PRODUCTIONOF60000MTPAOFOLEOCHEMICALMETHYLESTERFROMRBDPALMKERNELOIL

PRODUCTION OF 60,000 MTPA OF
OLEOCHEMICAL METHYL
ESTER FROM RBD PALM KERNEL
OIL
By
SAJJAD KHUDHUR ABBAS P81540
AIMAN MOHAMMED BELAL P81535
SITI IRHITH BUSHRAH P81536
WAN ADEEBAH P81526
A design project submitted to the Faculty of Engineering and Built Environment

in partial fulfilment of the requirements for Design of Chemical Processes
computer aided Class KKKK6014
Faculty of Engineering and Built Environment

The National University of Malaysia
DECEMBER 2015
Supervisors
PROF. DATO' IR. DR. WAN RAMLI BIN WAN DAUD
DR. NOR YULIANA BINTI YUHANA

Dr. DARMAN BIN NORDIN
The National University of Malaysia
Faculty of Engineering and Built Environment
The undersigned certify that they have read, and recommend to the Faculty of
Chemical and Natural Resources Engineering for acceptance, a design project
entitled Production of 60,000 MTPA of Oleochemical Methyl Ester from RBD
Palm Kernel Oil submitted by
SAJJAD KHUDHUR ABBAS P81540

AIMAN MOHAMMED BELAL P81535
SITI IRHITH BUSHRAH P81536
WAN ADEEBAH P81526
A design project submitted to the Faculty of Engineering and Built Environment

in partial fulfilment of the requirements for Design of Chemical Processes
computer aided Class KKKK6014
______________________________
DR. NOR YULIANA BINTI YUHANA

EXECUTIVE SUMMARY
The design project of the plant producing 60,000 MTPA of combined Methyl Ester products,
namely methyl octanoate/decanoate (CE-810), methyl laurate/myristate (CE-1214), and
methyl palmitate/oleate (CE-1618), is conducted since September 2014. To acquire a good
understanding of the process capability, this design project therefore involves a review on
product introduction, applications, market surveys, synthesis route screening, conceptual
design and feasibility study of the process for generating a process instrumentation and flow
diagram, detail unit and equipment sizing, and economic analysis that can be outlined as
follows:-
Chapter 1: To review the application of methyl ester products and survey its market (supply
and consumption) so that a feasible rate of methyl ester production can be deduced. A
discussion regarding the justification of choosing RBD palm kernel oil as raw material is also
outlined. The existing process related to the methyl ester production was subsequently
elaborated which consists of synthesis route screening, possible unit operations for respective
sections of the process and eventually the level 1 decision on the mode of operation based on
the production capacity and the nature of synthesis route.
Chapter 2: To conceptually design a feasible process flowsheet through hierarchical steps of

decisions from level 2 to level 4. Material and balance will simultaneously be analyzed and
calculated starting from level 2 and level 3, respectively, until level 4 along with the
engineering decisions made based on the heuristics and algorithm. Economic potential of the
level decisions by following the Douglas‘s method will be employed here in order to optimize
the process flow structures considering the costs those are incurred by expensive materials
and major operation units. Level 2 is to decide the structures of input and output flows
whereas Level 3 is to decide the optimum conversion and reactor operating conditions and
decision making on whether to recycle the raw material based on justifications. The process
flow diagram is then drawn to illustrate the flowsheet of the process at Level 4. This level is
then continue with the process simulation by using Aspen Plus software and finally results
comparison between the manual and results obtained from Aspen.
IV
TABLE OF CONTENTS
ACKNOWLEDGEMENT ....................................................................................................... III

EXECUTIVE SUMMARY ...................................................................................................... IV
TABLE OF CONTENTS .......................................................................................................... V
LIST OF FIGURES ................................................................................................................... X
LIST OF TABLES ................................................................................................................ XIII
LIST OF ABBREVIATIONS .............................................................................................. XVII
1 CHAPTER 1 ....................................................................................................................... 1
1.1 INTRODUCTION ....................................................................................................... 1
1.1.1 Oleochemicals ...................................................................................................... 1
1.1.2 Methyl Esters........................................................................................................ 2
1.1.3 Feedstocks ............................................................................................................ 6
1.1.4 Advantages of Methyl Esters ............................................................................... 8
1.2 APPLICATION OF PRODUCTS ............................................................................. 10
1.2.1 FAME as Biodiesel ............................................................................................ 10
1.2.2 FAME as Raw Materials for Other Products ..................................................... 11
1.2.3 Methyl Octanoate/Decanoate (Light Cut: C8-10) .............................................. 12
1.2.4 Methyl Laurate/Myristate (Middle Cut: C12-14)............................................... 13
1.2.5 Methyl Palmitate/Oleate (Heavy Cut: C16-18) .................................................. 13
1.2.6 Glycerine ............................................................................................................ 13
1.3 MARKET SURVEY ................................................................................................. 15
1.3.1 Production & Demand ........................................................................................ 15
1.3.2 Market Price ....................................................................................................... 18
1.3.3 Availability of Raw Material.............................................................................. 19
1.3.4 Competitors ........................................................................................................ 23
1.3.5 Methyl Esters Prospect ....................................................................................... 23
1.4 SCREENING OF SYNTHESIS ROUTE .................................................................. 25
1.4.1 Alkali/Base-catalyzed Transesterification.......................................................... 25
1.4.2 Acid-catalyzed Transesterification ..................................................................... 26
1.4.3 Non-catalytic Transesterification ....................................................................... 27
1.4.4 Enzymatic Transesterification ............................................................................ 30
1.4.5 Screening of Catalyst Types ............................................................................... 32
1.4.6 Selection of Synthesis Route .............................................................................. 33
1.4.7 Catalyst Options ................................................................................................. 34
1.5 OBJECTIVES ............................................................................................................ 37
1.6 LEVEL 1 DECISION ................................................................................................ 37
1.6.1 Economic Potential 1 (EP1) ............................................................................... 38
2 CHAPTER 2 ..................................................................................................................... 41
2.1 LEVEL 2 DECISION ................................................................................................ 41
2.1.1 Input: Raw Material Selection and Impurities Management ............................. 41
2.1.2 Output Materials Determination and Decision of Their Destinations ................ 43
2.1.3 Kinetic Data of Alkali-catalyzed Transesterification Process ............................ 44
2.1.4 Mole Balances in Terms of Extent of Reaction ................................................. 46
2.1.5 Yield and Reaction Stoichiometry ..................................................................... 47
2.1.6 Selectivity ........................................................................................................... 50
V
2.1.7 Material Balances for Level 2 Decision ............................................................. 50
2.1.8 Economic Potential 2 ......................................................................................... 52
2.2 LEVEL 3 DECISION ................................................................................................ 55
2.2.1 Block Flow Diagram .......................................................................................... 55
2.2.2 Mole Balances .................................................................................................... 56
2.2.3 Reactor Design ................................................................................................... 57
2.2.4 Reactor Heat Effect ............................................................................................ 64
2.2.5 Equipment Cost .................................................................................................. 69
2.2.6 Catalyst Cost ...................................................................................................... 72
2.2.7 Economic Potential 3 ......................................................................................... 73
2.2.8 Material Balances for Level 3 Decision ............................................................. 75
2.2.9 Energy Balances for Level 3 Decision ............................................................... 76
2.3 LEVEL 4 DECISION ................................................................................................ 79
2.3.1 Separation Decision............................................................................................ 79
2.3.2 Process Flow Diagram ....................................................................................... 83
2.3.3 Material Balance ................................................................................................ 91
2.3.4 Energy Balance ................................................................................................ 133
2.4 ASPEN PLUS SIMULATION ................................................................................ 138
2.4.1 Material Balance Comparison .......................................................................... 139
2.4.2 Production Rate Comparison ........................................................................... 140
2.4.3 Stream Energy Balance Comparison................................................................ 141
2.4.4 Reactor Energy Balance Comparison .............................................................. 142
2.4.5 Pump Energy Balance Comparison.................................................................. 143
2.4.6 Heat exchanger Energy Balance Comparison .................................................. 144
3 CHAPTER 3: EQUIPMENT SIZING ........................................................................... 145
3.1 INTRODUCTION ................................................................................................... 145
3.2 MAJOR EQUIPMENT SIZING ............................................................................. 145
3.2.1 Reactors ............................................................................................................ 145
3.2.2 Decanter ........................................................................................................... 148
3.2.3 Distillation Columns ........................................................................................ 149
3.2.4 Flash Drums ..................................................................................................... 151
3.3 MINOR EQUIPMENT SIZING .............................................................................. 153
3.3.1 Storage Tanks ................................................................................................... 153
3.3.2 Pumps ............................................................................................................... 155
3.3.3 Mixers............................................................................................................... 156
3.3.4 Heat exchangers ............................................................................................... 157
3.3.5 Boiler ................................................................................................................ 161
3.3.6 Steam Turbine .................................................................................................. 161
3.4 ECONOMIC POTENTIAL 4 .................................................................................. 162
4 CHAPTER 4: UTILITIES & HEAT INTEGRATION .................................................. 163
4.1 HEAT INTEGRATION .......................................................................................... 163
4.1.1 Introduction ...................................................................................................... 163
4.1.2 Pinch Technology ............................................................................................. 163
4.1.3 Process Flow of Pinch Analysis ....................................................................... 164
4.1.4 Heat Recovery Analysis ................................................................................... 172
4.2 UTILITIES .............................................................................................................. 173
4.2.1 Electricity ......................................................................................................... 173
VI
4.2.2 Cooling Water .................................................................................................. 175
4.2.3 Steam ................................................................................................................ 176
4.2.4 Refrigerant ........................................................................................................ 177
5 CHAPTER 5: PROCESS CONTROL & SAFETY ....................................................... 178
5.1 INTRODUCTION ................................................................................................... 178
5.1.1 General Safety Procedure ................................................................................. 178
5.1.2 Chemical Storage ............................................................................................. 178
5.1.3 Transportation .................................................................................................. 179
5.1.4 Permit Procedures ............................................................................................ 180
5.1.5 General Workers Safety ................................................................................... 180
5.1.6 Emergency Response Plan ............................................................................... 182
5.1.7 Waste Disposal Operation ................................................................................ 183
5.2 MATERIAL SAFETY DATA SHEET (MSDS) .................................................... 184
5.2.1 MSDS for Methanol ......................................................................................... 185
5.2.2 MSDS for Sodium Methoxide Solution ........................................................... 192
5.2.3 MSDS for RBD Palm Kernel Oil ..................................................................... 198
5.2.4 MSDS for Methyl Octanoate/Decanoate (CE-810) ......................................... 201
5.2.5 MSDS for Methyl Laurate/Myristate (CE-1214) ............................................. 207
5.2.6 MSDS for Methyl Palmitate/Oleate (CE-1618) ............................................... 213
5.2.7 MSDS for Glycerin .......................................................................................... 218
5.3 DOW, FIRE & EXPLOSION INDEX .................................................................... 224
5.4 TOXICITY INDEX ................................................................................................. 224
5.5 MAJOR EQUIPMENT CONTROL........................................................................ 224
5.6 HAZOP & SAFETY SUMMARY .......................................................................... 225
5.6.1 Definitions of Keywords in HAZOP ................................................................ 226
5.6.2 Usage of HAZOP ............................................................................................. 226
5.6.3 HAZOP Methodology ...................................................................................... 228
5.6.4 Analysis of Main Findings ............................................................................... 231
5.6.5 Actions Arising from the HAZOP ................................................................... 231
5.6.6 HAZOP Analysis on Methyl Ester Production Plant ....................................... 232
5.7 P&ID ........................................................................................................................ 253
6 CHAPTER 6 ................................................................................................................... 254
6.1 CONCLUSION ....................................................................................................... 254
6.2 RECOMMENDATION ........................................................................................... 254
REFRENCES ......................................................................................................................... 255
APPENDIX ............................................................................................................................ 264
Appendix A. 1 .................................................................................................................... 264
A.1. 1 Density of sodium methoxide solution............................................................. 264
A.1. 2 Heat effect calculation ...................................................................................... 265
A.1. 3 CSTR calculation ............................................................................................. 266
A.1. 4 Heat of formation estimation............................................................................ 267
A.1. 5 Heat capacity estimation for RBDPKO ........................................................... 268
A.1. 6 Heat capacity estimation for PKO methyl ester ............................................... 270
A.1. 7 Material balance for Level 3 Decision ............................................................. 271
Appendix A. 2 .................................................................................................................... 272
A.2. 1 R-101/2/3 material balance .............................................................................. 272
A.2. 2 C-101 material balance..................................................................................... 275
VII
A.2. 5 Distillation Column manual calculation ........................................................... 281
Appendix A. 3 .................................................................................................................... 295
A.3. 1 Calculation for streams‘ energy balance ............................................................. 295
A.3. 2 Calculation for pumps‘ energy balance ............................................................... 346
A.3. 3 Calculation for reactor energy balance ................................................................ 360
Appendix A. 4 .................................................................................................................... 363
A.4. 1 Aspen stream table results ................................................................................ 363
Appendix A. 5 .................................................................................................................... 367
A.5. 1 Summary of unit operations‘ specifications ..................................................... 367
Appendix A. 6 .................................................................................................................... 369
A.6. 1 Process flow diagram with manually calculated material balance ................... 369
Appendix B. 1 .................................................................................................................... 370
B.1. 1 R-101/2/3 Sizing and Costing .......................................................................... 370
B.1. 2 V-101 Sizing and Costing ................................................................................ 396
B.1. 3 C-101 Sizing and Costing ................................................................................ 399
B.1. 9 T-101 Sizing and Costing ................................................................................. 456
B.1. 10 T-102 Sizing and Costing ........................................................................... 464
B.1. 17 P-101 Sizing and Costing ........................................................................... 520
B.1. 30 M-101 Sizing and Costing .......................................................................... 546
B.1. 33 Heat Exchanger Sizing and Costing Microsoft Excel Spreadsheet ............ 556
VIII
B.1. 35 Boiler E-201 ............................................................................................... 567
B.1. 36 Steam Turbine K-201 ................................................................................. 569
IX
LIST OF FIGURES
Figure 1-1: Basic oleochemicals and their further downstream derivatives (Yuen, 2000) ...... 2
Figure 1-2: Alcoholysis reaction ..................................................................................... 2
Figure 1-3: Transesterification reaction ........................................................................... 3
Figure 1-4: Schematic process flow for transesterification ................................................. 4
Figure 1-5: Major uses of methyl esters ......................................................................... 12
Figure 1-6: Global Supply & Demand for Oleochemicals (MIDA, 2014) .......................... 15
Figure 1-7: Geographic breakdown of global oleochemicals market and projected growth
2013-2018 (Weller, 2013) ............................................................................................ 16
Figure 1-8: Basic Oleochemicals exported from Malaysia (in tonnes) (MPOB, 2013) ......... 17
Figure 1-9: Price trends of palm oil products in Malaysia (MPOB, 2014) .......................... 19
Figure 1-10: The usage of palm oil and palm kernel oil for oleochemical industry (tonnes)
(MPOB, 2014) ............................................................................................................ 21
Figure 1-11: Methyl Esters Future Capacity by Malaysia ................................................. 24
Figure 1-12: Schematic diagram of the one-step supercritical methanol method (Saka process)
(Saka & Minami, 2006) ............................................................................................... 28
Figure 1-13: Schematic diagram of the two-step supercritical methanol method (Saka-Dadan
process) by (Kusdiana & Saka, 2004a) .......................................................................... 29
Figure 1-14: Block flow diagram of level 1 decision ....................................................... 37
Figure 2-1: Block Flow Diagram of Level 2 Decision ..................................................... 43
Figure 2-2: Graph of yield against conversion ................................................................ 49
Figure 2-3: Economic Potential of Level 2 Decision ....................................................... 53
Figure 2-4: Block Flow Diagram of Level 3 Decision ..................................................... 55
Figure 2-5: Levenspiel Plot (Isothermal: constant k) ....................................................... 59
Figure 2-6: Levenspiel Plot (Adiabatic: k changes with temperature) ....................... 60
Figure 2-7: Graph of volume of each CSTRs against conversion ............................. 62
Figure 2-8: Graph of reactor outlet temperature against conversion using Polymath ........... 67
Figure 2-9: Graph of reactor outlet temperature against conversion using MS Excel ........... 68
Figure 2-10: Graph of reactor cost against conversion ..................................................... 71
Figure 2-11: Economic Potential of Level 3 Decision...................................................... 73
Figure 2-12: Economic Potential of Level 3 Decision (Magnified) ................................... 74
Figure 2-13: Calculation Path for Transesterification of Triglyceride to Methyl Ester ......... 76
Figure 2-14: Methanol recovery system (Zoller, 2008) .................................................... 79
Figure 2-15: Two-stage flash distillation methanol recovery process (Tang et al., 2010) ..... 80
Figure 2-16: Schematic diagram of fractional distillation employed by Armour and Company
in 1933 (Potts & White, 1953) ...................................................................................... 82
X
Figure 2-17: Process flow diagram for conventional sodium methoxide-catalyzed methyl
esters production process (Haas et al., 2006) .................................................................. 83
Figure 2-18: Process flow diagram for this plant design project (see Appendix A.6.1 for
enlarged version)......................................................................................................... 85
Figure 2-19: Process flow diagram designed using Aspen Plus v8.0 ................................. 86
Figure 2-20: Process Flow Diagram for Reactor R-101/2/3 .............................................. 94
Figure 2-21: Process Flow Diagram for Flash Column C-101 .......................................... 95
Figure 2-24: Process Flow Diagram for Distillation Column C-103 .................................. 98
Figure 2-25: Process Flow Diagram for Distillation Column C-104 .................................. 99
Figure 2-26: Process Flow Diagram for Distillation Column C-105 ................................ 100
Figure 2-27: Process Flow Diagram for Decanter V-101 ............................................... 101
Figure 2-28: Process Flow Diagram for Pump P-101..................................................... 102
Figure 2-41: Process Flow Diagram for Heat Exchanger E-101 ...................................... 115
XI
Figure 2-56: Process Flow Diagram for Mixer M-101 ................................................... 130
Figure 3-1: Configuration of CSTR ............................................................................. 146
Figure 4-1: Temperature Interval Diagram ................................................................... 168
Figure 4-2: Cascade Diagram ..................................................................................... 169
Figure 4-3: Heat exchange network designed based on pinch temperature (heat integration)
............................................................................................................................... 171
Figure 5-1: HAZOP Methodology .............................................................................. 228
Figure 5-2: HAZOP Examination Phase Process Flow (Extracted from IEC Standard 61882)
............................................................................................................................... 230
XII
LIST OF TABLES
Table 1-1: Commonly used methyl ester nomenclature ..................................................... 6
Table 1-2: Typical fatty acid compositions of oil and fat sources (Lotero et al., 2005) .......... 7
Table 1-3: Values for the American Society for Testing and Materials (ASTM) Standards of
Maximum Allowed Quantities in Diesel and Biodiesel (Lotero et al., 2005) ...................... 11
Table 1-4: Average B100 and B20 Emissions compared to normal diesel (Soifer, 2007) ..... 11
Table 1-5: Major ASEAN oleochemical producers (ADI Finechem, 2013) ........................ 16
Table 1-6: Number of oleochemical plants and capacities in 2013 (tonne/year) (MIDA, 2014)
................................................................................................................................. 17
Table 1-7: Price of Chemical Species ............................................................................ 18
Table 1-8: Potential feedstocks for oleochemical industry (Atabani et al., 2012) ................ 20
Table 1-9: Comparison on the specification of crude and processed palm kernel oil ........... 22
Table 1-10: List of RBD Palm Kernel Oil Supplier in Malaysia (MPOB, n.d.) ................... 22
Table 1-11: Methyl Ester Producers in Malaysia ............................................................. 23
Table 1-12: Methyl Ester Capacities by Malaysia ........................................................... 23
Table 1-13: Comparison of ester yield from various oils/fats feedstock by various methods
(Saka et al., 2006) ....................................................................................................... 28
Table 1-14: Comparisons in ester yield and total glycerol content of methyl ester prepared by
three different methods (Saka et al., 2006) ..................................................................... 30
Table 1-15: Comparison of enzymatic technology versus chemical (alkaline and acid)
technology production (Robles-Medina et al., 2009) ....................................................... 31
Table 1-16: Comparison of various catalysts for transesterification (Lam et al., 2010) ........ 32
Table 1-17: Comparison of various synthesis routes........................................................ 33
Table 1-18: Comparison of homogeneous and heterogeneous alkali catalysts .................... 34
Table 1-19: Comparison of different homogeneous alkali catalysts ................................... 36
Table 1-20: Calculation for average molecular weight of triglyceride ............................... 38
Table 1-21: Calculation for average molecular weight of combined methyl ester product .... 39
Table 1-22: Calculation for weight fraction of fractionated methyl ester products .............. 40
Table 2-1: Destination code for transesterification process............................................... 43
Table 2-2: Kinetic data (Rashid et al., 2014) .................................................................. 45
Table 2-3: Mole Balance for the Second Level of Decision .............................................. 46
Table 2-4: Yield and Reaction Stoichiometry ................................................................. 48
Table 2-5: Extent of Reaction ....................................................................................... 49
Table 2-6: Mole and mass balances for Level 2 Decision ................................................. 51
Table 2-7: Mole and mass balances for Level 2 Decision after correction .......................... 52
XIII
Table 2-8: Kinetic data (Rashid et al., 2014) .................................................................. 57
Table 2-9: Stoichiometric Table .................................................................................... 57
Table 2-10: Feed information ....................................................................................... 58
Table 2-11: Conversions according to number of CSTRs ........................................ 63
Table 2-12: Heat of formations of the components .......................................................... 64
Table 2-13: Heat capacity constants for liquid methanol (Smith et al., 2005) ..................... 65
Table 2-14: Heat capacity constants for liquid glycerol (Coker, 2007) .............................. 65
Table 2-15: Formulas of heat capacities of each component ............................................. 66
Table 2-16: Cost of Catalyst at different Conversion ....................................................... 71
Table 2-17: Molar and mass balances for Level 3 Decision .............................................. 75
Table 2-18: Calculation for energy balances at 60°C and 1 atm ........................................ 77
Table 2-19: Input streams information ........................................................................... 87
Table 2-20: Conversion of triglyceride at each reactor..................................................... 88
Table 2-21: Input streams information ........................................................................... 90
Table 2-22: Material Balance of Reactor R-101/2/3 ........................................................ 94
Table 2-23: Material Balance of Flash Column C-101 ..................................................... 95
Table 2-26: Material Balance of Distillation Column C-103 ............................................ 98
Table 2-27: Material Balance of Distillation Column C-104 ............................................ 99
Table 2-28: Material Balance of Distillation Column C-105 .......................................... 100
Table 2-29: Material Balance of Decanter V-101 .......................................................... 101
Table 2-30: Material Balance of Pump P-101 ............................................................... 102
XIV
Table 2-43: Material Balance of Heat Exchanger E-101 ................................................ 115
Table 2-58: Material Balance of Mixer M-101 ............................................................. 130
Table 2-61: Summarized results of streams‘ enthalpy flow ............................................ 134
Table 2-62: Summarized results of pumps‘ fluid power ................................................. 137
Table 2-63: Summarized results of pumps‘ fluid power ................................................. 138
Table 2-64: Comparison between manual and Aspen material balance ............................ 139
Table 2-65: Mass flow rate of combined methyl ester products ...................................... 140
Table 2-66: Comparison between manual and Aspen stream energy balance ................... 141
Table 2-67: Comparison between manual and Aspen reactor energy balance ................... 142
Table 2-68: Comparison between manual and Aspen pump energy balance ..................... 143
Table 2-69: Comparison between manual and Aspen heat exchanger energy balance ....... 144
Table 3-1: Conversion and temperature information at each reactor ................................ 146
Table 3-2: Reactor R-101/2/3 Design Summary ........................................................... 147
Table 3-3: Decanter V-101 Design Summary ............................................................... 148
Table 3-4: Distillation Column Design Summary ......................................................... 150
Table 3-5: Flash Drum Design Summary ..................................................................... 152
Table 3-6: Storage Tank Design Summary ................................................................... 153
Table 3-7: Storage Tank T-201 Design Summary ......................................................... 154
Table 3-8: Pump Design Summary.............................................................................. 155
XV
Table 3-9: Mixer Design Summary ............................................................................. 156
Table 3-10: Heat Exchanger Design Summary ............................................................. 159
Table 3-11: Boiler E-201 Design Summary.................................................................. 161
Table 3-12: Steam Turbine K-201 Design Summary ..................................................... 161
Table 3-13: Summary of Equipment Cost .................................................................... 162
Table 3-14: Summary of Utility Cost........................................................................... 162
Table 4-1: Stream table for involved equipment ........................................................... 165
Table 4-2: Summary of electricity consumption ........................................................... 174
Table 4-3: Steam Turbine K-201 Power Generation ...................................................... 175
Table 4-4: Summary of cooling water consumption ...................................................... 175
Table 4-5: Summary of steam consumption ................................................................. 176
Table 4-6: Summary of refrigerant consumption ........................................................... 177
Table 5-1: Type of personal protective equipments ....................................................... 181
Table 5-2: Definition of Keywords in HAZOP Analysis ................................................ 226
Table 5-3: Advantages and Disadvantages of HAZOP Usage ......................................... 227
Table 5-4: General HAZOP Identification on major equipment ..........Error! Bookmark not
defined.
Table 5-5: General HAZOP Identification on Reactor R-101 ......................................... 233
XVI
LIST OF ABBREVIATIONS
ASTM American Society for Testing and Materials
CARG Compound annual growth rate
FAME Fatty acid methyl ester
FFA Free fatty acid
HC Heavy cut
LC Light cut
MC Middle cut
MTPA Metric tons per annum
PKO Palm kernel oil
PPKO Processed palm kernel oil
RBD Refined, bleached, and deodorized
SCA Supercritical alcohol
SCM Supercritical methanol
SME Sucrose monoester
SPE Sucrose polyester
TG Triglyceride
XVII
1 CHAPTER 1
1.1 INTRODUCTION
1.1.1 Oleochemicals
The term ―oleochemicals‖ refers to any chemical compounds derived from natural oils and
fats of both plant and animal origins. They are analogous to petrochemicals derived from
petroleum oil. Oleochemicals are often categorised into basic oleochemical substances like
fatty acids, methyl esters, fatty alcohols, fatty amines and glycerol. They are essentially the
building blocks of the oleochemical industry. From these basic oleochemicals, a very wide
range of oleochemical derivatives can be produced. Figure 1-1 shows a flow chart leading
from palm oil to basic oleochemicals and their further downstream derivatives.
Prior to 1980, almost 95% of natural oils and fats are used in food application while only a
small percentage is applied in non-food purposes such as soap manufacturing and drying oils
(Soon, 2001). It was only after the 1980s that oleochemicals were found for their wide uses in
technical applications which previously are the domains of ―synthetic chemicals‖ derived
from petroleum or in other word, petrochemicals. Oleochemicals are widely used to
manufacture products such as soaps and detergents, cosmetics and personal care products,
lubricants and greases, drying oil, surface coatings and polymers, and biofuels. Similar
chemicals may be synthesized from crude oil, but they are classified as petrochemicals.
The advantages of using oleochemicals over petrochemicals are:
 Oleochemicals are derived from renewable resources, so the continued availability of

raw materials is assured.
 Oleochemicals are fully biodegradable and non-toxic, therefore they are easily
disposable and contribute to a healthier environment.
 Oleochemical production requires less energy and causes less pollution.
1
Figure 1-1: Basic oleochemicals and their further downstream derivatives (Yuen, 2000)
1.1.2 Methyl Esters

Methyl esters, often called fatty acid methyl esters (FAME) are a type of fatty acid ester that
are derived from either the transesterification of triglycerides (TGs) or the esterification of
free fatty acids (FFAs) with low molecular weight alcohols, typically methanol or ethanol
(Lotero et al., 2005). In most of the related industries, transesterification of vegetable oil with
methanol is usually used for FAME production.
Tranesterification is the displacement of alcohol from an ester by another alcohol in a process

similar to hydrolysis, except that an alcohol is used instead of water. This reaction, cleavage
of an ester by an alcohol, is more specifically called alcoholysis and is represented in Figure
1-2.
Figure 1-2: Alcoholysis reaction
2
―Transesterification‖ is a general term. More specifically, if methanol is used, the reaction is
termed ―methanolysis‖. Methanol is generally used because of its high reactivity and it is less
expensive than ethanol (Leung et al., 2010). For the creation of fatty acid methyl esters
(FAME), triglyceride oils (esters) are reacted with methanol (alcohol) to produce FAME
(mixture of fatty esters) and glycerol (alcohol). The process can be seen in Figure 1-3 where
R1, R2, and R3 are long hydrocarbon chains, often called fatty acid chains.
Figure 1-3: Transesterification reaction
As shown in Figure 1-3, the triglyceride contains three separated ester functional groups and
can react with three molecules of methanol to form three fatty acid methyl esters (fatty esters)
and glycerol (glycerin). Typically, homogeneous base catalysts such as sodium hydroxide
(NaOH) or another strong base such as potassium hydroxide (KOH) is used in this
transesterification process. These inexpensive catalysts shorten the reaction time and they are
easy to handle in terms of transportation and storage (Refaat, 2010). These hydroxides (OH-)
cause the methanol to dissociate and produce the methoxide ion (H3CO-), which is the actual
catalytic agent that drives the reaction forward to produce FAME. However, base-catalyzed
transesterification is very sensitive to the presence of free fatty acids (FFA), which leads to
undesired soap formation, causing decrease in yield and increase in the downstream
separation process (Gui et al., 2008; Canakci & Van Gerpen, 2001).
Some feedstocks require a pretreatment reaction before they can go through the
transesterification process. Feedstocks with more than 3% free fatty acids (FFA), which
include inedible animal fats and recycled greases, must be pretreated in an acid-catalyzed
esterification process (Ribeiro et al., 2011). This process reacts the feedstock with an alcohol
such as methanol in the presence of a strong acid catalyst such as sulfuric acid (H2SO4) in
order to convert the free fatty acids (FFA) into FAME. The remaining triglycerides are then
converted to FAME through the transesterification process. The overall FAME production
process is outlined in Figure 1-4.
3
Figure 1-4: Schematic process flow for transesterification
 Acid Esterification
Oil feedstocks containing more than 3% free fatty acids (FFA) go through an acid
esterification process to increase the yield of FAME. These feedstocks are filtered and
preprocessed to remove water and contaminants before being fed to the acid esterification
process. The catalyst, sulfuric acid (H2SO4), is dissolved in methanol and then mixed with the
pretreated oil. The mixture is heated and stirred, and the free fatty acids (FFA) are converted
to FAME. Once the reaction is complete, it is dewatered and then fed to the transesterification
process.
 Transesterification
Oil feedstocks containing less than 3% free fatty acids (FFA) are filtered and preprocessed to
remove water and contaminants and then fed directly to the transesterification process along
with any products of the acid esterification process. The catalyst, potassium hydroxide
(KOH), is dissolved in methanol and then mixed with and the pretreated oil. If an acid
esterification process is used, then extra base catalyst must be added to neutralize the acid
added in that step. Once the reaction is complete, the major co-products, FAME and glycerin,
are separated into two layers.
4
 Methanol recovery
The methanol is typically removed after the FAME and glycerin have been separated, to
prevent the reaction from reversing itself. The methanol is cleaned and recycled back to the
beginning of the process.
 FAME recovery
Once separated from the glycerin, the FAME goes through a clean-up or purification process
to remove excess alcohol, residual catalyst and soaps. This consists of one or more washings
with clean water. It is then dried and sent to storage. Sometimes the FAME goes through an
additional distillation step to produce fractionated methyl esters (e.g. methyl palmitate/oleate
with palm oil as feedstock).
 Glycerin recovery
The glycerin byproduct contains unreacted catalyst and soaps that are neutralized with an
acid. Water and alcohol are removed to produce 50%-80% crude glycerin. The remaining
contaminants include unreacted fats and oils. In large oleochemical plants, the glycerin can be
further purified, to 99% or higher purity, for sale to the pharmaceutical and cosmetic
industries.
Distillation is a major operation used to fractionate the methyl ester mixture into specific
defined methyl esters having the desired alkyl groups. The methyl ester formed without
distillation is still referred to its oil name. For example, methyl cocoate is a methyl ester
mixture derived from coconut oil. However, once it is fractionated, the material is then named
by its carbon distribution. For instant, methyl cocoate can be fractionated into methyl laurate
and methyl myristate. Fatty acid methyl esters that do not contain any double bond are called
saturated fatty acid methyl esters. Those contain at least one double bond are referred as
unsaturated fatty acid methyl esters because they have the potential to hold more hydrogen
atoms. Basically, those with only one double bond are mono-unsaturated while those with
multiple double bonds are polyunsaturated. Table 1-1 summarizes the nomenclature of
commonly used methyl esters according to their carbon distribution.
5
Table 1-1: Commonly used methyl ester nomenclature
Designator Name Formula
C6:0 Methyl hexanoate C7H14O2
C7:0 Methyl heptanoate C8H16O2
C8:0 Methyl octanoate C9H18O2
C9:0 Methyl nonanoate C10H20O2
C10:0 Methyl decanoate C11H22O2
C11:0 Methyl undecanoate C12H24O2
C12:0 Methyl laurate C13H26O2
C13:0 Methyl tridecanoate C14H28O2
C14:0 Methyl myristate C15H30O2
a
C14:1 Δ 9 cis Methyl myristoleate C15H28O2
C15:0 Methyl pentadecanoate C16H32O2
C16:0 Methyl palmitate C17H34O2
C16:1 Δ 9 cis Methyl palmitoleate C17H32O2
C17:0 Methyl heptadecanoate C18H36O2
C18:0 Methyl stearate C19H38O2
C18:1 Δ 9 cis Methyl oleate C19H36O2
C18:2 Δ 9,12 cis Methyl linoleate C19H34O2
C18:3 Δ 9,12,15 cis Methyl linolenate C19H32O2
C19:0 Methyl nonadecanoate C20H40O2
C20:0 Methyl arachidate C21H42O2
C20:1 Δ 11 cis Methyl eicosenoate C21H40O2
C20:2 Δ 11,14 cis Methyl eicosadienoate C21H38O2
C20:3 Δ 11,14,17 cis Methyl eicosatrienoate C21H36O2
C20:4 Δ 5,8,11,14 cis Methyl arachidonate C21H34O2
C21:0 Methyl heneicosanoate C22H44O2
C22:0 Methyl behenate C23H46O2
C22:1 Δ 13 cis Methyl erucate C23H44O2
C23:0 Methyl tricosanoate C24H48O2
C24:0 Methyl lignocerate C25H50O2
C24:1 Δ 15 cis Methyl nervonate C25H48O2
a
C14:1 Δ 9 cis, the alkyl chain contains 14 carbons and 1 double bond located on the 9th
carbon from the methyl end of the chain.
1.1.3 Feedstocks
FAME can be synthesized from a great variety of feedstocks. These feedstocks include most
vegetable oils (soybean oil, jatropha oil, rapeseed oil, palm oil, sunflower oil, corn oil, peanut
oil, canola oil, and cottonseed oil) and animal fats (tallow and lard). They can also be
produced from other sources like waste cooking oil, greases, and oleaginous microorganisms
with excess microbial lipid such as microalgae (Demirbas, 2007). Table 1-2 shows the fatty
acid compositions of some common vegetable oils, animal fats, and greases.
6
Table 1-2: Typical fatty acid compositions of oil and fat sources (Lotero et al., 2005)
Fatty acid composition (wt%)
Fatty Acid Myristic Palmitic Palmitoleic Stearic Oleic Linoleic Linolenic
14:00a 16:00 16:01 18:00 18:01 18:02 18:03
Rapeseed oil 0.0 3.5 0.0 0.9 64.4 22.3 8.2
Virgin olive oil 0.0 9.2 0.8 3.4 80.4 4.5 0.6
Sunflower oil 0.0 6.0 0.0 4.2 18.7 69.3 0.0
Safflower oil 0.0 5.2 0.0 2.2 76.3 16.2 0.0
Soybean 0.1 10.6 0.0 4.8 22.5 52.3 8.2
Palm oil 1.2 47.9 0.0 4.2 37.0 9.1 0.3
Choice white grease 0.0 23.3 3.5 11.0 47.1 11.0 1.0
Poultry fat 0.0 22.2 8.4 5.1 42.3 19.3 1.0
Lard 1.7 17.3 1.9 15.6 42.5 9.2 0.4
Edible tallow 4.8 28.4 0.0 14.8 44.6 2.7 0.0
Yellow grease 2.4 23.2 3.8 13.0 44.3 7.0 0.7
Brown grease 1.7 22.8 3.1 12.5 42.4 12.1 0.8
a
14:00, the alkyl chain contains 14 carbons and zero double bonds.
1.1.3.1 Vegetable Oils

Since vegetable oil is a feedstock that is available in large quantities, it has been widely used
for the conversion to FAME. Majority of vegetable oils have been employed for FAME
production such as soybean oil, rapeseed oil, canola oil, palm oil, and sunflower oil (Pereyra-
Irujo et al., 2009). However, producing FAME from vegetable oils competes with their use as
food and involves additional land use. Also, in industrial scale, FAME production requires
considerable use of arable lands.
1.1.3.2 Waste Cooking Oils

Fried oils and fats are usually broken down after a period of use and become unsuitable for
further cooking as a result of increasing of FFA content. Once this reached, they are discarded
or recycled. This type of feedstocks is of low cost, making them attractive for FAME
production (Phan & Phan, 2008). Using waste cooking oil, especially those that cannot be
treated, will reduce the environment pollution. Waste cooking oil conversion into FAME
through the transesterification process reduces their molecular weight to approximately one-
third, viscosity by about one-seventh, as well as reducing their flash point and volatility
(Demirbas, 2009). High oil conversion (>90%) has been reported by many investigators (Patil
et al., 2010; Wang et al., 2007) in spite of the high FFA contents that range from 5 to 15 wt%.
7
1.1.3.3 Animal Fats
Animal fats are received from cattle, hog, chicken, lamb, and fish. Tallow and animal meats
which are not allowed to be used as food can be used as methyl ester production feedstock.
However, these two sources have discontinuity problem in their supply. It is possible that
suddenly a high bulk of material is available followed by a period with no supply like in the
case of animal disease (Rutz & Janssen, 2007). Animal fats are characterized by the high
amount of saturated fatty acids (SFA) which are solid at room temperature. Taher et al. (2011)
had investigated the possibility of FAME production from lamb meat fat and tallow as
feedstock.
1.1.3.4 Oleaginous Microorganisms

As an alternative to vegetable oils and animal fats, oleaginous microorganisms have recently
attracted great attention. It has been reported that such microorganisms accumulate oils and
have microbial lipid content exceeding 20% (Demirbas, 2007). Using algae as a feedstock has
been studied worldwide by several decades. The potential of using algae for FAME
production can be seen from their ability to produce large amount of FAME and reduce the
production cost. Based on algae size, they are classified to macroalgae and microalgae.
Macroalgae are large and multicellular, whereas microalgae are small and unicellular. Due to
the simple cell structure, microalgae are widely used and have been accepted as promise
feedstock.
1.1.4 Advantages of Methyl Esters

Methyl esters have increasingly replaced fatty acids as starting materials for many
oleochemicals. The use of methyl esters instead of fatty acids as starting materials for many
oleochemicals is rapidly gaining ground because of the following advantages (Kirk-Othmer,
2012):
1. Lower Energy Consumption. The production of methyl esters requires much lower
reactor temperatures and pressures than the splitting of fats and oils to obtain fatty
acids.
2. Less Expensive Equipment. Methyl esters are non-corrosive and are produced at lower
operating pressure and temperature conditions, hence they can be processed in carbon
steel equipment; fatty acids are corrosive and require heavy-duty stainless steel
equipment.
8
3. More Concentrated Glycerine By-product. Transesterification is a dry reaction and
yields concentrated glycerine, while fat splitting produces glycerine water, which has
more than 80% water: thus, recovery of the latter uses more energy.
4. Easier to Distill-Fractionate. Esters are more easily distilled because of their lower
boiling points and are more heat stable than the corresponding fatty acids.
5. Superior to Fatty Acids as Chemical Intermediates in Some Applications. In the
production of alkanolamides, esters can produce superamides, with more than 90%
purity against fatty acids, which can only produce amides with a purity of 65-70%
amides.
6. Easier to Transport. As a result of their chemical stability and non-corrosive property,
esters are far easier to transport than fatty acids.
One major consideration is the need to recover and recycle the methanol. As methanol is a
toxic and an explosive material, use of explosion proof equipment and extra safety
precautions are mandatory.
9
1.2 APPLICATION OF PRODUCTS
1.2.1 FAME as Biodiesel
FAME, without further distillation, can be used either as a substitute for diesel fuel or more
commonly in fuel blends (Kinast, 2003). The flow and combustion properties of biodiesel are
almost similar to petroleum-based diesel. As a point of comparison, pure biodiesel (B100)
releases about 90% of the energy that normal diesel does. Hence, it is expected that the engine
performance is nearly the same in terms of engine torque and horsepower. Biodiesel
combustion is environmentally benign, offers good storage properties, bio-renewable in
nature, has a higher flash point and cetane number than petro-diesel, non-aromatic and
completely biodegradable (capable of being broken down into harmless products) (Pienaar &
Brent, 2012). These characteristics of biodiesel reduce the noxious emissions in the exhaust
gas compared to petro-diesel. In addition, biodiesel enhances the lubricant properties (even at
blends as low as 3% or less), which prolongs engine life and reduces the frequency of engine
part replacement. Biodiesel is called the environmentally friendly biofuel since it provides a
means to recycle carbon dioxide. In other words, biodiesel does not contribute to global
warming.
Table 1-3 shows a brief comparison of the ASTM standards for diesel and biodiesel. As can
be seen, biodiesel exhibits characteristics that are comparable to petroleum-based diesel fuel.
Table 1-4 summarizes the typical emission profiles of biodiesel and one of its blends, B20,
which consists of 20% biodiesel and 80% diesel, using petroleum-derived diesel emissions as
the reference. The information in the table shows how biodiesel significantly reduces
emissions compared to diesel even when it is used as the minor component of a fuel blend. In
addition, the amount of sulphur in biodiesel is quite low, which can significantly contribute to
helping meet current sulphur emission standards in diesel vehicles.
10
Table 1-3: Values for the American Society for Testing and Materials (ASTM) Standards of
Maximum Allowed Quantities in Diesel and Biodiesel (Lotero et al., 2005)
Property Diesel Biodiesel
Standard ASTM D975 ASTM D6751
Composition HCa (C10–C21) FAMEb (C12–C22)
Kin. viscosity (mm2/s) at 40 °C 1.9–4.1 1.9–6.0
Specific gravity (g/mL) 0.85 0.88
Flash point (°C) 60–80 100–170
Cloud point (°C) -15 to 5 -3 to 12
Pour point (°C) -35 to -15 -15 to 16
Water (vol %) 0.05 0.05
Carbon (wt %) 87 77
Hydrogen (wt %) 13 12
Oxygen (wt %) 0 11
Sulfur (wt %) 0.05 0.05
Cetane number 40–55 48–60
c
HFRR (ím) 685 314
d
BOCLE scuff (g) 3600 >7000
a
Hydrocarbons. b Fatty acid methyl esters. c High-frequency reciprocating rig. d Ball-on-
cylinder lubricity evaluator.
Table 1-4: Average B100 and B20 Emissions compared to normal diesel (Soifer, 2007)
Emission B100 (%) B20 (%)
Carbon monoxide -48 -12
Total unburned hydrocarbons -67 -20
Particulate matter -47 -12
Nitrogen oxides 10 2
Sulphates -100 -20
Air toxics -60 to -90 -12 to -20
Mutagenicity -80 to -90 -20
1.2.2 FAME as Raw Materials for Other Products

In addition to the use of methyl esters as biodiesel fuel, these chemicals also have potential as
intermediates to produce a number of oleochemical derivatives such as fatty alcohols, sucrose
esters, alkanolamides, soaps, alpha-sulfonated methyl esters, and other fatty esters as shown
in Figure 1-5. Among these uses fatty alcohols are the dominating application. Besides, fatty
alkanolamides are another product group for which methyl esters serve as chemical
intermediates. The methyl esters react with diethanolamine to produce the fatty alkanolamides
and methanol. However, the use of alkanolamides has declined in Western Europe due to
concern over nitrosamine contamination (Applewhite, 1991). Moreover, methyl esters are also
sulfonated to produce sulphonated methyl esters to serve as surfactants used in detergents
11
where they compete with petroleum derived products. When reacted with sucrose, methyl
esters form sucrose monoesters (SME) and sucrose polyesters (SPE). SME‘s are surfactants
used in foods, cosmetics, pharmaceuticals, emulsifiers, wetting agents, lubricants, plasticizers,
detergents, agricultural chemicals and antifoaming agents. Whereas SPE‘s are potential low
caloric dietary fats and agents for reducing blood plasma cholesterol. On the other hand, the
reaction of methyl esters with isopropyl alcohol is the preferred method of producing
isopropyl esters. Applications for isopropyl esters are as emollients and plasticizers.
Furthermore, saponification of methyl esters is one of the processes for making soap.
Figure 1-5: Major uses of methyl esters
1.2.3 Methyl Octanoate/Decanoate (Light Cut: C8-10)

Crude methyl esters can be fractionated to separate the C8-C10 fraction, known as plasticizer
range. The plasticizer range methyl ester is a liquid with good dissolving power. It can be
used in a limited way as a solvent for printing inks and lacquers (Kirk-Othmer, 2012). These
types of esters are also used as a direct solvent for defoaming in the paper, textile and oil field
industries. For dyestuffs and coatings process, it is used as a low-volatility and viscosity
ingredient in solvent blends. In agricultural sector, blends of C8-C10 are used in plant growth
regulators for tobacco sucker control.
12
1.2.4 Methyl Laurate/Myristate (Middle Cut: C12-14)
Middle cut methyl esters are most preferred for detergent use, as these chain lengths provide
an optimum trade-off between surfactancy on the one hand and (lack of) crystallinity on the
other. The C12-C14 methyl esters find special application as lubricant additives and in the
formulation of bearing and hydraulic oils (Kirk-Othmer, 2012). In addition, it is used to make
perfumes and fragrances.
1.2.5 Methyl Palmitate/Oleate (Heavy Cut: C16-18)

Most heavy-cut (C16-18) methyl ester is consumed as either biodiesel or in lubricant and
metalworking applications. According to Masjuki and Maleque (1997), an addition of 5vol%
of palm oil methyl ester (POME) which consists of mainly C16-C18 methyl esters in the
base-oil lubricant resulted in low wear rate of steel ball bearing. It is also used as a solvent, as
a plasticizer, and in various industrial oils. Personal care applications include its use as an
emollient and solvent for solid active ingredients in products as diverse as body lotions, facial
self-tanning creams, fade creams, hair conditioners and styling creams (HallStar, 2011).
1.2.6 Glycerine
Glycerine, also called glycerol, is a common by-product in the methyl esters manufacturing
process. The production of by-product glycerine is necessarily to be pointed out due to its
considerable value as an industrial chemical. Refined glycerine is marketed in several grades
such as chemically pure (CP) grade (96, 99, or 99.7%), USP grade (95% min), and dynamite
grade (99%). In general, for every 100 pounds of methyl esters produced, approximately 10
pounds of crude glycerine are created.
Glycerine is a nontoxic, edible, and biodegradable compound which will provide important
environmental benefits to the new production platform products. It is widely used in the
manufacture of drugs, giving the pills humidity and increasing the viscosity of liquid drugs.
For examples, it is used in cough syrups, ear infection medicines, as a carrier for antibiotics
and antiseptics, and also as plasticizers for medicine capsules (Singhabhandhu & Tezuka,
2010).
Besides, glycerine is an excellent solvent of iodine, bromine, phenol, tannins, alkaloids, and
mercury chloride. It is the major ingredient in toothpastes to prevent hardening and drying out
in the tube. Glycerine can also be used in personal care formulations, mainly as a means of
13
providing lubrication, improving smoothness, and as a humectant and moistener in many skin
and hair care products where moisturization is desired (Singhabhandhu & Tezuka, 2010).
In food and beverage industry, glycerine acts as a solvent, sweetener and preservative. It is
normally ingested in manufacturing extracts of tea, coffee, ginger and other vegetable
substances. It can be used as a softening agent in bread, cakes, meats, cheese and candy.
Moreover, glycerine can be used to preserve the freshness of tobacco in order to eliminate the
unpleasant irritating taste.
14
1.3 MARKET SURVEY
1.3.1 Production & Demand

Increasing demand for biodegradable and sustainable products coupled with recent changes in
regulations, are increasing the importance of oleochemicals. As shown in Figure 1-6, MIDA
has reported that the oleochemicals in terms of both demand and production is growing at a
CARG of 5% for the period from 2013 to 2018. It is forecasted that in year 2018/2020, the
global demand for the oleochemicals will exceed the global production capacity.
Figure 1-6: Global Supply & Demand for Oleochemicals (MIDA, 2014)
On the other hand, Weller (2013) has reported that the global oleochemicals market was
estimated at 13.5 million tonnes in the 2013 financial year and it is expected to grow at 6%
per year over the next five years (Figure 1-7) to reach 18.1 million tonnes. The Asia-Pacific
led by Malaysia, China, and Indonesia, accounts for 68% or around two-thirds of the global
oleochemicals market and this is expected to grow at 8% per year over the next five years
(Weller, 2013). Hence, the oleochemical market for Asia-Pacific area is expected to rise from
about 9.2 million tonnes to approximately 13.5 million tonnes in year 2018. This dramatic
increment over the next 5 years required investment and installation of new oleochemical
plants in order to cater the demand.
15
Figure 1-7: Geographic breakdown of global oleochemicals market and projected growth
2013-2018 (Weller, 2013)
The global industry of basic oleochemicals is changing at a dramatic phase. While in Europe,
USA and Japan, the production of oleochemicals remain constant or is seen decreasing,
ASEAN countries with their strong raw material base is expanding with world scale plants
and increasing rapidly their share in the worlds markets. As shown in Table 1-5, Malaysia is a
major producer of basic oleochemicals such as methyl esters, fatty acids and fatty alcohols
which have attracted investments from almost all the major companies in the field, such as
Emery Oleo, Wilmar, BASF and others.
Table 1-5: Major ASEAN oleochemical producers (ADI Finechem, 2013)

Country Production capacity (MTPA)
Malaysia 1,806,000
China 1,180,000
Indonesia 716,000
Philipines 103,000
India 100,000
Thailand 4,500
After almost two decades, Malaysia is still the world‘s oleochemical hub. Malaysia has
almost 70% of the total oleochemical production capacities in the ASEAN region, making it
the center of the oleochemical industry in the region. The demand to methyl esters is expected
to increase due to its environmental-friendly properties, and increase in demand for fatty
alcohol as well as other derivatives. The cost factor is also working in favour of
oleochemicals made from crude palm oil with current crude petroleum prices being at all-time
high. This makes it very attractive to use oleochemicals in many applications from the
economic point of view. Hence, this has resulted in companies substituting petroleum-based
16
products (detergents, surfactants, etc) with oleochemicals and hence increasing the demand
for methyl ester-based oleochemicals. Furthermore, petroleum, being a depleting resource,
cannot just compete with the renewable oleochemicals in term of dependability of supply.
According to the Malaysian Industrial Development Authority (MIDA), a total of 14 new and
expansion / diversification projects for the following products: fatty acids, fatty alcohols,
methyl esters, lauric acids, myristic acids and glycerine were approved in year 2010. At the
same time, the government has invested a total amount of RM 1.5 billion for these projects.
Table 1-6 shows the oleochemical plants available in Malaysia and their combined
oleochemical products capacity in year 2013.
Table 1-6: Number of oleochemical plants and capacities in 2013 (tonne/year) (MIDA, 2014)
In Operation Not In Operation Under Planning Total
State
No Capacity No Capacity No Capacity No Capacity
Johor 6 608,900 0 0 0 0 6 608,900
Penang 3 791,325 0 0 0 0 3 791,325
Selangor 6 817,746 0 0 0 0 6 817,746
Other States 1 365,000 1 16,000 1 60,000 3 441,000
Malaysia 16 2,582,971 1 16,000 1 60,000 18 2,658,971
Figure 1-8 shows the total capacity of basic oleochemicals being exported throughout the
world. In terms of methyl esters, its total export in year 2013 is almost double the export in
2010 while fatty acids export was reduced or maintained since year 2006. As a result, methyl
ester has started to gain world‘s attention and it has increasingly replaced fatty acids as
starting materials for many oleochemical derivatives (see Chapter 1.1.4 for detailed
information).
Figure 1-8: Basic Oleochemicals exported from Malaysia (in tonnes) (MPOB, 2013)
17
1.3.2 Market Price
This section studies the prices of raw materials and products to be selected for this whole
plant design project. All the prices achieved are based on the most recent market prices
obtained from reliable sources as shown in Table 1-7. According to Malaysia Palm Oil Board,
the selling price of RBD palm kernel oil in September 2014 is RM 2,950/MT which is about
10% higher than the crude palm kernel oil at RM 2,690/MT (see Figure 1-9). Due to their
insignificant difference in price, RBD palm kernel oil is selected as the raw material. Also,
RBD palm kernel oil does not require pre-treatment due to low FFA content while crude palm
kernel oil does. Hence, for simplicity and to save costs on the pretreatment unit, RBD palm
kernel oil is chosen. On the other hand, Zauba has reported the prices for methanol, sodium
methoxide solution, methyl octanoate/decanoate, methyl laurate/myristate, methyl
palmitate/oleate, and glycerine as can be seen in Table 1-7.
Table 1-7: Price of Chemical Species
Material Price Source Pricing date

RBD Palm Kernel Oil RM 2,950/MT (MPOB, 2014) September, 2014
a
Methanol RM 1,080/MT (Zauba, n.d.) October, 2014
Sodium Methoxide (30wt% a
RM 2,760/MT (Zauba, n.d.) September, 2014
in methanol)
Methyl Octanoate/Decanoate a
RM 3,460/MT (Zauba, n.d.) April, 2012
(CE-810)
Methyl Laurate/Myristate a
RM 4,650/MT (Zauba, n.d.) March, 2013
(CE-1214)
Methyl Palmitate/Oleate a
RM 3,840/MT (Zauba, n.d.) July, 2012
(CE-1618)
a
Glycerine (99.5% min) RM 3,250/MT (Zauba, n.d.) October, 2014
a
Crude Glycerine (80% min) RM 1,460/MT (Zauba, n.d.) March, 2014
a
INR 18.50 = RM 1 MYR
18
Crude PKO and RBD PKO Price Trend (RM/ MT)
8000
7000
6000
5000
4000
2950
3000
2000 2690
1000
0
Apr-05 Aug-06 Jan-08 May-09 Sep-10 Feb-12 Jun-13 Nov-14
RBDPKO CPKO
Figure 1-9: Price trends of palm oil products in Malaysia (MPOB, 2014)
1.3.3 Availability of Raw Material

The vegetable oils used as the source of methyl ester production highly depend on regional
climate, for example, rapeseed oil in Europe countries and Canada, soybean oil in United
States of America, and palm oil in tropical countries like Malaysia and Indonesia. Besides,
coconut oil is another feedstock used for methyl ester production in coastal area. Also, not to
forget the potential of non-edible oils as feedstock in India, that include jatropha oil (Jatropha
curcas) and keranja oil (Pongamia pinnata) (Issariyakul & Dalai, 2014). Table 1-8
summarizes the potential feedstocks for oleochemical industry in different countries.
19
Table 1-8: Potential feedstocks for oleochemical industry (Atabani et al., 2012)
Country Feedstock
Argentina Soybeans
Brazil Soybeans/palm oil/castor/cotton oil
Canada Rapeseed/animal fat/soybeans/yellow grease and tallow/mustard/flax
China Jatropha/waste cooking oil/rapeseed
France Rapeseed/sunflower
Germany Rapeseed
Greece Cottonseed
India Jatropha/Pongamia pinnata (karanja)/soybean/rapeseed/sunflower/peanut
Indonesia Palm oil/jatropha/coconut
Ireland Frying oil/animal fats
Italy Rapeseed/sunflower
Japan Waste cooking oil
Malaysia Palm oil
Mexico Animal fat/waste oil
New Zealand Waste cooking oil/tallow
Philippines Coconut/jatropha
Singapore Palm oil
Spain Linseed oil/sunflower
Sweden Rapeseed
Thailand Palm oil/jatropha/coconut
UK Rapeseed/waste cooking oil
USA Soybeans/waste oil/peanut
Palm kernel oil is an important feedstock for the oleochemical industry in Malaysia. Palm
kernel oil is commercially a major source of lauric acid, which are characterized by their high
lauric oil content of approximately 50%. The lauric oils are highly desirable materials in the
oleochemical industry worldwide because of the importance of the lauric fraction especially
in the manufacture of soap and detergents (Kirk-Othmer, 2012). Palm kernel oil is well
positioned because it has the unique advantage of having its fatty acid composition falling
within the carbon chain spectrum highly desired by the oleochemical industry where the C12
and C14 fatty acid fractions are sought after. The caproic to capric (C6-C10) fatty acid
fractions comprising approximately 15% are good materials for plasticizer range alcohol and
for poyol esters. The latter are used in high performance oil for jet engines and for the new
generation of lubricants. These acid fractions are also the basic material for the manufacture
of medium-chain triglycerides, a highly valued dietary fat. While the C12-C18 fatty acid
fractions, approximately 85% of the palm kernel oil fatty acid composition, are the primary
raw materials for detergent-grade fatty alcohols.
20
1.3.3.1 Raw Material Supply in Malaysia
Malaysia is nowadays the world‘s second biggest producer of palm oil. Large area and
growing palm oil industry, followed by a strong global demand for palm oil, In Malaysia, the
climate of hot and wet weather throughout the year has also encouraged the growth of the oil
palm and consequently the development of oil palm cultivation in Malaysia. Palm and palm
kernel oils are the major feedstocks for the manufacture of oleochemicals methyl esters. As
shown in Figure 1-10, the uses of crude palm oil (CPO), processed palm oil (PPO), crude
palm kernel oil (CPKO), and processed palm kernel oil (PPKO) in oleochemical industry has
increased over the recent years and it is expected to rise for the following years due to the
increasing demand of oleochemical products.
Figure 1-10: The usage of palm oil and palm kernel oil for oleochemical industry (tonnes)
(MPOB, 2014)
The refined, bleached, and deodorized palm kernel oil (RBDPKO) is categorized as one of the
processed palm kernel oil (PPKO). Due to lower free fatty acid (FFA), moisture and
impurities content (see Table 1-9) of RBD palm kernel oil compared to crude palm kernel oil,
it is potentially used as the feedstock for methyl esters production. Besides, increasing
production capacity of RBD palm kernel oil has made it a promising feedstock for the
production of methyl esters. Table 1-10 summarizes the RBD palm kernel oil supplier in
Malaysia.
21
Table 1-9: Comparison on the specification of crude and processed palm kernel oil
Specifications RBD Palm Kernel Oil Crude Palm Kernel Oil
Free Fatty Acids (FFA) 0.1% max 5.0% max
Moisture and Impurities (M&I) 0.1% max 0.5% max
Iodine Value (WIJS) 19 max 19 max
Melting Point 24°C min
Colour 1.5 Red; 15 Yellow max
Peroxide Value 1 Max
Saponification Value 240 min
Fatty Acid (wt%)
Caprylic (8:0) 4.4
Capric (10:0) 3.7
Lauric (12:0) 48.3
Myristic (14:0) 15.6
Palmitic (16:0) 7.8
Stearic(18:0) 2.0
Oleic (18:1) 15.1
Linoleic (18:2) 2.7
Others 0.4
Table 1-10: List of RBD Palm Kernel Oil Supplier in Malaysia (MPOB, n.d.)
No Company Location
1 Felda Global Ventures Holdings Berhad Kuala Lumpur
2 Inno-Wangsa Oils Fats Sdn Bhd Pasir Gudang, Johor
3 IOI Corporation Berhad Pasir Gudang,Johor
4 Intercontinental Specialty Fats Sdn Bhd Pelabuhan Klang, Selangor
5 Keck Seng (M) Berhad Masai, Johor
6 Khong Guan Vegetable Oil Refinery Sdn Bhd Butterworth, Penang
7 Kitra Industries (M) Sdn Bhd Kelana Jaya, Selangor
8 Kuala Lumpur Kepong Berhad Ipoh, Perak
9 Kwantas Oil Sdn Bhd Kota Kinabalu, Sabah
10 Lam Soon (M) Berhad Shah Alam, Selangor
11 Lee Oilmills Sdn Bhd Klang, Selangor
12 Mac World Industries Sdn Bhd Petaling Jaya, Selangor
13 Pacific Inter-Link Sdn Bhd Kuala Lumpur
14 Palmaju Edible Oil Sdn Bhd Pasir Gudang, Johor
15 Pan Century Edible Oils Sdn Bhd Putrajaya, Selangor
16 PGEO Group Sdn Bhd Pasir Gudang, Johor
17 Sime Darby Berhad Kuala Lumpur
18 Soon Soon Oilmills Sdn Bhd Prai, Penang
19 Unitata Berhad Teluk Intan, Perak
22
1.3.4 Competitors
Table 1-11 shows some of the methyl ester producers in Malaysia with their respective
production capacity. FPG Oleochemicals owns one of the largest oleochemical plants in the
world which dominates the market for methyl esters with a large capacity of 285,000 MTPA
of methyl ester production.
Table 1-11: Methyl Ester Producers in Malaysia

No Company Location Capacity Source
IOI Oleochemicals (IOI Oleochemical,
1 Prai, Penang 32,000 MTPA
Industries Berhad 2014)
Esterchem (M) Sdn (IOI Oleochemical,
2 Prai, Penang 20,000 MTPA
Bhd 2013)
Emery Oleochemicals Telok Panglima 10,000-20,000
3 (Ag-West Bio, 2013)
(M) Sdn Bhd Garang, Selangor MTPA
FPG Oleochemicals (FPG Oleochemicals,
4 Kuantan, Pahang 285,000 MTPA
Sdn Bhd n.d.)
Port Klang, 35,000-50,000
5 Oleon Sdn Bhd (Ag-West Bio, 2013)
Selangor MTPA
1.3.5 Methyl Esters Prospect

Malaysia continues to the leading producer and exporter of basic oleochemicals such as
methyl esters in the world. The methyl esters capacities by Malaysian Oleochemical
Manufacturers Group (MOMG) are shown in Table 1-12. A projection of the methyl esters
future capacities can be seen in Figure 1-11.
Table 1-12: Methyl Ester Capacities by Malaysia

Year Capacity ('000 tonnes) Source
1997 290 (Edward et al., 1999)
2007 498
2008 528
(Federation of Malaysian Manufacturers, 2010)
2009 528
2010 720
23
Methyl Esters Capacity ('000 tonnes)
1000
900
800 720
700
600 528 528
498
500
400
289.6
300
200
100
0
1997 1999 2001 2003 2005 2007 2009 2011 2013 2015 2017 2019
Forecast Actual
Figure 1-11: Methyl Esters Future Capacity by Malaysia
As mentioned before, Malaysia is the largest exporter of methyl esters throughout the world
due to availability of raw materials. Increase in the production capacity in Malaysia indicates
an increasing demand of methyl esters in the future market. As can be seen in Figure 1-11, the
production capacity in Malaysia is expected to rise from about 700,000 tonnes in 2014 to
880,000 tonnes of methyl esters in 2020. Hence, a new plant for methyl esters production is
required in Malaysia to cater this gap (about 180,000 tonnes) in year 2020. Considering the
other competitors might also contribute to this production gap, the production capacity of
methyl esters for this project is set to one-third of the total gap, thus, this plant design project
is set to produce 60,000 MTPA of methyl ester.
24
1.4 SCREENING OF SYNTHESIS ROUTE
1.4.1 Alkali/Base-catalyzed Transesterification

A base catalyst is a chemical with a pH value greater than 7. It has the ability to give extra
electrons. Sodium hydroxide (NaOH), potassium hydroxide (KOH), and sodium methoxide
(CH3ONa) are the most common homogeneous base catalysts employed during alkaline
transesterification (Helwani et al., 2009). The base catalyzed process is the most commonly
used because of its relative ease. It can be performed at low temperature and pressure and
yields high conversion (98%) within a short time (Fukuda et al., 2001).
Most important limitation of the base catalysis method is the process sensitivity to both FFA
and water contents. It works perfectly when the FFA and moisture contents are less than
certain limits, usually below 0.5 wt% for FFA (Sivasamy et al., 2009). In case of TGs where
FFA contents exceed this limit, pre-treatment step is required. The presence of FFA promotes
soap formation, which consumes the catalyst, lowers the yield, and more importantly results
in difficult downstream by-products separation and product purification (Al-Zuhair, 2007).
About 60–90% of FAME cost comes from the high cost of the raw material (Al-Zuhair,
2007). In addition, alkali catalyst needs effluent treatment.
Most of the base-catalyzed reactions were carried out at temperatures close to the alcohol
boiling point with alcohol to oil molar ratio of 6:1. Akoh et al. (2007) stated that to increase
methyl ester yield, a stoichiometric excess of substrates (6:1 molar ratio of methanol to oil) is
favoured.
Homogeneous catalysts have been used industrially for methyl ester production where
produced methyl ester and glycerol have to be purified to remove the catalyst. This
purification process requires large quantities of water and energy. Thus, heterogeneous
catalysts have been suggested to overcome this drawback. Heterogeneous catalysts can be
separated easily from the system at the end by filtration and could be reused (Sharma et al.,
2008). Alkaline earth oxides (Ebiura et al., 2005), zeolites (Peterson & Scarrah, 1984),
calcined hydrotalcites (Silva et al., 2010), and Magnesium and Calcium oxides (Granados et
al., 2007) have been suggested as heterogeneous catalysts and showed good results. However,
the high cost of the purified feedstock remains the main problem facing the alkali-catalyzed
process.
25
1.4.2 Acid-catalyzed Transesterification
The reaction of TGs and alcohol may also be catalyzed with an acid instead of a base. Most
commonly used acids are strong acids like sulphuric, sulphonic, phosphoric, and hydrochloric
acids (Meher et al., 2006).
Acid-catalyzed transesterification processes are not as popular as the base-catalyzed

processes, mainly because strong acids are corrosive and the processes are too slow. Several
reactions may be required in order to achieve high conversion. It has been stated that acid-
catalyzed reaction may be 4000 times slower than the base catalyst process (Marchetti et al.,
2007). Above that, it requires high amount of alcohol and higher concentration of catalyst.
Akoh et al. (2007) stated that a molar methanol : oil ratio of 30 : 1 in a range of 55–80°C with
0.5 to 1 mol% catalyst concentration is required to achieve 99% conversion in 50 h. On the
other hand, acid-catalyzed processes offer an important advantage for being independent of
feedstock FFA content. That is because feedstock FFA is not converted to soap using this
kind of catalysts, and hence FAME can be produced from low cost feedstock (Al-Zuhair et
al., 2007).
As mentioned before, feedstock of high FFA content requires a pretreatment step if a base
catalyst is to be used. This pretreatment step can be achieved using acid catalysis and
methanol, where the FFA is esterified to FAME. When equilibrium is reached, the acid
catalyst and produced water are removed from the reaction vessel by centrifugation (Helwani
et al., 2009). This is followed by adding fresh methanol and base catalyst to the oil in order to
catalyze the transesterification reaction.
Heterogeneous acid catalysts have been also used. This is important to avoid problems
associated with homogeneous catalysts. Sulphated tin oxide has been used as superacid
catalysts for waste cooking oil transesterification (Lam et al., 2009). Sulphated zirconia was
also used as catalysts in the alcoholysis of soybean oil and in the esterification of oleic acid
(Garcia et al., 2008). Heteropolyacid was used to transesterify yellow horn oil (Zhang et al.,
2010). Anion and cation exchange resins were used for triolein transesterification reactions
with ethanol to produce ethyl oleate (Shibasaki-Kitakawa et al., 2007).
26
1.4.3 Non-catalytic Transesterification
Although catalysts play a great role in reducing transesterification time, their presence
promotes complications of final product purification. This results in increased production
process cost.
To avoid catalyst drawbacks, supercritical alcohol (SCA) transesterification process was

suggested (Demirbas, 2007). SCA transesterification process is a catalyst free process, which
provides high conversion of oil to ester in a short time. Tan et al. (2009) compared SCM
transesterification with conventional catalytic methods. They reported that conventional
catalyst required 1 hr to convert palm oil to FAME, whereas SCM required only 20 min. As a
result of catalyst absence, purification of the products of the transesterification reaction is
much simpler and environmentally friendly compared to the previously mentioned processes.
In 2001, Saka and Kusdiana conducted a research on methyl ester production from vegetable
oils without any aid of catalysts. The oil-methanol mixture was heated above the supercritical
temperature. Methyl ester was removed from the reaction mixture, and the excess methanol
was removed by evaporation for 20 min at a temperature of 90°C. It was reported that 95%
conversion was achieved in the first 4 min of reaction with optimum process parameters of
alcohol : oil molar ratio of 42 : 1, pressure of 430 bar, and reaction temperature of 350°C.
After one year, Demirbas (2002) studied transesterification of six different vegetable oils in
supercritical methanol and reported that increasing reaction temperature to supercritical
condition had favorable influence on ester conversion.
Compared to catalytic reactions, SCM reactions are fast and can achieve high conversions in a
very short time. However, the reaction requires higher temperatures, pressures, and alcohol to
oil molar ratio in comparison to catalytic transesterification, which result in high production
cost (Sinha et al., 2008).
Specifically, the non-catalytic supercritical transesterification process can be further divided

into two types:
i) One-step supercritical methanol method (Saka process)

ii) Two-step supercritical methanol method (Saka-Dadan process)
27
1.4.3.1 Saka Process
Figure 1-12 shows a schematic diagram of the one-step supercritical methanol method (Saka
process). The superiority of the one-step method can be summarized, compared to the alkali-
catalyzed method as follows: i) the production process becomes much simpler; ii) the reaction
is so fast; iii) FFA in oils/fats can be converted to FAME through methyl esterification and iv)
the yield of FAME is higher (Table 1-13). The one-step method, therefore, offers potentially a
simple process for producing biodiesel fuel.
Although this process has many advantages, it requires restrictive reaction conditions of, for
example, 350°C, 20MPa, 9min and 42 in molar ratio of methanol to triglyceride (Tabe et al.,
2004). In such conditions, special alloys (e.g., Inconel and Hastelloy) are required for the
reaction tube to avoid its corrosion. In addition, FAME particularly from poly-unsaturated
fatty acids, such as methyl linolenate, are partly denatured under this severe condition (Tabe
et al., 2004).
Figure 1-12: Schematic diagram of the one-step supercritical methanol method (Saka process)
(Saka & Minami, 2006)
Table 1-13: Comparison of ester yield from various oils/fats feedstock by various methods
(Saka et al., 2006)
Ester yield, wt%
Feedstocks FFA (wt%) Water (wt%)
Alkali Acid SCM
Rapeseed oil 2 0.02 97 98.4 98.5
Palm oil 5.3 2.1 94.4 97.8 98.9
Waste cooking oil 5.6 0.2 94.1 97.8 96.9
Waste soybean oil 35.5 1.7 n/a 68.8 98.9
Waste industrial oil 37.7 3.3 n/a 71.2 97.9
Dark oil 40.5 1.6 n/a 66 96.3
Waste palm oil >20 61.7 n/a n/a 95.8
28
1.4.3.2 Saka-Dadan Process
To realize more moderate reaction conditions, further effort was made through the two-step
preparation (Saka-Dadan process) as shown in Figure 1-13. In this method, oils/fats are, first,
treated in subcritical water for hydrolysis reaction to produce fatty acids. After hydrolysis, the
reaction mixture is separated into oil phase and water phase by decantation. The oil phase
(upper portion) is mainly fatty acids, while the water phase (lower portion) contains glycerol
in water. The separated oil phase is then mixed with methanol and treated at supercritical
condition to produce FAME thorough methyl esterification. FAME is obtained after removing
unreacted methanol and water produced in reaction. Therefore, in this process, methyl
esterification is the main reaction for FAME formation, while in the one-step method,
transesterification is the major one.
As shown in Figure 1-13, the two-step method can achieve milder reaction conditions than
those of the one-step method. In designing a manufacturing plant for supercritical fluid
process, lower temperature and lower pressure are more desirable. It allows the use of
common stainless steel instead of special alloy for reactors such as Inconel or Hastelloy.
Furthermore, any denaturation was not found for poly-unsaturated FAME (Tabe et al., 2004).
Coincidentally, the two-step method can produce high-quality FAME, compared with the
one-step method, as can be seen in Table 1-14. In case of the one-step method, since glycerol
always exists in the reaction system, a backward reaction occurs to reproduce intermediate
compounds such as monoglycerides (MG) and diglycerides (DG). In the two-step method,
however, glycerol is removed after the hydrolysis reaction so that such a backward reaction
can be depressed in the methyl esterification step.
Figure 1-13: Schematic diagram of the two-step supercritical methanol method (Saka-Dadan
process) by (Kusdiana & Saka, 2004a)
29
Table 1-14: Comparisons in ester yield and total glycerol content of methyl ester prepared by
three different methods (Saka et al., 2006)
Method Ester Yield (wt%) Total glycerol (wt%)
Alkali-catalyzed 94.6 0.17
One-step (Saka process) 98.5 0.39
Two-step (Saka-Dadan process) 99.1 0.15
1.4.4 Enzymatic Transesterification

There is a great interest on using biocatalysts to catalyze TG transformation to FAME, which
has the advantage of having low operating conditions and high product purity. Enzymatic
transesterification can be carried out at 35 to 45°C (Kumar et al., 2004; De Paola et al., 2009).
Contrary to chemical catalysts, enzymes do not form soaps and catalyze esterification of FFA
and TG in one step without any need of the washing step. On the other hand, the major
disadvantages of the enzymatic transesterification are its slower reaction rate and possible
enzyme inactivation by methanol (Jegannathan et al., 2009). Lipase is an enzyme capable of
catalyzing methanolysis reactions. It can be obtained from microorganisms such as bacteria
and fungi. Lipases from Mucor miehei, Rhizopus oryzae, Candida antarctica, and
Pseudomonas cepacia are the most commonly used enzymes (Fjerbaek et al., 2009). Lipases
belong to a group of hydrolytic enzymes called hydrolases. In biological systems, lipases
hydrolyze TGs to fatty acids and glycerol (Marchetti et al., 2007). They work in mild
conditions and have an ability to work with TGs from different origins. They have the ability
to catalyze transesterification of both TGs and FFAs to give esters. The enzymatic process is
also less complicated and does not require as many upstream and downstream operations,
compared to conventional alkali-catalyzed processes.
Although this technology has not received much commercial attention, China has successfully
developed the first industrial scale for FAME production in the world with lipase as the
catalyst at a capacity of 20,000 tons per year which is currently in operation (Du et al., 2008).
Lipase catalyzed production of FAME has been proposed to overcome the most of the
drawbacks facing the conventional chemically catalyzed methods as can be seen in Table 1-15
30
Table 1-15: Comparison of enzymatic technology versus chemical (alkaline and acid)
technology production (Robles-Medina et al., 2009)
Parameter Enzymatic Chemical process
process Alkaline process Acid process
FFA FFA are Soaps formation FFA are converted to FAME
content in converted to
the raw FAME
material
Water It is not Soaps formation. Oil Catalyst deactivation
content in deleterious for hydrolysis resulting
the raw lipase more soaps
material
FAME High, usually High, usually >96% High yields (>90%) only for high
yield around 90% alcohol to oil molar ratio, high
catalyst concentration and high
temperature
Reaction Low High Slower than for alkaline process
rate
Glycerol Easy, high Complex, low grade Complex, low grade glycerol
recovery grade glycerol glycerol
Catalyst Easy, Difficult; neutralized Difficult, the catalyst ends up in the
recovery Reusability by an acid, Partially by-products, No reusable catalyst
and reuse proved but not lost in post-processing
sufficiently steps
studied.
Energy Low, Medium, Temperature: High, Temperature: >100°C
costs Temperature: 60-80°C
20-50°C.
Catalyst High Low Low, High cost of equipment due
cost to acid corrosion
Environme Low; High; wastewater High; wastewater treatment
ntal impact wastewater treatment needed. needed.
treatment not
needed
31
1.4.5 Screening of Catalyst Types
The transesterification reaction can be catalyzed by acids, bases or enzymes. Besides, acid
and base catalysts can be further categorised into homogeneneous and heterogeneous forms.
Table 1-16 shows the advantages and disadvantages of different types of catalyst.
Table 1-16: Comparison of various catalysts for transesterification (Lam et al., 2010)
Type of
Advantages Disadvantages
catalyst
Homogenous  Very fast reaction rate  Sensitive to FFA content
base  Mild reaction conditions  Soap formation (causing yield to
 Inexpensive decrease and increase difficulty for
product and catalyst separation)
Heterogeneous  Faster than acid-catalyzed  Poisoned at ambient air
base reaction  Sensitive to FFA content
 Mild reaction conditions  Soap formation
 Easy separation of catalyst  Leaching of catalyst causing
 Easy to reuse and contamination of product
regeneration of catalyst  Energy intensive
Homogenous  Insensitive to FFA and water  Very slow reaction rate
acid content  Corrosive catalyst (e.g. H2SO4)
 Simultaneous esterification  Separation of catalyst is difficult
and transesterification
possible
 Mild reaction conditions
Heterogeneous  Insensitive to FFA and water  Complicated reaction synthesis
acid content leading to higher processing costs
 Simultaneous esterification  High reaction temperature, high
and transesterification alcohol to oil molar ratio, long
 Easy separation of catalyst reaction time
 Easy to reuse and  Energy intensive
regeneration of catalyst  Leaching of catalyst causing
contamination of product
Enzyme  Low reaction temperature  Very slow reaction rate
(Lower than homogenous  High costs
base catalysts)  Sensitive to alcohol (typically
 Only one purification step methanol, causing deactivation)
required
32
1.4.6 Selection of Synthesis Route
Table 1-17: Comparison of various synthesis routes
Transesterification (1 = Not recommended to 5 = Highly recommended)
Parameter Non-
Base-catalyzed Acid-catalyzed Enzymatic
catalytic
Less Slightly
Familiarity Very familiar Familiar
familiar familiar
5 3 1 2
FAME Yield >96% >90% >98% >90%
4 2 5 2
Reaction rate Fast Very slow Very fast Very Slow
4 1 5 1
Very
Very low (20-
Operating cost Low (60-80°C) High (>100°C) High
50°C)
(>300°C)
4 2 1 5
Low (high
Catalyst cost Low equipment cost due - Very high
to acid corrosion)
4 2 5 1
Very
Alcohol : oil Low (e.g. 6 :
Low (e.g. 6 : 1) High (e.g. 30 : 1) high (e.g.
molar ratio 1)
42 : 1)
5 2 1 5
<0.5wt% FFA (high
Raw material FFA content causes High FFA
High FFA allowed All type
(FFA content) formation of soaps via allowed
saponification)
3 4 5 4
Low (high water Less effects
Raw material Low (high water content No
content causes (Enzyme is
(water causes formation of significan
catalyst not
content) soaps via hydrolysis) t effects
deactivation) deactivated)
3 3 5 4
Easy
Easy (high
Glycerol Complex (low grade Complex (low (high
grade
recovery glycerol) grade glycerol) grade
glycerol)
glycerol)
4 4 5 5
Environmental High (wastewater High (wastewater
Low Low
impact treatment required) treatment required)
2 2 4 4
Total 38 25 37 32
33
Table 1-18: Comparison of homogeneous and heterogeneous alkali catalysts
Base-catalyzed Transesterification (1 = Not recommended to 5 =
Highly recommended)
Characteristics
Heterogeneous
Homogeneous catalyst
catalyst
Familiarity Very familiar Less familiar
5 2
Ease of separation Difficult Easy
2 4
Cost Inexpensive Expensive
4 1
Catalyst regenerate Difficult (neutralized by an acid, partially lost in
Possible
and reuse post-processing steps)
2 4
Total 13 11
Four transesterification synthesis routes are compared based on different characteristics to

determine the most suitable route for FAME production as can be seen in Table 1-17. Each of
the characteristics is rated 1 to 5 where 5 represents for highly recommended while 1 is vice
versa. Base on the result, base-catalyzed transesterification (38 scores) is potentially the best
method to be selected as the synthesis route for the production of FAME. Similarly, this is
followed by comparing the catalyst types as shown in Table 1-18. In this case, the
homogeneous catalyst (13 scores) is preferred to the heterogeneous catalyst, mainly because
of less commercialization of the heterogeneous catalyst and its high prices. As a result, it is
concluded that homogeneous base-catalyzed transesterification technology is to be applied
and utilized as the whole concept of this project for the production of FAME.
1.4.7 Catalyst Options

Although different kinds of base and acid catalysts are available for transesterification
processes, virtually all commercial methyl ester producers use base catalyst. The most
common homogeneous alkali catalysts are:
1. Sodium hydroxide (NaOH)

2. Potassium hydroxide (KOH)
3. Sodium methoxide (NaOCH3)
4. Potassium methoxide (KOCH3)
34
At present, NaOH and KOH are the mostly used industrial catalysts. The reasons that those
two compounds are chosen, lie to the facts that they are widely available and economical and
they cause high conversion to methyl ester in low temperature and pressure in a short reaction
time (Lam, Lee & Mohamed, 2010). Comparing these two in terms of reactivity will not show
many differences but looking at their solubility in alcohols, KOH appears to have better
solubility in methanol than NaOH. However, as KOH is a heavier molecule than NaOH, it is
estimated that 1.4 times more KOH is needed compared to NaOH (Tech, 2014).
The key disadvantage of base catalysis is that if the feedstock has high concentration of FFA
in presence of water, the alkali catalyst will react with the fatty acid to form soaps.
Saponification reaction (see Equation 1.1) hinders the yield of desirable esters giving a tank
full of soap, instead. It was mentioned before that this situation could be faced by pre-treating
the feedstock. However, even if the feedstock is pre-treated NaOH and KOH seem to be very
sensitive catalysts (Enweremadu & Mbarawa, 2009).
R-COOH + NaOH H2O + R-COO-Na (1.1)

Fatty acid Base Water Soap
NaOCH3 and KOCH3 are known to be less sensitive to FFA. They are formed when NaOH
and KOH react with methanol, respectively (see Equation 1.2). They can be produced
industrially and are widely available but slightly more expensive than the alkoxides (i.e.
NaOH and KOH). They can act as catalysts, due to the methoxide anion (CH3O-) which is
their active site; the more the radicals the higher the catalytic activity.
Na+OH- + CH3OH H2O + CH3O-Na+ (1.2)
Moreover, methoxides are weak Lewis bases, therefore the chance of them react with FFA is
lower compared to alkoxides, especially after the pre-treatment. Comparing 1%wt NaOH and
0.5%wt NaOCH3 under same reaction conditions (53℃, 6:1 MeOH:Oil) the methoxide shows
better conversion than its corresponding alkoxide (Freedman et al., 1984). Summing up, after
multiple experiments by researchers comparing at different and same concentrations, reaction
temperatures, and feed molar ratios results showed that potassium-based catalysts gave better
yields than the sodium-based catalysts. Methoxide catalysts also gave higher yields than
corresponding hydroxides. That applies as, KOCH3 > NaOCH3 > KOH > NaOH in terms of
reactivity and catalytic character. However, potassium-based catalyst formulations resulted in
higher soap formation than the corresponding sodium-based catalysts. Using KOCH3, there is
35
going to be at least 1% soap formed even after pre-treatment of oil feesdstock (Thane, 2008).
Hence, that applies as, NaOCH3 > NaOH > KOCH3 > KOH in terms of soap formation
avoidability.
Table 1-19: Comparison of different homogeneous alkali catalysts

Homogeneous Catalysts (1 = Not recommended to 5 = Highly recommended)
Parameter Hydroxide Catalysts Methoxide Catalysts
NaOH KOH NaOCH3 KOCH3
Catalyst Higher than Higher than hydroxide
Low Low
Cost hydroxide catalysts catalysts
5 5 4 4
FAME Lower Lower than Lower than
Very high
Yield than KOH NaOCH3 KOCH3
2 3 4 5
Soap Less than
Very Likely Less than NaOH Less than KOH
Formation KOCH3
4 2 5 3
Higher than NaOH
Catalyst Higher than NaOH due
About 1% due to heavier About 1%
wt% in oil to heavier KOCH3
KOH
5 4 5 4
Total 16 14 18 16
Therefore, based on the summarized information and comparisons between the homogeneous
alkali catalysts as shown in Table 1-19, NaOCH3 (18 scores) is selected to be the best
homogeneous base catalyst.
36
1.5 OBJECTIVES
The objectives of this plant design project are as follow:
1. To produce methyl esters (light cut, middle cut, heavy cut) from RBD palm kernel oil.
2. To achieve the production of methyl esters by using homogeneous base-catalyzed
transesterification method with sodium methoxide (NaOCH3) as catalyst.
3. To achieve the production rate of 60,000 MTPA of combined methyl ester products.
1.6 LEVEL 1 DECISION

As referred to heuristic guidelines, for the process synthesis and flow sheeting, this process is
worth continuous mode. The reasons of the decision are mainly based on the capacity and the
nature of the reaction. This process produces more than 5,000 tons per annum and the raw
materials are only three: RBD palm kernel oil, methanol, and sodium methoxide. The
reactions are not too complex that would not require the use of well-controlled batch reactors.
The demand is considerably consistent and do not change much with years as it is free from
any seasonal difficulties.
At this level, the mole balance would be equated in algebraic terms and calculated through the
outmost boundary of the plant as can be seen in Figure 1-14 along with the gross profitability
analysis.
RBD PKO Methyl ester
Methanol Process Glycerol
Sodium methoxide Sodium methoxide
Figure 1-14: Block flow diagram of level 1 decision
37
1.6.1 Economic Potential 1 (EP1)
The average molecular weights of RBD palm kernel oil (triglyceride) containing three fatty
acids can be calculated (Biodiesel Fuel Education Program, 2014) as:
where 38.049 is the molecular weight of glycerol backbone. The average molecular weight of
fatty acid mixture can be calculated as follow:
∑
∑
where and
Table 1-20: Calculation for average molecular weight of triglyceride

Fatty Acid Composition (wt%) MW of Fatty Acids (kg/kgmol)
C8:0 4.4 144.2114 0.0305
C10:0 3.7 172.2646 0.0215
C12:0 48.3 200.3178 0.2411
C14:0 15.6 228.3709 0.0683
C16:0 7.8 256.4241 0.0304
C18:0 2.0 284.4772 0.0070
C18:1 15.1 282.4614 0.0535
C18:2 2.7 280.4455 0.0096
∑ 99.6 ∑ 0.4620
Assuming the methyl ester mixture produced contains the same carbon distribution as the
RBD PKO (triglyceride), then the average molecular weight of methyl ester mixture can be
calculated as follow:
∑
∑
where and
38
Table 1-21: Calculation for average molecular weight of combined methyl ester product
Methyl Ester Composition (wt%) MW of Methyl Esters (kg/kgmol)
C8 4.4 158.2380 0.0278
C10 3.7 186.2912 0.0199
C12 48.3 214.3443 0.2253
C14 15.6 242.3975 0.0644
C16 7.8 270.4507 0.0288
C18:0 2.0 298.5038 0.0067
C18:1 15.1 296.4879 0.0509
C18:2 2.7 294.4721 0.0092
∑ 99.6 ∑ 0.4330
The annually production rate of combined methyl ester products (CE-810, CE-1214, CE-
1618) is set to be 60,000 MTPA. Therefore, the flow rates can be calculated as shown below:
Hence, based on the stoichiometry of Eq. 1.2, for the production of 260,843.3675 kgmol/yr of
methyl esters and 86,947.7892 kgmol/yr of glycerol, 86,947.7892 kgmol/yr of RBD palm
kernel oil (triglyceride) and 260,843.3675 kgmol/yr of methanol are required.
39
Table 1-22: Calculation for weight fraction of fractionated methyl ester products
Methyl Ester Composition (wt%) Weight Fraction (Basis=99.6kg)
CE-810 (C8-10) 8.1 0.0813
CE-1214 (C12-14) 63.9 0.6416
CE-1618 (C16-18) 27.6 0.2771
Total 99.6 1
Assuming 100% conversion for the production of methyl ester and 100% separation for CE-
810, CE-1214, and CE-1618, the weight distribution for the final products can be determined
as shown in Table 1-22. According to the price lists in Table 1-7, the Economic Potential 1 is
calculated as shown below.
From the result of the economic potential analysis above, it clearly implies that the 60,000
MTPA production of methyl ester products is feasible (EP1>0) at the continuous mode of
operation.
40
2 CHAPTER 2
2.1.1 Input: Raw Material Selection and Impurities Management

Refined, bleached, and deodorized (RBD) palm kernel oil is selected as the raw material for
the alkali-catalyzed transesterification process based on the following consideration:
1. Ample supply of palm kernel oil in Malaysia. Malaysia currently accounts for 39% of
world palm oil production and 44% of world exports. If taken into account of other
oils & fats produced in the country, Malaysia accounts for 12% and 27% of the
world's total production and exports of oils and fats. In fact, Malaysia has become a
world leader in the oleochemicals sector with a total production of 2.3 million tonnes
of palm kernel oil in 2013. As discussed in Chapter 1.3.3.1, there are up to 19
suppliers in Malaysia which makes RBD palm kernel oil available and a promising
feedstock for methyl esters production.
2. Valuable lauric oil content. RBD palm kernel oil is characterized by its high lauric oil
content of approximately 50%. The lauric oils are highly desirable materials in the
oleochemical industry worldwide because of the importance of the lauric fraction
especially in the manufacture of soaps and detergents (Kirk-Othmer, 2012). In the
production of methyl esters, methyl laurate/myristate (C12-14) which is rich in lauric
content has significantly higher price compared to other methyl ester products (i.e.
methyl octanoate/decanoate and methyl palmitate/oleate) as discussed before in
Chapter 1.3.2.
3. Price of RBD palm kernel oil is close to crude palm kernel oil. As mentioned in
Chapter 1.3.2, the price of RBD palm kernel oil is approximately 10% higher than
crude palm oil at all time. Due to the insignificant difference in price, RBD palm
kernel oil is preferred. Also, RBD palm kernel oil as raw material for methyl esters
production tends to provide simplicity to the whole plant process since some
pretreatment steps (e.g. esterification of FFA to methyl esters) can be avoided. Also,
existence of pretreatment step might increase the capital and operating cost of the
plant.
4. Low FFA content. Alkali-catalyzed transesterification is very sensitive to the presence
of free fatty acids (FFA), which leads to undesired soap formation, causing decrease in
41
yield and increase in the downstream separation process. As discussed in Chapter
1.1.2, oil feedstocks containing more than 3% FFA must be pretreated in an acid-
catalyzed esterification process before directed to the transesterification process. Thus,
RBD palm kernel oil with a maximum 0.1% of FFA favours the transesterification
process compared to crude palm kernel oil with approximately 5% FFA content as can
be seen in Table 1-9.
Besides RBD palm kernel oil, the transesterification process involves the use of methanol and
the reaction is catalysed by sodium methoxide (NaOCH3). The reason of choosing NaOCH3
as catalyst is discussed in Chapter 1.4.7.
Before the transesterification process, RBD palm kernel oil needs to undergo pretreatment to
remove any moisture content. As discussed before, the presence of moisture in NaOCH3
reduces the yield from transesterification and results in the formation of soaps. Hence, it is
essential to remove any moisture content of the oil before proceeding to transesterification. In
this case, the RBD palm kernel oil is passed through vacuum oil dryer before it is sent to the
transesterification reactor. The oil at this stage has a moisture content of below 0.01% which
is low enough to assume no other side reaction held during the transesterification process.
42
2.1.2 Output Materials Determination and Decision of Their Destinations
As referred to the heuristics of the destination code in Table 5.1-3 of the Douglas textbook,
the destination of products and impurity of the process are classified based on the boiling
point of all species in the process (see Table 2-1).
Table 2-1: Destination code for transesterification process

Species Boiling Point (oC) Destination Code
RBD Palm Kernel Oil Not pertinent (Very high) Recycle (if X < 95%)
Methanol 64.7 Recycle
a
Sodium Methoxide (30wt% in methanol) 93.0 Waste
b
C8:0 193.0
CE-810 b
C10:0 224.0
b
C12:0 262.0
CE-1214 b
C14:0 295.0
Methyl Ester b
Primary product
C16:0 338.0
b
C18:0 352.0
CE-1618 b
C18:1 349.0
b
C18:2 366.0
Glycerol 290.0 By-product
a b
Source: (Leonid Chemicals, n.d.); (Graboski and McCormick, 1998)
As a rule of thumb in process design, it is desirable to recover more than 99% of all valuable
materials. Thus at the second level of decision, the mole balances are calculated for the
overall system in which the limiting reactant is 100% converted (various conversions are
evaluated inside the process and would appear in the third level of decision). Figure 2-1
depicts the input-output structure of the process.
RBD PKO, FT G,F Methyl ester, PME

(Raw material) (Primary product)
Methanol, FMeOH,F Glycerol, PGL

(Raw material) Process (By-product)
Sodium methoxide, FNaOCH3,F Sodium methoxide, PNaOCH3

(Catalyst) (Catalyst)
Figure 2-1: Block Flow Diagram of Level 2 Decision
43
2.1.3 Kinetic Data of Alkali-catalyzed Transesterification Process
Transesterification of triglyceride involves three consecutive reversible reactions. Partial
methanolysis of triglyceride (TG) results in the formation of diglycerides (DG) in first step,
monoglycerides (MG) in second step whereas glycerol (GL) during the third and final step.
During each one of the reaction step methyl esters (ME‘s) are also produced. The production
of methyl ester by transesterification reaction of triglyceride and methanol involves the
following reactions:
The consecutive reactions:

k1
TG + MeOH DG + ME (2.1)
Triglyceride Methanol Diglyceride Methyl ester
k3
DG + MeOH MG + ME (2.2)
k4
Diglyceride Methanol Monoglyceride Methyl ester
k5
MG + MeOH GL + ME (2.3)
k6
Monoglyceride Methanol Glycerol Methyl ester
The overall reaction:

kA
TG + 3 MeOH 3 ME + GL (2.4)
kB
Triglyceride Methanol Methyl ester Glycerol
where k1, k3, k5 and kA are rate constants for forward reactions and k2, k4, k6 and kB are rate
constants for backward reactions.
The three consecutive transesterification reactions can either be equilibrium reactions, reverse
or forward reactions depending on the working conditions, the chosen catalyst and molar ratio
of alcohol to oil. The kinetic rate constants were written as a function of reaction time using
as follows
44
where CTG, CDG, CMG, CGL, CMeOH, and CME are molar concentrations of TG, DG, MG, GL,
methanol, and methyl ester in a reaction mixture.
According to Rashid et al. (2014), due to the entire steps of reaction produce methyl ester
compound, for that reason, all the intermediate compounds, e.g., monoglyceride and
diglyceride can be negligible and over all reaction conversion as one step described in
Equation 2.4.
The rate law for the sodium methoxide-catalyzed transesterification reaction is defined as the
following (Rashid et al., 2014). According to Rashid et al. (2014), the reaction is proven to
follow the first order model in terms of the concentration of triglyceride and the reversible
reaction is negligible.
where the kinetic data are summarized in Table 2-2 below.
Table 2-2: Kinetic data (Rashid et al., 2014)

Kinetic data Values
k or
Activation energy, Ea 254.5 cal/mol or 1064.81 J/mol
Temperature 60°C
Pressure 1 atm
MeOH:TG molar ratio 6:1
NaOCH3 by weight of TG 1 wt%
45
2.1.4 Mole Balances in Terms of Extent of Reaction
Analysis of mole balance follows the extent of reaction method. The symbol 1 is used to
denote the extent of reaction for the Equation 2.4. The mole balance of all chemical species are
generally computed using the correlation as follows
̇ ̇ (2.12)
where ̇ is molar flow rate of the species i and i is the stoichiometric coefficient. Hence, the
final flow rate from Figure 2-1 can be summarised as in Table 2-3 below.
Table 2-3: Mole Balance for the Second Level of Decision
Species Inlet Change Outlet

Triglyceride –1 0
Methanol –31 0
Methyl Ester 0 31
Glycerol 0 1
Sodium Methoxide 0
In total, other than PME, there are 5 unknown variables. Information available to solve those
variables can be detailed out as follows, based on the material and energy balance textbook
(Felder & Rousseau, 2005).
7 unknown labelled variables (FTG,F, FMeOH,F, FNaOCH3,F, PGL, PNaOCH3) 5
1 independent reaction (Equation 2.4) +1
4 independent reactive species (extent of reactions) -4
1 independent non-reactive species (Inlet = Outlet, FNaOCH3,F = PNaOCH3) -1
1 catalyst concentration (1% of NaOCH3 by weight of TG) -1
Total 0
46
2.1.5 Yield and Reaction Stoichiometry
The definitions of yield and conversion are extracted in equations below (Fogler, 2006).
Therefore, the yield is reflected in the equation below:
As previously defined, the yield is the fraction of triglyceride converted in the reactor that
corresponds to the methyl ester flow at the reactor outlet. Also, this methyl ester is all
recovered and removed (100% separation efficiency for the second level of decision) from the
process. Hence, for a production of (32.6055 kmol/hr), the triglyceride fed to the process
must be
Also, from the stoichiometry Equation 2.4, the amount of methanol fed to the process,
FMeOH,F, should be
Glycerol produced in the reactor is defined as
47
The yield equations are summarized in Table 2-4 below.
Table 2-4: Yield and Reaction Stoichiometry

Component Amount Reacted Amount Produced
Triglyceride 0
Methanol 0
Glycerol 0
Methyl ester 0
Solving the extent of reaction,
From the annual production capacity of 60,000 MTPA of methyl esters, about 32.6054
kgmol/yr methyl esters can be computed using the 8000 operating hours for a year as about 760
hours of the rest time is for the plant turnaround works. The molar flow rate of each species can
be determined as follow.
Methyl ester produced:
Glycerol produced:
Triglyceride fed:
Methanol fed:
48
Therefore, the value of extent of reaction is determined. The molar flow rate of reacted and
produced species are summarized in Table 2-5.
Table 2-5: Extent of Reaction

Component Amount Reacted (kgmol/hr) Amount Produced (kgmol/hr)
Triglyceride 10.8685 0
Methanol 32.6055 0
Glycerol 0 10.8685
Methyl ester 0 32.6054
Hence, the yield can be calculated as follow:
Yield vs Conversion
4
3.5
Y=3
3
2.5
Yield, Y
1.5
0.5
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Conversion, X
Figure 2-2: Graph of yield against conversion
As shown in Figure 2-2, the yield equals to 3 over a conversion range from 0 to 1. Therefore,
it is concluded that the yield for methyl ester production is independent on the conversion.
49
2.1.6 Selectivity
Since there is no side reactions involved in the transesterification process, the selectivity of
conversion is equal to 100%. However, according to the conceptual design of chemical
process (Douglas, 1988) the selectivity is approximated to 95%.
2.1.7 Material Balances for Level 2 Decision
1% of sodium methoxide by weight of triglyceride:
̇ ̇
50
The mole and mass balance is tabulated in Table 2-6 below.
Table 2-6: Mole and mass balances for Level 2 Decision

Component Inlet Change Outlet
Mole Balance (kgmol/hr)
TG 10.8685 – 10.8685 0.0000
MeOH 32.6055 – 32.6055 0.0000
NaOCH3 1.3777 0.0000 1.3777
ME 0.0000 + 32.6055 32.6055
GL 0.0000 + 10.8685 10.8685
Total 44.8517 0.0000 44.8517
Mass Balance (kg/hr)
TG 7442.7727 – 7442.7727 0.0000
MeOH 1044.7422 – 1044.7422 0.0000
NaOCH3 74.4277 0.0000 74.4277
ME 0.0000 + 7500.0182 7500.0182
GL 0.0000 + 1000.9215 1000.9215
Total 8561.9426 + 13.4248 8575.3674
As can be seen in Table 2-6, it is noticed that there is a minor error occurred for the mass
balance calculation. Such insignificant error is expected since the molecular weight of
triglyceride used in the calculation is determined using estimation method which can be
slightly different from the actual value. However, a perfect material (mole and mass) balances
(0% error) can be achieved when the molecular weight of triglyceride is adjusted to 686.0374
kg/kgmol from the previous value (684.8022 kg/kgmol). This is proven in Table 2-7.
51
Table 2-7: Mole and mass balances for Level 2 Decision after correction
TG 10.8685 – 10.8685 0.0000
MeOH 32.6055 – 32.6055 0.0000
NaOCH3 1.3777 0.0000 1.3777
ME 0.0000 + 32.6055 32.6055
GL 0.0000 + 10.8685 10.8685
Total 44.8517 0.0000 44.8517
TG 7,456.1975 -7,456.1975 0.0000
MeOH 1,044.7422 -1,044.7422 0.0000
NaOCH3 74.5620 0.0000 74.5620
ME 0.0000 7,500.0182 7,500.0182
GL 0.0000 1,000.9215 1,000.9215
Total 8,575.5016 0.0000 8,575.5016
2.1.8 Economic Potential 2

Since the practical values of the design variables depend on the process economics, the stream
costs are calculated where all the costs of all raw materials and products streams equated in
term of design variables. The potential of economics at the second level is therefore
( )
] ̇ ̇
52
where
Hence, the equation for Economic Potential 2 is shown below:
Therefore, the graph of Economic Potential 2 against conversion can be seen in Figure 2-3.
EP2 vs Conversion
RM100.00
RM90.00
RM80.00
EP2 (RM million/yr)
RM70.00
RM60.00
RM50.00
RM40.00
RM30.00
RM20.00
RM10.00
RM0.00
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Conversion, X
Figure 2-3: Economic Potential of Level 2 Decision
53
As shown in Figure 2-3, EP2 is equivalent to RM 86,743,951.98/yr from conversion of 0 to 1.
This can be explained since the yield is independent of the conversion, resulting with a yield
equation without related to conversion, X. Hence, the EP2 is constant over the conversion.
54
2.2.1 Block Flow Diagram

At third level, the reactive unit is detailed out. A compressor and a pump, as the major utilities
(due to their significant cost), are necessary here to recycle the unconverted methanol and
triglyceride depending on the conditions (temperature, pressure, phase). The main route of
transesterification is the reaction in Equation 2.4 that occurs in one reactor at the isothermal
temperature of 60°C and the pressure of 1 atm. The molar feed ratio of methanol to RBD
palm kernel oil is fixed to 6:1 (Rashid et al., 2014). Also, the weight of catalyst is 1% by
weight of RBD palm kernel oil fed. The block flow diagram for level 2 decision is shown in
Figure 2-4.
FTG,0 (θMeOH -3X) Methanol recycle
1
FMeOH,F FMeOH,0
PME
FNaOCH3,F
Process Separation
FTG,0 (1-X) PGL
FTG,F FTG,0 FTG,0 (θMeOH -3X)
PNaOCH3
PME PNaOCH3
PGL
FTG,0 (1 -X) Triglyceride recycle

Figure 2-4: Block Flow Diagram of Level 3 Decision
55
2.2.2 Mole Balances
The degree of freedom of the reactor is analysed as follows:
Unknown variables (FTG,0, FMeOH,0, FNaOCH3,F, θMeOH, PNaOCH3, PGL, X) 7

1 independent reaction (Equation 2.4) +1
4 independent reactive species (extent of reactions) -4
1 independent non-reactive species (Inlet = Outlet, FNaOCH3,F = PNaOCH3) -1
1 methanol to triglyceride molar feed ratio (MeOH : TG = 6:1) -1
1 catalyst concentration (1% of NaOCH3 by weight of TG) -1
Total (leaving 1 design variable, X ) 1
There are two mixing points before the reactor which contribute mole change in the stream of
the feeds. The analysis of degree of freedom is started from the stream containing the limiting
reactant as the key component for calculating the recycle stream (at Junction 1). From Figure
4.1, the degree of freedom at Junction 2 is analysed as follows:
Unknown variables (FTG,F, FTG,0, X) 3

FTG,F = PME/Y and Y=3 equations -1
FTG,0 = FTG,F + FTG,0(1-X) -1
From the equation of FTG,0 above,
The analysis of degree of freedom for the mixing point number 1 can be written as follows:
Unknown variables (FTG,0, θMeOH, FMeOH,F, FMeOH,0, X) 5

FTG,0 = FTG,F/X, FTG,F = PME/Y and Y=3 equations -1
Specific molar feed ratio (θMeOH = 6) -1
Feed ratio (FMeOH,0 : FTG,0 = 6:1) -1
FMeOH,0 = FMeOH,F + FTG,0(θMeOH – 3X) -1
56
2.2.3 Reactor Design
The rate law for the sodium methoxide-catalyzed transesterification reaction is defined as the
following (Rashid et al., 2014). According to Rashid et al. (2014), the reaction is proven to
follow the first order irreversible model in terms of the concentration of triglyceride.
where the kinetic data are summarized in Table 2-8 below.
Table 2-8: Kinetic data (Rashid et al., 2014)

Kinetic data Values
k or
Activation energy, Ea 254.5 cal/mol or 1064.81 J/mol
Temperature 60°C
Pressure 1 atm
MeOH:TG molar ratio 6:1
NaOCH3 by weight of TG 1 wt%
From the overall Equation 2.4,
Table 2-9: Stoichiometric Table
Species Inlet Change Outlet Concentration
Triglyceride
Methanol
Sodium
0
methoxide
Methyl
ester
Glycerol
where molar feed ratio of methyl ester and glycerol, and molar feed ratio of
methanol to oil, (Rashid et al., 2014).
57
Hence, from the stoichiometry, the rate law can be further derived as follows:
The concentration of triglyceride fed to the reactor, can be determined as follows:
Table 2-10: Feed information

Inlet, Density (60°C)
Species, Source for density
kgmol/hr kg/kgmol kg/m3 m3/hr
TG 10.8685 684.8022 891.2 8.3514 (Timms, 1985)
(Thermal-Fluids Central,
MeOH 59.7911 32.0419 755.5 2.5358 2010)
NaOCH3
See Appendix A.1.1 (BASF,
30% 6.7976 54.0240 935.0 0.3928 2007)
solution
Total 77.46 = 11.2800
Since the system is a liquid-liquid reaction, the can be assumed as constant as liquid is
incompressible.
Combine,
58
For isothermal reaction,
where
The Levenspiel Plot based on isothermal reaction is as shown in Figure 2-5.
Levenspiel Plot (Isothermal)

1600
1400
1200
FTG,0/(-rTG) (m3)
1000
800
600
400
200
0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Conversion, X
Figure 2-5: Levenspiel Plot (Isothermal: constant k)
59
For adiabatic reaction,
where
[ ( )]
(Obtained from Chapter 2.2.4)
The Levenspiel Plot based on adiabatic reaction is as shown in Figure 2-6.
Levenspiel Plot (Adiabatic)

1600
1400
1200
FTG,0/(-rTG) (m3)
1000
800
600
400
200
0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Conversion, X
Figure 2-6: Levenspiel Plot (Adiabatic: k changes with temperature)
From the Levenspiel Plots in Figure 2-5 and Figure 2-6 above, it is concluded that there is no
significant differences between the isothermal trend and adiabatic trend (see Appendix A.1.2
for detailed tabulated data). Also, Plug Flow Reactor (PFR) will optimise the volume with
such Levenspiel Plot. However, the transesterification process requires agitator for proper
mixing of reactants. Hence, CSTRs in series (which is equivalent to a PFR) are used in this
case. Moreover, isothermal operation of CSTRs is preferred since adiabatic operation requires
bigger reactor size (see Appendix A.1.2). The CSTRs design is discussed as below.
60
The following formulas determine the volume of each equal-sized CSTRs connected in series
( ⁄ ) operating at the same temperature (
) (Fogler, 2006).
where
Rearranging,
*( ) +
where
The Equation 2.17 is used to determine the volume (m3) of each CSTR reactor by specifying
the number, n of CSTRs in series as can be seen in Figure 2-7. Theoretically, it is preferred to
have higher overall conversion (conversion of triglyceride from a combination of CSTRs in
series) but lower number, n of CSTRs due to high costs. Based on Figure 2-7, the best option
goes to three CSTRs in series with 53m3 of each CSTR which is capable to achieve 99%
overall conversion (see Appendix A.1.3 for detailed tabulated data). With a production rate of
60,000 MTPA of methyl esters, a volume of 53m3 for each CSTR is feasible.
61
Volume of each CSTRs vs Conversion
100
90
80
70
Volume of each CSTRs (m3)
60
50
40
30
20
10
0
0.7 0.75 0.8 0.85 0.9 0.95 1
Overall Conversion, X
1 CSTR 2 CSTRs 3 CSTRs 4 CSTRs 5 CSTRs
Figure 2-7: Graph of volume of each CSTRs against conversion
62
The conversion (Xi) of each CSTR reactor can be calculated using the following formula
(Fogler, 2006).
where
The conversions according to number of CSTRs are summarized in Table 2-11.
Table 2-11: Conversions according to number of CSTRs

Number of CSTRs, n Conversion, Xi
st
1 CSTR = 1 78.56 %
1st CSTR + 2nd CSTR = 2 95.40 %
1st CSTR + 2nd CSTR + 3rd CSTR = 3 99.01 %
63
2.2.4 Reactor Heat Effect
The study of reactor heat effect involves the following assumptions:
1. Adiabatic operation, Q = 0
2. No work involved
Table 2-12: Heat of formations of the components

Component (liquid) Heat of formation, Hf 298K (kJ/mol) Source
a
RBD Palm kernel oil (TG) -2068.01
a (Domalski, 1972)
Methyl Ester (ME) -700.53
Methanol (MeOH) -238.40 (Chao & Rossini, 1965)
Glycerol (GL) -669.60 (Bastos et al., 1988)
a
Estimated as shown in Appendix A.1.4.
The formula for Heat of Reaction, is as follows:
Hence, at 298 K,
[ ]
[ ]
Therefore, the reaction is slightly endothermic as the value for heat of reaction gives a
positive value of 12.02 kJ/mol.
64
The heat capacity for liquid methanol is defined as:
where T is in unit of Kelvin (K) and .
Table 2-13: Heat capacity constants for liquid methanol (Smith et al., 2005)
Component (liquid) A B C
Methanol (MeOH)
The heat capacity for liquid glycerol is defined as:
where T is in unit of Kelvin (K).
Table 2-14: Heat capacity constants for liquid glycerol (Coker, 2007)
Component (liquid) A B C D
Glycerol (GL)
According to the thermophysical data provided from Morad et al., (2000), the heat capacity
equation for RBD palm kernel oil can be defined as (see Appendix A.1.5):
Besides, according to Pauly et al., (2014), the heat capacity equation for PKO methyl esters
can be defined as (see Appendix A.1.6):
65
The formulas of heat capacities for each component at different temperature (Kelvin) are
tabulated in Table 2-15 below.
Table 2-15: Formulas of heat capacities of each component

Component Heat Capacity,
RBD Palm kernel oil
PKO Methyl Ester
Methanol
Glycerol
( )
The equation below is used to plot graph of reactor outlet temperature versus conversion to
study the heat effect of the reactor itself.
( )
[ [( ) ( )] ]
( )
[ [( ) ( )] ]
66
Figure 2-8: Graph of reactor outlet temperature against conversion using Polymath
According to Janajreh et al. (2014), the transesterification reaction is neither exothermic nor
endothermic. Because of this, the temperature effect does not reflect a unified trend and is
also less pronounced. Based on the Polymath-generated result in Figure 2-8, there is only a
slight decrease (-6 K) in reactor outlet temperature from conversion of 0 to 1. As calculated
before, the heat of reaction gives a value of 12.02 kJ/mol which is very small (slightly
endothermic) and this explains why the reaction is neither exothermic nor endothermic.
Therefore, this transesterification reaction does not require significant amount of heat input to
the reactor which is potentially more economic.
67
Reactor Outlet Temperature vs Conversion
350
345
340
335
Temperature, T (K)
330
T = -6.3376 X + 333.16
325
320
315
310
305
300
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Conversion, X
Figure 2-9: Graph of reactor outlet temperature against conversion using MS Excel
In order to obtain a relationship between reactor outlet temperature and conversion (T as a

function of X), the data obtained from Polymath software are used to generate graph in MS
Excel. From Figure 2-9, the relationship between reactor outlet temperature and conversion is
shown below.
68
2.2.5 Equipment Cost
The CSTR (mixer/settler) cost estimation follows the formula as below (Turton et al., 2013).
( ) [ ]
where,
Therefore,
( ) [ ]
* [ ] +
( )
Then,
( )
where for reactors.
Combine,
[ [ ] ]
The formula below is used to calculate the purchased equipment cost in year 2013. The
Chemical Enginnering Plant Cost Index (CEPCI) for year 2013 is equal to 567.3 (Chemical
Engineering, 2014). While the CEPCI for the base (September 2001) is 397.0 (Turton et al.,
2013).
69
( )
where C=CBM and I= Index cost
Combine,
[ [ ] ]
( )
By taking the currency rate USD 1 = RM 3.25,
[ [ ] ]
( )
*( ) +
where
(3 CSTRs in series decided in Chapter 2.2.3)
70
Relating Equation 2.18 and 2.19, the costs of reactor based on different conversions is
summarized in Table 2-16. Also, Figure 2-10 displays the trend of reactor cost over
conversion.
Table 2-16: Cost of Catalyst at different Conversion

Conversion, X Volume of 3 CSTRs in series (m3) Reactor Cost (2013) (RM/yr)
0.10 1.5507 1,163,843.00
0.20 3.3500 1,642,954.47
0.30 5.4772 2,047,144.02
0.40 8.0535 2,432,364.49
0.50 11.2766 2,827,437.20
0.60 15.4974 3,259,233.40
0.70 21.4234 3,766,708.06
0.80 30.8020 4,430,104.69
0.90 50.0847 5,504,374.24
0.91 53.4257 5,665,403.70
0.92 57.3022 5,845,396.07
0.93 61.8850 6,049,686.13
0.94 67.4355 6,286,181.89
0.95 74.3793 6,567,320.53
0.96 83.4728 6,914,306.41
0.97 96.2400 7,367,788.25
0.98 116.4457 8,021,853.67
0.99 157.9889 9,191,722.97
Reactor Cost vs Conversion

10.00
9.00
Reactor Cost (RM million)
8.00
7.00
6.00
5.00
4.00
3.00
2.00
1.00
0.00
0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00
Conversion, X
Figure 2-10: Graph of reactor cost against conversion
71
2.2.6 Catalyst Cost
As stated in Table 1-7, the price of sodium methoxide (30wt% NaOCH3 solution) catalyst is
RM 2,760/MT. Hence the cost of catalyst is determined as follow:
The catalyst used is 1.0% by weight of RBD palm kernel oil fed to the reactor. Hence,
where,
Combine,
At this level, the cost for the recycle stream can be ignored. This is because the pump to be
used at liquid recycle stream does not cost significantly.
72
2.2.7 Economic Potential 3
Therefore, the Economic Potential 3 can be determined as follows:
where,
[ [ ] ]
( )
*( ) +
EP3 vs Conversion
100.00
80.00
60.00
EP3 (RM million/yr)
40.00
20.00
0.00
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
-20.00
-40.00
-60.00
Conversion, X
Figure 2-11: Economic Potential of Level 3 Decision
73
EP3 vs Conversion (Magnified)
80.00
75.00
EP3 (RM million/yr)
70.00
65.00
60.00
55.00
50.00
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Conversion, X
Figure 2-12: Economic Potential of Level 3 Decision (Magnified)
Based on Figure 2-11 and Figure 2-12, the economic potential starts to be profitable above
conversion of 0.07. It is observed that the highest conversion which can be obtained is 0.81
with a profit of RM75,469,779.47/yr (RM 75.5 million/yr). However, a 99% conversion with
RM 72 million/yr profit is selected for the production of oleochemical methyl ester due to
complexity in recycling unreacted RBD palm kernel oil and high separation costs (i.e.
distillation column). Also, increasing the conversion from 0.81 to 0.99 does not significantly
decrease the profit (only RM 3.5 million/yr difference). Besides, as discussed before in
Chapter 2.2.3, 99% conversion requires three CSTRs in series with each volume of 53m3.
Therefore, it is feasible to select 99% conversion with RM 72 million/yr profit.
74
2.2.8 Material Balances for Level 3 Decision
The molar and mass balances are calculated based on selected conversion from Level 3
Decision which is X = 0.99. The molar and mass balances for the overall transesterification
process are calculated (see Appendix A.1.7) and tabulated in Table 2-17.
Table 2-17: Molar and mass balances for Level 3 Decision

TG 10.9783 -10.8685 0.1098
MeOH 65.8697 -32.6055 33.2642
NaOCH3 1.3916 0.0000 1.3916
ME 0.0000 32.6055 32.6055
GL 0.0000 10.8685 10.8685
Total 78.2396 0.0000 78.2396
TG 7,517.9522 -7,442.7727 75.1795
MeOH 2,110.5902 -1,044.7422 1,065.8481
NaOCH3 75.1795 0.0000 75.1795
ME 0.0000 7,500.0182 7,500.0182
GL 0.0000 1,000.9215 1,000.9215
Total 9,703.7220 13.4248 9,717.1468
75
2.2.9 Energy Balances for Level 3 Decision
The energy balances are calculated based on selected conversion from Level 3 Decision
which is X = 0.99. The energy balances for the transesterification process are visualized in
Figure 2-13.
TG
TG MeOH
MeOH Δ NaOCH3
NaOCH3 ME
T K GL
m T K
Δ ˚R Δ ˚P
TG
MeOH
NaOCH3
ME
GL
TG
MeOH
NaOCH3 Δ ˚ 98 K
Figure 2-13: Calculation Path for Transesterification of Triglyceride to Methyl Ester
˚ 98 K [ ]
[ ]
Reactants
TG:
98 K
∫ T
K
m
MeOH:
76
98 K
∫ T
K
m
Products
TG:
K
∫ T
98 K
m
MeOH:
K
∫ T
98 K
m
ME:
K
∫ T
98 K
m
GL:
K
∫ T
98 K
Table 2-18: Calculation for energy balances at 60°C and 1 atm

Fin Hin Fout Hout
Component
(kgmol/hr) (kJ/mol) (kgmol/hr) (kJ/mol)
TG 10.9783 -50.3297 0.1098 50.3297
MeOH 65.8697 -3.0025 33.2642 3.0025
ME - - 32.6055 16.9838
GL - - 10.8685 9.2285
∑ ( )( )
( )( )
77
∑ ( )( )
( )( )
( )( )
( )( )
Therefore,
̇ ̇ ˚ 98 K ∑ ∑
where ̇ m (amount of triglyceride converted).
̇ ( )( )
̇ ̇ ̇ ̇ ̇
̇ ̇
Thus, 38.8328 kW of heat energy must be supplied to the reactor to maintain the reaction
temperature at 60°C.
78
2.3.1 Separation Decision
2.3.1.1 Methanol Recovery System

Most methyl ester production process use excess methanol to get high yield. This excess
methanol is distributed between the two products (Gerpen, 2004). After the methyl ester
process is completed, a lot of methanol is available for recovery and reuse. Residual methanol
in the methyl ester is a major environmental and health safety issue since it is toxic,
flammable and more dangerous to handle and store. Besides, methanol recovery can be
carried out immediately following transesterification to reduce the load in downstream units
(Zhang, 2003). For these reasons, most conventional methyl ester manufacturers use
distillation column and flash evaporation for methanol recovery (Gerpen, 2004). Distillation
can do the separation very efficiently, but its major disadvantage is the high energy
requirement while flash evaporator is inexpensive but low in separation efficiency.
Figure 2-14: Methanol recovery system (Zoller, 2008)
79
According to Zoller (2008), the transesterification reactor effluent with excess methanol is
pumped over to the distillation system where methanol is separated for recycling to the
process (see Figure 2-14). The solution first enters a preheater where it is heated to the boiling
point and then is fed to the middle of distillation tower. The distillation column is equipped
with multiple beds of the overhead packing. Overhead vapours pass through a reflux
condenser, which returns a portion of the overhead (methanol stream) to the tower and
discharges a portion as recovered methanol. The tower bottoms stream (methyl ester and
glycerol) is discharged to downstream for further separation. The distillation tower system
may be located remotely from the methyl ester production plant and has its own control
systems local to the system. The distillation system may be taken offline periodically for
cleaning procedures (Zoller, 2008).
Figure 2-15: Two-stage flash distillation methanol recovery process (Tang et al., 2010)
According to Tang et al. (2010), a high purity of methanol recovery with lower energy cost
can be achieved using two-stage flash distillation process (see Figure 2-15). Compared to one-
stage flash distillation method, two-stage methanol recovery system allows lower feed
temperature which reduces the operating cost of preheaters. Besides, two-stage system operate
at lower temperatures prevents light methyl ester like methyl octanoate (C8:0) from being
recycled with methanol which could lower its yield in downstream (Tang et al., 2010).
80
2.3.1.2 Glycerol separation
Following the reaction, the glycerol is removed from the methyl esters. Due to the low
solubility of glycerol in the esters, this separation generally occurs quickly and may be
accomplished with either a settling tank or a centrifuge (Bray, 2004). Glycerol is separated
using a settling tank as also very often and is usually applied in the current methyl ester
industries.
2.3.1.3 Methyl ester washing process

A water washing step is intended to remove any remaining catalyst, soap, salts, methanol or
free glycerol from the methyl ester. Neutralization before washing reduces the water required
and minimizes the potential for emulsions to form when the wash water is added to the methyl
ester. Following the wash process, any remaining water is removed from the methyl ester by a
vacuum flash process. In recent years, so-called waterless wash processes have been
developed that minimize the need for waste water treatment and disposal (Extension, 2012).
2.3.1.4 Fractional distillation

Because methyl esters are derived from natural sources, their initial and distilled
compositional mixtures tend to vary even when the same type of fat or oil is used. Users
generally prefer pure methyl esters or mixtures of methyl esters of consistent composition and
known properties. Fractional distillation separates methyl esters based on their boiling points.
Methyl esters which differ in chain length by two carbons are easily separated, thus; methyl
ester fractions of 90% or better purity are obtained (Potts & White, 1953; Ruston, 1952).
Fundamentally, fractional distillation is carried out in the same manner as continuous
distillation. The main difference is in the design of the main fractionating column which is
fitted with several bubble cap trays, means for removal of side stream distillates of methyl
esters and return part of these streams as reflux (Muckerheide, 1952; Stage, 1984).
Fractionating stills are custom designed to suit the feedstock and product requirements. With
lauric type methyl ester from coconut and palm kernel oils, up to 30 fractionating trays can be
used for highest purity fraction because of the higher volatility and greater stability of the
shorter chain methyl esters. Long chain methyl ester like methyl arachidate (C20:0) in
rapeseed oil have much lower vapor pressure and would need a limited number of
fractionating trays to keep the reboiler below the decomposition temperature (Berger &
McPherson, 1979). The first continuous fractional distillation unit for separation of
81
oleochemical products was installed by Armour and Company in 1933 (see Figure 2-16). The
system consisted of conventional air ejectors and boosters to allow vacuum operating
condition.
Figure 2-16: Schematic diagram of fractional distillation employed by Armour and Company
in 1933 (Potts & White, 1953)
Fractional distillation makes it possible to separate the methyl esters mixture in to narrower
cuts or even individual component to give multiple fractions of higher value e.g. methyl esters
produced from palm kernel oil base gives light cut (usable feed stock for fatty alcohols) ,
middle cut (usable feed stock for MES – replacement of LABS ) and heavy cut - summer
grade biodiesel (C18 cut) from feed stock having C8-C18 chain fatty acids. Similarly the
multistage fractional distillation can give number of desired fractions by employing two or
more columns. Basically, each stage uses the deaerator, heat source, fractional column,
condensing system, and vacuum source. Vacuum system is provided independently for each
column to achieve highest vacuum and greater recovery of desired products (Specengineers,
2009).
82
2.3.2 Process Flow Diagram
The process flow diagram for the production of methyl esters is modified based on the several
references by Haas et al. (2006); Zhang et al. (2003); Dipesh & Ahmad (2013); West et al.
(2008); Martinez et al. (2010); Myint & El-Halwagi (2008); . The reference of process flow
diagram is studied and described according to its process before the decision making on our
process flow diagram. The actual process flow diagram for our plant is discussed and justified
from the modification of the reference flow diagram. Figure 2-17 shows the production of
methyl ester production plant that uses sodium methoxide as catalyst.
2.3.2.1 Process flow diagram based on industrial design
Figure 2-17: Process flow diagram for conventional sodium methoxide-catalyzed methyl
esters production process (Haas et al., 2006)
Transesterification of triglycerides with methanol, catalysed by sodium methoxide, was

modelled as a continuous reaction conducted in steam jacketed, stirred tank reactors at 60°C.
Sodium methoxide was chosen as the catalyst because it is employed by a substantial
proportion of industrial methyl ester facilities. Methyl, rather than ethyl, ester production was
modelled because methyl esters are the predominant product of commerce, because methanol
83
is considerably cheaper than ethanol, and due to the greater ease of downstream recovery of
unreacted alcohol.
Two sequential transesterification reactions were modelled. Product was removed from the
reactor at a rate equal to the rate of charging with reactants and catalyst in such manner as to
give a residence time of 1 hour in the reactor. The mixture of methyl esters, glycerol,
unreacted substrates and catalyst was fed to a continuous centrifuge. Typical municipal
quality water is used for this, and all subsequent, washes. The glycerol-rich aqueous stream
from this operation is sent to the glycerol recovery section while the impure methyl ester
product goes to the refining section for purification and dehydration.
The crude methyl ester stream is washed with water at pH 4.5 to neutralize the catalyst and
convert any soaps to free fatty acids, reducing their emulsifying tendencies. Centrifugation is
then employed to separate the methyl ester from the aqueous phase. The latter is cycled to the
glycerol recovery section.
The glycerol liberated during the transesterification has substantial commercial value of
purified to USP grade. However, this process is expensive. Small and moderately sized
operations, including those of the scale modelled here, often find it most cost effective to
partially purify the glycerol, removing methanol, fatty acids and most of the water, and selling
the product (80% glycerol by mass) to industrial glycerol refiners.
84
2.3.2.2 Process flow diagram for this plant design project
R-101 R-102 R-103 C-101 C-102 V-101 C-103 C-104 C-105 C-106 T-101 T-102 T-103 T-104
1st 2nd 3rd 1st MeOH 2nd MeOH ME Washing ME Purification CE-810 Vacuum CE-1214 and GL Purification CE-810 CE-1214 CE-1618 GL Storage
Transesterification Transesterification Transesterification Evaporator Evaporator Decanter Column Column CE-1618 Column Storage Tank Storage Tank Storage Tank Tank
CSTR CSTR CSTR Splitter
1.2 at m
60 °C 1 at m 1 at m
60 °C 129 °C
P-105 E-103 M-103

1.2 at m 1 at m 1 at m
25 °C 120 °C 160 °C
1 at m 1 at m
25 °C
MeOH 42 °C
M-101
1.2 at m 1 at m 1 at m 1 at m 1 at m 1 at m
P-101 25 °C 32 °C 60 °C 60 °C 120 °C 160 °C
C-101 C-102
1 at m
25 °C
NaOCH3
R-101 R-102 R-103
1.2 at m M-102 E-101 E-102 E-104
P-102 25 °C
1 at m
25 °C
TG 1 at m
1.2 at m 120 °C
P-103 25 °C
1 at m
1 at m 160 °C
25 °C
Water 1 at m 1.2 at m
50 °C 160 °C
P-104
V-101
1.2 at m
1 at m E-106 50 °C 1 at m
91 °C P-107 50 °C
E-105
1 at m P-106 1 at m
130 °C 25 °C
1 at m To waste water
50 °C treatment
1.2 at m 1 at m E-114
50 °C 130 °C
C-106
0.5 at m 0.5 at m
59 °C 25 °C
To waste water E-113 1 at m 1 at m
treatment P-113 130 °C 25 °C
E-107 T-104
1 at m (Glycerol)
0.25 at m 158 °C E-115
C-103 158 °C
1 at m
E-109 25 °C
0.7 at m 0.5 at m P-109
0.5 at m 236 °C 185 °C T-101
236 °C 0.07 at m (CE-810)
C-104 176 °C
E-108
1 at m 1 at m
P-108 176 °C
E-111 25 °C
0.45 at m 0.25 at m P-111
0.25 at m 226 °C 198 °C
226 °C T-102
C-105
(CE-1214)
E-110
P-110
1 at m 1 at m
0.07 at m 237 °C 25 °C
237 °C
T-103
(CE-1618)
E-112
P-112
Figure 2-18: Process flow diagram for this plant design project (see Appendix A.6.1 for enlarged version)
85
2.3.2.3 Process flow diagram designed using Aspen Plus v8.0
12
11 10
E-103
P-105 M-103
1
MEOH
4 9 15
M-101
P-101
2 5 6
NAOCH3
E-101 7 8 C-101 14 C-102
M-102
P-102
R-100 E-102 E-104
3 13
TG
P-103
19 16
WAT ER
P-104
22 21
20 18 17
E-106
E-105
V-101
P-107
P-106
40 43 44
E-114
41 42 C-106
E-113
P-113 45 46
23 24
E-115
E-107 29 30
C-103 28
E-109 36
35
26 27 C-104 P-109 34
25
E-111
E-108 32 33 P-111
C-105
P-108 31
E-110 38 39
P-110 37
E-112
P-112
Figure 2-19: Process flow diagram designed using Aspen Plus v8.0
86
2.3.2.4 Process descriptions
Figure 2-18 and Figure 2-19 show the process flow diagrams for this plant design work
designed using Microsoft Visio and Aspen Plus v8.0 respectively. The process synthesis
descriptions are discussed as follow. The major unit operations‘ specifications are
summarized in Appendix A.5.1.
Process input streams

In short, there are a total of four process input streams which are ―MeOH‖, ―NaOCH3‖,
―TG‖, and ―Water‖. Based on the material balances done in Level 3 Decision, 7530.69 kg/hr
of triglyceride (RBD palm kernel oil) is required to achieve a 60,000 MTPA methyl esters
production capacity. The process is carried out with a 100% excess of methanol to oil or 6:1
molar ratio with 1wt% sodium methoxide based on oil. Since excess methanol is recovered
during the process, the amount of fresh feed methanol can be reduced and this is also
calculated in Level 3 Decision. For the water fed to the decanter, the water input flow rate is
determined as 1:1 volume ratio of water to methyl esters fed to the decanter V-101 (Rahayu &
Mindaryani, 2011). The information of input streams is summarized in Table 2-19 below.
Table 2-19: Input streams information

Input stream
MeOH NaOCH3 TG WATER
Temp., °C 25 25 25 25
Pres., atm 1 1 1 1
Moleflow, kmol/hr 35.2503 1.3916 10.9783 485.2520
Massflow, kg/hr 1129.50 81.33 7530.69 8741.95
Mass fraction
TG-8 0.000 0.000 0.044 0.000
TG-10 0.000 0.000 0.037 0.000
TG-12 0.000 0.000 0.485 0.000
TG-14 0.000 0.000 0.157 0.000
TG-16 0.000 0.000 0.078 0.000
TG-18 0.000 0.000 0.199 0.000
ME-8 0.000 0.000 0.000 0.000
ME-10 0.000 0.000 0.000 0.000
ME-12 0.000 0.000 0.000 0.000
ME-14 0.000 0.000 0.000 0.000
ME-16 0.000 0.000 0.000 0.000
ME-18 0.000 0.000 0.000 0.000
GL 0.000 0.000 0.000 0.000
MEOH 1.000 0.000 0.000 0.000
WATER 0.000 0.000 0.000 1.000
NAOCH3 0.000 1.000 0.000 0.000
87
Transesterification reactor R-101/2/3
The transesterification reactions are carried out at 60°C and 1 atm by three continuous stirred
tank reactors (CSTRs) in series (53m3 each) to achieve a total of 99% conversion of
triglyceride. CSTRs in series are chosen instead of one PFR because the reaction requires
external mixing energy which can be done by stirrers. The conversion at each stage of CSTR
is summarized in Table 2-20 below as calculated before in Level 3 Decision.
Table 2-20: Conversion of triglyceride at each reactor

1st CSTR = 1 78.56 %
1st CSTR + 2nd CSTR = 2 95.40 %
1st CSTR + 2nd CSTR + 3rd CSTR = 3 99.01 %
1st methanol recovery column C-101

The reaction products which consist of methyl esters, glycerol, trace amount of unreacted
triglyceride, and excess methanol is then preheated to 130°C and fed to first methanol recover
flash column C-101 operated at atmospheric pressure (1 atm). At the first stage of methanol
recovery process, about 75% of methanol fed is recovered and recycle back to the reactor inlet
stream.
2nd methanol recovery column C-102

It is ideal to fully recover the excess methanol from the reactor outlet by using one unit
operator (i.e. flash drum). However, this approach requires higher heat duty of the preheater
(heat exchanger), which may result in higher operating cost. Theoretically, the higher the inlet
temperature of the stream fed to the flash drum, the higher the methanol recovery efficiency.
However, the higher the temperature, the higher the amount of primary product (e.g. light cut
methyl esters, C8:0) is being flashed off in vapour stream which is not preferred. Therefore, a
second methanol recovery flash drum, C-102 is installed to optimize the above considerations.
By two-stage methanol recovery process, a high purity of methanol recovery with lower
energy cost can be achieved and at the same time do not flash off the primary products (Tang
et al., 2010). In overall, the two-stage methanol recovery process recovers and recycles a total
of 92% methanol back to the reactor inlet stream. The decision of choosing flash drum instead
of a more efficient distillation column is also due to significant high operating cost of the
distillation column that requires large heat energy for condenser and reboiler.
88
Decanter V-101
Then, then liquid products (bottoms) from the flash drum C-102 enter a decanter (V-101) to
separate methyl esters and glycerol based on their density. Theoretically, the decanter is
favourable to separate methyl esters and glycerol at low temperature. This is because the
lower the temperature, the higher the density of the mixture components, resulting in more
glycerol being separated to the bottom liquid layer. In this case, the liquid product from flash
drum C-102 is being condensed to 50°C before entering the decanter. Fresh water is fed to the
decanter which also makes the decanter as a washing vessel to increase the efficiency of
methyl esters-glycerol separation. A 1:1 water to methyl esters volume ratio is assumed here
(Rahayu & Mindaryani, 2007).
Methyl ester purification column C-103

The upper layer liquid product from the decanter V-101 consisting mostly of methyl esters is
then preheated to 91°C before entering the distillation column C-103 with 21 theoretical
stages and the reflux ratio of 0.0796. The purpose of C-103 is to purify the methyl ester
products by removing most of the light components such as methanol and water to be further
processed in waste water treatment. The bottoms which consist mostly of methyl ester
products with carbon distribution from C8 to C18 is further separated in a series of distillation
columns to produce methyl esters at light-cut (methyl octanoate/decanoate), middle-cut
(methyl laurate/myristate), and heavy-cut (methyl palmitate/oleate) which are the final desired
products.
Light cut separation column C-104

The purpose of C-104 is to produce light product (methyl octanoate/decanoate) as distillate.
This distillation column consists of 16 theoretical stages with 4.0340 reflux ratio that operates
at vacuum pressure of 0.25 atm.
Middle/heavy cut separation column C-105

The purpose of C-105 is to separate middle product (methyl laurate/myristate) as distillate and
heavy product (methyl palmitate/oleate) as bottoms. This distillation column consists of 25
theoretical stages with 0.4777 reflux ratio that operates at vacuum pressure of 50 mmHg. C-
103, C-104 and C-105 are kept below the atmospheric pressure in order to maintain the
bottom product temperature under 250°C, which will prevent decomposition of methyl ester
products.
89
Glycerol purification column C-106
On the other hand, the high density products (i.e. glycerol, water, sodium methoxide) at
bottom layer of decanter are sent to a flash drum to flash out excess water and methanol to
produce crude glycerol at more than 80wt% purity.
Process output streams

There are a total of six process output streams which are stream number 24, 44, 46, 30, 36,
and 39 where streams 24 and 44 are conveyed to waste water treatment, stream 30 to methyl
octanoate/decanoate storage tank (T-101), stream 36 to methyl laurate/myristate storage tank
(T-102), stream 39 to methyl palmitate/oleate storage tank (T-103), and stream 46 to crude
glycerol storage tank (T-104). The information of output streams is summarized in Table 2-21
below.
Table 2-21: Input streams information

Output stream
24 44 46 30 36 39
Temp., °C 25 25 25 25 50 50
Pres., atm 0.5 1 1 1 1 1
Moleflow, kmol/hr 2.0450 475.5948 22.3026 3.4665 21.8801 7.3870
Massflow, kg/hr 60.96 8614.13 1231.42 598.13 4800.79 2170.60
Mass fraction
TG-8 0.000 0.000 0.000 0.000 0.000 0.002
TG-10 0.000 0.000 0.000 0.000 0.000 0.001
TG-12 0.000 0.000 0.000 0.000 0.000 0.017
TG-14 0.000 0.000 0.000 0.000 0.000 0.005
TG-16 0.000 0.000 0.000 0.000 0.000 0.003
TG-18 0.000 0.000 0.000 0.000 0.000 0.007
ME-8 0.208 0.000 0.000 0.533 0.000 0.000
ME-10 0.018 0.000 0.000 0.353 0.014 0.000
ME-12 0.004 0.000 0.000 0.112 0.744 0.000
ME-14 0.000 0.000 0.000 0.001 0.238 0.014
ME-16 0.000 0.000 0.000 0.000 0.002 0.266
ME-18 0.000 0.000 0.000 0.000 0.000 0.686
GL 0.000 0.003 0.781 0.000 0.002 0.000
MEOH 0.438 0.006 0.000 0.000 0.000 0.000
WATER 0.333 0.991 0.153 0.000 0.000 0.000
NAOCH3 0.000 0.000 0.066 0.000 0.000 0.000
90
2.3.3 Material Balance
The production plant is designed to produce 60,000 MTPA of methyl esters. This production
plant consists of three CSTRs in series for transesterification reaction, a two-stage methanol
recovery flash system, decanter, three distillation columns, and a flash column for glycerol
purification. By feeding the triglyceride at 60,143 MTPA, methanol at 9,036 MTPA, and
sodium methoxide at 651 MTPA, the targeted production of methyl esters can be achieved.
Procedure for material balance calculation

There are several rules of thumb to be followed. Below are the guidance followed when
performing the material balance calculation.
(a) Flowchart is constructed, all given variable values are filled in.
(b) A basis of calculation of amount or flow rate for one of the process streams is chosen.
If one such quantity is given, it is usually most convenient to use it as the basis of the
calculation; all subsequently calculated quantities will then be correctly scaled. If no
amounts or flow rate is specified, normally it assumes the amount of a stream with a
known composition. This value then will be put in the flowchart.
(c) All unknown stream variables on the chart, particularly mass or molar flow rates and
mass or mole fractions of the stream components are labelled. Relationship between
unknown quantities in the labelling should be incorporated as well.
(d) Problems are being book kept. Unknown and relations among them are identified. If
the numbers are equal, lie out the problem solution; if not, there are still more
information to be gathered (the flow chart may not consist the all required
information).
(e) Known stream volumes or volumetric flow rates will be converted to mass or molar
quantities using tabulated densities or gas laws.
(f) For given mixed mass and mole units for a stream (e.g., a total mass flow rate and
component mole fractions or conversely), they needed to be converted to one basis or
the other method.
(g) For information that is given in the problem but has not been used in labelling the
flowchart, they are translated into equations in the variables defined in step (c).
91
(h) Material balance equations are written. If no reactions occur and there are N species
present, there will be the most N balances, either on each component or on total mass
or moles and all but one species. Balances are written in order such that those involve
the fewest unknowns; if not, either the problems is underspecified or a relationship
between the variables not yet put in consideration.
(i) Equations derived in step (g) and (h) are solved for the unknown quantities. When the
value of an unknown has been calculated, the value should be written down in the
flowchart immediately. This value will then be substituted for calculation of
unknowns in any equations.
(j) If a stream quantity or flow rates was given in the problem statement and another
value Q was either taken as a basis or calculated for this stream, they must be scaled.
Assumptions of material balance calculation
Mass balance is the basis factor needs to be considered for designing a chemical plant. During
our design, mass balance is consists of two parts: calculated manual and carried out by using
simulation program, the Aspen Plus v8.0 simulator. The basic concept that is applied for
manual calculation is based on the general balance equation.
Unit Operation
Min (kg/hr) Mout (kg/hr)
The general mass balance equation is:
Input + Generation – Output – Consumption = Accumulation
where Input = total mass enters through system boundary

Generation = total mass produced within the system
Output = total mass leaves though system boundary
Consumption = total mass consumed within the system
Accumulation = total mass build up within the system
92
In this manual calculation, there are a few assumptions made and needed to be highlighted.
They are:
(a) This design is based on a basis of 60,000 MTPA of methyl esters production.
(b) Operating hours for the plant is 8,000 hours annually.
(c) The system is steady state.
(d) No leakage in pipes and vessel in the system.
(e) Catalyst (sodium methoxide) used in the process contributes in mass.
(f) The total input of any substance either to pump, or heat exchanger is assumed to be
equal to the total output of the substance where no reaction occur in that unit
operation.
Manual Material Balance

The annual production rate of combined methyl ester products (CE-810, CE-1214, CE-1618)
is set to be 60,000 MTPA. Therefore, the flow rates can be calculated as shown below:
The detailed manual calculation of material balance is given in Appendix A.2. Besides, a
process flow diagram with manual calculated material balances are attached in Appendix
A.6.1.
93
2.3.3.1 Reactor
R-101/2/3
1 at m 1 at m
60 °C 60 °C
R-101 R-102 R-103
1 at m 1 at m
60 °C 60 °C
Figure 2-20: Process Flow Diagram for Reactor R-101/2/3

Table 2-22 shows the material balance for reactor R-101/2/3. For further detail information
regarding R-101/2/3, please refer to Appendix A.2.1.
Table 2-22: Material Balance of Reactor R-101/2/3
Stream
Component 6 6a 6b 7
Mole Flow (kgmol/hr)
TG 10.9783 2.3537 0.5050 0.1098
ME-8 0.1860 1.6657 2.0228 2.0938
ME-10 0.0394 1.1883 1.4430 1.4956
ME-12 0.1357 13.4686 16.3557 16.9682
ME-14 0.0121 3.8439 4.6678 4.8462
ME-16 0.0017 1.7216 2.0906 2.1717
ME-18 0.0015 3.9856 4.8400 5.0300
GL 0.0092 8.6245 10.4733 10.8685
MeOH 65.8697 39.9961 34.4499 33.2642
Water
NaOCH3 1.3916 1.3916 1.3916 1.3916
Total 78.6252 78.2396 78.2396 78.2396
Mass Flow (kg/hr)

TG 7,517.9522 1,611.8490 345.8258 75.1795
ME-8 29.4362 263.5800 320.0806 331.3242
ME-10 7.3485 221.3613 268.8119 278.6136
ME-12 29.0846 2,886.9164 3,505.7513 3,637.0365
ME-14 2.9385 931.7397 1,131.4660 1,174.6950
ME-16 0.4539 465.6010 565.4065 587.3475
ME-18 0.4448 1,181.3929 1,434.6344 1,490.9591
GL 0.8427 794.2666 964.5243 1,000.9215
MeOH 2,110.5902 1,281.5504 1,103.8387 1,065.8481
Water
NaOCH3 81.3248 81.3248 81.3248 81.3248
Total 9,780.4164 9,719.5819 9,721.6643 9,723.2498
94
2.3.3.2 Flash Column
C-101
1 at m
120 °C
1 at m
120 °C
C-101
1 at m
120 °C
Figure 2-21: Process Flow Diagram for Flash Column C-101
Table 2-23 shows the material balance for flash column C-101. For further detail information
regarding C-101, please refer to Appendix A.2.2.
Table 2-23: Material Balance of Flash Column C-101
Stream
Component 8 9 13
TG 0.1098 0.0000 0.1098
ME-8 2.0938 0.0916 2.0022
ME-10 1.4956 0.0169 1.4787
ME-12 16.9682 0.0514 16.9168
ME-14 4.8462 0.0040 4.8421
ME-16 2.1717 0.0005 2.1713
ME-18 5.0300 0.0004 5.0296
GL 10.8685 0.0010 10.8675
MeOH 33.2642 24.8557 8.4085
Water
NaOCH3 1.3916 0.0000 1.3916
Total 78.2396 25.0214 53.2182
Mass Flow (kg/hr)

TG 75.1795 0.0000 75.1795
ME-8 331.3242 14.4933 316.8309
ME-10 278.6136 3.1405 275.4731
ME-12 3,637.0365 11.0096 3,626.0270
ME-14 1,174.6950 0.9764 1,173.7187
ME-16 587.3475 0.1268 587.2207
ME-18 1,490.9591 0.1140 1,490.8451
GL 1,000.9215 0.0905 1,000.8309
MeOH 1,065.8481 796.4235 269.4245
Water
NaOCH3 81.3248 0.0000 81.3248
Total 9,723.2498 826.3745 8,896.8753
95
C-102
1 at m
160 °C
1 at m
160 °C
C-102
1 at m
160 °C

Stream
Component 14 15 16
TG 0.1098 0.0000 0.1098
ME-8 2.0022 0.0944 1.9078
ME-10 1.4787 0.0226 1.4561
ME-12 16.9168 0.0843 16.8325
ME-14 4.8421 0.0081 4.8340
ME-16 2.1713 0.0012 2.1701
ME-18 5.0296 0.0011 5.0285
GL 10.8675 0.0082 10.8593
MeOH 8.4085 5.7641 2.6444
Water
NaOCH3 1.3916 0.0000 1.3916
Total 53.2182 5.9841 47.2341
Mass Flow (kg/hr)

TG 75.1795 0.0000 75.1795
ME-8 316.8309 14.9429 301.8881
ME-10 275.4731 4.2080 271.2651
ME-12 3,626.0270 18.0750 3,607.9519
ME-14 1,173.7187 1.9622 1,171.7565
ME-16 587.2207 0.3271 586.8936
ME-18 1,490.8451 0.3308 1,490.5143
GL 1,000.8309 0.7522 1,000.0788
MeOH 269.4245 184.6935 84.7311
Water
NaOCH3 81.3248 0.0000 81.3248
Total 8,896.8753 225.2916 8,671.5837
96
C-106
1 at m
130 °C
1 at m
130 °C
C-106
1 at m
130 °C

Stream
Component 42 43 45
TG 0.0000 0.0000 0.0000
ME-8 0.0000 0.0000 0.0000
ME-10 0.0000 0.0000 0.0000
ME-12 0.0000 0.0000 0.0000
ME-14 0.0000 0.0000 0.0000
ME-16 0.0000 0.0000 0.0000
ME-18 0.0000 0.0000 0.0000
GL 10.7469 0.1414 10.6054
MeOH 1.7478 1.7394 0.0084
Water 484.1268 476.9742 7.1526
NaOCH3 1.3916 0.0000 1.3916
Total 498.0131 478.8551 19.1580
Mass Flow (kg/hr)

TG 0.0000 0.0000 0.0000
ME-8 0.0000 0.0000 0.0000
ME-10 0.0000 0.0000 0.0000
ME-12 0.0000 0.0000 0.0000
ME-14 0.0000 0.0000 0.0000
ME-16 0.0000 0.0000 0.0000
ME-18 0.0000 0.0000 0.0000
GL 989.7222 13.0264 976.6958
MeOH 56.0036 55.7335 0.2701
Water 8,722.0284 8,593.1677 128.8608
NaOCH3 81.3225 0.0000 81.3225
Total 9,849.0768 8,661.9276 1,187.1491
97
2.3.3.3 Distillation Column
C-103
0.5 at m
59 °C
1 at m
91 °C
C-103
0.5 at m
236 °C
Figure 2-24: Process Flow Diagram for Distillation Column C-103

Table 2-26 shows the material balance for distillation column C-106. For further detail
information regarding C-106, please refer to Appendix A.2.5.1.
Table 2-26: Material Balance of Distillation Column C-103
Stream
Component 22 23 25
TG 0.1098 0.0000 0.1098
ME-8 1.9078 0.0095 1.8983
ME-10 1.4561 0.0000 1.4561
ME-12 16.8325 0.0000 16.8325
ME-14 4.8340 0.0000 4.8340
ME-16 2.1701 0.0000 2.1701
ME-18 5.0285 0.0000 5.0285
GL 0.1125 0.0000 0.1125
MeOH 0.8966 0.8965 0.0001
Water 1.1252 1.1195 0.0056
NaOCH3 0.0000 0.0000 0.0000
Total 34.4730 2.0256 32.4474
Mass Flow (kg/hr)

TG 75.1795 0.0000 75.1795
ME-8 301.8882 1.5094 300.3788
ME-10 271.2653 0.0092 271.2561
ME-12 3,607.9541 0.0010 3,607.9531
ME-14 1,171.7570 0.0000 1,171.7570
ME-16 586.8939 0.0000 586.8939
ME-18 1,490.5149 0.0000 1,490.5149
GL 10.3561 0.0000 10.3561
MeOH 28.7275 28.7252 0.0023
Water 20.2708 20.1694 0.1014
NaOCH3 0.0023 0.0000 0.0023
Total 7,564.8094 50.4142 7,514.3952
98
C-104
0.25 at m
158 °C
0.5 at m
185 °C
C-104
0.25 at m
226 °C

Stream
Component 27 28 31
TG 0.1098 0.0000 0.1098
ME-8 1.8983 1.8983 0.0000
ME-10 1.4561 1.4488 0.0073
ME-12 16.8325 0.0842 16.7483
ME-14 4.8340 0.0000 4.8340
ME-16 2.1701 0.0000 2.1701
ME-18 5.0285 0.0000 5.0285
GL 0.1125 0.0000 0.1125
MeOH 0.0001 0.0001 0.0000
Water 0.0056 0.0056 0.0000
NaOCH3 0.0000 0.0000 0.0000
Total 32.4474 3.4369 29.0105
Mass Flow (kg/hr)

TG 75.1795 0.0000 75.1795
ME-8 300.3788 300.3787 0.0001
ME-10 271.2561 269.8998 1.3563
ME-12 3,607.9531 18.0398 3,589.9133
ME-14 1,171.7570 0.0004 1,171.7566
ME-16 586.8939 0.0000 586.8939
ME-18 1,490.5149 0.0000 1,490.5149
GL 10.3561 0.0000 10.3561
MeOH 0.0023 0.0023 0.0000
Water 0.1014 0.1014 0.0000
NaOCH3 0.0023 0.0000 0.0023
Total 7,514.3952 588.4223 6,925.9729
99
C-105
0.07 at m
176 °C
0.25 at m
198 °C
C-105
0.07 at m
237 °C
Stream
Component 33 34 37
TG 0.1098 0.0000 0.1098
ME-8 0.0000 0.0000 0.0000
ME-10 0.0073 0.0073 0.0000
ME-12 16.7483 16.7483 0.0000
ME-14 4.8340 4.8099 0.0242
ME-16 2.1701 0.0109 2.1592
ME-18 5.0285 0.0000 5.0285
GL 0.1125 0.1123 0.0001
MeOH 0.0000 0.0000 0.0000
Water 0.0000 0.0000 0.0000
NaOCH3 0.0000 0.0000 0.0000
Total 29.0105 21.6886 7.3218
Mass Flow (kg/hr)

TG 75.1795 0.0000 75.1795
ME-8 0.0001 0.0001 0.0000
ME-10 1.3563 1.3563 0.0000
ME-12 3,589.9133 3,589.9129 0.0004
ME-14 1,171.7566 1,165.8978 5.8588
ME-16 586.8939 2.9345 583.9594
ME-18 1,490.5149 0.0006 1,490.5142
GL 10.3561 10.3423 0.0137
MeOH 0.0000 0.0000 0.0000
Water 0.0000 0.0000 0.0000
NaOCH3 0.0023 0.0000 0.0023
Total 6,925.9729 4,770.4446 2,155.5283
100
2.3.3.4 Decanter
V-101
1 at m
25 °C
1 at m
50 °C
V-101
1 at m
50 °C
1 at m
50 °C
Figure 2-27: Process Flow Diagram for Decanter V-101

Table 2-29 shows the material balance for decanter V-101.
Table 2-29: Material Balance of Decanter V-101
Stream
Component 18 19 20 40
TG 0.1098 0.1098 0.0000
ME-8 1.9078 1.9078 0.0000
ME-10 1.4561 1.4561 0.0000
ME-12 16.8325 16.8325 0.0000
ME-14 4.8340 4.8340 0.0000
ME-16 2.1701 2.1701 0.0000
ME-18 5.0285 5.0285 0.0000
GL 10.8593 0.1125 10.7469
MeOH 2.6444 0.8966 1.7478
Water 485.2520 1.1252 484.1268
NaOCH3 1.3916 0.0000 1.3916
Total 47.2341 485.2520 34.4730 498.0131
Mass Flow (kg/hr)

TG 75.1795 75.1795 0.0000
ME-8 301.8881 301.8882 0.0000
ME-10 271.2651 271.2653 0.0000
ME-12 3,607.9519 3,607.9541 0.0000
ME-14 1,171.7565 1,171.7570 0.0000
ME-16 586.8936 586.8939 0.0000
ME-18 1,490.5143 1,490.5149 0.0000
GL 1,000.0788 10.3561 989.7222
MeOH 84.7311 28.7275 56.0036
Water 8,742.3000 20.2708 8,722.0284
NaOCH3 81.3248 0.0023 81.3225
Total 8,671.5837 8,742.3000 7,564.8094 9,849.0768
101
2.3.3.5 Pump
P-101
1.2 at m
25 °C
1 at m
25 °C
MeOH
P-101
Figure 2-28: Process Flow Diagram for Pump P-101

Table 2-30 shows the material balance for pump P-101.
Table 2-30: Material Balance of Pump P-101
Stream
Component MeOH 1
TG
ME-8
ME-10
ME-12
ME-14
ME-16
ME-18
GL
MeOH 35.2499 35.2499
Water
NaOCH3
Total 35.2499 35.2499
Mass Flow (kg/hr)

TG
ME-8
ME-10
ME-12
ME-14
ME-16
ME-18
GL
MeOH 1,129.4733 1,129.4733
Water
NaOCH3
Total 1,129.4733 1,129.4733
102
P-102
1.2 at m
25 °C
1 at m
25 °C
NaOCH3
P-102

Stream
Component NaOCH3 2
TG
ME-8
ME-10
ME-12
ME-14
ME-16
ME-18
GL
MeOH
Water
NaOCH3 1.3916 1.3916
Total 1.3916 1.3916
Mass Flow (kg/hr)

TG
ME-8
ME-10
ME-12
ME-14
ME-16
ME-18
GL
MeOH
Water
NaOCH3 81.3248 81.3248
Total 81.3248 81.3248
103
P-103
1.2 at m
25 °C
1 at m
25 °C
TG
P-103

Stream
Component TG 3
TG 10.9783 10.9783
ME-8
ME-10
ME-12
ME-14
ME-16
ME-18
GL
MeOH
Water
NaOCH3
Total 10.9783 10.9783
Mass Flow (kg/hr)

TG 7,517.9522 7,517.9522
ME-8
ME-10
ME-12
ME-14
ME-16
ME-18
GL
MeOH
Water
NaOCH3
Total 7,517.9522 7,517.9522
104
P-104
1.2 at m
25 °C
1 at m
25 °C
Water
P-104

Stream
Component Water 19
TG
ME-8
ME-10
ME-12
ME-14
ME-16
ME-18
GL
MeOH
Water 485.2520 485.2520
NaOCH3
Total 485.2520 485.2520
Mass Flow (kg/hr)

TG
ME-8
ME-10
ME-12
ME-14
ME-16
ME-18
GL
MeOH
Water 8,742.3000 8,742.3000
NaOCH3
Total 8,742.3000 8,742.3000
105
P-105
1.2 at m
60 °C 1 at m
60 °C
P-105

Stream
Component 11 12
TG 0.0000 0.0000
ME-8 0.1860 0.1860
ME-10 0.0394 0.0394
ME-12 0.1357 0.1357
ME-14 0.0121 0.0121
ME-16 0.0017 0.0017
ME-18 0.0015 0.0015
GL 0.0092 0.0092
MeOH 30.6198 30.6198
Water
NaOCH3 0.0000 0.0000
Total 31.0054 31.0054
Mass Flow (kg/hr)

TG 0.0000 0.0000
ME-8 29.4362 29.4362
ME-10 7.3485 7.3485
ME-12 29.0846 29.0846
ME-14 2.9385 2.9385
ME-16 0.4539 0.4539
ME-18 0.4448 0.4448
GL 0.8427 0.8427
MeOH 981.1170 981.1170
Water
NaOCH3 0.0000 0.0000
Total 1,051.6661 1,051.6661
106
P-106
1 at m
160 °C
1.2 at m
160 °C
P-106

Stream
Component 16 17
TG 0.1098 0.1098
ME-8 1.9078 1.9078
ME-10 1.4561 1.4561
ME-12 16.8325 16.8325
ME-14 4.8340 4.8340
ME-16 2.1701 2.1701
ME-18 5.0285 5.0285
GL 10.8593 10.8593
MeOH 2.6444 2.6444
Water
NaOCH3 1.3916 1.3916
Total 47.2341 47.2341
Mass Flow (kg/hr)

TG 75.1795 75.1795
ME-8 301.8881 301.8881
ME-10 271.2651 271.2651
ME-12 3,607.9519 3,607.9519
ME-14 1,171.7565 1,171.7565
ME-16 586.8936 586.8936
ME-18 1,490.5143 1,490.5143
GL 1,000.0788 1,000.0788
MeOH 84.7311 84.7311
Water
NaOCH3 81.3248 81.3248
Total 8,671.5837 8,671.5837
107
P-107
1.2 at m
50 °C 1 at m
P-107 50 °C

Stream
Component 20 21
TG 0.1098 0.1098
ME-8 1.9078 1.9078
ME-10 1.4561 1.4561
ME-12 16.8325 16.8325
ME-14 4.8340 4.8340
ME-16 2.1701 2.1701
ME-18 5.0285 5.0285
GL 0.1125 0.1125
MeOH 0.8966 0.8966
Water 1.1252 1.1252
NaOCH3 0.0000 0.0000
Total 34.4730 34.4730
Mass Flow (kg/hr)

TG 75.1795 75.1795
ME-8 301.8882 301.8882
ME-10 271.2653 271.2653
ME-12 3,607.9541 3,607.9541
ME-14 1,171.7570 1,171.7570
ME-16 586.8939 586.8939
ME-18 1,490.5149 1,490.5149
GL 10.3561 10.3561
MeOH 28.7275 28.7275
Water 20.2708 20.2708
NaOCH3 0.0023 0.0023
Total 7,564.8094 7,564.8094
108
P-108
0.7 at m
0.5 at m 236 °C
236 °C
P-108

Stream
Component 25 26
TG 0.1098 0.1098
ME-8 1.8983 1.8983
ME-10 1.4561 1.4561
ME-12 16.8325 16.8325
ME-14 4.8340 4.8340
ME-16 2.1701 2.1701
ME-18 5.0285 5.0285
GL 0.1125 0.1125
MeOH 0.0001 0.0001
Water 0.0056 0.0056
NaOCH3 0.0000 0.0000
Total 32.4474 32.4474
Mass Flow (kg/hr)

TG 75.1795 75.1795
ME-8 300.3788 300.3788
ME-10 271.2561 271.2561
ME-12 3,607.9531 3,607.9531
ME-14 1,171.7570 1,171.7570
ME-16 586.8939 586.8939
ME-18 1,490.5149 1,490.5149
GL 10.3561 10.3561
MeOH 0.0023 0.0023
Water 0.1014 0.1014
NaOCH3 0.0023 0.0023
Total 7,514.3952 7,514.3952
109
P-109
1 at m
0.25 at m 158 °C
158 °C
P-109

Stream
Component 28 29
TG 0.0000 0.0000
ME-8 1.8983 1.8983
ME-10 1.4488 1.4488
ME-12 0.0842 0.0842
ME-14 0.0000 0.0000
ME-16 0.0000 0.0000
ME-18 0.0000 0.0000
GL 0.0000 0.0000
MeOH 0.0001 0.0001
Water 0.0056 0.0056
NaOCH3 0.0000 0.0000
Total 3.4369 3.4369
Mass Flow (kg/hr)

TG 0.0000 0.0000
ME-8 300.3787 300.3787
ME-10 269.8998 269.8998
ME-12 18.0398 18.0398
ME-14 0.0004 0.0004
ME-16 0.0000 0.0000
ME-18 0.0000 0.0000
GL 0.0000 0.0000
MeOH 0.0023 0.0023
Water 0.1014 0.1014
NaOCH3 0.0000 0.0000
Total 588.4223 588.4223
110
P-110
0.45 at m
0.25 at m 226 °C
226 °C
P-110

Stream
Component 31 32
TG 0.1098 0.1098
ME-8 0.0000 0.0000
ME-10 0.0073 0.0073
ME-12 16.7483 16.7483
ME-14 4.8340 4.8340
ME-16 2.1701 2.1701
ME-18 5.0285 5.0285
GL 0.1125 0.1125
MeOH 0.0000 0.0000
Water 0.0000 0.0000
NaOCH3 0.0000 0.0000
Total 29.0105 29.0105
Mass Flow (kg/hr)

TG 75.1795 75.1795
ME-8 0.0001 0.0001
ME-10 1.3563 1.3563
ME-12 3,589.9133 3,589.9133
ME-14 1,171.7566 1,171.7566
ME-16 586.8939 586.8939
ME-18 1,490.5149 1,490.5149
GL 10.3561 10.3561
MeOH 0.0000 0.0000
Water 0.0000 0.0000
NaOCH3 0.0023 0.0023
Total 6,925.9729 6,925.9729
111
P-111
0.07 at m
176 °C
1 at m
176 °C
P-111

Stream
Component 34 35
TG 0.0000 0.0000
ME-8 0.0000 0.0000
ME-10 0.0073 0.0073
ME-12 16.7483 16.7483
ME-14 4.8099 4.8099
ME-16 0.0109 0.0109
ME-18 0.0000 0.0000
GL 0.1123 0.1123
MeOH 0.0000 0.0000
Water 0.0000 0.0000
NaOCH3 0.0000 0.0000
Total 21.6886 21.6886
Mass Flow (kg/hr)

TG 0.0000 0.0000
ME-8 0.0001 0.0001
ME-10 1.3563 1.3563
ME-12 3,589.9129 3,589.9129
ME-14 1,165.8978 1,165.8978
ME-16 2.9345 2.9345
ME-18 0.0006 0.0006
GL 10.3423 10.3423
MeOH 0.0000 0.0000
Water 0.0000 0.0000
NaOCH3 0.0000 0.0000
Total 4,770.4446 4,770.4446
112
P-112
1 at m
0.07 at m 237 °C
237 °C
P-112

Stream
Component 37 38
TG 0.1098 0.1098
ME-8 0.0000 0.0000
ME-10 0.0000 0.0000
ME-12 0.0000 0.0000
ME-14 0.0242 0.0242
ME-16 2.1592 2.1592
ME-18 5.0285 5.0285
GL 0.0001 0.0001
MeOH 0.0000 0.0000
Water 0.0000 0.0000
NaOCH3 0.0000 0.0000
Total 7.3218 7.3218
Mass Flow (kg/hr)

TG 75.1795 75.1795
ME-8 0.0000 0.0000
ME-10 0.0000 0.0000
ME-12 0.0004 0.0004
ME-14 5.8588 5.8588
ME-16 583.9594 583.9594
ME-18 1,490.5142 1,490.5142
GL 0.0137 0.0137
MeOH 0.0000 0.0000
Water 0.0000 0.0000
NaOCH3 0.0023 0.0023
Total 2,155.5283 2,155.5283
113
P-113
1 at m
50 °C
1.2 at m
50 °C
P-113

Stream
Component 40 41
TG 0.0000 0.0000
ME-8 0.0000 0.0000
ME-10 0.0000 0.0000
ME-12 0.0000 0.0000
ME-14 0.0000 0.0000
ME-16 0.0000 0.0000
ME-18 0.0000 0.0000
GL 10.7469 10.7469
MeOH 1.7478 1.7478
Water 484.1268 484.1268
NaOCH3 1.3916 1.3916
Total 498.0131 498.0131
Mass Flow (kg/hr)

TG 0.0000 0.0000
ME-8 0.0000 0.0000
ME-10 0.0000 0.0000
ME-12 0.0000 0.0000
ME-14 0.0000 0.0000
ME-16 0.0000 0.0000
ME-18 0.0000 0.0000
GL 989.7222 989.7222
MeOH 56.0036 56.0036
Water 8,722.0284 8,722.0284
NaOCH3 81.3225 81.3225
Total 9,849.0768 9,849.0768
114
2.3.3.6 Heat Exchanger
E-101
1 at m 1 at m
32 °C 60 °C
E-101
Figure 2-41: Process Flow Diagram for Heat Exchanger E-101
Table 2-43 shows the material balance for heat exchanger E-101.
Table 2-43: Material Balance of Heat Exchanger E-101

Stream
Component 5 6
TG 10.9783 10.9783
ME-8 0.1860 0.1860
ME-10 0.0394 0.0394
ME-12 0.1357 0.1357
ME-14 0.0121 0.0121
ME-16 0.0017 0.0017
ME-18 0.0015 0.0015
GL 0.0092 0.0092
MeOH 65.8697 65.8697
Water
NaOCH3 1.3916 1.3916
Total 78.6252 78.6252
Mass Flow (kg/hr)

TG 7,517.9522 7,517.9522
ME-8 29.4362 29.4362
ME-10 7.3485 7.3485
ME-12 29.0846 29.0846
ME-14 2.9385 2.9385
ME-16 0.4539 0.4539
ME-18 0.4448 0.4448
GL 0.8427 0.8427
MeOH 2,110.5902 2,110.5902
Water
NaOCH3 81.3248 81.3248
Total 9,780.4164 9,780.4164
115
E-102
1 at m 1 at m
60 °C 120 °C
E-102

Stream
Component 7 8
TG 0.1098 0.1098
ME-8 2.0938 2.0938
ME-10 1.4956 1.4956
ME-12 16.9682 16.9682
ME-14 4.8462 4.8462
ME-16 2.1717 2.1717
ME-18 5.0300 5.0300
GL 10.8685 10.8685
MeOH 33.2642 33.2642
Water
NaOCH3 1.3916 1.3916
Total 78.2396 78.2396
Mass Flow (kg/hr)

TG 75.1795 75.1795
ME-8 331.3242 331.3242
ME-10 278.6136 278.6136
ME-12 3,637.0365 3,637.0365
ME-14 1,174.6950 1,174.6950
ME-16 587.3475 587.3475
ME-18 1,490.9591 1,490.9591
GL 1,000.9215 1,000.9215
MeOH 1,065.8481 1,065.8481
Water
NaOCH3 81.3248 81.3248
Total 9,723.2498 9,723.2498
116
E-103
1 at m 1 at m
60 °C 129 °C
E-103

Stream
Component 10 11
TG 0.0000 0.0000
ME-8 0.1860 0.1860
ME-10 0.0394 0.0394
ME-12 0.1357 0.1357
ME-14 0.0121 0.0121
ME-16 0.0017 0.0017
ME-18 0.0015 0.0015
GL 0.0092 0.0092
MeOH 30.6198 30.6198
Water
NaOCH3 0.0000 0.0000
Total 31.0054 31.0054
Mass Flow (kg/hr)

TG 0.0000 0.0000
ME-8 29.4362 29.4362
ME-10 7.3485 7.3485
ME-12 29.0846 29.0846
ME-14 2.9385 2.9385
ME-16 0.4539 0.4539
ME-18 0.4448 0.4448
GL 0.8427 0.8427
MeOH 981.1170 981.1170
Water
NaOCH3 0.0000 0.0000
Total 1,051.6661 1,051.6661
117
E-104
1 at m
160 °C
E-104
1 at m
120 °C

Stream
Component 13 14
TG 0.1098 0.1098
ME-8 2.0022 2.0022
ME-10 1.4787 1.4787
ME-12 16.9168 16.9168
ME-14 4.8421 4.8421
ME-16 2.1713 2.1713
ME-18 5.0296 5.0296
GL 10.8675 10.8675
MeOH 8.4085 8.4085
Water
NaOCH3 1.3916 1.3916
Total 53.2182 53.2182
Mass Flow (kg/hr)

TG 75.1795 75.1795
ME-8 316.8309 316.8309
ME-10 275.4731 275.4731
ME-12 3,626.0270 3,626.0270
ME-14 1,173.7187 1,173.7187
ME-16 587.2207 587.2207
ME-18 1,490.8451 1,490.8451
GL 1,000.8309 1,000.8309
MeOH 269.4245 269.4245
Water
NaOCH3 81.3248 81.3248
Total 8,896.8753 8,896.8753
118
E-105
1 at m 1 at m
50 °C 160 °C
E-105

Stream
Component 17 18
TG 0.1098 0.1098
ME-8 1.9078 1.9078
ME-10 1.4561 1.4561
ME-12 16.8325 16.8325
ME-14 4.8340 4.8340
ME-16 2.1701 2.1701
ME-18 5.0285 5.0285
GL 10.8593 10.8593
MeOH 2.6444 2.6444
Water
NaOCH3 1.3916 1.3916
Total 47.2341 47.2341
Mass Flow (kg/hr)

TG 75.1795 75.1795
ME-8 301.8881 301.8881
ME-10 271.2651 271.2651
ME-12 3,607.9519 3,607.9519
ME-14 1,171.7565 1,171.7565
ME-16 586.8936 586.8936
ME-18 1,490.5143 1,490.5143
GL 1,000.0788 1,000.0788
MeOH 84.7311 84.7311
Water
NaOCH3 81.3248 81.3248
Total 8,671.5837 8,671.5837
119
E-106
1.2 at m
1 at m E-106 50 °C
91 °C

Stream
Component 21 22
TG 0.1098 0.1098
ME-8 1.9078 1.9078
ME-10 1.4561 1.4561
ME-12 16.8325 16.8325
ME-14 4.8340 4.8340
ME-16 2.1701 2.1701
ME-18 5.0285 5.0285
GL 0.1125 0.1125
MeOH 0.8966 0.8966
Water 1.1252 1.1252
NaOCH3 0.0000 0.0000
Total 34.4730 34.4730
Mass Flow (kg/hr)

TG 75.1795 75.1795
ME-8 301.8882 301.8882
ME-10 271.2653 271.2653
ME-12 3,607.9541 3,607.9541
ME-14 1,171.7570 1,171.7570
ME-16 586.8939 586.8939
ME-18 1,490.5149 1,490.5149
GL 10.3561 10.3561
MeOH 28.7275 28.7275
Water 20.2708 20.2708
NaOCH3 0.0023 0.0023
Total 7,564.8094 7,564.8094
120
E-107
0.5 at m 0.5 at m
59 °C 25 °C
E-107

Stream
Component 23 24
TG 0.0000 0.0000
ME-8 0.0095 0.0095
ME-10 0.0000 0.0000
ME-12 0.0000 0.0000
ME-14 0.0000 0.0000
ME-16 0.0000 0.0000
ME-18 0.0000 0.0000
GL 0.0000 0.0000
MeOH 0.8965 0.8965
Water 1.1195 1.1195
NaOCH3 0.0000 0.0000
Total 2.0256 2.0256
Mass Flow (kg/hr)

TG 0.0000 0.0000
ME-8 1.5094 1.5094
ME-10 0.0092 0.0092
ME-12 0.0010 0.0010
ME-14 0.0000 0.0000
ME-16 0.0000 0.0000
ME-18 0.0000 0.0000
GL 0.0000 0.0000
MeOH 28.7252 28.7252
Water 20.1694 20.1694
NaOCH3 0.0000 0.0000
Total 50.4142 50.4142
121
E-108
0.7 at m 0.5 at m
236 °C 185 °C
E-108

Stream
Component 26 27
TG 0.1098 0.1098
ME-8 1.8983 1.8983
ME-10 1.4561 1.4561
ME-12 16.8325 16.8325
ME-14 4.8340 4.8340
ME-16 2.1701 2.1701
ME-18 5.0285 5.0285
GL 0.1125 0.1125
MeOH 0.0001 0.0001
Water 0.0056 0.0056
NaOCH3 0.0000 0.0000
Total 32.4474 32.4474
Mass Flow (kg/hr)

TG 75.1795 75.1795
ME-8 300.3788 300.3788
ME-10 271.2561 271.2561
ME-12 3,607.9531 3,607.9531
ME-14 1,171.7570 1,171.7570
ME-16 586.8939 586.8939
ME-18 1,490.5149 1,490.5149
GL 10.3561 10.3561
MeOH 0.0023 0.0023
Water 0.1014 0.1014
NaOCH3 0.0023 0.0023
Total 7,514.3952 7,514.3952
122
E-109
1 at m 1 at m
158 °C 25 °C
E-109

Stream
Component 29 30
TG 0.0000 0.0000
ME-8 1.8983 1.8983
ME-10 1.4488 1.4488
ME-12 0.0842 0.0842
ME-14 0.0000 0.0000
ME-16 0.0000 0.0000
ME-18 0.0000 0.0000
GL 0.0000 0.0000
MeOH 0.0001 0.0001
Water 0.0056 0.0056
NaOCH3 0.0000 0.0000
Total 3.4369 3.4369
Mass Flow (kg/hr)

TG 0.0000 0.0000
ME-8 300.3787 300.3787
ME-10 269.8998 269.8998
ME-12 18.0398 18.0398
ME-14 0.0004 0.0004
ME-16 0.0000 0.0000
ME-18 0.0000 0.0000
GL 0.0000 0.0000
MeOH 0.0023 0.0023
Water 0.1014 0.1014
NaOCH3 0.0000 0.0000
Total 588.4223 588.4223
123
E-110
0.45 at m 0.25 at m
226 °C 198 °C
E-110

Stream
Component 32 33
TG 0.1098 0.1098
ME-8 0.0000 0.0000
ME-10 0.0073 0.0073
ME-12 16.7483 16.7483
ME-14 4.8340 4.8340
ME-16 2.1701 2.1701
ME-18 5.0285 5.0285
GL 0.1125 0.1125
MeOH 0.0000 0.0000
Water 0.0000 0.0000
NaOCH3 0.0000 0.0000
Total 29.0105 29.0105
Mass Flow (kg/hr)

TG 75.1795 75.1795
ME-8 0.0001 0.0001
ME-10 1.3563 1.3563
ME-12 3,589.9133 3,589.9133
ME-14 1,171.7566 1,171.7566
ME-16 586.8939 586.8939
ME-18 1,490.5149 1,490.5149
GL 10.3561 10.3561
MeOH 0.0000 0.0000
Water 0.0000 0.0000
NaOCH3 0.0023 0.0023
Total 6,925.9729 6,925.9729
124
E-111
1 at m 1 at m
E-111
176 °C 50 °C

Stream
Component 35 36
TG 0.0000 0.0000
ME-8 0.0000 0.0000
ME-10 0.0073 0.0073
ME-12 16.7483 16.7483
ME-14 4.8099 4.8099
ME-16 0.0109 0.0109
ME-18 0.0000 0.0000
GL 0.1123 0.1123
MeOH 0.0000 0.0000
Water 0.0000 0.0000
NaOCH3 0.0000 0.0000
Total 21.6886 21.6886
Mass Flow (kg/hr)

TG 0.0000 0.0000
ME-8 0.0001 0.0001
ME-10 1.3563 1.3563
ME-12 3,589.9129 3,589.9129
ME-14 1,165.8978 1,165.8978
ME-16 2.9345 2.9345
ME-18 0.0006 0.0006
GL 10.3423 10.3423
MeOH 0.0000 0.0000
Water 0.0000 0.0000
NaOCH3 0.0000 0.0000
Total 4,770.4446 4,770.4446
125
E-112
1 at m 1 at m
237 °C 50 °C
E-112

Stream
Component 38 39
TG 0.1098 0.1098
ME-8 0.0000 0.0000
ME-10 0.0000 0.0000
ME-12 0.0000 0.0000
ME-14 0.0242 0.0242
ME-16 2.1592 2.1592
ME-18 5.0285 5.0285
GL 0.0001 0.0001
MeOH 0.0000 0.0000
Water 0.0000 0.0000
NaOCH3 0.0000 0.0000
Total 7.3218 7.3218
Mass Flow (kg/hr)

TG 75.1795 75.1795
ME-8 0.0000 0.0000
ME-10 0.0000 0.0000
ME-12 0.0004 0.0004
ME-14 5.8588 5.8588
ME-16 583.9594 583.9594
ME-18 1,490.5142 1,490.5142
GL 0.0137 0.0137
MeOH 0.0000 0.0000
Water 0.0000 0.0000
NaOCH3 0.0023 0.0023
Total 2,155.5283 2,155.5283
126
E-113
1 at m 1 at m
50 °C 130 °C
E-113

Stream
Component 41 42
TG 0.0000 0.0000
ME-8 0.0000 0.0000
ME-10 0.0000 0.0000
ME-12 0.0000 0.0000
ME-14 0.0000 0.0000
ME-16 0.0000 0.0000
ME-18 0.0000 0.0000
GL 10.7469 10.7469
MeOH 1.7478 1.7478
Water 484.1268 484.1268
NaOCH3 1.3916 1.3916
Total 498.0131 498.0131
Mass Flow (kg/hr)

TG 0.0000 0.0000
ME-8 0.0000 0.0000
ME-10 0.0000 0.0000
ME-12 0.0000 0.0000
ME-14 0.0000 0.0000
ME-16 0.0000 0.0000
ME-18 0.0000 0.0000
GL 989.7222 989.7222
MeOH 56.0036 56.0036
Water 8,722.0284 8,722.0284
NaOCH3 81.3225 81.3225
Total 9,849.0768 9,849.0768
127
E-114
1 at m 1 at m
130 °C 25 °C
E-114

Stream
Component 43 44
TG 0.0000 0.0000
ME-8 0.0000 0.0000
ME-10 0.0000 0.0000
ME-12 0.0000 0.0000
ME-14 0.0000 0.0000
ME-16 0.0000 0.0000
ME-18 0.0000 0.0000
GL 0.1414 0.1414
MeOH 1.7394 1.7394
Water 476.9742 476.9742
NaOCH3 0.0000 0.0000
Total 478.8551 478.8551
Mass Flow (kg/hr)

TG 0.0000 0.0000
ME-8 0.0000 0.0000
ME-10 0.0000 0.0000
ME-12 0.0000 0.0000
ME-14 0.0000 0.0000
ME-16 0.0000 0.0000
ME-18 0.0000 0.0000
GL 13.0264 13.0264
MeOH 55.7335 55.7335
Water 8,593.1677 8,593.1677
NaOCH3 0.0000 0.0000
Total 8,661.9276 8,661.9276
128
E-115
1 at m 1 at m
130 °C 25 °C
E-115

Stream
Component 45 46
TG 0.0000 0.0000
ME-8 0.0000 0.0000
ME-10 0.0000 0.0000
ME-12 0.0000 0.0000
ME-14 0.0000 0.0000
ME-16 0.0000 0.0000
ME-18 0.0000 0.0000
GL 10.6054 10.6054
MeOH 0.0084 0.0084
Water 7.1526 7.1526
NaOCH3 1.3916 1.3916
Total 19.1580 19.1580
Mass Flow (kg/hr)

TG 0.0000 0.0000
ME-8 0.0000 0.0000
ME-10 0.0000 0.0000
ME-12 0.0000 0.0000
ME-14 0.0000 0.0000
ME-16 0.0000 0.0000
ME-18 0.0000 0.0000
GL 976.6958 976.6958
MeOH 0.2701 0.2701
Water 128.8608 128.8608
NaOCH3 81.3225 81.3225
Total 1,187.1491 1,187.1491
129
2.3.3.7 Mixers
M-101
1.2 at m
60 °C
1.2 at m
25 °C
1 at m
M-101 42 °C
Figure 2-56: Process Flow Diagram for Mixer M-101
Table 2-58 shows the material balance for mixer M-101.
Table 2-58: Material Balance of Mixer M-101

Stream
Component 1 4 12
TG 0.0000 0.0000
ME-8 0.1860 0.1860
ME-10 0.0394 0.0394
ME-12 0.1357 0.1357
ME-14 0.0121 0.0121
ME-16 0.0017 0.0017
ME-18 0.0015 0.0015
GL 0.0092 0.0092
MeOH 35.2499 65.8697 30.6198
Water
NaOCH3 0.0000 0.0000
Total 35.2499 66.2553 31.0054
Mass Flow (kg/hr)

TG 0.0000 0.0000
ME-8 29.4362 29.4362
ME-10 7.3485 7.3485
ME-12 29.0846 29.0846
ME-14 2.9385 2.9385
ME-16 0.4539 0.4539
ME-18 0.4448 0.4448
GL 0.8427 0.8427
MeOH 1,129.4733 2,110.5902 981.1170
Water
NaOCH3 0.0000 0.0000
Total 1,129.4733 2,181.1394 1,051.6661
130
M-102
1 at m
42 °C
1.2 at m 1 at m
25 °C 32 °C
1.2 at m M-102
25 °C

Stream
Component 2 3 4 5
TG 10.9783 0.0000 10.9783
ME-8 0.1860 0.1860
ME-10 0.0394 0.0394
ME-12 0.1357 0.1357
ME-14 0.0121 0.0121
ME-16 0.0017 0.0017
ME-18 0.0015 0.0015
GL 0.0092 0.0092
MeOH 65.8697 65.8697
Water
NaOCH3 1.3916 0.0000 1.3916
Total 1.3916 10.9783 66.2553 78.6252
Mass Flow (kg/hr)

TG 7,517.9522 0.0000 7,517.9522
ME-8 29.4362 29.4362
ME-10 7.3485 7.3485
ME-12 29.0846 29.0846
ME-14 2.9385 2.9385
ME-16 0.4539 0.4539
ME-18 0.4448 0.4448
GL 0.8427 0.8427
MeOH 2,110.5902 2,110.5902
Water
NaOCH3 81.3248 0.0000 81.3248
Total 81.3248 7,517.9522 2,181.1394 9,780.4164
131
M-103
1 at m
129 °C
M-103
1 at m 1 at m
120 °C 160 °C

Stream
Component 9 10 15
TG 0.0000 0.0000 0.0000
ME-8 0.0916 0.1860 0.0944
ME-10 0.0169 0.0394 0.0226
ME-12 0.0514 0.1357 0.0843
ME-14 0.0040 0.0121 0.0081
ME-16 0.0005 0.0017 0.0012
ME-18 0.0004 0.0015 0.0011
GL 0.0010 0.0092 0.0082
MeOH 24.8557 30.6198 5.7641
Water
NaOCH3 0.0000 0.0000 0.0000
Total 25.0214 31.0054 5.9841
Mass Flow (kg/hr)

TG 0.0000 0.0000 0.0000
ME-8 14.4933 29.4362 14.9429
ME-10 3.1405 7.3485 4.2080
ME-12 11.0096 29.0846 18.0750
ME-14 0.9764 2.9385 1.9622
ME-16 0.1268 0.4539 0.3271
ME-18 0.1140 0.4448 0.3308
GL 0.0905 0.8427 0.7522
MeOH 796.4235 981.1170 184.6935
Water
NaOCH3 0.0000 0.0000 0.0000
Total 826.3745 1,051.6661 225.2916
132
2.3.4 Energy Balance
Energy balance, in process design, is made to determine the energy requirements of the
process which are heating, cooling and power required. For the energy balance calculation in
this project, some assumptions are made:
 The process follow the law of conversion of energy, where

Energy out = Energy in + Generation – Consumption – Accumulation
 All equipment are in steady state
 Kinetic energy and potential energy are neglected. Hence, the energy balance, Q = ΔH
 No heat of mixing or pressure effect on enthalpy changes
 Reference temperature for all calculation is 25°C
 Reference pressure for all calculation is 1 atm
 For comparisons, total enthalpy for every stream in simulation results are divided by
total mass flow rate
Please kindly refer to Appendix A.3 for more detailed energy balance calculation method and
results.
133
2.3.4.1 Streams
Table 2-61 shows the summarized results of manually calculated enthalpy flow of all the
streams for each component in unit of kW. Detailed calculation steps and methods for each
stream can be seen in Appendix A.3.1.
Table 2-61: Summarized results of streams‘ enthalpy flow

Stream
MeOH NaOCH3 TG Water 1 2 3 4
Component
Enthalpy Flow
kW kW kW kW kW kW kW kW
TG-8 0.00 0.00 -309.31 0.00 0.00 0.00 -309.31 0.00
TG-10 0.00 0.00 -237.91 0.00 0.00 0.00 -237.91 0.00
TG-12 0.00 0.00 -2892.25 0.00 0.00 0.00 -2892.25 0.00
TG-14 0.00 0.00 -835.41 0.00 0.00 0.00 -835.41 0.00
TG-16 0.00 0.00 -394.70 0.00 0.00 0.00 -394.70 0.00
TG-18 0.00 0.00 -971.66 0.00 0.00 0.00 -971.66 0.00
ME-8 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -27.28
ME-10 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -6.23
ME-12 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -23.00
ME-14 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -2.14
ME-16 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -0.32
ME-18 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -0.26
GL 0.00 0.00 0.00 0.00 0.00 0.00 0.00 -1.68
MeOH -2336.28 0.00 0.00 0.00 -2336.28 0.00 0.00 -4334.43
Water 0.00 0.00 0.00 -38529.01 0.00 0.00 0.00 0.00
NaOCH3 0.00 -158.87 0.00 0.00 0.00 -158.87 0.00 0.00
Total (Manual) -2336.28 -158.87 -5641.24 -38529.01 -2336.28 -158.87 -5641.24 -4395.35
Stream
5 6 7 8 9 10 11 12
Component
Enthalpy Flow
TG-8 -308.27 -303.96 -3.04 -2.94 0.00 0.00 0.00 0.00
TG-10 -237.02 -233.32 -2.33 -2.25 0.00 0.00 0.00 0.00
TG-12 -2882.16 -2839.81 -28.40 -27.38 0.00 0.00 0.00 0.00
TG-14 -832.08 -818.08 -8.18 -7.84 0.00 0.00 0.00 0.00
TG-16 -393.00 -385.86 -3.86 -3.69 0.00 0.00 0.00 0.00
TG-18 -967.25 -948.78 -9.49 -9.05 0.00 0.00 0.00 0.00
ME-8 -27.43 -26.99 -303.83 -292.40 -12.79 -25.82 -26.99 -26.99
ME-10 -6.27 -6.16 -233.64 -223.85 -2.52 -5.86 -6.16 -6.16
ME-12 -23.16 -22.71 -2839.38 -2708.37 -8.20 -21.49 -22.71 -22.71
ME-14 -2.16 -2.11 -844.36 -802.98 -0.67 -1.99 -2.11 -2.11
ME-16 -0.32 -0.32 -411.58 -390.70 -0.08 -0.30 -0.32 -0.32
ME-18 -0.26 -0.25 -847.55 -795.86 -0.06 -0.23 -0.25 -0.25
GL -1.69 -1.67 -1989.28 -1950.43 -0.18 -1.64 -1.67 -1.67
MeOH -4352.95 -4300.10 -2171.55 -1844.05 -1377.91 -1694.20 -1998.92 -1998.92
Water 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
NaOCH3 -158.78 -158.39 -158.39 -157.56 0.00 0.00 0.00 0.00
Total (Manual) -10192.82 -10048.53 -9854.85 -9219.34 -1402.41 -1751.53 -2059.14 -2059.14
134
Stream
13 14 15 16 17 18 19 20
Component
Enthalpy Flow
TG-8 -2.94 -2.86 0.00 -2.86 -2.86 -3.06 0.00 -3.06
TG-10 -2.25 -2.18 0.00 -2.18 -2.18 -2.35 0.00 -2.35
TG-12 -27.38 -26.63 0.00 -26.63 -26.63 -28.55 0.00 -28.55
TG-14 -7.84 -7.59 0.00 -7.59 -7.59 -8.23 0.00 -8.23
TG-16 -3.69 -3.56 0.00 -3.56 -3.56 -3.88 0.00 -3.88
TG-18 -9.05 -8.72 0.00 -8.72 -8.72 -9.56 0.00 -9.56
ME-8 -279.61 -271.76 -12.82 -258.94 -258.94 -278.46 0.00 -278.46
ME-10 -221.33 -214.27 -3.27 -210.99 -210.99 -228.96 0.00 -228.96
ME-12 -2700.18 -2605.94 -12.99 -2592.95 -2592.95 -2837.12 0.00 -2837.12
ME-14 -802.31 -772.05 -1.29 -770.76 -770.76 -848.68 0.00 -848.68
ME-16 -390.61 -375.38 -0.21 -375.17 -375.17 -414.51 0.00 -414.51
ME-18 -795.80 -757.73 -0.17 -757.56 -757.56 -855.27 0.00 -855.27
GL -1950.25 -1922.36 -1.44 -1920.92 -1920.92 -1993.74 0.00 -20.65
MeOH -466.14 -462.12 -316.79 -145.33 -145.33 -173.40 0.00 -58.79
Water 0.00 0.00 0.00 0.00 0.00 0.00 -38529.01 -88.72
NaOCH3 -157.56 -157.01 0.00 -157.01 -157.01 -158.53 0.00 0.00
Total (Manual) -7816.93 -7590.15 -348.98 -7241.17 -7241.17 -7844.30 -38529.01 -5686.79
Stream
21 22 23 24 25 26 27 28
Component
Enthalpy Flow
TG-8 -3.05 -2.99 0.00 0.00 -2.71 -2.71 -2.81 0.00
TG-10 -2.34 -2.29 0.00 0.00 -2.05 -2.05 -2.14 0.00
TG-12 -28.49 -27.89 0.00 0.00 -25.02 -25.02 -26.12 0.00
TG-14 -8.21 -8.01 0.00 0.00 -7.06 -7.06 -7.42 0.00
TG-16 -3.87 -3.77 0.00 0.00 -3.28 -3.28 -3.47 0.00
TG-18 -9.53 -9.27 0.00 0.00 -8.04 -8.04 -8.51 0.00
ME-8 -277.81 -271.58 -1.38 -1.41 -242.32 -242.32 -252.79 -258.03
ME-10 -228.37 -222.69 -0.01 -0.01 -196.43 -196.43 -206.40 -210.29
ME-12 -2828.98 -2751.10 0.00 0.00 -2398.23 -2398.23 -2531.34 -12.99
ME-14 -846.12 -821.51 0.00 0.00 -707.06 -707.06 -750.74 0.00
ME-16 -413.22 -400.77 0.00 0.00 -343.18 -343.18 -365.10 0.00
ME-18 -852.10 -821.41 0.00 0.00 -677.44 -677.44 -732.33 0.00
GL -20.62 -20.38 0.00 0.00 -19.30 -19.30 -19.70 0.00
MeOH -58.69 -50.01 -50.33 -59.42 0.00 0.00 0.00 0.00
Water -88.62 -87.62 -88.05 -88.89 -0.37 -0.37 -0.37 -0.38
NaOCH3 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Total (Manual) -5670.04 -5501.29 -139.77 -149.73 -4632.48 -4632.48 -4909.24 -481.69
135
Stream
29 30 31 32 33 34 35 36 37
Component
Enthalpy Flow
kW kW kW kW kW kW kW kW kW
TG-8 0.00 0.00 -2.73 -2.73 -2.79 0.00 0.00 0.00 -2.70
TG-10 0.00 0.00 -2.07 -2.07 -2.12 0.00 0.00 0.00 -2.04
TG-12 0.00 0.00 -25.25 -25.25 -25.85 0.00 0.00 0.00 -25.00
TG-14 0.00 0.00 -7.13 -7.13 -7.33 0.00 0.00 0.00 -7.05
TG-16 0.00 0.00 -3.32 -3.32 -3.42 0.00 0.00 0.00 -3.28
TG-18 0.00 0.00 -8.14 -8.14 -8.39 0.00 0.00 0.00 -8.03
ME-8 -258.03 -280.97 0.00 0.00 0.00 0.00 0.00 0.00 0.00
ME-10 -210.29 -231.36 -0.99 -0.99 -1.02 -1.04 -1.04 -1.14 0.00
ME-12 -12.99 -14.43 -2413.00 -2413.00 -2485.87 -2541.02 -2538.55 -2822.94 0.00
ME-14 0.00 0.00 -715.93 -715.93 -739.97 -754.26 -753.46 -844.43 -3.53
ME-16 0.00 0.00 -347.62 -347.62 -359.68 -1.84 -1.84 -2.07 -341.01
ME-18 0.00 0.00 -688.56 -688.56 -718.77 0.00 0.00 0.00 -676.32
GL 0.00 0.00 -19.38 -19.38 -19.60 -18.76 -18.75 -19.59 -0.91
MeOH 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Water -0.38 -0.45 0.00 0.00 0.00 0.00 0.00 0.00 0.00
NaOCH3 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Total (Manual) -481.69 -527.22 -4234.11 -4234.11 -4374.82 -3316.93 -3313.65 -3690.18 -1069.88
Stream
38 39 40 41 42 43 44 45 46
Component
Enthalpy Flow
kW kW kW kW kW kW kW kW kW
TG-8 -2.70 -3.06 0.00 0.00 0.00 0.00 0.00 0.00 0.00
TG-10 -2.04 -2.35 0.00 0.00 0.00 0.00 0.00 0.00 0.00
TG-12 -25.00 -28.55 0.00 0.00 0.00 0.00 0.00 0.00 0.00
TG-14 -7.05 -8.23 0.00 0.00 0.00 0.00 0.00 0.00 0.00
TG-16 -3.28 -3.88 0.00 0.00 0.00 0.00 0.00 0.00 0.00
TG-18 -8.03 -9.56 0.00 0.00 0.00 0.00 0.00 0.00 0.00
ME-8 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
ME-10 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
ME-12 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
ME-14 -3.53 -4.24 0.00 0.00 0.00 0.00 0.00 0.00 0.00
ME-16 -341.01 -412.44 0.00 0.00 0.00 0.00 0.00 0.00 0.00
ME-18 -676.32 -855.27 0.00 0.00 0.00 0.00 0.00 0.00 0.00
GL -0.99 -1.05 -1973.10 -1991.91 -1921.86 -25.29 -26.16 -1896.56 -1961.71
MeOH 0.00 0.00 -114.61 -116.18 -96.69 -96.22 -115.28 -0.47 -0.56
Water 0.00 0.00 -38174.98 -38510.48 -32465.41 -31985.76 -37871.75 -479.65 -567.91
NaOCH3 0.00 0.00 -158.53 -158.97 -157.42 0.00 0.00 -157.42 -158.87
Total (Manual) -1069.96 -1328.64 -40421.22 -40777.54 -34641.38 -32107.28 -38013.20 -2534.10 -2689.06
136
2.3.4.2 Pumps
Table 2-62 shows the summarized results of manually calculated fluid power of all the pumps
in unit of kW. Detailed calculation steps and methods for each pump can be seen in Appendix
A.3.2.
Table 2-62: Summarized results of pumps‘ fluid power

Fluid Power
Pump Manual Calculation Result
kW
P-101 0.008053
P-102 0.000237
P-103 0.034578
P-104 0.049475
P-105 0.007785
P-106 0.059666
P-107 0.050024
P-108 0.060870
P-109 0.016567
P-110 0.055166
P-111 0.168413
P-112 0.079416
P-113 0.054530
2.3.4.3 Heat Exchangers

Heat exchanger‘s net heat duty can be calculated using the equations below.
̇ ̇
where ̇ and ̇
which are calculated and summarized before in Chapter 2.3.4.1.
Table 2-63 shows the summarized results of manually calculated heat duty of all the heat
exchangers in unit of kW.
137
Table 2-63: Summarized results of pumps‘ fluid power
Heat Duty
Heat Exchanger Manual Result
kW
E-101 144.2853
E-102 635.5070
E-103 -307.6075
E-104 226.7729
E-105 -603.1311
E-106 168.7439
E-107 -9.9587
E-108 -276.7608
E-109 -45.5313
E-110 -140.7106
E-111 -441.6045
E-112 -286.5068
E-113 6136.1640
E-114 -5905.9235
E-115 -154.9570
2.4 ASPEN PLUS SIMULATION

In this work, the methyl ester production process is modelled using Aspen Plus v8.0. Basic
steps to process modelling and simulation using Aspen Plus v8.0 include defining chemical
components, selecting thermodynamic model and method, designing process flow sheet by
choosing proper operating units, determining plant capacity and setting up input parameters.
In methyl ester production, both methanol and glycerol are highly polar components. Hence,
NRTL and UNIQUAC models are recommended to predict the activity coefficients of
components in a liquid phase (Zhang et al., 2003). In this simulation, NRTL is used as the
main thermodynamic method. The process flow diagram designed using Aspen Plus v8.0 can
be seen in Figure 2-19. The results generated by Aspen for each stream‘s condition can be
viewed in Appendix A.4.
138
2.4.1 Material Balance Comparison
Table 2-64: Comparison between manual and Aspen material balance
Mole Flow Mass Flow
Manual Manual Aspen
Stream Aspen Result Error Stream Error
Result Result Result
kmol/hr kmol/hr kg/hr kg/hr
MeOH 35.2499 35.2503 0.00% MeOH 1129.4733 1129.4960 0.00%
NaOCH3 1.3916 1.3916 0.00% NaOCH3 81.3248 81.3285 0.00%
TG 10.9783 10.9783 0.00% TG 7517.9522 7530.6850 0.17%
Water 485.2520 485.2520 0.00% Water 8742.3000 8741.9510 0.00%
1 35.2499 35.2503 0.00% 1 1129.4733 1129.4960 0.00%
2 1.3916 1.3916 0.00% 2 81.3248 81.3285 0.00%
3 10.9783 10.9783 0.00% 3 7517.9522 7530.6850 0.17%
4 66.2553 66.5032 0.37% 4 2181.1394 2189.2910 0.37%
5 78.6252 78.8731 0.31% 5 9780.4164 9801.3050 0.21%
6 78.6252 78.8731 0.31% 6 9780.4164 9801.3050 0.21%
7 78.2396 78.8731 0.80% 7 9723.2498 9801.3050 0.80%
8 78.2396 78.8731 0.80% 8 9723.2498 9801.3050 0.80%
9 25.0214 25.8627 3.25% 9 826.3745 855.5202 3.41%
10 31.0054 31.2529 0.79% 10 1051.6661 1059.7950 0.77%
11 31.0054 31.2529 0.79% 11 1051.6661 1059.7950 0.77%
12 31.0054 31.2529 0.79% 12 1051.6661 1059.7950 0.77%
13 53.2182 53.0104 -0.39% 13 8896.8753 8945.7840 0.55%
14 53.2182 53.0104 -0.39% 14 8896.8753 8945.7840 0.55%
15 5.9841 5.5857 -7.13% 15 225.2916 211.6165 -6.46%
16 47.2341 47.4246 0.40% 16 8671.5837 8734.1680 0.72%
17 47.2341 47.4246 0.40% 17 8671.5837 8734.1680 0.72%
18 47.2341 47.4246 0.40% 18 8671.5837 8734.1680 0.72%
19 485.2520 485.2520 0.00% 19 8742.3000 8741.9510 0.00%
20 34.4730 34.7789 0.88% 20 7564.8094 7630.5420 0.86%
21 34.4730 34.7789 0.88% 21 7564.8094 7630.5420 0.86%
22 34.4730 34.7789 0.88% 22 7564.8094 7630.5420 0.86%
23 2.0256 2.0450 0.95% 23 50.4127 60.8403 17.14%
24 2.0256 2.0450 0.95% 24 50.4127 60.8403 17.14%
25 32.4474 32.7339 0.88% 25 7514.3967 7569.7000 0.73%
26 32.4474 32.7339 0.88% 26 7514.3967 7569.7000 0.73%
27 32.4474 32.7339 0.88% 27 7514.3967 7569.7000 0.73%
28 3.4369 3.4665 0.85% 28 588.4234 597.2062 1.47%
29 3.4369 3.4665 0.85% 29 588.4234 597.2062 1.47%
30 3.4369 3.4665 0.85% 30 588.4234 597.2062 1.47%
31 29.0105 29.2674 0.88% 31 6925.9733 6972.4940 0.67%
32 29.0105 29.2674 0.88% 32 6925.9733 6972.4940 0.67%
33 29.0105 29.2674 0.88% 33 6925.9733 6972.4940 0.67%
34 21.6830 21.8744 0.87% 34 4769.9296 4800.5740 0.64%
35 21.6830 21.8744 0.87% 35 4769.9296 4800.5740 0.64%
36 21.6830 21.8744 0.87% 36 4769.9296 4800.5740 0.64%
37 7.3274 7.3929 0.89% 37 2156.0437 2171.9230 0.73%
38 7.3274 7.3929 0.89% 38 2156.0437 2171.9230 0.73%
39 7.3274 7.3929 0.89% 39 2156.0437 2171.9230 0.73%
40 498.0131 497.8977 -0.02% 40 9849.0768 9845.5800 -0.04%
41 498.0131 497.8977 -0.02% 41 9849.0768 9845.5800 -0.04%
42 498.0131 497.8977 -0.02% 42 9849.0768 9845.5800 -0.04%
43 478.8551 475.5946 -0.69% 43 8661.9276 8614.1300 -0.55%
44 478.8551 475.5946 -0.69% 44 8661.9276 8614.1300 -0.55%
45 19.1580 22.3031 14.10% 45 1187.1491 1231.4500 3.60%
46 19.1580 22.3031 14.10% 46 1187.1491 1231.4500 3.60%
139
Comparison between manual and Aspen results for material balance is shown in Table 2-64.
From the material balance, the manual calculation is correspond to the Aspen results and
shows no significant deviation except for stream 15, 23, 24, 45, and 46. These errors arise
because Aspen estimated some properties of the triglycerides components instead of having
correct properties of the triglyceride components. For instant, the boiling point for some
triglyceride components estimated from the Aspen is different from the one obtained for
manual calculation. Therefore, separation process involving unit operations like flash drum
and distillation column (which relate with boiling points of components) tends to produce
large deviation between manual and Aspen result. Overall, the manual material balance
calculation is accepted as almost all streams are below 5% deviation.
2.4.2 Production Rate Comparison
Table 2-65: Mass flow rate of combined methyl ester products

Manual (kg/hr) Aspen (kg/hr)
Component 30 36 39 30 36 39
TG 0.00 0.00 75.30 0.00 0.00 75.25
ME-8 300.38 0.00 0.00 318.50 0.00 0.00
ME-10 269.90 1.36 0.00 218.76 59.18 0.00
ME-12 18.04 3589.91 0.00 59.58 3578.31 0.00
ME-14 0.00 1165.90 5.86 0.35 1149.43 24.64
ME-16 0.00 2.93 583.96 0.00 3.74 582.67
ME-18 0.00 0.00 1490.51 0.00 0.00 1488.41
GL 0.00 9.83 0.53 0.00 9.84 0.52
MeOH 0.00 0.00 0.00 0.00 0.00 0.00
Water 0.10 0.00 0.00 0.00 0.00 0.00
NaOCH3 0.00 0.00 0.00 0.00 0.00 0.00
Total 588.42 4769.93 2156.16 597.19 4800.49 2171.49
TOTAL 7514.51 7569.17
To evaluate the significance of the production rate deviation from our desired production rate
of methyl esters which is 60,000 MTPA (60,000,000 kg/yr), equation below is used.
As a result, the production rate of methyl esters from both manual and Aspen results meet the
required rate of 7,500 kg/hr of methyl esters.
140
The error between the production rate from manual calculation and aspen is calculated as
shown below.
The result between manual calculation and Aspen result is relatively small and can be
accepted.
2.4.3 Stream Energy Balance Comparison

Table 2-66: Comparison between manual and Aspen stream energy balance
Enthalpy Flow
Stream Manual Result Simulation Result Error
kW kW
MeOH -2336.28 -2334.55 -0.07%
NaOCH3 -158.87 -136.02 -16.80%
TG -5641.24 -6041.17 6.62%
Water -38529.01 -38480.40 -0.13%
1 -2336.28 -2334.50 -0.08%
2 -158.87 -136.02 -16.81%
3 -5641.24 -6040.75 6.61%
4 -4395.35 -4414.46 0.43%
5 -10192.82 -10591.19 3.76%
6 -10048.53 -10442.24 3.77%
7 -9854.85 -10638.47 7.37%
8 -9219.34 -10032.63 8.11%
9 -1402.41 -1427.72 1.77%
10 -1751.53 -1736.33 -0.88%
11 -2059.14 -2079.87 1.00%
12 -2059.14 -2079.87 1.00%
13 -7816.93 -8604.66 9.15%
14 -7590.15 -8320.99 8.78%
15 -348.98 -321.83 -8.44%
16 -7241.17 -7999.25 9.48%
17 -7241.17 -7998.83 9.47%
18 -7844.30 -8593.78 8.72%
19 -38529.01 -38479.98 -0.13%
20 -5686.79 -6444.92 11.76%
21 -5670.04 -6444.92 12.02%
22 -5501.29 -6281.33 12.42%
23 -139.77 -157.15 11.06%
24 -149.73 -159.04 5.86%
25 -4632.48 -5381.78 13.92%
26 -4632.48 -5381.78 13.92%
27 -4909.24 -5663.78 13.32%
28 -481.69 -544.25 11.49%
29 -481.69 -544.16 11.48%
141
30 -527.22 -592.49 11.02%
31 -4234.11 -4926.57 14.06%
32 -4234.11 -4926.57 14.06%
33 -4374.82 -5067.15 13.66%
34 -3316.93 -3798.67 12.68%
35 -3313.65 -3798.21 12.76%
36 -3690.18 -4179.91 11.72%
37 -1069.88 -1280.99 16.48%
38 -1069.96 -1280.70 16.46%
39 -1328.64 -1539.81 13.71%
40 -40421.22 -40691.18 0.66%
41 -40777.54 -40690.77 -0.21%
42 -34641.38 -34270.11 -1.08%
43 -32107.28 -31463.96 -2.04%
44 -38013.20 -37728.13 -0.76%
45 -2534.10 -2806.37 9.70%
46 -2689.06 -2895.86 7.14%
The detail stream energy balance calculation can be viewed in Appendix A.3.1. Table 2-66
shows the energy balance comparison for all the streams involved in the process. From the
comparison result, it is worth to mention that the errors are still within the acceptable
boundary of 30% error. Hence, the manual energy balance calculation is considered valid.
2.4.4 Reactor Energy Balance Comparison

The detail manual calculation of the reactor heat duty is shown in Appendix A.3.3. From the
comparison result in Table 2-67, there is only 3.84% deviation between manual and Aspen
calculation which is in the acceptable range of 30% error.
Table 2-67: Comparison between manual and Aspen reactor energy balance
Heat Duty (kW)
Equipment
Manual Aspen Error
R-101 31.3407 35.3846 11.43%
R-102 8.7167 10.0234 13.14%
R-103 3.8636 4.8790 20.81%
142
2.4.5 Pump Energy Balance Comparison
The detailed calculation for pump energy balance can be viewed Appendix A.3.2. Table 2-68
compare the manual and Aspen result on pump fluid power. As can be seen, there is no
significant error (> 30%) for all the pumps, thus, the manual calculation for pumps‘ fluid
power is considered valid.
Table 2-68: Comparison between manual and Aspen pump energy balance
Fluid Power
Pump Manual Result Simulation Result Error
kW kW
P-101 0.008053 0.008019 -0.42%
P-102 0.000237 0.000275 13.83%
P-103 0.034578 0.036131 4.30%
P-104 0.049475 0.049509 0.07%
P-105 0.007785 0.007942 1.98%
P-106 0.059666 0.065465 8.86%
P-107 0.050024 0.054184 7.68%
P-108 0.060870 0.065075 6.46%
P-109 0.016567 0.017065 2.92%
P-110 0.055166 0.059217 6.84%
P-111 0.168413 0.181218 7.07%
P-112 0.079416 0.084300 5.79%
P-113 0.054530 0.053629 -1.68%
143
2.4.6 Heat exchanger Energy Balance Comparison
Heat exchanger‘s net heat duty can be calculated using the equations below.
̇ ̇
where ̇ and ̇
which are calculated and summarized before in Chapter 2.3.4.1. Table 2-69 compares the
manual and .Aspen result on heat exchangers‘ heat duties. As a result, there are two heat
exchangers, E-107 and E-115 exceed the error boundary (>30%). As mentioned before, the
error is due to the difference in the properties of the triglyceride components from the real
properties as Aspen needs to estimate the triglyceride properties which is originally not
contained in the Aspen property database.
Table 2-69: Comparison between manual and Aspen heat exchanger energy balance
Heat Duty
Heat Exchanger Manual Aspen Error
kW kW
E-101 144.2853 149.1805 3.39%
E-102 635.5070 606.1581 -4.62%
E-103 -307.6075 -343.7673 11.76%
E-104 226.7729 284.1209 25.29%
E-105 -603.1311 -595.2771 -1.30%
E-106 168.7439 163.7360 -2.97%
E-107 -9.9587 -1.8936 -80.99%
E-108 -276.7608 -282.4307 2.05%
E-109 -45.5313 -48.3586 6.21%
E-110 -140.7106 -140.8079 0.07%
E-111 -376.5325 -382.0088 1.45%
E-112 -258.6810 -259.2798 0.23%
E-113 6136.1640 6425.0677 4.71%
E-114 -5905.9235 -6268.4952 6.14%
E-115 -154.9570 -89.5664 -42.20%
144
3 CHAPTER 3: EQUIPMENT SIZING
3.1 INTRODUCTION
Equipment sizing is the utmost important part in the plant design project especially when
analyzing the feasibility and profitability of the plant. This is because these parts will sized all
the equipment used as well as their particular cost which includes the constructing material,
length of vessel, diameter of pipeline and some even the inner diameter.
There are total of 55 equipments involved in this Methyl Ester production plant. This
comprises the major equipment like reactors, distillation columns, flash drums, pumps, heat
exchangers, mixers, and storage tanks. This section will show each equipment summary
starting from the reactor, separation, heat exchanger and also boiler. For sizing and costing,
the major references used are Sinnott (2005) and Turton et al. (2012).
3.2 MAJOR EQUIPMENT SIZING
3.2.1 Reactors
Reactors are the heart of a chemical production plant where the reactions take place to convert
the raw material to desired product which is Methyl Esters in this case of plant design. There
are various parameters need to be take into account when designing the reactors, namely type
of reaction, concentration, temperature, pressure, phase as well as the catalyst used. There are
also few types of reactors such as the batch reactor, continuous stirred tank reactor, fluidized
bed reactor and plug flow reactor. For the production of Methyl Esters, three Continuous
Stirred Tank Reactors (CSTRs) in series are used.
3.2.1.1 R-101/2/3
The transesterification reactions are carried out at 60°C and 1 atm by three continuous stirred
tank reactors (CSTRs) in series (53m3 each) to achieve a total of 99% conversion of
triglyceride. CSTRs in series are chosen instead of one PFR because the reaction requires
external mixing energy which can be done by stirrers. The conversion and temperature
information at each stage of CSTR is summarized in Table 3-1 below.
145
Table 3-1: Conversion and temperature information at each reactor
Reactor Conversion, Xi Outlet Temperature (K) Temperature drop (K)
1st CSTR 78.56 % 328.2 333.15 – 328.20 = 4.95
2nd CSTR 95.40 % 327.1 328.20 – 327.10 = 1.10
3rd CSTR 99.01 % 326.9 327.10 – 326.90 = 0.20
The reaction involved is:
TG + 3 MeOH 3 ME + GL
Triglyceride Methanol Methyl ester Glycerol
There are few assumptions needed to be highlighted:
 Steady state condition

 No radial and axial variation in concentration of reactants and products in the reactor
 The reaction occurs isothermally due to jacketed supply of heat duty
Detail calculation steps for the reactor R-101/2/3 are shown in Appendix B.1.1. The summary
of reactor sizing is tabulated in Table 3-2. The configuration of the CSTR can be seen in
Figure 3-1.
Figure 3-1: Configuration of CSTR
146
Table 3-2: Reactor R-101/2/3 Design Summary
EQUIPMENT SPECIFICATION SHEET
Design type Jacketed and agitated CSTR
Equipment R-101 R-102 R-103
Specification
Temperature (°C) 60
Pressure (atm) 1
Mixture volume (m3) 53
Reaction time (min) 12.77
Conversion (%) 78.56 95.4 99.01
Specification
Tank
Material of construction Stainless Steel 304
Heads and closures Ellipsoidal heads
Tank diameter, DT (m) 4.081
Tank height, HT (m) 4.89
Static liquid depth, ZL (m) 4.07
Volume (m3) 63.6
Working volume percentage (%) 83.33%
Shell Thickness (mm) 5.517
Impeller
Design type Six Flat Blade Turbine
Impeller speed (rpm) 90
Mixing time, tm (s) 14.25
Impeller diameter, DI (m) 1.357
Impeller distance from tank bottom, ZI (m) 1.357
Impeller disc diameter, Dd (m) 1.018
Impeller blade length, I (m) 0.339
Impeller blade width, b (m) 0.271
Shaft power (kW) 18.03 18.72 18.87
Baffle
Number of baffles 4
Baffle width, W (m) 0.407
Baffle tip distance from tank bottom, m (m) 0.814
Jacketing
Heat Duty (kW) 31.3407 8.7167 3.8636
Boiler feed water flow rate (kg/s) 1.9812 2.8524 7.1883
EQUIPMENT CAPITAL COST (RM) 2,907,705.48
147
3.2.2 Decanter
3.2.2.1 V-101
V-101 is a decanter to separate methyl esters and glycerol based on their density.
Theoretically, the decanter is favourable to separate methyl esters and glycerol at low
temperature. This is because the lower the temperature, the higher the density of the mixture
components, resulting in more glycerol being separated to the bottom liquid layer. In this
case, the liquid product from flash drum C-102 is being condensed to 50°C before entering
the decanter. Fresh water is fed to the decanter which also makes the decanter as a washing
vessel to increase the efficiency of methyl esters-glycerol separation. A 1:1 water to methyl
esters volume ratio is assumed here (Rahayu & Mindaryani, 2007).
Detail calculation steps for the decanter V-101 are shown in Appendix B.1.2. The summary of
decanter sizing is tabulated in Table 3-3.
Table 3-3: Decanter V-101 Design Summary

Item no. V-101
Identification Decanter
Function To separate glycerol from methyl esters
Operating condition
Pressure (atm) 1
Holding time (min) 6.57
Dispersed phase flow rate, Fd (kg/hr) 8734.17
Continuous phase flow rate, Fc (kg/hr) 8741.95
Specification
Design type Vertical cylindrical vessel
Material of construction Stainless steel 304
Vessel
Diameter (m) 3.94
Height (m) 7.88
Volume (m3) 96.14
148
3.2.3 Distillation Columns
According to Sinnott (2005), the simply trial-and-error procedures to design a distillation
column are as follow:
(a) Calculate the maximum and minimum vapour and liquid flow rates, for turn down
ratio required.
(b) Collect or estimate the system properties from simulation results.
(c) Select trial plate spacing.
(d) Estimate the column diameter, based on flooding considerations.
(e) Decide the liquid flow arrangement.
(f) Make a trial plate layout: down corner area, active area, hole area, hole size, weir
height etc.
(g) Check the weeping rate, if unsatisfied repeat step (f).
(h) Check the plate pressure drop, if too high return to step (f).
(i) Check down corner back up, if too high back to step (f) or (c).
(j) Decide plate layout details: calming zone, imperforated area. Check hole pitch if
unsatisfactory, back to step (f).
(k) Recalculate the percentage-flooding base on chosen column diameter.
(l) Check entrainment, if too high return to step (d).
(m) Optimized design: repeat step (c) to (l) to find smallest diameter and plate spacing
acceptable (lowest cost).
(n) Finalized design: draw up a plate specification and sketch the layout.
Detail calculation steps for the distillation columns are shown in Appendix B.1.5 to B.1.7.
The summary of distillation column sizing is tabulated in Table 3-4.
149
Table 3-4: Distillation Column Design Summary
Equipment C-103 C-104 C-105
Material of Construction SS 304 SS 304 SS 304
Feed Trays (from top) 10 7 20
Liquid Flow Pattern Single pass Single pass Single pass
Column
Tray spacing, lt (m) 0.6 0.6 0.6
Column diameter, Dc (m) 1.18 1.09 1.27
Column cross-sectional area, Ac (m2) 1.09 0.93 1.26
Column height, ht (m) 18.13 15.06 19.99
No. of trays 28 24 32
Provisional Plate Design
Plate thickness, tp (mm) 5 5 5
Plate area
Down comer area, Ad (m2) 0.16 0.14 0.19
2
Net area, An (m ) 0.93 0.79 1.07
Active area, Aa (m2) 0.76 0.65 0.88
2
Hole area, Ah (m ) 0.09 0.08 0.11
Hole Design
Hole diameter, dh (mm) 5 5 5
Single hole area, Ash (m2) 1.96E-05 1.96E-05 1.96E-05
Number of holes 4658 3960 5384
Weir Design
Weir length, lw (m) 0.88 0.81 0.95
Weir height, hw (m) 0.05 0.05 0.05
Weir liquid Crest
Maximum, how (mm liquid) 8.63 6.25 7.19
Minimum, how (mm liquid) 7.44 5.39 6.19
Weeping point
Minimun, uh min (m/s) 16.91 10.91 19.03
Actual, u(actual) (m/s) 25.07 14.79 26.1
Plate Pressure Drop
Total pressure drop (mm liquid) 127.25 116.13 116.58
Down comer Design
Down comer backup, hb (mm liquid) 184.85 171.58 172.86
Head loss, hdc (mm liquid) 0.158 0.06 0.091
Residence time, ts (s) 48.69 72.89 68.89
Perforate Area
Perforated area, Ap (m2) 0.76 0.65 0.88
EQUIPMENT CAPITAL COST (RM) 1,053,940.01 890,556.48 1,362,457.18
150
3.2.4 Flash Drums
3.2.4.1 C-101
C-101 is used as 1st methanol recovery column. The reaction products which consist of
methyl esters, glycerol, trace amount of unreacted triglyceride, and excess methanol is then
preheated to 130°C and fed to first methanol recover flash column C-101 operated at
atmospheric pressure (1 atm). At the first stage of methanol recovery process, about 75% of
methanol fed is recovered and recycle back to the reactor inlet stream.
3.2.4.2 C-102
C-102 is used as 2nd methanol recovery column. It is ideal to fully recover the excess
methanol from the reactor outlet by using one unit operator (i.e. flash drum). However, this
approach requires higher heat duty of the preheater (heat exchanger), which may result in
higher operating cost. Theoretically, the higher the inlet temperature of the stream fed to the
flash drum, the higher the methanol recovery efficiency. However, the higher the temperature,
the higher the amount of primary product (e.g. light cut methyl esters, C8:0) is being flashed
off in vapour stream which is not preferred. Therefore, a second methanol recovery flash
drum, C-102 is installed to optimize the above considerations. By two-stage methanol
recovery process, a high purity of methanol recovery with lower energy cost can be achieved
and at the same time do not flash off the primary products (Tang et al., 2010). In overall, the
two-stage methanol recovery process recovers and recycles a total of 92% methanol back to
the reactor inlet stream. The decision of choosing flash drum instead of a more efficient
distillation column is also due to significant high operating cost of the distillation column that
requires large heat energy for condenser and reboiler.
3.2.4.3 C-106
C-106 is used as glycerol purification column. The high density products (i.e. glycerol, water,
sodium methoxide) at bottom layer of decanter are sent to this flash drum to flash out excess
water and methanol to produce crude glycerol at more than 80wt% purity.
Detail calculation steps for the flash drums are shown in Appendix B.1.3, B.1.4, and B.1.8.
The summary of flash drum sizing is tabulated in Table 3-5.
151
Table 3-5: Flash Drum Design Summary
Item no. C-101 C-102 C-106
Identification Isothermal Flash Drum
Function 1st methanol 2nd methanol Glycerol
recovery drum recovery drum purification drum
Operating condition
Temperature (°C) 120 160 130
Pressure (atm) 1 1 1
Mass vapour flow rate, Wv
(kg/hr) 855.52 211.62 8614.13
Mass liquid flow rate, WL
(kg/hr) 8945.78 8734.17 1231.45
Specification
Design type Vertical vessel Vertical vessel Vertical vessel
Material of construction Stainless Steel 304 Stainless Steel 304 Stainless Steel 304
Vessel
Diameter (m) 1.8162 1.5464 2.6948
Height (m) 9.0808 7.732 13.4742
Volume (m3) 23.5278 14.5239 76.8633
EQUIPMENT CAPITAL
COST (RM) 710,090.29 507,557.44 2,686,090.12
152
3.3 MINOR EQUIPMENT SIZING
3.3.1 Storage Tanks

There are four storage tanks for raw materials and four storage tanks for products in this plant.
Detail calculation steps for the storage tanks are shown in Appendix B.1.9 to B.1.16. The
summary of storage tank sizing is tabulated in Table 3-6.
Table 3-6: Storage Tank Design Summary

Item no. T-101 T-102 T-103 T-104
Identification Storage Tank Storage Tank Storage Tank Storage Tank
Function To store raw To store raw To store raw To store raw
material, material, material, RBD material, water
methanol sodium palm kernel oil
methoxide (triglyceride)
30% solution
Specification
Type of storage tank Floating roof Fixed roof Fixed roof Fixed roof
Material of construction Carbon steel SS 304 Carbon steel Carbon steel
Tank volume (m3) 251.28 14.87 1132.23 1551.46
Tank diameter (m) 5.85 2.28 9.66 10.73
Tank height (m) 9.36 3.65 15.45 17.16
Wall thickness (mm) 5.00 3.00 7.00 7.00
Day of inventory (days) 7.00 7.00 7.00 7.00
EQUIPMENT
987,089.94 345,538.07 2,090,048.70 2,566,112.96
CAPITAL COST (RM)

Item no. T-105 T-106 T-107 T-108
Identification Storage Tank Storage Tank Storage Tank Storage Tank
Function To store To store To store To store
product, CE- product, CE- product, CE- product,
810 1214 1618 glycerol
Specification
Type of storage tank Fixed roof Fixed roof Fixed roof Fixed roof
Material of construction SS 304 SS 304 SS 304 SS 304
Tank volume (m3) 123.34 1074.34 473.77 166.79
Tank diameter (m) 4.61 9.49 7.22 5.10
Tank height (m) 7.38 15.18 11.56 8.16
Wall thickness (mm) 4.00 6.00 5.00 4.00
Day of inventory (days) 7.00 7.00 7.00 7.00
EQUIPMENT
1,567,373.85 3,071,799.91 2,408,220.27 1,695,620.49
CAPITAL COST (RM)
153
Besides, there is one storage tank T-201 for boiler feed water (BFW) to ensure enough supply
of water to the boiler E-201. Detail calculation steps for the storage tank T-201 are shown in
Appendix B.1.34. The summary of design is tabulated in Table 3-7.
Table 3-7: Storage Tank T-201 Design Summary

Item no. T-201
Identification BFW Storage tank
Function To hold up BFW
Specification
Type of storage tank Fixed roof
Material of construction Carbon steel
Tank volume (m3) 664.87
Tank diameter (m) 8.10
Tank height (m) 12.90
Wall thickness (mm) 6.00
Day of inventory (hours) 5
154
3.3.2 Pumps
Pump is a machine or mechanic equipment which is required to lift liquid from low level to high level or to flow liquid from low pressure area to
high pressure area and also as a debit booster in a piping network system. This is reached by making a low pressure at suction side of pump and a
high pressure at discharge side of pump. This covers P-101 A/B to P-113 A/B in our plant. The pressure drop is based on criteria as below:
1. The static pressure, to overcome the differences in head (height) and pressure.
2. The dynamic loss due to friction in the pipe, the miscellaneous losses, and the pressure loss through equipment.
Detail calculation steps for the pumps are shown in Appendix B.1.17 to B.1.29. The summary of its sizing is tabulated in Table 3-8.
Table 3-8: Pump Design Summary

Design type Centrifugal pump
Equipment P-101 P-102 P-103 P-104 P-105 P-106 P-107 P-108 P-109 P-110 P-111 P-112 P-113
A/B A/B A/B A/B A/B A/B A/B A/B A/B A/B A/B A/B A/B
Fluid Properties:
Mass flow rate, kg/s 0.314 0.226 2.092 2.428 0.294 2.426 2.120 2.103 0.166 1.937 1.333 0.603 2.735
3
Fluid density, kg/m 792.89 667.52 1173.25 993.94 751.14 751.03 798.42 654.80 738.75 662.81 696.55 677.44 962.05
Volumetric flow rate, m3/h 1.42 1.22 6.42 8.80 1.41 11.63 9.56 11.56 0.81 10.52 6.89 3.21 10.23
Inlet pressure (atm) 1.00 1.00 1.00 1.00 1.00 1.00 1.00 0.50 0.25 0.25 0.07 0.07 1.00
Outlet pressure (atm) 1.20 1.20 1.20 1.20 1.20 1.20 1.20 0.70 1.00 0.45 1.00 1.00 1.20
Pump head (m) 2.61 3.09 1.76 2.08 2.75 2.75 2.59 3.15 10.49 3.12 13.79 14.18 2.15
Required shaft power (kW) 0.0228 0.0208 0.0664 0.0855 0.0227 0.1077 0.0915 0.1072 0.0638 0.0991 0.3266 0.1820 0.0969
EQUIPMENT CAPITAL
COST (RM) 22,508 20,571 65,552 84,463 22,380 106,358 90,407 105,829 62,964 97,853 96,770 89,849 95,650
155
3.3.3 Mixers
There are three mixers involved in our plant. Detail calculation steps for the mixers are shown
in Appendix B.1.30 to B.1.32. The summary of mixer sizing is tabulated in Table 3-9.
Table 3-9: Mixer Design Summary

Equipment M-101 M-102 M-103
Operating condition
Density (kg/m3) 772.0000 595.1911 1.0659
Total flow rate (kg/hr) 2189.2910 9801.3050 211.6165
Agitator
Design type Propeller Propeller -
Agitator diameter (m) 0.1068 0.1920 -
Shaft power (kW) 0.2263 3.2734 -
Tank
Design type Vertical vessel Vertical vessel Vertical vessel
Material of construction SS 304 SS 304 SS 304
Diameter (m) 0.3560 0.6399 1.4673
Height (m) 0.4747 0.8532 1.9565
Volume (m3) 0.0473 0.2745 3.3089
EQUIPMENT CAPITAL COST (RM) 45,873.44 160,932.97 280,324.01
156
3.3.4 Heat exchangers
The heat exchanger really applies to all types of equipment in which heat is exchanged but is
often used specially to denote equipment in which heat is exchanged between two process
streams. Exchangers in which a process fluid is heated or cooled by a plant service stream are
referred to as heaters and coolers. If the process stream is vaporized the exchanger is called a
vaporized if the stream is essentially completely vaporized; a reboiler and condenser if
associated with a distillation column. The general equation for heat transfer across a surface
is:
where Q = heat transferred per unit time, W

U = overall heat transfer coefficient, W/m2.°C
A = transfer area, m2
= mean temperature difference, °C
The principal types of heat exchanger used in chemical process and allied industries are:
a. Double pipe heat exchanger: the simplest type, used for cooling and heating.
b. Shell and tube exchanger: used for all applications.
c. Plate and frame exchanger (plate heat exchangers): used for heating and cooling.
d. Air cooler: cooling and condensers.
e. Direct contact: cooling and quenching.
Since shell and tube heat exchanger is the most commonly used for the heat transfer
equipment used in chemical and allied industries, it was chosen as the exchanger type in the
design, the advantages of this type are:
a. The configuration gives a large surface area in a small volume.

b. Good mechanical layout: a good shape for pressure operation.
c. Uses well-established fabrication techniques.
d. Can be constructed from a wide range of materials.
e. Easily cleaned.
f. Well-established design procedures
157
The designing procedures are based on the Kern‘s and Bell‘s method (Sinnott, 1996). The
design procedures are shown below:
1. Define the duty: heat transfer rate, fluids flow rate and temperature.
2. Collect the fluid physical required: density, viscosity and thermal conductivity.
3. Decide the type of exchanger to be used.
4. Select the trial value for the exchanger to be used.
5. Select the trial value for the exchanger to be used.
6. Calculate the mean temperature different, ΔTm.
7. Calculate the area required.
8. Decide the exchanger layout.
9. Calculate the individual coefficients.
10. Calculate the overall coefficient and compare with the trial value. If the calculated
value differs from the estimate value, substitute the calculated value and return to step
(6).
Detail calculation steps for the heat exchangers are shown in Appendix B.1.33. The summary
of heat exchangers is tabulated in Table 3-10.
158
Table 3-10: Heat Exchanger Design Summary
Design Type Fixed- tube
Equipment E-101 E-102 E-103 E-104 E-105 E-106 E-107 E-108 E-109 E-110 E-111
Heat Duty, Q (kW) 149 606 344 284 595 164 2 282 48 141 382
Hot fluid properties:
Flow rate (kg/hr) 11,064 17,766 1,060 7,783 8,734 3,816 61 7,570 597 6,972 4,801
Inlet Temperature (°C) 160 160 129 254 160 160 59 236 158 226 176
Outlet Temperature (°C) 120 110 60 190 50 120 25 185 25 198 50
Cold fluid properties:
Flow rate (kg/hr) 9,801 9,801 596 8,946 18,355 7,631 82 4,167 1,432 2,099 10,088
Inlet Temperature (°C) 32 60 30 120 -40 50 -40 30 -40 30 30
Outlet Temperature (°C) 60 120 76 160 50 91 30 90 50 90 64
2
Heat transfer area, A (m ) 16.24 45.67 37.05 37.46 24.81 25.05 0.58 19.21 9.91 9.41 50.44
Number of passes 2 2 2 2 2 2 2 2 2 2 2
Number of tubes per pass, Nt 30 60 60 60 63 62 3 33 41 16 86
Tube outside diameter, do (mm) 19.05 19.05 19.05 19.05 19.05 19.05 19.05 19.05 19.05 19.05 19.05
Tube inside diameter, di (mm) 16.56 16.56 16.56 16.56 16.56 16.56 16.56 16.56 16.56 16.56 16.56
Length of tube, L (m) 4.5 6.4 5.2 5.2 3.3 3.4 1.5 4.88 2 4.88 4.88
Bundle diameter, Db (mm) 229 312 312 313 320 317 83 238 265 173 369
Shell internal diameter, Ds (mm) 240 324 324 325 332 329 93 249 276 183 381
2
Tube side heat transfer coefficient (W/m .K) 162 114 117 150 771 115 63 1,218 87 1,286 874
Heat side heat transfer coefficient (W/m2.K) 1,095 605 192 221 828 2,673 720 1,171 276 1,522 583
EQUIPMENT CAPITAL COST (RM) 621,582 655,468 590,863 654,851 606,548 559,160 27,508 520,813 484,664 450,360 611,232
159
Design Type Fixed-tube Kettle Reboiler Fixed-tube
Equipment E-112 E-113 E-114 E-115 C-103-R C-104-R C-105-R C-103-C C-104-C C-105-C
Heat Duty, Q (kW) 259 6,425 6,268 90 768 444 558 25 250 571
Hot fluid properties:
Flow rate (kg/hr) 2,172 16,862 8,614 1,231 34,063 7,439 21,051 1,060 1,060 61
Inlet Temperature (°C) 237 254 130 130 254 254 254 158 207 195
Outlet Temperature (°C) 50 150 25 25 224 220 228 59 158 176
Cold fluid properties:
Flow rate (kg/hr) 1,973 9,846 31,504 3,073 9,801 9,801 9,801 1,501 424 30
Inlet Temperature (°C) -40 50 -40 -40 158 207 195 -40 30 30
Outlet Temperature (°C) 80 130 50 50 236 226 237 50 90 50
Heat transfer area, A (m2) 11.44 82.17 212.1 6.06 137.05 104.31 144.18 2.91 13.95 132.05
Number of passes 2 4 4 2 4 4 4 2 2 4
Number of tubes per pass, Nt 25 62 104 20 59 52 74 12 29 77
Tube outside diameter, do (mm) 19.05 19.05 19.05 19.05 31.75 31.75 31.75 19.05 19.05 19.05
Tube inside diameter, di (mm) 16.56 16.56 16.56 16.56 28.45 28.45 28.45 16.56 16.56 16.56
Length of tube, L (m) 3.8 5.5 8.5 2.5 5.8 5 4.88 2 4 7.2
Bundle diameter, Db (mm) 211 457 573 191 745 706 822 152 226 500
Shell internal diameter, Ds (mm) 221 470 587 201 761 721 839 162 237 513
Tube side heat transfer coefficient (W/m2.K) 444 973 801 434 170 205 104 354 151 34
Heat side heat transfer coefficient (W/m2.K) 919 222 1,987 739 147 260 113 129 82 28
EQUIPMENT CAPITAL COST (RM) 552,133 780,837 1,175,426 296,379 1,012,999 881,126 964,206 142,103 578,398 884,386
160
3.3.5 Boiler
The sizing for boiler is not required, but the summary and the costing for it are given below.
For the production plant of methyl ester, a steam boiler (E-201) will be used to supply steam
as the heating agent for the chemical process. Detail calculation steps for the steam boiler E-
201 are shown in Appendix B.1.35. The summary of its design is tabulated in Table 3-11.
Table 3-11: Boiler E-201 Design Summary

Item no. E-201
Identification Steam boiler
Function To produce steam to be used as heating agent
Operating Condition
Pressure (atm) 41
Water flow rate (kg/hr) 119,844.12
Specifications
Material of construction Stainless steel
Actual Work (kW) 24,002.78
UTILITY COST (RM) 4,184,246.39
3.3.6 Steam Turbine

Steam turbine K-201 is used to produce electricity and will be sold off as a source of income.
Detail calculation steps for the steam turbine K-201 are shown in Appendix B.1.36. The
summary of its design is tabulated in Table 3-12.
Table 3-12: Steam Turbine K-201 Design Summary

Item no. K-201
Identification Steam Turbine
Function To generate electricity
Operating Condition
Pressure (atm) 41
Water flow rate (kg/hr) 32,646.58
Specifications
Type of turbine Steam Turbine
Actual Work (kW) 3,149.31
161
3.4 ECONOMIC POTENTIAL 4
The summary of equipment cost and utility cost are summarized in Table 3-13 and Table 3-14
respectively as can be seen below.
Table 3-13: Summary of Equipment Cost

Equipment Cost (RM)
Reactors 2,907,705.48
Decanter 2,760,092.42
Distillation columns 3,306,953.67
Flash drums 3,903,737.85
Storage tanks 16,381,345.45
Pumps 961,154.00
Mixers 487,130.42
Heat Exchangers 13,051,041.56
Boiler 11,705,327.50
Steam Turbine 5,167,360.08
Total 60,631,848.43
Table 3-14: Summary of Utility Cost

Utility Cost (RM/yr)
Cooling water 159,969.60
Steam 22,740.40
Fuel (coal) 4,161,505.99
Refrigerant 2,728,093.04
Total 7,072,309.03
The economic potential level 4 is performed in order to see whether this production plant is
deasible or not. From level 3 decision, the economic potential 3 is RM72 million/yr.
Therefore,
( )
The positive value indicates that this production plant is feasible in term of economic
potential.
162
4 CHAPTER 4: UTILITIES & HEAT INTEGRATION
4.1 HEAT INTEGRATION
4.1.1 Introduction
The term heat integration has two meanings. First, it refers to the physical arrangement of
equipment, process sections, production plants, entire sites and even the surroundings in case
of district heating or district cooling. Second, it refers to an area of process synthesis, with
methods and tools aiming at increased energy efficiency in industrial process and energy
plant. Such improved energy efficiency can be achieved by combining heating and cooling
demands and thereby reducing the need for external heating and cooling utilities. In
conjunction to these two terms, the one and only goal of heat integration is clearly to reduce
the operating cost of plant by means of utilities usage in order to achieve feasible economy
analysis. In case of this project, the heat integration method adopted is known as pinch
technology.
4.1.2 Pinch Technology

Based on thermodynamic principles, pinch technology offers a systematic approach to
optimum energy integration in a process. The improvements in the process associated with
this technique are not due to the use of advanced unit operations, but to the generation of a
heat integration scheme. One of the key advantages of pinch technology over conventional
design methods is the ability to set an energy target for the design. The energy target is the
minimum theoretical energy demand for the overall process. The principal objective of this
technology is to match cold and hot process streams with a network of exchangers so that
demands for externally supplied utilities are minimized. Pinch technology establishes a
temperature difference, designated as the pinch point, which separates the overall operating
temperature region observed in the process into two temperature regions. Once a pinch point
has been established, heat from external sources must be supplied to the process only at
temperatures above the pinch and removed from the process by cooling media only at
temperatures below the pinch. Such a methodology will maximize the heat recovery in the
process with the establishment of a heat exchanger network based on pinch analysis
principles. The best design for an energy-efficient heat exchanger network will result in a
trade-off between the energy recovered and the capital costs involved in this energy recovery.
163
4.1.3 Process Flow of Pinch Analysis
STEP 1: Hot and cold stream identification in the system
STEP 2: Construction of steam table
STEP 3: Selection of minimum approach temperature
STEP 4: Shifting of stream data
STEP 5: Construction of temperature interval diagram
STEP 6: Construction of cascade diagram
STEP 7: Heat exchange network design based on pinch
164
4.1.3.1 Hot and Cold Stream Identification in the System
This step involves the identification of hot stream, which is the stream to be cooled and cold
stream, which is the stream that needs to be heated.
4.1.3.2 Construction of Stream Table

This step shows the operating conditions of hot and cold stream which include inlet
temperature, outlet temperature and heat duty with respect to equipment. This step is essential
as it acts as a reference and guidance for the following steps. This step is done after
identification of hot and cold stream Table 4-1 shows the stream table for this plant.
Table 4-1: Stream table for involved equipment

Equipment Tin (°C) Tout (°C) H (kW) Type
E-103 129 60 343.77 Hot
E-105 160 50 595.28 Hot
E-107 59 25 1.90 Hot
E-108 236 185 282.44 Hot
E-109 158 25 48.36 Hot
E-110 226 198 140.81 Hot
E-111 176 50 382.01 Hot
E-112 237 50 259.28 Hot
E-114 130 25 6268.50 Hot
E-115 130 25 89.57 Hot
C-103-C 158 59 25.28 Hot
C-104-C 207 158 250.44 Hot
C-105-C 195 176 570.65 Hot
E-101 32 60 149.19 Cold
E-102 60 120 606.16 Cold
E-104 120 160 284.13 Cold
E-106 50 91 163.74 Cold
E-113 50 130 6425.07 Cold
C-103-R 158 236 767.90 Cold
C-104-R 207 226 443.66 Cold
C-105-R 195 237 558.17 Cold
165
4.1.3.3 Selection of Minimum Approach Temperature
This represents the smallest temperature difference that two streams leaving or entering a heat
exchanger can have. Typical values are from 5°C to 20°C. The value 10°C is chosen for this
plant as it is the most common value used by industry. Besides that, the range 5°C to 20°C is
typical but not cast in concrete.
4.1.3.4 Shifting of Stream Data

This step involves the calculation of new temperature by using obtained in the previous
step. The formulae involved include
This step is essential as it provides the data required for the following step which is to
construct the temperature interval diagram. The data below shows the data acquired from the
shifting of stream table.
Equipment Tin (°C) Tout (°C) H (kW) Type T Tin (°C) Tout (°C) CP(kW/°C)
E-103 129 60 343.77 Hot 134 65 4.98
E-105 160 50 595.28 Hot 165 55 5.41
E-107 59 25 1.90 Hot 64 30 0.06
E-108 236 185 282.44 Hot 241 190 5.54
E-109 158 25 48.36 Hot 163 30 0.36
E-110 226 198 140.81 Hot 231 203 5.03
E-111 176 50 382.01 Hot 181 55 3.03
E-112 237 50 259.28 Hot 242 55 1.39
E-114 130 25 6268.50 Hot 135 30 59.70
E-115 130 25 89.57 Hot 135 30 0.85
C-103-C 158 59 25.28 Hot 10 163 64 0.26
C-104-C 207 158 250.44 Hot 212 163 5.11
C-105-C 195 176 570.65 Hot 200 181 30.03
E-101 32 60 149.19 Cold 27 55 5.33
E-102 60 120 606.16 Cold 55 115 10.10
E-104 120 160 284.13 Cold 115 155 7.10
E-106 50 91 163.74 Cold 45 86 3.99
E-113 50 130 6425.07 Cold 45 125 80.31
C-103-R 158 236 767.90 Cold 153 231 9.84
C-104-R 207 226 443.66 Cold 202 221 23.35
C-105-R 195 237 558.17 Cold 190 232 13.29
166
4.1.3.5 Construction of Temperature Interval Diagram
In this step, all streams are presented by a vertical line, where cold stream (represented in blue
line) is placed on the left side of the diagram while hot stream (represented on red line) is
place on the right side of the diagram. The cold and heat duty for each temperature interval
(with lines) as shown in Figure 4-1 is calculated. The difference in cold and hot duty is then
calculated and the result is represented as deficit for (+) value and surplus for (-) value. This
step is essential as the difference in heat duty obtained will be used to construct the cascade
diagram at the following step.
167
Equipment E-101 E-102 E-104 E-106 E-113 C-103-R C-104-R C-105-R E-103 E-105 E-107 E-108 E-109 E-110 E-111 E-112 E-114 E-115 C-103-R C-104-R C-105-R
CP (kW/K) 5.328 10.103 7.103 3.994 80.313 9.845 23.351 13.290 4.982 5.412 0.056 5.538 0.364 5.029 3.032 1.387 59.700 0.853 0.255 5.111 30.034 Cold Hot Cold -
Heat Duty (kW) 149.2 606.2 284.1 163.7 6425.1 767.9 443.7 558.2 343.8 595.3 1.9 282.4 48.4 140.8 382.0 259.3 6268.5 89.6 25.3 250.4 570.7 (kW) (kW) Hot (kW)
Shiftted Temp (°C) COLD COLD COLD COLD COLD COLD COLD COLD HOT HOT HOT HOT HOT HOT HOT HOT HOT HOT HOT HOT HOT
242
13.29 0.00 13.29 Deficit
241
208.21 0.00 208.21 Deficit
232
23.13 1.39 21.75 Deficit
231
464.85 69.25 395.61 Deficit
221
418.37 107.58 310.79 Deficit
212
231.35 119.53 111.81 Deficit
202
46.27 34.13 12.14 Deficit
200
68.91 119.45 -50.54 Surplus
193
29.53 36.11 -6.57 Surplus
190
98.45 420.70 -322.25 Surplus
180
88.60 328.79 -240.18 Surplus
171
59.07 57.18 1.89 Deficit
165
33.90 19.06 14.84 Deficit
163
56.83 76.23 -19.41 Surplus
155
14.21 29.88 -15.68 Surplus
153
127.86 188.08 -60.22 Surplus
135
874.17 104.49 769.68 Deficit
125
90.42 71.00 19.41 Deficit
124
2531.65 2127.55 404.10 Deficit
96
2926.70 2355.51 571.20 Deficit
65
896.35 759.84 136.51 Deficit
55
5.33 71.00 -65.67 Surplus
54
47.95 637.22 -589.27 Surplus
45
42.63 495.78 -453.15 Surplus
37
0.00 1053.53 -1053.53 Surplus
20
Figure 4-1: Temperature Interval Diagram
168
4.1.3.6 Construction of Cascade Diagram
The cascade diagram (Figure 4-2) simply shows the net amount of energy in each temperature
interval presented in the previous step. If there is excess energy in a given temperature
interval, this energy can be cascaded down to the next temperature level. The heat flow
showed in this cascade diagram has to be positive throughout the course, if negative value is
present along the cascade diagram; normalization is required to convert the negative flow to
positive flow.As a result, the pinch temperature is located at 55°C (no heat flow).
Shiftted Temp (°C) H (kW) Net H (kW)
242 0.00 2276.38

13.29
241 -13.29 2263.09
208.21
232 -221.50 2054.88
21.75
231 -243.25 2033.13
395.61
221 -638.86 1637.53
310.79
212 -949.64 1326.74
111.81
202 -1061.46 1214.93
12.14
200 -1073.60 1202.79
-50.54
193 -1023.06 1253.32
-6.57
190 -1016.49 1259.90
-322.25
180 -694.24 1582.14
-240.18
171 -454.06 1822.32
1.89
165 -455.95 1820.43
14.84
163 -470.79 1805.59
-19.41
155 -451.38 1825.00
-15.68
153 -435.71 1840.68
-60.22
135 -375.49 1900.90
769.68
125 -1145.17 1131.22
19.41
124 -1164.58 1111.80
404.10
96 -1568.68 707.71
571.20
65 -2139.87 136.51
136.51
Pinch Point 55 -2276.38 0.00 Pinch Point
-65.67
54 -2210.71 65.67
-589.27
45 -1621.44 654.94
-453.15
37 -1168.29 1108.10
-1053.53
20 -114.76 2161.63
Figure 4-2: Cascade Diagram
169
4.1.3.7 Heat Exchange Network Design Based on Pinch Temperature
In this step, the heat integration between the heat duty of each equipment takes place and a
new heat exchange network can be achieved. This heat integration is done based on the pinch
temperature, 55°C, which is found at the previous step. Following that a hot pinch
temperature and a cold pinch temperature is calculated. The formula used is as below.
Heat integration falls under two categories, which is below pinch temperature where
integration occurs only for temperature which is below the pinch temperature and above pinch
temperature where integration only occurs for temperature which is above the pinch
temperature. No integration between temperature at below pinch and above pinch is
permitted. Besides that, in order to perform the heat integration correctly, a few pinch analysis
criteria have to be obeyed. The criteria include:
i) For below pinch,

ii) For above pinch,
iii) Integration between above pinch and below pinch temperature is not allowed
iv) If CP value is too large for either of the stream, try to split the stream
v) Set maximum heat recovery
vi) The remaining heat duty is to be covered by using heater or cooler
By obeying the rules as stated, Figure 4-3 shows the heat integration performed and carried
out for the heat exchange network of this plant.
170
Temperature (°C )
Equip. Cp (kW/K) H (kW) H (kW)
237
236
226
207
198
195
185
176
160
158
130
129
120
91
60
59
50
32
25
Figure 4-3: Heat exchange network designed based on pinch temperature (heat integration)
E-103 4.982 343.77 -
Integrated heat exchanger 60 54.12
E-105 5.412 541.16
Cooler 54.12
Heater 60 1.90
E-107 0.056 - 1.90
282.44
E-108 5.538 282.44 -
12.73
E-109 0.364 35.63 12.73
140.81 60
E-110 5.029 140.81 -
30.32
E-111 3.032 351.69 30.32
60 13.87
E-112 1.387 245.41 13.87
60 95.91 1993.59
E-114 59.700 4179.00 2089.50
60
E-115 0.853 59.71 29.86
60 29.86
C-103-C 0.255 25.02 0.26
250.44 25.28 60
C-104-C 5.111 250.44 -
C-105-C 30.034 570.65 -

570.65 53.28
E-101 5.328 53.28 95.91
262.39 50
E-102 10.103 606.16 -
38.72 343.77
E-104 7.103 284.13 -
245.41 35.63 128.11
E-106 3.994 163.74 -
351.69 59.71 50
E-113 80.313 6425.07 -
767.90 541.16 4179.00 1293.51 50
C-103-R 9.845 767.90 -
443.66
C-104-R 23.351 443.66 -
558.17
C-105-R 13.290 558.17 Pinch T=55°C -
171
4.1.4 Heat Recovery Analysis
Before heat integration,
After heat integration,
Total energy saved,
By integrating the heat exchangers as proposed in Figure 4-3, the energy which can be
saved for hot utility and cold utility is approximately 62.27% and 63.21% respectively.
172
4.2 UTILITIES
Utilities do not directly contact with the process streams. Normally, they exchange heat
energy in equipment such as heater, cooler and heat exchanger to either cool down or heat
up the process stream. Apart from dealing with heat energy balancing in the process, they
also supply work in terms of electrical power to operate rotary equipments.The utilities are
generally used for the ancillary services needed in the operation of methyl ester production
process. These services will normally be supplied from the plant itself and these include the
utilities as discussed in the following subchapters.
4.2.1 Electricity
Plant utilities are a vital service to the operation of methyl ester production plant. In our
plant, power is supplied primalrily in the form of electrical energy. Agitators, pumps,
hoists, blowers, compressors and fans are usually operated by electric motor, although
other prime movers such as stem engines, internal combustion engines and hydraulic
turbines are sometimes employed (Peters et al., 2004).
The voltage at which the supply is taken or generated will depend on the demand of our
plant. A number of large motors of operating methyl ester production plant is used, a
supply at an intermediate high voltage will also be provided, typically 6000 or 11,000 V. A
detailed account of the factors is to be considered when designing electrical distribution
systems for chemical process plants, and the equipment used in our plant.
Total electricity was determined from power use by motorized equipment in the plant such
as electricity for the pumps, reactor impellers, and mixer agitators. Table 4-2 indicates the
consumption of electricity used in our plant which has been performed calculation in
Chapter 3.
Apart from that, our plant is able to generate its own electricity using steam turbine K-201.
The power generated is summarized in Table 4-4.
173
Table 4-2: Summary of electricity consumption
Equipment Power, kW
P-101A/B 0.0228
P-102A/B 0.0208
P-103A/B 0.0664
P-104A/B 0.0855
P-105A/B 0.0227
P-106A/B 0.1077
P-107A/B 0.0915
P-108A/B 0.1072
P-109A/B 0.0638
P-110A/B 0.0991
P-111A/B 0.3266
P-112A/B 0.1820
P-113A/B 0.0969
R-101 18.0300
R-102 18.7200
R-103 18.8700
M-101 0.2263
M-102 3.2734
Total 60.4127
Lighting (10% of total electricity based on Turton, 2001) 6.0413
Total Consumption of Electricity 66.4539
The total cost of electricity per year can be calculated as below.
Table 4.3: Electricity pricing and tariff (Tenaga Nasional Berhad, 2014)
Description Price
For the first 200 kWh (1 -200 kWh) per month 38.00 sen/kWh
For the next kWh (201 kWh onwards) per month 44.10 sen/kWh
174
Table 4-4: Steam Turbine K-201 Power Generation
Equipment Power, kW
K-201 3149.31
In this case, our plant is able to generate sufficient power to compensate the power required
by rotary equipments. Hence, no external source of electricity is required.
4.2.2 Cooling Water

Cooling water is a type of cooling utilities used in cooler to cool down hot streams to a
lower temperature. In this plant, cooling water is supplied to some heat exchangers as
shown in Table 4-5.
Table 4-5: Summary of cooling water consumption

Equipment Flow rate (kg/hr)
E-103 595.93
E-108 4,166.77
E-110 2,099.15
E-111 10,087.71
C-104-C 424.93
C-105-C 30.30
Total 17,404.87
Cooling water needed

Cooling water required= 17,404.87 kg/hr = 4.83 kg/s
Volumetric flow rate of water,
The water rate is obtained from the reference: (MIDA, 2015),

Minimum charge = RM 1.15/m3
The cost of cooling water,
175
4.2.3 Steam
Steam is generated by boiler E-201 in this plant to be used as hot utilities for several heat
exchangers as shown in Table 4-6 below. The boiler is heated using coal as fuel. The steam
consumption is equivalent to the amount of boiler feed water required.
Table 4-6: Summary of steam consumption
Equipment Flow rate (kg/hr)
E-101 11,064.28
E-102 17,766.32
E-104 1,059.80
E-106 7,782.66
E-113 16,861.68
C-103-R 34,062.60
C-104-R 7,439.42
C-105-R 21,051.18
Total 119,844.12
Raw water needed

Raw water needed = flow rate of steam = 119,844.12 kg/hr = 33.29 kg/s
Used steam is recycled as boiler feed water. Assuming 10% of water lost for each 5 hours.
The holding tank T-201 takes 5 hours to be filled up. Volumetric flow rate of water,
( )
( )

The cost of raw water for boiler, E-201,
Coal needed
Q = 24002.78 kJ/s
From the utilities table (Turton et al., 2012),
Cost of coal = $1.72/GJ
176
4.2.4 Refrigerant
Refrigerant is used as cooling utilities for some heat exchangers as shown in Table 4-7.
Refrigerant is necessary when cooling water is not sufficient to cool down a hot stream. In
this plant, R-134a is used as refrigerant.
Table 4-7: Summary of refrigerant consumption

Equipment Heat duty (kW)
E-105 595.28
E-107 1.89
E-109 48.36
E-112 259.28
E-114 1,044.75
E-115 89.57
C-103-C 25.28
Total 7288.16
Refrigerant needed
Q = 2064.41 kJ/s
The refrigerant rate is obtained from the reference: (Turton et al., 2012),
Cost = $ 13.11/GJ
The cost of refrigerant used,
177
5 CHAPTER 5: PROCESS CONTROL & SAFETY
5.1 INTRODUCTION
Availability of advanced technology enables the chemical industries to embark into more
complex processes which involved higher pressure, more reactive chemicals and exotic
chemistry. As chemical process technology become more complex, chemical engineers
need a better fundamental understanding of safety in designing an industrial plant to
minimize the likelihood of accidents to happen and to assure the safety of the plant.
Safety in the industries has become an unavoidable issue and it is very vital especially to
the employees in the plant that always exposed to life-threatening situations. Besides that, it
has to be done to protect the public and the environment. Furthermore, a safe and
comfortable working environment plays a very important part to assure the efficient
production of the plant. Thus, a process safety study should always be considered during
the early stage of design of the plant with fully co-operation with the management,
contractors, employees and specialist in environment and industrial health
5.1.1 General Safety Procedure

There are three major hazards in a process plant such as hazardous and corrosive
chemicals, fire and explosion and mechanical accidents which are common to all industrial
activities. Unfortunately, hazards are not always identified until an accident occurs. Hence,
safety training regarding to general safety procedures for the plant should be practiced by
the workers before the plant starts its operation. This is one of the steps to ensure the
process and operation in safe condition throughout the life of a plant.
5.1.2 Chemical Storage

There are Chemical storage plays a vital role in a plant where various hazardous chemicals
are stored. The location of the storage tank should be at a suitable placing that avoid any
form of unnecessary risk. Some of the important aspects of storage layout are:
 Proper embankment of storage tank should be according to natural gas to control

spillage. Piping, valves, and flanges should be kept to a minimum when located
within the embankment and most likely to be installed outside the dikes area.
178
 The storage tank should be kept away from process areas. This is because fire and
explosion in a process unit may endanger the tank.
 Secondary containment systems such as drain valve and emergency exit door are
considered passive protective systems to the storage tank can be considered.
The design of the storage tanks should be considered properly in order to eliminate the
possibilities of fireball, vapour cloud explosion (VCE), and toxic cloud.
5.1.3 Transportation
Transportation of chemicals inside the plant is a part of the daily routine. Many
accidental released of hazardous liquid in process plants occurred at road and rail tanker of
loading and unloading stations. Thus, a safe handling program must be practiced by every
personnel. This is because they will be the one closely associated with these materials and
indirectly the safety of other workers is depending on them. Besides that, sites for loading
and unloading stations should be carefully selected with proper roof covering and good
ventilation to protect the transfer of chemicals to the storage.
Besides that, handling of hazardous materials depends on:

 State of material- Liquid, solid or gas.
 Method of transport- Piping, ducts, conveyors, and tanks
 Method of storage- Tanks, hoppers and pallets.
In this plant, the workers involved mainly in gas handling of raw materials and
some liquid handling. On the site, the hazardous liquid handling must be transported and
stored according to the appropriate codes and standards. Furthermore, specially designed
piping system with necessary safety devices such as relief valve and backflow preventer
(check valve) should be installed for transferring hazardous liquid to tank car or trucks. On
the other hand, the storage of solid material (if any) usually generates dust in the plant. The
generated dust that dispersed in air at certain concentration and are exposed to a source of
ignition will caused fire and explosion. In order to minimize the dust escape, the filling bin
can provided with metal or fabric skirt and air return duct. The maintenance of every
chemical handling should be well maintained for the safety of the process plant.
179
5.1.4 Permit Procedures
Permit and licenses are required by law before a plant is permitted to operate. It is
very important for every employee in the plant to acquire a permit before any operation
such as hot work, electrical work to begin and any confined space entry. In a plant, hot-
work permit involving welding, cutting and open flame is usually required for operation
because the operation involves flames and produces sparks. The permit intended to prevent
fire or injury to the person doing the work. A plant may choose to have specialized permits
to regulate certain types of work such as after-hours work and vehicle operation. All of this
permits introduced in the plant is to ensure that certain work is informed and is performed
safely in the plant. Here are some guidelines needs for documentation:
 Define the work to be done: Locations and area affected.

 Set duration for working period.
 Remove, or clearly mark all hazardous materials and conditions.
 Prepare the working site.
 Notify all personnel in and around the area of the work.
 Restrict access to the work area.
 Provide all necessary safety, emergency and personal protective equipment.
5.1.5 General Workers Safety

The safety of personnel is very important when working in the industrial plant.
Every worker should be familiarized with the safety instructions and danger signs around
the plant. Besides that, employees in the plant should have undergo safety training for
emergency response to ensure they are aware of every emergency escape plans in the plant.
In additional, the employers are also required to provide effective information and train
employees on the hazards of the hazardous chemicals in the work area. At least, employee
training must include: methods and observations that may be used to detect the present or
release of a hazardous chemical in the work area such as monitoring on any visual
appearance or odour of hazardous chemicals when being released. Some of the safety rules
should be informed to the workers is:
 No smoking except in specific areas designated for smoking.

 No eating, drinking of alcoholic liquor.
 Report all accidents to the supervisor.
180
 No flammable chemical substances and drugs allowed in the plant, except in need.
 Get immediate medical attention for serious injuries.
 Do not enter processing areas other than the place of work.
 Know the location of first aids, escape exits, fire alarms and fire extinguishers.
Besides that, personal protective equipment (PPE) is useful to protect the

respiratory system, skin, eyes, face, hands, feet, head, or hearing from chemical, physical
and biological hazards. To be effective, the selection and use of PEE must be appropriate
and accompanied by adequate training, so they know at least the following: when PPE is
necessary; what PPE is necessary; how to properly do not take off or put on, adjust and
wear PPE and the proper care of PPE. Every employee is provided their own protective
equipment and the employer is responsible for assuring its adequacy, proper maintenance
and sanitation. The types of personal protective equipment are listed in Table 5-1.
Table 5-1: Type of personal protective equipments
Body Part Type of clothing Type of protection Codes and Standards

or accessory
Head Safety helmet Protects the head from hard  ANSI Z89.1-2009
substances falling, electric ―American National
shock and burns. Standard for Industrial
Head Protection‖
Eyes and Face shield Protects against chemical  ANSI Z87.1-2003 ―
face splashes American National
Goggles Protects against vaporized Standard Practice for
chemicals, and splashes. Occupational and
Educational Eye and Face
Protection‖
Eyewash/ Drench Provides immediate
shower emergency use if exposed to
any corrosive materials.
Foot Safety boots Protect feet from contact with ASTM F-2412-2005
(Waterproof and chemicals or injured by ―Standard Specification for
slip resistant type) falling, moving and sharp Performance Requirements
objects. for Protective Footwear‖
Body Fully- Protects against splashes,  National Fire Protection
encapsulating suit dust, gases and vapors Association Standard 1991
–EPA level A & B
Ears Ear plugs Protect against high frequency OSHA Noise Standard
of noise. (Average noise level
of 85 dBA)
Hands and Insulating rubber Protect hands and arms from  No ANSI standard
arms gloves and sleeves chemical contact. available.
181
Safety is first important thing in industrial plant to ensure all process operating in good
condition. Hence, first aid is an essential primary care given to an injured person. Usually,
the location of the first aid kits box is easily visible and accessible by anyone during an
emergency. Furthermore, other first aid service such as CPR should be given to somebody
who having suffocation from chemical exposure and transfer promptly to a medical
facilities.
5.1.6 Emergency Response Plan

Working in processing plant is very dangerous because all the workers are exposed
themselves to life-threatening situations every day. With advance planning for potential
emergencies will help to avoid personal injury or any damage to property. A
comprehensive emergency management plan will allow quick and effective response and
so reduce the consequences of any incident. Key actions for practicing emergency response
are:
 Identify potential emergencies.

 Assess possible damage.
 Estimate available response time.
 Prepare plan such as emergency communications and response approach needed.
 Publish and disseminate plan
 Practice the plan through training.
Safe areas should be set aside for emergency assembly points for employees. The
workers will be evacuated and directed to the assembly point while the plant is running
shutting down process. At least one pre-arranged emergency control centre should be
established with proper communication with are around the works, as well as maps, site
plans and relevant data and equipment to assist in any emergencies. Besides that, outside
authorities must be prepared to deal with the effects of major accidents. They include
police, ambulance, hospital and other authority services.
Meanwhile, sounding alarm such as fire alarm should be installed in every corner in
the plant so that if any emergencies happen, it would alert the people in the plant. The
alarm should be actuated by an electrical signalling system with enough call points spread
over the work for the alert to be raised by anyone. For instances, automatic detection
182
equipment such as thermal sensor to detect the temperature rise around the work area to
alert any present of fire going on in the plant. The fire alarm should be well maintained to
prevent any failure of detection and to alert the workers.
5.1.7 Waste Disposal Operation

There is waste treatment to treat all the waste from the process before it getting exposed to
the environment. All information concerning the chemical, physical and toxicological
properties of each substance should be present on the site. This is to make sure the
employees performing their duties on the site alert of the substance present in the waste.
Besides that, training is required for all employees who work at the waste cleanup sites of
treatment storage and disposal sites. The training must cover the necessary information to
perform these jobs safely including information on the proper personal protective
equipment and procedure to safeguard employees against hazards and effect of exposure to
any toxic substances. Furthermore, necessary decontamination procedure must be used to
assure that hazardous substances are removed from workers before they leave the worksite
as well as from equipment that is to be taken off site.
The employer should provide showers, including change rooms, for all employees exposed
to hazardous substance and health hazard involved in hazardous waste cleanup operation.
Shower should be located in areas where exposure are below the permissible exposure
limits and published exposure levels. It is better if the shower areas are having a good
ventilation system that supplies sufficient air to the employees. Last but not least,
emergency response plan is very important. The plan must be developed and implemented
to handle any emergency happens during waste cleanup operation.
183
5.2 MATERIAL SAFETY DATA SHEET (MSDS)
This section covers the material safety data sheet of our major materials such as Methanol,
Sodium Methoxide Solution, RBD Palm Kernel Oil, Methyl Octanoate/Decanoate (CE-
810), Methyl Laurate/Myristate (CE-1214), Methyl Palmitate/Oleate (CE-1618), and
Glycerine. It is intended to provide workers and emergency personnel with procedures for
handling or working with that substance in a safe manner, and includes information such as
physical data, toxicity, health effects, first aid, reactivity, storage, disposal, protective
equipment, and spill-handling procedures. MSDS formats can vary from source to source
within a country depending on national requirements. MSDS for a substance is not
primarily intended for general use, focusing instead on the hazards of working with the
material in an occupational setting. The MSDS can be seen in the following subchapters.
184
5.2.1 MSDS for Methanol
185
186
187
188
189
190
191
5.2.2 MSDS for Sodium Methoxide Solution
192
193
194
195
196
197
5.2.3 MSDS for RBD Palm Kernel Oil
198
199
200
5.2.4 MSDS for Methyl Octanoate/Decanoate (CE-810)
201
202
203
204
205
206
5.2.5 MSDS for Methyl Laurate/Myristate (CE-1214)
207
208
209
210
211
212
5.2.6 MSDS for Methyl Palmitate/Oleate (CE-1618)
213
214
215
216
217
5.2.7 MSDS for Glycerin
218
219
220
221
222
223
5.3 DOW, FIRE & EXPLOSION INDEX
5.4 TOXICITY INDEX
5.5 MAJOR EQUIPMENT CONTROL
224
5.6 HAZOP & SAFETY SUMMARY
Hazard and Operability Analysis (HAZOP) is a structured and systematic technique for
system examination and risk management. In particular, HAZOP is often used as a
technique for identifying potential hazards in a system and identifying operability problems
likely to lead to nonconforming products. HAZOP is based on a theory that assumes risk
events are caused by deviations from design or operating intentions. Identification of such
deviations is facilitated by using sets of ―guide words‖ as a systematic list of deviation
perspectives. This approach is a unique feature of the HAZOP methodology that helps
stimulate the imagination of team members when exploring potential deviations.
This creativity results from the interaction of the team and their diverse backgrounds.
Consequently the process requires that all team members participate (quantity breeds
quality in this case), and team members must refrain from criticizing each other to the point
that members hesitate to suggest ideas. The team focuses on specific points of the design
one at a time. At each of these study nodes, deviations in the process parameters are
examined using the guide words. The guide words are used to ensure that the design is
explored in every conceivable way. Thus the team must identify a fairly large number of
deviations, each of which must then be considered so that their potential causes and
consequences can be identified. The best time to conduct a HAZOP is when the design is
fairly firm. At this point, the design is well enough defined to allow meaningful answers to
the questions raised in the HAZOP process. Also, at this point it is still possible to change
the design without a major cost. However, HAZOPs can be done at any stage after the
design is nearly firm.
As a risk assessment tool, HAZOP is often described as:
1. A brainstorming technique
2. A qualitative risk assessment tool
3. An inductive risk assessment tool, meaning that it is a ―bottom-up‖ risk
identification approach, where success relies on the ability of subject matter experts
(SMEs) to predict deviations based on past experiences and general subject matter
expertise
225
5.6.1 Definitions of Keywords in HAZOP
When describing the HAZOP methodology, the following definitions are useful:
Table 5-2: Definition of Keywords in HAZOP Analysis

Keywords Definition
Hazard Potential source of harm. Deviations from design or operational intent
may constitute or produce a hazard. Hazards are the focus of HAZOP
studies, and it should be noted that a single hazard could potentially
lead to multiple forms of harm.
Harm Physical injury or damage to the health of people or damage to
property or the environment. Harm is the consequence of a hazard
occurring and may take many forms: patient or user safety, employee
safety, business risks, regulatory risks, environmental risks and so on.
Risk Combination of probability of occurrence of harm and the severity of
that harm. In a strict sense, ―risk‖ is not always explicitly identified in
HAZOP studies since the core methodology does not require
identification (also referred to as rating) of the probability or severity
of harm. However, risk assessment teams may choose to rate these
factors in order to further quantify and prioritize risks if needed.
5.6.2 Usage of HAZOP

HAZOP is best suited for assessing hazards in facilities, equipment, and processes
and is capable of assessing systems from multiple perspectives:
1. Design
 Assessing system design capability to meet user specifications and safety
standards
 Identifying weaknesses in systems
2. Physical and operational environments
 Assessing environment to ensure system is appropriately situated,
supported, serviced, contained and so on.
226
3. Operational and procedural controls
 Assessing engineered controls (ex: automation), sequences of operations,
procedural controls (ex: human interactions) etc.
 Assessing different operational modes – start-up, standby, normal operation,
steady & unsteady states, normal shutdown, emergency shutdown and so on.
Table 5-3: Advantages and Disadvantages of HAZOP Usage

Advantages Disadvanatges
1. Helpful when confronting hazards that 1. No means to assess hazards involving
are difficult to quantify interactions between different parts of a
 Hazards rooted in human system or process
performance and behaviors
 Hazards that are difficult to detect, 2. No risk ranking or prioritization capability
analyze, isolate, count, predict,  Teams may optionally build-in such
etc. capability as required
 Methodology doesn‘t force you to
explicitly rate or measure 3. No means to assess effectiveness of
deviation probability of existing or proposed controls (safeguards)
occurrence, severity of impact, or  May need to interface HAZOP with
ability to detect other risk management tools (example:
HACCP) for this purpose
2. Built-in brainstorming methodology
3. Systematic & comprehensive

methodology
4. More simple and intuitive than other

commonly used risk management tools
227
5.6.3 HAZOP Methodology
The HAZOP analysis process is executed in four phases as illustrated in Figure 5-1.
Definition Preparation
 Define scope and objectives  Plan the study
 Define responsibilities  Collect data
 Select Team  Agree style of recording
 Estimate the time
 Arrange a schedule
Documentation and Examination

Follow-up  Divide the system into parts
 Record the examination  Select a part and define design
 Sign off the intent
documentation  Identify deviation by using guide
words on each element
 Produce the report of the
study  Identify consequences and causes
 Follow up that actions  Identify whether a significant
are implemented problem exists
 Re-study any parts of  Identify protection, detection, and
system if necessary indicating mechanisms
 Produce final output  Identify possible remedial/
report mitigating measures (optional)
 Agree actions
 Repeat for each element and then
Figure 5-1: HAZOP Methodology
each part
1. Definition Phase
The definition phase typically begins with preliminary identification of risk assessment
team members. HAZOP is intended to be a cross-functional team effort, and relies on
specialists (SMEs) from various disciplines with appropriate skills and experience who
display intuition and good judgment. SMEs should be carefully chosen to include those
with a broad and current knowledge of system deviations. HAZOP should always be
carried out in a climate of positive thinking and frank discussion. During the Definition
Phase, the risk assessment team must identify the assessment scope carefully in order to
focus effort. This includes defining study boundaries and key interfaces as well as key
assumptions that the assessment will be performed under.
228
2. Preparation Phase
The Preparation Phase typically includes the following activities:
 Identifying and locating supporting data and information
 Identification of the audience and users of the study outputs
 Project management preparations (ex: scheduling meetings, transcribing
proceedings, etc.)
 Consensus on template format for recording study outputs
 Consensus on HAZOP guide words to be used during the study
HAZOP guide words are key supporting elements in the execution of a HAZOP
analysis. According to IEC Standard 61882: The identification of deviations from the
design intent is achieved by a questioning process using predetermined ―guide words‖.
The role of the guide word is to stimulate imaginative thinking, to focus the study and
elicit ideas and discussion. Risk assessment teams are responsible for identifying the
guide words that will best suit the scope and problem statement for their analysis.
HAZOP guide words work by providing a systematic and consistent means of
brainstorming potential deviations to operations. Some common HAZOP guide words
include as below:
 No or not  Other than

 More  Early
 Less  Late
 As well as  Before
 Part of  After
 Reverse (of intent)  Others can crafted as
needed
3. Examination Phase
The Examination Phase begins with identification of all elements (parts or steps) of the
system or process to be examined. For example:
 Physical systems may be broken down into smaller parts as necessary
 Processes may be broken down into discrete steps or phases
 Similar parts or steps may be grouped together to facilitate assessment
The HAZOP guide words are then applied to each of the elements. In this fashion a
thorough search for deviations is carried out in a systematic manner. It must be note that
not all combinations of guide words and elements are expected to yield sensible or
229
credible deviation possibilities. As a general rule, all reasonable use and misuse
conditions which are expected by the user should be identified and subsequently
challenged to determine if they are ―credible‖ and whether they should be assessed any
further. There is no need to explicitly document the instances when combinations of
elements and guide words do not yield any credible deviations. The following Figure
5-2 graphically illustrates the HAZOP Examination Phase process flow.
Figure 5-2: HAZOP Examination Phase Process Flow (Extracted from IEC Standard
61882)
230
4. Documentation & Follow-up Phase
The documentation of HAZOP analyses is often facilitated by utilizing a template
recording form as detailed in IEC Standard 61882. Risk assessment teams may modify
the template as necessary based on factors such as:
 Regulatory requirements
 Need for more explicit risk rating or prioritization (ex: rating deviation
probabilities, severities, and/or detection)
 Company documentation policies
 Needs for traceability or audit readiness
 Other factors
5.6.4 Analysis of Main Findings

An indication of the criteria used to determine whether or not action was chosen to be taken
regarding the outcome of a deviation is required. The results of the HAZOP, giving
deviations, consequences and actions required, should be provided. Those events on which
the decision of no action was made should also be listed, along with the events for which
consequence or risk analysis was considered necessary. The decisions made after such
further analyses should also be given. Any alternative actions generated and considered
should be detailed.
5.6.5 Actions Arising from the HAZOP

This section should highlight those actions which are potentially hazardous to plant
personnel, the public or the environment or have the potential to jeopardize the operability
of the plant. Also included should be a clear statement of commitment to modify the design
or operational procedures in accordance with the identified required actions and a timetable
for implementation. Justification as to why no action was chosen for any actions identified
should also be made. The current status of the recommended actions at the time of the
report should also be given together with the designations of persons responsible for their
implementation.
231
5.6.6 HAZOP Analysis on Methyl Ester Production Plant
A HAZOP study is conducted to identify hazards and operability problems in our plant.
The concept involves investigating how the plant might deviate from the design intent.
Based on our analysis, the process of identifying problems during a HAZOP study, a
solution becomes apparent, it is recorded as part of the HAZOP result. It covers the major
equipment of our plant which are reactor, flash drum, decanter, distillation column, heat
exchanger and storage tank.
The process is systematic and the terms from Table 5-4 to Table 5-18 are used as below:
1. Paramaters are the criteria involved such as flow, pressure, temperature and level to
analyse the potential HAZOP occurs on each equipmeny
2. Guide words are simple words which are used to qualify or quantify the intention in
order to guide and stimulate the brainstorming process and so discover deviations.
The guide words shown in the following table are the ones most often used in a
HAZOP. We have made this list specific to their operations, to guide the team more
quickly to the areas where they have previously found problems. Each guide word
is applied to the process variables at the point in the plant which is being examined.
3. Causes are the reasons why deviations might occur. Once a deviation has been
shown to have a credible cause, it can be treated as a meaningful deviation. These
causes can be hardware failures, human errors, and unanticipated process state.
4. Consequences are the results of the deviations should they occur.
5. Recommendations are the method or solution to prevent or take further action in
order to reduce the high potential of consequence applied based on the possible
causes.
The HAZOP of our equipment is discussed and analysed from Table 5-4 to Table 5-18 with
each labeling for our production plant.
232
Table 5-4: General HAZOP Identification on Reactor R-101
Study Node Parameter Guidewords Causes Consequences Recommendations
Heating line Flow NONE 1. Control valve V-8 1. Loss of heating, 1. Install hot water flow meter and
fails and closes possible runaway low flow alarm to alert operator
2. Hot water source 2. As above 2. Check and monitor reliability
failure of hot water source
3. Plugged heating 3. As above 3. Install filter with maintenance
line procedure
LESS 1. Partially plugged 1. Diminished heating, 1. Install filter with maintenance
heating line possible runaway procedure
2. Partial hot water 2. As above 2. Check and monitor reliability
source failure of hot water source
3. Control valve V-8 3. As above 3. Place valve on critical
fails to respond instrumental list
Install hot water flow meter and
low flow alarm to alert operator
MORE 1. Control valve V-8 1. Reactor heats up, 1. Instruct operators and update
fails and opens possible runaway procedures
REVERSE 1. Failure of hot 1. Loss of heating, 1. Install low temperature alarm
water source possible runaway to alert operator
resulting in
backflow
2. Backflow due to 2. As above 2. Install check valve
high back-
pressure
Stirrer Agitation NONE 1. Stirrer motor 1. No mixing, possible 1. Interlock with reactant feed line
malfunction accumulation of
unreacted materials
2. Power failure 2. As above 2. Install control valve at reactant
feed
Feed valve must fail and close
on power loss
Reactor Temperature LESS 1. Control valve V-8 1. Diminished heating, 1. Place valve on critical
R-101 fails to respond possible runaway instrumental list
2. Partially plugged 2. As above 2. Install filter with maintenance
heating line procedure
MORE 4. Control valve V-8 1. Reactor heats up, 1. Instruct operators and update
fails and opens possible runaway procedures
Level LESS 1. Control valve V-9 1. Incomplete 1. Emergency shutdown
fails and opens conversion of Instruct operators and update
reactants procedures
2. Leakage at 2. Possible damage to 2. As above
reactor stirrer, leading to
vibration and leak
MORE 1. Control valve V-9 1. Accumulation of 1. Install flow meter and low flow
fails and closes reactant materials in alarm to alert operator
reactor
2. Plugged reactor 2. Overflow could 2. Instruct operators and update
outlet cause injury to procedures
operator in area
234
Heating line Flow NONE 1. Control valve V- 1. Loss of heating, 1. Install hot water flow meter and
10 fails and closes possible runaway low flow alarm to alert operator
line procedure
3. Control valve V- 3. As above 3. Place valve on critical
10 fails to respond instrumental list
MORE 1. Control valve V- 1. Reactor heats up, 1. Instruct operators and update
10 fails and opens possible runaway procedures
resulting in
backflow
high back-
pressure
unreacted materials
feed
on power loss
235
Reactor Temperature LESS 1. Control valve V- 1. Diminished heating, 1. Place valve on critical
R-102 10 fails to respond possible runaway instrumental list
Level LESS 1. Control valve V- 1. Incomplete 1. Emergency shutdown
11 fails and opens conversion of Instruct operators and update
vibration and leak
MORE 1. Control valve V- 1. Accumulation of 1. Install flow meter and low flow
11 fails and closes reactant materials in alarm to alert operator
reactor
operator in area
236
Heating line Flow NONE 1. Control valve V- 1. Loss of heating, 1. Install hot water flow meter and
12 fails and closes possible runaway low flow alarm to alert operator
line procedure
3. Control valve V- 3. As above 3. Place valve on critical
12 fails to respond instrumental list
resulting in
backflow
high back-
pressure
unreacted materials
feed
on power loss
237
Reactor Temperature LESS 1. Control valve V- 1. Diminished heating, 1. Place valve on critical
R-103 12 fails to respond possible runaway instrumental list
Level LESS 1. Control valve V- 1. Incomplete 1. Emergency shutdown
13 fails and opens conversion of Instruct operators and update
vibration and leak
MORE 1. Control valve V- 1. Accumulation of 1. Install flow meter and low flow
13 fails and closes reactant materials in alarm to alert operator
reactor
operator in area
238
Table 5-7: General HAZOP Identification on Decanter V-101
Decanter Flow NONE 1. Control valve V- 1. V-101 operation 1. Install flow meter and low flow
V-101 24 fails and closes failure alarm to alert operator
2. Plugged stream 19 2. As above 2. Interlock with stream 18
LESS 1. Partially plugged 1. V-101 operation 1. Instruct operators and update

stream 19 failure, ineffective with maintenance procedures
separation process
2. Control valve V- 2. As above 2. Install flow meter and low flow
24 fails to respond alarm to alert operator
MORE 1. Control valve V- 1. V-101 operation 1. Instruct operators and update
24 fails and opens failure, ineffective maintenance procedures
separation process
Level LESS 1. Control valve V- 1. V-101 operation 1. Instruct operators and update
23 fails and closes failure, ineffective maintenance procedures
separation process
2. Leakage at V-101 2. As above 2. As above
MORE 1. Control valve V- 1. Overflow could 1. Emergency shutdown

23 fails and opens cause injury to Place valve on critical
operator in area instrumental list
Instruct operators and update
procedures
239
Table 5-8: General HAZOP Identification on Flash Drum C-101
Flash Drum Pressure MORE 1. Control valve V- 1. Temperature rises, 1. Instruct operators and update
C-101 15 fails and closes more liquid with maintenance procedures
vaporised, bottom Install relief valve
product quality
changes
Level LESS 1. Control valve V- 1. Ineffective 1. Emergency shutdown
18 fails and opens separation process, Instruct operators and update
less methanol maintenance procedures
recycled
2. Leakage at C-101 2. Product loss 2. As above

18 fails and closes cause injury to Instruct operators and update
operator in area procedures
240
product quality
changes
less methanol maintenance procedures
recycled

241
Table 5-10: General HAZOP Identification on Distillation Column C-103
Distillation Pressure LESS 1. Control valve V- 1. Product quality does 1. Instruct operators and update
Column 26 fails and opens not meet required with maintenance procedures
C-103 specification
MORE 1. Control valve V- 1. Temperature rises, 1. Instruct operators and update
26 fails and closes more liquid with maintenance procedures
vaporised, product Install relief valve
quality changes
Level LESS 1. Control valve V- 1. Ineffective 1. Interlock to shutdown system
product quality maintenance procedures
changes
2. Pipe leakage 2. Product loss 2. As above

Condenser Temperature LESS 1. Control valve V- 1. Temperature drops, 1. Install temperature indicator
C-103-C 27 fails and open ineffective and low temperature alarm
separation, product
quality changes
MORE 1. Control valve V- 1. Diminished cooling, 1. Place valve on critical
27 fails to respond ineffective instrumental list
condensation Install refrigerant flow meter
and low flow alarm to alert
operator
2. Partially plugged 2. As above 2. As above
refrigerant line
3. Partial refrigerant 3. As above 3. Check and monitor reliability
service failure of refrigerant source
242
Reflux Level LESS 1. Control valve V- 1. Ineffective 1. Install level indicator and low
Drum 28 fails and open separation process, level alarm
product quality Instruct operators and update
changes with maintenance procedures
MORE 1. Control valve V- 1. Overflow could 1. Install level indicator and high
28 fails and closes cause injury to level alarm
operator in area Instruct operators and update
with maintenance procedures
Reboiler Composition PART OF 1. Control valve V- 1. Product composition 1. Install composition alarm
C-103-R 30 malfunctions altered, product system to alert operator
quality does not
meet required
specification
243
C-104 specification
quality changes
changes

separation, product
quality changes
condensation Install cooling line flow meter
operator
cooling line
3. Partial cooling 3. As above 3. Check and monitor reliability
water service of cooling water source
failure
244
quality does not
meet required
specification
245
C-105 specification
quality changes
changes

separation, product
quality changes
condensation Install cooling line flow meter
operator
cooling line
6. Partial cooling 6. As above 6. Check and monitor reliability
water service of cooling water source
failure
246
quality does not
meet required
specification
247
product quality
changes
changes

248
Table 5-14: General HAZOP Identification on Storage Tank T-105/8
Storage Level LESS 1. Drainage control 1. Product loss 1. Instruct operators and update
Tank valve fails and maintenance procedures
opens
2. Leakage at tank 2. As above 2. As above
MORE 1. Drainage control 1. Overflow could 1. Instruct operators and update

valve fails and cause injury to maintenance procedures
closes operator in area
249
Table 5-15: General HAZOP Identification on Storage Tank T-106/7
Storage Level LESS 1. Drainage control 1. Product loss 1. Instruct operators and update
Tank valve fails and maintenance procedures
opens
2. Leakage at tank 2. As above 2. As above
MORE 1. Drainage control 1. Overflow could 1. Instruct operators and update

valve fails and cause injury to maintenance procedures
closes operator in area
Temperaure LESS 1. Steam control 1. Diminished heating, 1. Install steam flow meter and
valve fails and possible turning low flow alarm to alert operator
closes product into solid
heating line
3. Steam source 3. As above 3. Check and monitor reliability
failure of steam source
MORE 1. Steam control 1. None identified 1. Instruct operators and update
valve fails and maintenance procedures
opens
250
Table 5-16: General HAZOP Identification on Heat Exchanger (Steam as Utility) E-101/2/4/6/13
Heat Temperaure LESS 1. Steam control 1. Diminished heating, 1. Install steam flow meter and
Exchanger valve fails and unable to achieve low flow alarm to alert operator
closes desired temperature
heating line
3. Steam source 3. As above 3. Check and monitor reliability
failure of steam source
MORE 1. Steam control 1. Overheated 1. Install high temperature alarm
valve fails and
opens
Table 5-17: General HAZOP Identification on Heat Exchanger (Cooling Water as Utility) E-103/8/10/11
Heat Temperaure LESS 1. Cooling water 1. Overcooled 1. Install low temperature alarm
Exchanger control valve fails
and opens
MORE 1. Cooling water 1. Diminished cooling, 1. Install cooling water flow
control valve fails unable to achieve meter and low flow alarm to
and closes desired temperature alert operator
cooling line
3. Cooling water 3. As above 3. Check and monitor reliability
service failure of cooling water source
251
Table 5-18: General HAZOP Identification on Heat Exchanger (Refrigerant as Utility) E-105/7/9/12/14/15
Heat Temperaure LESS 1. Refrigerant 1. Overcooled 1. Install low temperature alarm
Exchanger control valve fails
and opens
MORE 1. Refrigerant 1. Diminished cooling, 1. Install refrigerant flow meter
control valve fails unable to achieve and low flow alarm to alert
and closes desired temperature operator
refrigerant line
3. Refrigerant 3. As above 3. Check and monitor reliability
service failure of refrigerant source
252
5.7 P&ID
253
6 CHAPTER 6
6.1 CONCLUSION
As a summary, a production rate of 60,000 MTPA of combined methyl ester products, namely
methyl octanoate/decanoate (CE-810), methyl laurate/myristate (CE-1214), and methyl
palmitate/oleate (CE-1618) is decided in Level 1 Decision. The reaction occurs in three
CSTRs in series operated in isothermal condition of 60ºC and 1 atm pressure. A 6:1 molar
ratio of methanol is fed to the process and 1% of homogeneous sodium methoxide by weight
of RBD palm kernel oil is introduced to the process. An optimum conversion of 99% is
justified based on EP3. Next, for downstream separation, a two-stage methanol recovery flash
column is applied to achieve 92% methanol recovery. A series of distillation columns are used
to separate the crude methyl esters into various methyl ester products based on different
carbon distribution. Whereas glycerol is purified to at least more than 80% purity to be
marketed as crude glycerol product to optimize the plant costs. This plant is capable to
produce 96.9% purity of CE-810, 99.7% purity of CE-1214, and 96.3% purity of CE-1618 at
a combined production capacity of 60,115 MTPA that satisfy the set 60,000 MTPA
production rate.
6.2 RECOMMENDATION
In the level 4 decision, shortcut method is being employed for the major separator equipment
calculation. For example, Underwood‘s shortcut method is used to calculate the distillation
column minimum reflux ratio. Meanwhile, pressure drop in the heat exchanger is not
calculated at this stage. However, in reality, pressure drop is to be observed in these
equipments and throughout the pipeline, there will also be head loss in piping. Thus, for the
next level, a detailed design for distillation column as well as heat exchanger has to be
considered in order to ensure the plant design is feasible in real industrial practice. Next, the
heat generated from the process is to be discussed in detail in the next chapter for heat
integration.
254
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263
APPENDIX
Appendix A. 1
A.1. 1 Density of sodium methoxide solution
Figure 1: Density of Sodium methoxide (NaOCH3) at different temperature and concentration

(BASF, 2007)
264
A.1. 2 Heat effect calculation
Ea 1064.81 J/mol
k 0.78 hr-1
X T (K) k (hr-1) FTG,0/-rTG (Adiabatic) (m3) FTG,0/-rTG (Isothermal) (m3)

0.0 333.1600 0.7800 14 14
0.1 332.8431 0.7797 15 15
0.1 332.5262 0.7794 16 16
0.2 332.2094 0.7792 17 17
0.2 331.8925 0.7789 18 18
0.3 331.5756 0.7786 19 19
0.3 331.2587 0.7783 21 21
0.4 330.9418 0.7780 22 22
0.4 330.6250 0.7777 24 24
0.5 330.3081 0.7774 26 26
0.5 329.9912 0.7771 29 29
0.6 329.6743 0.7768 32 32
0.6 329.3574 0.7766 36 36
0.7 329.0406 0.7763 42 41
0.7 328.7237 0.7760 48 48
0.8 328.4068 0.7757 58 58
0.8 328.0899 0.7754 73 72
0.9 327.7730 0.7751 97 96
0.9 327.4562 0.7748 146 145
1.0 327.1393 0.7745 291 289
1.0 327.1076 0.7745 324 321
1.0 327.0759 0.7745 364 362
1.0 327.0442 0.7744 416 413
1.0 327.0125 0.7744 486 482
1.0 326.9808 0.7744 583 578
1.0 326.9492 0.7743 728 723
1.0 326.9175 0.7743 971 964
1.0 326.8858 0.7743 1457 1446
1.0 326.8541 0.7742 2914 2892
1.0 326.8287 0.7742 14569 14462
265
A.1. 3 CSTR calculation
k 0.78 hr-1
vo 11.28 m3/hr
Number of CSTRs, n
X 1 2 3 4 5
Volume of each CSTR (m3)
0 0 0 0 0 0
0.05 1 0 0 0 0
0.1 2 1 1 0 0
0.15 3 1 1 1 0
0.2 4 2 1 1 1
0.25 5 2 1 1 1
0.3 6 3 2 1 1
0.35 8 3 2 2 1
0.4 10 4 3 2 2
0.45 12 5 3 2 2
0.5 14 6 4 3 2
0.55 18 7 4 3 3
0.6 22 8 5 4 3
0.65 27 10 6 4 3
0.7 34 12 7 5 4
0.75 43 14 8 6 5
0.8 58 18 10 7 5
0.85 82 23 13 9 7
0.9 130 31 17 11 8
0.95 275 50 25 16 12
0.955 307 54 26 17 12
0.96 347 58 28 18 13
0.965 399 63 30 19 14
0.97 468 69 32 20 15
0.975 564 77 35 22 16
0.98 709 88 39 24 17
0.985 950 104 44 27 19
0.99 1432 130 53 31 22
0.995 2878 190 70 40 27
0.999 14447 443 130 67 43
266
A.1. 4 Heat of formation estimation
RBD PKO Wt. Frac MW (kg/kgmol) Mol frac. Hf 298K (kcal/mol) kJ/mol
470.6823 0.0644 a -82.42
C8:0 Trioctanoin C27H50O6 4.4 0.0093 -306.0 -1280.28
554.8420 0.0459 a -76.28
C10:0 Tridecanoin C33H62O6 3.7 0.0067 -397.0 -1661.02
C12:0 Trilaurin C39H74O6 48.3 639.0013 0.0756 0.5206 -489.0 -2045.94 -1065.02
C14:0 Trimyristin C45H86O6 15.6 723.1610 0.0216 0.1486 -520.0 -2175.64 -323.22
807.3200 0.0665 a
C16:0 Tripalmitin C51H98O6 7.8 0.0097 -546.3 -2285.68 -152.08
891.4800 0.0155 a -37.01
C18:0 Tristearin C57H110O6 2.0 0.0022 -572.5 -2395.30
885.4320 0.1174 a
C18:1 Triolein C57H104O6 15.1 0.0171 -572.5 -2395.30 -281.32
879.3844 0.0211 a -50.65
C18:2 Trilinolein C57H98O6 2.7 0.0031 -572.5 -2395.30
99.6 0.1452 1.0000 Average Hf 298K (kJ/mol) -2068.01
a
Interpolated based on carbon number
Methyl Ester Wt. Frac MW (kg/kgmol) Mol Frac. Hf 298K (kcal/mol) kJ/mol
C8:0 Methyl Octanoate C9H18O2 4.4 158.2380 0.0278 0.0642 -141.07 -590.23 -37.90
C10:0 Methyl Decanoate C11H22O2 3.7 186.2912 0.0199 0.0459 -153.07 -640.43 -29.38
C12:0 Methyl Laurate C13H26O2 48.3 214.3443 0.2253 0.5204 -165.66 -693.11 -360.70
C14:0 Methyl Myristate C15H30O2 15.6 242.3975 0.0644 0.1486 -177.80 -743.90 -110.57
C16:0 Methyl Palmitate 7.8 270.4507 0.0288 a
C17H34O2 0.0666 -177.80 -743.90 -49.55
C18:0 Methyl Stearate 2.0 298.5038 0.0067 a
C19H38O2 0.0155 -174.20 -728.84 -11.28
C18:1 Methyl Oleate C19H36O2 15.1 296.4879 0.0509 0.1176 -174.20 -728.84 -85.73
C18:2 Methyl linoleate 2.7 294.4721 0.0092 a
C19H34O2 0.0212 -174.20 -728.84 -15.43
99.6 0.4330 1.0000 Average Hf 298K (kJ/mol) -700.53
a
Interpolated based on carbon number
267
A.1. 5 Heat capacity estimation for RBDPKO
Temperature Cp (J/g.K)
Source
K Trilaurin Trimyristin Tripalmitin Tristearin
353.15 2.1414 2.1226 2.1142 2.1790
373.15 2.1894 2.1708 2.1624 2.2272
393.15 2.2384 2.2199 2.2115 2.2763
(Morad et al., 2000)
413.15 2.2881 2.2696 2.2612 2.3260
433.15 2.3381 2.3198 2.3114 2.3762
453.15 2.3884 2.3702 2.3614 2.4266
Temperature Cp (J/mol.K)
C Trilaurin Trimyristin Tripalmitin Tristearin
353.15 1368.3574 1534.9815 1706.8359 1942.5349
373.15 1399.0294 1569.8379 1745.7488 1985.5043
393.15 1430.3405 1605.3451 1785.3882 2029.2759
413.15 1462.0989 1641.2862 1825.5120 2073.5825
433.15 1494.0489 1677.5889 1866.0394 2118.3348
453.15 1526.1907 1714.0362 1906.4054 2163.2654
2200.0000
2100.0000
2000.0000
Tristearin: Cp = 2.2092 T + 1161.4
1900.0000
Cp (J/mol.K)
1800.0000
Tripalmitin: Cp = 1.9983 T + 1000.4
1700.0000
1600.0000
Trimyristin: Cp = 1.7921 T + 901.36
1500.0000
Trilaurin: Cp = 1.58 T + 809.71
1400.0000
1300.0000
340 360 380 400 420 440 460
Temperature (K)
Trilaurin Trimyristin Tripalmitin Tristearin
268
Components MW (g/gmol) Mol frac. Average MW Mol frac.
C8:0 Trioctanoin 470.6823 0.0644
C10:0 Tridecanoin 554.8420 0.0459 388.4175 0.6309
C12:0 Trilaurin 639.0013 0.5206
C14:0 Trimyristin 723.1610 0.1486 0.1486
C16:0 Tripalmitin 807.3200 0.0665 0.0665
C18:0 Tristearin 891.4800 0.0155
C18:1 Triolein 885.4320 0.1174 0.1540
C18:2 Trilinolein 879.3844 0.0211
Total 1 1.0000
Temperature Cp (J/mol.K)
K RBDPKO
353.15 1504.0806
373.15 1537.8169
393.15 1572.2250
413.15 1607.0943
433.15 1642.2338
453.15 1677.5325
1700.0000
1680.0000
1660.0000
1640.0000
1620.0000
Cp (J/mol.K)
1600.0000
1580.0000
RBDPKO: Cp = 1.7363 T + 890.19
1560.0000
1540.0000
1520.0000
1500.0000
1480.0000
340 360 380 400 420 440 460
Temperature (K)
RBDPKO
269
A.1. 6 Heat capacity estimation for PKO methyl ester
PKO Methyl Ester (mol frac.) mol frac.
C8:0 Methyl Octanoate 0.0642
0.1101
C10:0 Methyl Decanoate 0.0459
C12:0 Methyl Laurate 0.5204 0.5204
C14:0 Methyl Myristate 0.1486 0.1486
C16:0 Methyl Palmitate 0.0666 0.0666
C18:0 Methyl Stearate 0.0155
C18:1 Methyl Oleate 0.1176 0.1543
C18:2 Methyl linoleate 0.0212
Total 1.0000
Liquid molar heat capacity (J mol−1 K−1) of Methyl Average

T (K) Esters Cp
C10:0 C12:0 C14:0 C16:0 C18:0 (J/mol.K)
320 384.66 447.72 508.89 575.75 643.90 488.6617
330 389.79 454.57 515.95 582.16 650.59 495.2995
340 395.46 461.48 522.95 588.71 657.23 502.0208
350 401.69 468.46 529.90 595.39 663.81 508.8321
360 408.46 475.51 536.79 602.22 670.34 515.7326
370 415.78 482.62 543.62 609.19 676.82 522.7176
380 423.65 489.80 550.39 616.30 683.24 529.7907
390 432.06 497.04 557.11 623.55 689.60 536.9471
540.0000
530.0000
520.0000
Cp (J/mol.K)
510.0000
PKO Methyl Ester: Cp = 0.6898 T + 267.62
500.0000
490.0000
480.0000
310 320 330 340 350 360 370 380 390 400
Temperature, T (K)
PKO Methyl Ester
270
A.1. 7 Material balance for Level 3 Decision
From EP3, X=0.99
MeOH Recovery:
Species kgmol/hr kg/hr
TG 0.00 0.00
MeOH 33.26 1,065.85
NaOCH3 0.00 0.00
ME 0.00 0.00
GL 0.00 0.00
Solution wt/wt kgmol/hr kg/hr Total 33.26 1,065.85
NaOCH3 0.3 1.39 75.18
MeOH 0.7 5.47 175.42 Species wt/wt kgmol/hr kg/hr
Total 6.87 250.60 TG 0.11 75.18
MeOH
Fresh MeOH Feed: Mixer Species kgmol/hr kg/hr MeOH 33.26 1,065.85
Mixer
kgmol/hr kg/hr kgmol/hr kg/hr TG 0.11 75.18 NaOCH3 1.39 75.18
MeOH 27.13 869.32 MeOH 60.40 1935.17 MeOH 33.26 1,065.85 CE-810 0.0813 609.75 MeOH
Reactor
NaOCH3 1.39 75.18 CE-1214 0.6416 32.61 4,812.01 Recovery
kgmol/hr kg/hr ME 32.61 7,500.02 CE-1618 0.2771 2,078.26
TG 10.98 7,517.95 GL 10.87 1,000.92 GL 10.87 1,000.92 Species kgmol/hr kg/hr
60 Celsius Total 78.24 9,717.15 Total 78.24 9,717.15 TG 0.11 75.18
Status (Reactor Feed) 1 atm MeOH 0.00 0.00
MeOH:TG 6.00 mol/mol Species mol frac. kgmol/hr kg/hr NaOCH3 1.39 75.18
NaOCH3:TG 0.01 wt/wt ME-8 0.0642 2.09 481.63 ME 32.61 7,500.02
kgmol/hr kg/hr ME-10 0.0459 1.50 344.02 GL 10.87 1,000.92
Total 78.24 9,703.72 ME-12 0.5204 16.97 3903.08 Total 44.98 8,651.30
ME-14 0.1486 4.85 1114.73
ME-16 0.0666 2.17 499.55
ME-18 0.1543 5.03 1157.02
Total 1.0000 32.61 7500.02
271
Appendix A. 2
A.2. 1 R-101/2/3 material balance
The tranesterification reactor R-101/2/3 is located at the front part of the production plant.
The inlet consists of three main components, triglyceride, methanol, and sodium methoxide
which are also the reactants for the transesterification process for methyl ester generation.
The inlet condition of the transesterification process is 60°C at 1 atm. Therefore, the products
exist in liquid state. From the calculation of EP3, it was known that the optimum conversion
for transesterification process is by converting 99% of the triglyceride. From the backward
material balance calculation, the amount of methyl ester needed to be produced from the
transesterification process is 32.6055 kmol/hr, therefore the flow rate of all the input
components can be calculated.
The conversion of triglyceride is 0.99 while the yield is 3. Therefore, the amount of the
triglyceride at the inlet can be calculated based on the equation below.
The methanol feed is based on 6:1 methanol to triglyceride molar ratio and can be calculated
based on the equation below.
1 wt% of NaOCH3 based on triglyceride is fed and can be calculated using the equations
below.
272
The calculated values can be converted to either molar flow rate or mass flow rate using the
molar weight of each component as shown below. Also, the methyl ester of different carbon
chains can be calculated by multiplying the mole fraction with molar flow rate of total methyl
ester product.
Molecular weight of each component

Species MW
kg/kgmol
TG 684.8022
MeOH 32.0419
NaOCH3 54.0240
ME 230.0231
GL 92.0938
Molecular weight and mole fraction of methyl esters

PKO Methyl Ester (mol frac.) MW MW mol frac.
C8:0 Methyl Octanoate 158.2380 158.2380 0.0642
C10:0 Methyl Decanoate 186.2912 186.2912 0.0459
C12:0 Methyl Laurate 214.3443 214.3443 0.5204
C14:0 Methyl Myristate 242.3975 242.3975 0.1486
C16:0 Methyl Palmitate 270.4507 270.4507 0.0666
C18:0 Methyl Stearate 298.5038
C18:1 Methyl Oleate 296.4879 296.4134 0.1543
C18:2 Methyl linoleate 294.4721
Total 1.0000
273
Therefore, the all the inlet and outlet flow rates of all the components can be calculated and
are all shown in the table below.
Material balance results of R-101/2/3

Stream
Component 6 7
TG 10.9783 0.1098
ME-8 0.1860 2.0938
ME-10 0.0394 1.4956
ME-12 0.1357 16.9682
ME-14 0.0121 4.8462
ME-16 0.0017 2.1717
ME-18 0.0015 5.0300
GL 0.0092 10.8685
MeOH 65.8697 33.2642
Water
NaOCH3 1.3916 1.3916
Total 78.6252 78.2396
Mass Flow (kg/hr)

TG 7,517.9522 75.1795
ME-8 29.4362 331.3242
ME-10 7.3485 278.6136
ME-12 29.0846 3,637.0365
ME-14 2.9385 1,174.6950
ME-16 0.4539 587.3475
ME-18 0.4448 1,490.9591
GL 0.8427 1,000.9215
MeOH 2,110.5902 1,065.8481
Water
NaOCH3 81.3248 81.3248
Total 9,780.4164 9,723.2498
274
A.2. 2 C-101 material balance
The material balance for flash column can be calculated using Rachford-Rice flash equation
(Whitson & Michelsen, 1989) as shown below.
The material balance can be represented using the equations below.
Flash
F
Column
The calculation is done using Microsoft Excel spreadsheet as shown below.
C-101 material balance calculation spreadsheet

Temperature 120 ℃
393.15 K Manual input
Pressure 760 mmHg Goal Seek
V/F = β 0.3198 mol/mol
* Goal seek Rachford Rice eq.= 0 by changing V/F
* Adjust to maintain ME-8 at 95% as liquid.
Fi Feed mol. Rachford Liq. Vap. L*xi V*yi Liquid Vapour
No. Component Ki
(kmol/hr) Frac., zi Rice eq. Moles, xi Moles, yi (kmol/hr) (kmol/hr) Recovery Recovery
1 MeOH 6.287246 33.2642 0.4252 0.8354 0.1580 0.9934 8.4085 24.8557 25.28% 74.72%
2 Water - - - - - - - - - -
3 ME-8 0.097296 2.0938 0.0268 -0.0340 0.0376 0.0037 2.0022 0.0916 95.63% 4.37%
4 ME-10 0.024248 1.4956 0.0191 -0.0271 0.0278 0.0007 1.4787 0.0169 98.87% 1.13%
5 ME-12 0.006458 16.9682 0.2169 -0.3158 0.3179 0.0021 16.9168 0.0514 99.70% 0.30%
6 GL 0.000192 10.8685 0.1389 -0.2042 0.2042 0.0000 10.8675 0.0010 99.99% 0.01%
7 ME-14 0.001769 4.8462 0.0619 -0.0908 0.0910 0.0002 4.8421 0.0040 99.92% 0.08%
8 ME-16 0.000459 2.1717 0.0278 -0.0408 0.0408 0.0000 2.1713 0.0005 99.98% 0.02%
9 ME-18 0.000163 5.0300 0.0643 -0.0945 0.0945 0.0000 5.0296 0.0004 99.99% 0.01%
10 TG 0.000000 0.1098 0.0014 -0.0021 0.0021 0.0000 0.1098 0.0000 100.00% 0.00%
11 NaOCH3 0.000000 1.3916 0.0178 -0.0261 0.0261 0.0000 1.3916 0.0000 100.00% 0.00%
Total 78.2396 1.0000 0.0000 1.0000 1.0000 53.2184 25.0212
78.2396
275
Material balance results of C-101

Stream
Component 8 9 13
TG 0.1098 0.0000 0.1098
ME-8 2.0938 0.0916 2.0022
ME-10 1.4956 0.0169 1.4787
ME-12 16.9682 0.0514 16.9168
ME-14 4.8462 0.0040 4.8421
ME-16 2.1717 0.0005 2.1713
ME-18 5.0300 0.0004 5.0296
GL 10.8685 0.0010 10.8675
MeOH 33.2642 24.8557 8.4085
Water
NaOCH3 1.3916 0.0000 1.3916
Total 78.2396 25.0214 53.2182
Mass Flow (kg/hr)

TG 75.1795 0.0000 75.1795
ME-8 331.3242 14.4933 316.8309
ME-10 278.6136 3.1405 275.4731
ME-12 3,637.0365 11.0096 3,626.0270
ME-14 1,174.6950 0.9764 1,173.7187
ME-16 587.3475 0.1268 587.2207
ME-18 1,490.9591 0.1140 1,490.8451
GL 1,000.9215 0.0905 1,000.8309
MeOH 1,065.8481 796.4235 269.4245
Water
NaOCH3 81.3248 0.0000 81.3248
Total 9,723.2498 826.3745 8,896.8753
276
Flash
F
Column

Temperature 160 ℃

No. Component Ki
1 MeOH 17.205856 8.4085 0.1580 0.9073 0.0560 0.9633 2.6444 5.7641 31.45% 68.55%
2 Water - - - - - - - - - -
3 ME-8 0.390710 2.0022 0.0376 -0.0246 0.0404 0.0158 1.9078 0.0944 95.28% 4.72%
4 ME-10 0.122447 1.4787 0.0278 -0.0271 0.0308 0.0038 1.4561 0.0226 98.47% 1.53%
5 ME-12 0.039544 16.9168 0.3179 -0.3423 0.3564 0.0141 16.8325 0.0843 99.50% 0.50%
6 GL 0.005937 10.8675 0.2042 -0.2285 0.2299 0.0014 10.8593 0.0082 99.92% 0.08%
7 ME-14 0.013218 4.8421 0.0910 -0.1010 0.1023 0.0014 4.8340 0.0081 99.83% 0.17%
8 ME-16 0.004400 2.1713 0.0408 -0.0457 0.0459 0.0002 2.1701 0.0012 99.94% 0.06%
9 ME-18 0.001752 5.0296 0.0945 -0.1063 0.1065 0.0002 5.0285 0.0011 99.98% 0.02%
10 TG 0.000001 0.1098 0.0021 -0.0023 0.0023 0.0000 0.1098 0.0000 100.00% 0.00%
11 NaOCH3 0.000000 1.3916 0.0261 -0.0295 0.0295 0.0000 1.3916 0.0000 100.00% 0.00%
Total 53.2182 1.0000 0.0000 1.0000 1.0000 47.2342 5.9840
53.2182
277

Stream
Component 14 15 16
TG 0.1098 0.0000 0.1098
ME-8 2.0022 0.0944 1.9078
ME-10 1.4787 0.0226 1.4561
ME-12 16.9168 0.0843 16.8325
ME-14 4.8421 0.0081 4.8340
ME-16 2.1713 0.0012 2.1701
ME-18 5.0296 0.0011 5.0285
GL 10.8675 0.0082 10.8593
MeOH 8.4085 5.7641 2.6444
Water
NaOCH3 1.3916 0.0000 1.3916
Total 53.2182 5.9841 47.2341
Mass Flow (kg/hr)

TG 75.1795 0.0000 75.1795
ME-8 316.8309 14.9429 301.8881
ME-10 275.4731 4.2080 271.2651
ME-12 3,626.0270 18.0750 3,607.9519
ME-14 1,173.7187 1.9622 1,171.7565
ME-16 587.2207 0.3271 586.8936
ME-18 1,490.8451 0.3308 1,490.5143
GL 1,000.8309 0.7522 1,000.0788
MeOH 269.4245 184.6935 84.7311
Water
NaOCH3 81.3248 0.0000 81.3248
Total 8,896.8753 225.2916 8,671.5837
278
Flash
F
Column

Temperature 130 ℃

No. Component Ki
1 MeOH 8.256605 1.7478 0.0035 0.0032 0.0004 0.0036 0.0084 1.7394 0.48% 99.52%
2 Water 2.668038 484.1268 0.9721 0.6227 0.3733 0.9961 7.1526 476.9742 1.48% 98.52%
3 ME-8 0.142119 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 21.97% 78.03%
4 ME-10 0.037635 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 51.53% 48.47%
5 ME-12 0.010620 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 79.02% 20.98%
6 GL 0.000534 10.7469 0.0216 -0.5533 0.5536 0.0003 10.6054 0.1414 98.68% 1.32%
7 ME-14 0.003072 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 92.87% 7.13%
8 ME-16 0.000856 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 97.90% 2.10%
9 ME-18 0.000312 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 99.23% 0.77%
10 TG 0.000000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 100.00% 0.00%
11 NaOCH3 0.000000 1.3916 0.0028 -0.0726 0.0726 0.0000 1.3916 0.0000 100.00% 0.00%
Total 498.0131 1.0000 0.0000 1.0000 1.0000 19.1586 478.8545
498.0131
279

Stream
Component 42 43 45
TG 0.0000 0.0000 0.0000
ME-8 0.0000 0.0000 0.0000
ME-10 0.0000 0.0000 0.0000
ME-12 0.0000 0.0000 0.0000
ME-14 0.0000 0.0000 0.0000
ME-16 0.0000 0.0000 0.0000
ME-18 0.0000 0.0000 0.0000
GL 10.7469 0.1414 10.6054
MeOH 1.7478 1.7394 0.0084
Water 484.1268 476.9742 7.1526
NaOCH3 1.3916 0.0000 1.3916
Total 498.0131 478.8551 19.1580
Mass Flow (kg/hr)

TG 0.0000 0.0000 0.0000
ME-8 0.0000 0.0000 0.0000
ME-10 0.0000 0.0000 0.0000
ME-12 0.0000 0.0000 0.0000
ME-14 0.0000 0.0000 0.0000
ME-16 0.0000 0.0000 0.0000
ME-18 0.0000 0.0000 0.0000
GL 989.7222 13.0264 976.6958
MeOH 56.0036 55.7335 0.2701
Water 8,722.0284 8,593.1677 128.8608
NaOCH3 81.3225 0.0000 81.3225
Total 9,849.0768 8,661.9276 1,187.1491
280
A.2. 5 Distillation Column manual calculation
The material balance for distillation column can be calculated using equation (Geankoplis,
2003) as shown below.
Condenser
Distillation
F Column
Reboiler W
By setting the molar recovery of each component, the distillate and bottom flow rates of
respective components are obtained. From the overall flow rate, the molar composition of
each component in distillate and bottom stream of the purification column is calculated.
The distribution or compositions of the components other than light key and heavy key can be
calculated using the equations below.
αL,avg =√
where αLD=relative volatility of light key in distillate

αLW=relative volatility of light key in bottom
αL,avg= average relative volatility
*( )( )+
( )
where xLD = mole fraction of light key in distillate

xHD = mole fraction of heavy key in distillate
xHW = mole fraction of light key in bottom
xLW = mole fraction of light key in bottom
Nm = minimum number of stages
281
where xiF = feed molar composition
αi = relative volatility of respective component
q= condition of feed which is 1 (feed at bubble point) for this case
where Rm= minimum reflux ratio

XiD = molar composition of respective component in the distillate
The relative volatility of the light key in distillate and bottom are obtained using the above
equations. The number of minimum stages is obtained by using Fenske equation (Geankoplis,
2003). Besides, the Underwood‘s shortcut method (Geankoplis, 2003) is applied to obtain
minimum reflux ratio.
By having the Nm and Rm as results, the reflux ratio can be known by R=1.5Rm. Next, the
number of stages can be found by using Erbar-Maddox correlation (Geankoplis, 2003) as
shown in the figure below.
Erbar-Maddox correlation (Sinnott et al., 2005)
282
A.2.5. 1 C-103 material balance
The manual calculation for C-103 is done using spreadsheet in Microsfot Excel as can be seen
below.
Conditions Distillate, D Bottoms, W

Pressure 380 mmHg Light Key Heavy Key Heavy Key Light Key
Distillate: Light Key Water Recovery 99.50% Component Water ME-8 Component ME-8 Water
Bottom: Heavy Key ME-8 Recovery 99.50% Recovery 99.50% 0.50% Recovery 99.50% 0.50%
* NaOCH3 uses properties of NaCL (Aspen Plus & spreadsheet).

Feed, F Distillate, D Bottoms, W
Status Component
xiF xiF*F (kmol/hr) yiD = xiD yiD*D (kmol/hr) xiW xiW*W (kmol/hr)
MeOH Water 0.0260 0.8966 0.4426 0.8966 0.0000 0.0000
Light Key Water ME-8 0.0326 1.1252 0.5527 1.1195 0.0002 0.0056
Heavy Key ME-8 ME-10 0.0553 1.9078 0.0047 0.0095 0.0585 1.8983
ME-10 ME-12 0.0422 1.4561 0.0000 0.0000 0.0449 1.4561
ME-12 GL 0.4883 16.8325 0.0000 0.0000 0.5188 16.8325
GL ME-14 0.0033 0.1125 0.0000 0.0000 0.0035 0.1125
ME-14 ME-16 0.1402 4.8340 0.0000 0.0000 0.1490 4.8340
ME-16 ME-18 0.0629 2.1701 0.0000 0.0000 0.0669 2.1701
ME-18 TG 0.1459 5.0285 0.0000 0.0000 0.1550 5.0285
TG NaOCH3 0.0032 0.1098 0.0000 0.0000 0.0034 0.1098
NaOCH3 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
1.0000 F= 34.4730 1.0000 D= 2.0256 1.0000 W= 32.4474
Top Condition
Top Temperature 76 ℃ * Dew point of distillate
K reference, KR
Component KR Trial Error
ME-8 0.02659 1.77%
* Set SUM(yiD/αi)=KR by changing Top Temperature and Pressure
Status Component yiD Ki αi = Ki/KR yiD/αi xi

MeOH 0.4426 3.0743 115.6241 0.0038 0.1415
Light Key Water 0.5527 0.7934 29.8396 0.0185 0.6845
Heavy Key ME-8 0.0047 0.0266 1.0000 0.0047 0.1740
ME-10 0.0000 0.0049 0.1850 0.0000 0.0000
ME-12 0.0000 0.0009 0.0341 0.0000 0.0000
GL 0.0000 0.0000 0.0000 0.0000 0.0000
ME-14 0.0000 0.0002 0.0070 0.0000 0.0000
ME-16 0.0000 0.0000 0.0012 0.0000 0.0000
ME-18 0.0000 0.0000 0.0004 0.0000 0.0000
TG 0.0000 0.0000 0.0000 0.0000 0.0000
NaOCH3 0.0000 0.0000 0.0000 0.0000 0.0000
1.0000 0.02706 1.0000
283
Bottom Condition
Bottom Temperature 105 ℃ *Bubble point of bottoms
K reference, KR
ME-8 0.10525 -1.89%
* Set SUM(αi*xiW)=KR by changing Bottom Temperature and Pressure
Status Component xiW Ki αi = Ki/KR αi*xiW xi
MeOH 0.0000 8.1067 77.0231 0.0000 0.0000

Light Key Water 0.0002 2.3844 22.6550 0.0039 0.0380
Heavy Key ME-8 0.0585 0.1053 1.0000 0.0585 0.5666
ME-10 0.0449 0.0238 0.2265 0.0102 0.0984
ME-12 0.5188 0.0057 0.0545 0.0282 0.2736
GL 0.0035 0.0001 0.0006 0.0000 0.0000
ME-14 0.1490 0.0014 0.0137 0.0020 0.0197
ME-16 0.0669 0.0003 0.0031 0.0002 0.0020
ME-18 0.1550 0.0001 0.0011 0.0002 0.0016
TG 0.0034 0.0000 0.0000 0.0000 0.0000
NaOCH3 0.0000 0.0000 0.0000 0.0000 0.0000
1.0000 0.10326 1.0000
αLD 29.8396 * (T = 76 ℃ at column top)

αLW 22.6550 * (T = 105 ℃ at column bottom)
αL,av 26.0003
Nm 3.2493 * theoretical stages

2.2493 * theoretical trays (without reboiler)
xHD 0.0047 D 2.0256

xHW 0.0585 W 32.4474
(xiD*D) /
Status Component αi,av xiF*F xiD*D xiW*W
(xiW*W)
MeOH 94.3701 13122.0186 0.8966 0.8965 0.0001
Light Key Water
Heavy Key ME-8
ME-10 0.2047 0.0000 1.4561 0.0000 1.4561
ME-12 0.0431 0.0000 16.8325 0.0000 16.8325
GL 0.0001 0.0000 0.1125 0.0000 0.1125
ME-14 0.0098 0.0000 4.8340 0.0000 4.8340
ME-16 0.0019 0.0000 2.1701 0.0000 2.1701
ME-18 0.0006 0.0000 5.0285 0.0000 5.0285
TG 0.0000 0.0000 0.1098 0.0000 0.1098
NaOCH3 0.0000 0.0000 0.0000 0.0000 0.0000
284
The revised compositions are as follows:
Status Component
MeOH 0.0260 0.8966 0.4426 0.8965 0.0000 0.0001
Light Key Water 0.0326 1.1252 0.5527 1.1195 0.0002 0.0056
Heavy Key ME-8 0.0553 1.9078 0.0047 0.0095 0.0585 1.8983
ME-10 0.0422 1.4561 0.0000 0.0000 0.0449 1.4561
ME-12 0.4883 16.8325 0.0000 0.0000 0.5188 16.8325
GL 0.0033 0.1125 0.0000 0.0000 0.0035 0.1125
ME-14 0.1402 4.8340 0.0000 0.0000 0.1490 4.8340
ME-16 0.0629 2.1701 0.0000 0.0000 0.0669 2.1701
ME-18 0.1459 5.0285 0.0000 0.0000 0.1550 5.0285
TG 0.0032 0.1098 0.0000 0.0000 0.0034 0.1098
NaOCH3 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
1.0000 F= 34.4730 1.0000 D= 2.0256 1.0000 W= 32.4474
Tav 91.0 ℃ q 1.0 * Feed condition (q=1 at boiling point)

KR 0.0560 θ 2.1741 * Must between αL and αH
* Goal seek sum(Trial(q))=q by changing θ
Status Component xiF xiD Ki αi xiW Trial(q) Trial(Rm)
MeOH 0.0260 0.4426 5.1877 92.5696 0.0000 0.0266 0.4532

Light Key Water 0.0326 0.5527 1.4372 25.6462 0.0002 0.0357 0.6039
Heavy Key ME-8 0.0553 0.0047 0.0560 1.0000 0.0585 -0.0471 -0.0040
ME-10 0.0422 0.0000 0.0115 0.2060 0.0449 -0.0044 0.0000
ME-12 0.4883 0.0000 0.0025 0.0441 0.5188 -0.0101 0.0000
GL 0.0033 0.0000 0.0000 0.0001 0.0035 0.0000 0.0000
ME-14 0.1402 0.0000 0.0006 0.0101 0.1490 -0.0007 0.0000
ME-16 0.0629 0.0000 0.0001 0.0020 0.0669 -0.0001 0.0000
ME-18 0.1459 0.0000 0.0000 0.0007 0.1550 0.0000 0.0000
TG 0.0032 0.0000 0.0000 0.0000 0.0034 0.0000 0.0000
NaOCH3 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
1.0000 1.0000 1.0000 1.0001 1.0531
αL 25.6462
αH 1.0000 * θ must between αL and αH
Rm 0.0531 D/F 0.0588

R 0.0796
R/(R+1) 0.0738
Rm/(Rm+1) 0.0504
Nm/N 0.1600 * Obtained from Erbar-Maddox correlation

Nm 3.2493
N 20.3082 * theoretical stages
xHF 0.0553 xLW 0.0002 W 32.4474

xLF 0.0326 xHD 0.0047 D 2.0256
Ne/Ns 0.5065
Feed, Ne 6.8281 * Feed tray counted from the top
285

Stream
Component 22 23 25
TG 0.1098 0.0000 0.1098
ME-8 1.9078 0.0095 1.8983
ME-10 1.4561 0.0000 1.4561
ME-12 16.8325 0.0000 16.8325
ME-14 4.8340 0.0000 4.8340
ME-16 2.1701 0.0000 2.1701
ME-18 5.0285 0.0000 5.0285
GL 0.1125 0.0000 0.1125
MeOH 0.8966 0.8965 0.0001
Water 1.1252 1.1195 0.0056
NaOCH3 0.0000 0.0000 0.0000
Total 34.4730 2.0256 32.4474
Mass Flow (kg/hr)

TG 75.1795 0.0000 75.1795
ME-8 301.8882 1.5094 300.3788
ME-10 271.2653 0.0092 271.2561
ME-12 3,607.9541 0.0010 3,607.9531
ME-14 1,171.7570 0.0000 1,171.7570
ME-16 586.8939 0.0000 586.8939
ME-18 1,490.5149 0.0000 1,490.5149
GL 10.3561 0.0000 10.3561
MeOH 28.7275 28.7252 0.0023
Water 20.2708 20.1694 0.1014
NaOCH3 0.0023 0.0000 0.0023
Total 7,564.8094 50.4142 7,514.3952
286
below.

Distillate: Light Key ME-10 Recovery 99.50% Component ME-10 ME-12 Component ME-12 ME-10

Status Component
MeOH Water 0.0000 0.0001 0.0000 0.0001 0.0000 0.0000
Water ME-8 0.0002 0.0056 0.0016 0.0056 0.0000 0.0000
ME-8 ME-10 0.0585 1.8983 0.5523 1.8983 0.0000 0.0000
Light Key ME-10 ME-12 0.0449 1.4561 0.4215 1.4488 0.0003 0.0073
Heavy Key ME-12 GL 0.5188 16.8325 0.0245 0.0842 0.5773 16.7484
GL ME-14 0.0035 0.1125 0.0000 0.0000 0.0039 0.1125
ME-14 ME-16 0.1490 4.8340 0.0000 0.0000 0.1666 4.8340
ME-16 ME-18 0.0669 2.1701 0.0000 0.0000 0.0748 2.1701
ME-18 TG 0.1550 5.0285 0.0000 0.0000 0.1733 5.0285
TG NaOCH3 0.0034 0.1098 0.0000 0.0000 0.0038 0.1098
NaOCH3 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
1.0000 F= 32.4474 1.0000 D= 3.4369 1.0000 W= 29.0105
Top Condition
K reference, KR
ME-12 0.22443 0.45%

MeOH 0.0000 83.9681 374.1395 0.0000 0.0000
Water 0.0016 30.6208 136.4379 0.0000 0.0001
ME-8 0.5523 2.0504 9.1362 0.0605 0.2682
Light Key ME-10 0.4215 0.6734 3.0005 0.1405 0.6232
Heavy Key ME-12 0.0245 0.2244 1.0000 0.0245 0.1086
GL 0.0000 0.0424 0.1889 0.0000 0.0000
ME-14 0.0000 0.0780 0.3474 0.0000 0.0000
ME-16 0.0000 0.0271 0.1209 0.0000 0.0000
ME-18 0.0000 0.0111 0.0494 0.0000 0.0000
TG 0.0000 0.0000 0.0000 0.0000 0.0000
NaOCH3 0.0000 0.0000 0.0000 0.0000 0.0000
1.0000 0.22544 1.0000
287
Bottom Condition
Bottom Temperature 200 ℃ * Bubble point of bottoms
K reference, KR
ME-12 0.65882 1.42%

MeOH 0.0000 156.3670 237.3453 0.0000 0.0000
Water 0.0000 61.7120 93.6709 0.0000 0.0000
ME-8 0.0000 4.7609 7.2264 0.0000 0.0000
Light Key ME-10 0.0003 1.8159 2.7563 0.0007 0.0010
Heavy Key ME-12 0.5773 0.6588 1.0000 0.5773 0.8640
GL 0.0039 0.2200 0.3339 0.0013 0.0019
ME-14 0.1666 0.2580 0.3916 0.0652 0.0977
ME-16 0.0748 0.1023 0.1553 0.0116 0.0174
ME-18 0.1733 0.0456 0.0692 0.0120 0.0180
TG 0.0038 0.0001 0.0001 0.0000 0.0000
NaOCH3 0.0000 0.0000 0.0000 0.0000 0.0000
1.0000 0.66817 1.0000

αL,av 2.8758

xHD 0.0245 D 3.4369

xHW 0.5773 W 29.0105
Status Component αi,av (xiD*D) / (xiW*W) xiF*F xiD*D xiW*W
MeOH 297.9937 31456963345880400000000.0000 0.0001 0.0001 0.0000

Water 113.0498 1901402087778910000.0000 0.0056 0.0056 0.0000
ME-8 8.1254 6601109.5864 1.8983 1.8983 0.0000
Light Key ME-10
Heavy Key ME-12
GL 0.2512 0.0000 0.1125 0.0000 0.1125
ME-14 0.3688 0.0000 4.8340 0.0000 4.8340
ME-16 0.1371 0.0000 2.1701 0.0000 2.1701
ME-18 0.0585 0.0000 5.0285 0.0000 5.0285
TG 0.0001 0.0000 0.1098 0.0000 0.1098
NaOCH3 0.0000 0.0000 0.0000 0.0000 0.0000
288
Status Component
MeOH 0.0000 0.0001 0.0000 0.0001 0.0000 0.0000
Water 0.0002 0.0056 0.0016 0.0056 0.0000 0.0000
ME-8 0.0585 1.8983 0.5523 1.8983 0.0000 0.0000
Light Key ME-10 0.0449 1.4561 0.4215 1.4488 0.0003 0.0073
Heavy Key ME-12 0.5188 16.8325 0.0245 0.0842 0.5773 16.7484
GL 0.0035 0.1125 0.0000 0.0000 0.0039 0.1125
ME-14 0.1490 4.8340 0.0000 0.0000 0.1666 4.8340
ME-16 0.0669 2.1701 0.0000 0.0000 0.0748 2.1701
ME-18 0.1550 5.0285 0.0000 0.0000 0.1733 5.0285
TG 0.0034 0.1098 0.0000 0.0000 0.0038 0.1098
NaOCH3 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
1.0000 F = 32.4474 1.0000 D = 3.4369 1.0000 W = 29.0105

MeOH 0.0000 0.0000 117.0815 292.4131 0.0000 0.0000 0.0000
Water 0.0002 0.0016 44.5458 111.2540 0.0000 0.0002 0.0017
ME-8 0.0585 0.5523 3.2209 8.0442 0.0000 0.0841 0.7936
Light Key ME-10 0.0449 0.4215 1.1452 2.8602 0.0003 0.3099 2.9109
Heavy Key ME-12 0.5188 0.0245 0.4004 1.0000 0.5773 -0.3588 -0.0169
GL 0.0035 0.0000 0.1053 0.2630 0.0039 -0.0004 0.0000
ME-14 0.1490 0.0000 0.1483 0.3705 0.1666 -0.0266 0.0000
ME-16 0.0669 0.0000 0.0555 0.1385 0.0748 -0.0040 0.0000
ME-18 0.1550 0.0000 0.0237 0.0592 0.1733 -0.0038 0.0000
TG 0.0034 0.0000 0.0000 0.0001 0.0038 0.0000 0.0000
NaOCH3 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
1.0000 1.0000 1.0000 0.9995 3.6893
αL 2.8602
Rm 2.6893 D/F 0.1059
R 4.0340
R/(R+1) 0.8013
Rm/(Rm+1) 0.7289
Nm 10.0220
xHF 0.5188 xLW 0.0003 W 29.0105
xLF 0.0449 xHD 0.0245 D 3.4369
Ne/Ns 0.3892
289

Stream
Component 27 28 31
TG 0.1098 0.0000 0.1098
ME-8 1.8983 1.8983 0.0000
ME-10 1.4561 1.4488 0.0073
ME-12 16.8325 0.0842 16.7483
ME-14 4.8340 0.0000 4.8340
ME-16 2.1701 0.0000 2.1701
ME-18 5.0285 0.0000 5.0285
GL 0.1125 0.0000 0.1125
MeOH 0.0001 0.0001 0.0000
Water 0.0056 0.0056 0.0000
NaOCH3 0.0000 0.0000 0.0000
Total 32.4474 3.4369 29.0105
Mass Flow (kg/hr)

TG 75.1795 0.0000 75.1795
ME-8 300.3788 300.3787 0.0001
ME-10 271.2561 269.8998 1.3563
ME-12 3,607.9531 18.0398 3,589.9133
ME-14 1,171.7570 0.0004 1,171.7566
ME-16 586.8939 0.0000 586.8939
ME-18 1,490.5149 0.0000 1,490.5149
GL 10.3561 0.0000 10.3561
MeOH 0.0023 0.0023 0.0000
Water 0.1014 0.1014 0.0000
NaOCH3 0.0023 0.0000 0.0023
Total 7,514.3952 588.4223 6,925.9729
290
below.
Distillate: Light Key ME-14 Recovery 99.50% Component ME-14 ME-16 Component ME-16 ME-14

Status Component
MeOH Water 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
Water ME-8 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
ME-8 ME-10 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
ME-10 ME-12 0.0003 0.0073 0.0003 0.0073 0.0000 0.0000
ME-12 GL 0.5773 16.7484 0.7722 16.7484 0.0000 0.0000
GL ME-14 0.0039 0.1125 0.0052 0.1125 0.0000 0.0000
Light Key ME-14 ME-16 0.1666 4.8340 0.2218 4.8099 0.0033 0.0242
Heavy Key ME-16 ME-18 0.0748 2.1701 0.0005 0.0109 0.2949 2.1592
ME-18 TG 0.1733 5.0285 0.0000 0.0000 0.6868 5.0285
TG NaOCH3 0.0038 0.1098 0.0000 0.0000 0.0150 0.1098
NaOCH3 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
1.0000 F= 29.0105 1.0000 D= 21.6888 1.0000 W= 7.3217
Top Condition
K reference, KR
ME-16 0.19344 -1.38%
MeOH 0.0000 427.3983 2209.4194 0.0000 0.0000

Water 0.0000 161.7837 836.3350 0.0000 0.0000
ME-8 0.0000 11.5913 59.9208 0.0000 0.0000
ME-10 0.0003 4.0817 21.1003 0.0000 0.0001
ME-12 0.7722 1.4193 7.3370 0.1052 0.5517
GL 0.0052 0.3598 1.8600 0.0028 0.0146
Light Key ME-14 0.2218 0.5218 2.6972 0.0822 0.4310
Heavy Key ME-16 0.0005 0.1934 1.0000 0.0005 0.0026
ME-18 0.0000 0.0823 0.4252 0.0000 0.0000
TG 0.0000 0.0001 0.0005 0.0000 0.0000
NaOCH3 0.0000 0.0000 0.0000 0.0000 0.0000
1.0000 0.19077 1.0000
291
Bottom Condition
Bottom Temperature 212 ℃ * Bubble point of bottoms
K reference, KR
ME-16 0.61285 0.98%

MeOH 0.0000 738.5041 1205.0395 0.0000 0.0000
Water 0.0000 299.5392 488.7671 0.0000 0.0000
ME-8 0.0000 24.2323 39.5407 0.0000 0.0000
ME-10 0.0000 9.7501 15.9096 0.0000 0.0000
ME-12 0.0000 3.6269 5.9181 0.0000 0.0000
GL 0.0000 1.4105 2.3015 0.0000 0.0000
Light Key ME-14 0.0033 1.4802 2.4152 0.0080 0.0129
Heavy Key ME-16 0.2949 0.6128 1.0000 0.2949 0.4765
ME-18 0.6868 0.2820 0.4601 0.3160 0.5106
TG 0.0150 0.0007 0.0011 0.0000 0.0000
NaOCH3 0.0000 0.0000 0.0000 0.0000 0.0000
1.0000 0.61888 1.0000

αL,av 2.5523

xHD 0.0005 D 21.6888

xHW 0.2949 W 7.3217
Status Component αi,av (xiD*D) / (xiW*W) xiF*F xiD*D xiW*W
MeOH 1631.6978 9970747060358770000000000000000000.0000 0.0000 0.0000 0.0000

Water 639.3536 252021888777047000000000000000.0000 0.0000 0.0000 0.0000
ME-8 48.6755 58210767996388500.0000 0.0000 0.0000 0.0000
ME-10 18.3221 934742566787.9550 0.0073 0.0073 0.0000
ME-12 6.5895 8970351.4048 16.7484 16.7483 0.0000
GL 2.0690 18.5695 0.1125 0.1067 0.0057
Light Key ME-14
Heavy Key ME-16
ME-18 0.4423 0.0000 5.0285 0.0000 5.0285
TG 0.0007 0.0000 0.1098 0.0000 0.1098
NaOCH3 0.0000 0.0000 0.0000 0.0000 0.0000
292
Status Component
MeOH 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
Water 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
ME-8 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
ME-10 0.0003 0.0073 0.0003 0.0073 0.0000 0.0000
ME-12 0.5773 16.7484 0.7724 16.7483 0.0000 0.0000
GL 0.0039 0.1125 0.0049 0.1067 0.0008 0.0057
Light Key ME-14 0.1666 4.8340 0.2218 4.8099 0.0033 0.0242
Heavy Key ME-16 0.0748 2.1701 0.0005 0.0109 0.2947 2.1592
ME-18 0.1733 5.0285 0.0000 0.0000 0.6863 5.0285
TG 0.0038 0.1098 0.0000 0.0000 0.0150 0.1098
NaOCH3 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
1.0000 F = 29.0105 1.0000 D = 21.6830 1.0000 W = 7.3274

MeOH 0.0000 0.0000 572.3742 1592.2928 0.0000 0.0000 0.0000
Water 0.0000 0.0000 224.8299 625.4562 0.0000 0.0000 0.0000
ME-8 0.0000 0.0000 17.2019 47.8540 0.0000 0.0000 0.0000
ME-10 0.0003 0.0003 6.5015 18.0865 0.0000 0.0003 0.0004
ME-12 0.5773 0.7724 2.3481 6.5322 0.0000 0.6924 0.9264
GL 0.0039 0.0049 0.7620 2.1198 0.0008 0.0079 0.0101
Light Key ME-14 0.1666 0.2218 0.9129 2.5396 0.0033 0.2911 0.3875
Heavy Key ME-16 0.0748 0.0005 0.3595 1.0000 0.2947 -0.8724 -0.0058
ME-18 0.1733 0.0000 0.1593 0.4432 0.6863 -0.1195 0.0000
TG 0.0038 0.0000 0.0003 0.0008 0.0150 0.0000 0.0000
NaOCH3 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
1.0000 1.0000 1.0000 1.0002 1.3185
αL 2.5396
Rm 0.3185 D/F 0.7474

R 0.4777
R/(R+1) 0.3233
Rm/(Rm+1) 0.2416

Nm 11.2984
xHF 0.0748 xLW 0.0033 W 7.3274

xLF 0.1666 xHD 0.0005 D 21.6830
Ne/Ns 1.4747
293

Stream
Component 33 34 37
TG 0.1098 0.0000 0.1098
ME-8 0.0000 0.0000 0.0000
ME-10 0.0073 0.0073 0.0000
ME-12 16.7483 16.7483 0.0000
ME-14 4.8340 4.8099 0.0242
ME-16 2.1701 0.0109 2.1592
ME-18 5.0285 0.0000 5.0285
GL 0.1125 0.1123 0.0001
MeOH 0.0000 0.0000 0.0000
Water 0.0000 0.0000 0.0000
NaOCH3 0.0000 0.0000 0.0000
Total 29.0105 21.6886 7.3218
Mass Flow (kg/hr)

TG 75.1795 0.0000 75.1795
ME-8 0.0001 0.0001 0.0000
ME-10 1.3563 1.3563 0.0000
ME-12 3,589.9133 3,589.9129 0.0004
ME-14 1,171.7566 1,165.8978 5.8588
ME-16 586.8939 2.9345 583.9594
ME-18 1,490.5149 0.0006 1,490.5142
GL 10.3561 10.3423 0.0137
MeOH 0.0000 0.0000 0.0000
Water 0.0000 0.0000 0.0000
NaOCH3 0.0023 0.0000 0.0023
Total 6,925.9729 4,770.4446 2,155.5283
294
Appendix A. 3
A.3. 1 Calculation for streams’ energy balance
Streams‘ enthalpy can be calculated manually using the formula below.
( ) ∑( 98 ∫ )
98
where
98
or
98
Form 1:
(Felder & Rousseau, 2005)
Form 2:
(Green & Perry, 2008)
Heat capacity constants for each components at different phases
Cp constants for Liquid Cp constants for Gas
Component
A B C D A B C D
TG-8 101.84 2.3955 -8.00E-04 0.00E+00 14.433 2.499 -1.10E-03 0.00E+00
TG-10 85.094 3.0715 -1.20E-03 0.00E+00 -9.7909 3.1589 -1.50E-03 0.00E+00
TG-12 445.28 -0.2122 8.20E-03 -8.00E-06 445.28 -0.2132 8.20E-03 -8.00E-06
TG-14 523.24 -0.3279 9.60E-03 -9.00E-06 523.24 -0.3279 9.60E-03 -9.00E-06
TG-16 600.59 -0.4385 1.10E-02 -1.00E-05 600.59 -0.4385 1.10E-02 -1.00E-05
TG-18 -2.0406 5.1421 -2.30E-03 0.00E+00 -2.0406 5.1421 -2.30E-03 0.00E+00
ME-8 -281.54 3.61 -7.50E-03 6.00E-06 12.818 0.802 -3.00E-04 0.00E+00
ME-10 74.921 1.1424 -1.10E-03 1.00E-06 111.64 0.2406 1.40E-03 -1.00E-06
ME-12 224.15 0.5954 1.00E-04 2.00E-07 171.96 0.0416 2.10E-03 -2.00E-06
ME-14 272.79 0.2661 1.30E-03 -6.00E-07 193.01 0.0634 2.40E-03 -2.00E-06
ME-16 253.97 0.7071 5.00E-04 0.00E+00 218.3 0.0582 2.80E-03 -3.00E-06
ME-18 117.85 1.4462 -2.00E-04 0.00E+00 104.76 0.9514 1.00E-03 -1.00E-06
GL 141.67 0.0122 7.00E-04 -5.00E-07 78.698 -0.0514 8.00E-04 -7.00E-07
NaOCH3 29.273 0.0381 -7.00E-05 4.00E-08 29.311 0.0378 -7.00E-05 4.00E-08
MeOH -75.59 1.5126 -4.90E-03 6.00E-06 40.5 -0.0666 3.00E-04 -3.00E-07
Water -115.5 1.4197 -3.80E-03 4.00E-06 35.589 -0.0208 6.00E-05 -3.00E-08
Streams‘ enthalpy flow can be further calculated using the formula below.
̇ ( ) ( )
where
295
A.3.1. 1 Energy Balance for Stream MeOH
Stream MeOH * Stream name input

Pressure, P 760 mmHg
Temperature, T 25 ℃
298.15 K
Latent heat Stream
Heat of
* Boiling Point at P of MeOH
Component formation
vaporization Integrate(Cp,T@298,T) Molar Flow Enthalpy Enthalpy Flow
(K) (℃) kJ/kmol kJ/kmol kJ/kmol kmol/hr kJ/kmol kJ/hr kW
TG-8 655.90 382.75 -1575480 116000 0.00 0.0000 -1575480.00 0.00 0
TG-10 707.66 434.51 -1698720 124600 0.00 0.0000 -1698720.00 0.00 0
TG-12 741.29 468.14 -1821960 137700 0.00 0.0000 -1821960.00 0.00 0
TG-14 779.85 506.70 -1844000 147800 0.00 0.0000 -1844000.00 0.00 0
TG-16 798.53 525.38 -1945200 160800 0.00 0.0000 -1945200.00 0.00 0
TG-18 816.29 543.14 -2068440 167500 0.00 0.0000 -2068440.00 0.00 0
ME-8 739.47 466.32 -532850 44345 0.00 0.0000 -532850.00 0.00 0
ME-10 774.76 501.61 -574891 47315 0.00 0.0000 -574891.00 0.00 0
ME-12 812.90 539.75 -617400 50918 0.00 0.0000 -617400.00 0.00 0
ME-14 843.61 570.46 -643600 54440 0.00 0.0000 -643600.00 0.00 0
ME-16 872.57 599.42 -700700 57548 0.00 0.0000 -700700.00 0.00 0
ME-18 895.50 622.35 -626000 63625 0.00 0.0000 -626000.00 0.00 0
GL 560.60 287.45 -665900 65712 0.00 0.0000 -665900.00 0.00 0
MeOH 337.86 64.71 -238600 35141 0.00 35.2499 -238600.00 -8410622.36 -2336.28
Water 373.15 100.00 -285840 40812 0.00 0.0000 -285840.00 0.00 0
NaOCH3 2051.03 1777.88 -411000 170710 0.00 0.0000 -411000.00 0.00 0
Total 0.00 35.25 -16250581.00 -8410622.36 -2336.28
Manual Result -2336.28 kW
Simulation Result -2334.55 kW
Error -0.07%
296
A.3.1. 2 Energy Balance for Stream NaOCH3
Stream NaOCH3 * Stream name input

298.15 K
Latent heat Stream
Heat of
* Boiling Point at P of NaOCH3
Component formation
TG-8 655.90 382.75 -1575480 116000 0.00 0.0000 -1575480.00 0.00 0
TG-10 707.66 434.51 -1698720 124600 0.00 0.0000 -1698720.00 0.00 0
TG-12 741.29 468.14 -1821960 137700 0.00 0.0000 -1821960.00 0.00 0
TG-14 779.85 506.70 -1844000 147800 0.00 0.0000 -1844000.00 0.00 0
TG-16 798.53 525.38 -1945200 160800 0.00 0.0000 -1945200.00 0.00 0
TG-18 816.29 543.14 -2068440 167500 0.00 0.0000 -2068440.00 0.00 0
ME-8 739.47 466.32 -532850 44345 0.00 0.0000 -532850.00 0.00 0
ME-10 774.76 501.61 -574891 47315 0.00 0.0000 -574891.00 0.00 0
ME-12 812.90 539.75 -617400 50918 0.00 0.0000 -617400.00 0.00 0
ME-14 843.61 570.46 -643600 54440 0.00 0.0000 -643600.00 0.00 0
ME-16 872.57 599.42 -700700 57548 0.00 0.0000 -700700.00 0.00 0
ME-18 895.50 622.35 -626000 63625 0.00 0.0000 -626000.00 0.00 0
GL 560.60 287.45 -665900 65712 0.00 0.0000 -665900.00 0.00 0
MeOH 337.86 64.71 -238600 35141 0.00 0.0000 -238600.00 0.00 0
Water 373.15 100.00 -285840 40812 0.00 0.0000 -285840.00 0.00 0
NaOCH3 2051.03 1777.88 -411000 170710 0.00 1.3916 -411000.00 -571945.50 -158.874
Total 0.00 1.39 -16250581.00 -571945.50 -158.87
Error -16.80%
297
A.3.1. 3 Energy Balance for Stream TG
Stream TG * Stream name input

298.15 K
Latent heat Stream
Heat of
* Boiling Point at P of TG
Component formation
TG-8 655.90 382.75 -1575480 116000 0.00 0.7068 -1575480.00 -1113504.17 -309.307
TG-10 707.66 434.51 -1698720 124600 0.00 0.5042 -1698720.00 -856462.47 -237.906
TG-12 741.29 468.14 -1821960 137700 0.00 5.7148 -1821960.00 -10412100.95 -2892.25
TG-14 779.85 506.70 -1844000 147800 0.00 1.6310 -1844000.00 -3007493.25 -835.415
TG-16 798.53 525.38 -1945200 160800 0.00 0.7305 -1945200.00 -1420912.37 -394.698
TG-18 816.29 543.14 -2068440 167500 0.00 1.6911 -2068440.00 -3497974.96 -971.66
ME-8 739.47 466.32 -532850 44345 0.00 0.0000 -532850.00 0.00 0
ME-10 774.76 501.61 -574891 47315 0.00 0.0000 -574891.00 0.00 0
ME-12 812.90 539.75 -617400 50918 0.00 0.0000 -617400.00 0.00 0
ME-14 843.61 570.46 -643600 54440 0.00 0.0000 -643600.00 0.00 0
ME-16 872.57 599.42 -700700 57548 0.00 0.0000 -700700.00 0.00 0
ME-18 895.50 622.35 -626000 63625 0.00 0.0000 -626000.00 0.00 0
GL 560.60 287.45 -665900 65712 0.00 0.0000 -665900.00 0.00 0
MeOH 337.86 64.71 -238600 35141 0.00 0.0000 -238600.00 0.00 0
Water 373.15 100.00 -285840 40812 0.00 0.0000 -285840.00 0.00 0
NaOCH3 2051.03 1777.88 -411000 170710 0.00 0.0000 -411000.00 0.00 0
Total 0.00 10.98 -16250581.00 -20308448.18 -5641.24
Error 6.62%
298
A.3.1. 4 Energy Balance for Stream Water
Stream Water * Stream name input

298.15 K
Latent heat Stream
* Boiling Point at Heat of
of Water
Component P formation
TG-8 655.90 382.75 -1575480 116000 0.00 0.0000 -1575480.00 0.00 0
TG-10 707.66 434.51 -1698720 124600 0.00 0.0000 -1698720.00 0.00 0
TG-12 741.29 468.14 -1821960 137700 0.00 0.0000 -1821960.00 0.00 0
TG-14 779.85 506.70 -1844000 147800 0.00 0.0000 -1844000.00 0.00 0
TG-16 798.53 525.38 -1945200 160800 0.00 0.0000 -1945200.00 0.00 0
TG-18 816.29 543.14 -2068440 167500 0.00 0.0000 -2068440.00 0.00 0
ME-8 739.47 466.32 -532850 44345 0.00 0.0000 -532850.00 0.00 0
ME-10 774.76 501.61 -574891 47315 0.00 0.0000 -574891.00 0.00 0
ME-12 812.90 539.75 -617400 50918 0.00 0.0000 -617400.00 0.00 0
ME-14 843.61 570.46 -643600 54440 0.00 0.0000 -643600.00 0.00 0
ME-16 872.57 599.42 -700700 57548 0.00 0.0000 -700700.00 0.00 0
ME-18 895.50 622.35 -626000 63625 0.00 0.0000 -626000.00 0.00 0
GL 560.60 287.45 -665900 65712 0.00 0.0000 -665900.00 0.00 0
MeOH 337.86 64.71 -238600 35141 0.00 0.0000 -238600.00 0.00 0
Water 373.15 100.00 -285840 40812 0.00 485.2520 -285840.00 -138704431.68 -38529
NaOCH3 2051.03 1777.88 -411000 170710 0.00 0.0000 -411000.00 0.00 0
Total 0.00 485.25 -16250581.00 -138704431.68 -38529.01
Error -0.13%
299
A.3.1. 5 Energy Balance for Stream 1
Stream 1 * Stream name input

298.15 K
Latent heat Stream
Heat of
* Boiling Point at P of 1
Component formation
TG-8 661.56 388.41 -1575480 116000 0.00 0.0000 -1575480.00 0.00 0
TG-10 713.81 440.66 -1698720 124600 0.00 0.0000 -1698720.00 0.00 0
TG-12 747.39 474.24 -1821960 137700 0.00 0.0000 -1821960.00 0.00 0
TG-14 786.14 512.99 -1844000 147800 0.00 0.0000 -1844000.00 0.00 0
TG-16 804.59 531.44 -1945200 160800 0.00 0.0000 -1945200.00 0.00 0
TG-18 822.36 549.21 -2068440 167500 0.00 0.0000 -2068440.00 0.00 0
ME-8 746.63 473.48 -532850 44345 0.00 0.0000 -532850.00 0.00 0
ME-10 781.89 508.74 -574891 47315 0.00 0.0000 -574891.00 0.00 0
ME-12 820.97 547.82 -617400 50918 0.00 0.0000 -617400.00 0.00 0
ME-14 851.89 578.74 -643600 54440 0.00 0.0000 -643600.00 0.00 0
ME-16 881.19 608.04 -700700 57548 0.00 0.0000 -700700.00 0.00 0
ME-18 904.12 630.97 -626000 63625 0.00 0.0000 -626000.00 0.00 0
GL 568.39 295.24 -665900 65712 0.00 0.0000 -665900.00 0.00 0
MeOH 342.52 69.37 -238600 35141 0.00 35.2499 -238600.00 -8410622.36 -2336.28
Water 378.34 105.19 -285840 40812 0.00 0.0000 -285840.00 0.00 0
NaOCH3 2084.25 1811.10 -411000 170710 0.00 0.0000 -411000.00 0.00 0
Total 0.00 35.25 -16250581.00 -8410622.36 -2336.28
Error -0.08%
300

298.15 K
Latent heat Stream
Heat of
Component formation
TG-8 661.56 388.41 -1575480 116000 0.00 0.0000 -1575480.00 0.00 0
TG-10 713.81 440.66 -1698720 124600 0.00 0.0000 -1698720.00 0.00 0
TG-12 747.39 474.24 -1821960 137700 0.00 0.0000 -1821960.00 0.00 0
TG-14 786.14 512.99 -1844000 147800 0.00 0.0000 -1844000.00 0.00 0
TG-16 804.59 531.44 -1945200 160800 0.00 0.0000 -1945200.00 0.00 0
TG-18 822.36 549.21 -2068440 167500 0.00 0.0000 -2068440.00 0.00 0
ME-8 746.63 473.48 -532850 44345 0.00 0.0000 -532850.00 0.00 0
ME-10 781.89 508.74 -574891 47315 0.00 0.0000 -574891.00 0.00 0
ME-12 820.97 547.82 -617400 50918 0.00 0.0000 -617400.00 0.00 0
ME-14 851.89 578.74 -643600 54440 0.00 0.0000 -643600.00 0.00 0
ME-16 881.19 608.04 -700700 57548 0.00 0.0000 -700700.00 0.00 0
ME-18 904.12 630.97 -626000 63625 0.00 0.0000 -626000.00 0.00 0
GL 568.39 295.24 -665900 65712 0.00 0.0000 -665900.00 0.00 0
MeOH 342.52 69.37 -238600 35141 0.00 0.0000 -238600.00 0.00 0
Water 378.34 105.19 -285840 40812 0.00 0.0000 -285840.00 0.00 0
NaOCH3 2084.25 1811.10 -411000 170710 0.00 1.3916 -411000.00 -571945.50 -158.874
Total 0.00 1.39 -16250581.00 -571945.50 -158.87
Error -16.81%
301

298.15 K
Latent heat Stream
Heat of
Component formation
TG-8 661.56 388.41 -1575480 116000 0.00 0.7068 -1575480.00 -1113504.17 -309.307
TG-10 713.81 440.66 -1698720 124600 0.00 0.5042 -1698720.00 -856462.47 -237.906
TG-12 747.39 474.24 -1821960 137700 0.00 5.7148 -1821960.00 -10412100.95 -2892.25
TG-14 786.14 512.99 -1844000 147800 0.00 1.6310 -1844000.00 -3007493.25 -835.415
TG-16 804.59 531.44 -1945200 160800 0.00 0.7305 -1945200.00 -1420912.37 -394.698
TG-18 822.36 549.21 -2068440 167500 0.00 1.6911 -2068440.00 -3497974.96 -971.66
ME-8 746.63 473.48 -532850 44345 0.00 0.0000 -532850.00 0.00 0
ME-10 781.89 508.74 -574891 47315 0.00 0.0000 -574891.00 0.00 0
ME-12 820.97 547.82 -617400 50918 0.00 0.0000 -617400.00 0.00 0
ME-14 851.89 578.74 -643600 54440 0.00 0.0000 -643600.00 0.00 0
ME-16 881.19 608.04 -700700 57548 0.00 0.0000 -700700.00 0.00 0
ME-18 904.12 630.97 -626000 63625 0.00 0.0000 -626000.00 0.00 0
GL 568.39 295.24 -665900 65712 0.00 0.0000 -665900.00 0.00 0
MeOH 342.52 69.37 -238600 35141 0.00 0.0000 -238600.00 0.00 0
Water 378.34 105.19 -285840 40812 0.00 0.0000 -285840.00 0.00 0
NaOCH3 2084.25 1811.10 -411000 170710 0.00 0.0000 -411000.00 0.00 0
Total 0.00 10.98 -16250581.00 -20308448.18 -5641.24
Error 6.61%
302

315.15 K
Latent heat Stream
Heat of
Component formation
TG-8 661.56 388.41 -1575480 116000 12939.95 0.0000 -1562540.05 0.00 -5.6E-07
TG-10 713.81 440.66 -1698720 124600 15539.69 0.0000 -1683180.31 0.00 -4.3E-07
TG-12 747.39 474.24 -1821960 137700 15650.62 0.0000 -1806309.38 -0.02 -5.3E-06
TG-14 786.14 512.99 -1844000 147800 18120.80 0.0000 -1825879.20 -0.01 -1.5E-06
TG-16 804.59 531.44 -1945200 160800 20607.19 0.0000 -1924592.81 0.00 -7.2E-07
TG-18 822.36 549.21 -2068440 167500 23093.65 0.0000 -2045346.35 -0.01 -1.8E-06
ME-8 746.63 473.48 -532850 44345 4983.99 0.1860 -527866.01 -98196.10 -27.2767
ME-10 781.89 508.74 -574891 47315 5960.74 0.0394 -568930.26 -22442.06 -6.2339
ME-12 820.97 547.82 -617400 50918 7172.42 0.1357 -610227.58 -82802.32 -23.0006
ME-14 851.89 578.74 -643600 54440 7808.96 0.0121 -635791.04 -7707.53 -2.14098
ME-16 881.19 608.04 -700700 57548 8803.13 0.0017 -691896.87 -1161.23 -0.32256
ME-18 904.12 630.97 -626000 63625 9222.76 0.0015 -616777.24 -925.54 -0.25709
GL 568.39 295.24 -665900 65712 3345.99 0.0092 -662554.01 -6062.66 -1.68407
MeOH 342.52 69.37 -238600 35141 1708.66 65.8697 -236891.34 -15603960.58 -4334.43
Water 378.34 105.19 -285840 40812 1323.63 0.0000 -284516.37 0.00 0
NaOCH3 2084.25 1811.10 -411000 170710 603.95 0.0000 -410396.05 0.00 -8.5E-41
Total 156886.15 66.26 -16093694.85 -15823258.04 -4395.35
Error 0.43%
303

305.15 K
Latent heat Stream
Heat of
Component formation
TG-8 661.56 388.41 -1575480 116000 5261.52 0.7068 -1570218.48 -1109785.48 -308.274
TG-10 713.81 440.66 -1698720 124600 6316.91 0.5042 -1692403.09 -853277.61 -237.022
TG-12 747.39 474.24 -1821960 137700 6354.81 5.7148 -1815605.19 -10375784.61 -2882.16
TG-14 786.14 512.99 -1844000 147800 7355.83 1.6310 -1836644.17 -2995496.17 -832.082
TG-16 804.59 531.44 -1945200 160800 8363.35 0.7305 -1936836.65 -1414803.18 -393.001
TG-18 822.36 549.21 -2068440 167500 9378.47 1.6911 -2059061.53 -3482114.88 -967.254
ME-8 746.63 473.48 -532850 44345 2027.55 0.1860 -530822.45 -98746.07 -27.4295
ME-10 781.89 508.74 -574891 47315 2428.17 0.0394 -572462.83 -22581.40 -6.27261
ME-12 820.97 547.82 -617400 50918 2928.40 0.1357 -614471.60 -83378.20 -23.1606
ME-14 851.89 578.74 -643600 54440 3184.19 0.0121 -640415.81 -7763.59 -2.15655
ME-16 881.19 608.04 -700700 57548 3589.36 0.0017 -697110.64 -1169.98 -0.32499
ME-18 904.12 630.97 -626000 63625 3751.28 0.0015 -622248.72 -933.75 -0.25937
GL 568.39 295.24 -665900 65712 1367.25 0.0092 -664532.75 -6080.76 -1.6891
MeOH 342.52 69.37 -238600 35141 696.58 65.8697 -237903.42 -15670626.22 -4352.95
Water 378.34 105.19 -285840 40812 537.40 0.0000 -285302.60 0.00 0
NaOCH3 2084.25 1811.10 -411000 170710 248.46 1.3916 -410751.54 -571599.75 -158.778
Total 63789.53 78.63 -16186791.47 -36694141.65 -10192.82
Error 3.76%
304

333.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 27236.65 0.7068 -1548243.35 -1094254.09 -303.959
TG-10 707.66 434.51 -1698720 124600 32722.50 0.5042 -1665997.50 -839964.41 -233.323
TG-12 741.29 468.14 -1821960 137700 33031.99 5.7148 -1788928.01 -10223330.42 -2839.81
TG-14 779.85 506.70 -1844000 147800 38265.35 1.6310 -1805734.65 -2945083.94 -818.079
TG-16 798.53 525.38 -1945200 160800 43533.71 0.7305 -1901666.29 -1389112.26 -385.865
TG-18 816.29 543.14 -2068440 167500 48708.39 1.6911 -2019731.61 -3415603.37 -948.779
ME-8 739.47 466.32 -532850 44345 10472.26 0.1860 -522377.74 -97175.14 -26.9931
ME-10 774.76 501.61 -574891 47315 12507.43 0.0394 -562383.57 -22183.81 -6.16217
ME-12 812.90 539.75 -617400 50918 14992.98 0.1357 -602407.02 -81741.14 -22.7059
ME-14 843.61 570.46 -643600 54440 16363.01 0.0121 -627236.99 -7603.83 -2.11217
ME-16 872.57 599.42 -700700 57548 18446.21 0.0017 -682253.79 -1145.04 -0.31807
ME-18 895.50 622.35 -626000 63625 19403.85 0.0015 -606596.15 -910.26 -0.25285
GL 560.60 287.45 -665900 65712 6984.73 0.0092 -658915.27 -6029.36 -1.67482
MeOH 337.86 64.71 -238600 35141 3585.03 65.8697 -235014.97 -15480364.81 -4300.1
Water 373.15 100.00 -285840 40812 2793.47 0.0000 -283046.53 0.00 0
NaOCH3 2051.03 1777.88 -411000 170710 1245.28 1.3916 -409754.72 -570212.57 -158.392
Total 330292.85 78.63 -15920288.15 -36174714.45 -10048.53
Error 3.77%
305

333.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 27236.65 0.0071 -1548243.35 -10942.54 -3.03959
TG-10 707.66 434.51 -1698720 124600 32722.50 0.0050 -1665997.50 -8399.64 -2.33323
TG-12 741.29 468.14 -1821960 137700 33031.99 0.0571 -1788928.01 -102233.30 -28.3981
TG-14 779.85 506.70 -1844000 147800 38265.35 0.0163 -1805734.65 -29450.84 -8.18079
TG-16 798.53 525.38 -1945200 160800 43533.71 0.0073 -1901666.29 -13891.12 -3.85865
TG-18 816.29 543.14 -2068440 167500 48708.39 0.0169 -2019731.61 -34156.03 -9.48779
ME-8 739.47 466.32 -532850 44345 10472.26 2.0938 -522377.74 -1093772.70 -303.826
ME-10 774.76 501.61 -574891 47315 12507.43 1.4956 -562383.57 -841090.13 -233.636
ME-12 812.90 539.75 -617400 50918 14992.98 16.9682 -602407.02 -10221761.48 -2839.38
ME-14 843.61 570.46 -643600 54440 16363.01 4.8462 -627236.99 -3039685.49 -844.357
ME-16 872.57 599.42 -700700 57548 18446.21 2.1717 -682253.79 -1481675.09 -411.576
ME-18 895.50 622.35 -626000 63625 19403.85 5.0300 -606596.15 -3051177.90 -847.549
GL 560.60 287.45 -665900 65712 6984.73 10.8685 -658915.27 -7161420.65 -1989.28
MeOH 337.86 64.71 -238600 35141 3585.03 33.2642 -235014.97 -7817584.23 -2171.55
Water 373.15 100.00 -285840 40812 2793.47 0.0000 -283046.53 0.00 0
NaOCH3 2051.03 1777.88 -411000 170710 1245.28 1.3916 -409754.72 -570212.57 -158.392
Total 330292.85 78.24 -15920288.15 -35477453.73 -9854.85
Error 7.37%
306

393.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 79198.06 0.0071 -1496281.94 -10575.29 -2.93758
TG-10 707.66 434.51 -1698720 124600 95236.24 0.0050 -1603483.76 -8084.46 -2.24568
TG-12 741.29 468.14 -1821960 137700 97011.91 0.0571 -1724948.09 -98576.99 -27.3825
TG-14 779.85 506.70 -1844000 147800 112611.74 0.0163 -1731388.26 -28238.28 -7.84397
TG-16 798.53 525.38 -1945200 160800 128321.08 0.0073 -1816878.92 -13271.78 -3.6866
TG-18 816.29 543.14 -2068440 167500 142386.61 0.0169 -1926053.39 -32571.82 -9.04773
ME-8 739.47 466.32 -532850 44345 30116.68 2.0938 -502733.32 -1052640.54 -292.4
ME-10 774.76 501.61 -574891 47315 36063.80 1.4956 -538827.20 -805859.67 -223.85
ME-12 812.90 539.75 -617400 50918 42786.84 16.9682 -574613.16 -9750149.80 -2708.37
ME-14 843.61 570.46 -643600 54440 47102.49 4.8462 -596497.51 -2890717.35 -802.977
ME-16 872.57 599.42 -700700 57548 53056.75 2.1717 -647643.25 -1406510.13 -390.697
ME-18 895.50 622.35 -626000 63625 56399.96 5.0300 -569600.04 -2865087.48 -795.858
GL 560.60 287.45 -665900 65712 19855.68 10.8685 -646044.32 -7021532.73 -1950.43
MeOH 337.86 64.71 -238600 35141 3887.85 33.2642 -199571.55 -6638587.46 -1844.05
Water 373.15 100.00 -285840 40812 3263.32 0.0000 -241764.28 0.00 0
NaOCH3 2051.03 1777.88 -411000 170710 3392.40 1.3916 -407607.60 -567224.65 -157.562
Total 950691.42 78.24 -15223936.58 -33189628.46 -9219.34
Error 8.11%
307

393.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 79198.06 0.0000 -1496281.94 0.00 -6.4E-08
TG-10 707.66 434.51 -1698720 124600 95236.24 0.0000 -1603483.76 0.00 -4.9E-08
TG-12 741.29 468.14 -1821960 137700 97011.91 0.0000 -1724948.09 0.00 -6E-07
TG-14 779.85 506.70 -1844000 147800 112611.74 0.0000 -1731388.26 0.00 -1.7E-07
TG-16 798.53 525.38 -1945200 160800 128321.08 0.0000 -1816878.92 0.00 -8E-08
TG-18 816.29 543.14 -2068440 167500 142386.61 0.0000 -1926053.39 0.00 -2E-07
ME-8 739.47 466.32 -532850 44345 30116.68 0.0916 -502733.32 -46046.31 -12.7906
ME-10 774.76 501.61 -574891 47315 36063.80 0.0169 -538827.20 -9083.43 -2.52318
ME-12 812.90 539.75 -617400 50918 42786.84 0.0514 -574613.16 -29514.36 -8.19843
ME-14 843.61 570.46 -643600 54440 47102.49 0.0040 -596497.51 -2402.66 -0.6674
ME-16 872.57 599.42 -700700 57548 53056.75 0.0005 -647643.25 -303.61 -0.08434
ME-18 895.50 622.35 -626000 63625 56399.96 0.0004 -569600.04 -218.98 -0.06083
GL 560.60 287.45 -665900 65712 19855.68 0.0010 -646044.32 -635.08 -0.17641
MeOH 337.86 64.71 -238600 35141 3887.85 24.8557 -199571.55 -4960488.61 -1377.91
Water 373.15 100.00 -285840 40812 3263.32 0.0000 -241764.28 0.00 0
NaOCH3 2051.03 1777.88 -411000 170710 3392.40 0.0000 -407607.60 0.00 -5.8E-64
Total 950691.42 25.02 -15223936.58 -5048693.03 -1402.41
Error 1.77%
308

402.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 87549.20 0.0000 -1487930.80 0.00 -5.4E-07
TG-10 707.66 434.51 -1698720 124600 105286.70 0.0000 -1593433.30 0.00 -4.1E-07
TG-12 741.29 468.14 -1821960 137700 107402.32 0.0000 -1714557.68 -0.02 -5E-06
TG-14 779.85 506.70 -1844000 147800 124716.20 0.0000 -1719283.80 -0.01 -1.4E-06
TG-16 798.53 525.38 -1945200 160800 142152.36 0.0000 -1803047.64 0.00 -6.7E-07
TG-18 816.29 543.14 -2068440 167500 157497.71 0.0000 -1910942.29 -0.01 -1.6E-06
ME-8 739.47 466.32 -532850 44345 33224.42 0.1860 -499625.58 -92942.68 -25.8174
ME-10 774.76 501.61 -574891 47315 39827.04 0.0394 -535063.96 -21106.16 -5.86282
ME-12 812.90 539.75 -617400 50918 47190.55 0.1357 -570209.45 -77372.23 -21.4923
ME-14 843.61 570.46 -643600 54440 52020.49 0.0121 -591579.51 -7171.56 -1.9921
ME-16 872.57 599.42 -700700 57548 58584.68 0.0017 -642115.32 -1077.68 -0.29935
ME-18 895.50 622.35 -626000 63625 62351.71 0.0015 -563648.29 -845.81 -0.23495
GL 560.60 287.45 -665900 65712 21887.61 0.0092 -644012.39 -5892.99 -1.63694
MeOH 337.86 64.71 -238600 35141 4271.16 30.6198 -199188.24 -6099106.68 -1694.2
Water 373.15 100.00 -285840 40812 3577.60 0.0000 -241450.00 0.00 0
NaOCH3 2051.03 1777.88 -411000 170710 3715.23 0.0000 -407284.77 0.00 -8.4E-41
Total 1051254.98 31.01 -15123373.02 -6305515.82 -1751.53
Error -0.88%
309

333.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 27236.65 0.0000 -1548243.35 0.00 -5.6E-07
TG-10 707.66 434.51 -1698720 124600 32722.50 0.0000 -1665997.50 0.00 -4.3E-07
TG-12 741.29 468.14 -1821960 137700 33031.99 0.0000 -1788928.01 -0.02 -5.2E-06
TG-14 779.85 506.70 -1844000 147800 38265.35 0.0000 -1805734.65 -0.01 -1.5E-06
TG-16 798.53 525.38 -1945200 160800 43533.71 0.0000 -1901666.29 0.00 -7.1E-07
TG-18 816.29 543.14 -2068440 167500 48708.39 0.0000 -2019731.61 -0.01 -1.7E-06
ME-8 739.47 466.32 -532850 44345 10472.26 0.1860 -522377.74 -97175.14 -26.9931
ME-10 774.76 501.61 -574891 47315 12507.43 0.0394 -562383.57 -22183.81 -6.16217
ME-12 812.90 539.75 -617400 50918 14992.98 0.1357 -602407.02 -81741.14 -22.7059
ME-14 843.61 570.46 -643600 54440 16363.01 0.0121 -627236.99 -7603.83 -2.11217
ME-16 872.57 599.42 -700700 57548 18446.21 0.0017 -682253.79 -1145.04 -0.31807
ME-18 895.50 622.35 -626000 63625 19403.85 0.0015 -606596.15 -910.26 -0.25285
GL 560.60 287.45 -665900 65712 6984.73 0.0092 -658915.27 -6029.36 -1.67482
MeOH 337.86 64.71 -238600 35141 3585.03 30.6198 -235014.97 -7196114.37 -1998.92
Water 373.15 100.00 -285840 40812 2793.47 0.0000 -283046.53 0.00 0
NaOCH3 2051.03 1777.88 -411000 170710 1245.28 0.0000 -409754.72 0.00 -8.5E-41
Total 330292.85 31.01 -15920288.15 -7412903.00 -2059.14
Error 1.00%
310

333.15 K
Latent heat Stream
Heat of
Component formation
TG-8 661.56 388.41 -1575480 116000 27236.65 0.0000 -1548243.35 0.00 -5.6E-07
TG-10 713.81 440.66 -1698720 124600 32722.50 0.0000 -1665997.50 0.00 -4.3E-07
TG-12 747.39 474.24 -1821960 137700 33031.99 0.0000 -1788928.01 -0.02 -5.2E-06
TG-14 786.14 512.99 -1844000 147800 38265.35 0.0000 -1805734.65 -0.01 -1.5E-06
TG-16 804.59 531.44 -1945200 160800 43533.71 0.0000 -1901666.29 0.00 -7.1E-07
TG-18 822.36 549.21 -2068440 167500 48708.39 0.0000 -2019731.61 -0.01 -1.7E-06
ME-8 746.63 473.48 -532850 44345 10472.26 0.1860 -522377.74 -97175.14 -26.9931
ME-10 781.89 508.74 -574891 47315 12507.43 0.0394 -562383.57 -22183.81 -6.16217
ME-12 820.97 547.82 -617400 50918 14992.98 0.1357 -602407.02 -81741.14 -22.7059
ME-14 851.89 578.74 -643600 54440 16363.01 0.0121 -627236.99 -7603.83 -2.11217
ME-16 881.19 608.04 -700700 57548 18446.21 0.0017 -682253.79 -1145.04 -0.31807
ME-18 904.12 630.97 -626000 63625 19403.85 0.0015 -606596.15 -910.26 -0.25285
GL 568.39 295.24 -665900 65712 6984.73 0.0092 -658915.27 -6029.36 -1.67482
MeOH 342.52 69.37 -238600 35141 3585.03 30.6198 -235014.97 -7196114.37 -1998.92
Water 378.34 105.19 -285840 40812 2793.47 0.0000 -283046.53 0.00 0
NaOCH3 2084.25 1811.10 -411000 170710 1245.28 0.0000 -409754.72 0.00 -8.5E-41
Total 330292.85 31.01 -15920288.15 -7412903.00 -2059.14
Error 1.00%
311

393.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 79198.06 0.0071 -1496281.94 -10575.29 -2.93758
TG-10 707.66 434.51 -1698720 124600 95236.24 0.0050 -1603483.76 -8084.46 -2.24568
TG-12 741.29 468.14 -1821960 137700 97011.91 0.0571 -1724948.09 -98576.99 -27.3825
TG-14 779.85 506.70 -1844000 147800 112611.74 0.0163 -1731388.26 -28238.28 -7.84397
TG-16 798.53 525.38 -1945200 160800 128321.08 0.0073 -1816878.92 -13271.78 -3.6866
TG-18 816.29 543.14 -2068440 167500 142386.61 0.0169 -1926053.39 -32571.82 -9.04773
ME-8 739.47 466.32 -532850 44345 30116.68 2.0022 -502733.32 -1006594.24 -279.61
ME-10 774.76 501.61 -574891 47315 36063.80 1.4787 -538827.20 -796776.24 -221.327
ME-12 812.90 539.75 -617400 50918 42786.84 16.9168 -574613.16 -9720635.44 -2700.18
ME-14 843.61 570.46 -643600 54440 47102.49 4.8421 -596497.51 -2888314.70 -802.31
ME-16 872.57 599.42 -700700 57548 53056.75 2.1713 -647643.25 -1406206.53 -390.613
ME-18 895.50 622.35 -626000 63625 56399.96 5.0296 -569600.04 -2864868.49 -795.797
GL 560.60 287.45 -665900 65712 19855.68 10.8675 -646044.32 -7020897.66 -1950.25
MeOH 337.86 64.71 -238600 35141 3887.85 8.4085 -199571.55 -1678098.85 -466.139
Water 373.15 100.00 -285840 40812 3263.32 0.0000 -241764.28 0.00 0
NaOCH3 2051.03 1777.88 -411000 170710 3392.40 1.3916 -407607.60 -567224.65 -157.562
Total 950691.42 53.22 -15223936.58 -28140935.42 -7816.93
Error 9.15%
312

433.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 117393.25 0.0071 -1458086.75 -10305.34 -2.86259
TG-10 707.66 434.51 -1698720 124600 141199.95 0.0050 -1557520.05 -7852.72 -2.18131
TG-12 741.29 468.14 -1821960 137700 144727.46 0.0571 -1677232.54 -95850.15 -26.625
TG-14 779.85 506.70 -1844000 147800 168272.41 0.0163 -1675727.59 -27330.47 -7.5918
TG-16 798.53 525.38 -1945200 160800 191986.76 0.0073 -1753213.24 -12806.72 -3.55742
TG-18 816.29 543.14 -2068440 167500 211567.32 0.0169 -1856872.68 -31401.90 -8.72275
ME-8 739.47 466.32 -532850 44345 44230.95 2.0022 -488619.05 -978334.04 -271.759
ME-10 774.76 501.61 -574891 47315 53251.07 1.4787 -521639.93 -771361.03 -214.267
ME-12 812.90 539.75 -617400 50918 62841.22 16.9168 -554558.78 -9381378.79 -2605.94
ME-14 843.61 570.46 -643600 54440 69598.13 4.8421 -574001.87 -2779388.00 -772.052
ME-16 872.57 599.42 -700700 57548 78317.61 2.1713 -622382.39 -1351358.45 -375.377
ME-18 895.50 622.35 -626000 63625 83647.25 5.0296 -542352.75 -2727825.13 -757.729
GL 560.60 287.45 -665900 65712 29093.49 10.8675 -636806.51 -6920505.58 -1922.36
MeOH 337.86 64.71 -238600 35141 5608.89 8.4085 -197850.51 -1663627.48 -462.119
Water 373.15 100.00 -285840 40812 4668.30 0.0000 -240359.30 0.00 0
NaOCH3 2051.03 1777.88 -411000 170710 4827.75 1.3916 -406172.25 -565227.23 -157.008
Total 1411231.82 53.22 -14763396.18 -27324553.04 -7590.15
Error 8.78%
313

433.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 117393.25 0.0000 -1458086.75 0.00 -4.6E-07
TG-10 707.66 434.51 -1698720 124600 141199.95 0.0000 -1557520.05 0.00 -3.5E-07
TG-12 741.29 468.14 -1821960 137700 144727.46 0.0000 -1677232.54 -0.02 -4.3E-06
TG-14 779.85 506.70 -1844000 147800 168272.41 0.0000 -1675727.59 0.00 -1.2E-06
TG-16 798.53 525.38 -1945200 160800 191986.76 0.0000 -1753213.24 0.00 -5.8E-07
TG-18 816.29 543.14 -2068440 167500 211567.32 0.0000 -1856872.68 -0.01 -1.4E-06
ME-8 739.47 466.32 -532850 44345 44230.95 0.0944 -488619.05 -46141.64 -12.8171
ME-10 774.76 501.61 -574891 47315 53251.07 0.0226 -521639.93 -11782.95 -3.27304
ME-12 812.90 539.75 -617400 50918 62841.22 0.0843 -554558.78 -46764.28 -12.9901
ME-14 843.61 570.46 -643600 54440 69598.13 0.0081 -574001.87 -4646.43 -1.29067
ME-16 872.57 599.42 -700700 57548 78317.61 0.0012 -622382.39 -752.79 -0.20911
ME-18 895.50 622.35 -626000 63625 83647.25 0.0011 -542352.75 -605.35 -0.16815
GL 560.60 287.45 -665900 65712 29093.49 0.0082 -636806.51 -5201.06 -1.44474
MeOH 337.86 64.71 -238600 35141 5608.89 5.7641 -197850.51 -1140434.72 -316.787
Water 373.15 100.00 -285840 40812 4668.30 0.0000 -240359.30 0.00 0
NaOCH3 2051.03 1777.88 -411000 170710 4827.75 0.0000 -406172.25 0.00 -8.4E-41
Total 1411231.82 5.98 -14763396.18 -1256329.25 -348.98
Error -8.44%
314

433.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 117393.25 0.0071 -1458086.75 -10305.34 -2.86259
TG-10 707.66 434.51 -1698720 124600 141199.95 0.0050 -1557520.05 -7852.72 -2.18131
TG-12 741.29 468.14 -1821960 137700 144727.46 0.0571 -1677232.54 -95850.14 -26.625
TG-14 779.85 506.70 -1844000 147800 168272.41 0.0163 -1675727.59 -27330.47 -7.5918
TG-16 798.53 525.38 -1945200 160800 191986.76 0.0073 -1753213.24 -12806.71 -3.55742
TG-18 816.29 543.14 -2068440 167500 211567.32 0.0169 -1856872.68 -31401.89 -8.72275
ME-8 739.47 466.32 -532850 44345 44230.95 1.9078 -488619.05 -932192.39 -258.942
ME-10 774.76 501.61 -574891 47315 53251.07 1.4561 -521639.93 -759578.08 -210.994
ME-12 812.90 539.75 -617400 50918 62841.22 16.8325 -554558.78 -9334614.51 -2592.95
ME-14 843.61 570.46 -643600 54440 69598.13 4.8340 -574001.87 -2774741.58 -770.762
ME-16 872.57 599.42 -700700 57548 78317.61 2.1701 -622382.39 -1350605.66 -375.168
ME-18 895.50 622.35 -626000 63625 83647.25 5.0285 -542352.75 -2727219.78 -757.561
GL 560.60 287.45 -665900 65712 29093.49 10.8593 -636806.51 -6915304.52 -1920.92
MeOH 337.86 64.71 -238600 35141 5608.89 2.6444 -197850.51 -523192.76 -145.331
Water 373.15 100.00 -285840 40812 4668.30 0.0000 -240359.30 0.00 0
NaOCH3 2051.03 1777.88 -411000 170710 4827.75 1.3916 -406172.25 -565227.23 -157.008
Total 1411231.82 47.23 -14763396.18 -26068223.79 -7241.17
Error 9.48%
315

433.15 K
Latent heat Stream
Heat of
Component formation
TG-8 661.56 388.41 -1575480 116000 117393.25 0.0071 -1458086.75 -10305.34 -2.86259
TG-10 713.81 440.66 -1698720 124600 141199.95 0.0050 -1557520.05 -7852.72 -2.18131
TG-12 747.39 474.24 -1821960 137700 144727.46 0.0571 -1677232.54 -95850.14 -26.625
TG-14 786.14 512.99 -1844000 147800 168272.41 0.0163 -1675727.59 -27330.47 -7.5918
TG-16 804.59 531.44 -1945200 160800 191986.76 0.0073 -1753213.24 -12806.71 -3.55742
TG-18 822.36 549.21 -2068440 167500 211567.32 0.0169 -1856872.68 -31401.89 -8.72275
ME-8 746.63 473.48 -532850 44345 44230.95 1.9078 -488619.05 -932192.39 -258.942
ME-10 781.89 508.74 -574891 47315 53251.07 1.4561 -521639.93 -759578.08 -210.994
ME-12 820.97 547.82 -617400 50918 62841.22 16.8325 -554558.78 -9334614.51 -2592.95
ME-14 851.89 578.74 -643600 54440 69598.13 4.8340 -574001.87 -2774741.58 -770.762
ME-16 881.19 608.04 -700700 57548 78317.61 2.1701 -622382.39 -1350605.66 -375.168
ME-18 904.12 630.97 -626000 63625 83647.25 5.0285 -542352.75 -2727219.78 -757.561
GL 568.39 295.24 -665900 65712 29093.49 10.8593 -636806.51 -6915304.52 -1920.92
MeOH 342.52 69.37 -238600 35141 5608.89 2.6444 -197850.51 -523192.76 -145.331
Water 378.34 105.19 -285840 40812 4668.30 0.0000 -240359.30 0.00 0
NaOCH3 2084.25 1811.10 -411000 170710 4827.75 1.3916 -406172.25 -565227.23 -157.008
Total 1411231.82 47.23 -14763396.18 -26068223.79 -7241.17
Error 9.47%
316

323.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 19218.94 0.0071 -1556261.06 -10999.21 -3.05533
TG-10 707.66 434.51 -1698720 124600 23084.72 0.0050 -1675635.28 -8448.23 -2.34673
TG-12 741.29 468.14 -1821960 137700 23272.41 0.0571 -1798687.59 -102791.02 -28.5531
TG-14 779.85 506.70 -1844000 147800 26951.62 0.0163 -1817048.38 -29635.36 -8.23204
TG-16 798.53 525.38 -1945200 160800 30655.18 0.0073 -1914544.82 -13985.19 -3.88478
TG-18 816.29 543.14 -2068440 167500 34331.88 0.0169 -2034108.12 -34399.15 -9.55532
ME-8 739.47 466.32 -532850 44345 7397.60 1.9078 -525452.40 -1002463.43 -278.462
ME-10 774.76 501.61 -574891 47315 8840.60 1.4561 -566050.40 -824245.72 -228.957
ME-12 812.90 539.75 -617400 50918 10619.30 16.8325 -606780.70 -10213640.41 -2837.12
ME-14 843.61 570.46 -643600 54440 11573.99 4.8340 -632026.01 -3055231.93 -848.676
ME-16 872.57 599.42 -700700 57548 13047.71 2.1701 -687652.29 -1492245.11 -414.513
ME-18 895.50 622.35 -626000 63625 13695.02 5.0285 -612304.98 -3078974.45 -855.271
GL 560.60 287.45 -665900 65712 4950.88 10.8593 -660949.12 -7177477.56 -1993.74
MeOH 337.86 64.71 -238600 35141 2533.53 2.6444 -236066.47 -624250.43 -173.403
Water 373.15 100.00 -285840 40812 1968.20 0.0000 -283871.80 0.00 0
NaOCH3 2051.03 1777.88 -411000 170710 888.77 1.3916 -410111.23 -570708.69 -158.53
Total 233030.37 47.23 -16017550.63 -28239495.90 -7844.30
Error 8.72%
317

298.15 K
Latent heat Stream
of 19
TG-8 661.56 388.41 -1575480 116000 0.00 0.0000 -1575480.00 0.00 0
TG-10 713.81 440.66 -1698720 124600 0.00 0.0000 -1698720.00 0.00 0
TG-12 747.39 474.24 -1821960 137700 0.00 0.0000 -1821960.00 0.00 0
TG-14 786.14 512.99 -1844000 147800 0.00 0.0000 -1844000.00 0.00 0
TG-16 804.59 531.44 -1945200 160800 0.00 0.0000 -1945200.00 0.00 0
TG-18 822.36 549.21 -2068440 167500 0.00 0.0000 -2068440.00 0.00 0
ME-8 746.63 473.48 -532850 44345 0.00 0.0000 -532850.00 0.00 0
ME-10 781.89 508.74 -574891 47315 0.00 0.0000 -574891.00 0.00 0
ME-12 820.97 547.82 -617400 50918 0.00 0.0000 -617400.00 0.00 0
ME-14 851.89 578.74 -643600 54440 0.00 0.0000 -643600.00 0.00 0
ME-16 881.19 608.04 -700700 57548 0.00 0.0000 -700700.00 0.00 0
ME-18 904.12 630.97 -626000 63625 0.00 0.0000 -626000.00 0.00 0
GL 568.39 295.24 -665900 65712 0.00 0.0000 -665900.00 0.00 0
MeOH 342.52 69.37 -238600 35141 0.00 0.0000 -238600.00 0.00 0
Water 378.34 105.19 -285840 40812 0.00 485.2520 -285840.00 -138704431.68 -38529
NaOCH3 2084.25 1811.10 -411000 170710 0.00 0.0000 -411000.00 0.00 0
Total 0.00 485.25 -16250581.00 -138704431.68 -38529.01
Error -0.13%
318

323.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 19218.94 0.0071 -1556261.06 -10999.21 -3.05533
TG-10 707.66 434.51 -1698720 124600 23084.72 0.0050 -1675635.28 -8448.23 -2.34673
TG-12 741.29 468.14 -1821960 137700 23272.41 0.0571 -1798687.59 -102791.02 -28.5531
TG-14 779.85 506.70 -1844000 147800 26951.62 0.0163 -1817048.38 -29635.36 -8.23204
TG-16 798.53 525.38 -1945200 160800 30655.18 0.0073 -1914544.82 -13985.19 -3.88478
TG-18 816.29 543.14 -2068440 167500 34331.88 0.0169 -2034108.12 -34399.15 -9.55532
ME-8 739.47 466.32 -532850 44345 7397.60 1.9078 -525452.40 -1002463.90 -278.462
ME-10 774.76 501.61 -574891 47315 8840.60 1.4561 -566050.40 -824246.28 -228.957
ME-12 812.90 539.75 -617400 50918 10619.30 16.8325 -606780.70 -10213646.43 -2837.12
ME-14 843.61 570.46 -643600 54440 11573.99 4.8340 -632026.01 -3055233.20 -848.676
ME-16 872.57 599.42 -700700 57548 13047.71 2.1701 -687652.29 -1492245.80 -414.513
ME-18 895.50 622.35 -626000 63625 13695.02 5.0285 -612304.98 -3078975.68 -855.271
GL 560.60 287.45 -665900 65712 4950.88 0.1125 -660949.12 -74324.66 -20.6457
MeOH 337.86 64.71 -238600 35141 2533.53 0.8966 -236066.47 -211647.85 -58.7911
Water 373.15 100.00 -285840 40812 1968.20 1.1252 -283871.80 -319399.49 -88.7221
NaOCH3 2051.03 1777.88 -411000 170710 888.77 0.0000 -410111.23 -15.86 -0.00441
Total 233030.37 34.47 -16017550.63 -20472457.30 -5686.79
Error 11.76%
319

327.15 K
Latent heat Stream
Heat of
Component formation
TG-8 661.56 388.41 -1575480 116000 22403.57 0.0071 -1553076.43 -10976.70 -3.04908
TG-10 713.81 440.66 -1698720 124600 26912.42 0.0050 -1671807.58 -8428.94 -2.34137
TG-12 747.39 474.24 -1821960 137700 27145.23 0.0571 -1794814.77 -102569.70 -28.4916
TG-14 786.14 512.99 -1844000 147800 31440.34 0.0163 -1812559.66 -29562.15 -8.21171
TG-16 804.59 531.44 -1945200 160800 35764.00 0.0073 -1909436.00 -13947.88 -3.87441
TG-18 822.36 549.21 -2068440 167500 40038.87 0.0169 -2028401.13 -34302.64 -9.52851
ME-8 746.63 473.48 -532850 44345 8619.94 1.9078 -524230.06 -1000131.92 -277.814
ME-10 781.89 508.74 -574891 47315 10298.41 1.4561 -564592.59 -822123.50 -228.368
ME-12 820.97 547.82 -617400 50918 12360.07 16.8325 -605039.93 -10184344.92 -2828.98
ME-14 851.89 578.74 -643600 54440 13478.50 4.8340 -630121.50 -3046026.74 -846.119
ME-16 881.19 608.04 -700700 57548 15194.69 2.1701 -685505.31 -1487586.72 -413.219
ME-18 904.12 630.97 -626000 63625 15962.77 5.0285 -610037.23 -3067572.30 -852.103
GL 568.39 295.24 -665900 65712 5760.70 0.1125 -660139.30 -74233.59 -20.6204
MeOH 342.52 69.37 -238600 35141 2951.32 0.8966 -235648.68 -211273.28 -58.687
Water 378.34 105.19 -285840 40812 2295.70 1.1252 -283544.30 -319031.01 -88.6197
NaOCH3 2084.25 1811.10 -411000 170710 1031.32 0.0000 -409968.68 -15.86 -0.0044
Total 271657.83 34.47 -15978923.17 -20412127.83 -5670.04
Error 12.02%
320

364.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 53268.02 0.0071 -1522211.98 -10758.56 -2.99
TG-10 707.66 434.51 -1698720 124600 64032.75 0.0050 -1634687.25 -8241.78 -2.29
TG-12 741.29 468.14 -1821960 137700 64931.07 0.0571 -1757028.93 -100410.32 -27.89
TG-14 779.85 506.70 -1844000 147800 75293.33 0.0163 -1768706.67 -28846.92 -8.01
TG-16 798.53 525.38 -1945200 160800 85726.80 0.0073 -1859473.20 -13582.91 -3.77
TG-18 816.29 543.14 -2068440 167500 95549.00 0.0169 -1972891.00 -33363.90 -9.27
ME-8 739.47 466.32 -532850 44345 20379.77 1.9078 -512470.23 -977696.38 -271.58
ME-10 774.76 501.61 -574891 47315 24345.80 1.4561 -550545.20 -801668.59 -222.69
ME-12 812.90 539.75 -617400 50918 29017.16 16.8325 -588382.84 -9903964.12 -2751.10
ME-14 843.61 570.46 -643600 54440 31807.68 4.8340 -611792.32 -2957422.93 -821.51
ME-16 872.57 599.42 -700700 57548 35847.10 2.1701 -664852.90 -1442769.79 -400.77
ME-18 895.50 622.35 -626000 63625 37933.79 5.0285 -588066.21 -2957091.01 -821.41
GL 560.60 287.45 -665900 65712 13489.68 0.1125 -652410.32 -73364.46 -20.38
MeOH 337.86 64.71 -238600 35141 2669.70 0.8966 -200789.70 -180020.10 -50.01
Water 373.15 100.00 -285840 40812 5494.08 1.1252 -280345.92 -315432.34 -87.62
NaOCH3 2051.03 1777.88 -411000 170710 2353.24 0.0000 -408646.76 -15.81 0.00
Total 642138.98 34.47 -15573301.42 -19804649.91 -5501.29
Error 12.42%
321

332.15 K
Latent heat Stream
Heat of
Component formation
TG-8 635.20 362.05 -1575480 116000 26426.47 0.0000 -1549053.53 0.00 0.00
TG-10 685.24 412.09 -1698720 124600 31748.46 0.0000 -1666971.54 0.00 0.00
TG-12 718.98 445.83 -1821960 137700 32044.39 0.0000 -1789915.61 0.00 0.00
TG-14 756.84 483.69 -1844000 147800 37120.18 0.0000 -1806879.82 0.00 0.00
TG-16 776.32 503.17 -1945200 160800 42229.87 0.0000 -1902970.13 0.00 0.00
TG-18 793.99 520.84 -2068440 167500 47254.42 0.0000 -2021185.58 0.00 0.00
ME-8 714.46 441.31 -532850 44345 10162.00 0.0095 -522688.00 -4985.95 -1.38
ME-10 749.58 476.43 -574891 47315 12137.41 0.0000 -562753.59 -23.79 -0.01
ME-12 784.69 511.54 -617400 50918 14552.35 0.0000 -602847.65 -1.86 0.00
ME-14 814.56 541.41 -643600 54440 15879.94 0.0000 -627720.06 0.00 0.00
ME-16 842.36 569.21 -700700 57548 17901.70 0.0000 -682798.30 0.00 0.00
ME-18 865.10 591.95 -626000 63625 18827.05 0.0000 -607172.95 0.00 0.00
GL 534.11 260.96 -665900 65712 6779.94 0.0000 -659120.06 0.00 0.00
MeOH 321.22 48.07 -238600 35141 1357.22 0.8965 -202102.18 -181183.01 -50.33
Water 354.82 81.67 -285840 40812 2709.96 1.1195 -283130.04 -316972.07 -88.05
NaOCH3 1937.20 1664.05 -411000 170710 1209.61 0.0000 -409790.39 0.00 0.00
Total 318340.96 2.03 -15897099.44 -503166.68 -139.77
Error 11.06%
322

298.15 K
Latent heat Stream
Heat of
Component formation
TG-8 635.20 362.05 -1575480 116000 0.00 0.0000 -1575480.00 0.00 0.00
TG-10 685.24 412.09 -1698720 124600 0.00 0.0000 -1698720.00 0.00 0.00
TG-12 718.98 445.83 -1821960 137700 0.00 0.0000 -1821960.00 0.00 0.00
TG-14 756.84 483.69 -1844000 147800 0.00 0.0000 -1844000.00 0.00 0.00
TG-16 776.32 503.17 -1945200 160800 0.00 0.0000 -1945200.00 0.00 0.00
TG-18 793.99 520.84 -2068440 167500 0.00 0.0000 -2068440.00 0.00 0.00
ME-8 714.46 441.31 -532850 44345 0.00 0.0095 -532850.00 -5082.89 -1.41
ME-10 749.58 476.43 -574891 47315 0.00 0.0000 -574891.00 -24.30 -0.01
ME-12 784.69 511.54 -617400 50918 0.00 0.0000 -617400.00 -1.91 0.00
ME-14 814.56 541.41 -643600 54440 0.00 0.0000 -643600.00 0.00 0.00
ME-16 842.36 569.21 -700700 57548 0.00 0.0000 -700700.00 0.00 0.00
ME-18 865.10 591.95 -626000 63625 0.00 0.0000 -626000.00 0.00 0.00
GL 534.11 260.96 -665900 65712 0.00 0.0000 -665900.00 0.00 0.00
MeOH 321.22 48.07 -238600 35141 0.00 0.8965 -238600.00 -213903.01 -59.42
Water 354.82 81.67 -285840 40812 0.00 1.1195 -285840.00 -320005.95 -88.89
NaOCH3 1937.20 1664.05 -411000 170710 0.00 0.0000 -411000.00 0.00 0.00
Total 0.00 2.03 -16250581.00 -539018.06 -149.73
Error 5.86%
323

509.15 K
Latent heat Stream
Heat of
Component formation
TG-8 635.20 362.05 -1575480 116000 197383.93 0.0071 -1378096.07 -9739.99 -2.71
TG-10 685.24 412.09 -1698720 124600 237360.84 0.0050 -1461359.16 -7367.89 -2.05
TG-12 718.98 445.83 -1821960 137700 245607.23 0.0571 -1576352.77 -90085.08 -25.02
TG-14 756.84 483.69 -1844000 147800 286604.05 0.0163 -1557395.95 -25400.53 -7.06
TG-16 776.32 503.17 -1945200 160800 327906.52 0.0073 -1617293.48 -11813.86 -3.28
TG-18 793.99 520.84 -2068440 167500 356650.82 0.0169 -1711789.18 -28948.36 -8.04
ME-8 714.46 441.31 -532850 44345 73296.24 1.8983 -459553.76 -872358.06 -242.32
ME-10 749.58 476.43 -574891 47315 89253.80 1.4561 -485637.20 -707133.20 -196.43
ME-12 784.69 511.54 -617400 50918 104487.14 16.8325 -512912.86 -8633612.89 -2398.23
ME-14 814.56 541.41 -643600 54440 117037.74 4.8340 -526562.26 -2545418.19 -707.06
ME-16 842.36 569.21 -700700 57548 131392.36 2.1701 -569307.64 -1235430.96 -343.18
ME-18 865.10 591.95 -626000 63625 141007.07 5.0285 -484992.93 -2438787.03 -677.44
GL 534.11 260.96 -665900 65712 48132.17 0.1125 -617767.83 -69468.86 -19.30
MeOH 321.22 48.07 -238600 35141 8974.19 0.0001 -194485.21 -13.29 0.00
Water 354.82 81.67 -285840 40812 7402.69 0.0056 -237624.91 -1336.82 -0.37
NaOCH3 1937.20 1664.05 -411000 170710 7553.26 0.0000 -403446.74 -15.60 0.00
Total 2380050.03 32.45 -13794577.97 -16676930.61 -4632.48
Error 13.92%
324

509.15 K
Latent heat Stream
Heat of
Component formation
TG-8 645.08 371.93 -1575480 116000 197383.93 0.0071 -1378096.07 -9739.99 -2.71
TG-10 695.95 422.80 -1698720 124600 237360.84 0.0050 -1461359.16 -7367.89 -2.05
TG-12 729.64 456.49 -1821960 137700 245607.23 0.0571 -1576352.77 -90085.08 -25.02
TG-14 767.84 494.69 -1844000 147800 286604.05 0.0163 -1557395.95 -25400.53 -7.06
TG-16 786.95 513.80 -1945200 160800 327906.52 0.0073 -1617293.48 -11813.86 -3.28
TG-18 804.66 531.51 -2068440 167500 356650.82 0.0169 -1711789.18 -28948.36 -8.04
ME-8 726.19 453.04 -532850 44345 73296.24 1.8983 -459553.76 -872358.06 -242.32
ME-10 761.44 488.29 -574891 47315 89253.80 1.4561 -485637.20 -707133.20 -196.43
ME-12 797.92 524.77 -617400 50918 104487.14 16.8325 -512912.86 -8633612.89 -2398.23
ME-14 828.20 555.05 -643600 54440 117037.74 4.8340 -526562.26 -2545418.19 -707.06
ME-16 856.55 583.40 -700700 57548 131392.36 2.1701 -569307.64 -1235430.96 -343.18
ME-18 879.40 606.25 -626000 63625 141007.07 5.0285 -484992.93 -2438787.03 -677.44
GL 546.39 273.24 -665900 65712 48132.17 0.1125 -617767.83 -69468.86 -19.30
MeOH 329.05 55.90 -238600 35141 8974.19 0.0001 -194485.21 -13.29 0.00
Water 363.46 90.31 -285840 40812 7402.69 0.0056 -237624.91 -1336.82 -0.37
NaOCH3 1990.15 1717.00 -411000 170710 7553.26 0.0000 -403446.74 -15.60 0.00
Total 2380050.03 32.45 -13794577.97 -16676930.61 -4632.48
Error 13.92%
325

458.15 K
Latent heat Stream
Heat of
Component formation
TG-8 635.20 362.05 -1575480 116000 142655.00 0.0071 -1432825.00 -10126.80 -2.81
TG-10 685.24 412.09 -1698720 124600 171587.97 0.0050 -1527132.03 -7699.51 -2.14
TG-12 718.98 445.83 -1821960 137700 176504.27 0.0571 -1645455.73 -94034.16 -26.12
TG-14 756.84 483.69 -1844000 147800 205447.70 0.0163 -1638552.30 -26724.15 -7.42
TG-16 776.32 503.17 -1945200 160800 234602.11 0.0073 -1710597.89 -12495.42 -3.47
TG-18 793.99 520.84 -2068440 167500 257383.00 0.0169 -1811057.00 -30627.10 -8.51
ME-8 714.46 441.31 -532850 44345 53450.98 1.8983 -479399.02 -910029.74 -252.79
ME-10 749.58 476.43 -574891 47315 64603.26 1.4561 -510287.74 -743026.69 -206.40
ME-12 784.69 511.54 -617400 50918 76018.00 16.8325 -541382.00 -9112820.01 -2531.34
ME-14 814.56 541.41 -643600 54440 84510.23 4.8340 -559089.77 -2702657.19 -750.74
ME-16 842.36 569.21 -700700 57548 95028.04 2.1701 -605671.96 -1314343.67 -365.10
ME-18 865.10 591.95 -626000 63625 101712.70 5.0285 -524287.30 -2636378.77 -732.33
GL 534.11 260.96 -665900 65712 35140.42 0.1125 -630759.58 -70929.80 -19.70
MeOH 321.22 48.07 -238600 35141 6704.97 0.0001 -196754.43 -13.44 0.00
Water 354.82 81.67 -285840 40812 5557.84 0.0056 -239469.76 -1347.20 -0.37
NaOCH3 1937.20 1664.05 -411000 170710 5724.98 0.0000 -405275.02 -15.68 0.00
Total 1716631.47 32.45 -14457996.53 -17673269.34 -4909.24
Error 13.32%
326

431.15 K
Latent heat Stream
Heat of
Component formation
TG-8 615.77 342.62 -1575480 116000 115417.95 0.0000 -1460062.05 0.00 0.00
TG-10 664.19 391.04 -1698720 124600 138823.28 0.0000 -1559896.72 0.00 0.00
TG-12 697.97 424.82 -1821960 137700 142248.83 0.0000 -1679711.17 0.00 0.00
TG-14 735.14 461.99 -1844000 147800 165376.37 0.0000 -1678623.63 0.00 0.00
TG-16 755.30 482.15 -1945200 160800 188670.11 0.0000 -1756529.89 0.00 0.00
TG-18 772.88 499.73 -2068440 167500 207986.15 0.0000 -1860453.85 0.00 0.00
ME-8 692.41 419.26 -532850 44345 43506.75 1.8983 -489343.25 -928906.47 -258.03
ME-10 727.09 453.94 -574891 47315 52363.30 1.4488 -522527.70 -757044.97 -210.29
ME-12 759.86 486.71 -617400 50918 61808.69 0.0842 -555591.31 -46759.99 -12.99
ME-14 788.85 515.70 -643600 54440 68433.85 0.0000 -575166.15 -0.64 0.00
ME-16 815.67 542.52 -700700 57548 77011.77 0.0000 -623688.23 0.00 0.00
ME-18 838.02 564.87 -626000 63625 82236.31 0.0000 -543763.69 0.00 0.00
GL 511.73 238.58 -665900 65712 28618.85 0.0000 -637281.15 0.00 0.00
MeOH 306.37 33.22 -238600 35141 5521.82 0.0001 -197937.58 -13.52 0.00
Water 338.43 65.28 -285840 40812 4597.53 0.0056 -240430.07 -1352.60 -0.38
NaOCH3 1839.83 1566.68 -411000 170710 4755.96 0.0000 -406244.04 0.00 0.00
Total 1387377.51 3.44 -14787250.49 -1734078.20 -481.69
Error 11.49%
327

431.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 115417.95 0.0000 -1460062.05 0.00 0.00
TG-10 707.66 434.51 -1698720 124600 138823.28 0.0000 -1559896.72 0.00 0.00
TG-12 741.29 468.14 -1821960 137700 142248.83 0.0000 -1679711.17 0.00 0.00
TG-14 779.85 506.70 -1844000 147800 165376.37 0.0000 -1678623.63 0.00 0.00
TG-16 798.53 525.38 -1945200 160800 188670.11 0.0000 -1756529.89 0.00 0.00
TG-18 816.29 543.14 -2068440 167500 207986.15 0.0000 -1860453.85 0.00 0.00
ME-8 739.47 466.32 -532850 44345 43506.75 1.8983 -489343.25 -928906.47 -258.03
ME-10 774.76 501.61 -574891 47315 52363.30 1.4488 -522527.70 -757044.97 -210.29
ME-12 812.90 539.75 -617400 50918 61808.69 0.0842 -555591.31 -46759.99 -12.99
ME-14 843.61 570.46 -643600 54440 68433.85 0.0000 -575166.15 -0.64 0.00
ME-16 872.57 599.42 -700700 57548 77011.77 0.0000 -623688.23 0.00 0.00
ME-18 895.50 622.35 -626000 63625 82236.31 0.0000 -543763.69 0.00 0.00
GL 560.60 287.45 -665900 65712 28618.85 0.0000 -637281.15 0.00 0.00
MeOH 337.86 64.71 -238600 35141 5521.82 0.0001 -197937.58 -13.52 0.00
Water 373.15 100.00 -285840 40812 4597.53 0.0056 -240430.07 -1352.60 -0.38
NaOCH3 2051.03 1777.88 -411000 170710 4755.96 0.0000 -406244.04 0.00 0.00
Total 1387377.51 3.44 -14787250.49 -1734078.20 -481.69
Error 11.48%
328

298.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 0.00 0.0000 -1575480.00 0.00 0.00
TG-10 707.66 434.51 -1698720 124600 0.00 0.0000 -1698720.00 0.00 0.00
TG-12 741.29 468.14 -1821960 137700 0.00 0.0000 -1821960.00 0.00 0.00
TG-14 779.85 506.70 -1844000 147800 0.00 0.0000 -1844000.00 0.00 0.00
TG-16 798.53 525.38 -1945200 160800 0.00 0.0000 -1945200.00 0.00 0.00
TG-18 816.29 543.14 -2068440 167500 0.00 0.0000 -2068440.00 0.00 0.00
ME-8 739.47 466.32 -532850 44345 0.00 1.8983 -532850.00 -1011494.10 -280.97
ME-10 774.76 501.61 -574891 47315 0.00 1.4488 -574891.00 -832909.61 -231.36
ME-12 812.90 539.75 -617400 50918 0.00 0.0842 -617400.00 -51961.97 -14.43
ME-14 843.61 570.46 -643600 54440 0.00 0.0000 -643600.00 -0.71 0.00
ME-16 872.57 599.42 -700700 57548 0.00 0.0000 -700700.00 0.00 0.00
ME-18 895.50 622.35 -626000 63625 0.00 0.0000 -626000.00 0.00 0.00
GL 560.60 287.45 -665900 65712 0.00 0.0000 -665900.00 0.00 0.00
MeOH 337.86 64.71 -238600 35141 0.00 0.0001 -238600.00 -16.30 0.00
Water 373.15 100.00 -285840 40812 0.00 0.0056 -285840.00 -1608.07 -0.45
NaOCH3 2051.03 1777.88 -411000 170710 0.00 0.0000 -411000.00 0.00 0.00
Total 0.00 3.44 -16250581.00 -1897990.76 -527.22
Error 11.02%
329

499.15 K
Latent heat Stream
Heat of
Component formation
TG-8 615.77 342.62 -1575480 116000 186322.02 0.0071 -1389157.98 -9818.17 -2.73
TG-10 664.19 391.04 -1698720 124600 224075.04 0.0050 -1474644.96 -7434.88 -2.07
TG-12 697.97 424.82 -1821960 137700 231633.92 0.0571 -1590326.08 -90883.62 -25.25
TG-14 735.14 461.99 -1844000 147800 270157.49 0.0163 -1573842.51 -25668.76 -7.13
TG-16 755.30 482.15 -1945200 160800 308967.11 0.0073 -1636232.89 -11952.21 -3.32
TG-18 772.88 499.73 -2068440 167500 336593.36 0.0169 -1731846.64 -29287.56 -8.14
ME-8 692.41 419.26 -532850 44345 69285.93 0.0000 -463564.07 -0.13 0.00
ME-10 727.09 453.94 -574891 47315 84259.60 0.0073 -490631.40 -3572.03 -0.99
ME-12 759.86 486.71 -617400 50918 98733.45 16.7484 -518666.55 -8686809.59 -2413.00
ME-14 788.85 515.70 -643600 54440 110432.92 4.8340 -533167.08 -2577345.50 -715.93
ME-16 815.67 542.52 -700700 57548 124016.94 2.1701 -576683.06 -1251436.06 -347.62
ME-18 838.02 564.87 -626000 63625 133045.90 5.0285 -492954.10 -2478819.76 -688.56
GL 511.73 238.58 -665900 65712 45515.49 0.1125 -620384.51 -69763.11 -19.38
MeOH 306.37 33.22 -238600 35141 8526.88 0.0000 -194932.52 0.00 0.00
Water 338.43 65.28 -285840 40812 7037.61 0.0000 -237989.99 0.00 0.00
NaOCH3 1839.83 1566.68 -411000 170710 7195.11 0.0000 -403804.89 -15.62 0.00
Total 2245798.77 29.01 -13928829.23 -15242806.99 -4234.11
Error 14.06%
330

499.15 K
Latent heat Stream
Heat of
Component formation
TG-8 632.17 359.02 -1575480 116000 186322.02 0.0071 -1389157.98 -9818.17 -2.73
TG-10 681.96 408.81 -1698720 124600 224075.04 0.0050 -1474644.96 -7434.88 -2.07
TG-12 715.70 442.55 -1821960 137700 231633.92 0.0571 -1590326.08 -90883.62 -25.25
TG-14 753.46 480.31 -1844000 147800 270157.49 0.0163 -1573842.51 -25668.76 -7.13
TG-16 773.05 499.90 -1945200 160800 308967.11 0.0073 -1636232.89 -11952.21 -3.32
TG-18 790.71 517.56 -2068440 167500 336593.36 0.0169 -1731846.64 -29287.56 -8.14
ME-8 710.93 437.78 -532850 44345 69285.93 0.0000 -463564.07 -0.13 0.00
ME-10 746.00 472.85 -574891 47315 84259.60 0.0073 -490631.40 -3572.03 -0.99
ME-12 780.72 507.57 -617400 50918 98733.45 16.7484 -518666.55 -8686809.59 -2413.00
ME-14 810.45 537.30 -643600 54440 110432.92 4.8340 -533167.08 -2577345.50 -715.93
ME-16 838.09 564.94 -700700 57548 124016.94 2.1701 -576683.06 -1251436.06 -347.62
ME-18 860.78 587.63 -626000 63625 133045.90 5.0285 -492954.10 -2478819.76 -688.56
GL 530.47 257.32 -665900 65712 45515.49 0.1125 -620384.51 -69763.11 -19.38
MeOH 318.86 45.71 -238600 35141 8526.88 0.0000 -194932.52 0.00 0.00
Water 352.21 79.06 -285840 40812 7037.61 0.0000 -237989.99 0.00 0.00
NaOCH3 1921.43 1648.28 -411000 170710 7195.11 0.0000 -403804.89 -15.62 0.00
Total 2245798.77 29.01 -13928829.23 -15242806.99 -4234.11
Error 14.06%
331

471.15 K
Latent heat Stream
Heat of
Component formation
TG-8 615.77 342.62 -1575480 116000 156203.31 0.0071 -1419276.69 -10031.04 -2.79
TG-10 664.19 391.04 -1698720 124600 187879.18 0.0050 -1510840.82 -7617.37 -2.12
TG-12 697.97 424.82 -1821960 137700 193592.44 0.0571 -1628367.56 -93057.61 -25.85
TG-14 735.14 461.99 -1844000 147800 225475.72 0.0163 -1618524.28 -26397.51 -7.33
TG-16 755.30 482.15 -1945200 160800 257592.84 0.0073 -1687607.16 -12327.48 -3.42
TG-18 772.88 499.73 -2068440 167500 281961.25 0.0169 -1786478.75 -30211.45 -8.39
ME-8 692.41 419.26 -532850 44345 58371.72 0.0000 -474478.28 -0.14 0.00
ME-10 727.09 453.94 -574891 47315 70694.66 0.0073 -504196.34 -3670.79 -1.02
ME-12 759.86 486.71 -617400 50918 83070.00 16.7484 -534330.00 -8949146.55 -2485.87
ME-14 788.85 515.70 -643600 54440 92530.17 4.8340 -551069.83 -2663887.93 -739.97
ME-16 815.67 542.52 -700700 57548 104004.29 2.1701 -596695.71 -1294864.68 -359.68
ME-18 838.02 564.87 -626000 63625 111419.07 5.0285 -514580.93 -2587570.27 -718.77
GL 511.73 238.58 -665900 65712 38368.45 0.1125 -627531.55 -70566.80 -19.60
MeOH 306.37 33.22 -238600 35141 7279.92 0.0000 -196179.48 0.00 0.00
Water 338.43 65.28 -285840 40812 6024.13 0.0000 -239003.47 0.00 0.00
NaOCH3 1839.83 1566.68 -411000 170710 6191.37 0.0000 -404808.63 -15.66 0.00
Total 1880658.53 29.01 -14293969.47 -15749365.27 -4374.82
Error 13.66%
332

Pressure, P 50 mmHg
449.15 K
Latent heat Stream
Heat of
Component formation
TG-8 581.51 308.36 -1575480 116000 133439.76 0.0000 -1442040.24 0.00 0.00
TG-10 627.10 353.95 -1698720 124600 160504.35 0.0000 -1538215.65 0.00 0.00
TG-12 660.78 387.63 -1821960 137700 164897.33 0.0000 -1657062.67 0.00 0.00
TG-14 696.68 423.53 -1844000 147800 191858.69 0.0000 -1652141.31 0.00 0.00
TG-16 717.88 444.73 -1945200 160800 219015.69 0.0000 -1726184.31 0.00 0.00
TG-18 735.22 462.07 -2068440 167500 240667.11 0.0000 -1827772.89 0.00 0.00
ME-8 656.59 383.44 -532850 44345 50095.64 0.0000 -482754.36 -0.14 0.00
ME-10 689.89 416.74 -574891 47315 60461.87 0.0073 -514429.13 -3745.28 -1.04
ME-12 719.56 446.41 -617400 50918 71216.43 16.7483 -546183.57 -9147673.25 -2541.02
ME-14 746.86 473.71 -643600 54440 79064.95 4.8099 -564535.05 -2715334.32 -754.26
ME-16 772.14 498.99 -700700 57548 88929.20 0.0109 -611770.80 -6637.89 -1.84
ME-18 793.41 520.26 -626000 63625 95117.88 0.0000 -530882.12 -1.33 0.00
GL 477.12 203.97 -665900 65712 32939.17 0.1067 -632960.83 -67540.18 -18.76
MeOH 281.83 8.68 -238600 35141 6308.81 0.0000 -197150.59 0.00 0.00
Water 311.26 38.11 -285840 40812 5236.54 0.0000 -239791.06 0.00 0.00
NaOCH3 1687.11 1413.96 -411000 170710 5402.01 0.0000 -405597.99 0.00 0.00
Total 1605155.43 21.68 -14569472.57 -11940932.40 -3316.93
Error 12.68%
333

450.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 134456.99 0.0000 -1441023.01 0.00 0.00
TG-10 707.66 434.51 -1698720 124600 161727.92 0.0000 -1536992.08 0.00 0.00
TG-12 741.29 468.14 -1821960 137700 166177.81 0.0000 -1655782.19 0.00 0.00
TG-14 779.85 506.70 -1844000 147800 193357.25 0.0000 -1650642.75 0.00 0.00
TG-16 798.53 525.38 -1945200 160800 220734.02 0.0000 -1724465.98 0.00 0.00
TG-18 816.29 543.14 -2068440 167500 242512.19 0.0000 -1825927.81 0.00 0.00
ME-8 739.47 466.32 -532850 44345 50466.42 0.0000 -482383.58 -0.14 0.00
ME-10 774.76 501.61 -574891 47315 60918.98 0.0073 -513972.02 -3741.96 -1.04
ME-12 812.90 539.75 -617400 50918 71746.71 16.7483 -545653.29 -9138792.06 -2538.55
ME-14 843.61 570.46 -643600 54440 79665.68 4.8099 -563934.32 -2712444.87 -753.46
ME-16 872.57 599.42 -700700 57548 89602.21 0.0109 -611097.79 -6630.59 -1.84
ME-18 895.50 622.35 -626000 63625 95845.58 0.0000 -530154.42 -1.33 0.00
GL 560.60 287.45 -665900 65712 33182.40 0.1067 -632717.60 -67514.23 -18.75
MeOH 337.86 64.71 -238600 35141 6352.74 0.0000 -197106.66 0.00 0.00
Water 373.15 100.00 -285840 40812 5272.18 0.0000 -239755.42 0.00 0.00
NaOCH3 2051.03 1777.88 -411000 170710 5437.90 0.0000 -405562.10 0.00 0.00
Total 1617456.98 21.68 -14557171.02 -11929125.17 -3313.65
Error 12.76%
334

323.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 19218.94 0.0000 -1556261.06 0.00 0.00
TG-10 707.66 434.51 -1698720 124600 23084.72 0.0000 -1675635.28 0.00 0.00
TG-12 741.29 468.14 -1821960 137700 23272.41 0.0000 -1798687.59 0.00 0.00
TG-14 779.85 506.70 -1844000 147800 26951.62 0.0000 -1817048.38 0.00 0.00
TG-16 798.53 525.38 -1945200 160800 30655.18 0.0000 -1914544.82 0.00 0.00
TG-18 816.29 543.14 -2068440 167500 34331.88 0.0000 -2034108.12 0.00 0.00
ME-8 739.47 466.32 -532850 44345 7397.60 0.0000 -525452.40 -0.15 0.00
ME-10 774.76 501.61 -574891 47315 8840.60 0.0073 -566050.40 -4121.11 -1.14
ME-12 812.90 539.75 -617400 50918 10619.30 16.7483 -606780.70 -10162575.20 -2822.94
ME-14 843.61 570.46 -643600 54440 11573.99 4.8099 -632026.01 -3039956.33 -844.43
ME-16 872.57 599.42 -700700 57548 13047.71 0.0109 -687652.29 -7461.23 -2.07
ME-18 895.50 622.35 -626000 63625 13695.02 0.0000 -612304.98 -1.54 0.00
GL 560.60 287.45 -665900 65712 4950.88 0.1067 -660949.12 -70526.68 -19.59
MeOH 337.86 64.71 -238600 35141 2533.53 0.0000 -236066.47 0.00 0.00
Water 373.15 100.00 -285840 40812 1968.20 0.0000 -283871.80 0.00 0.00
NaOCH3 2051.03 1777.88 -411000 170710 888.77 0.0000 -410111.23 0.00 0.00
Total 233030.37 21.68 -16017550.63 -13284642.24 -3690.18
Error 11.72%
335

Pressure, P 50 mmHg
510.15 K
Latent heat Stream
Heat of
Component formation
TG-8 581.51 308.36 -1575480 116000 198498.84 0.0071 -1376981.16 -9732.11 -2.70
TG-10 627.10 353.95 -1698720 124600 238699.63 0.0050 -1460020.37 -7361.15 -2.04
TG-12 660.78 387.63 -1821960 137700 247015.23 0.0571 -1574944.77 -90004.62 -25.00
TG-14 696.68 423.53 -1844000 147800 288262.30 0.0163 -1555737.70 -25373.48 -7.05
TG-16 717.88 444.73 -1945200 160800 329817.02 0.0073 -1615382.98 -11799.90 -3.28
TG-18 735.22 462.07 -2068440 167500 358672.04 0.0169 -1709767.96 -28914.18 -8.03
ME-8 656.59 383.44 -532850 44345 73700.73 0.0000 -459149.27 0.00 0.00
ME-10 689.89 416.74 -574891 47315 89757.60 0.0000 -485133.40 0.00 0.00
ME-12 719.56 446.41 -617400 50918 105067.18 0.0000 -512332.82 -0.96 0.00
ME-14 746.86 473.71 -643600 54440 117704.39 0.0242 -525895.61 -12710.98 -3.53
ME-16 772.14 498.99 -700700 57548 132136.58 2.1592 -568563.42 -1227646.89 -341.01
ME-18 793.41 520.26 -626000 63625 141810.03 5.0285 -484189.97 -2434748.15 -676.32
GL 477.12 203.97 -665900 65712 30147.06 0.0057 -570040.84 -3275.60 -0.91
MeOH 281.83 8.68 -238600 35141 9018.96 0.0000 -194440.44 0.00 0.00
Water 311.26 38.11 -285840 40812 7439.30 0.0000 -237588.30 0.00 0.00
NaOCH3 1687.11 1413.96 -411000 170710 7589.07 0.0000 -403410.93 -15.60 0.00
Total 2375335.94 7.33 -13733579.96 -3851583.60 -1069.88
Error 16.48%
336

510.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 198498.84 0.0071 -1376981.16 -9732.11 -2.70
TG-10 707.66 434.51 -1698720 124600 238699.63 0.0050 -1460020.37 -7361.15 -2.04
TG-12 741.29 468.14 -1821960 137700 247015.23 0.0571 -1574944.77 -90004.62 -25.00
TG-14 779.85 506.70 -1844000 147800 288262.30 0.0163 -1555737.70 -25373.48 -7.05
TG-16 798.53 525.38 -1945200 160800 329817.02 0.0073 -1615382.98 -11799.90 -3.28
TG-18 816.29 543.14 -2068440 167500 358672.04 0.0169 -1709767.96 -28914.18 -8.03
ME-8 739.47 466.32 -532850 44345 73700.73 0.0000 -459149.27 0.00 0.00
ME-10 774.76 501.61 -574891 47315 89757.60 0.0000 -485133.40 0.00 0.00
ME-12 812.90 539.75 -617400 50918 105067.18 0.0000 -512332.82 -0.96 0.00
ME-14 843.61 570.46 -643600 54440 117704.39 0.0242 -525895.61 -12710.98 -3.53
ME-16 872.57 599.42 -700700 57548 132136.58 2.1592 -568563.42 -1227646.89 -341.01
ME-18 895.50 622.35 -626000 63625 141810.03 5.0285 -484189.97 -2434748.15 -676.32
GL 560.60 287.45 -665900 65712 48395.69 0.0057 -617504.31 -3548.33 -0.99
MeOH 337.86 64.71 -238600 35141 9018.96 0.0000 -194440.44 0.00 0.00
Water 373.15 100.00 -285840 40812 7439.30 0.0000 -237588.30 0.00 0.00
NaOCH3 2051.03 1777.88 -411000 170710 7589.07 0.0000 -403410.93 -15.60 0.00
Total 2393584.57 7.33 -13781043.43 -3851856.33 -1069.96
Error 16.46%
337

323.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 19218.94 0.0071 -1556261.06 -10999.21 -3.06
TG-10 707.66 434.51 -1698720 124600 23084.72 0.0050 -1675635.28 -8448.23 -2.35
TG-12 741.29 468.14 -1821960 137700 23272.41 0.0571 -1798687.59 -102791.02 -28.55
TG-14 779.85 506.70 -1844000 147800 26951.62 0.0163 -1817048.38 -29635.36 -8.23
TG-16 798.53 525.38 -1945200 160800 30655.18 0.0073 -1914544.82 -13985.19 -3.88
TG-18 816.29 543.14 -2068440 167500 34331.88 0.0169 -2034108.12 -34399.15 -9.56
ME-8 739.47 466.32 -532850 44345 7397.60 0.0000 -525452.40 0.00 0.00
ME-10 774.76 501.61 -574891 47315 8840.60 0.0000 -566050.40 0.00 0.00
ME-12 812.90 539.75 -617400 50918 10619.30 0.0000 -606780.70 -1.13 0.00
ME-14 843.61 570.46 -643600 54440 11573.99 0.0242 -632026.01 -15276.16 -4.24
ME-16 872.57 599.42 -700700 57548 13047.71 2.1592 -687652.29 -1484784.57 -412.44
ME-18 895.50 622.35 -626000 63625 13695.02 5.0285 -612304.98 -3078974.14 -855.27
GL 560.60 287.45 -665900 65712 4950.88 0.0057 -660949.12 -3797.98 -1.05
MeOH 337.86 64.71 -238600 35141 2533.53 0.0000 -236066.47 0.00 0.00
Water 373.15 100.00 -285840 40812 1968.20 0.0000 -283871.80 0.00 0.00
NaOCH3 2051.03 1777.88 -411000 170710 888.77 0.0000 -410111.23 -15.86 0.00
Total 233030.37 7.33 -16017550.63 -4783108.01 -1328.64
Error 13.71%
338

323.15 K
Latent heat Stream
of 40
TG-8 655.90 382.75 -1575480 116000 19218.94 0.0000 -1556261.06 0.00 -4.4E-19
TG-10 707.66 434.51 -1698720 124600 23084.72 0.0000 -1675635.28 0.00 -3.4E-19
TG-12 741.29 468.14 -1821960 137700 23272.41 0.0000 -1798687.59 0.00 -4.1E-18
TG-14 779.85 506.70 -1844000 147800 26951.62 0.0000 -1817048.38 0.00 -1.2E-18
TG-16 798.53 525.38 -1945200 160800 30655.18 0.0000 -1914544.82 0.00 -5.6E-19
TG-18 816.29 543.14 -2068440 167500 34331.88 0.0000 -2034108.12 0.00 -1.4E-18
ME-8 739.47 466.32 -532850 44345 7397.60 0.0000 -525452.40 0.00 -1E-12
ME-10 774.76 501.61 -574891 47315 8840.60 0.0000 -566050.40 0.00 -1.6E-13
ME-12 812.90 539.75 -617400 50918 10619.30 0.0000 -606780.70 0.00 -2.2E-13
ME-14 843.61 570.46 -643600 54440 11573.99 0.0000 -632026.01 0.00 -1.1E-14
ME-16 872.57 599.42 -700700 57548 13047.71 0.0000 -687652.29 0.00 -7.5E-16
ME-18 895.50 622.35 -626000 63625 13695.02 0.0000 -612304.98 0.00 -1.2E-16
GL 560.60 287.45 -665900 65712 4950.88 10.7469 -660949.12 -7103149.28 -1973.1
MeOH 337.86 64.71 -238600 35141 2533.53 1.7478 -236066.47 -412602.73 -114.612
Water 373.15 100.00 -285840 40812 1968.20 484.1268 -283871.80 -137429943.82 -38175
NaOCH3 2051.03 1777.88 -411000 170710 888.77 1.3916 -410111.23 -570692.69 -158.526
Total 233030.37 498.01 -16017550.63 -145516388.52 -40421.22
Error 0.66%
339

291.15 K
Latent heat Stream
of 41
TG-8 661.56 388.41 -1575480 116000 -5167.51 0.0000 -1580647.51 0.00 -4.4E-19
TG-10 713.81 440.66 -1698720 124600 -6201.47 0.0000 -1704921.47 0.00 -3.4E-19
TG-12 747.39 474.24 -1821960 137700 -6230.17 0.0000 -1828190.17 0.00 -4.2E-18
TG-14 786.14 512.99 -1844000 147800 -7209.02 0.0000 -1851209.02 0.00 -1.2E-18
TG-16 804.59 531.44 -1945200 160800 -8194.12 0.0000 -1953394.12 0.00 -5.7E-19
TG-18 822.36 549.21 -2068440 167500 -9193.71 0.0000 -2077633.71 0.00 -1.4E-18
ME-8 746.63 473.48 -532850 44345 -1991.39 0.0000 -534841.39 0.00 -1.1E-12
ME-10 781.89 508.74 -574891 47315 -2391.26 0.0000 -577282.26 0.00 -1.6E-13
ME-12 820.97 547.82 -617400 50918 -2893.69 0.0000 -620293.69 0.00 -2.2E-13
ME-14 851.89 578.74 -643600 54440 -3141.01 0.0000 -646741.01 0.00 -1.1E-14
ME-16 881.19 608.04 -700700 57548 -3540.10 0.0000 -704240.10 0.00 -7.7E-16
ME-18 904.12 630.97 -626000 63625 -3686.26 0.0000 -629686.26 0.00 -1.3E-16
GL 568.39 295.24 -665900 65712 -1352.74 10.7469 -667252.74 -7170893.56 -1991.91
MeOH 342.52 69.37 -238600 35141 -687.22 1.7478 -239287.22 -418232.04 -116.176
Water 378.34 105.19 -285840 40812 -526.59 484.1268 -286366.59 -138637741.00 -38510.5
NaOCH3 2084.25 1811.10 -411000 170710 -248.11 1.3916 -411248.11 -572274.74 -158.965
Total -62654.36 498.01 -16313235.36 -146799141.34 -40777.54
Error -0.21%
340

403.15 K
Latent heat Stream
of 42
TG-8 655.90 382.75 -1575480 116000 88485.89 0.0000 -1486994.11 0.00 -4.2E-19
TG-10 707.66 434.51 -1698720 124600 106413.98 0.0000 -1592306.02 0.00 -3.2E-19
TG-12 741.29 468.14 -1821960 137700 108569.36 0.0000 -1713390.64 0.00 -3.9E-18
TG-14 779.85 506.70 -1844000 147800 126076.31 0.0000 -1717923.69 0.00 -1.1E-18
TG-16 798.53 525.38 -1945200 160800 143706.98 0.0000 -1801493.02 0.00 -5.2E-19
TG-18 816.29 543.14 -2068440 167500 159193.25 0.0000 -1909246.75 0.00 -1.3E-18
ME-8 739.47 466.32 -532850 44345 33572.17 0.0000 -499277.83 0.00 -9.9E-13
ME-10 774.76 501.61 -574891 47315 40248.89 0.0000 -534642.11 0.00 -1.5E-13
ME-12 812.90 539.75 -617400 50918 47683.71 0.0000 -569716.29 0.00 -2E-13
ME-14 843.61 570.46 -643600 54440 52572.02 0.0000 -591027.98 0.00 -1E-14
ME-16 872.57 599.42 -700700 57548 59204.43 0.0000 -641495.57 0.00 -7E-16
ME-18 895.50 622.35 -626000 63625 63019.45 0.0000 -562980.55 0.00 -1.1E-16
GL 560.60 287.45 -665900 65712 22115.04 10.7469 -643784.96 -6918687.84 -1921.86
MeOH 337.86 64.71 -238600 35141 4313.90 1.7478 -199145.50 -348071.37 -96.6865
Water 373.15 100.00 -285840 40812 3612.58 484.1268 -241415.02 -116875481.99 -32465.4
NaOCH3 2051.03 1777.88 -411000 170710 3751.10 1.3916 -407248.90 -566709.60 -157.419
Total 1062539.05 498.01 -15112088.95 -124708950.80 -34641.38
Error -1.08%
341

403.15 K
Latent heat Stream
of 43
TG-8 655.90 382.75 -1575480 116000 88485.89 0.0000 -1486994.11 0.00 -1.2E-24
TG-10 707.66 434.51 -1698720 124600 106413.98 0.0000 -1592306.02 0.00 -9E-25
TG-12 741.29 468.14 -1821960 137700 108569.36 0.0000 -1713390.64 0.00 -1.1E-23
TG-14 779.85 506.70 -1844000 147800 126076.31 0.0000 -1717923.69 0.00 -3.1E-24
TG-16 798.53 525.38 -1945200 160800 143706.98 0.0000 -1801493.02 0.00 -1.5E-24
TG-18 816.29 543.14 -2068440 167500 159193.25 0.0000 -1909246.75 0.00 -3.6E-24
ME-8 739.47 466.32 -532850 44345 33572.17 0.0000 -499277.83 0.00 -7.7E-13
ME-10 774.76 501.61 -574891 47315 40248.89 0.0000 -534642.11 0.00 -7.3E-14
ME-12 812.90 539.75 -617400 50918 47683.71 0.0000 -569716.29 0.00 -4.3E-14
ME-14 843.61 570.46 -643600 54440 52572.02 0.0000 -591027.98 0.00 -7.3E-16
ME-16 872.57 599.42 -700700 57548 59204.43 0.0000 -641495.57 0.00 -1.5E-17
ME-18 895.50 622.35 -626000 63625 63019.45 0.0000 -562980.55 0.00 -8.7E-19
GL 560.60 287.45 -665900 65712 22115.04 0.1414 -643784.96 -91061.50 -25.2949
MeOH 337.86 64.71 -238600 35141 4313.90 1.7394 -199145.50 -346392.85 -96.2202
Water 373.15 100.00 -285840 40812 3612.58 476.9742 -241415.02 -115148743.35 -31985.8
NaOCH3 2051.03 1777.88 -411000 170710 3751.10 0.0000 -407248.90 0.00 -3.1E-54
Total 1062539.05 478.86 -15112088.95 -115586197.69 -32107.28
Error -2.04%
342

298.15 K
Latent heat Stream
of 44
TG-8 655.90 382.75 -1575480 116000 0.00 0.0000 -1575480.00 0.00 -1.2E-24
TG-10 707.66 434.51 -1698720 124600 0.00 0.0000 -1698720.00 0.00 -9.6E-25
TG-12 741.29 468.14 -1821960 137700 0.00 0.0000 -1821960.00 0.00 -1.2E-23
TG-14 779.85 506.70 -1844000 147800 0.00 0.0000 -1844000.00 0.00 -3.4E-24
TG-16 798.53 525.38 -1945200 160800 0.00 0.0000 -1945200.00 0.00 -1.6E-24
TG-18 816.29 543.14 -2068440 167500 0.00 0.0000 -2068440.00 0.00 -3.9E-24
ME-8 739.47 466.32 -532850 44345 0.00 0.0000 -532850.00 0.00 -8.3E-13
ME-10 774.76 501.61 -574891 47315 0.00 0.0000 -574891.00 0.00 -7.8E-14
ME-12 812.90 539.75 -617400 50918 0.00 0.0000 -617400.00 0.00 -4.6E-14
ME-14 843.61 570.46 -643600 54440 0.00 0.0000 -643600.00 0.00 -8E-16
ME-16 872.57 599.42 -700700 57548 0.00 0.0000 -700700.00 0.00 -1.6E-17
ME-18 895.50 622.35 -626000 63625 0.00 0.0000 -626000.00 0.00 -9.7E-19
GL 560.60 287.45 -665900 65712 0.00 0.1414 -665900.00 -94189.60 -26.1638
MeOH 337.86 64.71 -238600 35141 0.00 1.7394 -238600.00 -415019.83 -115.283
Water 373.15 100.00 -285840 40812 0.00 476.9742 -285840.00 -136338312.96 -37871.8
NaOCH3 2051.03 1777.88 -411000 170710 0.00 0.0000 -411000.00 0.00 -3.2E-54
Total 0.00 478.86 -16250581.00 -136847522.39 -38013.20
Error -0.76%
343

403.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 88485.89 0.0000 -1486994.11 0.00 -4.2E-19
TG-10 707.66 434.51 -1698720 124600 106413.98 0.0000 -1592306.02 0.00 -3.2E-19
TG-12 741.29 468.14 -1821960 137700 108569.36 0.0000 -1713390.64 0.00 -3.9E-18
TG-14 779.85 506.70 -1844000 147800 126076.31 0.0000 -1717923.69 0.00 -1.1E-18
TG-16 798.53 525.38 -1945200 160800 143706.98 0.0000 -1801493.02 0.00 -5.2E-19
TG-18 816.29 543.14 -2068440 167500 159193.25 0.0000 -1909246.75 0.00 -1.3E-18
ME-8 739.47 466.32 -532850 44345 33572.17 0.0000 -499277.83 0.00 -2.2E-13
ME-10 774.76 501.61 -574891 47315 40248.89 0.0000 -534642.11 0.00 -7.7E-14
ME-12 812.90 539.75 -617400 50918 47683.71 0.0000 -569716.29 0.00 -1.6E-13
ME-14 843.61 570.46 -643600 54440 52572.02 0.0000 -591027.98 0.00 -9.6E-15
ME-16 872.57 599.42 -700700 57548 59204.43 0.0000 -641495.57 0.00 -6.8E-16
ME-18 895.50 622.35 -626000 63625 63019.45 0.0000 -562980.55 0.00 -1.1E-16
GL 560.60 287.45 -665900 65712 22115.04 10.6054 -643784.96 -6827626.35 -1896.56
MeOH 337.86 64.71 -238600 35141 4313.90 0.0084 -199145.50 -1678.52 -0.46626
Water 373.15 100.00 -285840 40812 3612.58 7.1526 -241415.02 -1726738.64 -479.65
NaOCH3 2051.03 1777.88 -411000 170710 3751.10 1.3916 -407248.90 -566709.60 -157.419
Total 1062539.05 19.16 -15112088.95 -9122753.11 -2534.10
Error 9.70%
344

298.15 K
Latent heat Stream
Heat of
Component formation
TG-8 655.90 382.75 -1575480 116000 0.00 0.0000 -1575480.00 0.00 -4.4E-19
TG-10 707.66 434.51 -1698720 124600 0.00 0.0000 -1698720.00 0.00 -3.4E-19
TG-12 741.29 468.14 -1821960 137700 0.00 0.0000 -1821960.00 0.00 -4.1E-18
TG-14 779.85 506.70 -1844000 147800 0.00 0.0000 -1844000.00 0.00 -1.2E-18
TG-16 798.53 525.38 -1945200 160800 0.00 0.0000 -1945200.00 0.00 -5.7E-19
TG-18 816.29 543.14 -2068440 167500 0.00 0.0000 -2068440.00 0.00 -1.4E-18
ME-8 739.47 466.32 -532850 44345 0.00 0.0000 -532850.00 0.00 -2.3E-13
ME-10 774.76 501.61 -574891 47315 0.00 0.0000 -574891.00 0.00 -8.3E-14
ME-12 812.90 539.75 -617400 50918 0.00 0.0000 -617400.00 0.00 -1.7E-13
ME-14 843.61 570.46 -643600 54440 0.00 0.0000 -643600.00 0.00 -1E-14
ME-16 872.57 599.42 -700700 57548 0.00 0.0000 -700700.00 0.00 -7.5E-16
ME-18 895.50 622.35 -626000 63625 0.00 0.0000 -626000.00 0.00 -1.2E-16
GL 560.60 287.45 -665900 65712 0.00 10.6054 -665900.00 -7062166.22 -1961.71
MeOH 337.86 64.71 -238600 35141 0.00 0.0084 -238600.00 -2011.07 -0.55863
Water 373.15 100.00 -285840 40812 0.00 7.1526 -285840.00 -2044491.55 -567.914
NaOCH3 2051.03 1777.88 -411000 170710 0.00 1.3916 -411000.00 -571929.47 -158.869
Total 0.00 19.16 -16250581.00 -9680598.32 -2689.06
Error 7.14%
345
A.3. 2 Calculation for pumps’ energy balance
The power required by pump to deliver the fluid to a certain pressure, known as fluid power,
can be calculated using Bernoulli‘s equation as derived below.
where
Assumptions:
1. Since pumps are mostly used to maintain pressure and flow rate, then .
2. Same height or same level, .
3. No work loss, .
Simplifying,
( )
( ) ̇ ( )
where
∑[ ]
* Noted that will change with temperature which is considered in this calculation.
346
A.3.2. 1 Energy Balance for P-101
Temperature Pressure
Stream
℃ kPa
In MeOH 25 101.3250
Out 1 25 121.5900
Weight Average
Mass Flow Density
Component Frac. Density
kg/hr kg/kg kg/m3 kg/m3
TG-8 0.0000 1135.9170 0.0000
TG-10 0.0000 1693.6750 0.0000
TG-12 0.0000 1131.7290 0.0000
TG-14 0.0000 1802.9880 0.0000
TG-16 0.0000 1288.0210 0.0000
TG-18 0.0000 909.0465 0.0000
ME-8 0.0000 870.4749 0.0000
ME-10 0.0000 868.0052 0.0000
ME-12 0.0000 865.1342 0.0000
ME-14 0.0000 863.0826 0.0000
ME-16 0.0000 861.0490 0.0000
ME-18 0.0000 870.1786 0.0000
GL 0.0000 1258.0370 0.0000
MeOH 1129.4733 1.0000 789.5562 789.5562
Water 0.0000 994.6716 0.0000
NaOCH3 0.0000 1935.0350 0.0000
Total 1129.4733 1.0000 789.5562
Fluid Power
Manual Result 0.008053 kW
Simulation Result 0.008019 kW
Error -0.42%
347
Stream
℃ kPa
In NaOCH3 25 101.3250
Out 2 25 121.5900
Weight Average
Mass Flow Density
TG-8 0.0000 1135.9170 0.0000
TG-10 0.0000 1693.6750 0.0000
TG-12 0.0000 1131.7290 0.0000
TG-14 0.0000 1802.9880 0.0000
TG-16 0.0000 1288.0210 0.0000
TG-18 0.0000 909.0465 0.0000
ME-8 0.0000 870.4749 0.0000
ME-10 0.0000 868.0052 0.0000
ME-12 0.0000 865.1342 0.0000
ME-14 0.0000 863.0826 0.0000
ME-16 0.0000 861.0490 0.0000
ME-18 0.0000 870.1786 0.0000
GL 0.0000 1258.0370 0.0000
MeOH 0.0000 789.5562 0.0000
Water 0.0000 994.6716 0.0000
NaOCH3 81.3248 1.0000 1935.0350 1935.0350
Total 81.3248 1.0000 1935.0350
Fluid Power
Error 13.83%
348
Stream
℃ kPa
In TG 25 101.3250
Out 3 25 121.5900
Weight Average
Mass Flow Density
TG-8 332.6648 0.0442 1135.9170 50.1811
TG-10 279.7408 0.0371 1693.6750 62.9176
TG-12 3651.7520 0.4849 1131.7290 548.8204
TG-14 1179.4478 0.1566 1802.9880 282.3957
TG-16 589.7239 0.0783 1288.0210 100.8691
TG-18 1496.9915 0.1988 909.0465 180.7141
ME-8 0.0000 870.4749 0.0000
ME-10 0.0000 868.0052 0.0000
ME-12 0.0000 865.1342 0.0000
ME-14 0.0000 863.0826 0.0000
ME-16 0.0000 861.0490 0.0000
ME-18 0.0000 870.1786 0.0000
GL 0.0000 1258.0370 0.0000
MeOH 0.0000 789.5562 0.0000
Water 0.0000 994.6716 0.0000
NaOCH3 0.0000 1935.0350 0.0000
Total 7530.3209 1.0000 1225.8980
Fluid Power
Error 4.30%
349
Stream
℃ kPa
In Water 25 101.3250
Out 19 25 121.5900
Weight Average
Mass Flow Density
TG-8 0.0000 1135.9170 0.0000
TG-10 0.0000 1693.6750 0.0000
TG-12 0.0000 1131.7290 0.0000
TG-14 0.0000 1802.9880 0.0000
TG-16 0.0000 1288.0210 0.0000
TG-18 0.0000 909.0465 0.0000
ME-8 0.0000 870.4749 0.0000
ME-10 0.0000 868.0052 0.0000
ME-12 0.0000 865.1342 0.0000
ME-14 0.0000 863.0826 0.0000
ME-16 0.0000 861.0490 0.0000
ME-18 0.0000 870.1786 0.0000
GL 0.0000 1258.0370 0.0000
MeOH 0.0000 789.5562 0.0000
Water 8742.3000 1.0000 994.6716 994.6716
NaOCH3 0.0000 1935.0350 0.0000
Total 8742.3000 1.0000 994.6716
Fluid Power
Error 0.07%
350
Stream
℃ kPa
In 11 60 101.3250
Out 12 60 121.5900
Weight Average
Mass Flow Density
TG-8 0.0000 0.0000 1103.9530 0.0000
TG-10 0.0000 0.0000 1644.2070 0.0000
TG-12 0.0000 0.0000 1099.8880 0.0000
TG-14 0.0000 0.0000 1749.1790 0.0000
TG-16 0.0000 0.0000 1250.6590 0.0000
TG-18 0.0000 0.0000 885.0100 0.0000
ME-8 29.4362 0.0280 838.9597 23.4825
ME-10 7.3485 0.0070 840.6089 5.8737
ME-12 29.0846 0.0277 838.8745 23.1997
ME-14 2.9385 0.0028 836.5715 2.3375
ME-16 0.4539 0.0004 835.6723 0.3607
ME-18 0.4448 0.0004 845.1618 0.3575
GL 0.8427 0.0008 1234.9780 0.9896
MeOH 981.1170 0.9329 754.4104 703.8021
Water 0.0000 979.6066 0.0000
NaOCH3 0.0000 0.0000 1917.2360 0.0000
Total 1051.6661 1.0000 760.4033
Fluid Power
Error 1.98%
351
Stream
℃ kPa
In 16 160 101.3250
Out 17 160 121.5900
Weight Average
Mass Flow Density
TG-8 3.3266 0.0004 1008.8170 0.3870
TG-10 2.7974 0.0003 1498.1760 0.4833
TG-12 36.5175 0.0042 1006.1120 4.2368
TG-14 11.7945 0.0014 1591.8410 2.1651
TG-16 5.8972 0.0007 1141.5380 0.7763
TG-18 14.9699 0.0017 820.1045 1.4157
ME-8 301.8881 0.0348 739.8542 25.7565
ME-10 271.2651 0.0313 755.7998 23.6426
ME-12 3607.9519 0.4161 758.1992 315.4565
ME-14 1171.7565 0.1351 756.2574 102.1886
ME-16 586.8936 0.0677 758.9952 51.3681
ME-18 1490.5143 0.1719 769.9210 132.3359
GL 1000.0788 0.1153 1164.3620 134.2819
MeOH 84.7311 0.0098 627.1175 6.1276
Water 0.0000 908.6149 0.0000
NaOCH3 81.3248 0.0094 1866.5880 17.5052
Total 8671.7074 1.0000 818.1273
Fluid Power
Error 8.86%
352
Stream
℃ kPa
In 20 50 101.3250
Out 21 54 121.5900
Weight Average
Mass Flow Density
TG-8 3.3266 0.0004 1113.1470 0.4895
TG-10 2.7974 0.0004 1658.4170 0.6133
TG-12 36.5175 0.0048 1109.0310 5.3535
TG-14 11.7945 0.0016 1764.6120 2.7512
TG-16 5.8972 0.0008 1261.3730 0.9833
TG-18 14.9699 0.0020 891.8313 1.7648
ME-8 301.8882 0.0399 848.0984 33.8444
ME-10 271.2653 0.0359 848.5367 30.4270
ME-12 3607.9541 0.4769 846.4651 403.7058
ME-14 1171.7570 0.1549 844.2179 130.7636
ME-16 586.8939 0.0776 842.9890 65.3998
ME-18 1490.5149 0.1970 852.3690 167.9418
GL 10.3561 0.0014 1241.6440 1.6998
MeOH 28.7275 0.0038 764.7779 2.9042
Water 20.2708 0.0027 984.3816 2.6377
NaOCH3 0.0023 0.0000 1922.3180 0.0006
Total 7564.9331 1.0000 851.2804
Fluid Power
Error 7.68%
353
Stream
℃ kPa
In 25 236 50.6625
Out 26 236 70.9275
Weight Average
Mass Flow Density
TG-8 3.3266 0.0004 931.5603 0.4124
TG-10 2.7974 0.0004 1381.1400 0.5142
TG-12 36.5175 0.0049 931.2814 4.5256
TG-14 11.7945 0.0016 1467.6530 2.3036
TG-16 5.8972 0.0008 1055.5900 0.8284
TG-18 14.9699 0.0020 774.5786 1.5431
ME-8 300.3788 0.0400 649.6041 25.9667
ME-10 271.2574 0.0361 681.5630 24.6029
ME-12 3607.9534 0.4801 688.7186 330.6751
ME-14 1171.7570 0.1559 688.7949 107.4054
ME-16 586.8939 0.0781 694.9793 54.2788
ME-18 1490.5149 0.1984 707.5380 140.3411
GL 10.3561 0.0014 1104.6260 1.5223
MeOH 0.0022 0.0000 394.4131 0.0001
Water 0.1014 0.0000 819.7049 0.0111
NaOCH3 0.0023 0.0000 1828.2970 0.0005
Total 7514.5204 1.0000 694.9313
Fluid Power
Error 6.46%
354
Stream
℃ kPa
In 28 158 25.3313
Out 29 158 101.3250
Weight Average
Mass Flow Density
TG-8 0.0000 0.0000 1010.7840 0.0000
TG-10 0.0000 0.0000 1501.1760 0.0000
TG-12 0.0000 0.0000 1008.0350 0.0000
TG-14 0.0000 0.0000 1595.0490 0.0000
TG-16 0.0000 0.0000 1143.7600 0.0000
TG-18 0.0000 0.0000 821.3456 0.0000
ME-8 300.3787 0.5105 742.0095 378.7814
ME-10 269.9011 0.4587 757.6154 347.5070
ME-12 18.0398 0.0307 759.9142 23.2973
ME-14 0.0003 0.0000 757.9447 0.0003
ME-16 0.0000 0.0000 760.6019 0.0000
ME-18 0.0000 0.0000 771.4920 0.0000
GL 0.0000 0.0000 1165.8540 0.0000
MeOH 0.0022 0.0000 630.3344 0.0023
Water 0.1014 0.0002 910.4950 0.1568
NaOCH3 0.0000 0.0000 1867.5980 0.0000
Total 588.4234 1.0000 749.7452
Fluid Power
Error 2.92%
355
Stream
℃ kPa
In 31 226 25.3313
Out 32 226 45.5963
Weight Average
Mass Flow Density
TG-8 3.3266 0.0005 942.0319 0.4525
TG-10 2.7974 0.0004 1396.9100 0.5642
TG-12 36.5175 0.0053 941.3431 4.9632
TG-14 11.7945 0.0017 1484.2730 2.5276
TG-16 5.8972 0.0009 1067.0810 0.9086
TG-18 14.9699 0.0022 780.3906 1.6867
ME-8 0.0000 0.0000 662.6373 0.0000
ME-10 1.3563 0.0002 692.0221 0.1355
ME-12 3589.9136 0.5183 698.4190 362.0024
ME-14 1171.7567 0.1692 698.0984 118.1043
ME-16 586.8939 0.0847 703.7766 59.6356
ME-18 1490.5149 0.2152 716.0858 154.1036
GL 10.3561 0.0015 1112.8580 1.6640
MeOH 0.0000 0.0000 465.4186 0.0000
Water 0.0000 0.0000 833.5840 0.0000
NaOCH3 0.0023 0.0000 1833.3260 0.0006
Total 6926.0970 1.0000 706.7487
Fluid Power
Error 6.84%
356
Stream
℃ kPa
In 34 176 6.6661
Out 35 177 101.3250
Weight Average
Mass Flow Density
TG-8 0.0000 0.0000 992.9654 0.0000
TG-10 0.0000 0.0000 1474.0380 0.0000
TG-12 0.0000 0.0000 990.6516 0.0000
TG-14 0.0000 0.0000 1566.0770 0.0000
TG-16 0.0000 0.0000 1123.6910 0.0000
TG-18 0.0000 0.0000 810.2568 0.0000
ME-8 0.0000 0.0000 722.2783 0.0000
ME-10 1.3563 0.0003 741.0555 0.2107
ME-12 3589.9132 0.7526 744.2960 560.1672
ME-14 1165.8979 0.2444 742.6150 181.5149
ME-16 2.9345 0.0006 746.0129 0.4589
ME-18 0.0007 0.0000 757.2365 0.0001
GL 9.8269 0.0021 1152.2890 2.3739
MeOH 0.0000 0.0000 599.5708 0.0000
Water 0.0000 0.0000 892.8025 0.0000
NaOCH3 0.0000 0.0000 1858.5130 0.0000
Total 4769.9296 1.0000 744.7258
Fluid Power
Error 7.07%
357
Stream
℃ kPa
In 37 237 6.6661
Out 38 237 101.3250
Weight Average
Mass Flow Density
TG-8 3.3266 0.0015 930.5074 1.4356
TG-10 2.7974 0.0013 1379.5560 1.7898
TG-12 36.5175 0.0169 930.2712 15.7554
TG-14 11.7945 0.0055 1465.9850 8.0191
TG-16 5.8972 0.0027 1054.4370 2.8839
TG-18 14.9699 0.0069 774.0003 5.3738
ME-8 0.0000 0.0000 648.2755 0.0000
ME-10 0.0000 0.0000 680.5030 0.0000
ME-12 0.0004 0.0000 687.7374 0.0001
ME-14 5.8588 0.0027 687.8561 1.8691
ME-16 583.9594 0.2708 694.0923 187.9825
ME-18 1490.5141 0.6913 706.6766 488.5110
GL 0.5292 0.0002 1103.7960 0.2709
MeOH 0.0000 0.0000 381.5928 0.0000
Water 0.0000 0.0000 818.2748 0.0000
NaOCH3 0.0023 0.0000 1827.7940 0.0019
Total 2156.1674 1.0000 713.8931
Fluid Power
Error 5.79%
358
Stream
℃ kPa
In 40 50 101.3250
Out 41 18 121.5900
Weight Average
Mass Flow Density
TG-8 0.0000 0.0000 1113.1470 0.0000
TG-10 0.0000 0.0000 1658.4170 0.0000
TG-12 0.0000 0.0000 1109.0310 0.0000
TG-14 0.0000 0.0000 1764.6120 0.0000
TG-16 0.0000 0.0000 1261.3730 0.0000
TG-18 0.0000 0.0000 891.8313 0.0000
ME-8 0.0000 0.0000 848.0984 0.0000
ME-10 0.0000 0.0000 848.5367 0.0000
ME-12 0.0000 0.0000 846.4651 0.0000
ME-14 0.0000 0.0000 844.2179 0.0000
ME-16 0.0000 0.0000 842.9890 0.0000
ME-18 0.0000 0.0000 852.3690 0.0000
GL 989.7222 0.1005 1241.6440 124.7714
MeOH 56.0036 0.0057 764.7779 4.3487
Water 8722.0284 0.8856 984.3816 871.7370
NaOCH3 81.3225 0.0083 1922.3180 15.8723
Total 9849.0768 1.0000 1016.7293
Fluid Power
Error -1.68%
359
A.3. 3 Calculation for reactor energy balance
The energy balances are calculated based on selected conversion from Level 3 Decision
which is X = 0.99. The energy balances for the transesterification process are visualized in
Figure 2-13.
TG
TG MeOH
MeOH Δ NaOCH3
NaOCH3 ME
T K GL
m T K
Δ ˚R Δ ˚P
TG
MeOH
NaOCH3
ME
GL
TG
MeOH
NaOCH3 Δ ˚ 98 K
Calculation Path for Transesterification of Triglyceride to Methyl Ester
˚ 98 K [ ]
[ ]
Reactants
TG:
98 K
∫ T
K
m
MeOH:
360
98 K
∫ T
K
m
Products
TG:
K
∫ T
98 K
m
MeOH:
K
∫ T
98 K
m
ME:
K
∫ T
98 K
m
GL:
K
∫ T
98 K
Calculation for energy balances at 60°C and 1 atm

Fin Hin Fout Hout
Component
(kgmol/hr) (kJ/mol) (kgmol/hr) (kJ/mol)
TG 10.9783 -50.3297 0.1098 50.3297
MeOH 65.8697 -3.0025 33.2642 3.0025
ME - - 32.6055 16.9838
GL - - 10.8685 9.2285
∑ ( )( )
( )( )
361
∑ ( )( )
( )( )
( )( )
( )( )
Therefore,
̇ ̇ ˚ 98 K ∑ ∑
where ̇ m (amount of triglyceride converted).
̇ ( )( )
̇ ̇ ̇ ̇ ̇
̇ ̇
Thus, 38.8328 kW of heat energy must be supplied to the reactor to maintain the reaction temperature at 60°C.
362
Appendix A. 4
A.4. 1 Aspen stream table results
363
Units MEOH NAOCH3 TG WATER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
From P-101 P-102 P-103 M-101 M-102 E-101 R-100 E-102 C-101 M-103 E-103 P-105 C-101 E-104 C-102 C-102
To P-101 P-102 P-103 P-104 M-101 M-102 M-102 M-102 E-101 R-100 E-102 C-101 M-103 E-103 P-105 M-101 E-104 C-102 M-103 P-106
Phase: Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Mixed Vapor Mixed Liquid Liquid Liquid Mixed Vapor Liquid
Component Mole Flow
TG-8 KMOL/HR 0 0 0.707003 0 0 0 0.707003 1.70E-08 0.707003 0.707003 0.00707 0.00707 2.14E-09 1.70E-08 1.70E-08 1.70E-08 0.00707 0.00707 1.49E-08 0.00707
TG-10 KMOL/HR 0 0 0.503904 0 0 0 0.503904 8.88E-10 0.503904 0.503904 0.005039 0.005039 7.20E-11 8.88E-10 8.88E-10 8.88E-10 0.005039 0.005039 8.19E-10 0.005039
TG-12 KMOL/HR 0 0 5.715303 0 0 0 5.715303 7.15E-10 5.715303 5.715303 0.057153 0.057153 3.44E-11 7.15E-10 7.15E-10 7.15E-10 0.057153 0.057153 6.82E-10 0.057153
TG-14 KMOL/HR 0 0 1.631375 0 0 0 1.631375 1.33E-11 1.631375 1.631375 0.016314 0.016314 3.88E-13 1.33E-11 1.33E-11 1.33E-11 0.016314 0.016314 1.30E-11 0.016314
TG-16 KMOL/HR 0 0 0.730057 0 0 0 0.730057 5.59E-13 0.730057 0.730057 0.007301 0.007301 1.01E-14 5.59E-13 5.59E-13 5.59E-13 0.007301 0.007301 5.50E-13 0.007301
TG-18 KMOL/HR 0 0 1.690658 0 0 0 1.690658 5.03E-05 1.690709 1.690709 0.016907 0.016907 3.48E-05 5.03E-05 5.03E-05 5.03E-05 0.016872 0.016872 1.70E-05 0.016855
ME-8 KMOL/HR 0 0 0 0 0 0 0 0.19482 0.19482 0.19482 2.294617 2.294617 0.103239 0.19482 0.19482 0.19482 2.191378 2.191378 0.095505 2.095873
ME-10 KMOL/HR 0 0 0 0 0 0 0 0.038789 0.038789 0.038789 1.535383 1.535383 0.017971 0.038789 0.038789 0.038789 1.517412 1.517412 0.021558 1.495854
ME-12 KMOL/HR 0 0 0 0 0 0 0 0.129682 0.129682 0.129682 17.10413 17.10413 0.052807 0.129682 0.129682 0.129682 17.05132 17.05132 0.0791 16.97222
ME-14 KMOL/HR 0 0 0 0 0 0 0 0.01131 0.01131 0.01131 4.856494 4.856494 0.004002 0.01131 0.01131 0.01131 4.852493 4.852493 0.007478 4.845015
ME-16 KMOL/HR 0 0 0 0 0 0 0 0.001601 0.001601 0.001601 2.16987 2.16987 0.000489 0.001601 0.001601 0.001601 2.169381 2.169381 0.001132 2.168248
ME-18 KMOL/HR 0 0 0 0 0 0 0 0.00122 0.00122 0.00122 5.022624 5.022624 0.000308 0.00122 0.00122 0.00122 5.022316 5.022316 0.000925 5.021391
GL KMOL/HR 0 0 0 0 0 0 0 0.017455 0.017455 0.017455 10.88602 10.88602 0.005417 0.017455 0.017455 0.017455 10.88061 10.88061 0.012269 10.86834
MEOH KMOL/HR 35.2503 0 0 0 35.2503 0 0 66.10824 66.10824 66.10824 33.50254 33.50254 25.67846 30.85794 30.85794 30.85794 7.824087 7.824087 5.367758 2.456329
WATER KMOL/HR 0 0 0 485.252 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
NAOCH3 KMOL/HR 0 1.3916 0 0 0 1.3916 0 5.57E-19 1.3916 1.3916 1.3916 1.3916 9.02E-21 5.57E-19 5.57E-19 5.57E-19 1.3916 1.3916 5.49E-19 1.3916
Component Mass Flow
TG-8 KG/HR 0 0 332.7793 0 0 0 332.7793 8.00E-06 332.7793 332.7793 3.327793 3.327793 1.00E-06 8.00E-06 8.00E-06 8.00E-06 3.327792 3.327792 7.04E-06 3.327785
TG-10 KG/HR 0 0 279.592 0 0 0 279.592 4.93E-07 279.592 279.592 2.79592 2.79592 3.99E-08 4.93E-07 4.93E-07 4.93E-07 2.79592 2.79592 4.54E-07 2.795919
TG-12 KG/HR 0 0 3652.153 0 0 0 3652.153 4.57E-07 3652.153 3652.153 36.52153 36.52153 2.20E-08 4.57E-07 4.57E-07 4.57E-07 36.52153 36.52153 4.36E-07 36.52153
TG-14 KG/HR 0 0 1179.769 0 0 0 1179.769 9.64E-09 1179.769 1179.769 11.79769 11.79769 2.81E-10 9.64E-09 9.64E-09 9.64E-09 11.79769 11.79769 9.37E-09 11.79769
TG-16 KG/HR 0 0 589.4009 0 0 0 589.4009 4.52E-10 589.4009 589.4009 5.894009 5.894009 8.16E-12 4.52E-10 4.52E-10 4.52E-10 5.894009 5.894009 4.44E-10 5.894009
TG-18 KG/HR 0 0 1496.992 0 0 0 1496.992 0.044572 1497.036 1497.036 14.97036 14.97036 0.030844 0.044572 0.044572 0.044572 14.93952 14.93952 0.015038 14.92448
ME-8 KG/HR 0 0 0 0 0 0 0 30.82844 30.82844 30.82844 363.1019 363.1019 16.33667 30.82844 30.82844 30.82844 346.7652 346.7652 15.11285 331.6524
ME-10 KG/HR 0 0 0 0 0 0 0 7.226102 7.226102 7.226102 286.0335 286.0335 3.34788 7.226102 7.226102 7.226102 282.6856 282.6856 4.016185 278.6694
ME-12 KG/HR 0 0 0 0 0 0 0 27.7971 27.7971 27.7971 3666.241 3666.241 11.31913 27.7971 27.7971 27.7971 3654.921 3654.921 16.95493 3637.966
ME-14 KG/HR 0 0 0 0 0 0 0 2.741468 2.741468 2.741468 1177.224 1177.224 0.969972 2.741468 2.741468 2.741468 1176.254 1176.254 1.812619 1174.441
ME-16 KG/HR 0 0 0 0 0 0 0 0.432969 0.432969 0.432969 586.8538 586.8538 0.132315 0.432969 0.432969 0.432969 586.7215 586.7215 0.306271 586.4153
ME-18 KG/HR 0 0 0 0 0 0 0 0.361634 0.361634 0.361634 1489.176 1489.176 0.091375 0.361634 0.361634 0.361634 1489.085 1489.085 0.274137 1488.811
GL KG/HR 0 0 0 0 0 0 0 1.607542 1.607542 1.607542 1002.545 1002.545 0.498831 1.607542 1.607542 1.607542 1002.046 1002.046 1.129869 1000.916
MEOH KG/HR 1129.496 0 0 0 1129.496 0 0 2118.251 2118.251 2118.251 1073.494 1073.494 822.7932 988.7551 988.7551 988.7551 250.7006 250.7006 171.9946 78.70609
WATER KG/HR 0 0 0 8741.951 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
NAOCH3 KG/HR 0 81.32854 0 0 0 81.32854 0 3.26E-17 81.32854 81.32854 81.32854 81.32854 5.27E-19 3.26E-17 3.26E-17 3.26E-17 81.32854 81.32854 3.21E-17 81.32854
Mole Flow KMOL/HR 35.2503 1.3916 10.9783 485.252 35.2503 1.3916 10.9783 66.50317 78.87307 78.87307 78.87307 78.87307 25.86272 31.25287 31.25287 31.25287 53.01035 53.01035 5.585742 47.4246
Mass Flow KG/HR 1129.496 81.32854 7530.685 8741.951 1129.496 81.32854 7530.685 2189.291 9801.305 9801.305 9801.305 9801.305 855.5202 1059.795 1059.795 1059.795 8945.784 8945.784 211.6165 8734.168
Volume Flow L/MIN 23.74125 0.812862 106.9753 146.585 23.74221 0.81287 106.9778 47.2234 274.4582 280.1132 196.9957 14096.25 13905.67 17168.8 23.51517 23.51623 190.5809 3502.688 3308.861 193.8264
Temperature C 25 25 25 25 25.02689 25.06705 25.03366 42.1255 31.72569 60 60 120 120 129.0748 60 60.02668 120 160 160 160
Pressure BAR 1.01325 1.01325 1.01325 1.01325 1.2159 1.2159 1.2159 1.2159 1.2159 1.01325 1.01325 1.01325 1.01325 1.01325 1.01325 1.2159 1.01325 1.01325 1.01325 1.01325
Vapor Fraction 0 0 0 0 0 0 0 0 0 0 0 0.327903 1 0.999329 0 0 0 0.105371 1 0
Liquid Fraction 1 1 1 1 1 1 1 1 1 1 1 0.672097 0 0.000671 1 1 1 0.894629 0 1
Molar Enthalpy CAL/MOL -56984.8 -84100 -473470 -68232.2 -56984.1 -84099.5 -473460 -57114.4 -115540 -113920 -116050 -109450 -47498.8 -47804.2 -57262.1 -57261.3 -139670 -135060 -49574.9 -145130
Mass Enthalpy CAL/GM -1778.43 -1439.02 -690.225 -3787.46 -1778.41 -1439.01 -690.213 -1734.94 -929.784 -916.697 -933.914 -880.737 -1435.91 -1409.72 -1688.63 -1688.61 -827.644 -800.335 -1308.56 -788.022
Enthalpy Flow CAL/SEC -557980 -32509.3 -1443900 -9197200 -557970 -32509.1 -1443800 -1055100 -2531400 -2495800 -2542700 -2397900 -341240 -415000 -497110 -497110 -2056600 -1988800 -76920.2 -1911900
Molar Entropy CAL/MOL-K -57.5289 7.920556 -1482.43 -38.8501 -57.5268 7.918028 -1482.41 -58.0177 -254.135 -249.27 -191.035 -173.105 -29.96 -31.2415 -58.6847 -58.6826 -242.942 -231.83 -37.4022 -254.73
Mass Entropy CAL/GM-K -1.79541 0.135527 -2.16111 -2.15651 -1.79535 0.135484 -2.16107 -1.76238 -2.04507 -2.00593 -1.5373 -1.39301 -0.9057 -0.9213 -1.73059 -1.73052 -1.43961 -1.37376 -0.98725 -1.38313
Molar Density MOL/CC 0.024746 0.028533 0.00171 0.055173 0.024745 0.028533 0.00171 0.023471 0.00479 0.004693 0.006673 9.33E-05 3.10E-05 3.03E-05 0.022151 0.02215 0.004636 0.000252 2.81E-05 0.004078
Mass Density GM/CC 0.792921 1.667535 1.173275 0.993957 0.792889 1.667519 1.173247 0.772672 0.595191 0.583175 0.829232 0.011589 0.001025 0.001029 0.751143 0.751109 0.782326 0.042566 0.001066 0.75103
Average Molecular Weight 32.04216 58.44247 685.961 18.01528 32.04216 58.44247 685.961 32.9201 124.2668 124.2668 124.2668 124.2668 33.07928 33.91033 33.91033 33.91033 168.7554 168.7554 37.88511 184.1695
364
Units 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
From P-106 E-105 P-104 V-101 P-107 E-106 C-103 E-107 C-103 P-108 E-108 C-104 P-109 E-109 C-104 P-110 E-110 C-105
To E-105 V-101 V-101 P-107 E-106 C-103 E-107 P-108 E-108 C-104 P-109 E-109 P-110 E-110 C-105 P-111
Phase: Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid Liquid
Component Mole Flow
TG-8 KMOL/HR 0.00707 0.00707 0 0.00707 0.00707 0.00707 0 0 0.00707 0.00707 0.00707 0 0 0 0.00707 0.00707 0.00707 0
TG-10 KMOL/HR 0.005039 0.005039 0 0.005039 0.005039 0.005039 0 0 0.005039 0.005039 0.005039 0 0 0 0.005039 0.005039 0.005039 0
TG-12 KMOL/HR 0.057153 0.057153 0 0.057153 0.057153 0.057153 0 0 0.057153 0.057153 0.057153 0 0 0 0.057153 0.057153 0.057153 0
TG-14 KMOL/HR 0.016314 0.016314 0 0.016314 0.016314 0.016314 0 0 0.016314 0.016314 0.016314 0 0 0 0.016314 0.016314 0.016314 0
TG-16 KMOL/HR 0.007301 0.007301 0 0.007301 0.007301 0.007301 0 0 0.007301 0.007301 0.007301 0 0 0 0.007301 0.007301 0.007301 0
TG-18 KMOL/HR 0.016855 0.016855 0 0.016855 0.016855 0.016855 5.08E-10 5.08E-10 0.016855 0.016855 0.016855 2.30E-08 2.30E-08 2.30E-08 0.016855 0.016855 0.016855 2.58E-06
ME-8 KMOL/HR 2.095873 2.095873 0 2.095874 2.095874 2.095874 0.083062 0.083062 2.012812 2.012812 2.012812 2.0128 2.0128 2.0128 1.19E-05 1.19E-05 1.19E-05 1.19E-05
ME-10 KMOL/HR 1.495854 1.495854 0 1.495855 1.495855 1.495855 0.003932 0.003932 1.491923 1.491923 1.491923 1.17427 1.17427 1.17427 0.317652 0.317652 0.317652 0.317652
ME-12 KMOL/HR 16.97222 16.97222 0 16.97223 16.97223 16.97223 4.22E-05 4.22E-05 16.97219 16.97219 16.97219 0.277956 0.277956 0.277956 16.69423 16.69423 16.69423 16.69422
ME-14 KMOL/HR 4.845015 4.845015 0 4.845017 4.845017 4.845017 5.64E-09 5.64E-09 4.845017 4.845017 4.845017 0.001462 0.001462 0.001462 4.843555 4.843555 4.843555 4.741909
ME-16 KMOL/HR 2.168248 2.168248 0 2.168249 2.168249 2.168249 1.44E-12 1.44E-12 2.168249 2.168249 2.168249 1.39E-05 1.39E-05 1.39E-05 2.168235 2.168235 2.168235 0.013812
ME-18 KMOL/HR 5.021391 5.021391 0 5.021393 5.021393 5.021393 0 0 5.021393 5.021393 5.021393 9.09E-07 9.09E-07 9.09E-07 5.021392 5.021392 5.021392 1.38E-07
GL KMOL/HR 10.86834 10.86834 0 0.112545 0.112545 0.112545 3.01E-12 3.01E-12 0.112545 0.112545 0.112545 1.73E-05 1.73E-05 1.73E-05 0.112527 0.112527 0.112527 0.106872
MEOH KMOL/HR 2.456329 2.456329 0 0.832802 0.832802 0.832802 0.832802 0.832802 0 0 0 0 0 0 0 0 0 0
WATER KMOL/HR 0 0 485.252 1.125154 1.125154 1.125154 1.125154 1.125154 6.62E-09 6.62E-09 6.62E-09 6.62E-09 6.62E-09 6.62E-09 0 0 0 0
NAOCH3 KMOL/HR 1.3916 1.3916 0 3.87E-05 3.87E-05 3.87E-05 0 0 3.87E-05 3.87E-05 3.87E-05 0 0 0 3.87E-05 3.87E-05 3.87E-05 0
Component Mass Flow
TG-8 KG/HR 3.327785 3.327785 0 3.327786 3.327786 3.327786 0 0 3.327786 3.327786 3.327786 0 0 0 3.327786 3.327786 3.327786 0
TG-10 KG/HR 2.795919 2.795919 0 2.79592 2.79592 2.79592 0 0 2.79592 2.79592 2.79592 0 0 0 2.79592 2.79592 2.79592 0
TG-12 KG/HR 36.52153 36.52153 0 36.52154 36.52154 36.52154 0 0 36.52154 36.52154 36.52154 0 0 0 36.52154 36.52154 36.52154 0
TG-14 KG/HR 11.79769 11.79769 0 11.79769 11.79769 11.79769 0 0 11.79769 11.79769 11.79769 0 0 0 11.79769 11.79769 11.79769 0
TG-16 KG/HR 5.894009 5.894009 0 5.894012 5.894012 5.894012 0 0 5.894012 5.894012 5.894012 0 0 0 5.894012 5.894012 5.894012 0
TG-18 KG/HR 14.92448 14.92448 0 14.92449 14.92449 14.92449 4.50E-07 4.50E-07 14.92449 14.92449 14.92449 2.04E-05 2.04E-05 2.04E-05 14.92447 14.92447 14.92447 0.002287
ME-8 KG/HR 331.6524 331.6524 0 331.6525 331.6525 331.6525 13.14378 13.14378 318.5088 318.5088 318.5088 318.5069 318.5069 318.5069 0.00189 0.00189 0.00189 0.00189
ME-10 KG/HR 278.6694 278.6694 0 278.6695 278.6695 278.6695 0.73252 0.73252 277.937 277.937 277.937 218.7601 218.7601 218.7601 59.17689 59.17689 59.17689 59.17689
ME-12 KG/HR 3637.966 3637.966 0 3637.968 3637.968 3637.968 0.009038 0.009038 3637.959 3637.959 3637.959 59.57944 59.57944 59.57944 3578.38 3578.38 3578.38 3578.376
ME-14 KG/HR 1174.441 1174.441 0 1174.442 1174.442 1174.442 1.37E-06 1.37E-06 1174.442 1174.442 1174.442 0.354337 0.354337 0.354337 1174.088 1174.088 1174.088 1149.448
ME-16 KG/HR 586.4153 586.4153 0 586.4155 586.4155 586.4155 3.89E-10 3.89E-10 586.4155 586.4155 586.4155 0.003755 0.003755 0.003755 586.4118 586.4118 586.4118 3.735429
ME-18 KG/HR 1488.811 1488.811 0 1488.811 1488.811 1488.811 0 0 1488.811 1488.811 1488.811 0.00027 0.00027 0.00027 1488.811 1488.811 1488.811 4.09E-05
GL KG/HR 1000.916 1000.916 0 10.36476 10.36476 10.36476 2.77E-10 2.77E-10 10.36476 10.36476 10.36476 0.001597 0.001597 0.001597 10.36316 10.36316 10.36316 9.842333
MEOH KG/HR 78.70609 78.70609 0 26.68476 26.68476 26.68476 26.68476 26.68476 0 0 0 0 0 0 0 0 0 0
WATER KG/HR 0 0 8741.951 20.26996 20.26996 20.26996 20.26996 20.26996 1.19E-07 1.19E-07 1.19E-07 1.19E-07 1.19E-07 1.19E-07 0 0 0 0
NAOCH3 KG/HR 81.32854 81.32854 0 0.00226 0.00226 0.00226 0 0 0.00226 0.00226 0.00226 0 0 0 0.00226 0.00226 0.00226 0
Mole Flow KMOL/HR 47.4246 47.4246 485.252 34.77889 34.77889 34.77889 2.044999 2.044999 32.73389 32.73389 32.73389 3.466519 3.466519 3.466519 29.26737 29.26737 29.26737 21.87443
Mass Flow KG/HR 8734.168 8734.168 8741.951 7630.542 7630.542 7630.542 60.84028 60.84028 7569.7 7569.7 7569.7 597.2062 597.2062 597.2062 6972.494 6972.494 6972.494 4800.574
Volume Flow L/MIN 193.8312 175.4484 146.5869 159.2841 160.4318 165.8016 1.256473 1.199091 192.6707 192.6772 181.0879 13.47333 13.47576 11.6539 175.3267 175.3325 169.6341 114.8657
Temperature C 160.0248 50 25.01325 50 53.95002 91 58.8103 25 235.8399 235.8654 185 157.5058 157.6448 25 225.5555 225.5819 198 176.3786
Pressure BAR 1.2159 1.01325 1.2159 1.01325 1.2159 1.01325 0.506625 0.506625 0.506625 0.709275 0.506625 0.253313 1.01325 1.01325 0.253313 0.455963 0.253313 0.066661
Vapor Fraction 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Liquid Fraction 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Molar Enthalpy CAL/MOL -145130 -155920 -68232 -159450 -159440 -155400 -66120.9 -66917.3 -141470 -141460 -148880 -135090 -135070 -147070 -144840 -144840 -148970 -149420
Mass Enthalpy CAL/GM -788.007 -846.61 -3787.45 -726.739 -726.725 -708.274 -2222.49 -2249.26 -611.749 -611.733 -643.814 -784.121 -784.038 -853.663 -607.969 -607.952 -625.316 -680.862
Enthalpy Flow CAL/SEC -1911800 -2054000 -9197100 -1540400 -1540400 -1501300 -37560.3 -38012.7 -1286300 -1286300 -1353700 -130080 -130060 -141610 -1177500 -1177500 -1211100 -907920
Molar Entropy CAL/MOL-K -254.724 -283.151 -38.8493 -342.148 -341.404 -329.699 -60.5295 -63.0021 -302.28 -302.272 -317.562 -356 -355.967 -388.925 -301.816 -301.807 -310.319 -294.441
Mass Entropy CAL/GM-K -1.3831 -1.53745 -2.15647 -1.55946 -1.55607 -1.50272 -2.03455 -2.11766 -1.30716 -1.30713 -1.37325 -2.06642 -2.06623 -2.25754 -1.26689 -1.26685 -1.30258 -1.34166
Molar Density MOL/CC 0.004078 0.004505 0.055172 0.003639 0.003613 0.003496 0.027126 0.028424 0.002832 0.002832 0.003013 0.004288 0.004287 0.004958 0.002782 0.002782 0.002876 0.003174
Mass Density GM/CC 0.751011 0.8297 0.993944 0.798421 0.792709 0.767035 0.807024 0.845644 0.654805 0.654783 0.696687 0.738751 0.738618 0.854087 0.66281 0.662788 0.685052 0.696549
Average Molecular Weight 184.1695 184.1695 18.01528 219.4015 219.4015 219.4015 29.75076 29.75076 231.2496 231.2496 231.2496 172.2783 172.2783 172.2783 238.2344 238.2344 238.2344 219.4605
365
Units 35 36 37 38 39 40 41 42 43 44 45 46
From P-111 E-111 C-105 P-112 E-112 V-101 P-113 E-113 C-106 E-114 C-106 E-115
To E-111 P-112 E-112 P-113 E-113 C-106 E-114 E-115
Phase: Liquid Liquid Liquid Liquid Liquid Liquid Liquid Mixed Vapor Liquid Liquid Liquid
Component Mole Flow
TG-8 KMOL/HR 0 0 0.00707 0.00707 0.00707 1.01E-21 1.01E-21 1.01E-21 0 0 0 0
TG-10 KMOL/HR 0 0 0.005039 0.005039 0.005039 7.21E-22 7.21E-22 7.21E-22 0 0 0 0
TG-12 KMOL/HR 0 0 0.057153 0.057153 0.057153 8.18E-21 8.18E-21 8.18E-21 0 0 0 0
TG-14 KMOL/HR 0 0 0.016314 0.016314 0.016314 2.34E-21 2.34E-21 2.34E-21 0 0 0 0
TG-16 KMOL/HR 0 0 0.007301 0.007301 0.007301 1.05E-21 1.05E-21 1.05E-21 0 0 0 0
TG-18 KMOL/HR 2.58E-06 2.58E-06 0.016853 0.016853 0.016853 2.41E-21 2.41E-21 2.41E-21 0 0 0 0
ME-8 KMOL/HR 1.19E-05 1.19E-05 0 0 0 7.85E-15 7.85E-15 7.85E-15 0 0 0 0
ME-10 KMOL/HR 0.317652 0.317652 1.03E-11 1.03E-11 1.03E-11 1.04E-15 1.04E-15 1.04E-15 0 0 0 0
ME-12 KMOL/HR 16.69422 16.69422 1.76E-05 1.76E-05 1.76E-05 1.30E-15 1.30E-15 1.30E-15 0 0 0 0
ME-14 KMOL/HR 4.741909 4.741909 0.101646 0.101646 0.101646 6.29E-17 6.29E-17 6.29E-17 0 0 0 0
ME-16 KMOL/HR 0.013812 0.013812 2.154424 2.154424 2.154424 3.91E-18 3.91E-18 3.91E-18 0 0 0 0
ME-18 KMOL/HR 1.38E-07 1.38E-07 5.021392 5.021392 5.021392 7.19E-19 7.19E-19 7.19E-19 0 0 0 0
GL KMOL/HR 0.106872 0.106872 0.005655 0.005655 0.005655 10.75579 10.75579 10.75579 0.316739 0.316739 10.43905 10.43905
MEOH KMOL/HR 0 0 0 0 0 1.623528 1.623528 1.623528 1.618063 1.618063 0.005465 0.005465
WATER KMOL/HR 0 0 0 0 0 484.1268 484.1268 484.1268 473.6598 473.6598 10.46703 10.46703
NAOCH3 KMOL/HR 0 0 3.87E-05 3.87E-05 3.87E-05 1.391561 1.391561 1.391561 2.14E-18 2.14E-18 1.391561 1.391561
Component Mass Flow
TG-8 KG/HR 0 0 3.327786 3.327786 3.327786 4.76E-19 4.76E-19 4.76E-19 0 0 0 0
TG-10 KG/HR 0 0 2.79592 2.79592 2.79592 4.00E-19 4.00E-19 4.00E-19 0 0 0 0
TG-12 KG/HR 0 0 36.52154 36.52154 36.52154 5.23E-18 5.23E-18 5.23E-18 0 0 0 0
TG-14 KG/HR 0 0 11.79769 11.79769 11.79769 1.69E-18 1.69E-18 1.69E-18 0 0 0 0
TG-16 KG/HR 0 0 5.894012 5.894012 5.894012 8.44E-19 8.44E-19 8.44E-19 0 0 0 0
TG-18 KG/HR 0.002287 0.002287 14.92218 14.92218 14.92218 2.14E-18 2.14E-18 2.14E-18 0 0 0 0
ME-8 KG/HR 0.00189 0.00189 0 0 0 1.24E-12 1.24E-12 1.24E-12 0 0 0 0
ME-10 KG/HR 59.17689 59.17689 1.91E-09 1.91E-09 1.91E-09 1.93E-13 1.93E-13 1.93E-13 0 0 0 0
ME-12 KG/HR 3578.376 3578.376 0.003765 0.003765 0.003765 2.79E-13 2.79E-13 2.79E-13 0 0 0 0
ME-14 KG/HR 1149.448 1149.448 24.63925 24.63925 24.63925 1.52E-14 1.52E-14 1.52E-14 0 0 0 0
ME-16 KG/HR 3.735429 3.735429 582.6763 582.6763 582.6763 1.06E-15 1.06E-15 1.06E-15 0 0 0 0
ME-18 KG/HR 4.09E-05 4.09E-05 1488.811 1488.811 1488.811 2.13E-16 2.13E-16 2.13E-16 0 0 0 0
GL KG/HR 9.842333 9.842333 0.520828 0.520828 0.520828 990.5517 990.5517 990.5517 29.16997 29.16997 961.3817 961.3817
MEOH KG/HR 0 0 0 0 0 52.02134 52.02134 52.02134 51.84624 51.84624 0.175101 0.175101
WATER KG/HR 0 0 0 0 0 8721.68 8721.68 8721.68 8533.114 8533.114 188.5664 188.5664
NAOCH3 KG/HR 0 0 0.00226 0.00226 0.00226 81.32628 81.32628 81.32628 1.25E-16 1.25E-16 81.32628 81.32628
Mole Flow KMOL/HR 21.87443 21.87443 7.392938 7.392938 7.392938 497.8977 497.8977 497.8977 475.5946 475.5946 22.30311 22.30311
Mass Flow KG/HR 4800.574 4800.574 2171.923 2171.923 2171.923 9845.58 9845.58 9845.58 8614.13 8614.13 1231.45 1231.45
Volume Flow L/MIN 114.885 101.506 53.43421 53.44515 44.76241 170.5654 158.7864 262235 262218 144.5596 16.72855 15.75874
Temperature C 176.5271 50 237.0092 237.1852 50 50 17.651 130 130 25 130 25
Pressure BAR 1.01325 1.01325 0.066661 1.01325 1.01325 1.01325 1.2159 1.01325 1.01325 1.01325 1.01325 1.01325
Vapor Fraction 0 0 0 0 0 0 0 0.955205 1 0 0 0
Liquid Fraction 1 1 1 1 1 1 1 0.044795 0 1 1 1
Molar Enthalpy CAL/MOL -149400 -164420 -149090 -149060 -179210 -70319.8 -70319.6 -59223.8 -56923.9 -68257 -108270 -111720
Mass Enthalpy CAL/GM -680.773 -749.194 -507.483 -507.37 -610.019 -3556.12 -3556.11 -2994.99 -3142.83 -3768.54 -1960.85 -2023.38
Enthalpy Flow CAL/SEC -907810 -999040 -306170 -306100 -368030 -9725600 -9725500 -8190900 -7520200 -9017400 -670750 -692140
Molar Entropy CAL/MOL-K -294.398 -333.4 -365.589 -365.523 -438.171 -39.4774 -41.1582 -11.1675 -8.2209 -38.9397 -74.0015 -83.5389
Mass Entropy CAL/GM-K -1.34146 -1.51918 -1.24442 -1.24419 -1.49147 -1.9964 -2.0814 -0.56475 -0.45388 -2.1499 -1.34026 -1.513
Molar Density MOL/CC 0.003173 0.003592 0.002306 0.002305 0.002753 0.048652 0.052261 3.16E-05 3.02E-05 0.054833 0.022221 0.023588
Mass Density GM/CC 0.696432 0.788225 0.677445 0.677306 0.808686 0.962053 1.03342 0.000626 0.000548 0.993147 1.226894 1.302398
Average Molecular Weight 219.4605 219.4605 293.7834 293.7834 293.7834 19.7743 19.7743 19.7743 18.11234 18.11234 55.21426 55.21426
366
Appendix A. 5
A.5. 1 Summary of unit operations’ specifications
Operating specifications
Tranesterification reactor R-100
Reactor Model Rstoic
Temperature, °C 60
Pressure, atm 1
Alcohol:oil molar ratio 6:1
Conversion, % 99
First methanol recovery column C-101

Column model Flash2
Temperature, °C 120
Pressure, atm 1
First methanol recovery column C-102

Column model Flash2
Pressure, atm 1
Methyl ester purification column C-103

Column model Distl
Theoretical stages 21
Feed stages 7
Reflux ratio 0.0796
Distillate to feed mole ratio 0.0588
Condenser type Total
Condenser pressure, mm Hg 380
Reboiler pressure, mmHg 380
Light-cut distillation column C-104

Column model Distl
Feed stages 5
Reflux ratio 4.0340
Condenser pressure, mmHg 190
367
Operating specifications
Middle/heavy-cut separation column C-105
Column model Distl
Feed stages 15
Reflux ratio 0.4777
Condenser pressure, mmHg 50
Glycerol Purification Column C-106

Column model Flash2
Pressure, atm 1
368
Appendix A. 6
A.6. 1 Process flow diagram with manually calculated material balance
369
Appendix B. 1
B.1. 1 R-101/2/3 Sizing and Costing
R-101/2/3 Sizing
R-101/2/3
1 at m 1 at m
60 °C 60 °C
R-101 R-102 R-103
1 at m 1 at m
60 °C 60 °C
Material Balance of Reactor R-101/2/3:

Stream
Component 6 6a 6b 7
TG 10.9783 2.3537 0.5050 0.1098
ME-8 0.1860 1.6657 2.0228 2.0938
ME-10 0.0394 1.1883 1.4430 1.4956
ME-12 0.1357 13.4686 16.3557 16.9682
ME-14 0.0121 3.8439 4.6678 4.8462
ME-16 0.0017 1.7216 2.0906 2.1717
ME-18 0.0015 3.9856 4.8400 5.0300
GL 0.0092 8.6245 10.4733 10.8685
MeOH 65.8697 39.9961 34.4499 33.2642
Water
NaOCH3 1.3916 1.3916 1.3916 1.3916
Total 78.6252 78.2396 78.2396 78.2396
Mass Flow (kg/hr)

TG 7,517.9522 1,611.8490 345.8258 75.1795
ME-8 29.4362 263.5800 320.0806 331.3242
ME-10 7.3485 221.3613 268.8119 278.6136
ME-12 29.0846 2,886.9164 3,505.7513 3,637.0365
ME-14 2.9385 931.7397 1,131.4660 1,174.6950
ME-16 0.4539 465.6010 565.4065 587.3475
ME-18 0.4448 1,181.3929 1,434.6344 1,490.9591
GL 0.8427 794.2666 964.5243 1,000.9215
MeOH 2,110.5902 1,281.5504 1,103.8387 1,065.8481
Water
NaOCH3 81.3248 81.3248 81.3248 81.3248
Total 9,780.4164 9,719.5819 9,721.6643 9,723.2498
370
The following formulas determine the volume of each equal-sized CSTRs connected in series
( ⁄ ) operating at the same temperature (
) (Fogler, 2006).
where
Rearranging,
*( ) +
where
Theoretically, it is preferred to have higher overall conversion (conversion of triglyceride

from a combination of CSTRs in series) but lower number, n of CSTRs due to high costs.
Based on the graph of volume of each CSTRs against conversion (see below), the best option
goes to three CSTRs in series with 53m3 of each CSTR which is capable to achieve 99%
overall conversion. With a production rate of 60,000 MTPA of methyl esters, a volume of
53m3 for each CSTR is feasible.
371
Volume of each CSTRs vs Conversion
100
90
80
70
Volume of each CSTRs (m3)
60
50
40
30
20
10
0
0.7 0.75 0.8 0.85 0.9 0.95 1
Overall Conversion, X
1 CSTR 2 CSTRs 3 CSTRs 4 CSTRs 5 CSTRs
Graph of volume of each CSTRs against conversion
372
The conversion (Xi) of each CSTR reactor can be calculated using the following formula
(Fogler, 2006).
where
The conversions according to number of CSTRs are summarized as below.
Conversions according to number of CSTRs:

st
1 CSTR = 1 78.56 %
1st CSTR + 2nd CSTR = 2 95.40 %
st nd rd
1 CSTR + 2 CSTR + 3 CSTR = 3 99.01 %
̇ ̇ ˚ 98 K ∑ ∑
where ̇ amount of triglyceride converted.
Conversion, Xi Triglyceride converted, 

78.56 % 8.6246
95.40 % 1.8487
99.01 % 0.3952
̇ ( )( )
373
̇ ( )( )
̇ ( )( )
Temperature drop from 333.15K at different conversion:

Temperature drop Heat Duty
Reactor Conversion, Xi Outlet Temperature (K)
(K) Required (kW)
1st 333.15 – 328.20 =
78.56 % 328.2 31.3407
CSTR 4.95
2nd 328.20 – 327.10 =
95.40 % 327.1 8.7167
CSTR 1.10
3rd 327.10 – 326.90 =
99.01 % 326.9 3.8636
CSTR 0.20
374
Stirred tank configuration for a six flat blade turbine (Trambouze et al., 1988), provide for
the standard type agitation system. As shown below, the following are standard configuration:
where:
375
Solving and ,
By giving 20% allowance, solving ,
Solving ,
Solving ,
Solving ,
Solving ,
376
Solving ,
Solving ,
Solving ,
Mixing time:
To estimate the mixing time, Norwood and Metzner correlation provides for the equation
applicable for six flat blade turbine:
( ) ( )
where:
377
where g = acceleration due to gravity
Using N = 90 rpm = 1.5 rps. Solving,
( ) ( ) ( )
( ) ( ) ( )
( ) ( ) ( )
Impeller Reynold Number:
For R-101
Figure 2: Reynolds number vs. power number for six turbine impellers (Rushton et al., 1980)
378
The power requirement for a single impeller operating in a baffled vessel can be calculated
from
( ) ( )
For R-102
from
( ) ( )
For R-103
379
from
( ) ( )
Design of Cooling Jacket
For R-101
380
Log mean temperature difference:
( ) ( )
Impeller’s Reynold Number:
Now using a graph between ―j‖ and ―Re‖ taken from Process heat transfer by D.Q.Kern,
which is given in the figure below.
Heat-transfer coefficients from jackets and coils (Chilton el al., Industrial and Engineering
Chemistry)
From the figure, j = 500
Now calculations for film coefficient on reactor side ( )
( )( ) ( )
381
where ( ) is taken as unity. So,
For reactor mixture,
For water as heating substance for heavy organics and within the temperature range
considered;
For stainless steel 304,
Overall heat transfer transfer coefficient based on outer surface is given as:
( )
( )
As the heat load is given by 31340.7 J/s
And temperature difference =
Now the area of R-101 available for heat transfer is:
Total surface area of reactor is
(For elliptical head use table giving surface as a function of diameter. So 0.83 is factor for it
taken from literature.)
382
Boiler feed water flow rate
R-102
( ) ( )
383
Chemistry)
( )( ) ( )
considered;
384
(page no. 799 Kern)
( )
( )
R-103
385
( ) ( )
Chemistry)
386
( )( ) ( )
considered;
(page no. 799 Kern)
( )
( )
387
Shell Minimum Thickness
For cylindrical tanks, wall thickness is by:
Where
Hence,
Then outer diameter of shell is given by
Costing for R-101/2/3
The costing method for R-101/2/3 will be calculated based on the Capital Cost Equation. Data
and calculations are based on methods by Turton et al. (2012).
Equipment type: Jacketed and agitated
Material of construction: Stainless steel 304
Volume = m3
Purchased cost of reactor per unit of volume based on year 2001:
388
Bare module cost, equation for vessel is as shown below (Turton, 2012).
where (for Jacketed agitated reactor)
For three reactors with similar specifications,
Mechanical Design for R-101/2/3
Design methodology is based on Chemical Engineering Design (Coulson & Sinnott, 2005)
Design Pressure
The design pressure is taken as 10% above the opereating pressure,
𝑁
𝑃𝑖 𝑃
𝑚𝑚
= 0.1114575 N/mm2
Material used
The property of material is obtained from Table 13.2, Chemical Engineering Design,
Material of construction is stainless steel 304,
Tensile strength = 510 N/mm2
Design stress, f at 60 celsius = 145 N/mm2
Welded joint efficiency

Taking the factor as 1.0 implies that the joint is equally as strong as the virgin plate;
The use of lower joint factor factors in design will result in a thicker, heavier vessel.
Corrosion Allowance
The corrosion allowance is the aditional thickness of metal added to allow for material
lost by corrosion and erosion, or scaling. Since the process will not cause severe
corrosion, hence a minimum allowance of 2mm is used as accordance to Chemical
Engineering Design (Coulson & Sinnott, 2005)
389
Minimum wall thickness of vessel
For cylindrical vessel,
𝑃𝑖 𝐷𝑖
𝑒𝑖
𝑓 𝑃𝑖 = 1.57 mm
Thickness of wall, t
t = ei+ corrosion allowance = 3.57 mm
( 4 mm)
Weight of Vessel
a. Dead weight of vessel
𝑊𝑣 𝐶𝑣 𝐷𝑚 𝐻𝑣 𝐷𝑚 𝑡
where
Wv = total weight of shell, excluding internal fitting, such as plates, N
Cv = a factor to account for the weight of nozzles, manways, internal supports (1.05
= for vessels, 1.18 for distillation column)
Hv = height, orlength between tangent lines ( the length of the cylindrical section), m
t = wall thickness,mm
pm = density of vessel material, kg/cum
Dm = mean diamter of vessel
𝐷𝑚 𝐷𝑖 𝑡
= 4.09 m
Wv = 33592.03 N
= 33.59 kN
c. Weight of insulation
Mineral wool density = 130 kg/cum
Thickness of insulation, ti = 75 mm
Volume of insulation
𝑉𝑖 𝜋𝐷𝑚 𝐻𝑣 𝑡𝑖 = 4.71 cum
Weight of insulation
To allow for fittings,etc, the weight of insulation has to be doubled
𝑊𝑖 𝑝𝑉𝑖 𝑔 = 12006.34 N
= 12.01 kN
Total weight of vessel, plates and insulation = 45.60 kN
390
Wind loads
According to Chemical Engineering Design (Coulson & Sinnott, 2005), for preliminary
design:
Wind speed, uw = 160 km/hr
Wind pressure, Pw = 1280 N/m2
Mean diameter (includes insulation),

𝐷𝑚 𝐷𝑖 𝑡𝑠 𝑒𝑙𝑙 𝑡𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = 4.239 m
Loading (per linear metre), Fw = PwDm = 5425.92 N/m

= 5.43 kN/m
Bending moment at bottom tangent line
𝐹𝑤
𝑀𝑥 𝐻
= 64873 Nm
Analysis of stresses
Pressure stresses
𝑃𝑖 𝐷𝑖
𝜎𝐿
𝑡
= 28.43 N/mm2
𝑃𝑖 𝐷𝑖
𝜎𝐻
𝑡 = 56.86 N/mm2
Dead weight stress

𝑊𝑣
𝜎𝑤
𝜋 𝐷𝑖 𝑡 𝑡
= 0.655 N/mm2
Bending stresses
𝐷𝑜 𝐷𝑖 𝑡 = 4.089 m
Second moment of area of vessel about the plane of bending

𝜋
𝐼𝑣 (𝐷𝑜 𝐷𝑖 = 1.071E+11 mm2
391
The bending stresses will be compressive or tensile, depending on location
𝑀𝑥 𝐷𝑖
𝜎𝑏 ± 𝑡
𝑙𝑣
= 1.24 N/mm2
The resultant longitudinal stress is

𝜎𝑧 𝜎𝐿 𝜎𝑤 𝜎𝑏 = 29.01 N/mm2
(upwind)
(downwind)
Radial stress is negligible, (Pi / 2) = 0.056 N/mm2
The greatest difference between the principal stresses will be on the down-wind side
𝜎𝐻 𝜎𝑧 = 30.32 N/mm2
which is well below the maximum allowable design stress of 145 N/mm2
Elastic stability (buckling)

Critical buckling stress
𝑡
𝜎𝑐
𝐷𝑜
= 19.56 N/mm2
The maximum compressive stress will occur when the vessel is not under pressure
𝜎𝑤 𝜎𝑏 = 1.894 N/mm2
(satisfactory, well below the critical buckling stress)
Vessel support
A straight cylindrical skirt of carbon-molybdenum steel, design stress 180 N/mm2 and
Young's modulus 210000N/mm2 at ambient temperature
The maximum dead weight load on the skirt will occur when the vessel is full of water.
𝜋
𝐴𝑝𝑝𝑟𝑜𝑥𝑖𝑚𝑎𝑡𝑒 𝑤𝑒𝑖𝑔 𝑡 𝐷𝑖 𝐻𝑡 𝑝𝐿 𝑔
= 645560.13 N
= 645.56 kN
Total weight = approximate weight + Wv = 679.15 kN
392
Skirt height, x = 2 m
Bending moment at base of skirt,
𝐹𝑤 𝑥
𝑀𝑠
= 128.79 kNm
The skirt thickness, ts = 28 mm
Bending stress in the skirt,
𝑀𝑠
𝜎𝑏𝑠
𝜋 𝐷𝑠 𝑡𝑠 𝑡𝑠 𝐷𝑠 = 7.01 N/mm2
Dead weight stress in the skirt,
𝑊
𝜎𝑤𝑠
𝜋 𝐷𝑠 𝑡𝑠 𝑡𝑠 = 8.32 N/mm2
Thus, the maximum resultant stresses at the skirt,

𝜎𝑠 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 𝜎𝑏𝑠 𝜎𝑤𝑠 = 15.33 N/mm2
𝜎𝑠 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝜎𝑏𝑠 𝜎𝑤𝑠 = 1.31 N/mm2
Taking joint factor, J = 0.895
𝜎𝑠 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑓𝑠 𝐽𝑠𝑖𝑛𝜃
<
1.31 < 144.02
𝜎𝑠 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 𝑡𝑠
< 𝐸 ( ) 𝑠𝑖𝑛𝜃
𝐷𝑠
15.33 < 730.10
Both criteria are satisfied, add 2mm for corrosion gives a design thickness of 20mm.
Base ring and anchor bolt

Pitch diameter = 4.08 m
Bolt spacing = 600 mm
393
Circumference of bolt circle = 12822.50 mm
Number of bolts required, Nb = 21.37
= 24 bolts
( multiples of 4)
Assume bolt design stress, fb = 125 N/mm2
𝑀𝑠
𝐴𝑏 [ 𝑊]
𝑁𝑏 𝑓𝑏 𝐷𝑏 = 30.41 mm2
where
Ab = Area of one bolt at the root of thread, mm2
Nb = Number of bolts
fb = Maximu allowable bot stress, N/mm2
Ms = Bending (overturning) moment at the base, Nm
W = Weight of vessel, N
Db = Bolt circle diamter, m
𝐴𝑏
𝐵𝑜𝑙𝑡 𝑟𝑜𝑜𝑡 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝜋 = 6.22 mm
By comparing the area of bolt with Figure 13.30 in Chemical Engineer Design
(Coulson & Sinnott, 2005), M24 bolt with 353mm2 root area is chosen.
The base ring must ne sufficiently wide to distribute the load to the foundation.
The total compressive load on the base ring,
𝑀𝑥 𝑊
𝐹𝑏
𝜋𝐷𝑠 𝜋𝐷𝑠 = 113839.23 N/m
Assume the bearing pressure = 5000 N/m2

𝐹𝑏
𝐿𝑏
𝑓𝑐
= 22.77 mm
According to Chemical Engineer Design, for M24 bolt, Lr=76

Actual width of the design
Lr + ts + 50mm = 154 mm
Actual bearing pressure on concentrate foundation

𝐹𝑏
𝑓𝑐
𝐴𝑐𝑡𝑢𝑎𝑙 𝑤𝑖𝑑𝑡
394
= 0.74 N/mm2
The minimum thickness
𝑓𝑐
𝑡𝑏 𝐿𝑟
𝑓𝑟 = 9.57 mm
= 10 mm
Skirt to be welded flush with outer diameter of column shell.
395
B.1. 2 V-101 Sizing and Costing
V-101 Sizing
The detailed sizing and mechanical design for decanter V-101 is shown below.
According to Chemical Engineering Design (Coulson & Sinnott, 2005), Strokes‘ law is used
to determine the settling velocity of the droplets.
where droplet diameter, m,

settling (terminal) velocity of the dispersed phase droplets with diameter
d, m/s,
density of the continuous phase, kg/m3,
density of the dispersed phase, kg/m3,
viscosity of the continuous phase, N s/m2,
gravitational acceleration, 9.81 m/s2.
Required information:
The oil is the dispersed phase, while the water is the continuous phase.
Take
As the flow rate is small, use a vertical, cylindrical vessel.
396
Take the height as twice the diameter, a reasonable value for a cylinder:
Take the dispersion band as 10 per cent of the height = 0.788 m
Check the residence time of the droplets in the dispersion band,
Check the size of the water (continuous, heavy phase) droplets that could be entrained with
the oil (light phase).
From equation 10.7 in Chemical Engineering Design (Coulson & Sinnott, 2005),
[ ]
So the entrained droplet size will be
* +
which is satisfactory; below 150 .
Piping arrangement
To minimise entrainment by the jet of liquid entering the vessel, the inlet velocity for a
decanter should keep below 1 m/s.
[ ]
397
Take the position of the interface as half-way up the vessel and the light liquid off-take as at
90 per cent of the vessel height, then
Costing for Decanter V-101
The costing method for C-101 will be calculated based on the Capital Cost Equation. Data
Equipment type: Process vessel (vertical)
Volume =
Purchased cost of vessel per unit of volume based on year 2001:
where
398
B.1. 3 C-101 Sizing and Costing
C-101 Sizing
The detailed sizing and mechanical design for flash drum C-101 is shown below.
Information required:
Vapour to feed molar ratio, ⁄
Feed molar flow rate,
Total molecular weight of vapour,
Mass flow rate of vapour,
Mass flow rate of liquid,
Density of vapour,
Density of liquid,
By using method proposed by Watkins (1967), the permissible vapour velocity can be
calculated as follow.
[ ]
where
Therefore,
The vapour flow rate is calculated as below.
( )
Using the known vapour rate, V, convert into a horizontal area. The vapour flow rate,
V, in kmol/hr is
( ) ( )
( )
( )
399
Solving for the cross-sectional area,
The diameter of flash drum is calculated as below.
For vertical flash drums, the rule of thumb is that /D ranges from 3.0 to 5.0.
Therefore, the volume of the flash column can be calculated as below.
Costing for Flash Drum C-101
Volume = 23.5278 m3
400
where
Mechanical Design
Design methodology is based on Coulson & Richardson Chemical Engineering vol. 6.
Design pressure, take as 10 percent above operating pressure,
⁄ ⁄
Typical design stress for vessel, assumed to be stainless steel (304), ⁄ at

150°C.
Joint factor,
Mineral wool density as insulator
Internal diameter
Thickness of insulation
( )
( )
Corrosion allowance assumed to be 2 mm.
Therefore, total wall thickness of vessel,
Factor for weight of nozzle, manways, internal supports, etc is assumed to be
401
m
For fitting, double the weight of insulation,
( )
( )
402
For bending stress,
9
( )
( ) 9
( )
Therefore, the resultant longitudinal forces are,
The greatest difference between the principle stresses will be on the downwind side,
which is well below maximum allowable design stress.
Buckling stress,
( ) ( )
Maximum compressible stress = ⁄ , which is below the buckling

stress, thus, the design is satisfactory.
For vessel supports, it is assumed that
403
Take thickness of skirt to be equal to thickness of vessel without corrosion allowance,
0.78mm.
For bending stress in skirt,
404
The joint factor for support vessel is assumed to be .
Maximum allowable design stress for skirt material made of stainless steel (304),
⁄ at 20°C.
Thus, the criteria of design,
( )
( )
Both criteria are satisfied. Thus, corrosion allowance of 2 mm is added.
For base ring and anchor bolts,
Pitch circle diameter is assumed to be 1.5 m.
Number of bolts required at minimum recommended bolt spacing
Assuming bolt design stress to be ⁄ ,
( )
405
Total compressive load on the base ring per unit length,
Bearing pressure is assumed to be ⁄ .
Thus,
is rather small, thus straight cylindrical skirt is chosen.
406
C-102 Sizing
Density of vapour,
Density of liquid,
[ ]
where
Therefore,
( )
V, in kmol/hr is
( ) ( )
( )
( )
407
Material of construction: Stainless Steel 304
Volume = m3
408
where
Mechanical Design
⁄ ⁄

200°C.
Joint factor,
Internal diameter
( )
( )
409
m
( )
410
( )
For bending stress,
9
( )
( ) 9
( )
Buckling stress,
( ) ( )

411
0.75mm.
412
⁄ at 20°C.
( )
( )
413
(
( )
Thus,
414
C-103 Sizing
The detailed sizing and mechanical design for distillation column C-103 is shown below.
Column Diameter
Liquid vapour factor,
By assuming tray spacing = 0.6 m, Kv = 0.11 is obtained from Figure 11.27 in Chemical
Engineering Design (Coulson & Sinnott, 2005). Thus, the maximum allowable vapour
velocity in the tray is calculated as below.
( )
Multiplying the above by 0.91 to account for downspout area, by 0.90 for foaming, and by
0.80 for 80% flooding.
The tower cross-sectional area equals,
Column diameter,
For liquid flow pattern, assuming single pass plate is used.
Sieve plate design
Column Diameter, =
Column Area, =
Downcomer Area, = (15% 1st trial)
=
Net Area, =
=
415
Active Area, =
=
Hole Area, =
=
From Figure 11.31 in Chemical Engineering Design (Coulson & Sinnott, 2005),
Weir length,
Weep point
Maximum liquid rate,

Minimum liquid rate at 80% turn down,
Weir liquid crest
[ ]
Take
At minimum rate,
Minimum design vapour velocity,
Actual minimum vapour velocity,
Minimum operating rate will be well above weep point,
416
Plate Pressure Drop
Dry plate drop
Maximum vapour velocity through holes,
From Figure 11.34 in Chemical Engineering Design (Coulson & Sinnott, 2005), for plate
thickness/hole diameter = 1,
Orifice coefficient,
Pressure drop through the dry plate,
[ ]
where is the velocity through the holes, m/s.
Residual head,
Total plate pressure drop,
Downcomer liquid backup
Downcomer pressure drop,
Area under apron,
If is less than , use in equation 11.92 in Chemical Engineering Design (Coulson &
Sinnott, 2005).
Head loss in downcomer,
[ ]
417
Back-up in downcomer,
Therefore, tray spacing is acceptable.
Residence time
Residence time in downcomer,
Check entrainment
According to Figure 11.29 in Chemical Engineering Design (Coulson & Sinnott, 2005),
,
Number of holes
Efficiency
By using O'Connell correlation in Transport Processes and Separation Process Principles,

(Geankoplis, 2003),
Number of real stages,
No. of trays = 28
418
Column height
( )
Costing for C-103
Data and calculation are based on methods by Turton et al. (2012).
Required Information:
Vessel Pressure 380 mmHg
Column height 18.13 m
No. of trays 28
Inside diameter of column 1.18 m
Sizing orientation Vertical oriented
There are two parts of costing which are tower packing and sieve tray.
Purchased cost of tower packing based on year 1996:
99
99
99
where
419
Purchased cost of sieve trays based on year 1996:
99
99
99
Bare module cost, equation for sieve trays is as shown below (Turton, 2012).
where
Total Bare Module cost for C-103,
Mechanical Design
⁄ ⁄

150°C.
Joint factor,
Internal diameter
( )
( )
420
Weight of plates:
421
( )
( )
For bending stress,
9
( )
( ) 9
( )
422
Buckling stress,
( ) ( )


0.25mm.
423
⁄ at 20°C.
( )
( )
424
Thus,
425
C-104 Sizing
Column Diameter
( )
Column diameter,
Sieve plate design
Column Diameter, =
Column Area, =
=
Net Area, =
=
426
Active Area, =
=
Hole Area, =
=
Weir length,
Weep point

Weir liquid crest
[ ]
Take
At minimum rate,
427
Plate Pressure Drop
Dry plate drop
[ ]
Residual head,
Area under apron,
Sinnott, 2005).
[ ]
428
Residence time
Check entrainment
,
Number of holes
Efficiency

(Geankoplis, 2003),
No. of trays = 23
429
Column height
( )
Costing for C-104
No. of trays 24
99
99
99
where
430
99
99
99
where
Mechanical Design
⁄ ⁄

200°C.
Joint factor,
Internal diameter
( )
( )
431
Weight of plates:
432
( )
( )
For bending stress,
9
( )
( ) 9
( )
433
Buckling stress,
( ) ( )


0.25mm.
434
⁄ at 20°C.
( )
( )
435
Thus,
436
C-105 Sizing
Column Diameter
( )
Column diameter,
Sieve plate design
Column Diameter, =
Column Area, =
=
437
Net Area, =
=
Active Area, =
=
Hole Area, =
=
Weir length,
Weep point

Weir liquid crest
[ ]
Take
At minimum rate,
438
Plate Pressure Drop
Dry plate drop
[ ]
Residual head,
Area under apron,
Sinnott, 2005).
[ ]
439
Residence time
Check entrainment
,
Number of holes
Efficiency

(Geankoplis, 2003),
No. of trays = 32
440
Column height
( )
Costing for C-105
No. of trays 32
99
99
99
where
441
99
99
99
where
Mechanical Design
⁄ ⁄

250°C.
Joint factor,
Internal diameter
( )
( )
442
Weight of plates:
443
( )
( )
For bending stress,
9
( )
( ) 9
( )
444
Buckling stress,
( ) ( )

445
0.25mm.
⁄ at 20°C.
( )
( )
446
Thus,
447
C-106 Sizing
Density of vapour,
Density of liquid,
[ ]
where
Therefore,
( )
V, in kmol/hr is
( ) ( )
( )
( )
448
Material of construction: Stainless Steel 304
Volume = m3
449
where
Mechanical Design
⁄ ⁄

150°C.
Joint factor,
Internal diameter
( )
( )
450
m
( )
451
( )
For bending stress,
( )
( ) ( )
Buckling stress,
( ) ( )

452
0.75mm.
453
⁄ at 20°C.
( )
( )
454
( )
Thus,
455
B.1. 9 T-101 Sizing and Costing
T-101 Sizing
Storage tank T-101 for Methanol
Operating Condition:
Feed temperature ( C) 25
Feed Pressure (atm) 1
Flow rate (kg/h) 1129.5
Density (kg/m3) 792.921
Volumetric flow rate (m3/h) 1.42448
Assume methanol storage tank is able to cater the needs of production line for 7 days
duration.
Volume of Storage Tank
According to the rule of thumbs a storage tank H/D=1.6

Volume of storage tank = no. of days x volumetric flow rate = 239.312 m3
For safety factor, the capacity of the tank should be 5% bigger.

Therfore, Vactual = 251.277 m3
𝑉 𝜋𝑟 𝐻 𝜋𝑟 𝐷 𝜋𝑟
Therefore, radius of vessel, r = 2.92 m

Diameter of vessel, D = 5.8 m
Height of vessel, H = 9.4 m
Height of liquid, HL = 3.0 m
Thickness of Storage Tank
𝑝𝐿 𝐻𝐿 𝐷
𝑒𝑠
𝑓𝑡 𝐽
where es = tank thickness required at depth HL, mm

HL = liquid depth, m
pL = liquid density, kg/m3
J = joint factor ( assume is 1)
g = gravitational acceleration, 9.81m/s2
ft = design stress for tank material, N/mm2
Dt = tank diameter, m
456
From Table 13.2 in Chemical Engineering Design (Coulson & Sinnott, 2005),
Carbon steel is chosen for tank construction material,
Temperature of tank = 25 C
Design stress, ft = 135 N/mm2
Therefore, thickness of tank, es = 0.05 mm
According to Methanol MSDS (2005), the

evaporation rate of o-xylene to butyl acetate ratio is 4.1.
Based on MSDS Glossary (2014), evaporation rate ratio
above 3.0 is considered fast and thus a floating roof tank is required.
T-101 Mechanical Design

Design Pressure
𝑁
𝑃𝑖 𝑃
𝑚𝑚
= 0.1114575 N/mm2
Material used
Material of construction is carbon steel,

Corrosion Allowance

𝑃𝑖 𝐷𝑖
𝑒𝑖
𝑓 𝑃𝑖
= 2.40 mm
457
( 5 mm)
Weight of Vessel
where
Wv = total weight of shell, excluding internal fitting, such as plates,
N
= 5.81 m
Wv = 102722.03 N
= 102.72 kN
𝑊𝑖 𝑝𝑉𝑖 𝑔 = 32797.43 N
= 32.80 kN
Total weight of vessel, plates and

= 135.52 kN
insulation
458
Wind loads
design:


= 7.63 kN/m
𝐹𝑤
𝑀𝑥 𝐻
= 337040 Nm
Pressure stresses
𝑃𝑖 𝐷𝑖
𝜎𝐿
𝑡
= 32.32 N/mm2
𝑃𝑖 𝐷𝑖
𝜎𝐻
𝑡
= 64.65 N/mm2
Dead weight stress

𝑊𝑣
𝜎𝑤
= 1.127 N/mm2
Bending stresses
𝐷𝑜 𝐷𝑖 𝑡 = 5.810 m

𝜋
𝐼𝑣 (𝐷𝑜 𝐷𝑖 = 3.841E+11 mm2
459
𝑀𝑥 𝐷𝑖
𝜎𝑏 ± 𝑡
𝑙𝑣
= 2.55 N/mm2

(upwind)
(downwind)
𝜎𝐻 𝜎𝑧 = 36.00 N/mm2

𝑡
𝜎𝑐
𝐷𝑜
= 17.21 N/mm2
𝜎𝑤 𝜎𝑏 = 3.676 N/mm2
Vessel support
𝜋
= 2506562.2 N
= 2506.56 kN
460
𝐹𝑤 𝑥
𝑀𝑠
= 495.72 kNm
𝑀𝑠
𝜎𝑏𝑠
𝑊
𝜎𝑤𝑠

<
4.97 < 144.02
𝜎𝑠 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 < 𝑡𝑠
𝐸 ( ) 𝑠𝑖𝑛𝜃
𝐷𝑠
58.95 < 730.10

461
= 33 bolts
( multiples of 4)
𝑀𝑠
𝐴𝑏 [ 𝑊]
where
𝐴𝑏
𝜋
= 8.54 mm
The total compressive load on the base
ring,
𝑀𝑥 𝑊
𝐹𝑏
𝜋𝐷𝑠 𝜋𝐷𝑠
= 566051.1 N/m

𝐹𝑏
𝐿𝑏
𝑓𝑐
= 113.21 mm

Lr + ts + 50mm = 154 mm
462
𝐹𝑏
𝑓𝑐
= 3.68 N/mm2
𝑓𝑐
𝑡𝑏 𝐿𝑟
𝑓𝑟 = 21.33 mm
= 21 mm
Costing for T-101
The costing method for T-101 will be calculated based on the Capital Cost Equation. Data and
calculations are based on methods by Turton et al. (2012).
Equipment type: Floating roof tank
Material of construction: Carbon steel
Volume = m3
Purchased cost of tank per unit of volume based on year 2001:
Bare module cost, equation for tank is as shown below (Turton, 2012).
where
463
T-102 Sizing
Storage tank T-102 for NaOCH3 30% solution
Density (kg/m3) 965
Assume NaOCH3 storage tank is able to cater the needs of production line for 7 days
duration.



𝑒𝑠
𝑓𝑡 𝐽

464
Stainless steel 304 is chosen for tank construction material,
According to Sodium Methoxide Solution MSDS (1998), the

evaporation rate ratio is not available. Hence, fixed roof tank is chosen.
Design Pressure
𝑁
𝑃𝑖 𝑃
𝑚𝑚
= 0.1114575 N/mm2
Material used

Corrosion Allowance

𝑃𝑖 𝐷𝑖
𝑒𝑖
𝑓 𝑃𝑖
= 0.78 mm
465
( 3 mm)
Weight of Vessel
where
= 2.30 m
Wv = 9475.59 N
= 9.48 kN
𝑊𝑖 𝑝𝑉𝑖 𝑔 = 4983.18 N
= 4.98 kN
466
Wind loads
design:


= 3.14 kN/m
𝐹𝑤
𝑀𝑥 𝐻
= 20371 Nm
Pressure stresses
𝑃𝑖 𝐷𝑖
𝜎𝐿
𝑡
= 21.36 N/mm2
𝑃𝑖 𝐷𝑖
𝜎𝐻
𝑡
= 42.73 N/mm2
Dead weight stress

𝑊𝑣
𝜎𝑤
= 0.437 N/mm2
Bending stresses
𝐷𝑜 𝐷𝑖 𝑡 = 2.306 m

𝜋
𝐼𝑣 (𝐷𝑜 𝐷𝑖 = 1.439E+10 mm2
467
𝑀𝑥 𝐷𝑖
𝜎𝑏 ± 𝑡
𝑙𝑣
= 1.63 N/mm2

(upwind)
(downwind)
𝜎𝐻 𝜎𝑧 = 23.43 N/mm2

𝑡
𝜎𝑐
𝐷𝑜
= 26.02 N/mm2
𝜎𝑤 𝜎𝑏 = 2.072 N/mm2
Vessel support
𝜋
= 150956.85 N
= 150.96 kN
468
𝐹𝑤 𝑥
𝑀𝑠
= 49.29 kNm
𝑀𝑠
𝜎𝑏𝑠
𝑊
𝜎𝑤𝑠

𝜎𝑠 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝜎𝑏𝑠 𝜎𝑤𝑠 = -0.72 N/mm2
<
-0.72 < 144.02
𝐷𝑠
4.65 < 730.10

469
= 15 bolts
( multiples of 4)
𝑀𝑠
𝐴𝑏 [ 𝑊]
where
𝐴𝑏
𝜋
= 7.18 mm
𝑀𝑥 𝑊
𝐹𝑏
= 35367.98 N/m

𝐹𝑏
𝐿𝑏
𝑓𝑐
= 7.07 mm

Lr + ts + 50mm = 154 mm
470
𝐹𝑏
𝑓𝑐
= 0.23 N/mm2
𝑓𝑐
𝑡𝑏 𝐿𝑟
𝑓𝑟 = 5.33 mm
= 5 mm
Costing for T-102
Equipment type: Fixed roof tank
Volume = m3
where
471
T-103 Sizing
Storage tank T-103 for RBD palm kernel oil (Triglyceride)
Assume the storage tank is able to cater the needs of production line for 7 days
duration.



𝑒𝑠
𝑓𝑡 𝐽

472
A fixed roof tank is sufficient.
Design Pressure
𝑁
𝑃𝑖 𝑃
𝑚𝑚
= 0.1114575 N/mm2
Material used

Corrosion Allowance

𝑃𝑖 𝐷𝑖
𝑒𝑖
𝑓 𝑃𝑖
= 4.01 mm
473
( 7 mm)
Weight of Vessel
where
= 9.71 m
Wv = 398380.31 N
= 398.38 kN
𝑊𝑖 𝑝𝑉𝑖 𝑔 = 90432.91 N
= 90.43 kN
Wind loads
design:
474


= 12.63 kN/m
𝐹𝑤
𝑀𝑥 𝐻
= 1516689 Nm
Pressure stresses
𝑃𝑖 𝐷𝑖
𝜎𝐿
𝑡
= 38.61 N/mm2
𝑃𝑖 𝐷𝑖
𝜎𝐻
𝑡
= 77.22 N/mm2
Dead weight stress

𝑊𝑣
𝜎𝑤
= 1.867 N/mm2
Bending stresses
𝐷𝑜 𝐷𝑖 𝑡 = 9.714 m

𝜋
𝐼𝑣 (𝐷𝑜 𝐷𝑖 = 2.515E+12 mm2

𝑀𝑥 𝐷𝑖
𝜎𝑏 ± 𝑡
𝑙𝑣
= 2.93 N/mm2
475
(upwind)
(downwind)
𝜎𝐻 𝜎𝑧 = 43.41 N/mm2

𝑡
𝜎𝑐
𝐷𝑜
= 14.41 N/mm2
𝜎𝑤 𝜎𝑏 = 4.795 N/mm2
Vessel support
𝜋
= 11560319 N
= 11560.32 kN

𝐹𝑤 𝑥
𝑀𝑠
= 1933.34 kNm
476
𝑀𝑠
𝜎𝑏𝑠
𝑊
𝜎𝑤𝑠

<
41.23 < 144.02
𝐷𝑠
251.73 < 730.10

= 54 bolts
( multiples of 4)
477
𝑀𝑠
𝐴𝑏 [ 𝑊]
where
𝐴𝑏
𝜋
= 8.69 mm
𝑀𝑥 𝑊
𝐹𝑏
= 2524654.8 N/m

𝐹𝑏
𝐿𝑏
𝑓𝑐
= 504.93 mm

Lr + ts + 50mm = 154 mm

𝐹𝑏
𝑓𝑐
= 16.39 N/mm2
478
𝑓𝑐
𝑡𝑏 𝐿𝑟
𝑓𝑟 = 45.05 mm
= 45 mm
Costing for T-103
Volume = m3
where
479
T-104 Sizing
Storage tank T-104 for Water
Assume water storage tank is able to cater the needs of production line for 7 days
duration.



𝑒𝑠
𝑓𝑡 𝐽

480
The evaporation rate of water to butyl acetate ratio is 0.3.

Based on MSDS Glossary (2014), evaporation rate ratio
below 0.8 is considered slow and thus a fixed roof tank is sufficient.
Design Pressure
𝑁
𝑃𝑖 𝑃
𝑚𝑚
= 0.1114575 N/mm2
Material used

Corrosion Allowance

𝑃𝑖 𝐷𝑖
𝑒𝑖
𝑓 𝑃𝑖
= 4.42 mm
481
( 7 mm)
Weight of Vessel
where
= 10.71 m
Wv = 486638.70 N
= 486.64 kN
𝑊𝑖 𝑝𝑉𝑖 𝑔 = 110689.40 N
= 110.69 kN
Wind loads
design:
482


= 13.91 kN/m
𝐹𝑤
𝑀𝑥 𝐻
= 2056964 Nm
Pressure stresses
𝑃𝑖 𝐷𝑖
𝜎𝐿
𝑡
= 42.59 N/mm2
𝑃𝑖 𝐷𝑖
𝜎𝐻
𝑡
= 85.19 N/mm2
Dead weight stress

𝑊𝑣
𝜎𝑤
= 2.067 N/mm2
Bending stresses
𝐷𝑜 𝐷𝑖 𝑡 = 10.714 m

𝜋
𝐼𝑣 (𝐷𝑜 𝐷𝑖 = 3.375E+12 mm2

𝑀𝑥 𝐷𝑖
𝜎𝑏 ± 𝑡
𝑙𝑣
= 3.26 N/mm2
483
(upwind)
(downwind)
𝜎𝐻 𝜎𝑧 = 47.92 N/mm2

𝑡
𝜎𝑐
𝐷𝑜
= 13.07 N/mm2
𝜎𝑤 𝜎𝑏 = 5.332 N/mm2
Vessel support
𝜋
= 15609560 N
= 15609.56 kN
484
𝐹𝑤 𝑥
𝑀𝑠
= 2563.14 kNm
𝑀𝑠
𝜎𝑏𝑠
𝑊
𝜎𝑤𝑠

<
57.62 < 144.02
𝐷𝑠
336.69 < 730.10

= 59 bolts
( multiples of 4)
485
𝑀𝑠
𝐴𝑏 [ 𝑊]
where
𝐴𝑏
𝜋
= 9.02 mm
𝑀𝑥 𝑊
𝐹𝑏
= 3405014.3 N/m

𝐹𝑏
𝐿𝑏
𝑓𝑐
= 681.00 mm

Lr + ts + 50mm = 154 mm

𝐹𝑏
𝑓𝑐
= 22.11 N/mm2
486
𝑓𝑐
𝑡𝑏 𝐿𝑟
𝑓𝑟 = 52.31 mm
= 52 mm
Costing for T-104
Volume = m3
where
487
T-105 Sizing
Storage tank T-105 for CE-810
Assume the storage tank is able to store the product for 7 days
duration.



𝑒𝑠
𝑓𝑡 𝐽

488
Design Pressure
𝑁
𝑃𝑖 𝑃
𝑚𝑚
= 0.1114575 N/mm2
Material used
Material of construction is stainless steel
304,

Corrosion Allowance

𝑃𝑖 𝐷𝑖
𝑒𝑖
𝑓 𝑃𝑖
= 1.55 mm
489
( 4 mm)
Weight of Vessel
where
= 4.60 m
Wv = 51435.27 N
= 51.44 kN
𝑊𝑖 𝑝𝑉𝑖 𝑔 = 20477.50 N
= 20.48 kN
Wind loads
design:
490


= 6.09 kN/m
𝐹𝑤
𝑀𝑥 𝐻
= 166751 Nm
Pressure stresses
𝑃𝑖 𝐷𝑖
𝜎𝐿
𝑡
= 32.04 N/mm2
𝑃𝑖 𝐷𝑖
𝜎𝐻
𝑡
= 64.09 N/mm2
Dead weight stress

𝑊𝑣
𝜎𝑤
= 0.889 N/mm2
Bending stresses
𝐷𝑜 𝐷𝑖 𝑡 = 4.608 m

𝜋
𝐼𝑣 (𝐷𝑜 𝐷𝑖 = 1.533E+11 mm2

𝑀𝑥 𝐷𝑖
𝜎𝑏 ± 𝑡
𝑙𝑣
= 2.51 N/mm2
491
(upwind)
(downwind)
𝜎𝐻 𝜎𝑧 = 35.44 N/mm2

𝑡
𝜎𝑐
𝐷𝑜
= 17.36 N/mm2
𝜎𝑤 𝜎𝑏 = 3.396 N/mm2
Vessel support
𝜋
= 1241200.8 N
= 1241.20 kN
492
𝐹𝑤 𝑥
𝑀𝑠
= 269.07 kNm
𝑀𝑠
𝜎𝑏𝑠
𝑊
𝜎𝑤𝑠

<
1.19 < 144.02
𝐷𝑠
30.48 < 730.10

= 27 bolts
( multiples of 4)
493
𝑀𝑠
𝐴𝑏 [ 𝑊]
where
𝐴𝑏
𝜋
= 8.28 mm
𝑀𝑥 𝑊
𝐹𝑏
= 280270.81 N/m

𝐹𝑏
𝐿𝑏
𝑓𝑐
= 56.05 mm

Lr + ts + 50mm = 154 mm

𝐹𝑏
𝑓𝑐
= 1.82 N/mm2
𝑓𝑐
𝑡𝑏 𝐿𝑟
𝑓𝑟
494
= 15.01 mm
= 15 mm
Costing for T-105
Volume = m3
where
495
T-106 Sizing
duration.



𝑒𝑠
𝑓𝑡 𝐽

496
Design Pressure
𝑁
𝑃𝑖 𝑃
𝑚𝑚
= 0.1114575 N/mm2
Material used

Corrosion Allowance

𝑃𝑖 𝐷𝑖
𝑒𝑖
𝑓 𝑃𝑖
= 3.21 mm
497
( 6 mm)
Weight of Vessel
where
= 9.51 m
Wv = 327775.03 N
= 327.78 kN
𝑊𝑖 𝑝𝑉𝑖 𝑔 = 86846.28 N
= 86.85 kN
Wind loads
design:
498


= 12.37 kN/m
𝐹𝑤
𝑀𝑥 𝐻
= 1428677 Nm
Pressure stresses
𝑃𝑖 𝐷𝑖
𝜎𝐿
𝑡
= 44.12 N/mm2
𝑃𝑖 𝐷𝑖
𝜎𝐻
𝑡
= 88.24 N/mm2
Dead weight stress

𝑊𝑣
𝜎𝑤
= 1.830 N/mm2
Bending stresses
𝐷𝑜 𝐷𝑖 𝑡 = 9.512 m

𝜋
𝐼𝑣 (𝐷𝑜 𝐷𝑖 = 2.024E+12 mm2

𝑀𝑥 𝐷𝑖
𝜎𝑏 ± 𝑡
𝑙𝑣
= 3.36 N/mm2
499
(upwind)
(downwind)
𝜎𝐻 𝜎𝑧 = 49.30 N/mm2

𝑡
𝜎𝑐
𝐷𝑜
= 12.62 N/mm2
𝜎𝑤 𝜎𝑏 = 5.186 N/mm2
Vessel support
𝜋
= 10873903 N
= 10873.90 kN
𝐹𝑤 𝑥
𝑀𝑠
500
= 1829.38 kNm
𝑀𝑠
𝜎𝑏𝑠
𝑊
𝜎𝑤𝑠

<
37.62 < 144.02
𝐷𝑠
236.79 < 730.10

= 53 bolts
( multiples of 4)
501
𝑀𝑠
𝐴𝑏 [ 𝑊]
where
𝐴𝑏
𝜋
= 9.24 mm
𝑀𝑥 𝑊
𝐹𝑏
= 2361359.5 N/m

𝐹𝑏
𝐿𝑏
𝑓𝑐
= 472.27 mm

Lr + ts + 50mm = 154 mm

𝐹𝑏
𝑓𝑐
= 15.33 N/mm2
𝑓𝑐
𝑡𝑏 𝐿𝑟
𝑓𝑟
502
= 43.56 mm
= 44 mm
Costing for T-106
Volume = m3
where
503
T-107 Sizing
duration.



𝑒𝑠
𝑓𝑡 𝐽

504
Design Pressure
𝑁
𝑃𝑖 𝑃
𝑚𝑚
= 0.1114575 N/mm2
Material used

Corrosion Allowance

𝑃𝑖 𝐷𝑖
𝑒𝑖
𝑓 𝑃𝑖
= 2.43 mm
505
( 5 mm)
Weight of Vessel
where
= 7.21 m
Wv = 157635.60 N
= 157.64 kN
𝑊𝑖 𝑝𝑉𝑖 𝑔 = 50234.46 N
= 50.23 kN
Wind loads
design:
506


= 9.42 kN/m
𝐹𝑤
𝑀𝑥 𝐻
= 633831 Nm
Pressure stresses
𝑃𝑖 𝐷𝑖
𝜎𝐿
𝑡
= 40.12 N/mm2
𝑃𝑖 𝐷𝑖
𝜎𝐻
𝑡
= 80.25 N/mm2
Dead weight stress

𝑊𝑣
𝜎𝑤
= 1.393 N/mm2
Bending stresses
𝐷𝑜 𝐷𝑖 𝑡 = 7.210 m

𝜋
𝐼𝑣 (𝐷𝑜 𝐷𝑖 = 7.345E+11 mm2

𝑀𝑥 𝐷𝑖
𝜎𝑏 ± 𝑡
𝑙𝑣
= 3.11 N/mm2
507
(upwind)
(downwind)
𝜎𝐻 𝜎𝑧 = 44.63 N/mm2

𝑡
𝜎𝑐
𝐷𝑜
= 13.87 N/mm2
𝜎𝑤 𝜎𝑏 = 4.504 N/mm2
Vessel support
𝜋
= 4766697.9 N
= 4766.70 kN
508
𝐹𝑤 𝑥
𝑀𝑠
= 871.24 kNm
𝑀𝑠
𝜎𝑏𝑠
𝑊
𝜎𝑤𝑠

<
12.89 < 144.02
𝜎𝑠 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒 < 𝑡𝑠
𝐸 ( ) 𝑠𝑖𝑛𝜃
𝐷𝑠
107.75 < 730.10

509
= 41 bolts
( multiples of 4)
𝑀𝑠
𝐴𝑏 [ 𝑊]
where
𝐴𝑏
𝜋
= 9.04 mm
𝑀𝑥 𝑊
𝐹𝑏
= 1051935.8 N/m

𝐹𝑏
𝐿𝑏
𝑓𝑐
= 210.39 mm

Lr + ts + 50mm = 154 mm

𝐹𝑏
𝑓𝑐
510
= 6.83 N/mm2
𝑓𝑐
𝑡𝑏 𝐿𝑟
𝑓𝑟 = 29.08 mm
= 29 mm
Costing for T-107
Volume = m3
where
511
T-108 Sizing
Storage tank T-108 for Glycerol
duration.



𝑒𝑠
𝑓𝑡 𝐽

512
Design Pressure
𝑁
𝑃𝑖 𝑃
𝑚𝑚
= 0.1114575 N/mm2
Material used

Corrosion Allowance

𝑃𝑖 𝐷𝑖
𝑒𝑖
𝑓 𝑃𝑖
= 1.72 mm
( 4 mm)
513
Weight of Vessel
where
= 5.10 m
Wv = 63195.00 N
= 63.20 kN
𝑊𝑖 𝑝𝑉𝑖 𝑔 = 25155.58 N
= 25.16 kN
Wind loads
design:
514

= 6.73 kN/m
𝐹𝑤
𝑀𝑥 𝐻
= 226271 Nm
Pressure stresses
𝑃𝑖 𝐷𝑖
𝜎𝐿
𝑡
= 35.53 N/mm2
𝑃𝑖 𝐷𝑖
𝜎𝐻
𝑡
= 71.05 N/mm2
Dead weight stress

𝑊𝑣
𝜎𝑤
= 0.986 N/mm2
Bending stresses
𝐷𝑜 𝐷𝑖 𝑡 = 5.108 m

𝜋
𝐼𝑣 (𝐷𝑜 𝐷𝑖 = 2.089E+11 mm2

𝑀𝑥 𝐷𝑖
𝜎𝑏 ± 𝑡
𝑙𝑣
= 2.77 N/mm2

= 37.31 N/mm2 (upwind)
𝜎𝑧 𝜎𝐿 𝜎𝑤 𝜎𝑏
515
(downwind)
𝜎𝐻 𝜎𝑧 = 39.28 N/mm2

𝑡
𝜎𝑐
𝐷𝑜
= 15.66 N/mm2
𝜎𝑤 𝜎𝑏 = 3.753 N/mm2
Vessel support
𝜋
= 1690631.1 N
= 1690.63 kN
𝐹𝑤 𝑥
𝑀𝑠
= 350.11 kNm
516
𝑀𝑠
𝜎𝑏𝑠
𝑊
𝜎𝑤𝑠

<
2.42 < 144.02
𝐷𝑠
40.54 < 730.10

= 30 bolts
( multiples of 4)
517
𝑀𝑠
𝐴𝑏 [ 𝑊]
where
𝐴𝑏
𝜋
= 8.51 mm
𝑀𝑥 𝑊
𝐹𝑏
= 377976.67 N/m

𝐹𝑏
𝐿𝑏
𝑓𝑐
= 75.60 mm

Lr + ts + 50mm = 154 mm

𝐹𝑏
𝑓𝑐
= 2.45 N/mm2
𝑓𝑐
𝑡𝑏 𝐿𝑟
𝑓𝑟 = 17.43 mm
= 17 mm
518
Costing for T-108
Volume = m3
where
519
B.1. 17 P-101 Sizing and Costing
P-101 Sizing
According to Pump Handbook (Grundfos, 2004)
Properties Inlet Outlet

mass flow rate, kg/s 0.3137 0.3137
fluid density, kg/m3 792.8888 792.921
volumetric flow rate, m3/h 1.42453272 1.42448
pressure (atm) 1 1.2
Pump head,
𝑃
𝐻
𝑝𝑔
= 2.61 m
Based on the Figure 5.6 in Chemical Engineering Design (Coulson & Sinnott,
2005),
The suitable centrifugal pump used is a single-stage radial flow pumps.
𝜂 𝑙𝑛𝑄 𝑄
= 0.3518
𝑃𝐻 𝑝𝑔𝑄𝐻
= 8.02 W
𝜂𝑃 𝑃𝑠 𝑃𝑠
Ph = the hydraulic power

Ps = shaft power
Q = volumetric flow rate, cum/s
H = head, m
acceleration of gravity,
g = m/s2
p = density of liquid, kg/cum
Therefore, Ps = 22.7924 W
= 0.0228 kW
520
Costing for P-101
(i) Purchased Cost, Cp
For centrifugal pump, based on Figure A.5 (Turton et al., 2012),
Shaft Power, Ws (kW) 0.0228

Purchased cost per unit shaft power, Cpo/Ws ($/kW) 20,000
Purchased cost in 2001, Cpo ($) 455.85
(ii) Update Factor, UF
CEPCI in year 2001, Ibase 397

CEPCI in year 2014, I 576.2
Update Factor, UF 1.451
(iii) Material & Pressure Factor,
Based on Equation A.4 (Turton et al., 2012),
Based on Table A.3 and Figure A.18 (Turton et al., 2012),

Material Correction Factor, Fm 2.2
Based on Table A.4 (Turton et al., 2012),

Pump Type Centrifugal
B1 1.89
B2 1.35
Assume pressure correction factor,

Pressure Correction Factor, Fp 1.0
(v) Updated Bare Module Cost, CBM
Bare Module Cost at 2014 ($) 3,215.43

Bare Module Cost at 2014 (RM) 11,254.01 1$=RM3.50
521
P-102 Sizing

Pump head,
𝑃
𝐻
𝑝𝑔
= 3.09 m
2005),
= 0.3292
= 6.86 W

Ps = shaft power
H = head, m
g = m/s2
= 0.0208 kW
522
Costing for P-102

Purchased cost per unit shaft power, Cpo/Ws ($/kW) 20000



B1 1.89
B2 1.35


523
P-103 Sizing

1173.2
fluid density, kg/m3 1173.247
8
6.4185
volumetric flow rate, m3/h 6.4186699
2
Pump head,
𝑃
𝐻
𝑝𝑔
= 1.76 m
2005),
= 0.5443
= 36.13 W

Ps = shaft power
H = head, m
g = acceleration of gravity, m/s2
= 0.0664 kW
524
Costing for P-103

Purchased cost in 2001, Cpo ($) 1,327.60



B1 1.89
B2 1.35


525
P-104 Sizing

993.95
fluid density, kg/m3 993.9442
7
Pump head,
𝑃
𝐻
𝑝𝑔
= 2.08 m
2005),
= 0.5789
= 49.51 W

Ps = shaft power
H = head, m
g = acceleration of gravity, m/s2
= 0.0855 kW
526
Costing for P-104




B1 1.89
B2 1.35


527
P-105 Sizing

Pump head,
𝑃
𝐻
𝑝𝑔
= 2.75 m
2005),
The suitable centrifugal pump used is a single-stage radial flow
pumps.
= 0.3505
= 7.94 W

Ps = shaft power
H = head, m
g = m/s2
= 0.0227 kW
528
Costing for P-105




B1 1.89
B2 1.35


529
P-106 Sizing

Pump head,
𝑃
𝐻
𝑝𝑔
= 2.75 m
2005),
pumps.
= 0.6078
= 65.46 W

Ps = shaft power
H = head, m
g = m/s2
= 0.1077 kW
530
Costing for P-106




B1 1.89
B2 1.35


531
P-107 Sizing

Pump head,
𝑃
𝐻
𝑝𝑔
= 2.59 m
2005),
pumps.
= 0.5876
= 53.80 W

Ps = shaft power
volumetric flow rate,
Q = cum/s
H = head, m
g = m/s2
= 0.0915 kW
532
Costing for P-107




B1 1.89
B2 1.35


533
P-108 Sizing

pressure (atm) 0.5 0.7
Pump head,
𝑃
𝐻
𝑝𝑔
= 3.15 m
2005),
pumps.
= 0.6072
= 65.07 W

Ps = shaft power
H = head, m
g = m/s2
= 0.1072 kW
534
Costing for P-108




B1 1.89
B2 1.35


535
P-109 Sizing

pressure (atm) 0.25 1
Pump head,
𝑃
𝐻
𝑝𝑔
= 10.49 m
2005),
= 0.2676
= 17.06 W

Ps = shaft power
H = head, m
g = m/s2
= 0.0638 kW
536
Costing for P-109




B1 1.89
B2 1.35


537
P-110 Sizing

pressure (atm) 0.25 0.45
Pump head,
𝑃
𝐻
𝑝𝑔
= 3.12 m
2005),
pumps.
= 0.5976
= 59.22 W

Ps = shaft power
H = head, m
g = m/s2
= 0.0991 kW
538
Costing for P-110




B1 1.89
B2 1.35


539
P-111 Sizing

Pump head,
𝑃
𝐻
𝑝𝑔
= 13.79 m
2005),
pumps.
= 0.5523
= 180.40 W

Ps = shaft power
H = head, m
g = m/s2
= 0.3266 kW
540
Costing for P-111




B1 1.89
B2 1.35


541
P-112 Sizing

Pump head,
𝑃
𝐻
𝑝𝑔
= 14.18 m
2005),
pumps.
= 0.4612
= 83.92 W

Ps = shaft power
H = head, m
g = m/s2
= 0.1820 kW
542
Costing for P-112




B1 1.89
B2 1.35


543
P-113 Sizing

Pump head,
𝑃
𝐻
𝑝𝑔
= 2.15 m
2005),
pumps.
= 0.5948
= 57.61 W

Ps = shaft power
H = head, m
g = m/s2
= 0.0969 kW
544
Costing for P-113




B1 1.89
B2 1.35


545
B.1. 30 M-101 Sizing and Costing
M-101 Sizing
The data required is taken from simulations data.

 = 772 kg/m3
Total flowrate = 2189.291 kg/hr
= 2189.291 kg m3 1 hr
hr 772 kg 3600 s
= 0.000788 m3/s
Assumption,
Space time, ts = 60 s
Volume, V = 0.000788 m3 60 s
s
= 0.04726 m3
Viscosity, µ = 0.000465531 N.s/m2
From Figure 10.57 : Chemical Engineering Volume 6 First Edition (R.K. Sinnott, 1983)
Agitator selection type = Turbine or propeller (1750 rpm)

N = 1750 rpm
= 29.1667 rps
The form of mixer is a vertical cylindrical tank
V = 0.04726 m3
V = (DT2H) / 4
With:
1.5 H = 2.0 DT
H = ( 2.0 / 1.5) DT
V = DT2 (2.0/ 1.5) DT
4
= DT2 ( 2.0 DT )
4 x 1.5
= 2.0 DT3
6
= DT3
3
546
DT3 = 3V / 
DT = (3V / )1/3
With:
DT = Tank diameter
V = Tank volume
Tank diameter, DT = ( 3 x 0.04726 /  )1/3
= 0.35603 m
H = ( 2.0 / 1.5 ) x DT
= ( 2.0 / 1.5 ) x 0.35603
= 0.474703108 m
Choose
curve 1
D / DT = 0.3
p/D = 1.8
With:
p = Blast pitch
DT = Tank diameter
D = Agitator diameter
D = 0.30 x DT
= 0.3 x 0.35603
= 0.10681 m
p = 1.80 x D
= 1.8 x 0.10681
= 0.192254759 m
The Reynolds Number:
Re = D2N

With:
D = Agitator diameter, m
N = Agitator speed, rps
 = Fluid density, kg/ m3
547
 = Fluid viscosity, Ns/ m2
Re = (0.10681 x 29.1667 x 772)

4.6553E-04
= 5.5178E+05
Np = 0.85
Np = P
D5N3
P = NpD5N3
With:
P = Shaft power, W
Np = Power number
P = 0.85 x 0.10681 x 29.16673 x

= 226.3182552 W
= 0.22632 kW
Costing for M-101
Agitator Cost:
Power consumption, P = 0.22632 kW

Design type of mixer = Agitator mixer
From Figure A.15 (Turton et al. 2012)

Purchased equipment costs for propeller mixer for year 2001,
Cp/P, 2001
= ($/kW) 70.00
Cp, 2001 = $ 15.84
CEPCI (2014) = 576.2

CEPCI (2001) = 397
Update Factor, UF = 576.2

397
= 1.4514
548
Purchased equipment costs for propeller mixer for year 2014, Cp, 2014
= UF x Cp, 2001
= 1.4514 x 15.84
= $ 22.99
Bare Module Factor, FBM = 1.38 (for propeller)
Therefore,
Base bare module contribution, CBM = FBM x Cp, 2014
1.38 x
= 22.99
= 31.73 $
= 111.06 RM ($1=RM3.50)
Mixing vessel Cost:

Volume of
vessel = 0.04726 m3
Design type of vessel = Vertical cylindrical
From Figure A.7 (Turton et al., 2012)

Cp/P, 2001
= ($/m3) 20000.00
Cp, 2001 = $ 945.29
CEPCI (2014) = 576.2

CEPCI (2001) = 397

397
= 1.4514
= UF x Cp, 2001
= 1.4514 x 945.29
= $ 1371.98
Bare Module Factor, FBM = 9.53 (for stainless steel)
Therefore,
= 13074.97 $
= 45762.38 RM ($1=RM3.50)
Total CBM = 45,873.44 RM
549
M-102 Sizing

 = 595.1911 kg/m3
= 9801.305 kg m3 1 hr
595.1911
hr kg 3600 s
3
= 0.004574 m /s
Assumption,
Volume, V = 0.004574 m3 60 s
s
= 0.27446 m3
Viscosity, µ = 0.0133 N.s/m2
Agitator selection type = Turbine or propeller (1750 rpm)

N = 1750 rpm
= 29.1667 rps
V = 0.27446 m3
V = (DT2H) / 4
With:
1.5 H = 2.0 DT
H = ( 2.0 / 1.5) DT
V = DT2 (2.0/ 1.5) DT
4
= DT ( 2.0 DT )
2
4 x 1.5
= 2.0 DT3
6
= DT3
3
550
DT3 = 3V / 
DT = (3V / )1/3
With:
DT = Tank diameter
V = Tank volume
= 0.63993 m
H = ( 2.0 / 1.5 ) x DT
= ( 2.0 / 1.5 ) x 0.63993
= 0.853235997 m
Choose
curve 1
D / DT = 0.3
p/D = 1.8
With:
p = Blast pitch
DT = Tank diameter
D = Agitator diameter
D = 0.30 x DT
= 0.3 x 0.63993
= 0.19198 m
p = 1.80 x D
= 1.8 x 0.19198
= 0.34556 m
The Reynolds Number:
Re = D2N

With:
 = Fluid viscosity, Ns/ m2
551
Re = (0.19198 x 29.1667 x 595.1911)
1.3300E-02
= 4.8106E+04
Np = 0.85
Np = P
D N3 
5
P = NpD5N3
With:
P = Shaft power, W
Np = Power number
P = 0.85 x 0.191985 x 29.16673 x

= 3273.363141 W
= 3.27336 kW
Costing for M-102
Agitator Cost:
Power consumption, P = 3.27336 kW

Design type of mixer = Agitator mixer
From Figure A.15 (Turton et al. 2012)

Cp/P, 2001
= ($/kW) 65.00
Cp, 2001 = $ 212.77
CEPCI (2014) = 576.2

CEPCI (2001) = 397

397
= 1.4514
552
= UF x Cp, 2001
= 1.4514 x 212.77
= $ 308.81
Bare Module Factor, FBM = 1.38 (for propeller)
Therefore,
= 1.38 x 308.81
= 426.16 $
= 1491.55 RM ($1=RM3.50)
Mixing vessel Cost:

Volume of
vessel = 0.27446 m3

Cp/P, 2001
= ($/m3) 12000.00
Cp, 2001 = $ 3293.50
CEPCI (2014) = 576.2

CEPCI (2001) = 397

397
= 1.4514
= UF x Cp, 2001
= 1.4514 x 3293.50
= $ 4780.14
Therefore,
= 45554.69 $
= 159,441.42 RM ($1=RM3.50)
553
M-103 Sizing
Sizing for Mixer M-1:

 = 1.0659 kg/m3
= 211.6165 kg m3 1 hr
hr 1.0659 kg 3600 s
= 0.055148 m3/s
Assumption,
Volume, V = 0.055148 m3 60 s
s
= 3.30886 m3
Viscosity, µ = 1.30E-05 N.s/m2
V = 3.30886 m3
V = (DT2H) / 4
With:
1.5 H = 2.0 DT
H = ( 2.0 / 1.5) DT
V = DT2 (2.0/ 1.5) DT
4
= DT2 ( 2.0 DT )
4 x 1.5
= 2.0 DT3
6
= DT3
3
DT3 = 3V / 
DT = (3V / )1/3
With:
DT = Tank diameter
554
V = Tank volume
= 1.46734 m
H = ( 2.0 / 1.5 ) x DT
= ( 2.0 / 1.5 ) x 1.46734
= 1.95646 m
Costing for M-103
Mixing vessel Cost:

Volume of
vessel = 3.30886 m3

Cp/P, 2001
= ($/m3) 1750.00
Cp, 2001 = $ 5790.51
CEPCI (2014) = 576.2

CEPCI (2001) = 397

397
= 1.4514
= UF x Cp, 2001
= 1.4514 x 5790.51
= $ 8404.26
Therefore,
= 80092.57 $
= 280,324.01 RM ($1=RM3.50)
555
B.1. 33 Heat Exchanger Sizing and Costing Microsoft Excel Spreadsheet
Example: E-101 Sizing
Step 1: Specification
Heavy oil (kg/s) 2.7226

LPS (kg/s) 3.0734
Heat duty, Q (W) 149180
Temperature Heavy oil LPS

o
Tin ( C) 32 160
o
Tout ( C) 60 120
Step 2: Physical Properties
Heavy oil (Tube-side)

Operating Pressure 1 bar
o
Mean temperature 46 C
Fluid density, t 851.8243 kg/m3
Viscosity, tL 0.0074076 Ns/m2
Heat capacity, Ctp 3076.0493 J/kg.o C
Thermal conductivity, ktf 0.1998 W/m.o C
LPS (Shell-side)
Operating Pressure 5 bar
o
Mean temperature 140 C
Fluid density, s 0.5314013 kg/m3
Viscosity, sL 0.00001409 Ns/m2
Heat capacity, Csp 1907.445 J/kg.o C
Thermal conductivity, ksf 0.02830 W/m.o C
Step 3: Overall Coefficient
Overall heat transfer coefficient, U 100 (W/m2 o C) (Range 60-450)
556
Step 4: Exchanger Type and Dimensions
T1
T2
t2
t1
T1 = Inlet shell-side fluid temperature

T2 = Outlet shell-side fluid temperature
t1 = Inlet tube-side temperature
t2 = Outlet tube-side temperature
Heat exchanger type 1 shell and 2 tubes

Design type Fixed-tube
Heat exchanger orientation Horizontal
Heat transfer flow Counter-current
Tube side Heavy oil
Shell side LPS
Number of pass 2
R= 1.4286
S= 0.2188
Ft = 0.978
DTlm can be calculated from the equation,
DTlm = 93.87
557
The usual practice in the design of shell and tube exchangers is to estimate the
true temperature difference' from the dTlm by applying a correction factor
to allow for the departure from the true counter-current flow,
Therefore, the actual temperature difference is
DTm = 91.85
Step 5: Heat Transfer Area
Provisional area of heat exchanger, A can be obtained through the formulae,
Provisional area, A (m2 ) 16.2422
Step 6: Layout and Tube Size
Material Stainless Steel

BWG number 18
Length of tube Lt (m) 4.5
Outer diameter, Dto (m) 0.01905
Inner diameter, Dti (m) 0.01656
Material Thermal Conductivity, kw (W/m.K) 25
558
Step 7: Number of Tubes
Area of one tube, At (m2 ) 0.2693
Number of tube, N t 60
Tube per pass, N t 30
Tube cross-sectional area, Act (m2 ) 0.000215
Area per pass, AT (m2 ) 0.0065
3
Volumetric flow rate (m /s) 0.0032
(Liquid)
Tube-side velocity, ut (m/s) 0.49 low velocity =1 to 2 m/s
maximum is 4 m/s
559
Step 8: Bundle and Shell Diameter
Tube pitch is the distance between tube centres and formulated as
Pt
Triangle tube pitch,

Tube pitch, Pt (m) 0.0238
From Table 12.4 (Chemical Engineering , Vol. 6)

K 1 (for 2 passes) 0.249
n1 (for 2 passes) 2.207
Bundle diameter,
Bundle diameter, Db (m) 0.229
From Figure 12.10 (Chemical Engineering , Vol. 6)

Shell bundle clearance (m) 0.011
For Fixed-tube,
Ds = Db + shell bundle clearance
Shell internal diameter, Ds (m) 0.240
DPs  N p [8 j f ( L / D ti )(

 w
)  m
 2.5]

u
2
2
s
Step 9: Tube-side Heat Transfer Coefficient
Reynold number, Re 937.1

Prandtl number, Pr 114.0
L/Dti 271.7
From Figure 12.23 (Chemical Engineering, Vol. 6)

Heat transfer factor, jh 0.0030
0.14
k f j h Re Pr 0.33   
hi  
 
Dti  w 
Tube side heat transfer coefficient, hi (W/m2.K) 161.9150
( assuming viscosity of the fluid is identical at the wall and of the bulk fluid )
560
Step 10: Shell-side Heat Transfer Coefficient
Lets assume ratio of Shell internal diameter to Baffle spacing

Ratio of Ds to l B 2
Baffle spacing, l B (m) 0.1201

Tube pitch, Pt (m) 0.0238
Cross flow area, As (m2 ) 0.0058
1.1
De  ( pt2  0.971Dto
2
)
Dto
Shell side equivalent diameter, De (m) 0.0135
Volumetric flow rate (m3 /s) 5.7836
Shell-side velocity, us (m/s) 1002.692
Reynold number, Re 626384.64

Prandtl number, Pr 0.95
Selecting 25% for baffle cut

From Figure 12.29 (Chemical Engineering, Vol. 6)
Heat Transfer Factor, jh 0.0850
Shell side heat transfer coefficient, hs (W/m2 o C) 109516.00
561
Step 11: Overall Heat Transfer Coefficient
2 o
Outside fluid film coefficient, hs (W/m . C) 109516.00
2 o
Inside fluid film coefficient, hi (W/m . C) 161.915046
2 o
Outside dirt coefficient, hod (W/m . C) 5000
2 o
Inside dirt coefficient, hid (W/m . C) 3333.33333
o
Thermal conductivity of the tube wall material, k w (W/m. C) 25
Tube inside diameter, Dti (m) 0.01656
Tube outside diameter, Dto (m) 0.01905
1/Uo = 0.00771
Uo = 129.66 ( acceptable )
Deviation = 100%(Ucalc - U ass)/ Uass

= 29.66 % .
Step 12: Pressure Drop
Tube-side pressure drop
From Figure 12.24

Re 937.1
Friction factor, jf 0.0090
 m u s2
DPt  N p [8 j f ( L / Dti )( )  2.5]
w 2
where m = 0.25 for laminar flow, Re < 2100

m = 0.14 for turbulent flow, Re > 2100
N p = number of tube side passes
Tube side pressure drop, DPt 4551.8 0.046 bar

(<1 bar, satisfactory)
Shell-side pressure drop
From Figure 12.30

Re 626384.64
Friction factor, jf 0.026
u s2   0.14
DPs  8 j f ( D s / De )( L / l B ) ( )
2 w
Shell side presure drop, DPs 36969.995 0.370 bar

(<1 bar, satisfactory)
562
Example: Costing for E-101
(i) Purchased Cost, C p
Based on Figure A.5 (Turton et al., 2012),
Heat Transfer Area, A (m2 ) 16.2422

o 2
Purchased cost per unit of transfer area, C p /A ($/m ) 1200
o
Purchased cost in 2001, C p ($) 19,490.65


Material (Shell-side) Stainless Steel
Material (Tube-side) Stainless Steel

Exchanger Type Fixed Tube
B1 1.63
B2 1.66
Based on Figure A.2 (Turton et al., 2012),

Tube-side Pressure (bar) 1.0
Shell-side Pressure (bar) 5.0
Pressure Correction Factor, F p 1.0
(v) Updated Bare Module Cost, C BM

563
T-201 Sizing
Flow rate (kg/h) 119844
Assume the storage tank is able to store the product for 5 hour
duration.



564
Mechanical Design for T-201
Design methodology is based on Chemical Engineering Design (Coulson & Sinnott,

2005)
Design Pressure
= 0.1114575 N/mm2
Material used

Corrosion Allowance

𝑃𝑖 𝐷𝑖
𝑒𝑖
𝑓 𝑃𝑖 = 3.93 mm
( 6 mm)
565
Costing for T-201
Volume = m3
where
566
B.1. 35 Boiler E-201
Amount of steam needed = 119,844.12 kg/hr = 33.29 kg/s
From energy balance calculation, the energy needed to produce 33.29 kg/s of steam at 254 C
from boiler feed water (BFW) at 115 C is
Cost of boiler E-201
The costing method for E-201 will be calculated based on the Capital Cost Equation. Data and
Equipment type: Steam boiler
Material of construction: Stainless steel
Heat duty = 24002.78 kW
Purchased cost of steam boiler per unit of heat duty based on year 2001:
Bare module cost, equation for boiler is as shown below (Turton, 2012).
where
567
Cost of utilities
Raw water needed

Raw water needed = flow rate of steam = 119,844.12 kg/hr = 33.29 kg/s
Used steam is recycled as boiler feed water. Assuming 10% of water lost for each 5 hours.
The holding tank T-201 takes 5 hours to be filled up. Volumetric flow rate of water,
( )
( )

The cost of raw water for boiler, E-201,
Coal needed
Q = 24002.78 kJ/s
From the utilities table (Turton et al., 2012),
Cost of coal = $1.72/GJ
Total cost of utilities
Cost of utilities = Cost of raw water + Cost of coal = RM 4,184,246.39
568
B.1. 36 Steam Turbine K-201
Assume isentropic expansion for the steam turbine K-201.
Amount of steam entered = 32,646.58 kg/hr = 9.0685 kg/s
From steam tables, inlet condition = (T = 254 C, P = 41 bar),
H1 = 2830.3 kJ/kg
S1 = 6.1157 kJ/kg.K
Turbine outlet conditions for isentropic expansion to T = 160 C from steam tables are:
P2 = 6.18 bar
S2 = 6.1157 kJ/kg.K
The wetness fraction, X can be calculated from

S2 = X SL + (1-X) SV
At T = 160 C, P = 6.18 bar,

6.1157 = 1.9425 X + 6.7475 (1-X)
X = 0.1315
The turbine outlet enthalpy for an isentropic expansion can now be calculated from:
H2 = X HL + (1-X) HV
At T = 160 C, P = 6.18 bar,

H2 = X HL + (1-X) HV
= 0.1315 (675.5) + 2756.7 (1-0.1315)
= 2483.02 kJ/kg
Power generated,
569
Cost of Steam Turbine K-201
The costing method for K-201 will be calculated based on the Capital Cost Equation. Data
Equipment type: Radial gas turbine
Material of construction: Stainless steel
Power =
Purchased cost of steam turbine per unit of power based on year 2001:
Bare module cost, equation for steam turbine is as shown below (Turton, 2012).
where
570

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PRODUCTION OF 60,000 MTPA OF

A design project submitted to the Faculty of Engineering and Built Environment

Faculty of Engineering and Built Environment

DR. NOR YULIANA BINTI YUHANA

Faculty of Engineering and Built Environment

SAJJAD KHUDHUR ABBAS P81540

A design project submitted to the Faculty of Engineering and Built Environment

DR. NOR YULIANA BINTI YUHANA

Chapter 2: To conceptually design a feasible process flowsheet through hierarchical steps of

ACKNOWLEDGEMENT ....................................................................................................... III

The advantages of using oleochemicals over petrochemicals are:

 Oleochemicals are derived from renewable resources, so the continued availability of

1.1.2 Methyl Esters

Tranesterification is the displacement of alcohol from an ester by another alcohol in a process

Figure 1-2: Alcoholysis reaction

Figure 1-3: Transesterification reaction

1.1.3.1 Vegetable Oils

1.1.3.2 Waste Cooking Oils

1.1.3.4 Oleaginous Microorganisms

1.1.4 Advantages of Methyl Esters

1.2.1 FAME as Biodiesel

1.2.2 FAME as Raw Materials for Other Products

Figure 1-5: Major uses of methyl esters

1.2.3 Methyl Octanoate/Decanoate (Light Cut: C8-10)

1.2.5 Methyl Palmitate/Oleate (Heavy Cut: C16-18)

1.3.1 Production & Demand

Table 1-5: Major ASEAN oleochemical producers (ADI Finechem, 2013)

Table 1-7: Price of Chemical Species

Material Price Source Pricing date

1.3.3 Availability of Raw Material

Table 1-11: Methyl Ester Producers in Malaysia

1.3.5 Methyl Esters Prospect

Table 1-12: Methyl Ester Capacities by Malaysia

Figure 1-11: Methyl Esters Future Capacity by Malaysia

1.4.1 Alkali/Base-catalyzed Transesterification

Acid-catalyzed transesterification processes are not as popular as the base-catalyzed

To avoid catalyst drawbacks, supercritical alcohol (SCA) transesterification process was

Specifically, the non-catalytic supercritical transesterification process can be further divided

i) One-step supercritical methanol method (Saka process)

1.4.4 Enzymatic Transesterification

Four transesterification synthesis routes are compared based on different characteristics to

1.4.7 Catalyst Options

1. Sodium hydroxide (NaOH)

R-COOH + NaOH H2O + R-COO-Na (1.1)

Na+OH- + CH3OH H2O + CH3O-Na+ (1.2)

Table 1-19: Comparison of different homogeneous alkali catalysts

1.6 LEVEL 1 DECISION

RBD PKO Methyl ester

Methanol Process Glycerol

Sodium methoxide Sodium methoxide

Figure 1-14: Block flow diagram of level 1 decision

Table 1-20: Calculation for average molecular weight of triglyceride

2.1 LEVEL 2 DECISION

2.1.1 Input: Raw Material Selection and Impurities Management

Table 2-1: Destination code for transesterification process

RBD PKO, FT G,F Methyl ester, PME

Methanol, FMeOH,F Glycerol, PGL

Sodium methoxide, FNaOCH3,F Sodium methoxide, PNaOCH3

Figure 2-1: Block Flow Diagram of Level 2 Decision

The consecutive reactions:

The overall reaction:

where the kinetic data are summarized in Table 2-2 below.

Table 2-2: Kinetic data (Rashid et al., 2014)