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Plant Design

The document describes a project to design an ethanol production plant from molasses. It includes: 1) An outline of the project with problem statement, objectives, process flow diagram, equipment sizing, and economic analysis. 2) Details of the general and specific objectives, which are to design the plant and processes to maximize profit. 3) The process flow, which involves mixing molasses and water, fermentation with yeast, and distillation to produce ethanol.

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etayhailu
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1K views20 pages

Plant Design

The document describes a project to design an ethanol production plant from molasses. It includes: 1) An outline of the project with problem statement, objectives, process flow diagram, equipment sizing, and economic analysis. 2) Details of the general and specific objectives, which are to design the plant and processes to maximize profit. 3) The process flow, which involves mixing molasses and water, fermentation with yeast, and distillation to produce ethanol.

Uploaded by

etayhailu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
  • Statement of Problem
  • Objectives
  • Process Flow
  • Equipment Sizing
  • Economic Analysis
  • Profit Analysis
  • Conclusion
  • Recommendation

ADIGRAT UNIVERSITY

COLLEGE OF ENGINEERING &TECHNOLOGY


DEPARTMNT OF CHEMICAL ENGINEERING

PROJECT ON: ETHANOL PRODUCTION FROM


MOLASSES
GROUP MEMBERS ID NO
1. ALEMTSHAY H/KIROS 0111/06
2. ETAY HAILU 0457/06
3. KIROS G/MEDHIN 0937/06
4. LETU DESALEGN 0969/06
5. LICHIYA ALEM 0971/06
6. MERESA HILUF 1083/06
7. NGUS DEGU 1215/06
8. ZERAY G/SLASSIE 1703/06
Out line for our project
Problem statement of the project
Objective of the project
General objective
Specific objective

Flow diagram of ethanol production


 Equipment sizing
Economic analysis
Statement of problem
Ethanol is an alcoholic beverage that is usually needed by the people.
But in many reasons it cannot be found abundantly or in excess form. As
a result, the demand descends that is supply of the production is
decreased. Most of the time ethanol is produced from sugars, and other
vegetables. However, this method is somewhat costly and tired some.
Comparing that, ethanol production from molasses (byproduct of sugar)
by yeast is cheap and profitable. And it is a more environmental friend
than of petrol and other fuels .For this reason, we want to solve the
problem using the intermediate sugar molasses by yeast to grow the
supply of the product for the community. To maximize the profit of sugar
factories design of ethanol production from molasses plant is mandatory.
Objectives
 General objective
To design plant for production of ethanol from molasses

 Specific Objectives
To design equipment’s used to produce ethanol from molasses.
To make material and energy balance for the whole process of ethanol
production
Showing process flow diagram, process flow description of ethanol
production from molasses
To perform economic analysis for the plant and to recommend
preferable plant location
Process flow of molasses ethanol production

yeast
SIZING OF MAJOR EQUIPMENTS
 Sizing of molasses storage tank
 Sizing of water storage tank
 Sizing of mixer
 Sizing of Fermenter
 Sizing of ethanol Storage tank
 Sizing of distillation column
 column
 Pump for delivering of water
COST ESTIMATION
Total Capital Investment (TCI)
 Total purchased equipment cost
Equipment name Quantity Capacity Unit price ($) Total price ($)

Sugar molasses storage tank 1 284m3/day 17,121 17,121

Water Storage Tank 2 5.6m3/day 6,070 12,140


Fermenter 2 755m3/batch 11,500 23,000

Distillation 1 21m3/hr 7,000 7,000


Molecular sieve 1 45.27kg/hr 5,584 5,584

Ethanol St. Tank 1 0.6m3/week 6,059 6,059


Centrifugal pump 2 0.004m3/s 2,450 4,900

Total purchased equipment cost 75804


 Estimation cost of direct, indirect and fixed capital
investment
Direct cost (DC) Factor Cost (ETB)
Purchased equipment 1 2046697.13
Purchased equipment installation 0.47 961947.65
Instrumentation and control 0.18 368405.48
Piping (installed) 0.66 1350820.12
Electrical( installed) 0.11 225136.68
Building 0.18 368405.48
yard improvement 0.1 204669.71
Service facilities 0.3 614009.14
Land 0.06 122801.83
Total plant direct cost (TPDC) =Σ DC 6262893.22
Indirect cost (IDC) Factors Cost (ETB)
Engineering and supervision 0.33 675410.05
Construction and expense 0.41 839145.82
Contractors fee (CF) 0.21 429806.4
Contingency (C) 0.40 818678.85
Indirect cost (IDC) = ΣID 2763041.12
From the above table we can calculate the total capital
investment
TCI=FCI+WC
but WC= (10-20) % TCI
TCI =FCI+0.15TCI
TCI = FCI/0.85
TCI =9025934.34 /0.85,
TCI= 10,786,093.87 Birr
Manufacturing cost
 Variable Operating Costs
Item Cost (ETH
Birr)
Raw materials 0.5Birr/kg*10968 5484060
120kg
1 Operating labor(L) 84*1200*12 1209600
2 Direct supervisors and 0.1L 120960
clerical labor
3 Utilities(electric & water 217573 + 18901 236474
cost)
4 Maintenance and repair 0.06FCI 541556.06
5 Operating supplies 0.01FCI 90259.34
Total direct production cost = 7682906.4
 Fixed Operating Costs

S. No Items Cost (ETH


Birr)
1 Depreciation 0.1FCI 902593.43
2 Local taxes 0.02FCI 180518.69
3 Insurance 0.005FCI 45129.67
4 Rent 0.08(land + 39296.58
building)
Total fixed charges 1167538.37
 Plant overhead cost

S. No Item Cost
(ETH
Birr)
1 Plant overhead 2*8000*12 192000
cost

Manufacturing cost = variable + fixed operating cost + plant


overhead cost
= 7682906.4 + 1167538.37+ 192000
= 9,042,444.77 Birr
Total production cost
 General expense

S. No Item Cost(ETH Birr)

1 Administrative cost 0.5L = 0.5*1209600 604800

2 Distribution and sell cost 0.2L = 0.2*1209600 241920

Total general 846720


expense

Total production cost = manufacturing cost + general expense


= 9042444.77 + 846720
= 9889164.77
TPC = 9,889,164.77 Birr
Profit analysis
 Net income
Annual revenue = 6*3000000
= 18000000Birr
Total production cost = 9889164.77Birr
Gross annual profit = 18000000 - 9889164.77Birr
= 8110835.23Birr
Income tax on gross profit (35%) = 0.35*8110835.23
= 2433250.57Birr
Net income = 8110835.23- 2433250.57
= 5,677,584.66Birr
Percent profit
% profit = 57.41%
 Percent rate of return
% ROR = 52.64%
 Payback period
Payback period =1.37years
So, the payback period of the project is estimated to be 2years
CONCLUSION
The molasses that contains much enough sugar content biomass are
mixed with water to their component sugars for subsequent
conversion to ethanol by a fermentation process. Molasses are
usually treated with a chemical process (acid) or biological
(enzyme) to remove the impurity. Ethanol was produced molasses
through the process of fermentation, distillation and dehydration
using molecular sieve respectively. In ethanol plant distillation
column is the major equipment from the design part. Since the cost
estimation and cost analysis are acceptable the design is feasible.
RECOMMENDATION
Based on the project that we have done the following
recommendations are given:
 Further researches have to be carried out to increase the yield of
ethanol from molasses by use other microorganisms which are
capable of converting 5- and 6- carbon sugar into ethanol.
 Optimization of fermentation and distillation processes are
recommended to maximize the yield of ethanol from molasses.
Molasses is rich in sugar content, due to this reason further
research is required to utilize this largely available by-product
molasses
Detailed economic feasibility studies in the production process
are recommended, since it is critical for the rationale of
commercialization.

WELL COME TO OUR PRESETATION!
ADIGRAT UNIVERSITY COLLEGE OF ENGINEERING &TECHNOLOGY DEPARTMNT OF CHEMICAL ENGINEERING PROJECT ON: ETHANOL PRODUCTION FROM
GROUP MEMBERS ID NO 1. ALEMTSHAY H/KIROS 011
Out line for our project Problem statement of the project Objective of the project General objective Specific objectiv
Statement of problem Ethanol is an alcoholic beverage that is usually needed by the people. But in many reasons it cannot be
Objectives General objective To design plant for production of ethanol from molasses Specific Objectives To design equipmen
Process flow of molasses ethanol production yeast
SIZING OF MAJOR EQUIPMENTS Sizing of molasses storage tank Sizing of water storage tank Sizing of mixer Sizing of Ferme
COST ESTIMATION Total Capital Investment (TCI) Total purchased equipment cost Equipment name Quantity Capacity Unit pric

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