡𝑒𝑟
- Height of Reactor
Hr=Hs+Hc = 2D+d = 13.451
Hf= 12.228 m
Di = 0.35 x D = 0.35 x 5.978 = 2.092 m
Db = 0.1 x D = 0.1 x 5.978 = 0.598 m
Wbi = 1/3 x Di = 1/3 x 2.092 = 0.697 m
- Shell Thickness
𝑑𝑠 = [(𝑃𝑥𝑅)/(𝑆. 𝐸 − 0.6𝑃)] + (𝐶𝑥𝐴)
ds = 1.620 cm
107

H = 1/3 x D = 1.993 m
Power = 3 kW/m3
5. Coagulation Reactor
Coagulation reactor is where the coagulation process happens. The reactor is a
continuous CSTR reactor, and colloids will stabilize and react with impurities so
the coagulation process can occur. So, CSTR design equation for calculating
volume, is,
- Volume of Fluid
𝑉 = 𝑉𝑜𝑋/𝑘(1 − 𝑋)
𝑉 = 776.560 × 0.990/11103.653(1 − 0.990)
V = 24925.669 L
𝐷 = 2.542 𝑚
- Height of Reactor
Hr=Hs+Hc = 2D+d = 5.719 m
Hf= 5.199 m
Di = 0.35 x D = 0.35 x 2.542 = 0.890 meter
Db = 0.1 x D = 0.1 x 2.542 = 0.254
Wbi = 1/3 x Di = 1/3 x 0.890 = 0.297
- Shell Thickness
108
𝑑𝑠 = [(𝑃𝑥𝑅)/(𝑆. 𝐸 − 0.6𝑃)] + (𝐶𝑥𝐴)

ds = 0.43 inch = 1.296 cm
H = 1/3 x D = 0.837 m
Power= 1 kW/m3
6. Neutralization and Flocculation Reactor
Flocculation and neutralization reactor is a CSTR reactor in which the water is
simultaneously neutralized and cleaned from its impurities. So, CSTR design
equation for calculating volume, is,
- Volume of Fluid
𝑉 = 𝑉𝑜𝑋/𝑘(1 − 𝑋)
𝑉 = 543.657 × 0.950 /1493.148(1 − 0.950)
V = 24904.519 L
- Volume of Reactor = 1.1 x 24904.519 L = 27394.971 L
- Diameter of neutralisation reactor
𝐷 = 2.541 𝑚
- Height of Reactor
Hr=Hs+Hc = 2D+d = 5.717 m
Hf= 5.197 m
Di = 0.35 x D = 0.35 x 2.541 = 0.889 m
Db = 0.1 x D = 0.1 x 2.541 = 0.254 m
Wbi = 1/3 x Di = 1/3 x 0.889 = 0.296 m
109
- Shell Thickness
𝑑𝑠 = [(𝑃𝑥𝑅)/(𝑆. 𝐸 − 0.6𝑃)] + (𝐶𝑥𝐴)
ds = 1.296 cm
H = 1/3 x D = 0.847 m
Power = 1 kW/m3

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UNIVERSITAS INDONESIA

BIO-ETHANOL PRODUCTION THROUGH

CHEMICAL ENGINEERING DEPARTMENT

Figure 1.1. Mechanical Drawing of Hydrolysis/Delignification Reactor ..........2

vii Universitas Indonesia

The mechanical drawing of hydrolysis/delignification reactor is as below:

Figure 1.1. Mechanical Drawing of Hydrolysis/Delignification Reactor

1.1.2. Neutralizing Reactor

Neutralizing CSTR Reactor R-201

Figure 1.2. Mechanical Drawing of Neutralizing Reactor

1.1.3. Seed Fermenter

Component Glucose & Xylose

The mechanical drawing of the bioreactor fermenter is shown below:

Figure 1.3. Mechanical Drawing of Seed Fermenter Bioreactor

1.1.4. SSF Reactor

Main Fermenter Bioreactor R-203

The mechanical drawing of the SSF bioreactor is shown below:

Figure 1.4. Mechanical Drawing of SSF Bioreactor

1.1.5 Coagulation Reactor

Coagulation Reactor D-402

The mechanical drawing of the coagulation reactor is shown below:

Figure 1.5. Mechanical Drawing of Coagulation Reactor

1.1.6 Flocculation and Neutralization Reactor

The mechanical drawing of the coagulation reactor is shown below:

UNLESS OTHERWISE FLOCCULATION AND NEUTRALIZATION

Figure 1.6. Mechanical Drawing of Flocculation and Neutralization Reactor

1.2. Distillation Column

1.2.1. Main Distillation Column

1.2.2. Extractive Distillation Column

Table 1.6 Extractive Distillation Column Specifications

1.2.3. Recovery Distillation Column

Table 1.7 EG Recovery Column Specifications

The mechanical drawing of the clarifier is shown below:

Figure 1.5 Mechanical drawing of clarifier

Equipment Name CF-201

1.5.2 Centrifuge in Water Treatment Process

Equipment Name CF-202

The mechanical drawing of the centrifuge is shown below:

Figure 1.6 Mechanical drawing of centrifuge

1.6. Heat Exchanger

Equipment Specification Design Construction

Performance of One Unit and Liquid Properties Tube Construction Information

The drawings of the heat exchanger is shown below:

The drawings of the reboiler is shown below:

Table 1.13 Extractive Distillation Reboiler Specification

The drawings of the reboiler is shown below:

Table 1.14 Ethylene Glycol Recovery Reboiler Specification

The drawings of the reboiler is shown below:

Table 1.16 Extractive Distillation Condenser Specification

Table 1.17 Ethylene Glycol Recovery Condenser Specification

Heat Release Rate per Unit Volume

Table 1.19 Specification of furnace for biogas

Power produced (kW) 13964.143

The drawings of the furnace is shown below:

Figure 1.13 Drawing of Furnace

Table 1.21 Spesification pipe of EFB fibers

Name EFB Fibers Unit

Table 1.22 Spesification pipe of EFB to Delignification

Table 1.23 Spesification pipe of S-101

Table 1.24 Spesification pipe to SSF

1.9.2 Piping SSF Process

Table 1.26 Spesification pipe of sugar water

Name Sugar Water Unit

Fluid Non Water