Warm Water

32348.5153

WASHING TANK T-2

Washed Feathers
IN 34251.1880 YEY Solids Amount
OUT 34251.1880 U.R. Keratin
Collected Feathers AMOUNTS Water
Feathers 90.01% 1712.5594 Lipids
U.R. Keratin 91.04% 1559.0313 Liquids Amount
Water 8.02% 137.4119 Water
Lipids 0.94% 16.1162 Soluble dirt
Dirt 9.99% 190.1133
TOTAL 1902.6727

1919.29134 for 1490

 DEWATERING BELT SCREENER S-1
AMOUNTS
5.00% 1712.5594 IN 34251.1880 YEY
91.04% 1559.0313 OUT 34251.1880
8.02% 137.4119
0.94% 16.1162
95.00% 32538.6286
99.42% 32348.5153
0.58% 190.1133
TOTAL 34251.1880
Filtrate AMOUNTS
Water 99.42% 32063.3228
Soluble dirt 0.58% 188.4372
TOTAL 32251.7600
 HAMMERMILL C
Wet Feathers AMOUNTS
Solids Amount 85.65% 1712.5594 IN
U.R. Keratin 91.04% 1559.0313 OUT
Water 8.02% 137.4119
Lipids 0.94% 16.1162
Liquids Amount14.35% 286.8686
Water 99.42% 285.1925
Soluble dirt 0.58% 1.6761
TOTAL 1999.4280
 Oversize
Solids Amount 97.00%
HAMMERMILL CRUSH C-1
U.R. Keratin 91.04%
2195.5974 YEY Water 8.02%
2195.5974 Lipids 0.94%
Liquids Amount 3.00%
Water 99.42%
Soluble dirt 0.58%
TOTAL

Wet Feathers
Solids Amount 86.67%
U.R. Keratin 91.04%
Water 8.02%
Lipids 0.94%
Liquids Amount 13.33%
Water 99.42%
Soluble dirt 0.58%
TOTAL
AMOUNTS
190.2844
VIBRATORY SCREENER S-2
173.2257
15.2680 IN 2195.5974 YEY
1.7907 OUT 2195.5974
5.8851
5.8507
0.0344
196.1695

AMOUNTS
1902.8438
1732.2570 Discharge AMOUNTS
152.6799 Solids Amount 7.97% 17.1256
17.9069 U.R. Keratin 91.04% 15.5903
292.7537 Water 8.02% 1.3741
291.0432 Lipids 0.94% 0.1612
1.7105 Liquids Amount 92.03% 197.6352
2195.5974 Water 99.42% 196.4805
Soluble dirt 0.58% 1.1547
TOTAL 214.7608
Ground Feathers (Undersize) AMOUNTS
Solids Amount 95.00% 1695.4338
U.R. Keratin 91.04% 1543.4410
Water 8.02% 136.0378
Lipids 0.94% 15.9550
Liquids Amount 5.00% 89.2334
Water 99.42% 88.7120
Soluble dirt 0.58% 0.5214
TOTAL 1784.6672
 AMOUNTS Fraction
Chloroform 21203.2720 2/3 14.2303838762
Methanol 10601.6360 1/3 13.385904025
TOTAL 31804.9080 27.6162879012
LIPID EXTRACTOR J-1

IN 33589.5751 YEY
OUT 33589.5751

Assumption: All lipids are dissolved

m3
m3

Delipidized Feathers AMOUNTS

Solids Amount 5.00% 1679.4788
U.R. Keratin 91.90% 1543.4410
Water 8.10% 136.0378
Liquids Amount 95.00% 31910.0964
Chloroform 66.45% 21203.2720
Methanol 33.22% 10601.6360
Water 0.28% 88.7120
Soluble dirt 0.00% 0.5214
Dissolved Lipids 0.05% 15.9550
TOTAL 33589.5751275205

Dried Chicken Feathers

TURNING POINT

AMOUNTS
Chicken Feathers 99.96% 1543.4410
Soluble Dirt 0.0000180% 0.0003
Dissolved Lipids 0.0005493% 0.0085
Water 0.04% 0.6804
TOTAL 1544.13016121
 Filtrate
PLATE AND FRAME FILTER F-2
Chloroform 66.45%
IN 33589.5751 YEY Methanol 33.22%
OUT 33589.5751 Water 0.28%
Soluble dirt 0.00%
Assumptions: 1% Adhering Liquid Dissolved Lipids 0.05%
TOTAL

Wet Cake AMOUNTS

Solids Amount 99.00% 1679.4788
U.R. Keratin 91.90% 1543.4410
Water 8.10% 136.0378
Liquids Amount 1.00% 16.9644
Chloroform 66.45% 11.2723
Methanol 33.22% 5.6362
Water 0.28% 0.0472
Soluble dirt 0.00% 0.0003
Dissolved Lipids 0.05% 0.0085
TOTAL 1696.443188

ROTARY DRYER D-1

Hot Air
IN 1696.4432 YEY
OUT 1696.4432

Discharge AMOUNTS
Chloroform 11.2723 7.40%
Methanol 5.6362 3.70%
Water 135.4045 88.90%
TOTAL 152.3130
AMOUNTS
21191.9996
10595.9998
88.6648
0.5211
15.9466
31893.1319
 Amount of Chicken Feather
Total Volume Shindai Solution

Assumption: 90% Conversion, 10%

250ml solution / 7000mg Chicken F
Shindai Solution
25 mM Tris-HCl
2.6M Thiourea
5M Urea
5% v/v 2-mercaptoethanol
Water at 50 deg C

KERATIN REDUCTOR J-2

Dried Chicken Feathers IN 64191.4681

AMOUNTS OUT 64191.4681
Chicken Feathers 99.96% 1543.4410 f
Soluble Dirt 0.00% 0.0003 Reaction Mechanism AMOUNTS (kgs)
Dissolved Lipids 0.00% 0.0085 Cystine Reacted 160.4407
Water 0.04% 0.6804 Cysteine Produced 161.7777
TOTAL 1544.1302 R. Keratin Produced 1390.4339
Dithioethanol Produced 102.9494
2-Mercaptoethanol used 104.2864
nt of Chicken Feather 1543.4410 kgs
Volume Shindai Solution 55122.8920 liters

ption: 90% Conversion, 10% Unreduced

solution / 7000mg Chicken Feathers
AMOUNTS (kgs) AMOUNTS (liters)
217.1704 193.9022 0.35%
Thiourea 10909.6251 7764.8577 17.41%
ea 16553.4045 12512.0215 26.42%
v 2-mercaptoethanol 3071.1719 2756.1446 4.90%
at 50 deg C 31895.9660 31895.9660 50.91%
TOTAL 62647.3380 55122.8920

IN REDUCTOR J-2

YEY Reductate AMOUNTS

Solids Amount 0.24% 154.3529
U.R. Keratin 99.99% 154.3441
Soluble Dirt 1.80E-06 0.0003
Dissolved Lipids 0.01% 0.0085
Liquids Amount 99.76% 64037.1153
R. Keratin 2.17% 1390.4339
Shindai Solution 97.83% 62646.6814
Water 50.92% 31896.6464
Shindai Mixture 49.08% 30750.0349
TOTAL 64191.4681

Compostion of Shindai Mixture

Thiourea 35.4784% 10909.6251
Urea 53.8321% 16553.4045
2-hydroxyethyl disulfide 0.3348% 102.9494
Tris-HCl 0.7062% 217.1704
2-mercaptoethanol 9.6484% 2966.8855
30750.0349
 2

2.4347127E-05
0.0024347127

Assumption: 1% adhering liquid

CARTRIDGE FILTER F-3

IN 64191.4681 YEY Filtrate

OUT 64191.4681 R. Keratin
Diluted Shindai Soln
Wet Cake AMOUNTS Water
Solids Amount 99.00% 154.3529 Shindai Mixture
U.R. Keratin 99.99% 154.3441
Soluble Dirt 0.00% 0.0003 Compostion
Dissolved Lipids 0.01% 0.0085 Thiourea
Liquids Amount 1.00% 1.5591 Urea
R. Keratin 2.17% 0.0339 2-hydroxyethyl disulfide
Shindai Solution 97.83% 1.5253 Tris-HCl
Water 50.92% 0.7766 2-mercaptoethanol
Shindai Mixture 49.08% 0.7487
TOTAL 155.9120
Compostion of Shindai Mixture
Thiourea 35.4784% 0.2656
Urea 53.8321% 0.4030
2-hydroxyethyl disulfide 0.3348% 0.0025
Tris-HCl 0.7062% 0.0053
2-mercaptoethanol 9.6484% 0.0722
 Assumptions: R. Keratin concentrated to 42%
Diluted Shindai solution has same concentrations
in Retentate and Permeate

0.9999756529 Water 610481.1838

ULTRAFILTER F-4

AMOUNTS IN 674516.7399 YEY

2.17% 1390.4000 OUT 674516.7399
97.83% 62645.1561
50.92% 31895.8698 Permeate
49.08% 30749.2863 Water
TOTAL 64035.5561 Shindai Mixture
Compostion of Shindai Mixture
Thiourea 35.4784% 10909.3595 Compostion of Shindai Mixture
Urea 53.8321% 16553.0015 Thiourea
2-hydroxyethyl disulfide 0.3348% 102.9469 Urea
Tris-HCl 0.7062% 217.1651 2-hydroxyethyl disulfide
2-mercaptoethanol 9.6484% 2966.8132 Tris-HCl
2-mercaptoethanol
centrated to 42%
same concentrations

Retentate AMOUNTS
R. Keratin 42.00% 1390.4000
Diluted Shindai Soln 58.00% 1920.0762
Water 95.43% 1832.3647
95.43% 640544.6890 Shindai Mixture 4.57% 87.7116
4.57% 30661.5747 TOTAL 3310.4763
TOTAL 671206.2637 Compostion of Shindai Mixture
tion of Shindai Mixture Thiourea 35.4784% 31.1187
35.4784% 10878.2408 Urea 53.8321% 47.2170
53.8321% 16505.7844 2-hydroxyethyl disulfide 0.3348% 0.2937
0.3348% 102.6533 Tris-HCl 0.7062% 0.6195
0.7062% 216.5457 2-mercaptoethanol 9.6484% 8.4628
9.6484% 2958.3505 100.0000%
100.0000%
Assumption: Evaporate water
until keratin is 80% of the liquor
EVAPORATOR E-1

IN 3310.4763 ENGK Liquor

OUT 3310.4763 R. Keratin
Water
Components Removed Shindai Mixture

Water 99.42% 1563.3940 Compostion of Shindai Mixtu

Tris-HCl 0.04% 0.6195 Thiourea
2-mercaptoethanol 0.54% 8.4628 Urea
TOTAL 1572.4762 2-hydroxyethyl disulfide
 Assumption: 97% water removed

FREEZE DRYER D-2

AMOUNTS IN 1738.0000 YEY

R. Keratin 80.00% 1390.4000 OUT 1738.0000
Water 15.48% 268.9706
Shindai Mixture 4.52% 78.6294 Water Removed
TOTAL 1738.0000 Water 260.90153
Compostion of Shindai Mixture
Thiourea 39.58% 31.1187
Urea 60.05% 47.2170
2-hydroxyethyl disulfide 0.37% 0.2937
78.6294
 AMOUNTS
R. Keratin 94.13% 1390.4000
Water 0.55% 8.0691
Shindai Mixture 5.32% 78.6294
TOTAL 1477.0985
Compostion of Shindai Mixture
Thiourea 39.58% 31.1187
Urea 60.05% 47.2170
2-hydroxyethyl disulfide 0.37% 0.2937
78.6294
 Warm Water
35894.1642

WASHING TANK T-2

Washed Feathers
IN 38005.3847 YEY Solids Amount
OUT 38005.3847 U.R. Keratin
Collected Feathers AMOUNTS Water
Feathers 90.01% 1900.2692 Lipids
U.R. Keratin 91.04% 1729.9132 Liquids Amount
Water 8.02% 152.4733 Water
Lipids 0.94% 17.8827 Soluble dirt
Dirt 9.99% 210.9512
TOTAL 2111.2205
 DEWATERING BELT SCREENER S-1
AMOUNTS
5.00% 1900.2692 IN 38005.3847 YEY
91.04% 1729.9132 OUT 38005.3847
8.02% 152.4733
0.94% 17.8827
95.00% 36105.1155
99.42% 35894.1642
0.58% 210.9512
TOTAL 38005.3847
Filtrate AMOUNTS
Water 99.42% 35577.7124
Soluble dirt 0.58% 209.0914
TOTAL 35786.8039
 HAMMERM
Wet Feathers AMOUNTS
Solids Amount 85.65% 1900.2692 IN
U.R. Keratin 91.04% 1729.9132 OUT
Water 8.02% 152.4733
Lipids 0.94% 17.8827
Liquids Amount14.35% 318.3116
Water 99.42% 316.4518
Soluble dirt 0.58% 1.8598
TOTAL 2218.5808
 Oversize
Solids Amount 85.65%
HAMMERMILL CRUSH C-1
U.R. Keratin 91.04%
YEY Water 8.02%
Lipids 0.94%
Liquids Amount 14.35%
Water 99.42%
Soluble dirt 0.58%
TOTAL

Wet Feathers
Solids Amount 85.65%
U.R. Keratin 91.04%
Water 8.02%
Lipids 0.94%
Liquids Amount 14.35%
Water 99.42%
Soluble dirt 0.58%
TOTAL
AMOUNTS
190.0269
VIBRATORY SCREENER S-2
172.9913
15.2473 IN 2218.5808 YEY
1.7883 OUT 2218.5808
31.8312
31.6452
0.1860
221.8581

AMOUNTS
1900.2692
1729.9132
152.4733
17.8827
318.3116
316.4518
1.8598
2218.5808
Ground Feathers (Undersize) AMOUNTS
Solids Amount 85.65% 1710.2423
U.R. Keratin 91.04% 1556.9219
Water 8.02% 137.2260
Lipids 0.94% 16.0944
Liquids Amount 14.35% 286.4804
Water 99.42% 284.8066
Soluble dirt 0.58% 1.6738
TOTAL 1996.7227
 AMOUNTS Fraction
Chloroform 21257.4922 2/3 14.2667733171
Methanol 10628.7431 1/3 13.4201301868
TOTAL 31886.2354 27.6869035039
LIPID EXTRACTOR J-1

IN 33882.9581 YEY
OUT 33882.9581

Assumption: All lipids are dissolved

m3
m3

PLATE AND FRAM

Delipidized Feathers AMOUNTS
Solids Amount 5.00% 1694.1479 IN
U.R. Keratin 91.90% 1556.9219 OUT
Water 8.10% 137.2260
Liquids Amount 95.00% 32188.8102
Chloroform 66.04% 21257.4922 66.04%
Methanol 33.02% 10628.7431 33.02%
Water 0.88% 284.8066 0.88%
Soluble dirt 0.01% 1.6738 0.01%
Dissolved Lipids 0.05% 16.0944 0.05%
TOTAL 33882.9581

99.99999549346% PANG NORMALIZE LANG

ROTARY DR
Dried Chicken Feathers
IN
TURNING POINT OUT

AMOUNTS
Chicken Feathers 99.96% 1556.921925 99.9559%
Soluble Dirt 0.0000571% 0.0009
Dissolved Lipids 0.0005493% 0.0086
Water 0.04% 0.6869 0.0441%
TOTAL 1557.6183
 Filtrate
PLATE AND FRAME FILTER F-2
Chloroform 66.04%
33882.9581 YEY Methanol 33.02%
33882.9581 Water 0.88%
Soluble dirt 0.01%
Assumptions: 1% Adhering Liquid Dissolved Lipids 0.05%
TOTAL

Wet Cake AMOUNTS

Solids Amount 99.00% 1694.1479
U.R. Keratin 91.90% 1556.9219
Water 8.10% 137.2260
Liquids Amount 1.00% 17.1126
Chloroform 66.04% 11.3012
Methanol 33.02% 5.6506
Water 0.88% 0.1514
Soluble dirt 0.01% 0.0009
Dissolved Lipids 0.05% 0.0086
TOTAL 1711.26051

ROTARY DRYER D-1

Hot Air
1711.2605 YEY
1711.2605

Discharge AMOUNTS
Chloroform 11.3012 7.36%
Methanol 5.6506 3.68%
Water 136.6905 88.97%
TOTAL 153.6423
AMOUNTS
21246.1911
10623.0925
284.6552
1.6729
16.0859
32171.6976
 Unreduced Keratin 1,543.44 1.74 2685.58734
Water 31,896.65 1.53 48801.868992
Tris-HCl 217.1704 4.186 909.0752944
Thiourea 10,909.63 2.17 23673.886467
Urea 16,553.40 1.2 19864.0854
2-Mercaptoethanol 2,966.89 1.53 4539.334815
Reduced Keratin 1,390.43 1.93 2683.537427
2-hydroxyethyl disulfide 102.9494 1.11 114.273834
103271.6495694

3614507.73493
160.4407 -3071.6604 -492819.344738
3,071.17 3256.5285 10001358.8207

161.7777 -4126.774 -667620.00614

102.9494 -3021.5584 -311067.624345

2,243,051.05 -10,487,227.11 3,614,507.74