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CHAPTER VII

UTILITY DESIGN

7.1 INTRODUCTION

In this section, the utility design only involves heat transfer utility. For the process of
production of erythritol, there are two jacketed vessels, one cooler and one evaporator
will be used. Process integration which can lead to a substantial reduction in the energy
requirement of a process also will be carry out in this process.

7.2 PROCESS FLOW DIAGRAM BEFORE HEAT INTERGATION

In the process of production of erythritol, the heat utilities used are jacketed vessel, heat
exchanger and evaporator. In Figure 7.1 and 7.2, the simplified Process Flow Diagram
(PFD) of utility equipment before the heat integration are shown. The utilities equipment
used in the process and will be design are:

Seed fermenter F-101

Fermenter F-102
Heat exchanger HE-101
Evaporator E-101
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Figure 7.1 PFD of utility equipment before the heat integration (Upstream)

Figure 7.2 PFD of utility equipment before the heat integration (Downstream)
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7.3 DESIGN FOR JACKETED VESSEL (SEED FERMENTER F-101)

Feed 298.15K

Product

298.15K

Cooling Water
Water 293.15K
283.15K

Figure 7.3 Temperature of the inlet and outlet stream around seedfermenter

The medium from the seed fermenter F-101 will be cooled at 25°C. The flow rate of the
cooling water is 502 kg/h. Heat energy which as 5828.78 W will be produced by
Yarrowia lipolytica by their metabolism reaction such as respiration, excretion. Therefore,
it is used to maintain the temperature of seed fermenter so that the optimum of condition
to culture the Yarrowia lipolytica can be maintained. The cooling water is flow at 10 °C
and flow out at 20 °C.

Table 7.1 Physical Properties of Seed Fermenter

Part of Seed Fermenter Dimension
Diameter 0.8m
Height 0.5m
Spacing between the jackete and vessel 40mm
Pitch between the spirals 106mm
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The baffle forms a continuous spiral channel, section 40mm X 106mm.

Number of spirals= height of jacket/pitch = 1/ (0.106) = 9.434

Length of channel= 5 x x 0.8 = 12.57m

Cross-sectional area of channel= (40x 106) x 10-6 = 4.24 x 10-3 m2

Hydraulic mean diameter, de= 4x cross-sectional area/ wetted perimeter
= 4x(40x106)/(2(40+106))=58.08mm

Physical properties at mean temperature of 15 °C, from steam table: ρ=999kg/m3,

µ=1.135 mNm-2s, Pr=7.99, kf=595x10-3W/m°C.
Velocity through channel, u= 502/3600 x 1/999 x 1/4.24 x 10-3
=0.0329 m/s
Re=999x0.0329x58.08x10-3/(1.136 x 10-3)
=1680.388

Chilled water is not viscous, neglect the viscosity correction term:

Nu=0.023 Re0.8Pr0.33

= 0.023 (1680.388)0.8(7.99)0.33

Hj=177.99 W/m2°C
Therefore, the heat-transfer coefficient at the outside wall of seed fermenter is 177.99
W/m2°C

From the figure 19.24 (Gavin &Sinnot, 2013), for Re=1.680 x 10-3, jf= 8x10-3
Delta P= 8jf(L/de)ρu2/2
=8x8x10-3(12.57/58.08x10-3)999x0.03292/2
=7.489 x 10-3 N/m2
Therefore, the pressure drop on jacket is 7.489 x 10-3 N/m2.
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As the agitator speed (revs per sec)= 180/60=3/s, seed fermenter with a flat blade disc
turbine agitator 0.5 m diameter, the vessel is baffled and is constructed of stainless steel
plate 10 mm thick.
Table 7.2 Physical Properties of Medium
Medium Dimension
density 700kg/m3
µ 60mNm-2s
Kf 320W/m°C
Cp 2.68kJ/kg°C

Re= = =8750

Pr=

Nu=0.74 Re0.67Pr0.33 0.14

= 0.74 (8750)0.67(520.5)0.33

Hv=1632.96 W/m2°C
Therefore, by taking the thermal conductivity of stainless steel as 16 W/m°C
1/U=1/177.99+10x10-3/16+1/1632.96
U=145.86 W/m2°C

7.4 DESIGN FOR JACKETED VESSEL (FERMENTER F-102)

Jacketed vessel consists of an outer cylinder which surrounds part of vessel which is
fermenter. The cooling medium circulates in the annular space between jacket and vessel
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walls and the heat is transferred through the wall of the vessel. Through this way, the heat
released during the fermentation can be removed by cooling water and thus the fermenter

can be maintained at its optimum temperature, 37 .

Feed 303.15K

Product 310.15K

Cooling water Water 298.15K

298.15K

Figure 7.4 Temperature of the inlet and outlet stream around main fermenter

Based on the calculation of energy balance in Chapter V, the energy generated from the
fermenter as:

Qgen = 35034.87 – 87163.33 + (-1886) = - 54014.46 kJ/h

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The negative value of rate of change of enthalpy indicates that the fermentation process is
an exothermic reaction. Hence, cooling water is fed into the jacket of fermenter in order
to maintain the temperature at 37oC for the reaction to take place at its optimum
condition.

Assumption:

1. The temperature of cooling water is at the ambient temperature of 25oC.

2. The temperature rise of cooling water is limited to 15oC.
T2 = (25+15)oC + 273.15 K = 313.15 K

- 54014.46kJ/h= m (4.18 kJ/kg.K) (298.15-313.15K)

Mass flow rate of cooling water needed, mw = 861.47 kg/h

. The heat capacity flow rate, CP for each stream is calculated by using the formula:

where: m = mass flow rate, kg/s

Cp = average specific heat capacity between source temperature, Ts and target

temperature Tt, kJ/kg.˚C.

Cp = ( ) = 4.182 kJ/kg˚C

CP = 4.182( ) = 1.000 kW/˚C

Table 7.3 The design data of the jacketed vessel

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Stream Stream Heat capacity Source Target Heat

number type Flow Rate, temperature, temperature, load,Q
CP (kW/°C) Ts (°C) Tt (°C) (kW)

35 Cold 1.000 25 40 54014.46

The broth in the fermenter F-102will be maintained at 37°C. The flow rate of the
cooling water is 861.47kg/h. Heat energy which as 54014.46kWwill be produced by
Yarrowia lipolytica by their metabolism reaction such as respiration, excretion. Cooling
water is used to maintain the temperature of fermenter at the optimum of condition for the
production of erythritol. The cooling water is flow at 25 °C and its temperature at outlet is
limited at 40 °C.

Table 7.4 Dimension of Main Fermenter

Part of Fermenter Dimension
Diameter 1.42 m
Height 3.55 m
Jacket height 1.0 m
Spacing between the jacket and vessel 75mm
Pitch between the spirals 190mm

The baffle forms a continuous spiral channel, section 75mm × 190mm.

Number of spirals= height of jacket/pitch = 1/ (0.19) = 5.26 = 6

Length of channel= 6× ×1.42 = 26.77 m

Cross-sectional area of channel= (75×190) × 10-6 = 14× 10-3 m2

Hydraulic mean diameter, de= 4× cross-sectional area/ wetted perimeter

= 4×(75×190) / [2(75+190)] = 108 mm

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Physical properties at mean temperature of 32.5°C, from steam table: ρ=995.7kg/m3, µ=

0.759 mNm-2s, Pr= 5.43, kf= 618.5 x10-3W/m°C.

Velocity through channel, u= 861.47/3600 ×1/995.7× 1/14 x 10-3

=0.017 m/s

Re= 995.7 × 0.017×108×10-3/(0.759× 10-3)

= 2408.57

Cooling water is not viscous, neglect the viscosity correction term:

Nu=0.023 Re0.8Pr0.33

= 0.023 (2408.57)0.8(5.43)0.33

hj= 116.82 W/m2°C

The heat-transfer coefficient at the outside wall of seed fermenter is 177.99 W/m2°C

From the figure 19.24 (Gavin &Sinnot, 2013), for Re=2.41 , jf= 7.1 ×10-3

∆ P= 8jf(L/de)ρu2/2

=8×7.1×10-3(26.77/108×10-3)995.7×0.0172/2

= 2.026 N/m2

The pressure drop on jacket is 2.026 N/m2.

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As the agitator speed (revs per sec)= 120/60=2/s, fermenter with a flat blade disc turbine
agitator 0.7 m diameter, the vessel is baffled and is constructed of stainless steel plate 10
mm thick.

Table 7.5 Physical Properties of Medium

Medium Dimension
Density 1200 kg/m3
µ 90mNm-2s
kf 440×10-3W/m°C
Cp 2.82 kJ/kg°C

Re= = = 13067

Pr=

Nu=0.74 Re0.67Pr0.33 0.14

= 0.74 (13067)0.67(576.82)0.33

hv= 2170.54 W/m2°C

Therefore, by taking the thermal conductivity of stainless steel as 16 W/m°C

1/U=1/116.82+10x10-3/16+1/2170.54

U=103.67 W/m2°C
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7.5 DESIGN FOR SHELL AND TUBE HEAT EXCHANGER, HE-101

(HEATER)

The medium from the activated carbon column A-101 will be heated from 30°C (t1) to
65°C (t2) in a shell and tube heat exchanger. The input flow rate of the medium to heat

exchanger is 1946.27 kg/h. Direct steam injection with a temperature drop from 120 C

(T1) to 60 C (T2). The medium is placed into shell and steam is placed into tube, this is

due to the effluent fluid from activated column has the tendency to cause fouling.

Table 7.6 Physical Properties of Medium

Liquid Reaction Composition Shell (Medium) Tube (Steam)
Specific Heat Capacity, Cp(kJ/kg.K) 4.700 1.898
Thermal Conductivity, k (kW/m.K) 0.000439 0.000027
Density, ρ (kg/m3) 1200 0.5577
Viscosity, μ (mNs/m2) 2.763 0.232

Use one shell pass and two tube passes:

From Figure 19.19 (Towler&Sinnott 2013):

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Assumed overall coefficient, U = 600 W/m2. C

Provisional area:

Choose 20 mm outside diameter, 16 mm inside diameter, 4m-long tubes.

Use 1.25 triangular pitch,

From Table 19.4, K1 = 0.249, n1 = 2.207

Use a split-ring floating-head type.

From Figure 19.12, bundle diametrical clearance = 48.6mm

Tube Side Coefficient

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From Figure 19.23,

Shell-side Coefficient

Choose 25% baffle cur, from Figure 19.29

Without the viscosity:

Overall Coefficient
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Assume the fouling coefficient of liquid reaction composition = 5000 W/m2 C and steam

= 15000 W/m2. C.

The calculated overall coefficient is significantly higher than the assumed value of

650 W/m2 . Therefore, the calculations are repeated using a new trial value of overall

coefficient. The results of iteration are tabulated in the Table 7.7.

Table 7.7 Results of iteration for overall coefficient calculation

Parameter Value
Assumed overall coefficient, U (W/m2. ) 192.08
Trial surface area (m2) 14.39
Number of tubes 58
Tube bundle diameter, Db (mm) 236.39
Bundle diametrical clearance (mm) 51
Shell diameter, Ds 287.39
Re (Tube) 26508
Pr (Tube) 16.31
Tube-side heat transfer factor, jh 0.0023
Tube-side coefficient, hi(W/m2. ) 258.5
Baffle spacing, lB (mm) 57.478
Cross-flow area, As (m2) 0.003037
Mass velocity, Gs (kg/sm2) 178.01
Re (Shell) 927.7
Pr (Shell) 18.9
Shell-side heat transfer factor, jh 0.19
Shell-side coefficient, hs(W/m2. ) 12756.69
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U (W/m2. ) 190.77

Tube-Side Pressure Drop

Neglecting the viscosity correction term:

Re=26508 ,jf= 2.2x10-3

Shell-Side Pressure Drop

From Figure 19.30, at Re = 927, jf = 0.07

Neglecting the viscosity correction term:

This gives an overall coefficient of 190.77 W/m2.°C which is almost the same as the
assumed value of 192.08 W/m2.°C.

7.6 DESIGN FOR EVAPORATOR (EVA-101)

Evaporation, a widely used method for the concentration of aqueous solutions, involved
the removal of water from a solution by adding heat to the solution. In this process,
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evaporator is used to concentrate erythritol solution for crystallization. Figure 7.5 shows
the inlet and outlet streams of a single effect evaporator.

Figure 7.5 Single effect evaporator (EVA-101)

From material balance of the evaporator (EVA-101) design, the data are tabulated in Table
7.8.

Table 7.8 Details of Evaporator Streams

Stream (No) Temperature Pressure Flowrate (kg/hr)

(K) (kPa) Erythritol Water

25(Feed) 338.15 202.65 105 1801.97

26(Vapour) 393.15 101.325 - 865.58
27(Liquid) 393.15 101.325 105 216.39
Stream 415.15 101.325 - 700
Condensate 415.15 101.325 - 700

Assumptions:

(i) The solution in the evaporator is completely mixed, so the concentrated product
and the solution in the evaporator have the same composition and temperature.
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(ii) The vapour is in equilibrium with the boiling solution, so have the same
temperature.
(iii) Single effect evaporator is used for the reason of capability to work with thermo-
sensible products or with tendency to suffer partial or total deterioration.
(iv) Falling film evaporator is used because it suitable for processing food industry and
high heat transfer coefficients.

Physical Properties Stream 25 Stream 26 Stream 27 Condensate

(Feed) (Vapour) (Liquid)

Heat Capacity, 1.397 2.174 1.615 2.174

Cp(kJ/kg.K)

Table 7.9 Physical Properties for Components in Stream 25, 26 and 27

Table 7.10 Enthalpy of Water and Steam in Different Temperature (kJ/kg)

Temperature (K) Enthalpy (kJ/kg)

Water (h) Steam (H)

Ts1, 338.15 272.09 2617.51

T1 , 393.15 503.78 2705.93

Heat entering with the feed =

QF = 1186.97 x 1.397 x (338.15-298.15) x 1/3600

=18.45 kW

Heat leaving with the product (liquid) =

QL= 321.39 x 1.615 x (393.15-298.15) x 1/3600

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= 13.70 kW

Heat leaving with the evaporated water (vapour) = mv x H1

Qv= 865.58 x 2705.93 x 1/3600

=650.61 kW

Therefore, the heat transfer from the steam, q

By using equation (8.4-7) from Geankoplis 2004,

= 650.61+13.7-18.45

q= = 645.41 kW

Enthalpy of the condensate steam,hs =

=2.174 x (415.15-298.15)

=254.358 kJ/kg

Heat transfer from 1kg of steam Hst –hs

= 2617.51-254.358

= 2363.152 kJ/kg

Amount of steam required, S

=0.2731kg/s
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S = 983.21 kg/hr

From R.K. Sinnott, Figure 19.1, the overall heat transfer coefficient is assumed to be U=
800 W/m2.oC

o
The temperature difference, C

= 22oC

The total surface area for heat transfer, A =

A = 36.67m2

Steam Economy = E =

7.7 HEAT INTERGRATION

The energy analysis is done by using pitch analysis. Table 7.11 shows the details of the
streams needed for heat integration. It shows the relationship between interval
temperatures with hot and cold steams while Table 7.12 shows the heat balance for
interval temperatures, ∆Tmin = 20°C.

Table 7.11 Source Temperature and Target Temperature

Stream Type Specific Heat Source Target Heat Load
Number Capacity, CP Temperature, Temperature, (kW)
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(kW/°C) Ts (°C) Tt (°C)

33 Cold 0.3737 10 20 5.828
35 Cold 1.0007 25 40 15
37 Hot 1.026 120 60 88.93
39 Hot 0.5227 142 25 18.45

Hot stream:

Cold stream:

Table 7.12 Interval Temperature for ∆Tmin = 20°C

Stream Type Actual Changing to interval Intermediate
Temperature (°C) temperature Temperature (°C)
Source Target Source Target

33 Cold 10 20 + 20 30
35 Cold 25 40 + 35 50
37 Hot 120 60 - 110 50
39 Hot 142 25 - 132 15

Figure 7.6 shows the relationship between interval temperature with hot and cold
streams while Table 7.13 shows the mass balance for interval temperature.

39
132°C
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37
110°C 1 –0.5527

50°C 2 -1.026-0.5227=-1.5487

35°C 3 1.0007-0.5227= 0.478

35

30°C 4 -0.5527

20°C 5 0.3737-0.5227= -0.149

33

15°C 6 -0.5227
1.0007 0.3737 1.026 0.5227
Figure 7.6 Relationship between Interval Temperature with Hot and Cold Streams

Table 7.13 Mass Balance for Interval Temperature

Interval Interval, Interval Interval Heat Heat balance, Surplus/
Temperature i ∆T (°C) Capacity, CPi=∑CPC- ∆Hi =CPi∆Ti Deficit
(°C) ∑CPH (kW/°C) (kW)
132
110 1 22 -0.5227 -11.50 Surplus
50 2 60 -1.5487 -92.922 Surplus
35 3 15 0.478 7.17 deflicit
30 4 5 -0.5227 -2.6135 Surplus
20 5 10 -0.149 -1.49 Surplus
15 6 5 -0.5227 -2.6135 Surplus

Interval Part (a) Part (b)

132°C 0 kW 11.50= QHmin

-11.50 -11.50
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110°C 1 11.50 0

-92.922 -92.922
50°C 2 104.422 92.922

7.17 7.17
35°C 3 97.252 85.752

-2.6135 -2.6135
30°C 4 99.866 88.366

20°C 5 -1.49 101.356 -1.49 89.856

15°C 6 -2.6135 103.969 -2.6135 92.469= QCmin

Figure 7.7 Heat Cascade

From the heat cascade as shown in Figure 7.7, it can be conclude that the pitch point
temperature is 110°C. Summary of the result of heat integration is shown in Table 7.14.
Figure 7.8 shows the grid for four streams problem while Figure 7.9 and 7.10 show the
network design above the pitch and below the pitch respectively.

Table 7.14 Summary for the Result from Heat Integration

Minimum heat process required for hot utility, QHmin 11.50 kW
Minimum heat process required for cold utility, QCmin 92.469 kW
∆Tmin 20°C
Pinch temperature (interval) 110°C
Pinch temperature for hot stream 120°C
Pinch temperature for cold stream 100°C

∆H above pinch Pinch ∆H below pinch CP

120 °C

0 120 °C 40°C 25°C 15.01 1.0007

35

0 120 °C 33 20°C 10°C 3.737 0.3737

37
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20.52 120ºC 100 °C 60°C 41.04 1.026

21.9539 142°C 100 °C 25°C 39.20 0.5227

100 °C
Figure 7.8 Grids for Four Streams

CP ∆H above pinch

1.026 20.52 37 120ºC c 100 °C

20.52 kW

39
c
0.5227 21.95 142°C 100 °C
21.95 kW

Figure 7.9 Network Design above the Pitch

120°C ∆H below pinch CP

40°C 25°C 15.01 1.0007

35

20°C 10°C 33 3.737 0.3737

78.34°C
100°C 60°C 41.04 1.026
37 C
18.236 16.211
15.01 kW 3.737 kW 18.747 kW

39 100°C 25°C 39.20 0.5227

C

3.737 kW 0.15 kW
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Figure 7.10 Network Design below the Pitch

Table 7.15 below shows the total energy recovered from the heat integration.

Table 7.15 Total Energy Recovered

Before After
141.457 kW 103.969 kW
Total Energy Recovery 26.50 %

Therefore, there are 26.50 % of energy can be saved after energy integration where heat
released from the hot streams can be transferred to cold fluid and vice versa.

7.8 CONCLUSION

In the process of production of erythritol, there are four utility used which include two
jacketed vessels, one heat exchanger and one evaporator. The design of these utility
mainly depend on the mass flow rate and the type of medium need to be heat or cooled.
The value of the overall coefficient for heat exchanger HE-01 is 190.77W/m 2.˚C, jacketed
vessel F-101 is 145.86W/m2.˚C and jacketed vessel F-102 is 882.70W/m 2.˚C whereas
steam economy for evaporator EVA-101 is 0.8804.The cooling or condense medium used
is water as it is cheaper than refrigerant or others chemical. The water used in the
condenser will try to be reuse in the next utility to reduce the operating cost. Pinch
analysis had been done and pinch temperature 110oC can be obtained in this process. In
the heat integration part, 26.50% energy had been saved. Hence, purpose of reduce energy
requirement in the process is achieved
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