G32

PRODUCTION OF 1000 MT/A OF

ACETIC ACID FROM ETHANOL VIA
FERMENTATION USING
Acetobacter aceti
SIOW YIK FUNG
KE12052
KEE YEN DING
KE12059
MUHAMMAD FAZLI BIN ABDUL AZIZ KE12007
SITI RASIDAH BINTI CHE SAAD
KE12009
DINIE BIN JAMIL
KE12024

MARKET SURVEY

MARKET SURVEY: Global

Table 11: Acetic acid
consumption by application
(Tecnon
Types
of OrbiChem,
chemical 2012).
Amount of
application
VAM(vinyl acetate
monomer)
Anhydride
PTA(purified
terephthalic acid)
Butyl Acetate
Ethyl Acetate
Others (acidity
regulator, vinegar,
paint pigments)
Total

acetic acid
(million metric
tons)
4.1
1.7
2.35
0.858
1.48
1.86
12.4

Figure 11: Global acetic

acid consumption 2012

MARKET SURVEY: Worldwide

Table 12: Annual production
amount by region
(Grandviewresearch.com,
2015)
Regi
Production
on

Amount

China
US
Asia
Europ

(million tonnes)
4.8
5.4
2.5
0.75

e
Total

14.6

Figure 12: Production rate

annually worldwide (By Million
Tons).

Table 17: Global supply and demand of acetic acid from 2014-2022
(Grandviewresearch.com, 2015)
Production

Demand
Yea
Growth
r
Amount Growth Amount
rate
(tons/yr) rate (%) (tons/yr)
(%)
201 1351720
4.48
1212430
4.9
4
0
0
201 1419580
4.48
1271840
4.9
5
0
0
201 1490840
4.48
1334160
4.9
6
0
0
201 1560770
4.48
1399530
4.9
7
0
0
201 1633970
4.48
1468110
4.9
8
0
0
201 1707170
4.48
1540050
4.9
9
0
0
202 1783650
4.48
1615510
4.9
0
0
0
202 1863560
4.48
1694670
4.9
1
0
0

Decision

Supply

Difference
(tons/yr)

0.8% of
production in
Malaysia which
come from 5%
of Asia
production.

Production rate=
5% x 2.5 million
x 0.8%

1392.9
1477.4
1566.8
1612.4
1658.6
1671.2
1681.4
1688.9

= 1000 MT/year

Synthesis Route Information

(Park et al., 1991)
Microbes

Acetobacter aceti

Substrate

Ethanol

Nitrogen source
Fermentation time

Yeast extract
55 hours

Type of fermentation

Submerged Fermentation

Mode of fermentation

Batch

Substrate conversion

0.414

Reaction equation

Ethanol + Oxygen Acetic acid +

water

Technologies

Aeration, Heat transfer, Agitation

Process Synthesis and Flow Sheeting

(Gaddy et al., 2004)

SITE SELECTION &

PLANT LAYOUT

COMPARISON ON
CRITERIA BETWEEN
FOUR LOCATIONS
Location

Criteria

Tanjung

Westport

Gebeng

Lumut

Langsat

Port Klang

Industrial

Industrial

Estate

Park (LPIP)

Industrial
Complex
Availability of raw
3
materials

Port

The nearer the location of plant produce ethanol, the higher

Transport facilities

the rating.
3

The closer to two major forms of transportations, the higher

the rating.
Availability
labour

of

The bigger pool of unskilled labour available locally, the higher

the rating.

Electricity

Cheaper source of power can obtained, the higher the rating

Location

Tanjung

Westport

Langsat

Port Klang Industrial

Industrial
Criteria
Water supply

Complex
4

Gebeng
Estate

Lumut

Port

Industrial
Park (LPIP)
4

The nearer to source of water, the higher the rating.

Geographical
and weather

The more suitable load-bearing characteristics, safer

location of the plant and less changes in weather, the

Effluent disposal
facilities

higher the rating.

5
4

The nearer to responsible local authorities location, the

higher the rating.

Labour
community
consideration

The easier the local communities are able to reach and can
be alerted when accidents happen, the higher the rating.

Location

Tanjung

Westport

Langsat

Port Klang Industrial

Industrial
Criteria
Government tax

Complex
5

Gebeng
Estate

Lumut

Port

Industrial
Park (LPIP)
5

The more types of grants can offer by local government,

the higher the rating.
Political stability

The more stable in political issue, the higher the rating.

Total

43

41

48

43

Gebeng Industrial Estate, Pahang has

the highest ranking among all the locations
Selected as site location

PLANT LAYOUT

MATERIAL & ENERGY

BALANCE FROM
SIMULATION

SIMULATION STEPS

MAIN FERMENTERS
Outlet (kg/hr)
Component

Manual

SuperPro

Error %

Ethanol

85.5376

87.01

1.69

Oxygen

60.3851

64.82

6.84

Yeast extract

2.9039

3.025

4.00

Biomass

0.6044

0.647

6.54

85.9351

86.78

0.97

0.5318

0.503

5.72

339.2122

350.3

3.15

25.5474

27.83

8.20

Acetic acid
Carbon dioxide
Nitrogen
Water

ROTARY VACUUM FILTER

Component
Ethanol

Manual (kg/hr)
Filtrate

Filtrate

Cake

Filtrate

Cake

174.0245

1.69

5.8079

6.201

1.2089

1.2935

6.33
0

171.8702
0
74.3449 131.750
0

173.5590
71.3569

Biomass

Water

Cake

Error %

171.0752

Yeast Extract
Acetic Acid

SuperPro (kg/hr)

120.3

6.54

0.97
4.19

0
9.56

GAS STRIPPING COLUMN

(Andrew, 2010)

Component
Acetic acid
Water
Ethanol
Yeast extract
Carbon dioxide

Manual (kg/hr)
Liquid

SuperPro (kg/hr)

Vapour

171.8702

Liquid
0

Error %

Vapour

Liquid

Vapour

173.559
0

0.97

0 71.3569
0
8.5538 162.5214 8.7012 165.3233
5.8079
0
6.012
0

4.19

1.69

1.69

3.39

5.19

74.3449

520

0 494.3627

FLASH DRUM
Component
Carbon
dioxide
Ethanol

Manual (kg/hr)
Liquid
Vapour
0

SuperPro (kg/hr)
Error %
Liquid Vapour Liquid Vapour

512.2272

162.5214

0 494.3627

0 165.3216

3.61

1.69

EXTRACTOR
Manual (kg/hr)
Componen
t

SuperPro

(kg/hr)
Extract Raffinat Extract Raffinat Extract
e

Ethanol
Acetic Acid
Water
Yeast
Extract

Error %

e
168.536

0 171.0752

0
2
132.368
140.526
30.9083
28.5246
3
4
14.3677 57.4708 15.264 60.265
0

5.8079

Raffinate

5.8079

1.48

23.73
6.23

7.59
4.86

DISTILLATION COLUMN 1
Component

Manual (kg/hr)
SuperPro (kg/hr)
Error %
Distillate Bottoms Distillate Bottoms Distillate Bottom
s

Acetic Acid
Water
Co-solvent (L)
Solvent (H)

132.3684
14.3677
0.5129
0

6.9668 156.0122
12.321
0

7.1262

0.5512

10.236

13.265

9.7449
15.3867

15.16
16.60

2.23
0

6.94
0

4.79
15.94

DISTILLATION COLUMN 2
Component

Manual (kg/hr)
SuperPro (kg/hr)
Error %
Distillate Bottoms Distillate Bottoms Distillate Bottom
6.6184

125.7500

7.263

122.7816

8.87

s
2.42

13.6493

0.7184

14.236

0.7823

4.12

8.16

Co-solvent (L)

9.7449

10.326

5.62

Solvent (H)

0.7694

Acetic Acid
Water

EQUIPMENT SIZING

MAJOR EQUIPMENT
SIZING

SEED/MAIN FERMENTER
Seed fermenter
Produce seed culture for inoculation
into main fermenters
Main fermenters
Produce acetic acid

FERMENTER SIZING FLOW

SUMMARY OF
SEED FERMENTER SIZING

EQUIPMENT SPECIFICATION SHEET

Item No.
V-103
Function
To provide inoculation for Main
Fermenter (V-104 and V-105)
Type of Bioreactor
Mechanical Stirred Tank Bioreactor
Material
of
Construction
Type of Culture
Condition
Operation
Temperature (C)
Operation Pressure
(atm)
Aeration Rate (vvm)
Duration (h)

Stainless Steel 316L

Batch
Aerobic
30
1
0.1
55

SUMMARY OF
SEED FERMENTER SIZING
TANK SPECIFICATION
Design Type
Vertical with Hemispheral
Working

Volume,

VL

Head
4.9

(m3)
Volume of the Vessel,

6.2

Vt (m3)
Headspace (m3)
Vessel Diameter,

1.3
1.5

Dt

(m)
Vessel Height, Ht (m)
Liquid Height, HL (m)

2.9
2.2

SUMMARY OF
SEED FERMENTER
SIZINGIMPELLER SPECIFICATION

Type of Impeller
Rushton Turbine
No. of Blades, n
6
Flow Pattern
Radial Flow
Impeller Diameter, Di (m)
0.5
Width of Impeller Blade, Wi (m)
0.1
Length of Impeller Blade, Li (m)
0.125
Impeller Height from Bottom of the
2.2
Vessel, E (m)
Spacing between Impellers, Si (m)
0.75
First Impeller from the Bottom of
0.5
Vessel, Sf (m)
Number of Impeller
4
Disc Thickness (m)
0.025
Rotation Speed (rpm)
200
Power required to run the impeller
15.63
(kW)

SUMMARY OF
SEED FERMENTER
SIZING
BAFFLES SPECIFICATION
No. of Baffles
Baffles Diameter (m)
Height of the Baffles (m)
JACKETED VESSEL SPECIFICATION
SIP Temperature (C)
SIP Duration (min)
Power required for Sterilization (kW)
Power
required
to
maintain
Operating
Temperature (kW)
Average Steam Flow Rate (kg/h)
Heat Transfer Area (m2)
Maximum Heat Capacity (kW)
Maximum Steam Flow Rate (kg/h)
Amount of water required to maintain
operating temperature (kg/h)
SPARGER SPECIFICATION
Location of Sparger from bottom of the Vessel
(m)
Air Flow Rate (kg/h)

4
0.15
2.2
121
20
517.73
0.33
716.67
13.94
575.25
796.30
56.98
0.25
1083.79

SUMMARY OF
MAIN FERMENTER SIZING
EQUIPMENT SPECIFICATION SHEET
Item No.
V-104, V-105
Function
Fermentation of A. aceti to produce
acetic acid
Type of Bioreactor
Mechanical Stirred Tank Bioreactor
Material
of
Stainless Steel 316L
Construction
Type of Culture
Batch
Condition
Aerobic
Operation
30
Temperature (C)
Operation
Pressure
1
(atm)
Aeration Rate (vvm)
0.1
Duration (h)
55

SUMMARY OF
MAIN FERMENTER SIZING
TANK SPECIFICATION
Design Type

Vertical with
Hemispheral Head

Working Volume, VL (m3)

24.7

Volume of the Vessel, Vt

31

(m3)
Headspace (m3)

6.3

Vessel Diameter, Dt (m)

2.5

Vessel Height, Ht (m)

Liquid Height, HL (m)

3.6

SUMMARY OF
MAIN FERMENTER
IMPELLER SPECIFICATION
SIZING
Type of Impeller
Rushton Turbine
No. of Blades, n
Flow Pattern
Impeller Diameter, Di (m)
Width of Impeller Blade, Wi (m)
Length of Impeller Blade, Li (m)
Impeller Height from Bottom of
the Vessel, E (m)
Spacing between Impellers, Si (m)
First Impeller from the Bottom of
Vessel, Sf (m)
Number of Impeller
Disc Thickness (m)
Rotation Speed (rpm)
Power required to run the impeller
(kW)

6
Radial Flow
0.833
0.167
0.208
3.6
1.25
0.833
4
0.042
200
96.44

SUMMARY OF
MAIN FERMENTER
SIZING BAFFLES SPECIFICATION

No. of Baffles
Baffles Diameter (m)
Height of the Baffles (m)
Spacing between impeller (m)
JACKETED VESSEL SPECIFICATION
SIP Temperature (C)
SIP Duration (min)
Power required for Sterilization (kW)
Power
required
to
maintain
Operating
Temperature (kW)
Average Steam Flow Rate (kg/h)
Heat Transfer Area (m2)
Maximum Heat Capacity (kW)
Maximum Steam Flow Rate (kg/h)
Amount of water required to maintain operating
temp. (kg/h)
SPARGER SPECIFICATION
Location of Sparger from bottom of the Vessel

4
0.25
3.6
0.75
121
20
1896.55
0.97
2625.31
39.75
2107.28
2917.01
167.55
0.42

ROTARY DRUM FILTER

FUNCTION : Remove the biomass
from the fermentation product.

STEP TO DESIGN
ROTARY DRUM FILTER

SUMMARY OF
ROTARY DRUM FILTER
SIZING
Parameters

Total time for a cycle

Length of drum (m)
Column diameter (m)
Washing time (s)
Area (m2)
Frame material of the filter
Filter cloth material
Pore size

Description
30
5.0914
3.658
0.3
58.51
Carbon Steel

Polypropylene
0.3m

GAS STRIPPING COLUMN

FUNCTION : To strip the unreacted
ethanol by using carbon dioxide

DESIGN FLOW OF
GAS STRIPPING COLUMN
Number of
stages

Area of column

Type of contacting
device plates

Sieve plate design,

column diameter, column
area, downcomer area,
net area, active area and
hole area

Weir length
and weir
length crest

Downcomer pressure drop,

area under apron, head loss
in downcomer, residence
time in downcomer

Number
of holes

Plate
pressure

Total
column
height

SIZING SUMMARY OF
GAS STRIPPING COLUMN
PARAMETERS

Column sizing and material

a. Tray Spacing (m)
b. Diameter of column, Dc (m)
c. Area of column, Ac (m2)
d. Total height of column, HT (m)
e. Volume of column, (m3)
f. Column material
Provisional plate design
a. Plate thickness (mm)
b. Plate area:
i. Down comer area, Ad (m2)
ii. Net Area, An (m2)
iii. Active area, Aa (m2)
iv. Hole area, Ah (m2)
a. Trays type
b. Trays material
c. Liquid flow material
d. Downcomer material

0.6
0.5
0.196
3.8
0.7448
Stainless steel
5
0.024
0.172
0.148
0.017
Sieve plate
Stainless steel
Single-pass plate
Stainless steel

SIZING SUMMARY OF
GAS STRIPPING COLUMN

Weir Design
a. Weir Length, Iw (m)

b. Weir Height, Hw (mm)

c. Weir liquid crest:
Maximum, how (mm liquid)
Minimums, how (mm liquid)
Weep Point
a. Minimum Uh (m/s)
b. Actual Uh (m/s)
Hole Design
a. Hole diameter (mm)
b. Hole area (m2)
c. Number of holes
Total plate pressure drop (mm liquid)

0.37
23.04
24.03
21.18
12.98
55.56
5
1.96E-05
867
90.8

FLASH DRUM
FUNCTION : Separate a vapor
liquid mixture which is carbon
dioxide and ethanol.

STEP TO DESIGN
FLASH DRUM
Density of
vapor and
liquid.

Constant value
of drum,

Permissible
vapor velocity,

Length of the
drum

The flash drum

design

Area of the
drum

SUMMARY OF
FLASH DRUM SIZING
SUBJECT

FLASH UNIT, F-5

Diameter (m)

0.1110

Diameter practical (m)

0.5

Length (m)
Cross Sectional Area

1.3151

(m2)

9.68 x 10-3

Volume (m3)

0.4

STAGES EXTRACTOR
Function:
concentrate the acetic
acid by using solvent to
extract the acetic acid
from the water and broth
mixture.

DESIGN FLOW OF
STAGES EXTRACTOR
Assume as multiple stage and calculate .

Number of stages was determined.

Height of column was determine:

1) Number of stage
2 Height Equivalent to a Theoretical Stage (HETS)

Column diameter is determined.

Area of column and downcomer was determined.

Length of segment of downcomer was determined.

SUMMARY OF
STAGED EXTRACTOR SIZING

Equipment class

Continuous

counterflow
contactors, no
Extractor type
Commercial

mechanical agitation
Staged extractor
Sieve Tray column

column type
Column type

Two-section cascade

arrangement/casca
de configuration
Number of stage
Height of the

2
2

column (m)
Height Equivalent

to a Theoretical
Stage (m)
Diameter of
column (m)
Tray Construction

Tray spacing (m)

Height

of

0.6
the

coalesced layer (cm)

Length
of

0.45

downcomer (m)
Downcomer
area

0.0103

(m2)
Net area (m2)

0.0752

Number of holes

Stainless steel

93

Hole diameter (cm)

0.1831

Total hole area (m2)

0.015

Single hole area (m2)

0.33

2.63 x 10-6

Size of disperse drop 1.4709 x 10(m)

DISTILLATION COLUMN
Function:
Distillation 1:
Concentrate acetic acid by removing cosolvent (SX-18)

Distillation 2:
Concentrate acetic acid by removing solvent
(Acdogen 283)

DESIGN FLOW OF
DISTILLATION COLUMN
2

1
Specify degree of
separation.
3

Determine operating
conditions.
4

Determine type of
contacting devices
5

Determine stage, reflux

requirements
6

Column, diameter, number

of real stages calculations.

Column internal design :

plates, distributor, packing
supports.

DESIGN FLOW OF INTERIOR

PLATES OF DISTILLATION
COLUMN.
8. Check the plate pressure drop, if
1. Calculate the maximum and
minimum vapour and liquid flow-rates.

too high return to step 6.

2. Collect, or estimate, the system

physical properties.

9. Check downcomer back-up, if too

high return to step 6 or 3.

3. Select trial plate spacing.

10. Decide plate layout details, if

unsatisfactory return to step 6.

4. Estimate the column diameter.

11. Recalculate the percentage

flooding.

5. Decide the liquid flow arrangement.

12. Check entrainment, if too high

return to step 4.

6. Make a trial plate layout.

13. Optimize design: repeat steps 3

to 12 (smallest diameter).

7. Check the weeping rate, if

unsatisfactory return to step 6.

14. Finalize design: draw up the

plate specification and sketch the
layout.

SUMMARY OF
DISTILLATION
COLUMNS
SIZING
Parameters
C-104
C-105
Parameters
C-104
Number of

39

81

stages
Number of trays
Number of feed

38
1

80
1

trays
Feed point

20

38

location
Plate spacing,

0.8

0.8

m
Length of

29

80

column, m
Column

1.04

2.2

26.63

56.06

diameter, m
Column volume,
m3
Column and
ellipsoidal head

Stainless

Stainless

steel

steel

material of
construction
Tray
construction

Sieve plate

Sieve plate

Column area,
m2
Downcomer
area, m2
Net area, m2
Active area,
m2
Perforated
area, m2
Hole
area m2
Hole
pitch,mm
Weir length,
m
Hole
diameter, mm
Plate
thickness,
mm
Number of
holes
Downcomer
material of
construction
Type of

1.3273

C-105
3.8013

0.41

0.4562

2.98
2.57

3.3451
2.89

2.504

2.943

0.29

0.3345

302

313.5

1.54

1.63

14 796

17 066

Stainless steel

Stainless steel

Straight,

Straight,

MINOR EQUIPMENT
SIZING

PUMP AND BLOWER

PUMP :
Deliver fluid in desired flow rate
BLOWER :
Increase the pressure of air to be purged into
both seed and main fermenters with pressure
from 1.01 bar to 6.01 bar.

DESIGN FLOW OF PUMP

Define the flow rate of liquids and the inlet and outlet pressure
within the pump.
Compute the difference in pressure of inlet and outlet of pump.

Compute pump pressure head.

Assume efficiency of pump.

Compute power required for pumping.

DESIGN FLOW OF
BLOWER
Define the flow rate of liquids and the inlet and outlet
pressure within the blower.
Compute X.
Compute nominal blower efficiency.

Compute power required for pumping.

SUMMARY OF
PUMP AND BLOWER SIZING
Equipment

Power (W)

P-101 A/B

0.0024

P-102 A/B

0.0238

P-103 A/B

0.0238

P-104 A/B

0.0391

P-105 A/B

0.3912

P-106 A/B

0.3912

P-107 A/B

521.2093

P-108 A/B

521.2093

P-109 A/B

1374.8694

P-110 A/B

1374.8694

P-111 A/B

2749.7388

P-112 A/B

15.4233

P-113 A/B

2737.5709

P-114 A/B

583.4055

P-115 A/B

591.2597

P-116 A/B

1912.4851

P-117 A/B

294.0828

Equipment
B-101

Power (kW)
1.5403

B-102

7.7645

B-103

7.7645

HEAT EXCHANGER
7 heat exchangers
3 heaters and 4 coolers

Heat Exchanger
1 (HEX-1)

Heater

Heat Exchanger
2 (HEX-2)

Heater

Heat Exchanger
3 (HEX-3)

Heater

Heat Exchanger
4 (HEX-4)

Cooler

Heat Exchanger
5 (HEX-5)

Cooler

Heat Exchanger

Cooler

Increase the stream temperature from

30 C to 75 C before entering the
stripping column
Increase the stream temperature from
25 C to 75 C before entering the
stripping column
Increase the stream temperature from
30 C to 78.9 C before entering
distillation column 1
Decrease the stream temperature from
79.6 C to 65 C before entering
distillation column 2
Decrease the stream temperature from
230 C to 35 C before discharge the
waste;
Decrease the temperature of distillate

Design flow of Heat

Exchanger

SUMMARY OF HEAT EXCHANGER

Specificati
SIZING
Specification
HEX-1 HEX-2 HEX-3
on
Heat duty

HEX-1

(KW)
Tube side
Shell side
Heat

14.09
Mixture
Water
1 shell

6.10
Mixture
Water
1 shell

5.50
Mixture
Water
1 shell

exchanger

and 4

and 1

and 4

type
Design

tubes

tubes
Fixed-

tubes
Fixed-

tube

tube

type
Heat
exchanger
orientation
Heat
transfer
flow

Fixed-tube

Horizontal Horizontal

HEX-3

Horizont
al

Length of tube Lt

Countercurrent

Steel
12

Counter- Countercurrent

current

Stainless Stainles
Steel
14

s Steel
12

1.78

1.78

1.78

(m)
Outer diameter,

0.015 0.038 0.015

Dto (mm)
Inner diameter,

88
1
88
0.010 0.033 0.010

Dti (mm)
Material Thermal

33

88

33

Conductivity

16

16

16

(W/m.K)
Area of one tube, 0.088 0.213 0.088
At (m2)
Tube pitch type

Stainless
Material
BWG

HEX-2

8
1
8
triangl triangl triangl
e

Number of tube,
Nt
Tube pitch, Pt

3
22
2
0.019 0.047 0.019

(mm)
Shell internal

9
6
9
0.414 0.276 0.127

SUMMARY OF HEAT EXCHANGER

Specificatio
SIZING
HEX-4
HEX-5
HEX-6
HEX-7
Specification HEX-4 HEX-5 HEX-6

n
Heat duty
(KW)
Tube side
Shell side
Heat

1.34

3.41

0.53

2.82

Mixture
Water
1 shell

Mixture
Water
1 shell

Mixture
Water
1 shell

Mixture
Water
1 shell

exchanger

and 4

and 6

and 4

and 4

type

tubes
Fixed-

tubes
Fixed-

tubes
Fixed-

tubes
Fixed-

tube

tube

tube

tube

Design type
Heat
exchanger
orientation
Heat
transfer
flow
Material
BWG

Length of tube
Lt (m)
Outer
diameter, Dto
(mm)
Inner
diameter, Dti

(mm)
Horizont Horizont Horizont Horizont Material
Thermal
al
al
al
al
Conductivity
Counter- Counter- Counter- Counter- (W/m.K)
current

current

current

current

Area of one

2
Stainless Stainless Stainless Stainles tube, At (m )
Tube pitch
Steel
Steel
Steel
s Steel
type
12
12
12
12
Number of

tube, Nt
Tube pitch, P

1.78
0.015
9
0.010
3

16

0.088

3.66

0.0222

0.0197

16

0.2556

3.66

HEX7
3.66

0.015 0.015
9

0.010 0.010
3

16

16

0.182 0.182

8
6
6
triangl triangl triangl triang
e

le

0.019

0.019 0.019

CONDENSER
Function: To
condense the top part
(distillate section) of
distillation column.

Design flow of condenser

Preliminary calculation (steam heat capacity, steam temperature inlet
and outlet, mixture temperature inlet and outlet, entalphy change,
and steam flowrate) was determined.
Determine the in order to calculate that will be using in determining
the haet transfer area.
Tube rating (area of 1 tube, number of tube, square tube pitch, and
minimum bend radius) was Appendix A.5: Transport Processes and
Unit Operations Fourth Edition (Geankoplis, 2003)
Pressure drop at both shell and tube sides were calculated and
checked.
Condenser design was finalized.

SUMMARY OF CONDENSER SIZING

Specification
Heat
duty
Heat
duty
(kW)
(kW)
Tube side
Tube side

C-1

C-2

Ethanol, solvent,
Ethanol, solvent,
co-solvent, water
co-solvent, water

Shell side
Shell side
Design type
Design type

Ethanol,
Ethanol,
solvent, cosolvent, cosolvent, water
solvent, water
Cooling water
Cooling water
Split-ring
Split-ring
floating
head

Heat

Horizontal
floating
head

Horizontal
head

Horizontal

Horizontal

exchanger
Heat
orientation
exchanger
Heat transfer
orientation
flow transfer
Heat
Tube
inlet
flow
direction
Tube
inlet
Material
direction
BWG
Material
BWG

Cooling water
Cooling water
Split-ring floating
Split-ring
floating
head

Specification
C-1
Length
of 4.88
tube (m)
Outer
diameter (m)
Inner

C-2
4.88

0.025 0.025
40
40
0.001 0.001
65
65

diameter (m)
Area of heat 0.209 1.168
exchanger
(m2)
Tube

Counter-current

Counter-current

type
Number

Counter-current
Horizontal

Counter-current
Horizontal

tube
Tube

Horizontal
Stainless steel
16
Stainless steel

Horizontal
Stainless steel
16
Stainless steel

16

16

pitch Squar Squar

of

e
8

e
8

pitch 31.75 31.75

(mm)
Shell internal 341.2 341.2
diameter
(mm)

Reboiler
Function: To provide heat
to boil the liquid from the
bottom of a distillation
column.

DESIGN FLOW OF
REBOILER

List down all the basic information ( reboiler type, operating pressure,
crictical pressure, and reboiler duty).
Determine the preliminary calculation ( steam heat capacity, steam
temperature inlet and outlet, mixture temperature inlet and outlet,
maximum reboiler duty, and entalphy change)

Calculate the steam flow rate by dividing the maximum reboiler duty with
enthalphy change.
Determine the in order to calculate that will be using in determining the
heat transfer area.
Calculate the heat transfer area by using assumption of overall heat transfer
coefficient in Chemical Engineering Design Vol. 6 book.
Determine the tube rating (area of 1 tube, number of tube, square tube pitch,
and minimum bend radius.)
Calculate the boiling heat transfer coefficient.

SUMMARY OF REBOILER SIZING

Specificatio
n
Heat duty
(kJ/h)
Tube side

R-1 (DC1)
325 172.40

R-2 (DC2)
214 224.42

Organic
Organic
solvent
solvent
(acetic acid, (acetic acid
co-solvent &
&water)
solvent)
Shell side
Steam
Steam
Design type
Split-ring
Split-ring
floating head floating head
Heat
Horizontal
Horizontal
exchanger
orientation
Heat
CounterCountertransfer
current
current
flow
Tube inlet
Horizontal
Horizontal
direction
Material
Stainless
Stainless
steel 304
steel 304
BWG
16
16

Specification
Length of
tube (m)
Outer
diameter
(mm)
Inner
diameter
(mm)
Area of heat
exchanger
(m2)
Area of one
tube, (m2)
Tube pitch
type
Number of
tube
Tube pitch
(mm)

R-1
(DC1)
4.88

R-2
(DC2)
4.88

19.1

19.1

1.65

1.65

1.33

1.2997

0.29

0.29

Square Square
5

0.029

0.029

STORAGE TANKS
Function
To hold or store the material, the output
main product and side waste from the
upstream process and the downstream
process.
Fixed cone roof tank constructed by carbon
steel is used. No high strength temperature
elevated but high corrosion resistance.

SUMMARY OF
STORAGE TANKS SIZING
Parameters

V-101

V-102

V-106

V-107

Function

Yeast

Ethanol

Carbon dioxide

Acetic acid

storage

storage

storage

storage

Material of

Carbon steel

construction
Design type

Vertical with hemispheral heads

Mode

Batch

Mass

181.4

28562.18

28673.05

flow(kg/batch)
Working

7204.56

6.86

volume(m3)
Tank volume(m3)

44.8

52.21

8.58

Diameter(m)

0.48

2.8

1.6

Tank height(m)

0.96

5.6

3.2

Liquid height(m)

0.67

1.24

1.02

UTILITIES &
SCHEDULING

UTILITIES
Utilitie
s

Usage

Tariff

Cost

Electrici
ty

1,932,882.
4
kWh

RM 0.44/kWh
(reference)

RM 850,456.26

Steam

8,380,053.
40
kJ/h

RM
18.56/MMBTu

RM
1,178,684.01

Water

6744.72
m3

RM 0.92/m3
(first 227 m3)
RM 0.84/m3
(exceeding)

RM 5,665.56

TOTAL ,,.

SCHEDULI
NG

 Operation hours/batch: 58 hours (including 3

hours downtime)
Batch/year: 139 batches

PROCESS CONTROL &

SAFETY

MATERTIAL SAFETY DATA SHEET

(MSDS)
Chemical
Ethanol
Appearan Liquid
ce
Odour
Mild to strong, rather pleasant;
like wine or whiskey. Alcohol-like;
Ethereal, vinous.
Density
789 kg/m3
Ph
7
Boiling
78.5C
Point
Melting
-114.1C
Point
Flash
13C
Point
Solubility Easily soluble in cold water, hot
water. Soluble in methanol,
diethyl ether and acetone
Chemical Stable under normal temperature
Stability
and pressure

Acetic Acid
Clear colourless liquid
Strong vinegar like

1050 kg/m3
2.4
118C
16.6 C
39C
Infinitely soluble

Stable under ordinary conditions of

use and storage. Heat and sunlight
can contribute to instability.
Condition Incompatible materials, ignition Heat, flame, ignition sources,
freezing, incompatibles.
s to Avoid sources, excess heat, oxidizers.

Chemical
Incompatibil
ities with
Other
Materials

Ethanol
Strong oxidizing agents, acids,
alkali
metals,
ammonia,
hydrazine, peroxides, sodium,
acid
anhydrides,
calcium
hypochlorite, chromyl chloride,
nitrosyl
perchlorate,
bromine
pentaflouride, perchloric acid,
silver nitrate, mercuric nitrate,
potassium
tert-butoxide,
magnesium
perchlorate,
acid
chlorides,
platinum,
uranium
hexafluoride, silver oxide, iodine
heptafluoride, acetyl bromide,
disulfuryldiflouride,
tetrachlorosilane
plus
awter,
acetyl
chloride,
permanganic
acid, ruthenium (VIII) oxide,
uranyl perchlorate, potassium
dioxide.
Hazardous
Carbon monoxide, irritating and
Decompositi toxic fumes and gases, carbon
on Products dioxide.

Acetic Acid
Acetic Acid is incompatible
with chromic acid, nitric
acid, ethylene glycol,
perchloric acid,
phosphorous trichloride,
oxidizers, sodium peroxide,
strong caustics, most
metals (except aluminum),
carbonates, hydroxides,
oxides, and phosphates.

Carbon dioxide and carbon

monoxide may form when
heated to decomposition.
May also release toxic and
irritating vapours.

Potential Health Effect in Hazard Identification

Chemical Ethanol
Acetic Acid
s
Eye
Produces irritation, characterized Eye contact with concentrated
by a burning sensation, redness, solutions may cause severe eye
tearing,
inflammation,
and damage followed by loss of
sight. Exposure to vapour may
possible corneal injury. Vapours
cause intense watering and
may cause eye irritation. May irritation to eyes.
cause painful sensitization to
light.
Skin
May cause skin irritation.
May cause serious damage to
the skin. Effects may include
redness, pain, skin burns. May
cause skin sensitization.
Ingestio May cause irritation of the May cause severe injury leading
n
digestive tract. May cause to death. Symptoms include sore
throat, vomiting, and diarrhoea.
kidney damage.
Ingestion of as little as 1.0 mL
has resulted in perforation of the
oesophagus.
Inhalatio May cause respiratory tract May cause serious damage to
n
irritation May cause effects the lining of the nose, throat,
similar to those described for and lungs.
ingestion.
Chronic
Prolonged or repeated skin Repeated
or
prolonged
contact may cause dermatitis. exposures may cause darkening

First Aid Measures

Chemical Ethanol
Acetic Acid
Eyes
Flush eyes with plenty of water Flush eyes with plenty of water
at
least
15
minutes,
for
at
least
15
minutes, for
occasionally lifting the upper and occasionally lifting the upper and
lower lids. Get medical aid
lower lids. Get medical aid
immediately.
immediately.
Skin
Get medical aid. Flush skin with In case of contact, immediately
plenty of soap and water for at flush skin with plenty of water
least 15 minutes while removing for at least 15 minutes while
removing contaminated clothing
contaminated
clothing
and
and shoes. Wash clothing before
shoes.
reuse. Call a physician.
Ingestio
n

If victim is conscious and alert,

give 2-4 cupfuls of milk or water.
Never give anything by mouth to
an unconscious person. Get
medical aid immediately. Induce
vomiting by giving one teaspoon
of Syrup of Ipecac.

DO NOT INDUCE VOMITING! Give

large quantities of water or milk
if available. Never give anything
by mouth to an unconscious
person. Get medical attention
immediately. of water or milk if
available. Never give anything
by mouth to an unconscious
person. Get medical attention
immediately.
Inhalatio Remove from exposure to fresh Remove to fresh air. If not
n
air immediately. If not breathing, breathing,
give
artificial
give artificial respiration. If respiration.
If
breathing
is

DOW FIRE & EXPLOSION

INDEX
Equipment
Fire & Explosion Degree of Hazard
V-101

Index
151.31

Heavy

V-102

153.27

Heavy

V-104

127.8

Intermediate

V-105

127.8

Intermediate

V-106

96.04

Moderate

V-107

131.71

Heavy

C-101

147.00

Heavy

C-102

122.12

Intermediate

C-103

100.8

Intermediate

C-104

129.75

Heavy

C-105

131.71

Heavy

TOXICITY INDEX
Equipment

Toxicity Index

Degree of Hazard

V-102

4.77

Light

V-104

23.01

High

V-105

21.01

High

V-106

4.43

Light

V-107

23.70

High

C-103

20.74

High

C-104

22.00

High

C-105

22.13

High

PIPING & INSTRUMENTATION

DIAGRAM AND HAZOP

Main/Seed Fermenter

Controlled
Variable
Flow
Pressure
Temperature
pH

Manipulated Disturbance
Variable
Inlet flow rate
Outlet flow
rate
Safety relief Tank pressure
valve
Jacketed
Inlet
temperature
Acid base
Inlet pH

Type of
controller
Feedback
Feedback
Feedback
Feedback

Temperature
Possib
Possible
Guide
le
conseque
word cause
nces
s
Medium
Control cold,
Low
valve
fermenta
failed
tion
delayed

Cooling
High system
Medium
failure
warm

Safeguard

Recomm
endation

Monitoring
temperatures at all
times. Alarms are
active
Monitoring
temperatures at all
times. Alarms are
active

NA

NA

Rotary Drum Filter

Controlled
Variable

Manipulated
Variable

Disturbance

Type of
controller

Flow

Inlet flow rate

Outlet flow
rate

Feedback, PLC

Flow
Guid
Possible
e
causes
word
No Clogging

Consequen
Safeguard
ces
P-111 A/B
working
harder to
provide
flow

Recommendation

Maintenan
ce of pipe
to ensure
clean

Less

Control

valve

malfuncti
on

Leaking

Clogging

Less feed Mainteanc

Control
e
valve
procedures
damage
to identify
equipment
operation

Provide interlock
to shut down the
system and to
prevent
backward flow
into the vessel
Backup water
supplied to the
equipment
Provide interlock
to shut down the
system and to
prevent
backward flow
into the vessel
Backup water
supplied to the

Flow
Guid
e
Possible Conseque
wor causes
nces
d
More Contro Control

l valve
valve
malfun
damage
ction. Ineffectiv
e
filtration
process

Safeguard

Recommend
ation

Perform regular
checking

Install
backup
valve

Gas Stripping Column

Controlled
Variable
Flow
Pressure
Temperature
Level

Type of

Manipulated Variable

Disturbance

Inlet flow rate

Outlet flow rate

controller
Feedback

Safety relief valve

Tank pressure

Feedback

Steam, cooling water

Inlet temperature

Feedback

Inlet flow rate

Outlet flow rate

Feedback

Temperature
Guid
Possible Consequen
e
Safeguard
causes
ces
word
Low HEX-102 Unable to Temperature
failure
reboil
indicator is
volatile
active
compone Proper
nt into
monitoring of
the tower
temperature
indicator
High HEX-102 Ineffectiv Temperature
failure
e
indicator is
separatio
active
n
Proper
monitoring of
temperature
indicator

Recommenda
tion

NA

NA

Flash
Drum

Controlled
Variable
Level

Manipulated
Variable
Outlet flow
rate

Disturbance

Type of
controller
Inlet flow rate Feedback, PLC

Level
Guide Possible
word
causes
High Malfunctio
n of
control
valve
Low Malfunctio
n of control
valve

Conseque
nce
Overfill

happen
Ineffective
separation
Column

dries out

Safeguar Recommendat
d
ion

Regular
Install flow
checking
sensor alarm at
on control control valve
valve
Regular
Install flow
checking
sensor alarm at
on control control valve
valve

Staged
Extractor

Controlle
Manipulated
d
Variable
Variable
Pressure
Safety relief valve
Level
Inlet flow rate

Disturbance

Type of
controller

Tank pressure

Feedback

Outlet flow
rate

Feedback

Pressure
Guid Possible Consequenc
Safegua
e
causes
e
rd
word
High Malfuctio Rupture of
Flow
n of P- extractor
alarm is
114 A/B Overfill
active
happen and
chemicals
might split
into
environment
Low
No credible scenario

Recommend
ation

Install
pressure relief
valve.

Distillation
Column

Controlled
Variable
Flow
Pressure
Temperature

Manipulated
Variable
Inlet flow rate
Safety relief
valve
Steam, cooling
water

Disturbance
Outlet flow rate
Tank pressure
Inlet
temperature

Type of
controller
Feedback
Feedback
Feedback

Flow
Guide Possible Consequen
word causes
ce
No

Cloggin
g at
Stream
36

Column
dries out

Less
High

As NO
Control
valve
failure

As NO

Ineffectiv
e
separatio
n
Product
compositi

Recommendat
ion

Flow alarm Provide

is active
interlock to
shut down the
system and to
prevent
backward flow
into the vessel
Safeguar
d

As NO
As NO
Flow alarm Provide
is active
interlock to
shut down the
system and to
prevent
backward flow

WASTE MANAGEMENT &

POLLUTION CONTROL

RELATED ENVIRONMENTAL
ACT

Environmental Quality (Industrial

Effluents) Regulation 2009
Environmental Quality (Sewage and
Industrial Effluents) Regulations 1979
Recommended Malaysian Air Quality
Guideline

STANDARD A & B
Parameter

STANDARD A

STANDARD B

BOD5

20

50

COD

120

200

SUMMARY OF
WASTE/POLLUTION
Source of Waste
C-103 Raffinate of

Composition of waste water

Adogen 283

extractor

Ethanol
Water

C-104 Bottom of

Acetic acid

distillation column 1

Adogen 283
SX-18
Water

C-105 Distillate of

Acetic acid

distillation column 2

BOD = 8700 mg/L

Water

COD = 14600 mg/L

(E-archives.lib.purdue.edu, 2016)

WASTEWATER TREATMENT PLANT

AND COST
Influent

Primary
Aeration Tank

Secondary
Aeration Tank

Clarifie
r

Sludge Waste

Cost estimation = RM2,320,127.04

Effluen
t

Drying

WASTE AFTER
TREATMENT
Parameter

STANDAR STANDAR
DA
DB

Effluent

BOD5

20

50

47.85

COD

120

200

102.2

ECONOMIC ANALYSIS

EQUIPMENT COST
Equipment

Units

Total Purchased Cost (RM)

Seed fermenter

131,639.80

Main fermenter

123,788.18

Rotary Drum Filter

134,994.82

Stripping Column

Flash Drum

128,035.90
77,895.71

Staged Extractor

69,689.14

Sizing
Distillation Column

3,478,439.68

Storage Tank

199,042.66

17

13,409,766.22

Blowers

Condenser

65,442.64
51,371.63

Heat Exchanger

1,283,996.77

Centrifugal Pump

Total

19,154,103.15

FIXED AND TOTAL CAPITAL

INVESTMENT COST
Fixed Capital Investment:
Component
Total Direct and Indirect

Cost (RM)
30,863,804.16

Cost
Grass Root Capital (GRC)
Total

31,647,840.56
62,511,644.72

Total Capital Investment:

Component
Working Capital (10% of TCI)
Fixed Capital Investment

Cost (RM)
6,945,738.30
62,511,644.72

(FCI)
Total

69,457,383.02

COST OF
MANUFACTURING
Component
Total Direct Production Cost
(TDPC)
Total Fixed Charges (TFC)
Total Plant Overhead Cost
(TPOC)
Total

Cost (RM/yr)
16,828,578.05
7,126,327.50
2,511,976.41
26,466,881.96

DISCOUNTED CASH FLOW

700,000,000

Discounted Cash Flow

632,737,526

600,000,000

592,665,684
552,593,842

500,000,000
400,000,000
Cumulative
300,000,000
Cash
Flow
(RM)

200,000,000

512,522,000

DCF
432,378,316
0%
392,306,474
361,725,127.09
345,868,699.22
DCF
352,234,632
329,218,848.88
311,735,504.23
293,378,593.43
312,162,790
274,104,037.44
5%
253,863,750.06
272,090,948
232,613,652.26
211,534,713.34
210,301,650.66
232,019,106
DCF
204,325,788.97
196,399,578.63
218,086,459.51
187,679,945.82
186,871,644.66
178,086,746.85
191,947,264
167,535,830.86
162,271,540.87
155,927,018.24
10%
143,160,129.39
136,441,231.54
133,300,506.36
130,062,701.53
151,875,422 129,114,948.78
126,340,027.41
122,056,347.50
472,450,158

117,131,518.12
111,469,366.85
136,117,556.85
109,320,608.89113,667,253.7097,468,265.27
96,672,785.5288,856,826.43104,957,692.53
111,803,581
86,310,858.51
85,056,609.85
83,549,908.59
81,742,668.52
80,841,550.81
79,574,781.87
78,951,067.09
77,979,271.25
76,974,119.33
73,852,522.84
70,105,805.61
67,558,642.4260,216,075.02
65,609,744.95
57,414,401.95
54,499,229.12
53,744,472.54
50,939,942.33
71,731,739 45,978,549.56
39,436,223.73
36,657,839.12
34,793,847.16
25,473,788.03
22,113,166.44
19,543,654.15
12,053,728.15
9,913,240.48
31,659,897
2,189,446.62
-4,051,145.13
-13,423,450.24
-17,455,827.59
-20,837,214.91
-20,723,632.62
-23,377,794.52
-8,411,945
-45,462,153.95
-45,815,159.02
-46,126,951.21
-46,387,800.82
0-20,837,215
2
4
6
8
10
12
14
16
18
20
-61,352,401.00 -46,573,963
-63,117,313.10
-65,037,809.74
-67,143,063.02
-69,457,383

100,000,000

-100,000,000
-200,000,000

Years

NET PRESENT VALUE

FOR DISCOUNTED
RATE
Interest, i

Net Present Value, NPV

(RM)

0
5
10
15
20

632,737,526.11
361,725,127.09
218,086,459.51
136,117,556.85
86,310,858.51

Discounted Cash Flow Rate of Return = 28.67 %

FINANCIAL RATIO
Component
Gross Profit Margin
Cost of Goods Sold (RM)
Sales (RM)
Gross Profit Margin (%)

Value
28,130,377.72
81,033,300.00
34.71

Operating Profit Margin

Operating Profit (RM)
Sales (RM)
Operating Profit Margin (%)

52,902,922.28
81,033,300.00
65.29

Net Profit Margin

Net Profits After Taxes (RM)
Sales (RM)
Net Profit Margin (%)

37,032,045.60
81,033,300.00
45.70

FEASIBILITY
The Total Capital Investment (TCI) = RM
69,457,383.02
Total Product Cost (TPC) = RM 32,083,200.58
The Annual Net Profit (ANP) = RM
48,004,831.78
Start-up = 2 years
Operating life = 20 years with a depreciation
of 10% of fixed capital investment.

THANK YOU!
Q&A Session