Assignment 2 - BIO 05 - Report

86
UNIVERSITAS INDONESIA
PRODUCTION OF L-GLUTAMIC ACID BY FERMENTATION
Assignment 2
GROUP BIO-05
GROUP PERSONNEL:
Ahmad Haryanto 1806207614
Aldina Nabila 1806150023
Alya Fadhila Ismail 1806207495
Andika Mardianto 1806207362
Devinta Aurelia 1806207545
Riva Marcella 1806150175
CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
OCTOBER 2021
EXECUTIVE SUMMARY
Glutamic acid is a white clear crystalline amino acid that can be produced
through several process pathway. One of that are describe in this paper, a production
of glutamic acid through bio-fermentation of molasses. Bio-fermentation is using
the sugar molecules that taken from molasses with Corynebacterium glutamicum.
The main production divide by three different section, which pre-treatment,
fermentation, and purification. Others utility unit to support the main process also
include in this design. The utility unit call it storage tank, water treatment and
supply, boiler, cooling tower, and generator also waste treatment. Every equipment
that involved in the production of this paper have been designed.
The pre-treatment section has of three equipment, call it acid hydrolysis
reactor (R-101), filtration (F-101), mixer tank (MX-101). Continuous Stirred Tank
Reactor (CSTR) is the type of reactor that used and the type of filtration is rotary
vacuum filtration. Cylindrical tank with stirred is used to be mixer tank, this process
is design to work continuously.
Main reaction/fermentation section equipment consist of heat sterilization
(ST-101), fermenter both seeding (BR-101) and main (BR-301). Heat sterilization
is design to kill some other bacteria before the fermentation. All the process in this
section is design to work as batch process. Seed fermenter has design to have at
least 10% of total volume of main fermenter.
Purification section are work as continuously process, consist of 5
equipment call it rotary vacuum filtration (F-301), ion exchange column (IEX-301),
evaporation (EV-301), crystallizer (CR-301) and fluidized bed dryer (DR-301).
Utility section has divided into smaller section call it water treatment,
cooling water and chilled water process, steam generation, wastewater treatment,
and generator. The water treatment process consists of 7 equipment namely Feed
water storage tank (TK-401), clarifier, GM filtration, RO filtration, and storage
tank. Cooling and chilled water process with 3 equipment namely, cooling tower
(CT-501), cooling water storage (TK-501), and chiller (HE-501). Steam generator
have 2 equipment, deaerator (DA-601) and boiler (B-601). Wastewater treatment
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consists of clarifier (CL-701), aerobic bio-oxidator (AEB-701), clarifier 2(CL-702).
Generator having 2 equipment which is generator set and fuel tank.
All the equipment have a pump design specifically to corresponding
equipment that need a pump system.
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TABLE OF CONTENTS
EXECUTIVE SUMMARY................................................................................... ii
TABLE OF CONTENTS..................................................................................... iv
LIST OF FIGURES ............................................................................................ vii
LIST OF TABLES ............................................................................................. viii
1 CHAPTER I MATERIAL VESSEL ............................................................ 1
Molasses Storage Vessel .......................................................................... 1
Ammonium Hydroxide Storage Vessel .................................................... 1
Nutrients Storage Vessel .......................................................................... 2
H2SO4 0.1 M Storage Vessel................................................................... 3
NaOH 0.1 M Storage Vessel .................................................................... 4
HCl Storage Vessel .................................................................................. 5
Unpurified Product Storage Vessel .......................................................... 6
Final Product Storage Vessel.................................................................... 7
2 CHAPTER II PRE-TREATMENT SECTION........................................... 9
Acid Hydrolysis Reactor .......................................................................... 9
Rotary Vacuum Filter ............................................................................. 10
Mixer Tank ............................................................................................. 11
Material Handler ..................................................................................... 12
3 CHAPTER III MAIN REACTION (FERMENTATION) ....................... 17
Air Filter ................................................................................................. 17
Heat Sterilization .................................................................................... 18
Seeding Fermentation Reactor ............................................................... 18
Main Fermentation Reactor .................................................................... 20
Compressor ..................................................................................... 25
4 CHAPTER IV PURIFICATION SECTION............................................. 28

Rotary Vaccum Filtration (F-301) .......................................................... 28
Ion Exchange Column (IEX-301) .......................................................... 28
Evaporation (EV-301) ............................................................................ 29
Crystallizer (CR-301) ............................................................................. 30
Fluidized Bed Dryer (DR-301)............................................................... 31
Pump ............................................................................................... 32
CR-301 to DR-301 Screw Conveyor (SC-301) .............................. 37
5 CHAPTER V UTILITY EQUIPMENT .................................................... 39

Water Treatment ..................................................................................... 39
Feed Water Storage Tank (TK-401) ............................................... 39
Clarifier (CL-401) ........................................................................... 40
GM Filtration (F-401) ..................................................................... 41
RO Filtration (F-402) ...................................................................... 41
Sanitation Water Storage Tank (TK-402) ....................................... 42
Pure Water Storage Tank (TK-403) ................................................ 43
Sediment Storage Tank (TK-404) ................................................... 44
Cooling Water and Chilled Water Process ............................................. 45

Cooling Tower ................................................................................ 45
Cooling Water Storage Tank ........................................................... 46
Chiller .............................................................................................. 46
Steam Generation ................................................................................... 47

Deaerator ......................................................................................... 47
Boiler ............................................................................................... 48
Wastewater Treatment ............................................................................ 50

Clarifier ........................................................................................... 50
Aerobic Bio-Oxidator...................................................................... 51
Clarifier ........................................................................................... 51
Generator ................................................................................................ 52
Generator Set ................................................................................... 52
Fuel Tank ........................................................................................ 53

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Utility Pump ........................................................................................... 54
6 CHAPTER VI CONCLUSION .................................................................. 64
REFERENCES .................................................................................................... 65
APPENDICES ..................................................................................................... 67
APPENDIX A: Design Calculation of Storage Vessel ..................................... 67
APPENDIX B: Design Calculation of Pre-treatment Equipment ..................... 79
APPENDIX C: Design Calculation of Main Reaction (Fermentation) Equipments
89
APPENDIX D: Design Calculation of Purification Section ........................... 113
APPENDIX E: Design Calculation of Utility Equipments ............................. 117
APPENDIX F: Mechanical Drawing of Equipment ....................................... 131
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LIST OF FIGURES
Figure 5. 1 Generator Set ..................................................................................... 52
Figure B. 1 Design Scheme of CSTR .................................................................. 79
Figure B. 2 Polymath Results of Hydrolysis Vessel ............................................ 81
Figure B. 3 Polymath Graph of Hydrolysis Vessel Calculation .......................... 81
Figure C. 1 Calculation Data from simulation Polymath in Seed Fermenter ...... 90
Figure C. 2 Graph Convertion vs Time Polymath Seed Fermenter ..................... 91
Figure C. 3 Calculation Data from simulation Polymath in Main Fermenter...... 91
Figure C. 4 Graph Convertion vs Time Polymath Seed Fermenter ..................... 92
Figure C. 5 Allowable Stress Data ....................................................................... 96
Figure C. 6 Maximum Allowable Joint Efficiency .............................................. 96
Figure C. 7 Reynold Number vs. Power Number (Propeller with Baffle is Line 4)
............................................................................................................................... 99
Figure C. 8 Plot W/T vs. Viscosity .................................................................... 103
Figure D. 1 Schematic of Torispherical Head .................................................... 116
Figure E. 1 A Schemating of An Oil, Gas, or Pulverized Coal Fired Furnace .. 126
Figure E. 2 Compressor Types and Application Conditions ............................. 128
Figure F. 1 Acid Hydrolysis Reactor Mechanical Drawing............................... 132
Figure F. 2 Seed Fermenter Mechanical Drawing ............................................. 133
Figure F. 3 Main Fermenter Mechanical Drawing ............................................ 134
Figure F. 4 Boiler Mechanical Drawing ............................................................ 135
Figure F. 5 Dryer Mechanical Drawing ............................................................. 136
Figure F. 6 Ion Exhange Mechanical Drawing .................................................. 137
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LIST OF TABLES
Table 1. 1 Molasses Storage Specification ............................................................. 1
Table 1. 2 NH4OH Storage Vessel Specifcation.................................................... 2
Table 1. 3 Nutrients Storage Vessel ....................................................................... 2
Table 1. 4 H2SO4 0,1 M Storage Vessel................................................................ 3
Table 1. 5 NaOH 0,1M Storage Vessel .................................................................. 4
Table 1. 6 HCl 1M Storage Vessel ......................................................................... 5
Table 1. 7 Unpurified Product Storage Vessel ....................................................... 6
Table 1. 8 Final Product Storage Vessel ................................................................ 7
Table 2. 1 Hydrolysis Reactor (R-101) Equipment Specification .......................... 9
Table 2. 2 Rotary Vacuum Filter (F-101) Equipment Specification .................... 10
Table 2. 3 Mixer Tank (MX-101) Equipment Specification ................................ 11
Table 2. 4 Pump (P-101) Equipment Specification .............................................. 12
Table 3. 1 Air Filter Specification ........................................................................ 17
Table 3. 2 Heat Sterilization Specification ........................................................... 18
Table 3. 3 Seed Fermenter Specification .............................................................. 19
Table 3. 4 Main Fermenter Specification ............................................................. 20
Table 3. 5 Pump (P-201) Specification ................................................................ 22
Table 3. 10 Compressor CO-201 Specification .................................................... 26
Table 4. 1 Rotary Vaccum Filter (F-301) Specification ....................................... 28
Table 4. 2 Ion Exchanger (IEX-301) Specification ............................................. 29
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Table 4. 3 Evaporator (EV-301) Specification ..................................................... 30
Table 4. 4 Crystallizer Specification .................................................................... 30
Table 4. 5 Fluidized Bed Dryer Specification ...................................................... 31
Table 4. 10 Pump (P-305) Specification .............................................................. 34
Table 4. 14 Screw Conveyor Specification .......................................................... 37
Table 5. 1 Total Water Requirement .................................................................... 39
Table 5. 2 Specification of TK-401 ...................................................................... 39
Table 5. 2 Specification of TK-401 (Cont’d) ....................................................... 40
Table 5. 3 Water Clarifier Specification............................................................... 40
Table 5. 3 Water Clarifier Specification (Cont’d) ................................................ 41
Table 5. 4 GM Filtration Specification ................................................................ 41
Table 5. 5 RO Specification ................................................................................. 42
Table 5. 6 Sanitation Water Storage Tank Specification ..................................... 42
Table 5. 7 Pure Water Storage Tank Specification .............................................. 43
Table 5. 8 Sediment Storage Tank Specification ................................................. 44
Table 5. 9 Cooling Tower Specification............................................................... 45
Table 5. 10 Cooling Water Storage Tank Specification ....................................... 46
Table 5. 11 Water Chiller Specification ............................................................... 47
Table 5. 12 Deaerator Specification ..................................................................... 47
Table 5. 13 Boiler Specification ........................................................................... 49
Table 5. 14 Waste Water Clarifier (CL-701) Specification ................................. 50
Table 5. 15 Aerobic Bio-Oxidator Specification .................................................. 51
Table 5. 16 Waste Water Clarifier (CL-702) Specification ................................. 51
Table 5. 17 Generator Specification ..................................................................... 53
Table 5. 18 Fuel Tank Specification..................................................................... 53
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Table A. 1 Calculation for Molasses Storage Vessel ........................................... 68
Table A. 2 Calculation for NH4OH Storage Vessel............................................. 70
Table A. 3 Calculation for Nutrients Storage Vessel ........................................... 71
Table A. 4 Calculation for H2SO4 Storage Vessel .............................................. 72
Table A. 5 Calculation for NaOH Storage Vessel ................................................ 74
Table A. 6 Calculation for HCl Storage Vessel ................................................... 75
Table A. 7 Calculation for Unpurified Storage Vessel......................................... 77
Table A. 8 Calculation for Final Product Storage Vessel .................................... 78
Table B. 1 Process Condition of Acid Hydrolysis ............................................... 79
Table B. 2 Polymath Calculation of Hydrolysis Vessel ....................................... 81
Table B. 3 Impeller Design Rule of Thumb ......................................................... 82
Table B. 4 Properties of SS 316 Material ............................................................. 84
Table B. 5 Impeller Design Calculation ............................................................... 85
Table B. 6 Ratio for Impeller Calculation ............................................................ 88
Table C. 1 Fermentation Tank Volume ................................................................ 92
Table C. 2 Vessel Dimension (Seed Fermenter) .................................................. 93
Table C. 3 Vessel Dimension (Main Fermenter) ................................................. 93
Table C. 4 Pressure Design (Seed Fermenter) ..................................................... 94
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Table C. 5 Fermentation Tank Volume ................................................................ 95
Table C. 6 Vessel Thickness (Seed Fermenter) ................................................... 97
Table C. 7 Vessel Thickness (Main Fermenter) ................................................... 97
Table C. 8 Agitator Size Ratio ............................................................................. 98
Table C. 9 Mixed Viscosity in Seed Fermenter ................................................. 100
Table C. 10 Mixed Viscosity in Main Fermenter............................................... 100
Table C. 11 Agitator and Power Specification (Seed Fermenter) ...................... 101
Table C. 12 Agitator and Power Specification (Main Fermenter) ..................... 102
Table C. 13 Baffle Design (Seed Fermenter) ..................................................... 103
Table C. 14 Baffle Design (Main Fermenter) .................................................... 104
Table C. 15 Jacket Design (Seed Fermenter) ..................................................... 105
Table C. 16 Jacket Design (Main Fermenter) .................................................... 105
Table C. 17 Jacket Heat Transfer Coefficient (Seed Fermenter) ....................... 109
Table C. 18 Jacket Heat Transfer Coefficient (Main Fermenter) ...................... 110
Table C. 19 Jacket Heat Transfer Rate (Seed Fermenter) .................................. 111
Table C. 20 Jacket Heat Transfer Rate (Main Fermenter) ............................ 111
Table C. 21 Sparger Specification (Seed Fermenter) ......................................... 111
Table C. 22 Sparger Specification (Main Fermenter) ........................................ 112
Table D. 1 Properties of SS 302 Material .......................................................... 115
Table E. 1 Feed Water Storage Tank Calculation .............................................. 117
Table E. 2 Clarifier Calculation ......................................................................... 118
Table E. 3 Sanitation Water Storage Tank Calculation ..................................... 120
Table E. 4 Pure Water Storage Tank Calculation .............................................. 121
Table E. 5 Sediment Storage Tank Calculation ................................................. 122
Table E. 6 Makeup Water Calculation ............................................................... 124
Table E. 7 Typical Values of Volumetric Heat Release Rate (qv) in MW/m3 ... 124
Table E. 8 Upper Limits of qF ............................................................................ 125
Table E. 9 First Waste Water Clarifier Calculation ........................................... 126
Table E. 10 Second Waste Water Clarifier Calculation ..................................... 127
Table E. 11 Loss Factor According to Flow Rate .............................................. 129
Table E. 12 Rule of Thumb for Choosing Compressor Number of Stages ........ 129
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1 CHAPTER I
MATERIAL VESSEL
Material vessel is a unit to store a material from either supplier or from
previous process due to the procedure.
Molasses Storage Vessel
Table 1. 1 Molasses Storage Specification
Molasses Storage Vessel

Identity
Item Storage vessel
Equipment name Molasses Storage Vessel
Number of unit 3
Function Storing Molasses
mode operation batch
Operating Conditions
Mass flow rate 2300000 kg/batch
Density 1400.00 kg/m3
o
Temperature 25 C
Pressure 1 atm
Residence Time 5 Days
Working volume 85 %
Specification Design
Type Storage vessel
Material Carbon Steel A285 Grade A
Volume 645.25 m3
Diameter 9.37 m
Cylinder Height 9.37 m
Shell Thickness 38.37 mm
Head Design
Type of Head Torispherical
External Head Diameter 9.37 m
Head Thickness 24.62 mm
Straight Flange Height 86.16 mm
Dishing Height 1801.39 mm
Total Head Height 1887.55 mm
Ammonium Hydroxide Storage Vessel

Ammonium Hydroxide storage vessel is a vessel where the molasses store
from the supplier, before used to the production of glutamic acid.
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2
Table 1. 2 NH4OH Storage Vessel Specifcation
NH4OH Storage Vessel

Identity
Item Storage vessel
Equipment name NH4OH Storage Vessel
Number of unit 1
Function Storing NH4OH
mode operation Batch
o
Temperature 25 C
Pressure 2 Atm
Working volume 85 %
Type Storage vessel
Volume 613.33 m3
Diameter 9.21 M
Cylinder Height 9.21 M
Shell Thickness 42.18 Mm
Head Design
External Head Diameter 9.21 M
Head Thickness 24.83 Mm
Straight Flange Height 86.89 Mm
Dishing Height 1770.91 Mm
Total Head Height 1857.80 Mm
Nutrients Storage Vessel

Table 1. 3 Nutrients Storage Vessel
Nutrients Storage Vessel

Identity
Item Storage vessel
Equipment name H2SO4 Storage Vessel
Number of unit 1
Function Storing Nutrients
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3
Table 1. 3 Nutrients Storage Vessel (Cont’d)
operating conditions
o
Temperature 25 C
Pressure 1 atm
Working volume 85 %
Type Storage vessel
Volume 7.84 m3
Diameter 1.49 m
Head Design
Saddle Support Design
A 1371.6 mm
B 990.6 mm
C 254 mm
D 12.7 mm
E 584.2 mm
F 152.4 mm
G 6.35 mm
H 635 mm
Saddle Angle (θ) 124 0
H2SO4 0.1 M Storage Vessel

Table 1. 4 H2SO4 0,1 M Storage Vessel
H2SO4 Storage Vessel

Identity
Item Storage vessel
Equipment name H2SO4 Storage Vessel
Number of unit 1
4
Table 1. 4 H2SO4 0.1 M Storage Vessel (Cont’d)
Identity
Function Storing H2SO4
o
Temperature 25 C
Pressure 2 atm
Working volume 85 %
Type Storage vessel
Volume 216.98 m3
Diameter 6.51 m
Head Design
NaOH 0.1 M Storage Vessel

Table 1. 5 NaOH 0,1M Storage Vessel
NaOH 0,1M Storage Vessel

Identity
Item Storage vessel
Equipment name NaOH Storage Vessel
Number of unit 1
Function Storing NaOH
mode operation Batch
Mass flow rate 2639.73542 kg/h
o
Temperature 25 C
Pressure 1 atm
5
Table 1. 5 NaOH 0.1M Storage Vessel (Cont’d)
Working volume 85 %
Type Storage vessel
Volume 8.73 m3
Diameter 1.55 m
Head Design
A 54 In
B 39 In
C - In
D 0.5 In
E 23 In
F 6 In
G 0.25 In
H 25 In
HCl Storage Vessel

Table 1. 6 HCl 1M Storage Vessel
HCl 1M Storage Vessel

Identity
Item Storage vessel
Equipment name HCl Storage Vessel
Number of unit 1
Function Storing HCl
6
Table 1. 6 HCl 1M Storage Vessel (Cont’d)
Density 39.72 kg/m3
o
Temperature 25 C
Pressure 1 atm
Working volume 85 %
Type Storage vessel
Volume 5.82 m3
Diameter 1.35 m
Head Design
A 48 in
B 36 in
C - in
D 0.5 in
E 20 in
F 6 in
G 0.25 in
H 22.7 in
0
Saddle Angle (θ) 121
Unpurified Product Storage Vessel

Table 1. 7 Unpurified Product Storage Vessel
Unpurified Product Storage Vessel

Identity
Item Storage vessel
Equipment name Unpurified Product Storage Vessel
Number of unit 5
7
Table 1. 7 Unpurified Product Storage Vessel (Cont’d)
Identity
Function Storing Unpurified Product
Mass flow rate 3,051,755.424 kg/batch
o
Temperature 25 C
Pressure 1 atm
Working volume 85 %
Type Storage vessel
Volume 701.04 m3
Diameter 9.63 m
Head Design
Final Product Storage Vessel

Table 1. 8 Final Product Storage Vessel
Final Product Storage Vessel+B20

Identity
Item Storage vessel
Equipment name Final Product Storage Vessel
Number of unit 2
Function Storing Final Product
o
Temperature 25 C
Pressure 1 atm
8
Table 1. 8 Final Product Storage Vessel (Cont’d)
Residence Time 1 h
Working volume 85 %
Type Storage vessel
Volume 26.71 m3
Diameter 2.25 m
Bottom Design
Type of Bottom Connical Bottom
2 CHAPTER II
PRE-TREATMENT SECTION
Acid Hydrolysis Reactor
Acid Hydrolysis reactor is a vessel where a hydrolysis process reaction takes
place. In this process, we use CSTR reactor to convert sucrose into glucose and
fructose. Acid (H2SO4) is used in this process as a catalyst. The specification of the
reactor is shown below.
Table 2. 1 Hydrolysis Reactor (R-101) Equipment Specification
General Information
Item Reactor
Item Number R-101
Equipment Name Acid Hydrolysis Reactor
Number of Unit 1
Breakdown sucrose to
Function
glucose and fructose
Mode of Operation Continuous
Operating Condition
Mass flow rate (Mt/h) 27,69
Mixture density (kg/m3) 1206,12
Temperature (oC) 55
Pressure (atm) 1
Residence Time (h) 0,25
Working volume (%) 80
Type CSTR
Material Stainless Steel 316
3
Tank Volume (m ) 48,47
Tank Diameter (m) 3,05
Tank Height 3,70
Cylinder Height 3,66
Shell Thickness (m) 0,0180
Head Design
External Head Diameter (in) 144,265
Head Thickness (in) 0,6401
Straight Flange Height (in) 2,24
Dishing Height (in) 27,62
Total Head Height (in) 29,86
10
Table 2. 1 Hydrolysis Reactor (R-101) Equipment Specification (cont’d)
Stirrer Design
Impeller type Torispherical
Impeller diameter (m) 1,02
Impeller to bottom (m) 1,02
Baffle diameter (m) 0,25
Impeller speed (rpm) 114
Power (kWh) 3,62
Jacket Design
Jacket space (m) 0,01
Outside radius of jacket (m) 3,08
Inside radius of jacket (m) 3,05
Heat Transfer Area (m2) 0,13
Height of Jacket (m) 0,01
Rotary Vacuum Filter

The specification of Rotary Vacuum Filtration used is taken from the vendor
as follows.
Table 2. 2 Rotary Vacuum Filter (F-101) Equipment Specification
General Information
Item Filter
Item Number F-101
Equipment Name Rotary Vacuum Filtration
Number of Unit 1
Filtering impurities left
behind (mainly ash) from
Function
the acid hydrolysis
process
Operating Condition
Mass flow rate (Mt/h) 27.69
3
Volumentric flowrate (m /h)
Mixture density (kg/m3) 1206.12
Construction Information
Model GW-50
Type of Tank Steel Plate Cylinder Body
2
Filtration Area (m ) 50
Speed of Cylinder 0.12-0.56
Agitating Frequency (times/min) 23
11
Table 2. 2 Rotary Vacuum Filter (F-101) Equipment Specification (Cont’d)
Max. Production Capacity (t/h) 7.5-20
Length (mm) 8960
Width (mm) 8170
Height (mm) 5780
Total Weight (kg) 21500
Mixer Tank
Mixer is used to mix two compounds that entered mixing tank. Reason for
using mixer is to make output concentration of the compound is evenly distributed.
Dimension of mixer is listed as below.
Table 2. 3 Mixer Tank (MX-101) Equipment Specification
General Information
Item Mixer
Item Number MX-101
Equipment Name Mixing Tank
Number of Unit 1
Mixing the nutrition with
Function carbon source media of
fermentation
Material Composition
Ash 0.52%
Fructose 18.62%
Glucose 33.42%
Nutrients 0.29%
Organic Solid 9.93%
Sucrose 0.00%
Sulfuric Acid 0.73%
Operating Condition
o
Temperature ( C) 25
Pressure (atm) 1
Retention Time (h) 97.4
3
Capacity (m ) 2800
Cylindrical tank with
Type
ellipsoidal top and bottom
12
Table 2. 3 Mixer Tank (MX-101) Equipment Specification (Cont’d)
Tank Volume (L) 2800.46
Safety factor 20%
Height of Fluid (m) 14.76
Pressure design (atm) 3.07
Tank Diameter (m) 11.80
Tank Height (m) 17.71
Cylinder Height (m) 5.90
Type of head Ellipsoidal
Head Height (m) 5.90
Wall Thickeness (mm) 17.17
Head Thickeness (mm) 0.93
Stirrer Design
Impeller type Vertical blade
Impeller diameter (m) 3.935
Width of leaf impeller (m) 0.787
Impeller to bottom (m) 3.935
Baffle width (m) 0.984
Impeller speed (rpm) 155
Utilities
Motor power (kWh) 71005.3091
Material Handler
There are six pumps operated in the pre-treatment process and the summary
of all pumps specifications is summarized in the following table.
Table 2. 4 Pump (P-101) Equipment Specification
General Information
Item Pump
Item Number P-101
Type Rotary Pump
To pump water to rotary
Function
filter (F-101)
Operating Condition
o
Temperature ( C) 25
Pressure Inlet (Pa) 101,000
Pressure Outlet (Pa) 202,000
Pressure Vapor (Pa) 3,079.00
3
Density (kg/m ) 997.00
Length of Pipe (m) 10
13
Table 2. 4 Pump (P-101) Equipment Specification (Cont’d)
Operating Condition
Friction Loss (m2/s2) 4.54
Flowrate (kg/s) 0.61
Flowrate (m3/s) 0.000613
Efficiency (%) 0.75
Power (Watt) 86.23
Head (m) 14.40
NPSHr (m) 10.02
NPSHa (m) 10.49
General Information
Item Pump
Item Number P-102
Type Rotary Pump
To pump molasses to acid
Function
hydrolysis reactor (R-101)
Operating Condition
o
Temperature ( C) 25
Pressure Vapor (Pa) 3,079
3
2 2 3.25
Friction Loss (m /s )
3 ) 0.004693
Flowrate (m /s
Efficiency (%) 0.75
Power (Watt) 660.32
Head (m) 10.31
NPSHr (m) 7.18
NPSHa (m) 7.51
14
General Information
Item Pump
Item Number P-103
Type Rotary Pump
To pump water to acid
Function
Operating Condition
Temperature (oC) 25
3
Density (kg/m ) 997
2 2 4.54
Efficiency (%) 0.75
Power (Watt) 80.44
Head (m) 14.40
NPSHr (m) 9.81
NPSHa (m) 10.27
General Information
Item Pump
Item Number P-104
Type Rotary Pump
To pump H2SO4 to acid
Function
Operating Condition
Temperature (oC) 25
3
Density (kg/m ) 1,060
Length of Pipe (m) 10.00
2 2 4.27
15
Operating Condition
Efficiency (%) 0.75
Power (Watt) 75.66
Head (m) 13.54
NPSHr (m) 9.22
NPSHa (m) 9.66
General Information
Item Pump
Item Number P-105
Type Rotary Pump
To pump R-101 output into
Function Rotary Vacuum Filter (F-
101)
Operating Condition
o
Temperature ( C) 55
Pressure Inlet (Pa) 1,115,000
Pressure Outlet (Pa) 1,200,000
3
Density (kg/m ) 1,206.12
2 2 3.75
3 ) 0.006377
Flowrate (m /s
Efficiency (%) 0.75
Power (Watt) 761.25
Head (m) 10.10
NPSHr (m) 67.52
NPSHa (m) 67.90
General Information
Item Pump
Item Number P-106
Type Rotary Pump
To pump nutrients into MX-
Function
101
16
Operating Condition
Temperature (oC) 25
Density (kg/m3) 809
Efficiency (%) 0.75
Power (Watt) 3.65
Head (m) 17.75
NPSHr (m) 12.34
NPSHa (m) 12.91
3 CHAPTER III
MAIN REACTION (FERMENTATION)
Air Filter
Air Filtration has a function to filter the incoming air to be used in
bioreactor. This is important because impurities will interfere of reaction and
shorten the life of the reactors and other utilities. The specification of air filtration
is shown below.
Table 3. 1 Air Filter Specification
Equipment Specification
Equipment Name Air Filtration
Number of Unit 1
Equipment Code F-201
Function Air Filter
Operating Condition
Flowrate (m3/h) 17,830
Pressure (bar) 1
Temperature (℃) 25
Design Specification
Type Medium Fiber Dust Removal
Air Output (m3/h) 18624
Temperature Range (℃) 25-80
Equipment Resistance (Pa) 600-800
Filter Method Pulse Jet Blowing
Efficiency (%) 99,98%
Width (mm) 1385
Length (mm) 2830
Hight (mm) 6364
Cleaning Control System PLC
Vendor Name Foshan
(source: alibaba.com)
18
Heat Sterilization
Heat sterilization serves as a sterilizer of glucose and fructose before
entering the fermentation process. Heat sterilization bought from vendor. The
specification is showed below.
Table 3. 2 Heat Sterilization Specification
Equipment Name Dry Heat Sterilizers
Number of Unit 10
Equipment Code ST-101
Function Sterilize Material
Operating Condition
Flowrate (L/batch) 173,000
Temperature (℃) 120
Type Sterile Hood
Capacity (L) 18,000
Temperature Range (℃) 25-300
Material Stainless steel 316
Heating power (kW) 28
Circulating fan power (kW) 4
Width Chamber (mm) 1000
Hight Chamber (mm) 1200
Length Chamber (mm) 1500
Control System HMI automatic
Vendor Name Bionicsscientific
Seeding Fermentation Reactor

The table below shows the specification of bioreactor for seed fermenter as
a place for bacterial growth before entering stationary phase.
19
Table 3. 3 Seed Fermenter Specification
Equipment Name Batch Stirred Bioreactor
Equipment Code BR-101
Number of Unit 8
Function Seed Fermenter
Mode of Operation Batch
Operating Condition
Temperature (℃) 32.00
Pressure (bar) 1.013
Mass Flowrate (kg/batch) 35,743.625
Volume Kinetic Simulation (L) 36,373.000
Volume Flowrate (L/batch) 35,253.625
Density (kg/L)BR 1.014
Viscosity (cP) 2.800
Vessel Design and Specification
Tank Material Stainless Steel
Tank Type Horizontal Cylinder
Tank Volume (L) 58,756.042
Tank Thickness (cm) 17.784
Head Type Ellipsoidal
Head Volume (L) 4898.832
Head Thickness (cm) 16.886
Agitator and Power Specification
Agitator Type 3-Bladed Marine
Propeller
Agitator Material Stainless Steel
Propeller Quantity 3
Propeller Diameter (cm) 111.497
20
Table 3. 3 Seed Fermenter Specification (Cont’d)

Propeller Height (cm) 22.299
Propeller Width (cm) 27.874
Agitator to Bottom (cm) 111.497
Agitator Speed (rpm) 120
Power (HP) 187.428
Baffle Specification
Baffle Material Stainless Steel
Quantity 4
Baffle Width (cm) 30.104
Baffle Height (m) 1.606
Jacket Specification
Jacket Material Carbon Steel
Jacket Type Cooling
Jacket Length (m) 6.422
Jacket Thickness (cm) 26.519
Sparger Specification
Sparger Type Nozzle Type
Flowrate (L/min) 1398.940
Heat Transfer Coef. (W/m2.K) 160.714
Heat Transfer Rate (kW) 23.065
Main Fermentation Reactor

The table below shows the specification of bioreactor for main fermenter as
a place for bacterial fermentation of glutamic acid.
Table 3. 4 Main Fermenter Specification
Equipment Name Batch Stirred Bioreactor
Equipment Code BR-301
Number of Unit 8
21
Table 3. 4 Main Fermenter Specification (Cont’d)

Function Main Fermenter
Operating Condition
Temperature (℃) 32.00
Pressure (bar) 1.013
Mass Flowrate (kg/batch) 353,324.125
Volume Kinetic Simulation 356,000.000
(L)
Volume Flowrate (L/batch) 349,582.375
Density (kg/L) 1.011
Viscosity (cP) 2.600
Vessel Design and Specification
Tank Material Stainless Steel
Tank Type Horizontal Cylinder
Tank Volume (L) 582,637.292
Tank Thickness (cm) 54.590
Head Type Ellipsoidal
Head Volume (L) 48,577.848
Head Thickness (cm) 50.736
Agitator Type 3-Bladed Marine Propeller
Agitator Material Stainless Steel
Propeller Diameter (cm) 239.540
Propeller Height (cm) 47.908
Propeller Width (cm) 59.885
Agitator to Bottom (cm) 239.540
22
Table 3. 4 Main Fermenter Specification (Cont’d)

Agitator Speed (rpm) 120
Power (HP) 8551.463
Baffle Specification
Baffle Material Stainless Steel
Quantity 4
Baffle Width (cm) 71.862
Baffle Height (m) 3.449
Jacket Specification
Jacket Material Carbon Steel
Jacket Type Cooling
Jacket Length (m) 13.798
Jacket Thickness (cm) 78.169
Sparger Specification
Sparger Type Nozzle Type
Flowrate (L/min) 4721.610
Heat Transfer Coef. (W/m2.K) 56.618
Heat Transfer Rate (kW) 37.505
Material Handler
Pump
There are five pumps operated in main process and the summary of all
pumps specifications is summarized in the following table.
Table 3. 5 Pump (P-201) Specification
General Information
Item Pump
Item Number P-201
Type Rotary Pump
To pump unsterilized media
Function into Heat Sterilization (HE-
201)
Operating Condition
Temperature (oC) 35
23
Table 3. 5 Pump (P-201) Specification (Cont’d)
Operating Condition
Pressure Vapor (Pa) 5.194
Density (kg/m3) 1,091.46
Efficiency (%) 0.75
Power (Watt) 936.01
Head (m) 13.15
NPSHr (m) 8.96
NPSHa (m) 9.38
General Information
Item Pump
Item Number P-202
Type Rotary Pump
To pump water into seed
Function and main fermenter (BR-
201 & 202)
Operating Condition
o
Temperature ( C) 25
3
2 2 4.54
3 ) 0.000028
Flowrate (m /s
Efficiency (%) 0.75
Power (Watt) 3.95
Head (m) 14.40
NPSHr (m) 9.81
NPSHa (m) 10.27
24
General Information
Item Pump
Item Number P-203
Type Rotary Pump
To pump NH4OH into seed
Function and main fermenter (BR-
201 & 202)
Operating Condition
o
Temperature ( C) 25
3
2 2 5.03
3 ) 0.001520
Flowrate (m /s
Efficiency (%) 0.75
Power (Watt) 213.86
Head (m) 15.95
NPSHr (m) 10.86
NPSHa (m) 11.38
General Information
Item Pump
Item Number P-204
Type Rotary Pump
To pump BR-201 output
Function
into BR-202
Operating Condition
o
Temperature ( C) 35
3
2 2 4.46
25
Operating Condition
Efficiency 0.75
Power (Watt) 113.38
Head (m) 14.16
NPSHr (m) 9.64
NPSHa (m) 10.10
General Information
Item Pump
Item Number P-205
Type Rotary Pump
To pump BR-202 output
Function
into storage (TK-201)
Operating Condition
o
Temperature ( C) 35
3
2 2 4.48
3/s) 0.007977
Flowrate (m
Efficiency 0.75
Power (Watt) 1,122.30
Head (m) 14.20
NPSHr (m) 9.67
NPSHa (m) 10.13
Compressor
Compressor is an equipment to increase gas pressure. The specification of
this plant’s compressors in the main process and utility section is shown in the tables
below.
26
Table 3. 10 Compressor CO-201 Specification
Parameter Values
Equipment Identity
Equipment Name Compressor
Equipment Code CO-201
Temperature 25℃
Pressure Inlet (kPa) 101.3
Pressure Outlet (kPa) 601.3
Mass Flow Rate (m3/h) 17830.1
Flow Rate (106 std m3/d) 0.43
Construction Data
Type Centrifugal Compressor
Head (m) 17616.3
Power (kW) 1579.0
Number of Impeller 6
Impeller Diameter (m) 0.56
Compression Ratio 5.94
Number of Stages 2
Parameter Values
Equipment Identity
Temperature 25℃
3
Mass Flow Rate (m /h) 731794.5
Construction Data
Head (m) 17616.3
Power (kW) 64805.3
Number of Stages 2
27
Parameter Values
Equipment Identity
Temperature 25℃
Mass Flow Rate (m3/h) 4491.6
Construction Data
Head (m) 17616.3
Power (kW) 410.8
Number of Stages 2
4 CHAPTER IV
PURIFICATION SECTION
Rotary Vaccum Filtration (F-301)

The specification for the Rotary Vacuum Filter is taken from vendor as
follows.
Table 4. 1 Rotary Vaccum Filter (F-301) Specification
Parameter Value
Equipment Identity
Item Filter
Item Number F-301
Equipment Name Rotary Vacuum Filtration
Number of Unit 1
To increase the purity of
Function L-Glutamic Acid by
removing cell mass
Mode of Operation Continous
Operating Condition
Mass flow rate (kg/h) 3229.25
Model GW-20
Steel Plate Cylinder
Type of Tank Body
2
Filtration Area (m ) 20
Speed of Cylinder 0,14-0,54
Agitating Frequency
(times/min) 23
Max. Production Capacity
(t/h) 3-8
Length (mm) 4480
Width (mm) 4085
Height (mm) 2890
Total Weight (kg) 10600
(sumber: www.alibaba.com)
Ion Exchange Column (IEX-301)

The summary of IEX-501 specifications are listed on the following table.
Calculation for this section will be elaborated in the Appendix D section.
29
Table 4. 2 Ion Exchanger (IEX-301) Specification
Parameter Value
Equipment Identity
Equipment Identity Ion Exchange
Equipment Code IEX-301
Number of Unit 1
Semi-continue, 2 hours per
Mode of Operation
cycle
Operating Condition
Pressure 1 bar
Input Mass Rate (kg/h) 3055.682 kg/h
Input Volumetric Rate
3023.953 kg/m3
(kg/m3)
Ion Exchanger Column Design
Working Volume 4.1667 m3
Vessel Volume 2.245866182 m3
Material SA-302
Cylindrical Height 2.400931587 m
Head Height 0.220891797 m
Vessel Height 2.400931587 m
Cylindrical Thickness 0.00290836 m
Head Thickness 0.125660125 in
Resin Description
Type DOWEX MARATHON C
Resin Density 820 kg/m3
Capacity 80 g/L
Resin Mass 837.09557 kg
Total Resin Volume 1.020848265 m3
Resin Bed Height 1.09133254 m
Evaporation (EV-301)
Since the hydrolysis of molasses resulted a high fructose content, we use
evaporator to concentrate the fructose, so it reaches the standard purity of glutamic
acid with 21% water content. The specification is taken from vendor as follows.
30
Table 4. 3 Evaporator (EV-301) Specification
Equipment Identity
Item Evaporator
Item Number EV-301

Multiple Effect
Equipment Name
Vacuum Evaporator
Number of Unit 1
To concentrate the
high purity glutamic
Function acid with 21% water
content to transported
to crystallizer
Mode of Operation Continous
Operating Condition
Mass flow rate (kg/h) 3055.68
Temperature 1 (oC) 152.00
Steam Pressure (atm) 1

Multiple Effect
Type Vacuum Evaporator
Steam 185
Weight (kg) 2,060
Dimension (mm) 7,080 ; 900; 3500
Crystallizer (CR-301)
Table 4. 4 Crystallizer Specification
General Information
Equipment Name Crystallizer
Equipment Code CR-301
Quantity 1
Function Crystallizing L-Glutamic Acid
31
Table 4. 4 Crystallizer Specification (Cont’d)
General Information
Type of System Closed system
Operation Data
T (°C) 40
P (bar) 0.074
Retention Time (h) 2
Mass Flowrate (kg/h) 237,522.00
Volumetric Flowrate (m3/h) 191.749
Slurry density (kg/m3) 134,512.86
Material Stainless Steel
Capacity (m3) 3.53
Diameter (m) 2.75
Height (m) 2.95
Heat Preservation Layer
0.06
(m)
Rotation Speed of Blending 1.5
Fluidized Bed Dryer (DR-301)

Table 4. 5 Fluidized Bed Dryer Specification
General Information
Equipment Name Fluidized Bed Dryer
Equipment Code DR-301
Quantity 1
Drying glutamic acid
Function dehydrate up to
99.45% crystal purity
Operation Data
Temperature (°C) 55
Pressure (kPa) 1.01
Mass Flowrate (kg/h) 237.52
3
Volumetric Flowrate (m /h) 0.19
Weight Feed (kg water/kg dry) 24.21
Weight Product (kg water/kg dry) -
Solid Heat Capacity (kJ/kg.K) 1.19
Solid Density (kg/m3) 1,603.00
32
Average Particle Size (m) 0.0004

Table 4. 5 Fluidized Bed Dryer Specification (Cont’d)
Model XSG-4
Minimum Fluidizing Rate
(kg/m2.h) 7,306.66
Expanded Bed Ratio 1.16
Drying Time (min) 1-2
Water Evaporation (kg/h) 58-73
Maximum Height (m) 4.6
Body Diameter (m) 0.4
Material Handler
Pump
General Information
Item Pump
Item Number P-301
Type Rotary Pump
To pump water into Rotary
Function
Vacuum Filtration (F-301)
Operating Condition
o
Temperature ( C) 25
3
Density (kg/m ) 997
2 2 4.54
3 0.000028
Flowrate (m /s)
Efficiency 0.75
Power (Watt) 3.95
Head (m) 14.40
NPSHr (m) 10.02
NPSHa (m) 10.49
33
General Information
Item Pump
Item Number P-302
Type Rotary Pump
To pump unpurified product
Function to Rotary Vacuum
Filtratiuon (F-301)
Operating Condition
o
Temperature ( C) 25
3
2 2 4.48
3 0.007968
Flowrate (m /s)
Efficiency 0.75
Head (m) 14.20
NPSHr (m) 9.89
NPSHa (m) 10.34
General Information
Item Pump
Item Number P-303
Type Rotary Pump
To pump NaOH for Ion
Function
Exchanger (IEX-301)
Operating Condition
o
Temperature ( C) 25
Density (kg/m )3 1,043
34
Operating Condition
Efficiency 0.75
Power (Watt) 98.88
Head (m) 13.77
NPSHr (m) 9.58
NPSHa (m) 10.02
General Information
Item Pump
Item Number P-304
Type Rotary Pump
To pump HCL for Ion
Function
Exchanger (IEX-301)
Operating Condition
o
Temperature ( C) 25
Density (kg/m3) 39.72
2 2 113.91
3 0.000705
Flowrate (m /s)
Efficiency 0.75
Power (Watt) 99.19
Head (m) 361.47
NPSHr (m) 251.57
NPSHa (m) 263.19
General Information
Item Pump
Item Number P-305
Type Rotary Pump
35
General Information
To pump water for Ion
Function
Exchanger (IEX-301)
Operating Condition
Temperature (oC) 25
3
2 2 4.54
3 0.000993
Flowrate (m /s)
Efficiency 0.75
Power (Watt) 139.71
Head (m) 14.40
NPSHr (m) 10.02
NPSHa (m) 10.49
General Information
Item Pump
Item Number P-306
Type Rotary Pump
To pump feed from F-301
Function
into IEX-301
Operating Condition
Temperature (oC) 25
3
2 2 2.24
3 0.003306
Flowrate (m /s)
Efficiency 0.75
36
Power (Watt) 465.21
Head (m) 7.12
NPSHr (m) 4.96
NPSHa (m) 5.19
General Information
Item Pump
Item Number P-307
Type Rotary Pump
To pump feed from IEX-
Function
301 into EV-301
Operating Condition
o
Temperature ( C) 25
3
2 2 4.54
3 0.006684
Flowrate (m /s)
Efficiency 0.75
Power (Watt) 940.44
Head (m) 14.40
NPSHr (m) 10.02
NPSHa (m) 10.49
General Information
Item Pump
Item Number P-308
Type Rotary Pump
To pump feed from EV-301
Function
into CR-301
37
Operating Condition
Temperature (oC) 25
Efficiency 0.75
Power (Watt) 447.22
Head (m) 14.99
NPSHr (m) 10.43
NPSHa (m) 10.91
CR-301 to DR-301 Screw Conveyor (SC-301)

The specification for the Screw Conveyor is taken from vendor as follows.
Table 4. 14 Screw Conveyor Specification
Screw Conveyor
Equipment Identity
Item Screw Conveyor
Item Number SC-301
Equipment Name Screw Conveyor
Number of Unit 1
Moving feed from crystallizer CR-
Function 301 to Fluidized Bed Dryer DR-
301
Operating Condition
Mass Flow Rate (kg/h) 10960.00
Volumetric Flow Rate (m3/h) 0.19
Temperature (oC) 15
Pressure (atm) 0.06908463
Model DZLS-100
Material Carbon Steel
Spiral Diameter 100
38
Table 4. 14 Screw Conveyor Specification (Cont’d)
Screw Pitch 100
Rotational Speed Maximum
(RPM) 140
Rotational Speed Minimum
(RPM) 112
5 CHAPTER V
UTILITY EQUIPMENT
Water Treatment
The needs of water for our plant are summarized in Table 5.1. The raw water
will be sourced from city-owned water treatment company (PDAM). To meet the
required process water, the in-plant water treatment process will consist of clarifier,
granular media filter, and RO filter.
Table 5. 1 Total Water Requirement
Total Water Requirement

No
Specification Amount (kg/h)
1 Water for Main Process 26882
2 Cooling Water 628218.01
3 Chilled Water 14368.66
4 Make Up Water 19200.34
5 Sanitation Water 50
Total 688719.02
Feed Water Storage Tank (TK-401)

Table 5. 2 Specification of TK-401
Feed Water Storage Tank

Identity
Item Storage Tank
Code TK-401
Equipment name Feed Water Storage Tank
Number of unit 2
Function Storing Water
Operation Mode Continuous
Mass flow rate 700,734 kg/h
oC
Temperature 25
Pressure 1 atm
Residence Time 1 h
Working Volume 85 %
40
Table 5. 3 Specification of TK-401 (Cont’d)
Type Storage Tank
Volume 404.13 m3
Diameter 8.01 m
Head Design
Clarifier (CL-401)
Table 5. 4 Water Clarifier Specification
Clarifier
Identification
Item Clarifier
Item Number CL-401
Equipment Name Clarifier
Number of Unit 10
Function Precipitates the solid in the water

Operating Condition
Mass flow rate (kg/h) 70073
Density (kg/m3) 997
Temperature (oC) 25
Pressure (atm) 1
Settling Time (h) 1.5
41
Table 5. 5 Water Clarifier Specification (Cont’d)
Type Upflow
Material Carbon Steel SA-212 Grade B
Cylinder Volume (m3) 126.51
Clarifier Height (m) 8.72
Clarifier Diameter (m) 4.75
Agitator Power (kW) 0.1356
GM Filtration (F-401)
The specification for the Granular Media Filter is taken from vendor as
follows.
Table 5. 6 GM Filtration Specification
Equipment Name Sand Filter Tank
Equipment Number F-401
Function Remove solids in feed water
Material Carbon Steel SA285
Type Multigrade Sand Filter
Filter Media Material Sand
Number of Unit 1
Operation Data
Temperature 25oC
Pressure 1600 kPa
Filter Area 9.2 kg/m2
Capacity 1000000 L/h
Construction Data
Inlet 50.8 mm
Outlet 50.8 mm
Filter Diameter 2.20 m
Height 3.65 m
(Source: alibaba.com)
RO Filtration (F-402)
Reverse osmosis (RO) is a water purification process that uses a partially
permeable membrane to remove ions, unwanted molecules and larger particles from
water. The following equations are used to design reverse osmosis filter. The
detailed calculation step is present on Appendix E.
42
Table 5. 7 RO Specification
Equipment Name Reverse Osmosis
Equipment Code F-402
Membrane Type
NF90
(Dupont)
Surface water,
Feed Source Generic
Conventional
SDI <5
Permeate Flow
3071,838
(gpm)
Recovery (%) 90
Flow
Plug Flow
Configuration
Active Surface
37
Area (m2)
Number of
605
Element (Ne)
Number of
100
Pressure Vessels
Number of Stages 3
Staging Ratio 2.154
Sanitation Water Storage Tank (TK-402)

Table 5. 8 Sanitation Water Storage Tank Specification
Sanitation Water Storage Tank

Identity
Item Storage Tank
Code TK-402
Equipment name Sanitation Water Storage Tank
Number of unit 1
Function Storing Sanitation Water
43
Table 5. 6 Sanitiation Water Storage Tank Specification (Cont’d)
Temperature 25 oC
Pressure 1 atm
Residence Time 1 h
Working volume 85 %
Type Storage Tank
Volume 0.08 m3
Diameter 0.47 m
Head Design
Pure Water Storage Tank (TK-403)

Table 5. 9 Pure Water Storage Tank Specification
Pure Water Storage Tank

Identity
Item Storage Tank
Code TK-403
Equipment name Pure Water Storage Tank
Number of unit 2
Function Storing Pure Water
oC
Temperature 25
Pressure 1 atm
Residence Time 1 h
Working volume 85 %
44
Table 5. 7 Pure Water Storage Tank Specification (Cont’d)
Type Storage Tank
Volume 400.03 m3
Diameter 7.99 m
Head Design
Sediment Storage Tank (TK-404)

Table 5. 10 Sediment Storage Tank Specification
Sediment Storage Tank

Identity
Item Storage Tank
Code TK-404
Equipment name Sediment Storage Tank
Number of unit 1
Function Storing Sediment
Mode of operation Continuous
oC
Temperature 25
Pressure 1 atm
Residence Time 1 h
Working volume 85 %
type Storage Tank
material Stainless Steel 304
Volume 8.08 m3
Diameter 1.51 m
45
Table 5. 8 Sediment Storage Tank Specification (Cont’d)
Head Design
A 54 in
B 39 in
C 0 in
D 0.5 in
E 23 in
F 6 in
G 0.25 in
H 25 in
Cooling Water and Chilled Water Process

Cooling Tower
Cooling water that are needed for this plant are used in Heat Sterilization,
Gas Compression, Seed Fermenter dan Fermenter. Cooling tower is used to produce
cooling water. The specification of cooling tower is obtained from Ebara Indonesia.
Table 5. 11 Cooling Tower Specification
Model of Cooling Tower

Equipment Name Cooling Tower
Equipment Code CT-501
Water Flowrate (L/min) 10,792
Water Temp. Inlet (ºC) 35
Water Temp. Outlet (ºC) 25
Construction Data
Model No. 1050ASSY
Length (m) 3.87
Width (m) 7.05
Height (m) 3.79
Type Cross Flow Square Type
(source: ebaraindonesia.com)
46
Cooling Water Storage Tank

Cooling water storage tank is used to store cooling water from cooling
tower. The specification of cooling water storage tank is shown in the table below.
Table 5. 12 Cooling Water Storage Tank Specification
Cooling Water Storage Tank

Identity
Equipment Name Cooling Water Storage Tank
Equipment Code TK-501
Number of Unit 2
Function Storing Cooling Water
Density 997 kg/m3
Temperature 25 oC
Pressure 1 atm
Working volume 85 %
Type Storage Tank
Volume 357.91 m3
Diameter 7.70 m
Head Design
Chiller
Water chiller is used to produce chilled water. Chilled water that are needed
for this plant is required for crystallizer coils. This is used to reduce the temperature
47
of the feed that enters the crystallizer. Water chiller specification data is obtained
from Dongguan Baiyi Tongyong Machiney Co., Ltd. via Alibaba.com.
Table 5. 13 Water Chiller Specification
Model of Water Chiller

Equipment Name Water Chiller
Equipment Code HE-501
Water Flow Rate 14,295.42 L/h
Water Temp. Inlet 25℃
Water Temp. Outlet 5℃
Type Water-cooled
Model BY-60WSCS
Cooling Capacity 164,776 kcal/h
Power 43.3 kW
Length 2290 mm
Width 760 mm
Height 1420 mm
(source: Alibaba.com)
Steam Generation
Deaerator
Deaerator is used to remove soluble gases in the feed water before entering
the boiler. Deaerator protects the steam generation system from the effects of
corrosive gases. The specification of deaerator tank is shown in the table below.
Table 5. 14 Deaerator Specification
Deaerator Tank
Parameter Value
Equipment Identity
Equipment Name Deaerator
Equipment Code DA-601
Number of Unit 1
Function Remove soluble gases in water
Operating Condition
Mass flow rate (kg/h) 22,500
Volumetric Flowrate
22.57
(m3/h)
Density (kg/m3) 997
48
Table 5. 12 Deaerator Specification (Cont’d)
Operating Condition
Temperature (oC) 25
Pressure (atm) 1
Residence Time (h) 0.25
3
Tank Volume (m ) 6.77
Cylinder Height (m) 3.17
Shell Thickness (m) 0.0169
Head Design
External Head Diameter
62.38
(in)
Head Thickness (in) 0.63
Straight Flange Height
2.19
(in)
Dishing Height (in) 11.78
Total Head Height (in) 13.98
A (in) 60
B (in) 42
C (in) -
D (in) 0.5
E (in) 26
F (in) 6
G (in) 0.25
H (in) 27.2
Saddle Angle (θ) 127°
Boiler
Steam as the heating agent in this plant will be generated using steam
generator/boiler. Fuel requirement is calculated in the previous assignment. The
specification of the boiler, especially the furnace, is shown in the table below.
49
Table 5. 15 Boiler Specification
Boiler
Equipment Name Boiler
Equipment Code B-601
Heat Release Rate per Unit Volume
ṁc (kg/h) 1325.38
ṁc (kg/s) 0.37
LHV (kJ/kg) 47100.00
qv (kW/m3) 350.00
V (m3) 49.54
Heat Release Rate per Unit Cross Sectional Area
ṁc (kg/h) 1325.38
ṁc (kg/s) 0.37
qf (kW/m2) 2130.00
Fgrate or A (m2) 8.14
Hfu+Hb 6.09
Heat Release Rate per Unit Wall Area of Burner
qb (kW/m2) 4400.00
b or depth (m) 2.72
Hb (m) 0.34
Hfu (m) 5.74
a or width (m) 2.99
Type of Burner
Power produced (kW) 14739.33
Determination of Furnace Size
α 30°
β 45°
γ 50°
E (m) 0.80
d (m) 0.90
50
Table 5. 13 Boiler Specification (Cont’d)

Furnace Material
Inner case material SS-304
Furnace wall Fire Brick
Wastewater Treatment
Clarifier
The specification for the first clarifier is as written on Table 5.14. The full
calculation table is attached on Appendix E.
Table 5. 16 Waste Water Clarifier (CL-701) Specification
First Clarifier
Identification
Item First Clarifier
Item Number CL-701
Number of Unit 8
Function Precipitates the solid in the solution

Operating Condition
Density (kg/m3) 997
Temperature (oC) 25
Pressure (atm) 1
Type Upflow
Cylinder Volume (m3) 89.81

Clarifier Diameter (m) 4.24
51
Aerobic Bio-Oxidator
Table 5. 17 Aerobic Bio-Oxidator Specification
General Information
Item Tank (Open Pond)
Item Number AEB-701
Equipment Name Aerobic Bio-Oxidator
Number of Unit 1
To separate the
Function
biological sludge
Operating Condition
Temperature (Celcius) 25
Pressure (bar) 1 bar
Retention Time (h) 6
Type Open Pond with Blower
Mass Flow Rate (kg/h) 9066.58
Volumetric Flow Rate (m3/h) 11.37
Vessel Volume (m3) 68.20
Blower Power (kW/h) 0.06
L x W x H (m) 6.63 x 3.45 x 2
Clarifier
The specification for the second clarifier is as written on Table 5.16. The
full calculation table is attached on Appendix E.
Table 5. 18 Waste Water Clarifier (CL-702) Specification
Second Clarifier
Identification
Item Second Clarifier
Item Number CL-702
Number of Unit 8
Function Precipitates the solid in the solution

Operating Condition
Density (kg/m3) 997
52
Table 5. 16 Waste Water Clarifier (CL-702) Specification (Cont’d)
Operating Condition
Temperature (oC) 25
Pressure (atm) 1
Type Upflow

Cylinder Volume
48.35
(m3)
Clarifier Diameter
3.45
(m)
Generator
Generator Set
A generator is needed as a source of electric power when the electricity is
cut off. The specification of the generator is obtained from Krisbow. The
specification of Krisbow Generator is shown in the table below.
Figure 5. 1 Generator Set
(Krisbow, 2021)
53
Table 5. 19 Generator Specification
Equipment Name Generator Set
Model KTA38-G2A
Type Silent Type
Frequency 50 Hz
Output (Phase/Volt) 3 / 380
Power Factor 0.8
Rotation Speed 1500 rpm
Power 720 kW
Fuel Type Diesel
Fuel Tank Capacity 1000 L
Fuel Consumption 191 L/h
Length 6060 mm
Width 2440 mm
Height 2600 mm
(source: Krisbow, 2021)
Fuel Tank
Fuel tank is used to store fuel for generator. Diesel is used as a fuel for
generator. The specification of the fuel tank is shown in the table below.
Table 5. 20 Fuel Tank Specification
Fuel Tank
Equipment Identity
Equipment name Fuel Storage Vessel
Number of Unit 1
Function Storing Diesel
Volumetric Flow Rate 191 L/h
0.191 m3/h
Temperature 20 oC
Pressure 1 atm
Working volume 85 %
54
Table 5. 18 Fuel Tank Specification (Cont’d)
Volume 5.27 m3
Diameter 1.31 m
Head Design
A 48 in
B 36 in
C - in
D 0.5 in
E 20 in
F 6 in
G 0.25 in
H 22.7 in
Saddle Angle (θ) 121°
Utility Pump
There are five pumps operated in main process and the summary of all
pumps specifications is summarized in the following table.
General Information
Item Pump
Item Number P-401
Type Rotary Pump
To pump feed water into
Function
storage
55
Operating Condition
Temperature (oC) 25
Flowrate (kg/s) 138,889.00
Flowrate (m3/s) 139.306921
Efficiency 0.75
Power (Watt) 19,414,576.65
Head (m) 14.26
NPSHr (m) 10.06
NPSHa (m) 10.52
General Information
Item Pump
Item Number P-402
Type Rotary Pump
To pump treated wastewater
Function
into storage
Operating Condition
o
Temperature ( C) 25
3
2 2
Friction Loss (m /s ) 4.53
Efficiency 0.75
Head (m) 14.39
NPSHr (m) 10.01
NPSHa (m) 10.48
56
General Information
Item Pump
Item Number P-403
Type Rotary Pump
To pump water from storage
Function
to clarifier
Operating Condition
Temperature (oC) 25
3
2 2 4.53
Efficiency 0.75
Head (m) 14.27
NPSHr (m) 103.30
NPSHa (m) 103.77
General Information
Item Pump
Item Number P-404
Type Rotary Pump
To pump water from
Function
clarifier into GM Filtration
Operating Condition
Temperature (oC) 25
3
2 2
Friction Loss (m /s ) 4.53
57
Operating Condition
Efficiency 0.75
Head (m) 14.25
NPSHr (m) 113.54
NPSHa (m) 114.00
General Information
Item Pump
Item Number P-405
Type Rotary Pump
To pump water from GM
Function Filtration into Sanitation
Storage Tank
Operating Condition
Temperature (oC) 25
3
2 2 4.53
3 0.000019
Flowrate (m /s)
Efficiency 0.75
Power (Watt) 2.65
Head (m) 14.25
NPSHr (m) 123.77
NPSHa (m) 124.23
58
General Information
Item Pump
Item Number P-406
Type Rotary Pump
To pump water from
Function
Storage to Main Process
Operating Condition
Temperature (oC) 25
3
Efficiency 0.75
Head (m) 14.25
NPSHr (m) 103.83
NPSHa (m) 104.29
General Information
Item Pump
Item Number P-407
Type Rotary Pump
To pump water from
Function Storage to Cooling and
Chilled Process
Operating Condition
o
Temperature ( C) 25
3
2 2 4.53
59
Operating Condition
Efficiency 0.75
Head (m) 14.25
NPSHr (m) 103.83
NPSHa (m) 104.29
General Information
Item Pump
Item Number P-408
Type Rotary Pump
To pump water from
Function
Storage to Steam Process
Operating Condition
o
Temperature ( C) 25
3
2 2 4.53
3 0.005368
Flowrate (m /s)
Efficiency 0.75
Power (Watt) 748.11
Head (m) 14.25
NPSHr (m) 103.83
NPSHa (m) 104.29
60
General Information
Item Pump
Item Number P-501
Type Rotary Pump
To pump water to cooling
Function
tower
Operating Condition
Temperature (oC) 25
3
Efficiency 0.75
Head (m) 11.75
NPSHr (m) 8.18
NPSHa (m) 8.56
General Information
Item Pump
Item Number P-502
Type Rotary Pump
To pump water from
Function cooling tower to storage and
HE
Operating Condition
o
Temperature ( C) 25
3
2 2 4.53
61
Operating Condition
Efficiency 0.75
Head (m) 14.39
NPSHr (m) 10.01
NPSHa (m) 10.48
General Information
Item Pump
Item Number P-601
Type Rotary Pump
Function To pump water into storage
Operating Condition
Temperature (oC) 25
Efficiency 0.75
Power (Watt) 881.33
Head (m) 14.39
NPSHr (m) 10.01
NPSHa (m) 10.48
62
General Information
Item Pump
Item Number P-602
Type Rotary Pump
To pump water from storage
Function
into deaerator
Operating Condition
Temperature (oC) 25
3
Efficiency 0.75
Power (Watt) 881.33
Head (m) 14.39
NPSHr (m) 10.01
NPSHa (m) 10.48
General Information
Item Pump
Item Number P-701
Type Rotary Pump
Function To pump water into clarifier
Operating Condition
Temperature (oC) 25
63
Operating Condition
Efficiency 0.75
Power (Watt) 598.04
Head (m) 14.39
NPSHr (m) 10.01
NPSHa (m) 10.48
General Information
Item Pump
Item Number P-702
Type Rotary Pump
To pump water from aerobic
Function
tank into clarifier
Operating Condition
o
Temperature ( C) 25
Pressure Inlet (Pa) 101.000
Pressure Outlet (Pa) 202.000
3
2 2 4.53
3 0.002526
Flowrate (m /s)
Efficiency 0.75
Power (Watt) 355.35
Head (m) 14.39
NPSHr (m) 10.01
NPSHa (m) 10.48
6 CHAPTER VI
CONCLUSION
Based on the design of the equipment as have been demonstrated by the

calculation, simulation, and equipment selection by operating conditions, the
conclusion of this report is as below.
1. Material vessel is used to store raw material and product. The material vessel
needed in this plant are molasses storage vessel, ammonium hydroxide storage
vessel, nutrients storage vessel, H2SO4 storage vessel, NaOH storage vessel,
HCl storage vessel, unpurified product storage vessel, and final product storage
vessel.
2. The equipment needed in the pre-treatment section are acid hydrolysis reactor
(CSTR), rotary vacuum filter, mixer tank, and material handler.
3. In the main reaction (fermentation) process, the equipment needed are air filter,
heat sterilization, seed fermenter, main fermenter, and material handler such as
pump and compressor.
4. In the purification section, the equipment needed are rotary vacuum filter, ion
exchange column, evaporator, crystallizer, fluidized bed dryer, and screw
conveyor.
5. The utility unit consist of feed water storage tank, clarifier, GM filter, RO,
water storage tank, cooling tower, chiller, deaerator, boiler, and aerobic bio-
oxidator.
6. The design and sizing of all equipment have been made, including those which
can be bought from manufacturers.
REFERENCES
Basu, P., Kefa, C., & Jestin, L. (2000). Boilers and Burners: Design and Theory.
New York: Springer.
Coker, A. K. (2001) Modeling of chemical kinetics and reactor design. Boston, MA:
Gulf Professional Pub.
Dongguan Baiyi Tongyong Machiney Co., Ltd. Water Chiller. Retrieved October
26, 2021, from https://www.alibaba.com/product-detail/60WSCS-Water-
screw-chiller-machine-
Electrical_1600068627233.html?spm=a2700.galleryofferlist.normal_offer.
d_title.53ed59a5SyP2M3
Douglas, J. M. (1988) ‘CONCEPTUAL DESIGN OF CHEMICAL PROCESSES’,
p. 309.
Ebara Indonesia. Open Circuit Cross Flow Square Type Cooling Tower. Retrieved
October 25, 2021, from
http://www.ebaraindonesia.com/products/item/19/open_circuit_cross_flow
_square_type_cooling_tower
Eduljee G.H.; Boyes A.P.: Viscosity of some Binary Liquid Mixtures of Oleic Acid
and Triolein with Selected Solvents. J.Chem.Eng.Data 25 (1980) 249-252
K.-S. Choi and H. G. Cha, US Pat, 9598780B2, Wisconsin Alumni Research
Foundation (US), 2017
Krisbow. (2021). Generator. Retrieved September 24, 2021, from
https://ecatalog.krisbow.com/pdf/catalog/10%20Generator%20catalog%20
update.pdf
Merdhah, A. B. B. and Yassin, A. A. M. (2008) ‘Laboratory Study and Prediction
of Calcium Sulphate at High-Salinity Formation Water’, The Open
Petroleum Engineering Journal, 1(1), pp. 62–73. doi:
10.2174/1874834100801010062.
Myerson, A. (2001). Handbook of Industrial Crystallization. 2nd ed. Elsevier and
Technology Books.
65
Platvoet, E., Baukal, C. (2013). Process Burners 101. American Institute of
Chemical Engineers (AIChE).
R. Latsuzbaia, R. Bisselink, A. Anastasopol, H. van der Meer, R. van Heck, M. S.
Yagüe, M. Zijlstra, M. Roelands, M. Crockatt, E. Goetheer and E. Giling, J.
Appl. Electrochem., 2018, 48(6), 611–626.
Smith, R. (2015) ‘Chemical Process Design and Integration’, p. 713.
Soliman K.; Marschall E.: Viscosity of Selected Binary, Ternary, and Quaternary
Liquid Mixtures. J.Chem.Eng.Data 35 (1990) 375-381
Towler, G. P. and Sinnott, R. K. (2008) Chemical engineering design: principles,
practice and economics of plant and process design. Amsterdam ; Boston:
Elsevier/Butterworth-Heinemann.
V.R.N. Telis, J. Telis-Romero, H.B. Mazzotti & A.L. Gabas (2007) Viscosity of
Aqueous Carbohydrate Solutions at Different Temperatures and
Concentrations, International Journal of Food Properties, 10:1, 185-195,
doi: 10.1080/10942910600673636
Walas, S. M. (1990). Chemical process equipment: selection and design. Boston:
Butterworth-Heinemann.
Woods, D. R. (2007) Rules of thumb in engineering practice. Weinheim: Wiley-
VCH.
66
APPENDICES
APPENDIX A: Design Calculation of Storage Vessel
1. Introduction:
The calculation design output of cylindrical pressure storage vessel are the
geometry parameter like diameter(D), height(H), and vessel thickness(tc).
Procedure used to calculate the geometry of pressure storage vessel are written
in this section.
1.1 Diameter (D) and Height (H)
Liquid volume =VL
Cylindrical Shell Volume: V = (1+ safety factor)VL
1
Cylindrical Shell Dimension: 𝑉𝑆 = 4 𝜋𝐷 2 𝐻
Safety factor usually represented as void percentage of total volume. The

ratio of diameter and height of vessel are determined by the total volume of
vessel. Ratio between 1-5 are genuinely used for vessel with volume 4-
40m3. For vessel higher than 40 m3, ratio between 0.5-1.5 are generally
used.
1.2 Working Pressure (P)
𝑃 = 𝑃0 + 𝑃ℎ
P0 = Atmospheric pressure = 1 atm = 1.013 x 105 Pa
Ph = hydrostatic pressure of liquid = ρL.g.HL
ρL= liquid density(kg/m3)
HL= Height of Liquid
1.3 Material Selection
Material is chosen by some criteria depending on significant
properties used in the process like heating and cooling, high pressure, and
resistance to corrosion, and the economic parameter of the material.
Allowable stress (S) and Corrosion rate (C) then is calculated to the material
that was chosen.
1.4 Cylindrical Shell Thickness (tc)
𝑃𝑅
𝑡𝑐 = + 𝐶𝑌
𝑆𝐸
67
S = allowable stress
P = Pressure
R = cylindrical radius
E = joint efficiency
C = Corrosion rate
Y = Lifetime
1.5 Vessel Head
For the standard used, torispherical head is commonly used. Torispherical
head dimension consist of head thickness (th), external diameter (D),
knuckle radius (KR), Crown radius (CR), straight flange height (SF),
dishing head (DH), and total height (TH) as illustrated below.
Figure A.1 Torisperical Head Schematic
CR= D
KR = 6%CR
0.885𝐶𝑅
𝑡ℎ = + 𝐶𝑌
𝑆𝐸 − 0.1𝑃
DH =0.1935D -0.455th
SF = 3,5 th
TH = DH + SF
2. Storage Vessel
2.1 Molasses Storage Vessel
Table A. 1 Calculation for Molasses Storage Vessel
Volume Tank
Void Percentage 15%
Total Volume 645.25 m3
68
Table A. 2 Calculation for Molasses Storage Vessel (Cont’1)
Tank Dimension
Diameter (m) 9.37 M
Height of Shell (Hs) (m) 9.37 M
Height Tank (Ht) (m) 11.25 M
Pressure Design
Height of Fluid 8.15 m
Total density 1400 kg/m3
Hydrostatic Pressure 111756.99 Pa
Hydrostatic Pressure 1.10 atm
Operasional pressure 1.00 atm
Pressure Abs 2.10 atm
Pressure Design 2.31 atm
Shell Thickness
Pressure Design 34 psi
Shell Diameter 368.79 in
Allowable stress (S) 12890.50 psi
Efficiency (E) 85%
Corrosion Factor (C) 0.063 in/year
Shelf life (A) 15 year
1.51 in
Shell Thickness 0.038 m
38.37 mm
Torispherical Flanged and Dished Head
Diameter (D) 368.79 in
Crown Radius (CR) 368.79 in
Knuckle Radius (KR) 36.88 in
Efficiency (E) 85%
Lifetime (A) 15 Year
head thickness(th) 0.97 In
Dishead Height (DH) 70.92 In
Straight flange height (SF) 3.39 In
74.31 In
Total Height (TH)
1.89 m
69
2.2 NH4OH Storage Vessel
Table A. 3 Calculation for NH4OH Storage Vessel
Volume Tank
Void Percentage 15%
Tank Dimension
Diameter (m) 9.21 M
Height of cylinder (Hs) (m) 9.21 M
Pressure Design
Height of Fluid 8.01 M
Hydrostatic Pressure 0.70 Atm
Operasional pressure 2.00 Atm
Pressure Abs 2.70 Atm
Pressure Design 2.97 Atm
Shell Thickness
Pressure Design 43.61 Psi
Shell Diameter 362.61 In
Allowable stress (S) 12890.50 Psi
Efficiency (E) 85%
Shelf life (A) 15 Year
1.66 In
Shell Thickness 0.042 M
42.18 Mm
Diameter (D) 362.61 In
Crown Radius (CR) 362.61 In
Knuckle Radius (KR) 36.26 In
Efficiency ( E ) 85%
Corrosion Factor ( C) 0.063 in/year
Head thickness(th) 0.98 In
Dishead Height(DH) 69.72 In
Straight flange height(SF) 3.42 In
73.14 In
Total Height(TH)
1.86 M
70
2.3 Nutrients Storage Vessel
Table A. 4 Calculation for Nutrients Storage Vessel
Volume Tank
Void Percentage 15%
Tank Dimension
Diameter (D) 1.49 m
Height of cylinder (Hs) 4.48 m
5.21 m
Pressure Design
total Density 809 kg/m3
0.30 atm
Operational Pressure 1.00 atm
Shell Thickness
Pressure Design 21.09 psi
Shell Diameter(D) 58.78 in
Efficiency (E) 85%
shelf life (A) 15 year
0.99 in
Shell Thickness(tw) 0.025 m
25.25 mm
Efficiency (E) 85%
head thickness(th) 0.99 In
71
Table A. 5 Calculation for Nutrients Storage Vessel (Cont’1)
14.40 In
Total Height (TH)
0.37 m
Saddle
Vessel Diameter 58.78 In
38000 Pound
Maximum Operating Weight
17236.496 Kg
Operating Weight 8000 Kg
A 54 In
B 39 In
C 10 In
D 0.5 In
E 23 In
F 6 In
G 0.25 In
H 25 In
2.4 H2SO4 Storage Vessel

Table A. 6 Calculation for H2SO4 Storage Vessel
Volume Tank
Void Percentage 15%
Tank Dimension
Diameter (m) 6.51 M
Height of cylinder (Hs) (m) 6.51 M
Pressure Design
Height of Fluid 5.66 M
Operational pressure 2.00 Atm
72
Table A. 7 Calculation for H2SO4 Storage Vessel (Cont’1)
Shell Thickness
Efficiency (E) 85%
1.43 in
36.24 mm
Diameter(D) 256.46 in
Efficiency (E) 85%
Lifetime (A) 15 year
head thickness(th) 0.96 in
Dishead Height (DH) 49.19 in
Straight flange height (SF) 3.38 in
52.56 in
Total Height (TH)
1.34 m
73
2.5 NaOH Storage Vessel
Table A. 8 Calculation for NaOH Storage Vessel
Volume Tank
Void Percentage 15%
Tank dimension
Diameter (D) 1.55 m
Height Tank (Ht) 5.40 m
Pressure Design
total Density 1043 kg/m3
Hidrostatic Pressure 41270.07 Pa
0.41 atm
Operational Pressure 1.00 Atm
Shell Thickness
Shell Diameter(D) 60.94 In
Efficiency (E) 85%
1.00 In
Shell Thickness(tw) 0.025 M
25.42 Mm
Diameter (D) 60.94 In
Crown Radius (CR) 60.94 In
Efficiency (E) 85%
74
Table A. 9 Calculation for NaOH Storage Vessel (Cont’1)
Head thickness (th) 1.00 In

14.84 In
Total Height (TH)
0.38 M
Saddle
Vessel Diameter 60.94 In
38000 Pound
17236.496 Kg
Operating Weight 8000 Kg
A 54 In
B 39 In
C - In
D 0.5 In
E 23 In
F 6 in
G 0.25 in
H 25 in
Saddle Angle (θ) 124 o
2.6 HCl Storage Vessel

Table A. 10 Calculation for HCl Storage Vessel
Volume Tank
Void Percentage 15%
Tank dimension
Diameter (D) 1.35 m
Height Tank (Ht) 4.73 m
Pressure Design
Total Density 39.72 kg/m3
Hidrostatic Pressure 1372.96 Pa
0.01 atm
Operational Pressure 1.00 atm
75
Table A. 11 Calculation for HCl Storage Vessel (Cont’1)
Shell Thickness
Shell Diameter (D) 53.23 in
Efficiency (E) 85%
shelf life (A) 15 year
0.98 in
Shell Thickness (tw) 0.025 m
24.82 mm
Efficiency (E) 85%
Lifetime (A) 15 year
head thickness (th) 0.98 in
Dishead Height (DH) 9.86 in
13.28 in
Total Height (TH)
0.34 m
Saddle
Vessel Diameter 53.23 in
26330 pound
11943.07736 kg
Operating Weight 200.46 kg
A 48 in
B 36 in
C - in
D 0.5 in
E 20 in
F 6 in
G 0.25 in
H 22.7 in
76
2.7 Unpurified Storage Vessel
Table A. 12 Calculation for Unpurified Storage Vessel
Volume Tank
Void Percentage 15%
Tank Dimension
Diameter (m) 9.63 m
Height of cylinder (Hs) (m) 9.63 m
Height Tank (Ht) (m) 11.57 m
Pressure Design
Total density 1014.86 kg/m3
Hydrostatic Pressure 0.82 atm
Operational pressure 1.00 atm
Shell Thickness
Efficiency (E) 85%
1.45 in
36.78 mm
Diameter(D) 379.13 in
Efficiency (E) 85%
Head thickness (th) 0.97 In
76.30 In
Total Height (TH)
1.94 m
77
2.8 Final Product Vessel
Table A. 13 Calculation for Final Product Storage Vessel
Volume Tank
Void Percentage 15%
Tank Dimension
Diameter (m) 2.25 m
Height of cylinder (Hs) (m) 6.74 m
Height Tank (Ht) (m) 7.39 m
Pressure Design
Total density 997.07 kg/m3
Operational pressure 1.00 Atm
Shell Thickness
Shell Diameter 88.46 In
Efficiency (E) 85%
1.04 In
Shell Thickness 0.026 M
26.41 mm
Diameter(D) 88.46 In
Lower Diameter 8.85 In
Efficiency (E) 85%
Bottom thickness (bh) 0.94 In
Angle of slope 30 Degree
Height 25.54 In
0.65 m
78
APPENDIX B: Design Calculation of Pre-treatment Equipment
1. Acid Hydrolysis Reactor
The hydrolysis reaction occurs in a Continuous Stirred Tank Reactor (CSTR).
The reactor consists of head, jacketed body, impeller, and bottom. The vessel used
is a cylindrical vessel, because the operating pressure is in the range 1-400 psi and
it is easier to put up an impeller since the cylindrical vessel usually used as a mixer
tank. Besides that, following the rules of thumb of vessels, the shape will be vertical
tank with flat bottom on concrete foundation. Since the pressure system is 25.81
psi, we choose the torispherical head. The material used to construct the reactor and
the head is Stainless Steel 316, because it has a high content of Molybdenum (Mo)
so the corrosion rate is slower. The design steps for the vessel and torispherical head
is already described in appendix A.
Figure B. 1 Design Scheme of CSTR
(Source: semanticsholar.org)
The hydrolysis reaction refers to a literature from Hartanto et al. (2020) to find
the operating condition and the kinetics data of the reaction, as described below.
Table B. 1 Process Condition of Acid Hydrolysis
Parameter Value
Reaction Temperature 55 oC
Rate Constant Specification Kh,sucrose = 19.44/h
Operating Pressure 1 atm
Concentration of Sulphuric Acid 1M
Reaction Time 15 Minutes
Conversion 99.23%
(Source: Hartanto, et al, 2020)
79
Hydrolysis reactors use CSTR reactor to hydrolize the sucrose and with acid
(H2SO4). The sizing procedures are as below:
1. Calculation of residence time and reactor volume
The reaction in CSTR is shown below:
𝐴 → 𝐵+𝐶 dengan k = 19.44/h
Where:
A = sucrose
B = glucose
C = fructose
The step to calculate residence time and reactor volume:
a. Calculate the rate of the decomposition reaction of sucrose
Hydrolysis reactions mainly use a reagent in the form of water, which is made
in excess, which can be written as:
𝑑𝐶𝐴
𝑟𝐴 = = −𝑘𝐶𝐴 𝐶𝐵
𝑑𝑡
Where:
𝑟𝐴 = rate of the decomposition of sucrose (gmol/L)
𝐶𝐴 = sucrose concentration (gmol/L)
𝐶𝐵 = water concentration (gmol/L)
𝑡 = reaction time (minute)
With an excessive amount of water, it can be assumed that the water
concentration remains constant during the reaction, so the equation becomes:
𝑑𝐶𝐴
𝑟𝐴 = = −𝑘𝐶𝐴
𝑑𝑡
Assumption: Steady state
b. Rate of reaction
−𝑟𝐴 = 𝑟𝐵 = 𝑟𝑐
Rate of reaction for all of components:
𝑟𝐴 = 𝑟𝐴 = −𝑘𝐶𝐴
𝑟𝐵 = 𝑟1𝐵 = 𝑘𝐶𝐴
𝑟𝐶 = 𝑟𝐶 = 𝑘𝐶𝐴
c. Calculate the reaction conversion with polymath
80
In this calculation we used polymath to calculate the conversion. This is our
polymath program and result:
Table B. 2 Polymath Calculation of Hydrolysis Vessel
Figure B. 2 Polymath Results of Hydrolysis Vessel
Figure B. 3 Polymath Graph of Hydrolysis Vessel Calculation
81
These data used to calculate the vessel volume required, using the equation
from Missen, et al. (1998) below.
𝑞𝑜 𝑓𝐴
𝑉𝐿 =
𝑘𝐴 (1 − 𝑓𝐴 )
Where,
𝑞𝑜 = Volumetric Flowrate (m3/h)
𝑓𝐴 = Conversion
𝑘𝐴 = Rate constant (h-1)
The type of impeller used in this reactor is propeller. It is chosen based on
the impeller selection guide in Holland, F. A., et al (1966) and designed using the
rule of thumb adapted from Kayode (2001) described in the table below.
Table B. 3 Impeller Design Rule of Thumb
Parameter Value
Da : Dt 1:3
W : Da 1:5
Da : Db 6:1
C : Dt 1:3
Dt : J 12 : 1
(Source: Kayode, 2001)
The temperature in the reactor needs to be maintained constant during the

hydrolysis reaction, so a heating jacket is needed. The heating jacket is designed
using these calculations below, adapted from repository.wima.ac.id.
1
𝑉𝑠 = 𝐴𝑣 = 4 𝜋(𝐼𝐷𝑗2 − 𝑂𝐷𝑠2 )𝑣 (B.2)
1
4𝑉𝑠 2
𝐼𝐷𝑗 = ( 𝑣𝜋 + 𝑂𝐷𝑠2 ) (B.3)
𝑂𝐷𝑗 = 𝐼𝐷𝑗 + 2(𝑗𝑠) (B.4)
82
Where, Vs is the inflow steam volumetric rate (m3/s), ID is inner diameter of
jacket (m), OD is shell outer diameter (m), v is steam velocity (m/s), A is heat
transfer area (m2), and js is the jacket spacing (m). The summary of reactor R-101
specifications is summarized in the following table.
Cylindrical Shell Diameter and Height

The operating pressure in this process is 1 atm (14.69 psi), thus the type of
the reactor chosen is the cylindrical shell. The cylindrical shell is usually used as a
mixer tank because the impeller installation is easier.
The calculation for the Liquid Volume (VL) using the equation below (adapted
from Missen, et al, 1999), using the kinetic data for the hydrolysis of molasses from
V. H. Hartofylax, et al (1989) where 𝑘𝑠𝑢𝑐𝑟𝑜𝑠𝑒 = 19.44 ℎ−1 and the conversion of
sucrose is 99.23%.
𝑞𝑜 𝑓𝐴
𝑉𝐿 =
𝑘𝐴 (1 − 𝑓𝐴 )
VL = 40.39 m3
Where,
𝑉𝐿 = Working Volume (m3)
𝑞𝑜 = Volumetric Flowrate (m3/h)
𝑓𝐴 = Conversion of Sucrose
𝑘𝐴 = Kinetic of sucrose (ℎ−1)

As for the cylindrical shell volume, the calculation using the equation below
with the safety factor is 20% of the VL.
𝑉𝑠 = (1 + 𝑠𝑎𝑓𝑒𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟) 𝑥 𝑉𝐿
VS = 48.47 m3
The calculation for the diameter of the cylindrical shell using the equation
below.
3 24𝑉
𝐷 = √ 13𝜋𝑠
83
The optimum design for stirred tank reactors with volume beyond 40 m3 is
vertical tank flat bottom on concrete foundation with ratio of D = Hc of a range 0.5
to 1.5 (Peters et al, 2003). Therefore, it is chosen D : Hc = 1 : 1.2. Therefore D =
3.05 m and Hc = 6.1 m.
Working Pressure
Working pressure, P = P0 + Ph
where P0 = atmospheric pressure = 1 atm = 1.013 × 105 Pa
Ph = hydrostatic liquid pressure = ρL .g. HL
From the simulator and calculation above, it is known that ρL = 1206.12
kg/m3 and HL = 5.12 m (the cylindrical shell height is used as liquid depth for the
safety reason). Therefore,
P = 1.013 × 105 Pa + (1206.12 kg/m3) (9.8 m/s2) (5.12 m)
P = 1.60 × 105 Pa = 1.6 atm
Construction Material Selection

The hydrolysis process proceeds using sulfuric acid which belongs to the
strong acid group and the reactor needs to be equipped with heating jacket. Hence,
the reactor has to be built with proper corrosive allowance and suitable with
heating jacket. For that requirements, Stainless Steel 316 is chosen as the reactor
material.
The properties of the material are as follow.
Table B. 4 Properties of SS 316 Material
Parameter Value
16%—18% Cr
10%—14% Ni
Material Composition
max. 0,08% C
2%—3% Mo
Maximum Temperature 1500 oF
Not exceeding 100 oF = 18,700 Psi
Maximum Allowable Stress
Not exceeding 200 oF = 16,100 Psi
Corrosion Rate 0.031 inch/year
Source: Towler and Sinnott, 2007
84
Impeller & Jacket Design
The type of impeller used is propeller, based on the impeller selection guide
(Holland, F. A., et al., 1966). It is design using the heuristic from Kayode (2001)
and resulted as follow.
Table B. 5 Impeller Design Calculation
Parameter Value
Impeller Diameter (Da) 1.02 m
Stirrer Leaf Width (W) 0.20 m
Stirrer Height from The Bottom (C) 1.02 m
Stick Diameter (Db) 0.34 m
Baffle Diameter (J) 0.25 m
Jacket Design
Shell thickness, tc 0.018 m
Jacket thickness, tj 0.018 m tj=tc
Inflow steam mass rate, M 44.57 kg/h
Steam density, 𝜌𝑠 2.67 kg/m3
Inflow steam volumetric rate, 𝑀𝑠 16.6928 m3/h
𝑉𝑠 = 𝐴𝑣
Inflow steam volumetric rate, 𝑉𝑠 m3/s 1
= 𝜋(𝐼𝐷𝑗2 − 𝑂𝐷𝑠2 )𝑣
0.004637 4
Steam velocity, V 1.00 ft/s
Shell outer diameter, 𝑂𝐷𝑠 3.281 m/s
1
Jacket inner diameter, 𝐼𝐷𝑗 m 4𝑉𝑠 2
3.05 𝐼𝐷𝑗 = ( + 𝑂𝐷𝑠2 )
𝑣𝜋
Jacket spacing, js 3.0539 m
Jacket outer diameter, 𝑂𝐷𝑗 0.0125 m 𝑂𝐷𝑗 = 𝐼𝐷𝑗 + 2(𝑗𝑠)
oC
Feed temperature, T1 25
oC
Product temperature, T2 55
Steam temperature, T 152 oC
85
Table B. 5 Impeller Design Calculation (Cont’d)
Parameter Value
𝑇1 − 𝑇 𝑈𝐴𝑡
LMTD 0.27 ln (
𝑇2 − 𝑇
) = 𝐿𝑇𝑀𝐷 =
𝑀𝐶𝑝
Overall heat capacity, U 25 kJ/hm2

Heat Transfer Area, A 0.135 m2
Jacket Height, hj 0.014 m
2. Mixer Tank
Calculation Mixing Tank
Mixing tank is a vertical cylindrical tank with ellipsoidal head and bottom.
In this plant, the mixing tank is used in main reaction for fermentation and
purification process. The steps of calculation are described below
Volume Tank
The volume of tank can be calculated from data flow rate and density. The
equation can be seen below.
𝑀𝑡
𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 ( )
𝑉𝑜𝑙𝑢𝑚𝑒 𝑡𝑎𝑛𝑘 = ℎ
𝑀𝑡
𝑑𝑒𝑛𝑠𝑖𝑡𝑦 ( 3 )
𝑚
1 1 13
𝑉 = 𝑉𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 + 𝑉ℎ = 𝜋2𝐷 3 + 𝜋𝐷 3 = 𝜋𝐷 3
4 24 24
Tank Dimension
From the data volume tank, the diameter of tank. The calculation of
diameter can use the volume cylinder equation. The ratio between diameter tank
and height tank is 1:2.
3 24𝑉𝑠
𝐷=√
13𝜋
1
𝑉𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 = 𝜋2𝐷 2 𝐻𝑠
4
1
𝑉𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 = 𝜋2𝐷 3
4
86
The equation of volume head tank can be seen below. The ration between
diameter tank and height head is 4:1.
1
𝑉ℎ 𝑒𝑙𝑙𝑖𝑝𝑠𝑜𝑑𝑎𝑙 = 𝜋𝐷 2 𝐻ℎ
4
1 1 1
𝑉ℎ 𝑒𝑙𝑙𝑖𝑝𝑠𝑜𝑑𝑎𝑙 = 𝜋𝐷 2 𝑥 𝐷 = 𝜋𝐷 3
4 6 24
Pressure Design
The equation of pressure design for mixing tank can be seen below.
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑 𝑖𝑛 𝑡𝑎𝑛𝑘 𝑥 ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑡𝑎𝑛𝑘

𝐻𝑓 =
𝑡𝑎𝑛𝑘 𝑣𝑜𝑙𝑢𝑚𝑒
∑(𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑥 𝑑𝑒𝑛𝑠𝑖𝑡𝑦)
𝜌𝑡𝑜𝑡𝑎𝑙 =
𝑡𝑜𝑡𝑎𝑙 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒
Tank Thickness
The equation for calculate tank thickness can be seen below.
Where:
𝑃𝑥𝑅
𝐶𝑦𝑙𝑖𝑛𝑑𝑒𝑟 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 (𝑑) = + (𝐶𝑥𝐴)
𝑆. 𝐸 − 0.6𝑃
P = pressure design (atm)
R = tank inner radius (in)
S = allowable stress
E = efficiency (85%)
C = corrosion factor
A = usage time (year)
87
Design Head
The equation for calculate design head can be seen below.
𝑃𝑥𝐷𝑖 𝑥𝐾
𝑡ℎ = + (𝐶𝑥𝐴)
2𝑆. 𝐸 − 0.2𝑃
K is constanta, can be calculated using the equation below.
1 𝐷 2
𝐾 = [2 + ( ) ]
6 2ℎ
Impeller
The calculation for impeller can be determine using the ratio below.
Table B. 6 Ratio for Impeller Calculation
Dimension Ratio
Diameter stirrer (Da): Diameter tank (Dt) 1:3
Width of leaf stirrer (W): Diameter stirrer (Da) 1:5
Diameter stirrer (Da): Stick Diameter (Db) 6:1
Distance from bottom of the tank (C): Tank
1:3
Diameter (Dt)
Diameter tank (Dt): Baffle diameter (J) 1:12
88
APPENDIX C: Design Calculation of Main Reaction (Fermentation)
Equipments
1. Tank Dimension
From Eyer (1965), to calculate tank diameter, this equation is used with
recommended L/D is 2.
1
3
𝑉𝑙𝑖𝑞
𝐷=( )
1 𝐿
𝜋 ( ) 0.8
4 𝐷
Where,
D = Tank Diameter (dm)
Vliq = Volume (L)
L/D = Length to Diameter ratio
Vliq can be calculate from kinetic calculation in Polymath with reaction and
input bellow
2 Glucose + 2 NH4OH + 3 Oxygen → 2 Glutamic Acid + 2 CO2 + 8 H2O
To make easier to work, the material can be shortened as follow
Glucose = CS
NH4OH = CN
Oxygen = CO
CO2 = CO2
Glutamic A= GU
Water = H2O
With equation batch reactor
aA + bB → cC + dD
1 1 1 1
− 𝑟𝐴 = − 𝑟𝐵 = 𝑟𝑐 = 𝑟𝐷
𝑎 𝑏 𝑐 𝑑
Parameters input to Polymath

𝑘 = 0.16
𝛼 = 3.278
89
𝐹𝑆0 = 4
(𝐶𝑆0 − 𝐶𝑆)
𝑋=
𝐶𝑆0
𝑟𝑆 = −𝑘𝐶𝑆
𝑟𝑁 = 𝑟𝑆
3
𝑟𝑂 = ( ) 𝑟𝑆
2
𝑟𝐶𝑂2 = −𝑟𝑆
𝑟𝐺𝑈 = 𝑟𝑆
𝑟𝐻2𝑂 = −4𝑟𝑆
𝐹𝑆𝑂. 𝑋
𝑉=
𝑟𝑆 −1
Input concentration flow from simulation Superpro to input first value
concentration after that, run the Polymath. The data obtained are as bellow.
Figure C. 1 Calculation Data from simulation Polymath in Seed Fermenter
90
Figure C. 2 Graph Convertion vs Time Polymath Seed Fermenter
Figure C. 3 Calculation Data from simulation Polymath in Main Fermenter
91
Figure C. 4 Graph Convertion vs Time Polymath Seed Fermenter
Table C. 1 Fermentation Tank Volume
Volume Tank
Tank Volume
Volume
Quantity Tank
290.984 m2
Seed Fermenter 8 36373 L
290984 L
2848 m2
Main Fermenter 8 356000 L
2848000 L
After calculating tank volume, tank height can be obtained with known L/D
2. Then tank volume can be calculated using cylinder volume calculation.
𝑉 = 𝜋𝑟 2 𝐿
Where,
V = Cylinder volume (m3)
R = Cylinder radius (m)
L = Cylinder length (m)
92
Beside calculating tank dimension, ellipsoidal head and bottom of the vessel
also need to be calculated with ratio vessel diameter:head length is 4:1 and this
equation (Walas, 2010).
𝑉 = 0,1309𝐷 2
V = Head and bottom volume
D = Cylinder diameter
Table C. 2 Vessel Dimension (Seed Fermenter)
Vessel Dimension Unit

H_t/D_t 2
V liquid 36373.000 L
33.449 dm
Tank Diameter
3.345 m
Tank Height 6.690 m
58.756 m3
Tank Volume
58756.042 dm3
Head volume 4898.8318 dm3
Table C. 3 Vessel Dimension (Main Fermenter)
Vessel Dimension Unit

H_t/D_t 2
V liquid 356000.000 L
71.862 dm
Tank Diameter
7.186 m
Tank Height 14.372 m
582.637 m3
Tank Volume
582637.292 dm3
Head volume 48577.8481 dm3
93
2. Pressure Design
To calculate pressure design, fluid height needs to be calculated using ratio
fluid height:tank height is 0,8. Based on Towler and Sinnott (2012), the design
pressure is normally 5% to 10% above the normal working pressure. When
deciding the design pressure, the hydrostatic pressure is the base of the tank
should be added to operating pressure. Thus, these equations should be used.
𝑃ℎ = 𝜌 × 𝑔 × 𝐹𝑙𝑢𝑖𝑑 ℎ𝑒𝑖𝑔ℎ𝑡
Using the 10% margin, the pressure design can be obtained using this equation.
𝑃𝑑 = (100% + 10%)(𝑃𝑜 + 𝑃ℎ)
Where,
Ph = Hydrostatic pressure (Pa)
Po = Operating pressure (Pa)
Pd = Design pressure (Pa)
R = Density (kgm-3)
L = Gravitational acceleration (ms-2)
Table C. 4 Pressure Design (Seed Fermenter)
Pressure Design Unit

H_L/H_t 0.8 M
H fluid 5.351854222 M
1.01390 kg/L
Density
1013.89928 kg/m3
Gravity 9.8 m/s2
53177.16318 Pa or
Ph
kg/ms2
1.013 Bar
Pop
101300 a or kg/ms2
Margin 0.1
169924.8795 pa or kg/ms2
Pdesign
16.99248795 bar
94
Table C. 5 Fermentation Tank Volume
Pressure Design Unit

H_L/H_t 0.8 m
H fluid 11.49792641 m
1.01070 kg/L
Density
1010.703486 kg/m3
Gravity 9.8 m/s2
Ph 113885.7441 Pa or kg/ms2
1.013 bar
Pop
101300 pa or kg/ms2
Margin 0.1
236704.3185 pa or kg/ms2
Pdesign
23.67043185 bar
3. Tank Thickness
To calculate thickness, cylindrical shell and ellipsoidal head thickness
equation is used. The equations based on Walas (2010) is written below.
𝑃𝑅
𝐶𝑦𝑙𝑖𝑛𝑑𝑟𝑖𝑐𝑎𝑙 𝑆ℎ𝑒𝑙𝑙 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠 =
𝑆𝐸 − 0,6𝑃
𝑃𝐷
𝐸𝑙𝑙𝑖𝑝𝑠𝑜𝑖𝑑𝑎𝑙 𝐻𝑒𝑎𝑑 𝑇ℎ𝑖𝑐𝑛𝑒𝑠𝑠 =
2𝑆𝐸 − 0,2𝑃
Where,
P = Pressure (kPa)
R = Radius (in)
D = Diameter (in)
S = Allowable stress (lbin-2)
E = Joint efficiency
95
Allowable stress and joint efficiency obtained from Towler and Sinott
(2012) in the table below.
Figure C. 5 Allowable Stress Data
(Source : Towler and Sinott, 2012)
Figure C. 6 Maximum Allowable Joint Efficiency
(Source : Towler and Sinott, 2012)
96
From the calculation above, tank thickness of reactors shown below:
Table C. 6 Vessel Thickness (Seed Fermenter)
Vessel Thickness Unit

16.99248795 bar
Pressure (P)
1699.248795 kPa
3.344908888 m
Diameter (D)
131.6893974 in
Radius (R) 65.84469872 in
Allowable stress (S) 20000 psi
Joint efficiency (E) 0.85
7.001462405 in
Tank thickness
17.78371451 cm
6.648011025 in
Head thickness
16.885948 cm
Table C. 7 Vessel Thickness (Main Fermenter)
Vessel Thickness Unit

23.67043185 bar
Pressure (P)
2367.043185 kPa
7.186204004 m
Diameter (D)
282.9215703 in
Radius (R) 141.4607851 in
Allowable stress (S) 20000 psi
Joint efficiency (E) 0.85
21.4922107 in
Tank thickness
54.59021519 cm
19.97481843 in
Head thickness
50.7360388 cm
97
4. Agitator and Power Specification
To calculate agitator dimension, dimensions ratio is used as the table below
(Eyer, 1965).
Table C. 8 Agitator Size Ratio
(Source : Eyer, 1965)
For power calculation, the Reynold number and Power number should be
obtained first. Reynold number can be obtained with equation below.
𝐷𝑎2 𝑁𝜌
𝑁𝑅𝑒 =
𝜇
Where,
NRe = Reynold number
Da = Agitator diameter (m)
N = Rotation speed (rps)
ρ = Density (kgm-3)
μ = Viscosity (kgm-1s-1)
After Reynold number obtained, Power number can be obtained from the
plot of Reynold number vs. Power number.
98
Figure C. 7 Reynold Number vs. Power Number (Propeller with Baffle is Line 4)
(Source: Walas, 2010)
After Power number obtained, the power required can be calculated from
equation below.
𝑃𝑖 = 0,001 (𝑁𝑝 × 𝜌 × 𝑁 2 × 𝐷𝑎5 )
Where,
Pi = Power required (kW)
Np = Power number
N = Rotation speed (rps)
ρ = Density (kgm-3)
Da = Agitator diameter (m)
Viscosity can be calculated from mixed viscosity in flow fermenter

𝑐𝑃 𝑥 𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒
𝑀𝑖𝑥𝑒𝑑 𝑉𝑖𝑠𝑐𝑜𝑠𝑖𝑡𝑦 =
𝑇𝑜𝑡𝑎𝑙 𝐹𝑙𝑜𝑤𝑟𝑎𝑡𝑒
Where
Flowrate = Rate flow material (MT/h)
cP = Specific Heat Capacities (kJ/Kg.K)
99
Table C. 9 Mixed Viscosity in Seed Fermenter
Mixed Viscosity in Seed Fermenter

Material Flowrate (MT/h) Cp (kJ/kg.K) Flowrate x Cp
Ash 0.01368 0.95 0.012996
Glutamicum 0.036 1.81 0.06516
Glucose 0.00189 1.22 0.0023058
Glutamic 1.05512 1.19 1.2555928
Nutrients 0.00118 1.67 0.0019706
Organic Solid 0.25949 1.5 0.389235
Sucrose 0.00002 1.17 0.0000234
Sulfuric Acid 0.01897 1.38 0.0261786
Water 1.55516 4.18 6.5005688
Total 2.94151 8.254031
Viscosity 2.806052334
Table C. 10 Mixed Viscosity in Main Fermenter
Mixed Viscosity in Main Fermenter

Material Flowrate (MT/h) Cp (kJ/kg.K) Flowrate x Cp
Ash 0.13682 0.95 0.129979
Glutamicum 0.32565 1.81 0.5894265
Glutamic 10.61382 1.19 12.6304458
Nutrients 0.01746 1.67 0.0291582
Organic Solid 2.5949 1.5 3.89235
Sucrose 0.00018 1.17 0.0002106
Sulfuric Acid 0.18973 1.38 0.2618274
Water 15.14313 4.18 63.2982834
Total 29.02169 80.8316809
Viscosity 2.785216192
100
Table C. 11 Agitator and Power Specification (Seed Fermenter)
Agitator and Power Specification Unit

D_a/D_t 0.33
1.114969629 M
Propeller Diameter
111.4969629 Cm
W/D_a 0.2
0.222993926 M
Propeller Height
22.29939259 Cm
L/D_a 0.25
0.278742407 M
Propeller Width
27.87424074 Cm
C/D_t 0.33
1.114969629 M
Propeller to Bottom
111.4969629 Cm
120 Rpm
Agitator Speed
2 Rps
1.01389928 kg/L
Density
1013.89928 kg/m3
2.8 cP
Viscosity
0.0028 kg/ms
Reynold Number (N_re) 900311.6183
Power Number (N_p) 1
139.7655027 kW
Power
187.4283344 HP
101
Table C. 12 Agitator and Power Specification (Main Fermenter)
Agitator and Power Specification Unit

D_a/D_t 0.33
2.395401335 M
Propeller Diameter
239.5401335 Cm
W/D_a 0.2
0.479080267 M
Propeller Height
47.90802669 Cm
L/D_a 0.25
0.598850334 M
Propeller Width
59.88503337 Cm
C/D_t 0.33
2.395401335 M
Propeller to Bottom
239.5401335 Cm
120 Rpm
Agitator Speed
2 Rps
1.010703486 kg/L
Density
1010.703486 kg/m3
2.785 cP
Viscosity
0.002785 kg/ms
Reynold Number (N_re) 4164713.533
Power Number (N_p) 1
6376.835099 kW
Power
8551.463405 HP
5. Baffle Design
For baffle design, baffle width and height should be determined. In baffle
width, W/T value should be obtained from graph first. The graph is shown
below.
102
Figure C. 8 Plot W/T vs. Viscosity
(Source: euromixers.co.uk)
After W/T obtained, baffle width (W) can be obtained from the ratio itself.
For baffle height, it is calculated with ratio baffle height:liquid height is 0,3
based on Jung, et al (2012).
Table C. 13 Baffle Design (Seed Fermenter)
Baffle Design Unit

Viscosity 2.8 cP
W/T 0.09
Tank Diameter 3.344908888 m
0.3010418 m
Baffle width
30.10418 cm
Liquid height 5.351854222 m
Factor 0.3
Baffle height 1.605556266 m
103
Table C. 14 Baffle Design (Main Fermenter)
Baffle Design Unit

Viscosity 2.785 cP
W/T 0.1
0.7186204 m
Baffle width
71.86204004 cm
Liquid height 11.49792641 m
Factor 0.3
Baffle height 3.449377922 m
6. Jacket Design
For jacket design, the length of the jacket is calculated with 1,2 factor and
the thickness is calculated using equation below with corrosion allowance 0,6
for carbon steel material.
𝑃𝑅
𝑡= +𝐶
𝑆𝐸 − 0,6𝑃
Where,
P = Pressure (kPa)
R = Radius (in)
S = Allowable stress (lbin-2)
E = Joint efficiency
C = Corrosion factor (in)
104
Table C. 15 Jacket Design (Seed Fermenter)
Jacket Design Unit
Allowable stress (S) 12900 Psi
0.6 Cm
Corrosion allowance
0.236220472 In
10.44063662 In
Jacket thickness
26.51921702 Cm
Factor 1.2
Jacket length 6.422225066 M
Table C. 16 Jacket Design (Main Fermenter)
Jacket Design Unit

Allowable stress (S) 12900 Psi
0.6 Cm
Corrosion allowance
0.236220472 In
30.77506645 In
Jacket thickness
78.16866877 Cm
Factor 1.2
Jacket length 13.79751169 M
7. Jacket Heat Transfer

To calculate heat transfer coefficient, heat transfer coefficient in and outside
tank (in jacket) needs to be calculated. The first thing is to calculate is heat
transfer coefficient in tank. First, batch temperature average (used as the
temperature reference for determining properties) and determine agitated batch
liquid physical properties required for heat transfer calculation. The properties
determined from data and the temperature is calculated as shown below.
𝑇𝑖𝑛𝑖𝑡𝑖𝑎𝑙 + 𝑇𝑓𝑖𝑛𝑎𝑙
𝑇𝑎𝑣𝑔 =
2
105
After collecting the data needed, the next step is to calculate Reynold and
Prandtl number. Since Reynold number of fluids is already calculated in
previous calculation section, in this step only Prandtl number will be calculated
using equation below.
𝐶𝑝 𝜇
Pr =
𝑘
Where,
Pr = Prandtl Number
Cp = Heat capacity (J/kgoC)
μ = Viscosity (Ns/m2)
k = Conductivity (W/m.K)
Next is to determine agitated liquid individual heat transfer coefficient in

tank using the coefficient written below (Briggs of Burton,2014).
𝑘
ℎ𝑖𝑛 = 0,023 𝑅𝑒 0.8 𝑃𝑟 0,4
𝐷
Where,
hin = Heat Transfer Coefficient in Tank (W/(m2°C))
Re = Reynold Number
D = Tank Diameter (m)
After calculating heat transfer coefficient in tank, heat transfer coefficient

in jacket (outside tank) also needs to be calculated. Before that, calculate jacket
water temperature average (used as the temperature reference for determining
properties) and determine agitated batch liquid physical properties required for
heat transfer calculation. The properties determined from data and the
temperature is calculated as shown below.
𝑇𝑖𝑛𝑖𝑡𝑖𝑎𝑙 + 𝑇𝑓𝑖𝑛𝑎𝑙
𝑇𝑎𝑣𝑔 =
2
After collecting the data needed, the next step is to calculate Reynold and
Prandtl number of water in jacket. The Prandtl number calculated using
equation in previous step and Reynold number calculated using equation below.
106
𝑢𝐿
𝑅𝑒 =
𝑣
Where,
Re = Reynold Number
u = Flow Speed (m/s)
L = Characteristic Linear Dimension (m)
v = Kinematic Viscosity (cm2/s)
Next is to determine agitated liquid individual heat transfer coefficient in

jacket using the coefficient written below (Silva Rosa and Moraes Junior, 2016).
0,8
1 𝜇 0,14
𝑁𝑢 = 0,027𝑅𝑒 𝑃𝑟 3 ( )
𝜇𝑤
𝑘 1 𝜇 0,14
ℎ𝑜𝑢𝑡 = 0,027𝑅𝑒 0,8 𝑃𝑟 3 ( )
𝐷 𝜇𝑤
Where,
hout = Heat Transfer Coefficient in Jacket (W/(m2°C))
D = Jacket Thickness (m)
μ = Viscosity of Liquid at Average Temperature
μw = Viscosity of Liquid at Wall Temperature
After the heat transfer coefficient in and outside tank (in jacket) determined,
the next step is to calculate the overall heat transfer coefficient using equation
below.
1 1 1 1
= + +
𝑈 ℎ𝑖𝑛 λ ℎ𝑜𝑢𝑡
Where,
U = Overall Heat Transfer Coefficient (W/(m2°C))
L = Thickness of Wall (m)
λ = Thermal Conductivity of Wall (W/(m°C))
107
To calculate heat transfer rate, log mean temperature difference (LMTD)
and surface area needs to be calculated first. The calculation for LMTD and
surface area is written below.
∆𝑡1 − ∆𝑡2
𝑇𝐿𝑀 =
∆𝑡1
ln (
∆𝑡2)
𝐴 = 2𝜋𝑟𝐿
Where,
A = Surface Area (m2)
r = Tank Radius (m)
L = Jacket Height (m)
After LMTD assnd surface area of heat transfer obtained, the heat transfer
rate can be calculated using heat transfer coefficient that already calculated in
previous step. The equation to calculate heat transfer rate is shown below.
𝑄 = 𝑈𝐴∆𝑇𝐿𝑀
Where,
Q = Heat Transfer Rate (W)
U = Heat Transfer Coefficient (W/(m2°C))
108
Table C. 17 Jacket Heat Transfer Coefficient (Seed Fermenter)
Jacket Heat Transfer Coefficient Unit

Tinitial 40 °C
Tfinal 32 °C
Tavg 36 °C
Cp 4180 kJ/kgoC
Dynamic Viscosity_miu 0.000653 Ns/m2
Conductivity_k 0.6285 W/m K
Pr 4.342943516
Gravity 9.8 m/s2
Thermal Expansion Coef 0.00021 1/K
Jacket Length 6.422225066 m
Kinematic Viscosity_v 0.000000658 m2/s
Gr 1.00726E+13
h_in 8855.822564 W/m2°C
Tinitial 25 °C
Tfinal 30 °C
Tavg 27.5 °C
Flow Speed 1.7 m/s
Jacket Thickness 0.26519217 m
Re 563533.3616
Cp 4200 kJ/kgoC
Pr 5.064054258
h_out 4626.073012 W/m2°C
Jacket Thermal Conductivity 45 W/m.K
1/U 0.006222245
U 160.7136855 W/m2K
109
Table C. 18 Jacket Heat Transfer Coefficient (Main Fermenter)
Jacket Heat Transfer Coefficient Unit

Tinitial 40 °C
Tfinal 32 °C
Tavg 36 °C
Cp 4180 kJ/kgoC
Pr 4.342943516
Gravity 9.8 m/s2
Thermal Expansion Coef 0.00021 1/K
Jacket Length 13.79751169 M
Gr 9.98817E+13
Tank Diameter 2.395 M
h_in 43453.88644 W/m2°C
Tinitial 25 °C
Tfinal 30 °C
Tavg 27.5 °C
Flow Speed 1.7 m/s
Jacket Thickness 0.781686688 M
Re 1661084.211
Cp 4200 kJ/kgoC
Pr 5.064054258
h_out 3726.645474 W/m2°C
Jacket Thermal Conductivity 45 W/m.K
1/U 0.017662166
U 56.61819726 W/m2K
110
Table C. 19 Jacket Heat Transfer Rate (Seed Fermenter)
Jacket Heat Transfer Rate Unit

del_t1 8 °C
del_t2 5 °C
LMTD 6.382929436 °C
A 22.48423973 m2
23064.8753 W
Q
23.0648753 kW
Table C. 20 Jacket Heat Transfer Rate (Main Fermenter)
Jacket Heat Transfer Rate Unit

del_t1 8 °C
del_t2 5 °C
LMTD 6.382929436 °C
A 103.7788146 m2
37504.62145 W
Q
37.50462145 kW
8. Sparger Specification
For sparger design, the flowrate is calculated by the needs of the nitrogen to
fill the empty space of the tank to eliminate oxygen from the tank. Thus, the
flowrate is calculated by empty space per gas flushing time.
Table C. 21 Sparger Specification (Seed Fermenter)
Sparger Specification Unit

Volume 22383.042 L
Time 16 h
Flowrate 1398.940104 L/min
111
Table C. 22 Sparger Specification (Main Fermenter)
Sparger Specification Unit

Volume 226637.292 L
Time 48 h
Flowrate 4721.610243 L/min
112
APPENDIX D: Design Calculation of Purification Section
1. Crystallizer
To calculate the capacity of the crystallizer, we use a formula taken from
Myerson (2001) and obtain the volume of the crystallizer. Then, we calculate
the height and diameter of the crystallizer using the formula for cone volume
and straight side, also taken from Myerson (2001). We use approximation for
the height and diameter, then calculate the total volume from the sum of cone
volume and straight side, and match it to the volume obtained using Leva’s
formula. All the formulas used are provided below.
𝑀𝑎𝑠𝑠 𝐹𝑙𝑜𝑤 𝑅𝑎𝑡𝑒 × 𝑅𝑒𝑡𝑒𝑛𝑡𝑖𝑜𝑛 𝑇𝑖𝑚𝑒
𝑉𝑜𝑙𝑢𝑚𝑒 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = 𝑆𝑙𝑢𝑟𝑟𝑦 𝐷𝑒𝑛𝑠𝑖𝑡𝑦
𝐶𝑜𝑛𝑒 𝑉𝑜𝑙𝑢𝑚𝑒 = 0.2267 × (𝐴𝑝𝑝𝑟𝑜𝑥. 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟)3

𝜋
𝑆𝑡𝑟𝑎𝑖𝑔ℎ𝑡 𝑆𝑖𝑑𝑒 = (𝐴𝑝𝑝𝑟𝑜𝑥. 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟)2 × (𝐴𝑝𝑝𝑟𝑜𝑥. 𝐻𝑒𝑖𝑔ℎ𝑡)
4
𝑇𝑜𝑡𝑎𝑙 𝑉𝑜𝑙𝑢𝑚𝑒 = 𝐶𝑜𝑛𝑒 𝑉𝑜𝑙𝑢𝑚𝑒 + 𝑆𝑡𝑟𝑎𝑖𝑔ℎ𝑡 𝑆𝑖𝑑𝑒
2. Fluidized Bed Dryer

To calculate the minimum fluidizing rate of the fluidized bed dryer, we use
Leva’s formula taken from Walas (1990).
𝑮𝒎𝒇 = 688𝐷𝑝1.83 [𝜌𝑔 (𝜌𝑠 − 𝜌𝑔 )]0.94 /𝜇0.88
We also calculate the expanded bed ratio using a formula taken from Walas
(1990).
𝐺𝑓 = 2𝐺𝑚𝑓
0.22
𝐿 𝐺𝑔
( )=( )
𝐿0 𝐺𝑚𝑓
3. Ion Exchange
Resin Bed Design
This design formula is summarized by Intelligent (--).
𝑉𝑓 𝑉𝑓 𝑚𝑖𝑜𝑛
𝑉𝑏 = 𝐹𝐷 ( ) (𝑡𝐸𝐵𝐶 ) = 𝐹𝐷 ( ) = 𝐹𝐷 ( )
𝑡𝑝 𝑁𝑠 𝑊𝑏
𝑡𝑝 = 𝑁𝑠 (𝑡𝐸𝐵𝐶 )
Where,
113
FD = equipment’s overdesign factor
• VF = total feed volume per procedure cycle
• tp = breakthrough (process) time
• tEBC = empty-bed contact time
• Ns = service volume (expressed as number of bed volumes)
• mion = total mass of ions that bind to the resin(s) per procedure cycle
• Wb = resin binding capacity (expressed as mass of ions per bed volume)
Let assumed tEBC = 3 min (optimal range: 1.5 min – 7.5 min (Clifford, 1990)),
FD = 1.2. Therefore,
Vb = FD (VF/Ns) = 1.020848265 m
The refered resin material is Dowex 99-Ca2+ with denisity = 1,230 kg/m3 .
Hence, the required resin mass is 1,230 kg/m3×0.2676 m3 = 329.15 kg.
The height, hb and diameter, Db of the resin can be calculated as follow.
Vb = (1/4)(πDB )2(HB)
Dow (--) suggest that optimal hb/Db should be in range 2/3 to 3/2. Say
designed hb/Db = 1/1. Hence,
Vb = (1/4)(πDB )2(HB)
Db = [Vb/(1/4π)]1/3
hB = Db = 1.09133254 m
Vessel Design
The main consideration in vessel’s dimension design is that the vessel can properly
overcome the resin expansion when backwashing is performed (80%-- 100% bed
height (Dow, --)). With safety factor = 20%, the proposed vessel height, hv is
hv = (1 + 100% + 20%)hB = (220%)hB
hv = 2.4 m
Working Pressure
Working pressure, P = P0 + Ph
where P0 = atmospheric pressure = 1 atm = 1,013×105 Pa
114
Ph = hydrostatic liquid pressure = ρL .g. HL
From the simulator and calculation above, it is known that HL = 1.091 m.
Therefore,
P = P0 + P h
P = 16.195 psi
Construction Material Selection

Based on the work by Ada et al (2016), the good material for sugar mixture process
is SS 302. The properties of the material are listed below.
Table D. 1 Properties of SS 302 Material
Parameter Value
17%—19% Cr
Material Composition 8%—10% Ni
0.15% C
Maximum Allowable Stress 30,000 Psi = 205 MPa
In 149oC of nitric acid 10% = 5 mpy =
Corrosion Rate
0.13 mm/year
Peters et al. (2003), STAL
Cylindrical Shell Thickness

Cylindrical shell thickness,
tc = 𝑃𝑅 𝑆𝐸−0,6𝑃 + 𝐶𝑌
(Couper et al., 2012 with modification)
Where
tc = cylindrical shell thickness (in)
S = allowable stress (psi)
P = pressure (psig)
R = radius (cylindrical radius) (in)
E = joint efficiency (unitless)
C = corrosion rate (in/year)
Y = lifetime (year)
115
Reactor Head
For the head closure, standard torispherical heads (dished ends) are the most
commonly used and closure for vessels with operating pressures up to 15 bar
(Towler and Sinnott, 2007). Therefore, it is also used in this design. Torispherical
heads dimension aspects consist of th (head thickness), D (external head diameter),
KR (knuckle radii), CR (crown radii), SF (straight flange height), DH (dishing
height), and TH (total head height) as illustrated below.
Figure D. 1 Schematic of Torispherical Head
The formulas to calculate the parameters above are listed below (Towler and
Sinnott, 2007; Slawinski, ---)
• CR = D
• KR = 6% CR
• th = (0.885𝑃(𝐶𝑅)/ 𝑆𝐸−0,1𝑃 )+ 𝐶𝑌
• DH = 0.1935D – 0.455th
• SF = 3.5th
• TH = DH + SF
116
APPENDIX E: Design Calculation of Utility Equipments
1. Feed Water Storage Tank
Table E. 1 Feed Water Storage Tank Calculation
Tank Volume
Working Volume 351,42 m3
Void Percentage 15%
Total Volume 404,13 m3
Tank Dimension
Diameter (m) 8,01 m
Height of Shell (Hs) (m) 8,01 m
Height Tank (Ht) (m) 9,57 m
Pressure Design
Height of Fluid 6,97 m
Total Density 997,00 kg/m3
Hydrostatic Pressure 68094,00 Pa
Hydrostatic Pressure 0,67 atm
Operational Pressure 1,00 atm
Pressure Abs 1,67 atm
Pressure Design 1,84 atm
Shell Thickness
Pressure Design 27,03 psi
Shell Diameter 315,54 in
Allowable Stress (S) 20000,00 psi
Efficiency (E) 85%
Corrosion Factor (C) 0,003 in/year
Shelf Life (A) 15 year
0,30 in
Shell Thickness 0,008 m
7,52 mm
Diameter (D) 315,54 in
Crown Radius (CR) 315,54 in
Knuckle Radius (KR) 31,55 in
Allowable stress (S) 20000,00 psi
Efficiency (E) 85%
Head Thickness (th) 0,05 in
Dishead Height (DH) 61,04 in
Straight flange height (SF) 0,16 in
61,20 in
Total Height (TH)
1,55 m
117
2. Clarifier
Up flow clarifiers have water depth of 3 – 10 m and settling time of 1 –
3 hours (Metcalf, 1984). Settling time of 1,5 hours is chosen for the design.
The clarifier tank volume can be determined based on the fluid volume and the
leeway factor of the tank. In this case, the leeway factor is 20%.
Table E. 2 Clarifier Calculation
Tank Volume
Settling Time 1,50 jam
Leeway Factor 20%
Clarifier Volume (Vc) 126,51 m3
Clarifier Diameter (Dc) 4,75 m
Cylinder Diameter and Height
Cylinder Diameter (Ds) 4,75 m
Cylinder Height (Hs) 6,34 m
Cylinder Volume (Vs) 112,45 m3

Cone Diameter and Height
Cone Diameter (Dc) 4,75 m
Cone Height (Hc) m

2,38
Cone Volume (Vc) 14,06 m3
Clarifier Height and Volume
Clarifier Volume 126,51 m3
Clarifier Height 8,72 m
Agitation Power
Agitation Power 0,135601589 kW
118
3. RO Filtration
The calculation steps are based on Filmtec RO Membranes Technical Manual
by DuPont.
1. Consider feed source, feed quality, feed flow rate, and permeate flow rate
requirement.
2. Select flow configuration and number of passes.
3. Select membrane element type.
4. Select membrane active surface area and average membrane flux.
5. Calculate the number of elements needed.
𝑄𝑃
𝑁𝐸 =
𝑓 × 𝑆𝐸
6. Calculate number of pressure vessels needed.
𝑁𝐸
𝑁𝑣 =
6
7. Select number of stages.
8. Select the staging ratio.
1
1 𝑛
𝑅=[ ]
(1 − 𝑌)
119
4. Sanitation Water Storage Tank
Table E. 3 Sanitation Water Storage Tank Calculation
Tank Volume
Void Percentage 15%
Tank Dimension
Diameter (m) 0,47 m
Pressure Design
Shell Thickness
Efficiency (E) 85%
0,05 in
1,37 mm
Diameter(D) 18,45 in
Crown Radius(CR) 18,45 in
Knuckle Radius(KR) 1,85 in
Efificiency ( E ) 85%
3,71 in
Total Height (TH)
0,09 m
120
5. Pure Water Storage Tank
Table E. 4 Pure Water Storage Tank Calculation
Tank Volume
Leeway Factor 15%
Actual Volume 400,03 m3
Tank Dimension
Diameter (m) 7,99 m
Pressure Design
Fluid height in tank 6,95 m
Hydrostatics Pressure 67862,57 Pa
Hydrostatics Pressure 0,67 atm
Operation Pressure 1,00 atm
Shell Thickness
Efficiency (E) 85%
0,29 in
7,49 mm
Efisiensi (E) 85%
60,99 in
Total Height (TH)
1,55 m
121
6. Sediment Storage Tank
Table E. 5 Sediment Storage Tank Calculation
Tank Volume
Void Percentage 15%
Tank Dimension
Diameter (m) 1,51 m
Pressure Design
Shell Thickness
Efficiency (E) 85%
0,08 in
2,13 mm
Efficiency (E) 85%
11,63 in
Total Height (TH)
0,30 m
Saddle
Tank Diameter 59,38 in
38.000 pound
17236,496 kg
Operating Weight 7.006 kg
122
Table E. 5 Sediment Storage Tank Calculation (Cont’d)
Saddle
A 54 in
B 39 in
C in
D 0,5 in
E 23 in
F 6 in
G 0,25 in
H 25 in
7. Cooling Tower
Calculation of cooling tower is shown below.
1. Determine the water temperature inlet (Tin) and water temperature outlet
(Tout). Based on the simulation using SuperPro Designer from previous
assignment, Tin of feed water is 35℃ and Tout of cooling water is 25℃.
2. The water loss from evaporation:
1
0.85 × 100 × ∆𝑇
𝑊𝑒 = × 𝑐𝑖𝑟𝑐𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑓𝑙𝑜𝑤
10
Where ∆𝑇 is the temperature difference between water inlet and outlet.
Rate of evaporation is approximately 1% of the circulation flow for each
10°F (5.56°C) of rise between the outlet and inlet across the tower. A
correction is needed for factors such as wind, relative humidity, etc.
Factor of 0.85 works out to be reasonable approximation.
3. Drift is entrained water in the tower discharge vapours. This plant assumed
the water loss from drift loss is 0.2%.
𝑊𝑑 = %𝑑𝑟𝑖𝑓𝑡 𝑙𝑜𝑠𝑠 × 𝑐𝑖𝑟𝑐𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑓𝑙𝑜𝑤
4. Water losses from blow down depend on the amount of cooling water cycle,
usually between 3 – 5 cycles. This plant assumed 4 cycles.
𝑊𝑒
𝑊𝑏 =
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑦𝑐𝑙𝑒𝑠 − 1
5. The total makeup cooling water required:
𝑚𝑎𝑘𝑒𝑢𝑝 𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑤𝑎𝑡𝑒𝑟 = 𝑊𝑒 + 𝑊𝑑 + 𝑊𝑏
123
Table E. 6 Makeup Water Calculation
Determine Tin and T out

Tin 35 ºC
Tout 25 ºC
ΔT 10
Cooling Water Balance
634,809 kg/h
Flowrate
10,792 L/min
% drift loss 0.2%
Cooling water cycle 4
Water loss from evaporation (We) 5,396 kg/h
Water loss from drift (Wd) 1,270 kg/h
Water loss from blow down (Wb) 1,799 kg/h
Make up cooling water 8,464 kg/h
8. Boiler
This boiler uses natural gas as fuel to generate steam. The only designed data
are furnace width and depth. The calculation steps are based on “Boilers and
Burners: Design and Theory” by Basu et al. (2000).
1. Determine the volume of the furnace.
𝑚𝑐 𝐿𝐻𝑉
𝑞𝑣 =
𝑉
Where mc is the design fuel consumption rate and LHV is lower heating
value of natural gas. The value of qv or volumetric heat release rate can be
determined through the rule of thumb as follow.
Table E. 7 Typical Values of Volumetric Heat Release Rate (qv) in MW/m3
124
(source: Basu et al., 2000)
2. Determine Hfu + Hb and heat transfer area in boiler (Fgrate).

𝑞𝐹 =
𝐹𝑔𝑟𝑎𝑡𝑒
The value of qF or heat release rate per unit cross sectional area can be
determined through the following table.
Table E. 8 Upper Limits of qF
3. Determine furnace width (a) and furnace depth (b).

𝑞𝑏 =
2(𝑎 + 𝑏)𝐻𝑏
The value of qb or heat release rate per unit wall area of the burner region
in most process is 0.3 – 4.4 MW (Platvoet & Baukal, 2013).
125
Figure E. 1 A Schemating of An Oil, Gas, or Pulverized Coal Fired Furnace
9. First Clarifier in Wastewater Treatment

Table E. 9 First Waste Water Clarifier Calculation
Volume Tank
Settling Time 1,50 h
Leeway Factor 20%
Volume Clarifier (Vc) 89,81 m3
Diameter Clarifier (Dc) 4,24 m
Cylinder diameter (Ds) 4,24 m
Cone Height (Hc) 2,12 m
Clarifier Volume and Height
Agitator Power
Agitator Power 0,107906979 kW
126
10. Second Clarifier in Wastewater Treatment
Table E. 10 Second Waste Water Clarifier Calculation
Volume Tank
Settling Time 1,50 h
Leeway Factor 20%
Volume Clarifier (Vc) 48,35 m3
Diameter Clarifier (Dc) 3,45 m
Cylinder diameter (Ds) 3,45 m
Cone Height (Hc) 1,72 m
Clarifier Volume and Height
Agitator Power
Agitator Power 0,071408583 kW
11. Compressor
Calculation of compressor is shown below.
1. Find out physical properties of the stream and other information needed in
the calculation, such as pressure inlet, pressure outlet, temperature inlet,
compressibility factor, and flow rate.
2. Determine the type of the compressor using general range of application of
compressor graph below.
127
Figure E. 2 Compressor Types and Application Conditions
(source: Hoopes et al., 2019)
3. Calculate the specific gravity (SG) and isentropic heat capacity ratio.
𝑀𝑊𝑔𝑎𝑠
𝑆𝐺 =
𝑀𝑊𝑎𝑖𝑟
𝛾 = 1.3 − (0.31)(𝑆𝐺 − 0.55)
4. Calculate the isentropic enthalpy change (head).
𝛾−1⁄
𝑇1 𝑍𝑎 𝑅 𝑃2 𝛾
∆ℎ = [( ) − 1]
𝛾 − 1⁄ 𝑃1
( 𝛾)(𝑀𝑊)
5. Calculate the isentropic efficiency.
𝛾−1⁄
𝑃 𝛾
(𝑃2 ) −1
1
𝐸𝑖𝑠𝑒𝑛 = 𝑛−1⁄
𝑃 𝑛
(𝑃2 ) −1
1
6. Calculate the actual flowrate and compression power (kW/stage).

3
𝑠𝑡𝑑 𝑚 ⁄𝑑 𝑃2 𝑇2
𝑞=( ) ( ) ( ) 𝑍𝑎
86400 𝑃1 𝑇1
𝛾−1⁄
𝑘𝑊 𝐴 𝛾 𝑃2 𝑃2 𝛾
= ( )( ) (𝑞) ( ) (𝑇1 ) [( ) − 1] (𝑍𝑎 )
𝑠𝑡𝑎𝑔𝑒 𝐸 𝛾−1 𝑃1 𝑃1
7. Calculate the diameter of impeller and compressor speed.
128
𝑞
𝑑=√
0.050 𝑢
60 𝑢
𝑁=
𝑑𝜋
8. Determine loss factor.
Table E. 11 Loss Factor According to Flow Rate
9. Calculate mechanical losses and total power.

𝑁 2
𝑊𝐿 = 𝐹𝐿 ( )
1000
𝑘𝑊
𝑇𝑜𝑡𝑎𝑙 𝑃𝑜𝑤𝑒𝑟 = + 𝑊𝐿
𝑠𝑡𝑎𝑔𝑒
10. Calculate compression ratio.
𝑃𝑑
𝑅=
𝑃𝑠
11. Choosing a one-stage or two-stage compressor using rule of thumb below.
Table E. 12 Rule of Thumb for Choosing Compressor Number of Stages
(source: Blackmer Inc., 2017)
12. Pump
Here is the explanation of how to calculate the pump technical aspects in
our plant. Technical aspects which are in concern in pump are head, power,
efficiency, NPSHa, and NPSHr. These technical aspects are vital to concern
because they are required for determining pump specification when the pump is
129
ordered from supplier. Thus, a slightly differences in plant system can affect the
pump works.
Before starting the calculation, some data are collected which are flow rate,
room pressure, pipe length, pressure in and pressure out, density, and temperature.
Pipe length is estimated based on plant area which has been decided in Assignment
1. After collecting these data, the power of the pump can be estimated by these
steps:
a) Step 1: determine the pressure difference between inlet and outlet flow
∆𝑃 = 𝑃𝑜𝑢𝑡 − 𝑃𝑖𝑛
b) Step 2: calculate height differences between the suction height and discharge
height
∆𝐻 = 𝐻𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒 − 𝐻𝑠𝑢𝑐𝑡𝑖𝑜𝑛
c) Step 3: calculate Friction Horse Power (FHP)
𝐹𝐻𝑃 = (∆𝑃𝜌 + 𝑔∆𝑧 + 𝐹). 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒
d) Step 4: calculate the Break Horse Power (BHP)
𝐵𝐻𝑃 = 𝐹𝐻𝑃. 𝜂
e) Step 5: calculate head and actual head
𝐹𝐻𝑃
𝐻𝑒𝑎𝑑 =
𝑔 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒
f) Step 6: calculate Net Positive Suction Head required (NPSHr)
𝑃𝑖𝑛 − 𝑃𝑣𝑎𝑝
𝑁𝑃𝑆𝐻𝑟 =
𝜌𝑔
g) Step 7: calculate Net Positive Suction Head actual (NPSHa)
𝐹
𝑁𝑃𝑆𝐻𝑎 = 𝑁𝑃𝑆𝐻𝑟 + 𝐻𝑠𝑢𝑐𝑡𝑖𝑜𝑛
𝑔
Making assumptions are important to make the calculation comprehensive

and reasonable. These assumptions which are used in this calculation are:
• Velocity difference for inlet and outlet is so small so it can be neglected
• Pump efficiency is about 75 %
• No fitting
130
APPENDIX F: Mechanical Drawing of Equipment
131
PRE-TREATMENT
HYDROLYSIS REACTOR (R-101)
MECHANICAL DRAWING
CHEMICAL ENGINEERING
ENGINEERING FACULTY
PLANT DESIGN COURSE SIZE FSCM NO DWG NO REV
GROUP BIO 05 SCALE 1:20 SHEET 1 OF 6
Figure F. 1 Acid Hydrolysis Reactor Mechanical Drawing
132
Figure F. 2 Seed Fermenter Mechanical Drawing
133
Figure F. 3 Main Fermenter Mechanical Drawing
134
BOILER (B-601)
MECHANICAL DRAWING
CHEMICAL ENGINEERING
ENGINEERING FACULTY
PLANT DESIGN COURSE SIZE FSCM NO DWG NO REV
GROUP BIO 05 SCALE 1:20 SHEET 4 OF 6
Figure F. 4 Boiler Mechanical Drawing
135
Figure F. 5 Dryer Mechanical Drawing
136
Figure F. 6 Ion Exhange Mechanical Drawing
137

Assignment 2 - BIO 05 - Report

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86

PRODUCTION OF L-GLUTAMIC ACID BY FERMENTATION

CHEMICAL ENGINEERING DEPARTMENT

iii Universitas Indonesia

4 CHAPTER IV PURIFICATION SECTION............................................. 28

CR-301 to DR-301 Screw Conveyor (SC-301) .............................. 37

5 CHAPTER V UTILITY EQUIPMENT .................................................... 39

Clarifier (CL-401) ........................................................................... 40

GM Filtration (F-401) ..................................................................... 41

RO Filtration (F-402) ...................................................................... 41

Sanitation Water Storage Tank (TK-402) ....................................... 42

Pure Water Storage Tank (TK-403) ................................................ 43

Sediment Storage Tank (TK-404) ................................................... 44

Cooling Water and Chilled Water Process ............................................. 45

Cooling Water Storage Tank ........................................................... 46

Steam Generation ................................................................................... 47

Wastewater Treatment ............................................................................ 50

Fuel Tank ........................................................................................ 53

vii Universitas Indonesia

viii Universitas Indonesia

Molasses Storage Vessel

Ammonium Hydroxide Storage Vessel

Table 1. 2 NH4OH Storage Vessel Specifcation

NH4OH Storage Vessel

Nutrients Storage Vessel

Nutrients Storage Vessel

Table 1. 3 Nutrients Storage Vessel (Cont’d)

H2SO4 0.1 M Storage Vessel

H2SO4 Storage Vessel

Table 1. 4 H2SO4 0.1 M Storage Vessel (Cont’d)

NaOH 0.1 M Storage Vessel

NaOH 0,1M Storage Vessel

Table 1. 5 NaOH 0.1M Storage Vessel (Cont’d)

HCl Storage Vessel

HCl 1M Storage Vessel

Table 1. 6 HCl 1M Storage Vessel (Cont’d)

Unpurified Product Storage Vessel

Unpurified Product Storage Vessel

Table 1. 7 Unpurified Product Storage Vessel (Cont’d)

Final Product Storage Vessel

Final Product Storage Vessel+B20

Table 1. 8 Final Product Storage Vessel (Cont’d)

Table 2. 1 Hydrolysis Reactor (R-101) Equipment Specification (cont’d)

Rotary Vacuum Filter

Table 2. 2 Rotary Vacuum Filter (F-101) Equipment Specification (Cont’d)

Table 2. 3 Mixer Tank (MX-101) Equipment Specification (Cont’d)

Table 2. 4 Pump (P-101) Equipment Specification (Cont’d)

Table 2. 5 Pump (P-102) Equipment Specification

Table 2. 6 Pump (P-103) Equipment Specification

Table 2. 7 Pump (P-104) Equipment Specification

Table 2. 7 Pump (P-104) Equipment Specification (Cont’d)

Table 2. 8 Pump (P-105) Equipment Specification

Table 2. 9 Pump (P-106) Equipment Specification

Table 2. 9 Pump (P-106) Equipment Specification (Cont’d)

Seeding Fermentation Reactor

Table 3. 3 Seed Fermenter Specification

Table 3. 3 Seed Fermenter Specification (Cont’d)

Main Fermentation Reactor

Table 3. 4 Main Fermenter Specification

Table 3. 4 Main Fermenter Specification (Cont’d)

Table 3. 4 Main Fermenter Specification (Cont’d)

Table 3. 5 Pump (P-201) Specification (Cont’d)

Table 3. 6 Pump (P-202) Specification