University of San Agustin

College of Technology
Chemical Engineering Department

Mass Balance Calculations: Fermenter

Fermentation General Equation:

C6H12O6 + O2 + NH3 --> C2H5OH + CO2

C12H22O11 + H2O --> 2C6H12O6

From Schuler's Balanced Reaction

C6H12O6 + 0.013NH3 --> 0.126 CH1.83O0.56N0.17 + 0.391C2H5OH + 0.079C3H8O3 + 0.403CO2 + 0.025H2O
C6H12O6 --> 2C2H5OH +2CO2
1g Glucose --> 0.51g C2H5OH + 0.49g CO2
Molecular Weights of Each component:
NH3 = 17 kg/kmol
C2H6O = 46 kg/kmol
C6H12O6 = 180 kg/kmol
C12H22O11 = 366 kg/kmol
H2O = 18 kg/kmol
CH1.83O0.56N0.17 = 25.17 kg/kmol
C3H8O3 = 92 kg/kmol
CO2 = 44 kg/kmol

Mass Flowrate data obtained from Backward Calculation:

Total Pure Ethanol produced in Fermentation = 83.832 MT/day
Pure Ethanol per Fermenter :
83.832 MT
Ethanol   27.944
3 day
Sucrose needed
MT  kmol   kmolC12H22O11   366 kg 
139.829     kmol 
dayGlucose  180kg   2kmolC6H12O6  
equal to 142.1595MT/day


Syrup from third effect evaporator

kg of 60 degree Brix sugar

Fsugar  1948
hr
From 60 degree Brix to 15 degree brix
1948 is to 60 degree brix = xsugar is to 15 degree brix
kg
xsugar  487
hr
3
wneeded  1948  xsugar  1.461  10

Therefore 1461 water is needed to dilute concentrated molasses

 University of San Agustin
College of Technology
Chemical Engineering Department

Inlet Mass Flow Rates:

Based on the pitching rate of Safdistil
MT
50( 442.15 3)
Yeast   663.225 day
100
Ethanol  1000 18 3 kg
Glucose   1.165  10
24 46 0.391 hr

Ethanol  1000 0.013 14 kg

Ammonia   11.782
24 46 0.391 hr
Outlet Mas Flow Rates:
C6H12O6 + 0.013NH3 --> 0.126CH1.83O0.56N0.17 + 0.391C2H5OH + 0.079C3H8O3 + 0.403CO2 + 0.025H2O
kg
Ethanol  1000 0.025 18
OutletWater   29.131 hr
24 46 0.391
kg
Ethanol  1000 0.403 44 3
CarbonDioxide   1.148  10 hr
24 46 0.391
kg
Ethanol  1000 0.126 25.17 3
Biomass   2.361  10 hr
24 4 0.391
 University of San Agustin
College of Technology
Chemical Engineering Department

Bioethanol Process Calculations

Total production per day : 100 m 3 anhydrous ethanol @ 99% v/v

Pure ethanol produced per hour:

( 0.79) ( 0.999) MT
P  100  3.288
24 hr
MSDH Feed @96% v/v:
Total pure ethanol feed =Final Product + Product Loss in MSDH
MT
TPM  P  0.0655  3.354
hr
MSDH Feed or Distillation/Rectifier Distillate
TPM MT
RD   3.494
0.96 hr

Rectifier Feed @ 60% v/v:

Total Pure Ethanol feed to Rectifier = Feed to MSDH + Product Loss in Rectifier

TPR  TPM  0.0685  3.422 MT

Rectifier Feed:
TPR MT
RF   5.704
0.6 hr
Beer Column Feed @ 10% v/v:
Total Pure Ethanol Feed to Beer Column = Feed to Rectifier + Product Loss in Beer Column
MT
TPB  TPR  0.0699  3.492
hr
Beer Column Feed:
TPB MT
BF   34.923
0.1 hr
Fermentation :
Total Pure Ethanol produced in fermentation per day:
( 24)TPB 3 MT
TPF   1.061  10
0.79( 0.1) day

Number of Fermenter in Plant = 3 Fermenters

Total Fermenter Mash Volume: (with 20% Head Space)
TPF
TFM   442.06
3( 0.8)
TFM = 500 m3

At 88% Efficiency or yeild:

24( TPB)
T   95.244
0.88
Fermentation Loss:
MT
FL  T  [ 24( TPB) ]  11.429 Pure Ethanol
day
 University of San Agustin
College of Technology
Chemical Engineering Department

Fermentable Sugar: (2% Contamination)

C6H12O6 ---> 2 C2H5OH + 2 CO2
180T
FS   186.347 MT
2( 46)
Total Sucrose Required:
C12H22O11 + H2O ---> 2 C6H12O6

( 342) ( FS) MT
TS   177.029 Sucrose
2( 180) day

Total Fermented Mash Weight:

Computing for the specific gravity of Mash using Brix:

SG  0.9977  0.06908( .15)  1.008

MT
  SG  1.008
3
Weight of Mash: m
3
M  ( TPF) ( )  1.069  10 MT
Estimated brix of Mash:
( TS)100
BM   16.553 Degree Brix
M
Yeast Cultivation: Sugar Required
Rule : 1:5 cultivation is to fermentation
90m3 : 450m3
Number of Cultivation Tanks = 2
Number of Batches = 3

At 50% full, Cultivation Volume, CV:

3
CV  ( 90) ( 0.8) ( 3)  216 m
At 5 degree Brix:
SGC  0.9977  0.06908( 0.05)  1.001

Total Weight of Cultivation:

MT
TWC  ( CV) ( SGC)  216.249
day
Total Fermentable Sugar:
MT
FSC  ( TWC) ( 0.05)  10.812
day
Total Sucrose needed: (88% efficiency)
( FSC) ( 342) MT
TSC   11.673 Sucrose
( 0.88) ( 2) ( 180) day
 University of San Agustin
College of Technology
Chemical Engineering Department

Total Sucrose needed per day for both fermentation and cultivation:
MT
TFS  TS  TSC  188.702
day

For Inlet Water Calculation:

FSC  186.347
( FSC) ( 1000) ( 18) 3 kg
Wi   9.317  10
( 180) ( 1) ( 2) day
 University of San Agustin
College of Technology
Chemical Engineering Department

Pump for Ammonia

Dsuction is 30 in sch. 30
  0.8764
NH3  0.000255 Ddischarge is 24 in sch. 40

22.624 28.750
Ds   0.575 Dd   0.73
12 3.28 12 3.28
2 2
  Ds   Dd
A s   0.259 A d   0.419
4 4

11.7819 3
mf   3.273  10
3600
mf 3
Q   3.734  10


Suction side Velocity:

Q
Us   0.014
As

Discharge side Velocity:

Q 3
Ud   8.912  10
Ad

Head Velocity:

At suction:

Us 2 5
h vs   1.056  10
2 9.81

At Discharge:

Ud 2 6
h vd   4.048  10
2 9.81

Friction Losses at Suction Side:

1. Due to pipe length
L  3

  0.000152

Ds  Us  
NRe1   28.429
 NH3
 University of San Agustin
College of Technology
Chemical Engineering Department

1
fs   0.676
  0.27  7  
0.9
4 log    
  Ds
   NRe1  

 2
 L   Us  3
FLs  4 fs      1.461  10
Ds   2 
 
2. Due to Valves (Butterfly, 5 degrees)
n  1
kv  0.05

 U 2 
s 6
Fvs  n kv     5.178  10
 2 
3. Due to bends (90 degrees)
nb  1
kb  0.17

 U 2 
s 5
FBs  nb  kb    1.76  10
 2 

4. Tee used as elbow branch

ne  1
ke  1

 U 2 
s 4
FTs  n e ke    1.036  10
 2 
3
F s  FLs  Fvs  FBs  FTs  1.587  10

F s 4
hfs   1.618  m
10
9.81

Friction Losses at Discharge Side:

1. Due to pipe length
L d  3
 University of San Agustin
College of Technology
Chemical Engineering Department

Dd  Ud  
NRe2   22.372
 NH3

1
fd   0.742
  0.27  7  
0.9
4 log    
  Dd
   NRe2  

 2
 L d   Ud  4
FLd  4 fd      4.84  10
Dd  2 
 

2. Due to Valves (Gate Valve(fully open), NRV(ball), )

nd  1 knrv  70
kg  0.17
 U 2   U 2 
d d 3
Fvd  nd  kg    nd  knrv  2   2.786  10
 2   

3. Due to bends (90 degrees)

nbd  2
kbd  0.17

 U 2 
d 5
FBd  nbd  kbd     1.35  10
 2 

3
F d  FLd  Fvd  FBd  3.284  10

F d 4
h fd   3.347  10 m
9.81
100
Ps   11.798
Suction Head Loss: 0.864 9.81
2
Us
h s  L  hfs  Ps   14.798
2

Discharge Head Loss: 150

Pd   17.697
0.864 9.81
2
Ud
h d  L d  hfd  Pd   20.697
2
 University of San Agustin
College of Technology
Chemical Engineering Department

Total Dynamic Head

TDH  hd  hs

TDH  5.899

Net Positive Suction Head

Antoine Equation
TNH3  20
A  4.4854
B  926.13
C  240.17


 A
B 
C T NH3

Pv  10    0.119

 Pv  101325 
 Ps  
NPSHa  h s   760
  15.266
  9.81 

Suction Specific Speed:

Capacity  2000

0.5
Capacity  
Q 1000 60 

S 
 3.7854   1.992  10
3

NPSHa 0.75

Pump Rating
P  10 kW
 University of San Agustin
College of Technology
Chemical Engineering Department

Pump for ethanol-water out

Dsuction is 30 in sch. 30
  790
w  0.001 Ddischarge is 24 in sch. 40

22.624 28.750
Ds   0.575 Dd   0.73
12 3.28 12 3.28
2 2
  Ds   Dd
A s   0.259 A d   0.419
4 4

670.656
mf   0.186
3600
mf 4
Q   2.358  10


Suction side Velocity:

Q 4
Us   9.088  10
As

Discharge side Velocity:

Q 4
Ud   5.627  10
Ad

Head Velocity:

At suction:

Us 2 8
h vs   4.209  10
2 9.81

At Discharge:

Ud 2 8
h vd   1.614  10
2 9.81

Friction Losses at Suction Side:

1. Due to pipe length
L  10

  0.000152

Ds  Us  
NRe1   412.661
w
 University of San Agustin
College of Technology
Chemical Engineering Department

1
fs   0.396
  0.27  7  
0.9
4 log    
  Ds
   NRe1  

 2
 L   Us  5
FLs  4 fs      1.139  10
Ds   2 
 
2. Due to Valves (Gate Valve, fully open)
n  2
kv  0.17

 U 2 
s 7
Fvs  n kv     1.404  10
 2 
3. Due to bends (90 degrees)
nb  1
kb  0.17

 U 2 
s 8
FBs  nb  kb    7.02  10
 2 

4. Tee used as elbow branch

ne  1
ke  1

 U 2 
s 7
FTs  n e ke    4.129  10
 2 
5
F s  FLs  Fvs  FBs  FTs  1.201  10

F s 6
hfs   1.224  m
10
9.81

Friction Losses at Discharge Side:

1. Due to pipe length
L d  26
 University of San Agustin
College of Technology
Chemical Engineering Department

Dd  Ud  
NRe2   324.732
w

1
fd   0.408
  0.27  7  
0.9
4 log    
  Dd
   NRe2  

 2
 L d   Ud  6
FLd  4 fd      9.207  10
Dd  2 
 

2. Due to Valves (Gate Valve(fully open), NRV(ball), )

nd  2 knrv  70
kg  0.17
 U 2   U 2 
d d 5
Fvd  nd  kg    nd  knrv  2   2.222  10
 2   

3. Due to bends (90 degrees)

nbd  3
kbd  0.17

 U 2 
d 8
FBd  nbd  kbd     8.076  10
 2 

5
F d  FLd  Fvd  FBd  3.151  10

F d 6
h fd   3.212  10 m
9.81
3 100000
Suction Head Loss: Ps   30.635
998.23 9.81
2
Us
h s  L  hfs  Ps   40.635
2

Discharge Head Loss: 5 100000

Pd   51.059
998.23 9.81
2
Ud
h d  L d  hfd  Pd   77.059
2
 University of San Agustin
College of Technology
Chemical Engineering Department