Department of Chemical Engineering

Final Year Design Project Proposal

A Plant Design Project on manufacture of 200 Metric tons per day of
Industrial Alcohol from Molasses

Project Supervisor
Dr.Farukh Jamil

Group Members:
Jawad Kashif (FA15-CHE-041)
Mubashir Rehmat (FA15-CHE-052)
Muhammad Iqbal Tabassum (FA15-CHE-068)
Rana Asad Ali (FA15-CHE-035)
Muhammad Kashif (FA15-CHE-074)

Supervisor Signature: ----------------------------

Date: ----------------------------------
Contents
Project Description.............................................................................................................................. 7
Introduction ......................................................................................................................................... 9
1.1 History ..................................................................................................................... 10
1.2 Properties ................................................................................................................. 10
1.2.1 Physical Properties ................................................................................................. 11
1.2.2 Chemical properties ............................................................................................... 11
1.3 Uses and application................................................................................................ 12
1.3.1 Industrial Uses ....................................................................................................... 12
1.3.2 Commercial Uses ................................................................................................... 13
Raw Material (Molasses) .................................................................................................................. 14
Literature Review.............................................................................................................................. 16
1.4 Available processes ................................................................................................. 17
1.5 Fermentation of Starch/Cellulose ............................................................................ 17
1.5.1 Hydrolysis of the Cellulose:................................................................................... 17
1.5.2 Fermentation of the Hydrolyzed Cellulose: ........................................................... 17
1.6 Fermentation of Molasses ....................................................................................... 17
1.6.1 Dilution off molasses ............................................................................................. 18
1.6.2 Addition of Ammonium Sulphate .......................................................................... 18
1.6.3 Addition of sulphuric acid ..................................................................................... 18
1.6.4 Fermentation .......................................................................................................... 18
1.6.5 Distillation.............................................................................................................. 18
1.7 Hydration of Ethylene ............................................................................................. 18
1.7.1 Process for production ........................................................................................... 18
Various processes of manufacturing methanol ................................................................................. 20
1.8 Hydration of Ethylene ............................................................................................. 21
1.8.1 Effect of temperature ............................................................................................. 21
1.8.2 Effect of pressure ................................................................................................... 21
1.9 Fermentation of molasses ........................................................................................ 21
1.9.1 Effect of pH............................................................................................................ 21
 1.9.2 Effect of temperature ............................................................................................. 21
Process selection ............................................................................................................................... 23
Process parameter ............................................................................................................................. 25
1.10 ...................................................................................................................................... 25
1.11 Fermenter ................................................................................................................ 26
1.12 Heat Exchanger ....................................................................................................... 26
1.13 Pre-heater ................................................................................................................ 26
1.14 Stripper .................................................................................................................... 26
1.15 Aldehyde column .................................................................................................... 26
1.16 Rectifying column ................................................................................................... 26
Process Description ........................................................................................................................... 27
Equipment Description ..................................................................................................................... 29
1.17 Molasses Storage tank ............................................................................................. 30
1.18 Diluter...................................................................................................................... 30
1.19 Sterilizer .................................................................................................................. 30
1.20 Fermenter ................................................................................................................ 30
1.21 Heat Exchanger ....................................................................................................... 30
1.22 Stripper .................................................................................................................... 31
1.23 Scrubber .................................................................................................................. 31
Process Flow Diagram ...................................................................................................................... 33
Hazards identification ....................................................................................................................... 34
1.24 Flammable: .............................................................................................................. 35
1.24.1 ............................................................................................... Distillation process area35
1.24.2Fuel storage tank area ........................................................................................... 35
1.24.3 .....................................................................................................Storage tank headspace
35
1.24.4 ......................................................................................................... Heated storage tanks
35
1.24.5 ........................................................................................................ Ethanol loading areas
36
1.25 Equipment Ruptures ................................................................................................ 36
1.26 Exposure to hazardous substances .......................................................................... 36
 1.27 Hazardous Noise Levels .......................................................................................... 36
Safety Measures ................................................................................................................................ 37
1.28 Flammable liquids ................................................................................................... 37
1.28.1Preventing measures
37
1.28.2Engineering controls
37
1.29 Exposure to hazardous substances .......................................................................... 37
1.29.1Engineering controls:
37
1.30 Equipment Ruptures ................................................................................................ 37
1.30.1Safe work practices
37
1.30.2Engineering controls
37
1.31 Hazardous noise levels ............................................................................................ 37
1.31.1Engineering controls
37
Material balance ................................................................................................................................ 39
Basic Calculations: .............................................................................................................. 40
Molasses required: .......................................................................................................... 40
Yeast required: ............................................................................................................... 40
CO2 produced: ................................................................................................................ 40
Fusel Oil Formed: ........................................................................................................... 40
Aldehyde Produced: ....................................................................................................... 41
H2SO4 Required: ............................................................................................................. 41
(NH4)2SO4 (Nutrients) Required: ................................................................................... 41
Balance Around CO2 Scrubber: ........................................................................................... 41
Around diluter: .................................................................................................................... 42
Around Sterilizer: ................................................................................................................ 43
Around Seeding Vessel: ...................................................................................................... 43
Around Mother Tank: .......................................................................................................... 44
 Around Fermenter: .............................................................................................................. 44
Around Mash Storage Tank ................................................................................................ 45
Around Stripper: .................................................................................................................. 45
Around Surge Drum: ........................................................................................................... 46
Around Rectifying Column: ................................................................................................ 47
Overall Material Balance..................................................................................................... 47
Heat Balance ..................................................................................................................................... 48
Around Fermenter: .............................................................................................................. 49
Around Pre-heater: .............................................................................................................. 50
Around Heat Exchanger: ..................................................................................................... 50
Around Stripper: .................................................................................................................. 51
Around Condenser 1:........................................................................................................... 52
Around Condenser 2:........................................................................................................... 53
Equipment Design ............................................................................................................................. 55
1.32 Alcohol Storage Tank.............................................................................................. 56
1.33 Scrubber .................................................................................................................. 57
1.34 Fermenter ................................................................................................................ 58
1.35 Heat Exchanger ....................................................................................................... 61
Project Description
Molasses contains about 50% of fermentable sugars (sucrose, glucose and fructose). Molasses
because of its strong concentration of sugar does not support direct yeast fermentation, therefore
in diluter the percentage of fermentable sugar is reduced up to 10-15% by diluting the molasses
using process water. This is called mash and represents the carbohydrates ready for yeast
inoculation. The mash after sterilizing (heating at 120 -130°C to kill bacteria) is divided into
two streams. The main stream 93%-94% of the total is taken straight away to the fermenter,
while the remaining stream is pumped to the yeast culture unit, which contains seeding vessel
and a mother tank. Nutrients (ammonia sulphate, urea and DAP) are added to the seeding vessel
to facilities the activity of selected yeast. Sulphuric acid is also added to the mother tank, in
order to maintain the PH between 3.5 and 4.5 which also helps in controlling the activity of the
selected yeast. Sulphuric acid is usually added in amount 2-3 Kg of the alcohol produced.
The mash from the mother tank when needed is added into the fermenter. There are six
fermenters in the series. Fermentation can take place for 24Hr in each fermenter and finally
mash containing 8% alcohol is pumped into the mash storage tank. as a result of exothermic
nature of the reaction the temperature tends to rise in the fermenter, which is controlled using a
coolant in the fomenter so that it ranges 30-35°C.
Yeast secretes then enzymes known as a maltose, Invertase and zymase. Maltase catalysis is the
hydrolysis of maltose to glucose and invertase the hydrolysis of sucrose to glucose and fructose.
The fermented mash is taken in a heat exchanger in which it is heated by the hot product
coming out of the bottom of the stripper at 100°C.the temperature of the cold stream rises from
32°C to nearly 60°C then it is passed through a pre-heater where temperature in the column is
maintained at 100°C.as the mash passes through down the stripper, it loses its light boiling
fractions.
The liquid discharged from the bottom of the stripper is known as slope or still age which
carries protein residential sugar and in some instance the vitamin product’s, it is frequently
evaporated and used as a constituent in animal feed.
The overhead containing alcohol, water and aldehyde pass through a condenser which takes
away latent heat of the vapors and liquid distillation is taken through a surge drum (to remove
aldehydes) to a distillation column. The feed to distillation column contain 60% by weight
alcohol which is concentrated to 95.4% alcohol and collected as top product while is removed at
the bottom from column. The fusel oil is taken as side stream. The alcohol is then stored in a
storage tank. [Error! Reference source not found.]
Introduction
The term Industrial Alcohol implies the industrial use of ethyl alcohol. Ethyl alcohol is probably
one of the world oldest and best known chemical compounds. The word alcohol itself is derived
from two Arabic word al and kohl which were first used to donate a finally ground powder
employed by oriental women to darken their eyebrow.
Ethyl alcohol has been described as one of the most exotic synthetic oxygen containing
chemical. So compounds obtained by replacing one or more hydrogen atoms of alkanes by
hydroxyl-OH group are called alcohol. It has the functional group (OH) but if (OH) is Attached
with benzene or cyclic insisted of aliphatic than product form is called Phenol. In IUPAC
system its Chemical name is ethanol. It has unique combination of properties as a solvent, a
beverage, a germicide, antifreeze as a fuel and a chemical Intermediate for another organic
Chemical [Error! Reference source not found.].
1.1 History
Ethanol is an alcohol made through the fermentation of plant sugars from agricultural crops and
biomass resources (NEVC, 1998). With rapid depletion of the world reserves of petroleum,
ethanol in recent years has emerged as one of the alternative liquid fuel and has generated
immense activities of research in the production of ethanol and its environmental impact.
Production of alcoholic beverages is in fact as old as human civilization. The production of pure
ethanol apparently begins in the 12-14th century along with improvement of distillation. During
the middle ages, alcohol was used mainly for production of medical drugs but also for the
manufacture of painting pigments. The knowledge of using starchy materials for ethanol
production was first employed in the 12th century in typical beer countries like Ireland. Ethanol
was one of the most popular lamp illuminants used in 1850s and approximately 90 million
gallons ethanol was produced in the United States. But due to the tax imposition on ethanol to
assist in financing the civil war and the cheaper price of kerosene, it quickly replaced ethanol as
the premier illuminant in 1861 (Morris, 1993). It was only in the 19th century that this trade
became an industry with enormous production figures due to the economic improvements of the
distilling process. It was at the beginning of the 20th century that it had become known that
alcohol might be used as fuel for various combustion engines, especially for automobiles. In the
1970‟s, the interest in fuel ethanol was renewed due to the oil crisis. Nearly 25 federal agencies
administered various ethanol programs and the National Alcohol Fuels Commission was
established to study the potential for alcohol-based fuels (Lansing, 1983). Ethanol gained
further support in 1980 when Chrysler, Ford and General Motors released statements that
ethanol with blends of up to 10% would be covered in their vehicle warranties (RFA, 1998). Its
market grew from less than a billion liters in 1975 to more than 39 billion liters in 2006 and is
expected to reach 100 billion liters in 2015 (Licht, 2006). Interest in the use of biofuels
worldwide has grown strongly in recent years due to the limited oil reserves, concerns about
climate change from greenhouse gas emissions and the desire to promote domestic rural
economies. [Error! Reference source not found.]
1.2 Properties
Properties of alcohol are described under two headings:
 Physical properties
 Chemical properties
1.2.1 Physical Properties
Ethyl alcohol under normal conditions is a volatile flammable, clear and colorless liquid with
pleasant odor.
The physical and chemical properties of alcohol are primarily dependent upon the hydroxyl
group. This group imparts polarity to the molecules and also gives rise to inter-molecular
hydrogen bonding. These two properties count for the difference between the physical behavior
of low molecular Wight alcohol and that, in liquid state, hydrogen bonds are formed by the
attraction:

1.2.2 Chemical properties

Ethyl alcohol gives all the general reaction of the class described before. [Error! Reference
source not found.]
1. Reaction with sodium or potassium:
Ethyl alcohol reacts with sodium or potassium to form the corresponding ethoxides

2CH3CH2OH + 2Na 2CH3CH2ONa + H2

2. Reaction with phosphorous halides:

Ethyl alcohol reacts with phosphate halide to give ethyl halides.

CH3CH2OH + PCl5 CH3CH2Cl + POCl3+HCl

 (ethyl chloride)

CH3CH2OH + PBr3 3CH3CH2Br + H3PO3

(Ethyl bromide)
3. Reaction with thionyl chloride:
Ethyl alcohol reacts with thionyl chlorides (SOCl2) to give ethyl chloride,

CH3CH2OH + SOCl2 CH3CH2Cl +SO2 + HCl

4. Reaction with hydrogen halides:

Ethyl alcohol reacts with HBr, HCl or HI to give the corresponding ethyl halides. HCl reacts in
the presence of ZnCl2 catalyst. No catalyst is required in the case of HBr or HI.

CH3CH2OH + HBr CH3CH2Br + H2O

5. Reaction with nitric acid:

Ethyl alcohol reacts with nitric acid to form ethyl nitrate

CH3CH2OH + HNO3 CH3CH2ONO2 + H2O

(Ethyl alcohol) (ethyl nitrate)

6. Reaction with sulphuric acid:

The reaction of ethyl alcohol with sulphuric acid is very sensitive to reaction condition

C2H5OH + HO-SO2OH C2H5-O-SO2OH + H2O

(Ethyl alcohol) (Ethyl hydrogen sulphate)

7. Reaction with carboxylic acids:

Ethyl alcohol reacts with carboxylic acid in the presence of sulphuric acid to form esters

CH3CH2OH + HO-CO-CH3 C2H5O-O-CH3 + H2O

(Iodoform)

1.3 Uses and application

Industrial alcohol is one of the largest volume organic chemical uses in industrial and consumer
products. We study its uses under two categoriesError! Reference source not found.];
 Industrial uses
 Commercial uses
1.3.1 Industrial Uses
Chemical industry is the best consumer of the product and some uses are listed below;
1. As a solvent ethanol is secondry only to water. In recent year ethanol is role as a solvent
has increase sharply. The fastest growing solvent use of ethanol is in cleaning
preparations. As a solvent its use in drug, oil, perfume, printing inks, dyes, varnishes,
cosmetic, pharmaceutical products and in smokeless powder manufacture.
 2. It is use as a raw material for a large number of organic compounds including ethylene,
ether, acetic acid, acetaldehyde, glucose, hydro form, chloroform and chloral etc.
3. It is used in the manufacture of synthetic rubber.
1.3.2 Commercial Uses
Ethanol uses in industries as well as commercially, some commercial uses are listed below;

1. Ethanol has been used to a considerable extent as an anti-freeze, but it has largely been
replaced for such use by ethylene glycol for automobile radiator.
2. It is used as beverages.
3. It is used as a preservative for biological specimens as a low freezing (freezing point-
117 °C) and mobile fluid in scientific apparatus such as thermometer and spirit level.
4. It is used as a fuel for lamps and stoves. The combustion of ethanol is smokeless. The
calorific value is 7100 cal/kg which is slightly lower than that of coal. For the sake of
convenience, in transportation it is converted into solid state by dispersion in saturated
calcium acetate and a little stearic acid.
5. In hospitals it is used as an antiseptic.
6. End usage growth pattern of industrial alcohol. The uses of ethanol are the following:
 Solvent 40%
 Acetaldehyde production 36%
 Miscellaneous chemical uses 15%
 Ether, glycol ether, ethyl acetate and chloral 9%
Raw Material (Molasses)
Molasses (sometimes called blackstrap) can be defined as the final residue obtained in the
preparation of sugar by repeated crystallization. It is the residual syrup purged from a
massecuite incapable of crystallizing after concentration or cooling is called “blackstrap
molasses” in a raw sugar house and Refinery Blackstrap or barrel syrup in a refinery is a very
viscous product with a rather bitter taste. The approximate weight of one gallon is 12.8lb.
The US custom laboratory defines Blackstrap as molasses in which the non-sugar solids are
more than 60% of the total soluble solids excluding any foreign substance that may have been
added or developed in the product.
It is roughly estimated that 4 to 5 tons of molasses required to prepare one ton of alcohol. It has
been found that on average 4 tons of molasses (88Brix) sp. Gravity 1.47 is produced from every
100 tons of cane crushes [Error! Reference source not found.].
Literature Review
1.4 Available processes
By Keeping in mind demand of the ethanol, the production has recently seen that there is
increasing the production of the ethanol due to economic and environmental security concerns.
In the specific countries just like Europe, India, China, and Brazil, the ethanol production
is target for reducing petroleum import and increasing the consumption and production of
renewable fuel as the ethanol is renewable fuel. There are many ways for the production of
ethanol. These methods are including:
 Fermentation of Starch/Cellulose
 Fermentation of molasses
 Hydration of ethylene
1.5 Fermentation of Starch/Cellulose
It was French chemist Anselme Payen, who discovered cellulose in 1838. Anselme Payen found
that the cellulose is consist of 44% to 45% Carbon, 6% to 6.5%of hydrogen and the remaining
part of the cellulose is mainly consists of oxygen. Then a chemist Staudinger proof in 1920 that
the cellulose in natural polymer of carbohydrates [Error! Reference source not found.].
Now, the cellulosic ethanol is ethanol which extracts from cellulosic materials such as forestry
or agricultural waste. For the production of cellulosic ethanol, the woods are commonly used as
raw material. The firstly in the history the extraction of ethanol from cellulose was published on
1819 by Baronet. After the research of Braconnet the door for the other researcher were opened.
After the research of Braconnet, Simonsen in 1894 put forward the method for treatment of
sawdust with diluted acid in the high pressure about 7-8atm to produce Ethanol. After that in
1899 Classen put forward another method to produce ethanol. He used the diluted sulphuric
acid as hydrolysis solvent for the hydrolysis of wood. For this process, he set the conditions as
150°C temperature and 7atm pressure for 4to 6 hrs., then the solid parts from the reaction was
removed by filtration and the ethanol fermented.
To produce the ethanol from the cellulose the most common procedure is consists of two steps:
a) Hydrolysis of the cellulose
b) Fermentation of the hydrolyzed cellulose
1.5.1 Hydrolysis of the Cellulose:
In this method we use acid for the hydrolysis of the cellulose (C6H10O5)n. This method was
introduced in the last 19th century and the starting of the 20th century. By hydrolysis of the
cellulose (C6H10O5)n we convert it to the glucose(C6H12O6) which has to be fermented and
covert to the ethanol. For hydrolysis we commonly we use sulphuric acid which may be used in
concentrated (25-80%) or diluted (3-8%).
1.5.2 Fermentation of the Hydrolyzed Cellulose:
This process is the chemical transformation of the glucose to ethanol in the presence of some
specific enzyme. It is earlier mentioned that the fermentation is the breakdown of the molecules
in the absence of air. The following reaction is involved in fermentation:
C6H12O6 2C2H5OH + 2CO2
In this process ethanol produced with94-96% purity.
1.6 Fermentation of Molasses
Molasses is sweet, dark and viscous byproduct of sugar manufacturing. It was a German
chemist Andreas Marggraf discovered the presence of sugar in the molasses first time in the mid
of 1700. Then in 1793 another German chemist named as Franz Karl Achard first time utilized
the molasses to extract sugar from it. The composition of molasses on dry basis 62.2% alcohol-
soluble sugars, 32.1% sucrose, 8.5% glucose and 15.1% of fructose. Some percentage of
nitrogen is also present in the form of amino acid, but it is not more than 1%.
As earlier mentioned, that the ethanol is the most valuable product. Its demand increased from
20th century due to energy crises, ethanol can reduce these crises because it is the renewable
fuel. For this reason, its market grew from a billion liters to 65 billion in from 1975 to 2008.To
over these energy crises many countries played their roles, which include Brazil, India, China,
Ireland, Japan and Indonesia. United States produced the largest amount of the ethanol, it
produces 50% of the global production of ethanol. Brazil is the second largest producer of the
ethanol by bio-mass it produces 39% global ethanol [Error! Reference source not found.].
To produce ethanol from the molasses the following steps are includes:
1.6.1 Dilution off molasses
First of all, molasses is diluted with water with the ratio of 1:5(Molasses: Water)
1.6.2 Addition of Ammonium Sulphate
Ammonium Sulphate is used for the growth of the yeast, the amount of the Ammonium
Sulphate is added depend upon the Nitrogen content in the molasses.
1.6.3 Addition of sulphuric acid
Sulphuric acid is added to the solution to give the optimum pH to the solution as 4.8. It will
increase the working of those enzymes which are useless.
1.6.4 Fermentation
The resulting solution then recovered in a fermenter for 48-70hours at 30°C. During this period
the reactions are taking placed in the presence of enzyme yeast and glucose converted into the
ethanol. The following reactions are here:
C12H22O11+H2O C6H12O6 +C6H12O6
C6H12O6 C2H5OH + 2CO2
1.6.5 Distillation
The ethanol which we obtained from fermentation called WASH, will 18-20% pure. For
increasing in the purity, we will distillate WASH and increased its purity.[Error! Reference
source not found.Error! Reference source not found.]
1.7 Hydration of Ethylene
Ethanol is produced by the direct hydration of ethylene. The method of direct hydration firstly
was introduced by Shell in 1997. Shell manufactured the ethanol bychemical reaction of the
ethylene (C2H4) with water.
1.7.1 Process for production
First of all, water is vaporized and then added to the vapors of ethylene at pressure 65-70 atm
and the reaction is proceed at temperature about 250°-300°C. The mixture of water and ethylene
is fed to the reaction tower from top of the tower. A catalyst solution of H3PO4 is also fed to the
top of the tower which will be the added as per required. The concurrent flow passes through
the packing material of catalyst [Error! Reference source not found.]. Due to presence of the
catalyst the following reactions are proceeding:
H2O + CH2=CH2 CH3CH2OH

Due to presence of impurities such as acetylene (C2H2), the following reaction also be
occurred.

C2H2 + H2O CH3CHO

 (Acetaldehyde)
After the above mention reactions, the product mixture has ethanol, unreacted ethylene,
acetaldehyde and water. We will send the mixture for the separation, were the water and the
ethanol will separate from bottom. Then we will use the high pressure that will be separate the
acetaldehyde and send it to hydrogenator, were the following reaction will proceed:

CH3CHO + H2O CH3CH2OH

Finally, ethanol (C2H5OH) will produced at a different concentration as our requirement in

separators with a yield of 95-97% ethanol.
Various processes of manufacturing
methanol
1.8 Hydration of Ethylene
Ethanol is manufactured from ethylene by reaction with steam. This is a reversible and
exothermic reaction. Only 5% ethylene is converted to ethanol at each pass of reactor. By
removing ethanol from ethylene and recycling the ethylene we can achieve an overall 95%
conversion [Error! Reference source not found.].
a) Reaction

CH2=CH2 (g) + H2O (g) CH3CH2OH (g) ∆H=-45KJ/mole

b) Reaction Conditions
 Temperature: 300°C
 Pressure: 60-70atm
 Catalyst: Phosphoric (v) acid
1.8.1 Effect of temperature
The reaction is controlled by Le-Chatelier’s principle and we need to shift the equilibrium to the
right and this can be done by lowering the temperature, but lower temperature make reaction get
slower, so we choose a compromise temperature of 300°C which give acceptable amount of
ethanol in short time over the catalyst.
1.8.2 Effect of pressure
There are 2 molecules on the left-hand side of equation and only 1 on the right-hand side. So,
when we increase the pressure the system will shift to the left-hand side and produce less
molecules and cause pressure to fall again. To produce as much ethanol, we need as much high
pressure as we can and achieving high pressure will be costly and 60-70 atm is not that high.
High pressures are expensive as we will need very strong pipes and containment vessels. Also,
at high pressures ethylene polymerizes to polyethylene.
1.9 Fermentation of molasses
Fermentation of molasses also known as ethanol fermentation is anaerobic pathway carried out
by yeasts in which simple sugars from molasses are converted to ethanol and carbon dioxide
[Error! Reference source not found.].
Reaction Conditions
 Temperature: 30°C
 pH: 4.5
1.9.1 Effect of pH
The effect of pH shows that pH = 4.5 produces the highest ethanol concentration and had the
highest ethanol yield.
1.9.2 Effect of temperature
The effect of temperature showed that at 30°C, the optimal temperature for alcoholic
fermentation which increases the rate of fermentation to achieve the maximum yield.
Comparison:

PROCESS TEMPERATURE PRESSURE CATALYST

(°C) (atm)
Hydration of Ethylene 300 60-70 Phosphoric Acid
Fermentation of Molasses 30 1 Yeast
Process selection
Yeast can grow aerobically as well as an aerobically. Aerobic conditions favor yeast cell
production, which is not of interest to ethanol producers. However, growth during anaerobic
condition is very marginal and major reaction is conversion of sugar to ethanol for energy
production. For growth and multiplication, yeast requires utilizable organic carbon (sugars),
nitrogen source, and various organic and inorganic trace growth factors. Proper nutrition, as for
any living organism, is the key to making yeast thrive and obtain optimum performance. In
reality, distillers often nutritionally stress the yeast. The two most important nutrients for
growth are nitrogen and oxygen. Still age and purified adjuncts lack sufficient free amino
nitrogen (FAN). Yeast extract, protein digests and oats are good sources of FAN. In addition to
this optimum and environmental parameter are also required. During the conversion of sugar to
ethanol, energy is produced, which is utilized by cells for different functions. Thus, overall
metabolism of yeast is catabolism (energy production and cell multiplication). This is called
fermentation.
Yeast has major importance in fermentation. The length of individual yeast cell ranges between
20 up to 30 micron and width, one to five microns. There are different types of yeast having
different morphological and biochemical properties. Yeast is identified by its single cell nature.
Each yeast cell by itself is an independently existing live entity and cells possess different
shapes such as spherical, globular, oval, elongated, etc.
We selected fermentation process on behalf of following reasons:
1. Temperature:
The temperature required in fermentation is far less as compared to hydration process and this is
important in terms of economics of the process and very less energy will be required to achieve
30°C in fermentation instead of 300°C in hydration.
2. Pressure:
The process of fermentation occurs at normal pressure i.e. standard pressure (1atm) whereas
pressure requirement for hydration is very high which makes hydration a expensive process
than fermentation.
3. Catalyst:
The catalyst used in fermentation is yeast that is cheaper and easily available than that of
phosphoric acid used in hydration of ethylene.
4. Other Reasons:
There are some other reasons that play a vital role in selection of fermentation instead of
hydration process. In hydration we are using ethylene as a raw material which itself is a useful
product and on other hand we are using molasses (a waste of sugar cane) as a raw material to
produce a useful product and this is a very good thing to convert some waste thing into a useful
thing in an economical way.
Process parameter
1.10
1.11 Fermenter
 Inlet temperature 30° to 35°C
 pH range is 3 to 4.5
 Exothermic reaction
 Out let temperature 32°C
 8-10% alcohol is produced in fermenter
They are following reaction occur in the fermenter
Main reaction
C12H22O11 + H2O Invertase 2C6H12O6

C6H12O6 Zymase 2C2H5OH + 2CO2

(Glucose) (Ethanol)
Side Reaction:
2C6H12O6 + H2O ROH +R/CHO
1.12 Heat Exchanger
 Shell and tube heat Exchanger
 Inlet temperature 32°C in shell
 Outlet temperature is 60°C
 Cold stream
1.13 Pre-heater
 Inlet temperature is 60°C
 Outlet temperature is 99°C
1.14 Stripper
 In let temperature is 99°C at the top of stripper
 Slops is the bottom product of the stripper
 Outlet temperature of the bottom product is 100°C
 Slops are remove from the stripper from bottom and added to heat exchanger at 100°C
and removed at 68°C (outlet temperature)
1.15 Aldehyde column
 Aldehyde column operate at around 0.6-0.7Mpa.
1.16 Rectifying column
 In the rectifying column, alcohol is withdrawing as a top product which is concentrated
to 95.4% and collected in the storage tank.
 In rectifying column alcohol and water are rectified to increase the strength of alcohol.
Process Description
Molasses contains about 50% of fermentable sugars (sucrose, glucose and fructose). Molasses
because of its strong concentration of sugar does not support direct yeast fermentation, therefore
in diluter the percentage of fermentable sugar is reduced up to 10-15% by diluting the molasses
using process water. This is called mash and represents the carbohydrates ready for yeast
inoculation. The mash after sterilizing (heating at 120 -130°C to kill bacteria) is divided into
two streams. The main stream 93%-94% of the total is taken straight away to the fermenter,
while the remaining stream is pumped to the yeast culture unit which contains seeding vessel
and a mother tank. Nutrients (ammonia sulphate, urea and DAP) are added to the seeding vessel
to facilities the activity of selected yeast. Sulphuric acid is also added to the mother tank, in
order to maintain the PH between 3.5 and 4.5 which also helps in controlling the activity of the
selected yeast. Sulphuric acid is usually added in amount 2-3 Kg of the alcohol produced.
The mash from the mother tank when needed is added into the fermenter. There are six
fermenters in the series. Fermentation can take place for 24Hr in each fermenter and finally
mash containing 8% alcohol is pumped into the mash storage tank. As a result of exothermic
nature of the reaction the temperature tends to rise in the fermenter, which is controlled using a
coolant in the fomenter so that it ranges 30-35°C.
Yeast secretes then enzymes known as a maltose, Invertase and zymase. Maltase catalysis used
to the hydrolysis of maltose to glucose and invertase the hydrolysis of sucrose to glucose and
fructose.
Now the product from the coming from the former fermentation step is preheated to enter to the
first distillation column, the stripping column, where the mixture of aldehyde and alcohol is
removed from top and bottom product is slops; this mixture constitutes the feed stream to the
second column, the aldehyde column. At the top of the second column, aldehyde is removed,
and impure alcohol is obtained with a 40-45% w/w composition of ethanol will be sent to
rectifying column, while at the bottoms, a stream of fusel oil will be obtained.
Now the (alcoholic vapors) rich in ethanol, 40-45% w/w, is extracted to be sent to the rectifier
column. In the rectifier column, the ethanol contained in the alcoholic vapors is recovered in
and known as rectified alcohol with 95% w/w of ethanol. The rectified alcohol is stored tank
and at bottom product we will get fusel oil [Error! Reference source not found.].
Main reaction:
C12H22O11 + H2O Invertase 2C6H12O6

C6H12O6 Zymase 2C2H5OH + 2CO2

(Glucose) (Ethanol)
Side Reaction:
2C6H12O6 + H2O ROH +R/CHO
Equipment Description
1.17 Molasses Storage tank
Tanks are widely used in sugar industries for the storage and processing of liquids, molasses,
juices include storage, pasteurization boiling and maintain the utmost quality sugar. These are
well known for corrosion resistance, high strength and robust construction, leak proof and
require less maintenance. The product is available in different specification and sizes at
reasonable prices [Error! Reference source not found.].
1.18 Diluter
Diluter is holding equipment where dilution of any material occurs. According to our project we
are using diluter to dilute the molasses containing 50-55% of fermentable sugar this highly
concentration of fermentable sugar doesn’t support direct yeast fermentation so percentage of
fermentable sugar in molasses is reduced to 10-15% by diluting the molasses using process
water
1.19 Sterilizer
Sterilizing is term to destroy microorganism by bringing to a high temperature with steam, dry
heat or boiling liquid. According to our project we are killing bacteria by high temperature 120-
130°C because the presence of bacteria can be harmful for the yeast growth
1.20 Fermenter
A fermenter is an enclosed and sterilized vessel that maintains optimal conditions for the growth
of a microorganism;
 The microorganism undergoes fermentation to produce large quantities of a desired
metabolite for commercial use.
 Probes and sensors are used to monitor conditions within the fermenter in order to
maintain optimal levels of microbial growth.
Microorganisms are used in industry to produce a range of chemical compounds, enzymes and
drugs because of reasons listed below;
 They are small and so can be grown economically in fermenters on either solid or liquid
media.
 They have a fast growth rate and so can produce large yields in short periods of time
 They can be genetically modified with relative ease to synthesize non-natural products
of interest.
 May be able to tolerate unusual growth conditions (e.g. extremephiles can grow in high
temperatures or acidic conditions).
1.21 Heat Exchanger
A shell and tube heat exchanger is installed due to more efficient heat transfer between the
process fluids among various other options.
A shell and tube heat exchanger is a class of heat exchanger designs. It is the most common
type of heat exchanger in oil refineries and other large chemical processes and is suited for
higher-pressure applications. As its name implies, this type of heat exchanger consists of a shell
with a bundle of tubes inside it. One fluid runs through the tubes, and another fluid flows over
the tubes (through the shell) to transfer heat between the two fluids. The set of tubes is called a
tube bundle, and may be composed of several types of tubes: plain, longitudinally finned, etc
[Error! Reference source not found.].
1.22 Stripper
Stripping is essentially a distillation process where the heavy product is water/liquid and the
lighter product is generally mixture of organic volatile materials. Generally, steam/air is used
for heating purpose in the column.
According to our project the product coming out the fermenter is preheated to enter to the first
distillation column, the degasifying column, where the lighter compounds (CO2, acetaldehyde,
methanol and other fermentation by-products) are removed. These light compounds are
recovered at the top of the degasifying column along with a small fraction of ethanol; this
mixture constitutes the feed stream to the second column, the aldehyde column
1.23 Scrubber
The exhaust gases produced during chemical reaction may contain substances considered
harmful to the environment, and the scrubber may remove or neutralize those. A wet scrubber is
used for cleaning air, fuel gas or other gases of various pollutants and dust particles. Wet
scrubbing method works through the contact of target compounds or particulate matters with the
scrubbing solution. Solutions may simply be water (for dust) or solutions of reagents that
specifically target certain compounds in particularly in this case scrubber is installed for the
removal of CO2 from the process stream by the conventional method (using water).
Process exhaust gas can also contain water-soluble toxic and/or corrosive gases
like hydrochloric acid (HCl) or ammonia (NH3). These can be removed very well by a wet
scrubber. Removal efficiency of pollutants is improved by increasing residence time in the
scrubber or by the increase of surface area of the scrubber solution by the use of a spray
nozzle, packed towers or an aspirator. Wet scrubbers may increase the proportion of water in the
gas, resulting in a visible stack plume, if the gas is sent to a stack.
Process Flow Diagram
Hazards identification
A HAZOP (hazard and operability) survey is one of the most common and widely accepted
methods of systematic qualitative hazard analysis. It is used both for new and existing facilities.
It can be applied to the whole plant, to a particular production unit, or even to a single
equipment. It is based on the usual plant information and relies on the judgment of engineering
and safety experts. The result is more reliable operation [Error! Reference source not found.].
The objectives of the HAZOP study are:
 To identify those areas of design which have a potential to cause accidents?
 To find out the probability that a particular accident occurs
 To ensure a systematic study of all the possible hazards
 To reduce the probability of a hazard occurring
 To find out the ways to reduce the risk associated with each hazard
1.24 Flammable:
Large ethanol manufacturing facilities produce more than 100 million gallons of ethanol each
year and store large quantities of the chemical on site at any given time; because ethanol is
flammable, the production and storage quantities have the potential to cause catastrophic fires
and explosions.
1.24.1 Distillation process area
Ethanol is initially formed at manufacturing facilities prior to distillation. However, the
distillation process area is typically where the liquid contains high concentrations of ethanol and
becomes flammable. This part of the facility, therefore, has significant flammability hazards due
to the presence of highly concentrated ethanol vapors and heat. Overpressure or mechanical
damage in the distillation columns can cause ethanol vapors to leak, which presents a hazardous
situation.
1.24.2 Fuel storage tank area
Ethanol manufacturing facilities usually store their finished products both ethanol and denatured
ethanol in large storage tanks before the product is distributed into commerce. Proper handling
of the ethanol is critical to avoid leaks in tanks and interconnecting equipment and to prevent
more catastrophic ruptures. Some important concerns include pipe ruptures, tank ruptures, and
lightning strikes.
1.24.3 Storage tank headspace
The headspace is the gas-phase area above liquids inside a tank or other vessel. Recent research
found the headspace vapors of denatured ethanol to be flammable at room temperature (64°F)
and all temperatures down to approximately 22°F. Fire occurs when there is an ignitable vapor-
air mixture and a source of ignition, such as a static discharge.
1.24.4 Heated storage tanks
There are specific hazards related to storing flammable liquids in heated tanks. For example,
draining flammable liquids below high temperature tank heating elements can result in the
ignition of the flammable headspace vapors, as the liquid is pumped out of the tank and oxygen
flows into the tank, if the maximum temperature of the heating element can exceed the ignition
temperature of the mixture.
Also, excessive tank heating in general (with the heating elements submerged or with the use of
heating jackets) can cause boiling and release large quantities of flammable vapor, which is
unsafe if the vapors are venting inside a building or close to ignition sources.
1.24.5 Ethanol loading areas
Ethanol manufacturing facilities usually have loading docks or loading zones where flammable
chemicals are transferred to the facility (e.g., the facility receives gasoline for use as a
denaturant) and where the denatured ethanol is loaded into trucks or railcars for distribution into
commerce. Overfilling, leaking equipment, and other unanticipated releases in the loading areas
are extremely hazardous, especially when ignition sources are present (e.g., idling vehicles).
1.25 Equipment Ruptures
Ruptures can occur in fermentation vessels, product storage tanks, or pipes for various reasons,
for example, due to the lack of safety systems or improperly functioning safety systems.
Ruptures may also be the result of fires. If hazardous substances (e.g., anhydrous ammonia,
ethanol, gasoline, sulfuric acid) released during ruptures are not controlled and contained this
may result in fires, explosions, and workers’ exposure to hazardous air contaminants.
1.26 Exposure to hazardous substances
OSHA standards address employer’s responsibilities when there is a potential for workers to be
exposed to harmful concentrations of toxic and other hazardous substances in the workplace.
Chemicals, feed stocks, catalysts, enzymes, intermediates, products, and other substances
involved in ethanol manufacturing may be hazardous to workers
1.27 Hazardous Noise Levels
Noise is a prevalent potential hazard throughout many processing operations. However, noise
levels may not translate into high exposure levels because of workers' mobility between
operations and tasks, and equipment not being operated continuously.
Safety Measures
1.28 Flammable liquids
1.28.1 Preventing measures
Maintaining mechanical integrity
Management of change
Incident investigations
Contractor safety
1.28.2 Engineering controls
Storing flammable liquids in approved containers and portable tanks.
Maintaining equipment in an optimal working condition
1.29 Exposure to hazardous substances
1.29.1 Engineering controls:
Using proper ventilation systems
Enclosing emission sources
Substituting or eliminating hazardous substances when feasible
1.30 Equipment Ruptures
1.30.1 Safe work practices
Implementing equipment/process inspection, maintenance programs and including PSM
requirements for covered processes.
1.30.2 Engineering controls
Maintaining equipment in safe operating condition at all times to preclude malfunction.
Purchase equipment with design features that preclude/limit the occurrence of ruptures.
1.31 Hazardous noise levels
1.31.1 Engineering controls
Grain unloading areas: enclosing pneumatic blowers in booths or separating them from work
areas.
Grain elevators: using quieter and/or low speed/high volume conveyor equipment, shutting off
conveyor equipment when not in use, minimizing the use of compressed air.
Material balance
Basic Calculations:
Basis =200 ton/day ethanol
=200tons/day×1000kg/ton×1day/24hr =8333.3kg/hr.
Molasses required:
C6H12O6 2C2H5OH + 2CO2
180 92 88

For 92tons of C6H12O6, F.S required = 180tons

For 1ton of C6H12O6 production =180/92
=1.957tons
For 200tons of C6H12O6 production =1.957×200
=391.304tons F.S required

So,for concentration, of C2H5OH, 95.4%

F.S required =391.304×954
=373.304tons/day
Molasses of 50% total sugar content contain 43% F.
So,
Molasses required =373.304/0.43
=868.149 ton/day
If conversion is 90%
Then molasses required =868.149/0.9
=964.610 ton/day
Yeast required:
Yeast required = 4kg dry yeast /1000 ltr molasses
Yeast required per day = 4kg yeast×964.61/1000 ltr molasses
4kg yeast /1000 kg ×1 ton / 1000 ltr molasses ×964.64 ton molasses/day×1000kg/1ton
(Unit Conversion)
Yeast required =3.85ton/day
CO2 produced:
For production of 92tons of C2H5OH, CO2Produced =88tons
For production of 1ton of C2H5OH, CO2 Pro =88/92
For production of 200 tons of C2H5OH, CO2 pro = 88/92×200
=191.304 ton/day
For alcohol of 95.4% quality
CO2 pro =191.304×0.954
=182.504 ton/day
Fusel Oil Formed:
1.1 liters produced per 1000 liters of molasses
Molasses used per day =964.61ton/day×1000 kg /ton×1ltr/1.4kg
=689007.143 ltr /day
1000 ltr molasses produced fusel oil =1.1 ltr
1 ltr molasses produced fusel oil = 1.1/1000 liters
 657987.722 ltr molasses produced fusel oil =1.1/1000×689007.143
Fusel oil formed =957.908 ltr/day
Aldehyde Produced:
4-4.5 % alcohol = 190.8×.04
=7.63 ton /day
H2SO4 Required:
From literature 0.17lb/gal ethanol H2SO4 acid is require. So,
017 lb. /gal ethanol = 017 lb. /gal ethanol ×.454kg /lb. ×1 gal/3.7845 ltr× 1 ton/1000kg×
1 ltr ethanol/.8031 kg ethanol×1000 kg ethanol/ 1-ton ethanol×200 ton /day
=.025 ton H2SO4/ton ethanol
For 200 ton/ day ethanol H2SO4 required =0.025×200
=5.078 ton /day
(NH4)2SO4 (Nutrients) Required:
0.015 lb/gal ethanol nutrients are require.
0.015 lb. /gal ethanol = 0.015 lb. /gal ethanol ×.454 kg / lb. ×1000 kg ×1 gal ethanol/
3.7854 ltr × 1 ltr /0.8031 kg ethanol × 1000kg ethanol/ 1-ton ethanol
=.0022 ton / ton ethanol
For 200 ton/day ethanol =0.0022×200
=0.4480 ton/day
(NH4)2SO4 required =0.448 ton/day

Balance Around CO2 Scrubber:

M2

M1 M4
SCRUBBER

M3

L/G for scrubber = 1.5-2.7

L = 1.5×G
= 1.5×182.504 ton /day
M2=L1 =273.756 ton/day
M2=M1 =273.75 ton /day
M4=M3 =182.504 ton/day
Around diluter:

M5 M6
M4

DILUTER M7

Molasses composition
F.S = 45%
Inert sugar =5%
Other =19.6%
Ash =9.8%
H2O =20.6%
(X1) F. S = 0.45 (M4)F.S = 434.0745
(X1) I. S =0.05 (M4)I.S =48.2305
(X1) Oth =0.196 (M4)Oth =189.06356
(X1) Ash =0.098 (M4)Ash =94.53178
(X1) H2O =0.206 (M4)H2O =198.70966

(M4) S =794×964.610
=765.90 ton/day
(M4) H2O =206×964.610
=198.71 ton/day
M7 solid balance
X7s =0.17
x7L =0.83
(M7) S =M7×(X7) S
M7 =(M7) S/(X7) S
=765.9/1.7
=4505.29 ton/day
(M7) H2O =3739.39 ton/day
(M7) S =765.9 ton/day
H2O balance around diluter
M4+M5+M6 =M7
198.71+M5+273.756 =3739.39
M5 =3266.168471 ton/day
Around Sterilizer:

M9

M10
STERLIZER
M7 M8

M7=M8 =4505.29 ton/day

(M8)F.S =434.0745 (X8) F. S =0.096351067
(M8)IS =48.0745 (X8) I. S =0.010671047
(M8) =189.06356 (X8) Oth =0.041966242
(M8) =94.53178 (X8) Ash =0.020983121

(M8) H2O = 3739.39 ton/day

(X8) H2O = 0.830028523
Now almost 6% goes to M9(for yeast culture) and remaining goes directly to fermenter.
M9 = 4505.29×0.06
= 270.32 ton/day
M10 =1405.29-270.32
=4234.97 ton/day
25% of M9 goes to seeding vessel.
75% of M9 goes to mother tank.
M9A =0.25×M9
=0.25×270.32
=67.58 ton /day
M9B =0.75×270.32
=202.74 tons/day

Around Seeding Vessel:

M11 M12
 M9A M13
SEEDING VESSEL

M9A = molasses to seeding vessel

M11 = yeast to seeding vessel
M12 = Nutrients to seeding vessel
M13 = outlet form seeding vessel
M12 = 50% of M9A
M9A + M11 + M12 = M13
67.5770151+3.85+0.224 =M13
M13 = 71.6510151 ton/day

Around Mother Tank:

M14 M9B M15

MOTHER TANK
M13

M16

M9B = molasses to mother tank.

M15 = H2SO4 to mother tank (6% of the total).
M13 = outlet of seeding vessel.
M14 = nutrients to mother tank (50% of total).
M16 = outlet of mother tank.
M9B+M15+M13+M14 = M16
202.7310453 + 0.30468 + 71.6510151 +0.224 = M16
M16 = 274.9107404 tons/day

Around Fermenter:

M16
M17

FERMENTER
 M18
M10
M19

M10 = molasses to fermenter

M17 = H2SO4 to fermenter
M16 = outlet from mother tank
M18 = CO2 outlet
M19 = outlet of fermenter
M10 +M17 +M16 = M18 +M19
4234.82628 + 4.77332 + 274.9107404 = 182.504 + M19
M19 = 4332.00634 ton/day

Around Mash Storage Tank

Fermented mash tank

M20

M21

M20 = M21
M21 = 4332.00634 tons/day

Around Stripper:

stripper
 M21
M23
M22

M21 = fermented mash to stripper

M22 = slope from stripper
M23 = Top product from stripper
From literature, if top product from stripper contain 60% alcohol, then
M22 = 190.8/0.6
= 318 ton/day
M21 = M22 + M23
M22 = M21 – M23
M22 = 4332.00634 + 318
M22 = 4014.00634 ton/day

Around Surge Drum:

M23 Surge drum M24

M25
M23 = top product from stripper
M24 = aldehyde from surge
M25 = outlet from surge drum (feed to distillation column)
M23 = M24 + M25
M24 = M23 – M25
M24 = 318 – 7.63
M24 = 310.37 tons/day
Around Rectifying Column:

M27

M24

M28

M26

M24 = feed to distillation column

M26 = bottom from distillation column
M27 = top product from distillation
M28 = fusel oil from distillation column

M24 = M26 + M27 + M28

M26 = M24 – M27 – M28
M26 = 310.37 – 200 – 1.34
M26 = 109.03 tons/day

Overall Material Balance

M1 + M2 + M5 + M11 + M12 + M9A = M18 + M22 + M25 + M26 + M27 +M28

964.610 + 273.756 + 3266.168471 + 3.85 + 0.448 + 5.078
= 182.504+ 4014.00634 + 7.63 + 109. 03 + 200 + 1.34

4514Tons/day = 4514Tons/day
So,
Mass In = Mass Out
Heat Balance
Around Fermenter:

CO2 40°C

Feed 30°C Mash 40°C

For the calculation of heat to be removed in the fermenter

Reaction:
C6H12O6 2C2H5OH +2CO2
Formula used to calculate heat of Reaction,
ΔH = mass of reactant × specific heat of products × temperature difference
Mass of reactant = 964610 kg
Specific heat of ethanol = 2.72 kJ/kg C
Specific heat carbon dioxide = 0.844 kJ/kg C
Temperature difference = 10°C
Now putting values in above formula
ΔH = 964610 × (2.72+0.844) ×10
= 34378700.4 kJ
= 8216715.67 kcal
Heat of Reaction (ΔH) = 8216715.67 kcal/1000 gallon Alcohol
Density of ethanol ρA =0.81 kg/ltr
1 gallon =3.78ltr
1000 gallon =3.78× 1000
=3780 ltr
Weight of Alcohol =3780× 0.810kg/ltr
3061.8 kg of Alcohol in 1000 gallons
Now for the heat of reaction in terms of kcal/ton
H =8216715.67 kcal/3061.81kg×1000kg/ton
 H = 2683622.6 kcal/ton
Alcohol =190.8tons/day
Heat released in the Reaction =2683622.6 ×190.8
= 512035192 kcal/day
As the heat released during the fermentation reaction must be removed frequently to maintain
the temperature in the reactor to (35-40 C) the heat released will be used as heat to be removed.
Heat to be Removed = 512034589.2 kcal/day
To remove this heat a Coolant (water) is used in the Reactor for this Purpose
Q in = Q out
Q heat released = Q Coolant

Q =mCp∆T
512034589.2 = m× 0.99 kcal/kg°C×(40-30)
M = 51203459 kg
M = 51203.459 tons

Around Pre-heater:

Mash 60°C Mash 99°C

Heat in = mCp∆T
=4332 × 1000/24 Kg / hr × .97kcal/kg°C(99-60)
=6828315 kcal/hr
Q for steam =Msλs
Ms = Q /λs
=6828315 /519.45
= 13145.27 kg/hr (mass Flow rate of Steam)

Around Heat Exchanger:

Mash 40°C Mash 60°

Slope 79°C Slope 100°C

Cold Fluid
Heat in = mCp∆T
=4332×1000/24 Kg / hr ×.97 kcal/kg°C (60-40)
=3501700 kcal/hr
Hot Fluid
Q =mCp∆T
3501700 kcal/hr =4014×1000/24 Kg / hr×1kcal/kg°C(100-T)
T = 79.07oC

Around Stripper:

Top Product 92°C

Mash 99°C

Slope 99°C
Heat In
Heat in = mCp∆T
= 4332× 1000/24Kg / hr×.97kcal/kg°C(99-30)
=12080865 kcal/hr
Heat out = mCp∆T
=4014×1000/24 Kg / hr ×1 kcal/kg°C (100-30)
=11707500 kcal/hr
Heat Out
Heat out =mCp∆T + mλ
=318×1000/24 Kg / hr ×0.727 kcal/kg°C(92-30)+318×1000/24Kg / hr×521.4
=597230.5+6907225
=7504455.5kcak/hr
Heat to be provided by steam = (7504455.5 +11707500)-12080865
 =7131090.5 kcal/hr

Around Condenser 1:

92°C
MA

Reflux ratio =0
Mv =MA
MA = 318ton/day

Top product contains 60% alcohol, so

Components Fraction Specific Heat Heat of Vaporization
Alcohol 0.6 0.581 204
Water 0.3735 0.99 374.41
Aldehyde 0.0243 0.269 12.82
Fusel oil 0.0026 0.768 1274

Cp mean =.6×.581+.3735×.99+.0243×.269+.0026×.768
=0.727kcal/kg
Hl =mCp∆T
=1×.727kcal/kg°C×(92-30)
=45.074 kcal/kg
Hvap =45.074 +XH2Oλ+XC2H5OHλ+XF.Oλ+XAldehydeλ
=45.074 +139.845+122.4+3.31488+.3117
=310.94558kcal/kg
Hvap =318×1000/24Kg / hr×45.074 kcal/kg
=597230.5 kcal/hr
Hvap =318×1000/24Kg / hr×310.94558 kcal/kg
=4120028.935 kcal/hr
Duty =4120028.935 kcal/hr-597230.5 kcal/hr
= 3522798.435 kcal/hr
Mass of H2O required in condenser
mCp∆T = 3522798.435
m = 3522798.435kcal/hr/.99kcal/kg°C(40-30)
 m = 355838.2258kg/hr
m = 8540.11tons/day

Around Condenser 2:

82°C
30°C
40°C

MA

MB MA

Reflux ratio =3:1

MB = 3MA
MV =MA+MB
MV =MA
MA =200ton/day
=200×1000/24
=8333.3 kg/hr
Mole Fractions,
XC2H5OH =.95
XH20 = .05
Specific Heat of Mixture,
Cp mean = .05×.99kcal/kg°C+.95×.93kcal/kg°C
= .933 kcal/kg
Formula used,
Hl = mCp∆T
=1×.933kcal/kg°C(82-30)
= 48.516 kcal/kg
For Heat of Vaporization,
Hvap =48.516 +XH20λ+XC2H5OHλ
=48.516 +18.75+193.8
= 261.066 kcal/kg
Duty Of Condenser,
Duty =4×261.066 ×8333.33
=8702196.579kcal/hr
Mass of water required in condenser
m = 8702196.579kcal/hr/.99kcal/kg°C(40-30)
m = 879009.7499kg/hr
m = 21096.23 tons/day
Equipment Design
1.32 Alcohol Storage Tank
Mass of alcohol handle per day = 200 ton/day
= 200000kg
Density of alcohol = 810 kg/m3
Volume = Mass/Density
= 200000/810
= 246.91m3
Clearance = 10%
Total volume = 246.91 + 246.91(0.1)
= 272m3
Dimension,
L:D = 2:1
L =2D
Volume = Area × Length
Volume = (π/4)D2 ×2D
V = (π/2) ×D3
D = ∛ (2V/π)
V = 272 m3
D = 5.51 m
Total length of tank = 2 ×D
= 2 × 5.51
= 11.02 m
Pressure due to liquid head
Pressure head = ρ×g×h
= 810 ×9.81 ×10.35
= 82.27 KN/m2
Volume = area ×height
Height = Volume/Area
H = (246.91/4×3.14)× (5.51)2
= 10.35 m
Minimum Allowable pressure = 101.31 +82.27
= 183.57 KN/m2
Material of construction is carbon steel so,
Stress = 135 N/mm2
1m2 = (1000mm)2
Stress = 135× (1000)2/1000
= 135000KN/m2
Joint efficiency = 0.85
(Double welded butt joint, Chemical Engineering Vol. 6 Table 13.3)
Inner radius =diameter/2
= 5.51/2
= 2.755 m
 Thickness = P × R/(SE-0.6p)
= 183.57 ×2.755/135000 ×0.35-0.6(183.57)
= 0.0041m
=4.1mm
Corrosion Allowance is 2mm,
Total Thickness = 4.1+2
= 6.1mm
=0.24inch
Volume of material for shell = π (OD2 – ID2) ×L/4
OD = ID+2 ×tm
= 5.51+2(0.0061)
OD = 5.5122m
Volume of material for shell = π [(5.5122)2-(5.51)2] ×10.35/4
= 0.197m3
Volume of flat top and bottom = 2 ×π×OD2 ×tm/4
Volume of flat top and bottom = 2× (3.14/4) × (5.5122)2× 0.0061
= 0.29m3

1.33 Scrubber
Water flow rate = 273.756 ton/day
= 11406.25 kg/hr.
CO2 flow rate = 182.504 ton/day
= 7604.33kg/hr.
Density of H2O = 997.045kg/m3
As, PV = (m/M) ×RT
Density = PM/RT
M = Molecular Mass of feed =44kg/mole
P = 1atm
Density = (1atm/298k)(44g/1gmol)(1gmol.K/0.08205L.atm)(1000L/1m3)(1Kg/1000g)
=1.79kg/m3
Uf = 0.07 2 [(fl-fv)/fv]1/2
= 0.07 [(997.045-1.79)/1.79)]1/2
= 1.65 m/s
Demister pad is not used so,
Uf = 0.15 × 1.65 = 0.2475m/s
Vapor volumetric rate = 7604.33/1.79 ×3600
= 1.18m3/s
Vessel area =A =Q/Uv
= 1.18/0.2475
= 4.76m2
Area = (π/4)×D2
 D = [(Area × 4) /π ]1/2
D = [(4.76 ×4)/3.14]1/2
D = 2.46m
Allow a minimum hold time up to = 10min
Liquid volumetric flow rate = 11406.25/ (997.045 ×3600)
= 3.17 ×10-3
Volume held in vessel = 3.17 ×10-3×10 ×6
=1.902m3
Liquid depth = volume held up /vessel cross sectional area
= 1.902/ (3.14/4)× (2.46)2
= 1.902/4.75
=0.4m
Divergent zone = 0.3m
Total = 0.4+0.3 = 0.7m
Thickness of scrubber:
tm =9mm (Che. Engineering, Vol. 6, page 814)
OD = ID + 2tm
= 2.46 ×1000+2(9)
= 2478mm
= 2.478m
Area of material used = (Outer area – inner area) × L
= [(3.14/4) (OD)2] – [(3.14/4) (ID)2] × L
= [(3.14/4) (2.478)2-(3.14/4) (2.46)2] × (0.7)
= (0.0697) (0.7)
=0.05m3
Volume of top and bottom plate:
V = 2 × (3.14/4) (OD) 2×tm
= 2 × (3.14/4) (2478)2× 9
= 867650mm3
= 0.086 m3
Total volume = 0.086+0.05
= 0.136 m3
Carbon steel (material of construction)
Density = ρ = 7850 kg/m3
Weight of tank =V×ρ
= 7850 × 0.136
= 1067.4kg
1.34 Fermenter
Residence Time = 48hr
Mass Flow Rate = 4514.5Tons/day
= (4514.5×1000)/24 Kg/hr
 =188104.58Kg/hr
Density = 0.85(1000) + 0.15(1474)
=1071.1Kg/m3
Temperature = 32°C
Pressure = 1atm
# of fermenters used =9
Mass Flow Rate in One Fermenter = 188104.58/9 Kg/hr
=20900.53Kg/hr
Vol. Flow Rate = 20900.53/1071.1m3/hr
=19.5m3/hr
Volume of Fermenter = Vol. Flow Rate × Residence Time
=19.5 × 48
=936m3
At 10% Allowance;
Volume = 936 × 1.1
=1029.6m3
Diameter and Length of Fermenter:
L:D = 3:1
L = 3D
Volume = Area × Length
1029.6 = (π D2/4) × 3D
D3 = (1029.6 ×4 )/(3×4.14)
By taking cube root
D = 7.58m
L = 3(7.58)
L = 22.7m
Volume occupied by head and bottom
=2(π×D3)/24
=2×3.14 × (7.58)3/24
= 113.96m3
Total Volume = 1029.6 – 113.96
=915m3
Pressure head due to liquid =ρ × g × h
Here, h = Volume / Area
Volume of liquid =Vol. of fermn. –Vol. of ellipsoidal Bottom
=936 – 113.96/2
= 879.02m3
H = 879.02 / [(π/4) (7.58)2]
=19.48m
Height of Ellipsoidal head = 0.5m
Total height =19.48 + 0.5
= 19.98m
 Pressure head due to liquid =ρ × g × h
=1071.1 × 9.81 × 19.98
=209939.6N/m2
= 209. 94KN/m2
Material of construction is Carbon Steel
Working Stress of CS = 135000KN/m2
Thickness,
tm = PRi / (SE-0.6P) +Cc
P = 209.94 + 101.3 + 0.002
=311.24KN/m2
tm = [311.24 × (7.58/2)] / [(0.85×135000) – (0.6×311.24)] + 0.002
=0.012m
=0.472 inch
Outer Diameter = 7.58 + (2×0.012)
=7.604m
1.35 Heat Exchanger
T1 = 212οF
T2 = 174.2οF
t2 =140οF
t1 = 104οF

T1 = hot stream inlet temperature = 100 οC

T2 = hot stream outlet temperature = 79οC
t1 = cold stream inlet temperature = 40οC
t2 = hot stream outlet temperature = 60οC
Heat gain by fluid = 3501700 kcal/hr.
= 3501700 × 3.96
= 13866732btu/hr
Hot fluid Cold fluid Difference
T1 = 212.0 t2 = 140 72.0
T2 = 174.2 t1 = 104 70.2

T1 – T2 = 37.8 t2 – t1 = 36
LMTD:
LMTD = ∆T2-∆T1/ln(∆T2/∆T1)
= (72 – 70.2)/ln (72/70.2)
R = (T1 – T2) / (t2 – t1)
R = 37.8 / 36
 = 1.05
S = (t2 – t1) / (T1 – T2)
S = 36 / 212-104
= 0.33
For 1 shell, 2 tube passes
Ft = 0.95 (fig 18,Karen)
∆T = LMTD × Ft
= 71 × 0.96
= 68.16 οF
Since the temp difference on the hot and cold stream is less than 100οF, so average temp on
both stream can be used,
Ta = 212 + 174.2 /2
= 193.1οF
TB = 140 + 104 / 2
= 122οF
Assume
,Ud = 150 btu/hr.ft2.F
Q = UA∆T
A = q / Ud∆T
=13866732 / 150 ×68.16
= 1356.29 ft2
Tube diameter assume = 3/4 inch
Outer surface per line ft = 0.1963
BWG = 16
Length = 16 ft.
No of tubes = area / (length ×outer surface)
Area = 1356.29 ft2
Length = 16 ft
Outer surface per line ft = 01963 ft2
= 432 tubes
From table (a) for 2 pass the nearest tube is 460 at 27 inch inner diameter of shell.
Corrected UD:
Area = no of tubes ×L × outer surface
= 460 ×16 ×0.1963
=1444.768 m2
UD = Q / A∆𝑇
= 13866732 / (1444.768) (68.16)
= 141 Btu / hr.ft2 F
Tube side calculation (Mash)
Flow area = at/ = 0.302 inch2 (Table 10 )
/
at = Nt × at / 144 × n
= 460 × 0.302 / 144 × 2
 = 0.4823 ft2
Mass velocity G = w / at
= 4332 ton / day
Conversion factor:
1 ton = 1000kg
1 kg = 2.2 lb.
1 day = 24 hr.
Then, G = 397100 lb / hr.
Gt = w / at
= 397100 / 0.4823
= 823346.4 lb/hr.ft2
For µ of mash at 122οF
µ = 0.662 CP × 2.42 (conversion factor)
= 1.602 lb / hr.ft
Inner diameter (I.D) = 0.62 / 12
= 0.0517 ft.
Re = DGL / µ
= 0.0517 × 823346.4 / 1.602
= 26571.16
Heat transfer coefficient:
Jh = 95 (from fig 24)
°
At t = 122 F
K = 0.339 btu / hr.ft.F
hi = Jh (K / D) (CPµ / K)1/3
= 95 (0.339 / 0.0517) (0.97 × 1.602 / 0.339 )1/3
= 95 ×6.55 × 1.66
= 1032 btu / hr.ft2.F
hio =hi × ID / OD
= 1032 × 0.62 / 0.75
= 853.12 btu / hr.ft2.F
Shell side calculation: -
Flow area a5
Baffle space = ID of shell / 5 (equation 11.4)
= 21.25 / 5
= 4.25
Clearance = 0.25
Square pitch Pt = 1 inch
Flow area=AS = ID × C/ B / 144 ×pt
= 21.25 × (0.25 × 4.25) / 144 ×1
=0.156 ft2
Mass velocity = GS = W / aS
W = 4014 ton / day
Conversion factors,
1 ton = 1000 kg
1 kg = 2.2 lb
1 day = 24 hr
W = 367950 lb / hr
GS = w / aS
= 367950 / 0.156
= 2358653.84 lb / hr.ft2
Diameter = 0.95 / 12
= 0.0792 ft
Re = De GS / µ
= 0.0792 × 2358653.84 / 0.876
= 213248
JH = 290 (Karen fig 28)
°
At t = 193 F
K = 0.353 btu / hr.ft.F
hο = JH (k / De) (CP µ / k)1/3
= 290 (0.353 / 0.0792) (1 × 0.876 /0.353)
=3200 btu / hr.ft2.F
Clean overall coefficient
UC = hio × ho / hio + ho
UC = 673.55 btu / hr.ft2.F
Dirt factor = Rd = uC – UD / UC × UD
= 673.55 – 141 / 673.55 × 141
=0.0256
Pressure drop (tube side)
NRe = 26571.16
f = 0.00018 ft2 / in2 (fig 26)
S = 0.87 (fig 6)
∆Pt = f Gt Ln / 5.22 × 10 × D × S × θT
2 10

= 0.00018 × 823346.4 × 16 × 2 / 5.22 × 1010 × 0.0517 × 0.87 × 1

= 1.66 psi
∆pr = (4n/S) × (V2/2g) (fig 27)
= (4 ×2/0.87) ×0.023
= 0.211 psi
∆pT = 1.66 + 0.211
= 1.87 psi
Pressure drop (shell side)
∆ps = f × GS2 × D (N + 1) / 5.22 × 1010 ×De × S ×θt
Friction factor = 0.0013 ft2 / in2
Re = 213248
Specific gravity =1
No of cross = (N+1) = 12 × L / B
= 12 × 16 / 4.25
= 45
Shell diameter = 21.25 / 12
= 1.77ft
∆pt = 0.0013 × (235865.84)2 × 1.77×45 / 5.22×1010×0.0792×1×1
=1.39psi