Part 2

Central Philippine University
College of Engineering
Chemical Engineering Department
Jaro, Iloilo City, Philippines
CHAPTER 4
EQUIPMENT DESIGN
A. List of Equipment
Table 4.1 - Equipment Used and Their Corresponding Unit Operation
Equipment Unit Operation

Roller Mill Milling
Steam Explosion Reactor Steam Explosion
Pre-cooler
Cooling
(SE Reactor/Hydrolyzer)
Hydrolyzer Hydrolysis
Fermenter Fermentation
Beer Column Beer Distillation
Pre-cooler
Cooling
(Beer/Absorber Column)
Absorber Gas Absorption
Ethanol Column Ethanol Distillation
Adsorber Adsorption
Condenser Condensation
B. Individual Equipment Design Specification
1. Roller Mill
Design of the Equipment:
a. An understanding of the raw material to be milled should be established.
b. Capacity, circumference and speed of the roller mill is calculated based on
assumptions and dimensions.
Assumptions:
33
a. The roller mill has a speed of 300 rpm.
b. The roller mill has 2 rollers.
c. The particle size of the feed entering the roller mill is 12 mm with a product particle
size of 4 mm.
d. The roller has a diameter of 910 mm.
e. The length of the face of the rolls is 410 mm.
f. The distance between the rolls is 4 mm.
EQUIPMENT SPECIFICATION SHEET
GENERAL DETAIL
Equipment Name: Roller Mill
Type/Description: Smooth roller mill
Function: For size reduction of the corn
Operation: Continuous
TECHNICAL DETAIL
No. of unit: 1
Speed: 300 rev/min
Roller diameter: 910 mm
34
Length of rolls: 410 mm
Distance between rolls: 4 mm
Circumference of the roller mill: 285.8849 cm
Feed particle size: 12 mm
Product particle size: 4 mm
Capacity of the roller mill: 522, 183.6437 cm3/min
OPERATING CONDITIONS
Temperature: 25°C
Pressure: 1 atm
Flowrate in: 123 784.3803 kg/day corn
Materials of construction: Steel
Method of procurement: Purchase
2. Steam Explosion Reactor
Design of the Equipment
a. Mass flow rates and characteristics of the reactant should be clearly defined.
b. Operating conditions must be established.
Assumptions
a. The bulk density of milled corn is 130 to 160 kg/m3.
35
GENERAL DETAIL
Equipment Name: SE Reactor
Type/Description: Pressure Vessel/Autoclave
Function: Prepares the raw corn for hydrolysis by releasing the cellulose and hemicellulose
from lignin
TECHNICAL DETAIL
No. of unit: 1
Dimensions:
Head Thickness: 0.0418 m
Shell Thickness: 0.0475 m
Diameter: 2.6103 m
Length: 7.8309 m
Volume: 48.2482 m3
36
Inside Depth of Dish: 0.9876 m
Temperature: 210°C
Pressure: 19.74 atm
Materials of construction: Carbon Steel
Method of procurement: Shop Fabrication
3. Pre-cooler (SE Reactor to Hydrolyzer)
a. Mass flow rate of entering fluid should be clearly defined.
Assumptions
a. The specific heat of pre-treated corn is 2.7 kJ/kg°C
b. The pre-treated corn is the fluid 1 and water is the fluid 2.
c. The overall heat transfer coefficient of water-medium organics is 250 to 600 W/m2-K
(Peters, Timmerhaus & West, 2004).
d. The heat exchanger is shell-and-tube (one shell and two-tube pass) floating head type.
e. The flow of fluid is countercurrent.
37
GENERAL DETAIL
Equipment Name: Pre-cooler (SE Reactor to Hydrolyzer)
Type/Description: Heat Exchanger
Function: Prepares the pre-treated corn for hydrolyzer
TECHNICAL DETAIL
No. of unit: 1
Area: 22.9824 m2
Type: Floating Head
One-shell and two-tube pass
Temperature: 20 - 90°C
Pressure: 1 - 2.5 atm
4. Hydrolyzer
38
a. Characterization of pretreated corn must be established.
b. Feed conditions must be clearly defined.
Assumptions:
a. Density of glucan is 1, 110 kg/m3.
b. Density of xylan is 1, 130 kg/m3.
c. Density of water at 25°C is 997.08 kg/m3.
GENERAL DETAIL
Equipment Name: Hydrolyzer
Type/Description: CSTR
Function: Converts glucan and xylan into fermentable sugars
TECHNICAL DETAIL
No. of unit: 1
Dimensions of the Reactor Vessel:
Rector Height: 4.1110 m
Reactor Diameter: 2.0555 m
Dimensions of the Impeller:
Impeller Diameter: 0.61665 m
39
Impeller Distance from Tank Bottom: 0.61665 m
Temperature: 50°C
Pressure: 1atm
Materials of Construction:
Shell: Stainless Steel
Outer Jacket: Carbon Steel
Method of Procurement: Shop Fabrication
5. Fermenter
a. Feed and operating conditions must be established.
Assumptions
a. Density of yeast is 905.105 kg/m3.
b. Density of sugar =(density of glucose + density of xylose)/2
= (1, 540 + 1, 520) kg/m3 /2
Density of sugar = 1, 530 kg/m3.
GENERAL DETAIL
Equipment Name: Fermenter
40
Type/Description: CSTR
Function: Converts the fermentable sugars, glucose and xylose into ethanol
TECHNICAL DETAIL
No. of unit: 1
Dimensions of the Reactor Vessel:
Thickness: 0.0045 m
Height: 2.3858 m
Diameter: 1.5905 m
Volume: 5.8120 m3
Dimensions of the Impeller:
Impeller Diameter: 0.5302 m
Impeller Distance from Tank Bottom: 0.5302 m
Impeller Disc Diameter: 0.3977 m
Impeller Blade Length: 0.1326 m
Impeller Blade Width: 0.10604 m
Blade Tip Distance from Tank Bottom: 0.3181 m
Temperature: 40°C
Pressure: 1atm
41
Materials of Construction: Carbon Steel
6. Beer Column
a. Feed conditions should be established.
b. Calculations on the number of stages must be fully supported by appropriate equations.
c. The height/diameter ratio of a tower should be based upon established design guidelines.
Assumptions:
a. Feed is in the vapor phase (Peters, Timmerhaus, & West, 2004).
b. R = 1.2Rmin (Peters, Timmerhaus, & West, 2004)
c. There is an 60% flooding (Peters, Timmerhaus, & West, 2004).
d. The downcomer is assumed to be 15% (Peters, Timmerhaus, & West, 2004).
e. Height over diameter ratio is 20 (Green & Perry, 2008).
GENERAL DETAIL
Equipment Name: Beer Column
Type/Description: Closed, Vertical
Function: Separate the liquid content of the fermented broth from its solid parts
42
TECHNICAL DETAIL
No. of unit: 1
No. of Stages: 15
Reflux Ratio: 1.8692
Location of Feed: Stage 5
Type of Column Internal: Sieve Tray
Tray Spacing: 0.61 m
Dimensions of the Column:
Column Height: 13.568 m
Column Diameter: 0.6784 m
Pressure: 1- 2.5 atm
7. Pre-cooler (Beer Column to Absorber Column)
Assumptions:
43
a. The specific heat of beer is 3.542 kJ/kg-°C.
b. Fluid 1 is beer and fluid 2 is water.
c. The overall heat transfer coefficient for water-light organics is 375 - 750W/m2-K (Peters,
Timmerhaus, & West, 2004).
d. The heat exchanger is shell-and-tube (one-shell and two-tube pass) floating head type.
e. The fluid flow is countercurrent.
GENERAL DETAIL
Equipment Name: Pre-cooler (Beer Column to Absorber Column)
Function: Cools the beer before entering the absorber column
TECHNICAL DETAIL
No. of unit: 1
Area: 5.1095 m2
Type: Floating Head
44
8. Absorber Column
a. Feed and product conditions must be established.
b. An equilibrium must be established between solute and absorbent.
Assumptions:
a. Assume sieve tray as column internal
GENERAL DETAIL
Equipment Name: Absorber
Function: Absorbs carbon dioxide gas from ethanol-water mixture using water as absorbent
TECHNICAL DETAIL
No. of unit: 1
No. of Stages: 20
Type of Column Internal: sieve tray
45
Column Height: 10 m
Temperature: 33°C
Pressure: 1, 992 atm
9. Ethanol Column
a. Feed conditions should be established.
b. Calculations on the number of stages must be fully supported by appropriate equations.
c. The height/diameter ratio of a tower should be based upon established design guidelines.
Assumptions:
a. Feed is in the vapor phase (Peters, Timmerhaus, & West, 2004).
b. R = 1.2Rmin (Peters, Timmerhaus, & West, 2004)
c. There is an 80% flooding (Peters, Timmerhaus, & West, 2004).
d. The downcomer is assumed to be 15% (Peters, Timmerhaus, & West, 2004).
e. Height over diameter ratio is 20 (Green & Perry, 2008).
46
GENERAL DETAIL
Equipment Name: Ethanol Column
Function: Concentrates ethanol-water mixture until it reaches 95.6 wt. %
TECHNICAL DETAIL
No. of unit: 1
No. of Stages: 30
Reflux Ratio: 1.4927
Location of Feed: Stage 5
Type of Column Internal: Sieve Tray
Tray Spacing: 0.61 m
Column Diameter: 0. 0454 m
47
10. Adsorber Column
a. Identification of the adsorbent to be used which depends upon the feed containing the
adsorbate must be established.
b. Properties of the adsorbent such as pore diameter, particle density, particle porosity,
surface area, and water capacity and regeneration temperature must be specified.
c. Finally, selection of an appropriate adsorption cycle is done based upon the process
condition of the feed. Adsorption cycles vary depending on the phase of the feed and the
regeneration used.
Assumptions:
a. Properties of the adsorbent, 3A molecular zeolite (Peters, Timmerhaus, & West, 2004):
Pore Diameter: 0.3 mm
Particle Density: 670-740 kg/m3
Particle Porosity: 0.2
Surface Area: 7 x 10-5 m2/kg
H2O Capacity: 20 wt%
b. Water adsorbed is 0.2 kg of water per kg of adsorbent. (Peters, Timmerhaus, & West,
2004) is used.
GENERAL DETAIL
48
Equipment Name: Adsorber Column
Type/Description: Closed, Vertical, Pressure Swing with Regeneration
Function: Adsorbs water from azeotropic ethanol using an adsorbent
Operation: Continuous, Bulk Separation
TECHNICAL DETAIL
No. of unit: 2
Properties of Adsorbent:
Adsorbent: 3A molecular zeolite
Pore Diameter: 0.3mm
Particle Density: 670-740 kg/m3
Particle Porosity: 0.2
Surface Area: 7 x 10-5 m2/kg
Amount: 23171.3735 kg
Water Capacity: 20%
Height of Adsorbent inside the column: 2.8956 m
49
11. Pre-cooler (Around Adsorber Column)
Assumptions:
a. The specific heats of adsorbed fluid and cooling fluid are 2.046 and 2.484 kJ/kg-°C,
respectively.
b. Fluid 1 is adsorbed fluid and fluid 2 is cooling fluid.
c. The overall heat transfer coefficient is the same for water-light organics is 375-750
W/m2-K (Peters, Timmerhaus, & West, 2004).
d. The heat exchanger is shell-and-tube (one-shell and two-tube pass) floating head type.
e. The fluid flow is countercurrent.
50
GENERAL DETAIL
Equipment Name: Pre-cooler (around Adsorber Column)
Function: Cools ethanol from adsorber column
TECHNICAL DETAIL
No. of unit: 1
Area: 7.2788 m2
Type: Floating Head
51
52

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Central Philippine University

Table 4.1 - Equipment Used and Their Corresponding Unit Operation

Equipment Unit Operation

B. Individual Equipment Design Specification

Design of the Equipment:

a. An understanding of the raw material to be milled should be established.

b. Capacity, circumference and speed of the roller mill is calculated based on

assumptions and dimensions.

a. The roller mill has a speed of 300 rpm.

b. The roller mill has 2 rollers.

d. The roller has a diameter of 910 mm.

e. The length of the face of the rolls is 410 mm.

f. The distance between the rolls is 4 mm.

EQUIPMENT SPECIFICATION SHEET

Equipment Name: Roller Mill

Type/Description: Smooth roller mill

Function: For size reduction of the corn

Speed: 300 rev/min

Roller diameter: 910 mm

Length of rolls: 410 mm

Distance between rolls: 4 mm

Circumference of the roller mill: 285.8849 cm

Feed particle size: 12 mm

Product particle size: 4 mm

Capacity of the roller mill: 522, 183.6437 cm3/min

Flowrate in: 123 784.3803 kg/day corn

Materials of construction: Steel

Method of procurement: Purchase

2. Steam Explosion Reactor

Design of the Equipment

b. Operating conditions must be established.

a. The bulk density of milled corn is 130 to 160 kg/m3.

EQUIPMENT SPECIFICATION SHEET

Equipment Name: SE Reactor

Type/Description: Pressure Vessel/Autoclave

Head Thickness: 0.0418 m

Shell Thickness: 0.0475 m

Inside Depth of Dish: 0.9876 m

Pressure: 19.74 atm

Materials of construction: Carbon Steel

Method of procurement: Shop Fabrication

3. Pre-cooler (SE Reactor to Hydrolyzer)

Design of the Equipment

a. Mass flow rate of entering fluid should be clearly defined.

b. Operating conditions must be established.

a. The specific heat of pre-treated corn is 2.7 kJ/kg°C

b. The pre-treated corn is the fluid 1 and water is the fluid 2.

(Peters, Timmerhaus & West, 2004).

e. The flow of fluid is countercurrent.

EQUIPMENT SPECIFICATION SHEET

Equipment Name: Pre-cooler (SE Reactor to Hydrolyzer)

Type/Description: Heat Exchanger

Function: Prepares the pre-treated corn for hydrolyzer

Type: Floating Head

One-shell and two-tube pass

Pressure: 1 - 2.5 atm

Materials of construction: Carbon Steel

Method of procurement: Shop Fabrication

Design of the Equipment:

a. Characterization of pretreated corn must be established.

b. Feed conditions must be clearly defined.

a. Density of glucan is 1, 110 kg/m3.

b. Density of xylan is 1, 130 kg/m3.

c. Density of water at 25°C is 997.08 kg/m3.