Revised-Manuscript (Sec 1 and 2) Plant Design

MAPÚA UNIVERSITY
School of Chemical, Biological, Materials Engineering and Sciences
PANGASINAN POLYLACTIC ACID PLANT
Submitted by:
Asuncion, Jose Daniel G.

Bagumba, Ivan Harold P.
Garcia, Gwenneth P.
Nagayo, Juan Augustus A.
Panghulan, Ann Justine B.
Soller, Alexis I.
A Plant Design Report Submitted in Partial Fulfillment of the

Requirements for the Degrees of Bachelor of Science in Chemical
Engineering and Bachelor of Science in Biological Engineering
Dr. Rhoda B. Leron
October 2018
i
APPROVAL SHEET
This is to certify that I have supervised the preparation and I have read the report entitled
“PANGASINAN POLYLACTIC ACID PLANT” prepared by Jose Daniel G. Asuncion, Ivan
Harold P. Bagumba, Gwenneth P. Garcia, Juan Augustus A. Nagayo, Ann Justine B. Panghulan,
and Alexis I. Soller that the said report has been submitted for final examination. I certify that I
have examined this report and hereby recommend that it be accepted as a partial fulfillment of the
requirements in Plant Design 1 (CHE181-1D) for the Degree of Bachelor of Science in Chemical
Engineering.
Dr. Rhoda B. Leron

Course Adviser
This plant design report is hereby approved and accepted by the School of Chemical, Biological,
Materials Engineering and Sciences as a partial fulfillment of the requirements in Plant Design 1
(CHE181-1D) for the Degree of Bachelor of Science in Chemical.
Dr. Alvin R. Caparanga

Program Chair, Chemical Engineering
Dr. Alvin R. Caparanga

Dean, School of Chemical, Biological, Materials Engineering and Sciences
ii
LETTER OF TRANSMITTAL
Prof. Rhoda B. Leron

School of Chemical, Biological, Materials Engineering and Sciences
Mapúa University
Dear Ma’am,
In line with the requirements in Plant Design 1 (CHE181-1D), we are presenting the design
report entitled “PANGASINAN POLYLACTIC ACID PLANT”. The said project aims to
design a sustainable insulin production plant in Binalonan, Pangasinan. Accordingly, presented in
this paper are: product description, raw materials, process flow diagram, process description,
material and energy balances, piping and instrumentation diagram, equipment sizing and
specifications, and hazard and operability analysis.
Respectfully yours,
Asuncion, Jose Daniel D. Bagumba, Ivan Harold P.
Garcia, Gwenneth P. Nagayo, Juan Augustus A.
Panghulan, Ann Justine B. Soller, Alexis I.
iii
TABLE OF CONTENTS
Title Page
Approval Sheet
Letter of Transmittal
Table of Contents
Chapter1: Introduction 2
Project Design 3
Product Design 4
Market Analysis 6
Plant Location 21
Environmental Impact Assessment 23
Chapter 2: Base Case Design 26
Chapter 3: Process Flow Diagram 34
PFD 35
Process Description 40
Chapter 4: Material and Energy Balances 42
Material Balance Summary 43
Energy Balance Summary 54
Chapter 5: Piping & Instrumentation Diagram 55
Chapter 6: Hazard and Operability Analysis 61
Chapter 7: Site and Plant Layout 93
Chapter 8: Equipment Sizing 97
Equipment List 98
Equipment Specification 101
Appendices 140
Material and Energy Balance Calculations 141
Equipment Sizing Calculations 229
References 347
iv
Abstract
This plant focuses on the manufacturing of polylactic acid pellets. Polylactic acid is an eco-
friendly and biodegradable thermoplastic produced from renewable sources (mostly crops) such
as corn, sugar beets, wheat and other starch-rich products. Using statistical data such as the supply
and demand as well as the projected value, the plant’s projected market share is 1%. In an hourly
basis, the estimated capacity of the plant is 160kg of plastic. The polylactic acid plant
manufactured by Pangasinan PLA Producers (Triple P) is located in Binalonan, Pangasinan. The
said location was considered due to the abundance of raw material that is needed in the production
process which is corn. In terms of environmental concerns, sustainable development concept and
economical reason, bioplastics are now being used in the industry, e.g. PLA, which can be an
alternative for PET. From the data and projection, the demand of PLA increases while the supply
remains constant. The assumption is based on the price the market has set. As there is currently no
producers of polylactic lactic acid within the country, the company took the initiative to be the first
and aim to lessen the gap between the supply and demand for polylactic acid. Moreover,
Philippines can be less dependent on the imports of polylactic acid once the country has started
putting up polylactic acid producing plants.
The raw material used for the polylactic acid in this plant is milled-corn, a main product of
agriculture in Pangasinan. The main concern for waste in the plant is wastewater since all
processes, especially fermentation process, generate an abundant amount of wastewater. The
production of polylactic acid involves 3 major process namely: Pre-treatment, Fermentation, and
Polymerization.
1
CHAPTER 1
INTRODUCTION
2
Project Description
Plastic is a prevalent and universal material that is commonly used by various industries in
the production of numerous products. In the Philippines, industries such as automotive,
construction, cosmetics, electronics, food and packaging are associated with the sustainability of
the plastics industry. However, plastics take too long to decompose and imposes serious
environmental impacts. Among these environmental impacts is the large amount of plastic waste
due to improper disposal and also the amount of toxins released during photo-decomposition which
takes up hundreds of years to finish. Because of this occurrence, the concept of bioplastics or bio-
based polymers remain a significant interest with respect to solid waste accumulation. Bio-based
polymers are obtained from renewable biomass sources such as crops, food waste, agricultural by-
products and microorganisms. Greater efforts have been made in developing degradable biological
materials without any environmental pollution to replace oil-based traditional plastics. Among
numerous kinds of degradable poylmers, polylactic acid (PLA) is currently the most promising
and popular material with the brightest development prospect. Since it comes from crops, usually
corn starch or sugar cane, PLA can breakdown into natural elements in compost facilities without
releasing any toxic material.
PLA has been a target alternative to the petrochemical-based plastic polyethylene terephthalate
(PET) since it has the same quality yet less environmental-impact in both production and
decomposition than the latter. Some of the advantages of PLA compared to PET are as follows:
(a) Less amount of energy is needed for the production,
(b) Less amount of greenhouse gases is released during the production,
(c) PLA may not be recyclable but it may be converted back to lactic acid.
3
Among the goals of the Philippine Plastics Industry Association, Inc. (PPIA) is to develop a
sustainable industry mindful of our limited/finite resources. According to the annual report of the
Philippine Statistics Authority, corn is 2nd on the list of the country’s major crops regionally and
provincially. Hence, the production of PLA from corn starch can contribute to the accomplishment
of PPIA’s goals, which serves as the foundation for this project.
This project aims to construct a plant for the synthesis of polylactic acid (PLA) with corn starch
as its raw material. Since PLA is not commonly produced in the Philippines, this paper intends to
expand the production of this material due to its properties and the abundance of the raw material
in the country. Moreover, the scope of this design project is within the production of PLA derived
from corn starch having the final product in the form of pellets. Operating this proposed plant will
provide job opportunities to those near the plant site, the need for thermoplastics would be less,
and the waste generated would be minimized.
4
Product Description
Polylactic acid, also known as PLA, is a biodegradable thermoplastic produced from
renewable sources (mostly of crops) such as corn, sugar beets, wheat and other starch-rich products
as well. Although the name suggests that it is derived from lactic acid, PLA is classified as aliphatic
polyester. Wallace Carothers discovered PLA in 1932 and at the time, production is of high cost
and is limited to medical grade sutures, implants and controlled drug release applications.
Table 1.1 shows the different properties of PLA where its tensile strength and modulus of
elasticity are comparable to plastic polyethylene terephthalate (PET) . It has a flavor and odor
barrier characteristics similar to PET, which is used for beverage bottles (mostly of soft drinks)
and other packaging products. It is also soluble in water and has a great moisture and barrier
resistance. PLA plastic is identified “7” to the SPI resin code and is labeled as “others”.
Table 1.1 Properties of PLA
Properties PLA
Density (g/cm3) 1.21 – 1.43
Melting point (°C) 150-160
Tensile Strength (MPa) 50
Modulus of Elasticity (MPa) 3500
5
The proposed PLA is to be derived from corn, to which the said raw material is to be
converted to corn sugar through wet milling. The corn sugar (dextrose) is then converted to lactic
acid through fermentation, to which PLA is derived and is converted to the end product. There are
mainly four types of polylactic acid that are available for packaging purposes: PLA polymers
4041D, 4031D, 1100D, and 2000D. Uses include as general purpose film, for high temperature
applications, for extrusion coating on paper, and for extrusion and thermoforming applications
respectively. These various polymers share a common form of the intended product, in pellet form;
which is then reshaped for intended purposes.
Additionally, PLA being a bioplastic, it is environmentally viable as it is generally easier
to decomposed as to other plastics. With an industrial composting facility present, decomposition
is possible with the heating of the said bioplastic to 140 degrees Fahrenheit and fed a steady diet
of digestive microbes. Moreover, incineration of PLA would not result to emission of toxic fumes,
an edge to other plastics produced.
6
Market Analysis
The number of issues concerning the problem on plastic usage is growing quickly. People
are now being more aware of the long-term effects of plastics in their health and the environment.
In 2011, about 300 million tons of plastic is produced globally each year and only about 10 percent
of that of that is being recycled. The plastic that is simply thrown out gathers an estimated amount
of seven million tons and ends up in the sea each year. The per capita consumption of plastic
materials worldwide by region in 2015 can be seen in figure 1.1. Since the use of plastic is of great
demand, alternatives of synthetic plastic are now being developed. Polylactic acid, PLA, is a bio-
based aliphatic polyester derived from renewable source and is the most common bioplastic in use
today. It is biodegradable, compostable and plays a major role in replacing synthetic polymers for
many applications such as solid waste disposal problems.
Figure 1.1 Per Capita Consumption of Plastic Materials in 2015
7
Polyethylene Terephthalate (PET) has become one of the most widely used plastic material
for packaging due to its high resistance to moisture and chemicals, lightweight and easily
accessible. In 2016, the market for PET resin was over 23.5 million tons. However, high production
of PET isn’t safe for the environment since it is not biodegradable. In order to attain sustainable
development, bioplastics, such as PLA, are now being produced in the market as an alternative to
PET.
The growing demand for plastic paves way to more production of bioplastics globally. At
present, bioplastics represent about one percent of the about 32 million tonnes of plastic produced
annually. Figure 1.2 shows the data of the global production capacities of bioplastics where its
capacity is expected to increase in 2022.
Figure 1.2 Global production capacities of bioplastics
8
PLA is one of the largest sources of the growing production of bioplastics, which
contributes to above 35% in the bioplastics market because of its versatile material and barrier
properties that can be of great replacement for PS (polystyrene) and PP (polypropylene).
Moreover, PLA possesses higher strength and toughness, as well as low permeability performance
against the transfer of several gases. The PLA application market is subdivided into the packaging,
biomedical, electronics, textile and agricultural industries. Figure 1.3 shows the global PLA
application market in 2013 with over 75% of PLA packaging is being used for film and plastic bag
packaging. PLA market is expected to reach $5.16 billion by 2020 with an increasing CAGR of
20.9% during the forecast period. As seen in figure 1.4, Europe was estimated to dominate the
PLA market in 2015 followed by North America. In 2020, it is projected that the Asia Pacific
market will grow at the highest CAGR as the demand also increases in this region.
Figure 1.3 Global PLA application market, 2013
9
Figure 1.4 PLA market size, by region, 2015-2020
PLA in the Philippines
The use of bioplastics in the Philippines is now being implemented and being further
developed by emphasizing its advantages for the community and environment. Non-biodegradable
plastic materials are slowly being phased out, making bioplastic an alternative to these materials
that will increase its market. The PLA is expected to be the main contributor of these bioplastics
that will grow the fastest because of its excellent mechanical properties, ease of processability and
accessibility to raw materials.
Since PLA is processed from starch, the corn, being the raw material, will not be a major
problem during the manufacturing process here in the Philippines since the country is very
abundant in corn plantations. This shows that PLA production has great potential in the country
because of its availability of resources.
10
Figures 1.6 and 1.7 shown below summarize the supply and demand of polylactic acid in
the Philippines from year 2010 to 2017. The supply shows an increase at the first half where
bioplastics were just being introduced in the country being an alternative to non-biodegradable
materials because of environmental matters. Although it shows a drastic decrease from 2014 to
2016, it gradually increased on the following year.
The demand, on the other hand, shows an increase in growth rate from 2013 to 2016. As
the population of the country increases through the years, the plastic consumption also increases
as well as the demand for bioplastics because of its functions in packaging, biomedical purposes,
etc. From the figures, it is evident that the demand is much greater than the supply.
Supply
14
QUANTITY (kilo Tons)
12
10
0
2010 2011 2012 2013 2014 2015 2016 2017
YEAR
Figure 1.5 PLA Supply in the Philippines
11
Demand
180
160
QUANTITY (kilo Tons)
140
120
100
80
60
40
20
0
2010 2011 2012 2013 2014 2015 2016 2017
YEAR
Figure 1.6 PLA Demand in the Philippines
The projection of supply and demand shown in figure 1.7 was established using
arithmetical geometric curve method. The data utilized was from 2010 to 2017, the projected data
for the next five years, including this year, i.e. 2018-2022 was obtained for both supply and
demand. Both the demand and supply were projected on a 3-5-10 years for feasibility and the 5-
year projection is the most accurate. The projection for years 2018-2022 was assumed that the
percentage is linearly increasing. The graph is also based on the assumption that the price is based
on the quotient of the Free-On-Board and the quantity produced per year. It can be concluded that
while the demand and the supply fluctuate from each year, it is evident that there is a big gap
between the supply and demand of polylactic acid in the Philippines.
12
180
160
140
120
QUANTITY (kilo tons)
100
80 Supply
60 Demand
40
20
0
2008 2010 2012 2014 2016 2018 2020 2022 2024
-20
YEAR
Figure 1.7 Projected supply and demand
𝑃𝑙𝑎𝑛𝑡 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦
𝑀𝑎𝑟𝑘𝑒𝑡 𝑆ℎ𝑎𝑟𝑒 = × 100 %
𝑆𝑢𝑝𝑝𝑙𝑦 𝑎𝑡 𝑌𝑒𝑎𝑟 2022
𝑃𝑙𝑎𝑛𝑡 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦
1%= × 100 %
125.89
𝑃𝑙𝑎𝑛𝑡 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 1.2589 𝐾𝑖𝑙𝑜 𝑇𝑜𝑛𝑠 𝑝𝑒𝑟 𝑦𝑒𝑎𝑟
13
Plant Location
For the geological location of the plant, various factors were taken into account. All
decision-making under certainty are based on a quantitative analysis. The 1st consideration the
plant location should be to where the raw source for the production of polylactic acid is abundant.
Since the plant is near the raw source, the cost for production and distribution is at minimum. Other
sources like the area of land for expansion, availability of labor around the area, environmental
impact and effluent disposal, climate, etc. will also be considered. The location of the plant will
be situated along Binalonan-Asingan, Pangasinan City and most of the land are agricultural lands.
The Binalonan-Asingan road is connected to two roads, Cambayanan road and Binalonan-
Urdaneta road. The only municipality close to the site is Binalonan, which helds also Sinocalan
river.
One of the concerns regarding the plant location is the travel time of delivering goods to
the main city due to traffic congestion and on-going construction of Skyway Phase 3 under Build,
Build, Build project of the government. Pangasinan is a growing province, meaning that the human
resources is plentiful. Pangasinan is also one of the largest suppliers of corn in Luzon, so the plant
location is ideally good if placed around this area. Upon expansion, the plant can cater around
Visayas and Mindanao. The main source of the water for the plant will underground water,
secondary source can be from the irrigation of the local government. The effluent of the plant,
which is wastewater, will be disposed under the regulations and standards of DENR and the
disposal area would be the river near the site, which is Sinocalan river. Otherwise, to any areas
proposed by the local government. Figure 1 will show the proposed plant location.
14
Figure 1.8 Proposed Plant Location
15
Environmental Impact Assessment
Environmental Assessment and Waste Management Plan
In line with the plant location, it is also important to consider the environmental impact of
the plant to nearby communities and the environment. For this plant, potential of pollution will
be wastewater and solid waste generation.
Air Emission
Main emissions from the plant will come from the fermentation area and the dryer from
the polymerization plant, which consist of CO2 and VOC. Other minor sources will come from
filters or storages. Due to possible dangers surrounding these emissions, the plant insures that the
requirement for air quality standards are met under RA 8749: Clean Air Act of the Philippines.
Installation of Vacuum vents and gas absorbers/wet walls maybe required as the concentration of
these emissions continue to rise during the plant operation.
Water Quality
Generation of wastewater accumulates during construction and operation phase. For
operation plants, most wastewater generation comes from the Fermentation section of the plant,
next to the Pre-treatment and polymerization process. These wastewaters will be intoxicated
since these waters contain TSS, and other solutions and compounds that maybe harmful to the
environment. In line with the said problem, each process will be monitored, meeting the
minimum accumulation of harmful components to the environment and the required quality of
discharge streams regulated by RA 9275: Philippine Clean Water Act of 2004. These streams are
assumed to be connected to the Wastewater treatment plant, so no amount of the wastewater will
be discharged without treatment.
16
Land Quality: Soil and Geology
During construction phase will affect the land quality of the proposed site. For
construction phase, dust settling will be the major concern as this will also pose a threat to
human health. The plant’s source of water will come from underground. Digging will be required
for the installation of pipes and wells and it might affect the soil quality within the area, as well
as the reduction in plant diversity. Water Sprinkler will be used for the dust settling and the
installation will be double/triple-checked to prevent leakage when on operational phase. 6-
months maintenance will be implemented to ensure the quality of pipes.
Noise Pollution
Possible noise accumulation will come from the construction of the plant. Once the plant
has been constructed, the plant will follow the guidelines posted by DENR concerning noise
pollution.
Waste Disposal
Accumulation of solid waste disposal will only come from filter during pre-treatment. As
the solid waste generation is minimal, no hazardous components are found. Proper segregation,
recycling will be implemented and disposal to the landfill will be shipped after inspection of the
waste. Any other waste from offices and other facilities will also be included during operational
phase.
Human Toxicity
The major concern will be during the construction phase of the plant for the plant
operators and workers, no concerns for those nearby the site since the place is isolated from the
17
residential area. During operational phase, possible areas would be from the wastewater
treatment plant or from the handling of waste. Both may contain hazardous compounds which
were found during the collection but will be at minimum. No critical process poses a threat to the
employees.
Flora and Fauna
The site contains only grasslands. Most of the land will be retained. No significant
concerns has been identified for the impacts of the proposed plant site.
18
CHAPTER 2
BASE CASE
DESIGN
19
Section 1. Pre-Treatment
Operating Temperature = 25oC
Operating Pressure = 101.325 kPa

Storage Tank ST-101
Design Temperature = 55oC
Design Pressure = 111.458 kPa

Mixer M-101

Reactor R-101

Storage Tank ST-102

Mixer M-102
Design Pressure =111.458 kPa

Reactor R-102
Operating Pressure = 110 KPa
20
Design Pressure = 121 kPa

Storage Tank ST-103
Operating Pressure = 110 kPa

Reactor R-103
Design Pressure = 121 kPa

Holding Tank HT-101
21
Section 2. Fermentation and Purification.
Mixer ( M-201) Operating Temperature= 25 oC
Operating Pressure= 101.325 Kpa
Design temperature = 55 oC
Design Pressure = 111.45 Kpa
Fermentation Tank (BR-201) Operating Temperature= 37oC

Design Pressure =111.45 Kpa
Centrifuge (CF-201) Operating Temperature= 37oC

Operating Pressure= 100 Kpa
Design Pressure =110 Kpa
Esterification Reactor (ER-201) Operating Temperature= 80 oC

Operating Pressure=26.66 Kpa

Extraction Column (EX-201) Operating Temperature= 37 oC

Operating Pressure= 150 Kpa
Design temperature =67 oC

Design Pressure = 325 Kpa
Hydrolysis (HR-201) Operating Temperature= 100 oC


Evaporator (EC-201) Operating Temperature= 89oC


22
Section 3. Polymerization
23
CHAPTER 3
PROCESS FLOW
DIAGRAM
24
1% H2SO4 Cooling Water
solution (in)
[2]
[9]
M-101 HE-101
NOTES:
ST-101
(Wet Milled [1] [1] [6]
Wastewater
Corn Feed) Furfural Treatment
CB-101
Storage Tank Facility
ST-102 01. ST – Storage Tank
[10] Cooling Water 02. CB – Conveyor
(out)
[5]
03. M – Mixer
Cooling Water
(in)
[16] 04. P – Pump
05. R – Reactor
[3]
[13]
06. HE – Heat Exchanger
[4]
HE-101
HE-102 [15] 07. F – Filter
R-
PU-101 [11] [12]
F-101
08. HT – Holding Tank
101 [17]
P-101
[8] [7] P-102 Ethanol
Cooling Water
[14] (out)
CB-102
Ethanol NaOH
Cooling Water Storage Tank
(in) Condensing
Water ST-103
[23] Steam [17] [18]
[26]
M-102
HE-103
[22] [25] [27] [19]
Cooling Water
[24]
(out)
[20]
Cellulose
enzyme, water
Cooling Water
[31] (in) [36]
[21] R- HE-104
[33] [35] [35] R-
[30]
102 F-102 103
CB-103
[28] [29] Pangasinan
P-103
Condensing [32] Cooling Water Polylactic
Water (out) [34]
Steam
Acid Plant
[37]
F-103
[42] To P-201
[38] [40] [41] Wastewater
Treatment
[39]
HT-101 P-105 Facility Process Flow Diagram
P-104
CB-104
(Pre-treatment Section)
Solid waste
[39]
management facility
Drawing No. D-G03-11819
Sheet 1 of 3 Rev. No.
25
ST-201
Biomass ST-203
Butanol
ST-202 NOTES:
Ammonia
[44]
ST-203
[53] Butanol
Cooling Water
01. M – Mixer
From P-105
M-201 [46] (in) 02. BR – Bioreactor
[43] [56]
A/B ER-201 03. P – Pump
CF-201
[52] [54]
HE-201 [59]
04. CF – Centrifuge
BR-201
[49] [51] 05. ER – Esterification Reactor
[45] [48]
[57] [58] 06. HE – Heat Exchanger
P-202 Cooling Water
(out)
07. EX – Extractor
P-201 [50] [54] EX-201 08. HR – Hydrolysis Reactor
09. EC - Evaporator
[47]
Wastewater Wastewater
[60]
Treatment Treatment
Facility Facility [61]
Wastewater
Treatment Wastewater
Facility Treatment
Facility
Cooling Water
[76]
(in)
HE-202
[78] [75]
P-203
To Water [77]
Storage Tank [62]
Cooling Water
(out)
[70] [66]
To Water
To HE-301 [80] EC-203 EC-202 To Water EC-201 [64] HR-201
Storage Tank
[71] Storage Tank
[67] [65] Pangasinan
[79]
[74] [63]
Polylactic
Steam (in)
P-206
Acid Plant
[69]
To Water Butanol
Storage [73] Storage Tank
Tank
P-204
Process Flow Diagram
[68]
P-205
[72]
(Fermentation Section)

26
NOTES:
Wastewater
Treatment
01. PPR – Prepolymer Reactor

[90]
Facility
02. P – Pump
[87] DC-301 03. LR – Lactide Reactor
[82]
PPR-301
Zinc Diiminate
Catalyst [94]
PR-301
04. DC – Distillation Column
[89]
P-303 [92] 05. PR – Polymer Reactor
From P-206 [81]
Tin Octonoate
Catalyst
[91] [95]
06. DV – Devolatilizer
[85]
LR-301
P-302 [101]
07. HE – Heat Exchanger
[84]
[93] 08. C – Crystallizer
[86]
Catalyst
Storage 09. CB – Conveyor
[83]
[88] P-305 10. D – Dryer
P-304 11. CF – Centrifugal Fan
12. DH – Dehumidifier
Cooling Water(in)
[98]
Catalyst HE-305
Storage [100] [97]
[99]
P-301
Cooling Water(out)
DV-301
[96]
[105]
D-301
Polylactic Acid
[102] C-301 [103] CB-301 [104] [106] CB-302 [107]
Packaging
[111]
[110]
CF-301
Air
[108] [109]
DH-301 Water
Pangasinan
Polylactic
Acid Plant
Process Flow Diagram

(Polymeriation Section)

27
Process Flow Description
The production of polylactic acid comprises of three different sections namely, (1) Pretreatment
Section, (2) Fermentation Section, and (3) Polymerization Section
Pre-treatment Section
The purchased milled corn stocked inside the storage tank (ST-101) with water will be
transported to the mixer (M-101) by means of using a conveyor belt (CB-101). Addition of sulfuric
acid as a catalyst is necessary in M-101 in preparation for the acid hydrolysis process in the first
reactor (R-101). Furfural, a by-product obtained from the acid hydrolysis process from R-101, is
cooled in a heat exchanger prior to being moved in a storage tank (ST-102). The said by-product
can be sold off in the market for extra profit. The acquired solids in slurry from the filtration tank
(F-101) will be transported to the second mixer (M-102) where it will be mixed with ethanol and
NaOH. Thereafter, the mixture will be pumped towards the second reactor (R-102) for the
delignification process where ethanol can be recovered and purged into its corresponding storage
tank (ST-103). After the filtration in F-102, the solids in the slurry will undergo through the last
stage of treatment which is the enzymatic hydrolysis inside the third reactor (R-103). The
enzymatic hydrolysis incorporates the use of a cellulose enzyme as catalyst. From R-103, the
mixture will undergo filtration once again in F-103. The resulting liquor from F-103 is rich in
dextrose and will be stored in a holding tank (HT-101) before being transferred onto the
fermentation section.
28
Fermentation Section
Production of lactic acid
From section 1, xylose, dextrose, and water will enter the mixer, and from a different
stream the biomass will enter the mixer. The mixture will be divided equally and pumped to five
fermentation tanks where each fraction will be mixed with inoculum and ammonia. The
fermentation will 12 hours for the biomass to complete the digestion of the substrates in the
mixture. Following the completion of the fermentation, the broth will be placed in holding tanks
to proceed to the succeeding process.
Purification
After fermentation, the broth will be subjected to several processes such as centrifugation
to remove biomass from the broth. The broth will undergo esterification on a reactor to convert
ammonium lactate to butyl lactate by reacting butanol in the mixture. To remove remaining xylose
in the mixture, the solution is passed through an extraction column, where butanol is utilized for
extraction. The remaining solution containing water and butyl lactate is subjected to hydrolysis to
convert butyl lactate to lactic acid, undergoing specific operating condition and using a catalyst
(Amberlyst 15). The lactic acid solution from the reactor will be concentrated using evaporators,
and will then proceed to polymerization.
Polymerization Section
From the Evaporator of the fermentation process, lactic acid is pumped into the pre-
polymer reactor(PPR-301) to produce the lactic acid prepolymer with composition of 97.1%
prepolymer and the latter for water. Used unreacted stream will be sent to the wastewater treatment
plant. Lactic acid prepolymer is, then, pumped into the lactide reactor(LR-301) for the cyclization
29
of low molecular weight Lactic acid, forming lactide. The product contains 97.5% lactide and
2.45% water. A Tin Octanoate catalyst was used to further boost the process. Lactide is then
pumped into the Distillation Column(DC-301) to further remove the water content and to purify
the entering lactide. A recycle stream was also introduced in the distillation column which came
from the devolatilizer equipment(DV-301). Mass flow rate for water is low, so it can be sent to the
wastewater treatment plant. Purified Lactide is then pumped into the Polymerization reactor(PR-
301) to produce the polylactic acid. Tin Octoate was also used as a catalyst to make the reaction
faster. Polylactic acid and some purified lactide is, then, pumped into the devolatilizer(DV-301)
to extract the polylactic acid. Unreacted lactide is pumped back into the distillation column.
Polylactic acid, then, undergoes crystallization from the crystallizer(C-301), transported next to
the dryer(D-301) for drying. After the crystallized polylactic acid has dried, it is sent to the
packaging area for finishing and packaging.
30
CHAPTER 4
MATERIAL AND
ENERGY
BALANCES
31
1% H2SO4 Cooling Water
solution (in)
[2]
[9]
M-101 HE-101
ST-101
(Wet Milled [1] [1] [6]
Wastewater
Corn Feed) Furfural Treatment
CB-101
Storage Tank Facility
ST-102
[10] Cooling Water

[5] (out)
Cooling Water [16]

(in)
Pangasinan
[3]
[13]
Polylactic
[4]
HE-101
HE-102 [15] Acid Plant
R- F-101
PU-101 [11] [12]
101 [17]
P-101
[8] [7] P-102 Ethanol
Cooling Water
[14] (out)
CB-102
Ethanol NaOH
Material Balance
Cooling Water Storage Tank
(in) Condensing
Water ST-103
[23] Steam [17] [18]
[26]
M-102
HE-103
[22] [25] [27] [19]
Cooling Water
[24]
(out)
[20]
[21] R-
102 [30]
Pangasinan
[28] [29] Polylactic
Condensing
Acid Plant
Water
Steam
Material Balance
Drawing No. D-G03-11819 Rev. No. 0

Sheet 1 of 6
32
Cellulose
enzyme, water
Cooling Water
[31] (in) [36]
HE-104
[33] [35] [35] R-
F-102 103
CB-103
[32] Cooling Water

(out) [34]
[37]
Bulacan
F-103 Insulin Plant
[42] To P-201
[38] [40] [41] Wastewater
Treatment
[39]
HT-101 P-105 Facility
P-104
Material Balance
CB-104
Solid waste
[39]
management facility
Pangasinan
Polylactic
Acid Plant
Material Balance

Rev. No. 0
Sheet 2 of 6
33
ST-201
Biomass ST-203
Butanol
ST-202
Ammonia
[44]
ST-203
[53] Butanol
Cooling Water
M-201 [46] (in)
From P-105 [43] [56]
A/B ER-201
HE-201
CF-201 [59]
[52] [54]
BR-201
[49] [51]
[45] [48]
[57] [58]
P-202 Cooling Water

(out)
P-201 [50] [54] EX-201
[47]
[60]
Treatment Treatment
Facility Facility [61]
Wastewater
Facility Treatment
Facility
Pangasinan
Polylactic
Acid Plant
Material Balance

Sheet 3 of 6 Rev. No. 0
34
Cooling Water
[76]
(in)
HE-202
[78] [75]
P-203
To Water [77]
Storage Tank [62]
Cooling Water
(out)
[70] [66]
To Water
To HE-301 [80] EC-203 EC-202 To Water EC-201 [64] HR-201
Storage Tank
[71] Storage Tank
[67] [65]
[79]
[74] [63]
Steam (in)
P-206 [69]
To Water Butanol
Storage [73] Storage Tank
Tank
P-204
[68]
P-205
[72]
Pangasinan
Polylactic
Acid Plant
Material Balance

35
Wastewater
Treatment
[90]
Facility
[87] DC-301
[82]
PPR-301
[89]
From P-206 [81] [91]

Tin Octonoate
Catalyst
P-302 [101]
LR-301
[85]
[84]
[86]
[88]
[83]
Catalyst
Storage
P-301
Pangasinan
Polylactic
Acid Plant
Material Balance

36
Zinc Diiminate
Catalyst [94]
PR-301
[92]
[95]
[93]
Catalyst
Storage
P-305
P-304
Cooling Water(in)
[98]
HE-305
[100] [97]
[99]
Cooling Water(out)
DV-301
[96]
[105]
D-301
Polylactic Acid
[102] C-301 [103] CB-301 [104] [106] CB-302 [107]
Packaging
Pangasinan
Polylactic
Acid Plant
Material Balance

37
CHAPTER 5
PIPING AND
INSTRUMENTATION
DESIGN
38
1% H2SO4 Cooling Water NOTES:
solution (in)
[2]
[9]
ST-101
M-101 HE-101 Valves
[6]
(Wet Milled [1] [1] Wastewater
Corn Feed) CB-101 Treatment 01. LCV – Level Control Valve
LT
101 TT
Facility 02. FCV – Flow Control Valve
TV-101
03. TV – Temperature Valve
101
Cooling Water
LC
LCV-101 [5] TY
[10]
TIC (out) 04. RV – Relief Valve
101 101 101
Cooling Water
05. GV – Gate Valve
FIC FT [16]
PI 101 101 (in)
101 PI
TT TIC TY 102
[13]
[3] 102 102 102
Instruments
[4]
LCV-102 HE-101
HE-102 [15]
FCV-101 R- [12] MV-101
F-101 06. F - Flow
PU-101 [11]
101 [17]
07. L - Level
P-101 TV-102
ST-103
[8] [7] P-102
Ethanol
08. P - Pressure
LT LIC Cooling Water 09. T – Temperature
[14]
10. X – Composition
102 102 (out)
CB-102
ST-104 11. A -Alarm

TY TIC
Cooling Water
(in) Condensing
Ethanol
Storage Tank
NaOH 12. H – High
Water
13. I – Indicator
103 103
[23] Steam [17] [18]
TT
103
[26]
M-102 14. T -Transmitter
HE-103
[22] [25] [27] [19] 15. C - Controller
TV-103
Cooling Water
[24]
(out)
[20]
LT
103
Cellulose
LC FIC FT TT LIC TY enzyme, water
PI
103 102 102 Cooling Water 103 103 103
103
[31] (in) [36]
R- LCV-104 HE-104 R-
[21] [30] [33] [35] [35]
102 F-102 103
LCV-102 FCV-102 TV-103 CB-103
[28] [29]
P-103
Condensing
Water
[32] Cooling Water
(out) [34]
LT
105 Pangasinan
Steam LT
104 LT
104 PI
105 [37]
Polylactic
PI LC
104 105
F-103
Acid Plant
[42] To P-201
[38] [40] [41] LCV-106 Wastewater
LCV-105 Treatment
[39]
HT-101 P-105 Facility
P-104
CB-104
LT
106
LC
106 Piping and Instrumentation
Diagram
Solid waste
[39]
management facility

39
NOTES:
ST-201
Biomass ST-203
Butanol
Valves
ST-202
Ammonia
01. LCV – Level Control Valve
[44]
TIT I/P ST-203
02. FCV – Flow Control Valve
[53]
202
TY TIC TT
Butanol 03. TV – Temperature Valve
04. RV – Relief Valve
PIT 201 201 201
t. M-201
TIT
201
202
HS
From P-105
A/B
[43]
PIT
201
[46]
PIA
LIC
203
LT
203
ER-201
202 [56]
TV-201
Cooling Water
(in)
LT 202
LIC LT
201 PIA HE-201
201
202 202 CF-201 [59]
[52] [55]
HS
LC 201
BR-201
LCV-203
201
LCV-101
LCV-202
[49] [51]
FCV-202 [57] LIC

LT
Instruments
[45] [48] [58] 204
204
FCV-201 P-202 Cooling Water
P-201
FT
202
FIC
202
(out) 06. F - Flow
[50] [54] EX-201
FT
201
FIC
201 LCV-204 07. L - Level
[47] 08. P - Pressure
[60]
09. T – Temperature
Treatment Treatment
Facility Facility [61] 10. X – Composition
Wastewater
FT
203 11. A -Alarm
Treatment
Facility
Facility FCV-203
FIC
203
12. H – High
I/P
13. I – Indicator
TY
202
TIC
202
TT
202 14. T -Transmitter
PIA
203 15. C - Controller
Cooling Water
(in)
TV-202
[76]
HE-202
15. LAH – Level Alarm High
[78] [75]
P-203
TIT
PIT
PIT 203
To Water [77] PIT 205
204
Storage Tank 206 TIT
TIT FIC FT PIT
Cooling Water TIT 205
204 204 204 203
(out) 206
HS
[70] [66]
203 LT LIC
FIC FT 205 205
207 207
To Water
Storage Tank
To P-301 [80] EC-203 [71] EC-202 To Water EC-201 [64] HR-201 [62]
PIA
LCV-207
206 Storage Tank FCV-204 LCV-205
[79]
[67] [65]
Pangasinan
[74]
FIC
206
FT
206
FIC
205
FT
205
[63]
Polylactic
Steam (in)
P-206 [69] Acid Plant
To Water LCV-205 Butanol
Storage [73] PIA Storage Tank
Tank 204
LCV-206
PIA
205
P-204
P-205
[68]
Piping and Instrumentation
[72]
Diagram

40
NOTES:
Valves
01. LCV – Level Control Valve
02. FCV – Flow Control Valve
03. TV – Temperature Valve
04. RV – Relief Valve
Wastewater
Treatment
Facility
[90]
GV-303 XI
TAH TIT 301
303 303
GV-301 TAH TIT
PAH PIT
[82]
TAH
301
TIT
301
303 303
RV-303
DC-301
FI
304
FC
304
PR-301
304
PAH
304
304
PIT
304
Instruments
FI FC PAH PIT Zinc Diiminate
Tin Octonoate [87] RV-304 LAH LIC
301 301 PPR-301 301 301 Catalyst 303
Catalyst FCV-303 [94] 303
LAH
301
LIC
301
[89]
[92]
06. F - Flow
From P-206 [81]
FCV-301
GV-302
FI FC
[91]
GV-304
FCV-304
07. L - Level
303
RV-301
LR-301
[88]
P-302
303
[101]
P-303
[95]
08. P - Pressure
LCV-301
[85]
TAH
302
TIT
302
PIT
FCV-306
FC
306
LCV-303 09. T – Temperature
10. X – Composition
PAH
[84] 302 302 [93]
FI
LAH LIC 306
[86] 302
302
RV-302
P-305 Catalyst 11. A -Alarm
Storage
12. H – High
TIT TIC
305 301
LCV-302
[83] FC
FCV-302
13. I – Indicator
302
P-304
Cooling Water(in)
[98]
FI TCV-301
302
HE-305
14. T -Transmitter
Catalyst
Storage [100]
GV-305
[97] 15. C - Controller
FC FI
[99] 305 305
P-301
Cooling Water(out)
DV-301
[96]
FCV-305
PI TI
301 301
TI
302
TI
303
[105]
D-301
Polylactic Acid
[102] C-301 [103] CB-301 [104] [106] CB-302 [107]
GV-306 Packaging
[111]
[110]
TI
304
CF-301
Air
[108] [109]
Pangasinan
DH-301 Water
Polylactic
Acid Plant
Piping and Instrumentation

Diagram

41
CHAPTER 6
HAZARD AND
OPERABILITY
STUDY
42
PRE-TREATMENT SECTION
43
44
FERMENTATION SECTION
45
Equipment Deviations from What event could Consequence of the Additional Process indications Notes and questions
Reference and operating cause this Deviation on item of implication of this
Operating conditions deviation? equipment under consequence
Conditions consideration
Mixer Level
M-201 Less LCV-106 is Wrong ratio of Less supply in the LCV-106 Regular maintenance
damaged components in solution. fermentation tank checkups
Empty mixer Maintenance and repair

LCV-106 is closed Damage the mixer of instrument
Mechanical strain in the Over supply in the

More Excessive loading equipment. fermentation tank LCV-106

Damage in LCV- equipment fermentation tank LCV-106
106
Damage in LCV- equipment fermentation tank LCV-106
106
Mechanical strain in the No supply in the
LCV-101 is closed equipment fermentation tank
LCV-101
Bioreactor Pressure
BR-101
More PIT-201 is Potential Rupture in the Potential Explosion PIT-201 Monitor flow
Damaged reactor
Damage on reactor
FCV-201 is closed Strain on the reactor None
Damage on reactor
FIC-201 fails
Strain on the reactor Damage on reactor FIC-201
FT-201 fails Potential Fire

46
Strain on the reactor FT-201
Temperature TIT-201 is
More damaged Thermal strain on the TIT-201
tank
TIT-201 fails
Less Inefficient process TIT-201
Pump Flow
P-201 Less FCV-201 is closed Pump cavities Damage to pump None Monitor flow
Lines plugged
Pump cavities Damage to pump None
LCV-202 is closed
Deadhead pump Damage to pump None
FIC-202 fails
Deadhead pump Damage to pump FIC-202
FIC-202 fails
More Upset in the reactor Damage to reactor. FIC-202
Damage to reactor.
FIC-202 fails FIC-202
to open LCV-203 Upset in the reactor
Damage to pump
Pressure
Less LCV-202 closed
Deadhead pump Damage to pump FIC-202
PIA-201 fails Damage to pump

Deadhead pump PIA-201
FIC-202 fails
More to open LCV-203 Upset in the reactor Damage to pump FIC-202
FIC-202 fails Damage to pump

Upset in the reactor FIC-202
PIA-201 fails
Deadhead pump Damage to pump PIA-201
Temperature LCV-202 closed Damage to pump

More Deadhead pump FIC-202
47
FIC-202 fails to
close LCV-202 Deadhead pump FIC-202
Pump Flow
P-202 Less LCV-202 closed Pump cavities Damage to pump None
Check for repairs,
Lines plugged Pump cavities Damage to pump None maintenance and
irregularities.
LCV-202 closed Deadhead pump Damage to pump None
LIC-202 fails Deadhead pump Damage to pump LIC-202
More LIC-203 fails Upset in the reactor Damage to reactor. FLC-203
Damage to reactor.
LIC-203 fails Upset in the reactor LIC-203
to open LCV-203
Damage to pump
Pressure LCV-203 closed Deadhead pump FIC-203

Less
Damage to pump
More PIA-307 fails Deadhead pump Damage to pump PIA-307
FIC-203 fails Upset in the reactor FIC-203

to open LCV-203 Damage to pump
48
FIC-203 fails Upset in the reactor Damage to pump FIC-203
PIA-307 fails Deadhead pump PIA-307

Damage to pump
Temperature LCV-203 closed Deadhead pump Damage to pump FIC-203

More
FIC-203 fails to Deadhead pump FIC-203
close LCV-203
Pump Flow
Always monitor PI-101,
Lines plugged Pump cavities Damage to pump None pump replacement and
cavitation reliever.
LCV-203 closed Deadhead pump Damage to pump None
FIC-203 fails Deadhead pump Damage to pump FIC-203
More FIC-203 fails Upset in the reactor FIC-203
FIC-203 fails Upset in the reactor Damage to reactor. FIC-203

to open LCV-203
Pressure Damage to reactor.

Less LCV-203 closed Deadhead pump FIC-203
Damage to pump

More Damage to pump

FIC-203 fails Upset in the reactor Damage to pump FIC-203
49
Temperature Damage to pump
More
LCV-203 closed Deadhead pump Damage to pump FIC-203

close LCV-203
Esterification Level
Reactor Less LCV-203 is closed Upset the reactor Damage to reactor LIC-201
ER-201 Damage to reactor Check pipes and supply
LIC-203 Fails Upset the reactor LIC-201 stream
Damage to reactor
LIC-203 fails to Upset the reactor Damage to reactor LIC-201

open LCV-201
Damage to reactor
Pipe Blockage Upset the reactor None
Damage to reactor Repair pipeline system
LT-201 fails Upset the reactor Damage to reactor LT-201
Damage to reactor Instruct operators on

More LCV- 201 is Overflow FIC-201 procedures
closed None
LT-201 fails Overflow None FIC-201 Instruct operators on

procedures
Pipe Blockage Upset the reactor Possible explosion None
Pressure Possible explosion

Less LCV-201 fails Inefficient process LIC-201
Possible explosion
PIT-201 fails Inefficient process PIT-201
Possible explosion
More LCV-201 is closed Strain on the reactor FIC-201
50
FIC-201 fails Strain on the reactor None FIC-201
FIC-201 fails to Strain on the reactor Damage on reactor FIC-201

open LCV-201
Potential Explosion
PIT-201 fails Strain on the reactor PIT-201
Temperature
Less TIT-201 fails Inefficient Process TIT-201
More TIT-201 fails Thermal stress on the TIT-201

reactor
HS-202 fails Thermal stress on the HS-202

reactor
Heat Exchanger Flow

HE-201
Less Failure of cooling Temperature of process Pump starvation Low temperature alarm
water valve fluid remains constant
Temperature of process High temperature alarm

More Pipe blockage fluid remains constant Eventual leakage
Temperature
Insufficient load of Check for repairs,
corresponding materials maintenance and
Less Leakage on HR- Reduced output TIC-201 irregularities
201
Excessive load of
corresponding materials Check for repairs,
maintenance and
More TV-201 closing Excessive output TIC-201 irregularities
failure. Outlets lead to spoilage
blocked.
51
Extractor Level
EX-201 More FCV-203 is closed Strain on the equipment Damage on FIC-203
equipment Always monitor PI-101,
FIC-203 fails Strain on the equipment pump replacement and
Damage on FIC-203 cavitation reliever.
equipment
Strain on the equipment

LT-204 fails
Damage on LR-204
equipment
Pump Flow
Always monitor PI-101,
Lines plugged Pump cavities Damage to pump None pump replacement and
cavitation reliever.
FCV-203 closed Deadhead pump Damage to pump None
FCV-203 fails Deadhead pump Damage to pump FIC-203
More FIC-205 fails Upset in the reactor FIC-205
FIC-205 fails Upset in the reactor Damage to reactor. FIC-205

to open LCV-205
Pressure Damage to reactor.

Less FCV-203 closed Deadhead pump FIC-203
52
Damage to pump
More PIA-203 fails Deadhead pump PIA-203

Damage to pump


Damage to pump
Damage to pump
Temperature
More LCV-205 closed Deadhead pump Damage to pump FIC-205

close LCV-205
Hydrolysis Level
Reactor
HR-201 Less LCV-205 is closed Upset the reactor Damage on reactor FIC-205 Low temperature alarm
Damage on reactor
LT-205 fails Upset the reactor LT-205 High temperature alarm
Damage on reactor
LIC-205 fails Upset the reactor Damage on reactor FIC-205
LIC-205 fails to Upset the reactor Damage on reactor FIC-205

open LCV-205
Damage on reactor
Check for repairs,
More Pipe blockage Overflow None maintenance and
Potential explosion irregularities
53
FCV-204 is closed Overflow Potential explosion FIC-204
FIC-204 fails
Check for repairs,
Increase pressure on the Damage on reactor FIC-204 maintenance and
FT-204 fails reactor irregularities
Increase pressure on the FT-204

reactor Damage on reactor
TIT-203 fails
Temperature
More Thermal stress on the TIT-102
reactor
PIT-201
Pressure
More Stress on the reactor PIT-201
Evaporator Flow
EC- Less FCV-204 is closed No product produced None FIC-204
201,202,203
FIC-204 fails
More No product produced None FIC-204
Pump Flow
P-204 Less FCV-204 is closed Cavitation Damage on pump FIC-204 Evaluate need for
hydraulic relief
FIC-205 fails
Cavitation Damage on pump FIC-204
FT-205 fails
More Increased pressure in Potential explosion FT-205
EC-201
LCV-205 is closed Damage on pump
54
Increased pressure FIC-205
Pump Flow
hydraulic relief
FIC-206 fails
LCV-206 is closed
More Increased pressure Damage on pump FIC-206
Pump Flow
hydraulic relief
FIC-207 fails
55
POLYMERIZATION SECTION
56
Equipment Deviations from What event could cause Consequences of this Additional implications Process Notes and
reference and operating conditions the deviation? deviation on item of of this consequence indications questions
operating conditions equipment under
consideration
Prepolymer Reactor Level

PPR-301 Less 1. FCV-301 closed Stoppage in production Minimal to no yield LIC-301, LAH- Always monitor FC-
of prepolymer 301 301.
Estimate release
quantity and check
2. Rupture in discharge Reagent released Delay in process LIC-301, LAH- pipes regularly.
line production 301
What external
events could cause
3. Tank rupture Reagent released Delay in process LIC-301, LAH- rupture?
production 301
More 4. FCV-301 broken Overflow in reactor Wasted raw materials/ LIC-301, LAH- Check FCV-301 for
reagent released 301 repairs. Monitor
LIC-301 always.
Waste product retained Inefficient yield LIC-301, LAH- Monitor and check
5. GV-301 fails to open
in the reactor 301 GV-301 for repairs.
No
6. Same as less
Composition
As well as 7. Impurity in reagent Reaction might not Low to no yield FC-301 Consider materials
proceed first before
unloading.
What are possible

impurities?
Monitor FCV-301.
Pressure
Less 8. Operating pressure Possible implosion Reagent PIT-301, PAH- Check for any
dropped released/production 301 damaged parts.
delayed Monitor PIT-301.
57
More 9. Overfill in reactor Overflow in reactor Tank ruptures if RV-301 PIT-301, PAH-
fails 301
Temperature
Less 10. Temperature of inlet is Possible vacuum Thermal stress on tank TIT-301, TAH- Consider
colder than normal 301 temperature limits
of reactor.
11. Low tank pressure Tank implodes Thermal stress on tank TIT-301, TAH- Monitor PIT-301.
More 301
12. Temperature of inlet is Thermal stress on tank TIT-301, TAH- Monitor TIT-301.
hotter than normal 301
13. External fire Tank fails Reagent released TIT-301, TAH- Give necessary
301 actions in case of
fire breakout.
Pump Flow
P-301 Less 14. LCV-301 closed Pump cavitates Damage to pump FC-302, FI-302 Can reagent
react/explode if
overheated in
pump?
15. FCV-302 closed Deadhead pump Damage to pump FC-302, FI-302 Estimate release
quantity.
Pressure
Less 16. LCV-301 closed Pump cavitates Damage to pump Evaluate need for
hydraulic relief
17. FCV-302 closed Deadhead pump Damage to pump
More 18. LCV-301 and FCV- Deadhead pump Overpressure in pump or

302 closed line
Lactide Reactor Level

LR-301 Less 19. FCV-302 closed Stoppage in production Minimal to no yield FC-302, FI-302 Always monitor FC-
of prepolymer 302.
Estimate release
quantity and check
20. Rupture in discharge Reagent released Delay in process LIC-302, LAH- pipes regularly.
line production 302
58
21. Tank rupture Reagent released Delay in process LIC-302, LAH- What external
production 302 events could cause
rupture?
Wasted raw materials/
More 22. FCV-302 broken Overflow in reactor reagent released LIC-302, LAH- Check FCV-302 for
302 repairs. Monitor
LIC-302 always.
No .
23. Same as less
Pressure
fails 302
Temperature
of reactor.
302
More
fire breakout.
Pump Flow
react/explode if
overheated in
pump?
quantity.
59
Pressure
hydraulic relief

303 closed line
Distillation Column Pressure
DC-301 Less 35. Operating pressure Possible implosion Reagent PIT-303, PAH- Check for any
fails 303
37. GV-302 fails to open Waste product retained Inefficient yield PIT-303, PAH- Monitor and check
in the reactor 303 GV-302 for repairs.
Temperature
of reactor.
More 303
fire breakout.
Pump Flow
P-304 Less 42. GV-303 closed Pump cavitates Damage to pump FC-304, FI-304 Can reagent
react/explode if
overheated in
pump?
quantity.
60
Pressure
Less 44. GV-303 closed Pump cavitates Damage to pump Evaluate need for
hydraulic relief
More 46. GV-303 and FCV-304 Deadhead pump Overpressure in pump or

closed line
Polymer Reactor Level
PR-301 Less 47. FCV-304 closed Stoppage in production Minimal to no yield LIC-303,LAH- Always monitor FC-
of polymer 303 304.
48. Rupture in discharge Delay in process Estimate release

line Reagent released production LIC-303,LAH- quantity and check
303 pipes regularly.
49. Tank rupture Delay in process What external

Reagent released production LIC-303,LAH- events could cause
303 rupture?
More 50. FCV-304 broken Wasted raw materials/ Check FCV-304 for
Overflow in reactor reagent released LIC-303,LAH- repairs. Monitor
303 LIC-303 always.
.
No 51. Same as less
Composition
As well as 52. Percent composition Reaction might not Low to no yield XI-301, FC-304 Consider materials
of inlet lactide did not proceed first before
meet requirements unloading.
What are possible

impurities?
Monitor XI-301.
Pressure
fails 304
61
Temperature
of reactor.
More 304
57. Temperature of inlet is Thermal stress on tank Monitor TIT-304.

hotter than normal
fire breakout.
Pump Flow
react/explode if
overheated in
pump?
quantity.
Pressure
hydraulic relief

305 closed line
Devolatilizer Temperature
DV-301 More 64. Vapor release fails Rupture in equipment Possible explosion TI-301 Always monitor TI-
301.
Pressure
More 65. Vapor release fails Pressure build up Damage to equipment PI-301 Always monitor PI-
301.
Heat Exchanger Temperature

HE-301 More 66. TCV-301 fails Overheating of heat Damage to equipment TIT-305, TIC- Check TIC-301
exchanger 301 always.
62
Pump Flow
P-305 Less 67. GV-304 closed Pump cavitates Damage to pump FC-306, FI-306 Can reagent
react/explode if
overheated in
pump?
quantity.
Pressure
Less 69. GV-304 closed Pump cavitates Damage to pump Evaluate need for
hydraulic relief
More 71. GV-304 and FCV-306 Deadhead pump Overpressure in pump or

closed line
Crystallizer Flow
C-301 More 72. GV-305 fails to close Overfill in the equipment Inefficient yield/reagent Monitor inlet flow
released rate.
Temperature
More 73. Inlet temperature Possible problem in Inefficient yield TI-302 Always monitor Ti-
hotter than usual equipment 302.
Conveyor Flow
CB-301 Less 74. Rupture/tear in Failure of product Delay in production Monitor GV-305.
conveyor belt line transport
No 75. Same as less

Dryer Temperature
D-301 More 76. Operating temperature Hotter temperature of Decrease in quality of TI-303 Monitor TI-303.
hotter than usual inlet air product
Conveyor Flow
CB-302 Less 77. Rupture/tear in Failure of product Delay in production Monitor CB-301.
conveyor belt line transport
No 78. Same as less

Centrifugal Fan Flow
CF-301 Less 79. No inlet flow Failure to blow air to D- Product mishandled Always check for
301 repairs and
maintenance of
pipes and CF-301.
63
Dehumidifier Temperature
DH-301 Less 80. Operating temperature Deviation in outlet Product mishandled TI-304 Monitor TI-304.
colder than usual temperature
More 81. Operating temperature Deviation in outlet Delay in meeting TI-304 Monitor TI-304.
colder than usual temperature product specifications
64
CHAPTER 7
SITE AND PLANT
LAYOUT
65
ROAD
Gate Gate
SECURITY
ADMIN OFFICES CANTEEN
PARKING AREA Fire
Department
ROOM FOR EXPANSION

PLANT UTILITIES
CONTROL
ROOM
MILLED CORN MRF
PLANT AREA
STORAGE
Pangasinan
WASTEWATER Polylactic
TREATMENT
Acid Plant
SOLID WASTE
ROOM FOR EXPANSION MANAGEMENT FACILITY
Site Layout
BUTANOL STORAGE

66
Door
RESTROOM
Control Room
Door
PACKAGING AREA
Door
BR-201 M-201
Door
HR-101 M-101 WMM
Door
D-301 C-301
CF-201 ER-201 HE-
F-103 101
HE-
PR-301 DV-301
102
HE-
HT-101
201
HR-103 F-101
Pangasinan
HE-
DC-301
104 EX-201 Polylactic
Acid Plant
F-102
M-101
HE-
LR-301 PPR-301 EC-201-203 HR-201
104
HR-102 Plant Layout

67
CHAPTER 8
EQUIPMENT
SIZING
68
EQUIPMENT
SPECIFICATION
69
PRE-TREATMENT
SECTION
70
STORAGE TANK
IDENTIFICATION
EQUIPMENT CODE ST-101
FUNCTION Storage
MATERIAL HANDLED Wet milled corn
# OF EQUIPMENT 1
EQUIPMENT DESIGN
m3
CAPACITY 11.24 day
OPERATING DESIGN
TEMPERATURE
25℃ 55℃
OPERATING DESIGN
PRESSURE
101.325 kPa 111.458 kPa
MATERIAL OF
Titanium
CONSTRUCTION
CORROSION ALLOWANCE 0.0038 m
INSIDE DIAMETER 1.20 m
HEIGHT 3.59 m
THICKNESS 0.00386 m
EQUIPMENT FIGURE
71
CONVEYOR BELT
IDENTIFICATION
EQUIPMENT CODE CB - 101
FUNCTION Transport of materials from storage to mixer
NO. OF EQUIPMENT 1
MATERIAL HANDLED Wet milled corn
EQUIPMENT DESIGN
m3
CAPACITY 11.24
𝑑𝑎𝑦
LENGTH 16.16 m
OPERATING DESIGN
TEMPERATURE
25℃ 55℃
OPERATING DESIGN
PRESSURE
101.325 kPa 111.458 kPa
MATERIAL OF
Stainless Steel (316 L)
CONSTRUCTION
POWER REQUIREMENT 1.81 kW
WIDTH 0.61 m
ANGLE OF REPOSE 20°
m2
CONVEYING SPEED 1.52 s
EQUIPMENT FIGURE
72
73
MIXER
IDENTIFICATION
EQUIPMENT CODE M-101
FUNCTION Mixing of components
NO. OF EQUIPMENT 1
MATERIAL HANDLED Sulfuric acid, milled corn
EQUIPMENT DESIGN
m3
CAPACITY 41.93
day
HEIGHT 2.76 m
THICKNESS 0.0091 m
OPERATING DESIGN
TEMPERATURE
60 ℃ 90℃
OPERATING DESIGN
PRESSURE
101.325 kPa 111.458 kPa
MATERIAL OF
Tensile steel
CONSTRUCTION
IMPELLER DIAMETER 2.48 m
IMPELLER SPEED 3.85 rpm
EQUIPMENT FIGURE
74
PUMP
IDENTIFICATION
EQUIPMENT CODE P-101
FUNCTION Transport treated mixture to reactor
NO. OF EQUIPMENT 1
MATERIAL HANDLED Water, sulfuric acid and milled corn mixture
EQUIPMENT DESIGN
𝑘𝑔
CAPACITY 56.22
𝑑𝑎𝑦
OPERATING DESIGN
TEMPERATURE
25℃ 55℃
DISCHARGE HEAD 108.58 𝑚
POWER INPUT 16.83 𝑘𝑊
EQUIPMENT FIGURE
75
REACTOR
IDENTIFICATION
EQUIPMENT CODE R-101
FUNCTION Acid hydrolysis
NO. OF EQUIPMENT 19
MATERIAL HANDLED Sulfuric acid, water and milled corn mixture
EQUIPMENT DESIGN
𝑚3
CAPACITY 41.93
𝑑𝑎𝑦
LENGTH 21.69 𝑚
THICKNESS 0.0125 𝑚
OUTSIDE DIAMETER 7.26 m
OPERATING DESIGN
TEMPERATURE
175 ℃ 205℃
OPERATING DESIGN
PRESSURE
911.925 𝑘𝑃𝑎 1003.12 𝑘𝑃𝑎
MATERIAL OF
Carbon steel
CONSTRUCTION
MASS OF TANK 57315.6 𝑘𝑔
EQUIPMENT FIGURE
76
HEAT EXCHANGER
IDENTIFICATION
EQUIPMENT CODE HE-101
FUNCTION For acid hydrolysis
NO. OF EQUIPMENT 1
MATERIAL HANDLED Water, furfural
EQUIPMENT DESIGN
HEAT TRANSFER W
1875 m2 −𝐾
COEFFICIENT
HEAT TRANSFER AREA 4.29 𝑚2
# OF TUBES 14 tubes
HOT FLUID COLD FLUID
TEMPERATURE Inlet = 175℃ Inlet = 25℃
Outlet = 85℃ Outlet = 80℃
OPERATING DESIGN
PRESSURE
101.325 kPa 111.458 kPa
MATERIAL OF
Carbon Steel
CONSTRUCTION
LENGTH 4.9 m
THICKNESS 0.0038 m
INSIDE OUTSIDE
DIAMETER
0.203 m 0.2106 m
EQUIPMENT FIGURE
77
STORAGE TANK
IDENTIFICATION
FUNCTION Storage
MATERIAL HANDLED Furfural
# OF EQUIPMENT 1
EQUIPMENT DESIGN
m3
CAPACITY 24.67
day
OPERATING DESIGN
TEMPERATURE
25℃ 55℃
OPERATING DESIGN
PRESSURE
101.325 kPa 111.458 kPa
MATERIAL OF
Titanium
CONSTRUCTION
HEIGHT 4.66 m
THICKNESS 0.00387 m
EQUIPMENT FIGURE
78
HEAT EXCHANGER
IDENTIFICATION
FUNCTION For acid hydrolysis
NO. OF EQUIPMENT 2
MATERIAL HANDLED Water, corn solution
EQUIPMENT DESIGN
HEAT TRANSFER W
1875
COEFFICIENT m2 −𝐾
2
HEAT TRANSFER AREA 20.29 𝑚
# OF TUBES 70
OPERATING DESIGN
PRESSURE
101.325 kPa 111.458 kPa
MATERIAL OF
Carbon Steel
CONSTRUCTION
LENGTH 4.9 m
THICKNESS 0.0038 m
INSIDE OUTSIDE
DIAMETER
0.264 m 0.2716 m
EQUIPMENT FIGURE
79
80
PUMP
IDENTIFICATION
FUNCTION Transport cooled mixture to filtration unit
NO. OF EQUIPMENT 1
MATERIAL HANDLED Dextrose solution
EQUIPMENT DESIGN
𝑚3
CAPACITY 50.92
𝑑𝑎𝑦
OPERATING DESIGN
TEMPERATURE
25℃ 55℃
DISCHARGE HEAD 110 𝑚
15.44 𝑘𝑊
POWER INPUT
EQUIPMENT FIGURE
81
FILTRATION UNIT
IDENTIFICATION
EQUIPMENT CODE F-101
FUNCTION Filter
NO. OF EQUIPMENT 1
EQUIPMENT DESIGN
𝑚3
CAPACITY 50.92
𝑑𝑎𝑦
LENGTH 1.77 m
THICKNESS 0.00387 m
DIAMETER 1.78 m
MASS 602.91 𝑘𝑔
AREA OF FILTERING
2.46 𝑚2
SURFACE
OPERATING DESIGN
PRESSURE
101.325 kPa 111.458 kPa
MATERIAL OF
Stainless steel (316 L)
CONSTRUCTION
EQUIPMENT FIGURE
82
CONVEYOR BELT
IDENTIFICATION
EQUIPMENT CODE CB-102
FUNCTION Transport of solution from filtration unit to mixer
NO. OF EQUIPMENT 1
MATERIAL HANDLED Hydrolysate residue
EQUIPMENT DESIGN
𝑚3
CAPACITY 20.88
𝑑𝑎𝑦
LENGTH 16.16 m
WIDTH 0.61 m
OPERATING DESIGN
TEMPERATURE
25℃ 55℃
OPERATING DESIGN
PRESSURE
101.325 kPa 111.458 kPa
MATERIAL OF
CONSTRUCTION
POWER REQUIREMENT 1.86 𝑘𝑊
WIDTH 0.61 m
m2
CONVEYING SPEED 1.52 s
EQUIPMENT FIGURE
83
MIXER
IDENTIFICATION
FUNCTION Mixing of components
NO. OF EQUIPMENT 1
MATERIAL HANDLED NaOH, ethanol, hydrolysate residue
EQUIPMENT DESIGN
𝑚3
CAPACITY 37.19
𝑑𝑎𝑦
OPERATING DESIGN
TEMPERATURE
60 ℃ 90 ℃
84
OPERATING DESIGN
PRESSURE
101.325 kPa 111.458 kPa
THICKNESS 0.0091 m
DIAMETER 2.84 m
HEIGHT 2.84 m
IMPELLER SPEED 3.36 rpm
EQUIPMENT FIGURE
PUMP
IDENTIFICATION
FUNCTION Pump mixture to reactor
NO. OF EQUIPMENT 1
EQUIPMENT DESIGN
CAPACITY 𝑚3
10.73
𝑑𝑎𝑦
TEMPERATURE OPERATING DESIGN
25℃ 55℃
DISCHARGE HEAD 380.1 m
85
POWER INPUT 17.37 kW
EQUIPMENT FIGURE
86
REACTOR
IDENTIFICATION
FUNCTION Delignification process
NO. OF EQUIPMENT 24
EQUIPMENT DESIGN
𝑚3
CAPACITY 37.14
𝑑𝑎𝑦
LENGTH 22.31 𝑚
OPERATING DESIGN
TEMPERATURE
150 ℃ 180 ℃
OPERATING DESIGN
PRESSURE
110 kPa 121 kPa
MATERIAL OF
Carbon steel
CONSTRUCTION
EQUIPMENT FIGURE
87
HEAT EXCHANGER
IDENTIFICATION
NO. OF EQUIPMENT 1
MATERIAL HANDLED Water, corn solution
EQUIPMENT DESIGN
HEAT TRANSFER W
1875 m2 −𝐾
COEFFICIENT
# OF TUBES 20 𝑡𝑢𝑏𝑒𝑠
OPERATING DESIGN
PRESSURE
101.325 kPa 111.458 kPa
MATERIAL OF
Carbon Steel
CONSTRUCTION
LENGTH 4.9 m
THICKNESS 0.0038 m
INSIDE OUTSIDE
DIAMETER
0.203 m 0.2106 m
EQUIPMENT FIGURE
88
89
STORAGE TANK
IDENTIFICATION
FUNCTION Storage
MATERIAL HANDLED Ethanol
# OF EQUIPMENT 1
EQUIPMENT DESIGN
m3
CAPACITY 0.4038 day
OPERATING DESIGN
TEMPERATURE
25℃ 55℃
OPERATING DESIGN
PRESSURE
101.325 kPa 111.458 kPa
MATERIAL OF
Titanium
CONSTRUCTION
DIAMETER 0.39 m
HEIGHT 1.17 m
THICKNESS 0.00902 m
EQUIPMENT FIGURE
90
HEAT EXCHANGER
IDENTIFICATION
NO. OF EQUIPMENT 1
MATERIAL HANDLED Water, dextrose solution
EQUIPMENT DESIGN
HEAT TRANSFER W
1875 m2 −𝐾
COEFFICIENT
# OF TUBES 26 𝑡𝑢𝑏𝑒𝑠
OPERATING DESIGN
PRESSURE
101.325 kPa 111.458 kPa
MATERIAL OF
Carbon Steel
CONSTRUCTION
LENGTH 4.9 m
THICKNESS 0.0038 m
INSIDE OUTSIDE
DIAMETER
0.203 m 0.2106 m
EQUIPMENT FIGURE
91
FILTRATION UNIT
IDENTIFICATION
FUNCTION Filter
NO. OF EQUIPMENT 1
EQUIPMENT DESIGN
𝑚3
CAPACITY 16.55
𝑑𝑎𝑦
LENGTH 1.66 m
THICKNESS 0.00386 m
DIAMETER 1.66 m
MASS OF THE TANK 360.64 𝑘𝑔
AREA OF FILTERING
2.16 𝑚2
SURFACE
OPERATING DESIGN
PRESSURE
101.325 kPa 111.458 kPa
MATERIAL OF
Stainless steel (316)
CONSTRUCTION
EQUIPMENT FIGURE
92
CONVEYOR BELT
IDENTIFICATION
FUNCTION Transport of solution from filtration unit to mixer
NO. OF EQUIPMENT 1
MATERIAL HANDLED Delignified residue
EQUIPMENT DESIGN
𝑚3
CAPACITY 20.88
𝑑𝑎𝑦
LENGTH 16.16 m
WIDTH 0.61 m
OPERATING DESIGN
TEMPERATURE
25℃ 55℃
OPERATING DESIGN
PRESSURE
101.325 kPa 111.458 kPa
MATERIAL OF
CONSTRUCTION
WIDTH 0.61 m
m2
CONVEYING SPEED 1.52
s
EQUIPMENT FIGURE
93
REACTOR
IDENTIFICATION
FUNCTION Delignification process
NO. OF EQUIPMENT 7
EQUIPMENT DESIGN
CAPACITY 𝑚3
37.14
𝑑𝑎𝑦
LENGTH 14.23 𝑚
150 ℃ 180 ℃
PRESSURE OPERATING DESIGN
110 kPa 121 kPa
MATERIAL OF Carbon steel
CONSTRUCTION
MASS OF TANK 157078.77 kg
EQUIPMENT FIGURE
94
PUMP
IDENTIFICATION
FUNCTION Pump mixture from reactor to filtration unit
NO. OF EQUIPMENT 1
EQUIPMENT DESIGN
CAPACITY 𝑚3
26.96
𝑑𝑎𝑦
25℃ 55℃
DISCHARGE HEAD 110 m
POWER INPUT 8175.24 W
EQUIPMENT FIGURE
95
FILTRATION UNIT
IDENTIFICATION
FUNCTION Filter
NO. OF EQUIPMENT 1
EQUIPMENT DESIGN
𝑚3
CAPACITY 11.06
𝑑𝑎𝑦
LENGTH 1.45 m
THICKNESS 0.00386 m
DIAMETER 1.45 m
AREA OF FILTERING
1.65 𝑚2
SURFACE
OPERATING DESIGN
PRESSURE
100 kPa 110 kPa
MATERIAL OF
Stainless steel (316 L)
CONSTRUCTION
EQUIPMENT FIGURE
96
CONVEYOR BELT
IDENTIFICATION
FUNCTION Transport of solution from filtration unit to SWMF
NO. OF EQUIPMENT 1
MATERIAL HANDLED Treated residue
EQUIPMENT DESIGN
𝑚3
CAPACITY 15.91
𝑑𝑎𝑦
LENGTH 15 m
WIDTH 0.61 m
OPERATING DESIGN
TEMPERATURE
15 ℃ 45 ℃
OPERATING DESIGN
PRESSURE
100 kPa 110 kPa
MATERIAL OF
CONSTRUCTION
EQUIPMENT FIGURE
97
HOLDING TANK
IDENTIFICATION
EQUIPMENT CODE HT-101
FUNCTION Storage
NO. OF EQUIPMENT 10
MATERIAL HANDLED Dextrose, xylose and water solution
EQUIPMENT DESIGN
𝑚3
CAPACITY 14.71
𝑑𝑎𝑦
LENGTH 12.42 m
DIAMETER 4.14 m
THICKNESS 0.004 m
MASS 5774.54 𝑘𝑔
OPERATING DESIGN
TEMPERATURE
25℃ 55℃
OPERATING DESIGN
PRESSURE
101.325 𝑘𝑃𝑎 111.458 𝑘𝑃𝑎
MATERIAL OF
Titanium
CONSTRUCTION
EQUIPMENT FIGURE
98
PUMP
IDENTIFICATION
FUNCTION Fluid transport
NO. OF EQUIPMENT 1
EQUIPMENT DESIGN
CAPACITY
OPERATING DESIGN
TEMPERATURE
15 ℃ 45 ℃
OPERATING DESIGN
PRESSURE
100 kPa 120 kPa
DISCHARGE HEAD 110 𝑚
POWER INPUT 3.352 𝑘𝑊
EQUIPMENT FIGURE
99
MIXER
IDENTIFICATION
FUNCTION Mixing of Xylose, dextrose, water, and biomass.
MATERIAL HANDLED Xylose, dextrose, water, and biomass
EQUIPMENT DESIGN
CAPACITY 40.52 m3
LENGTH 3.44 m
THICKNESS 10 mm
24oC 55oC
101.325 Kpa 111.45 Kpa
MATERIAL OF Carbon Steel
CONSTRUCTION
CORROSION ALLOWANCE 9 mm
IMPELLER SPEED 0.76 m/s
POWER REQUIREMENT 1.62 KW
EQUIPMENT FIGURE
100
FERMENTATION TANK
IDENTIFICATION
EQUIPMENT CODE BR-201
FUNCTION Supply operating condition for fermentation
NO. OF EQUIPMENT 5
MATERIAL HANDLED Xylose, Biomass, dextrose, water, inoculum, ammonia
EQUIPMENT DESIGN
CAPACITY 11 m3
LENGTH 3.44 m
THICKNESS 0.01 m
37oC 67oC
101.325 Kpa 111.45 Kpa
MATERIAL OF CONSTRUCTION Carbon steel
IMPELLER SPEED 0.308 m/s
POWER REQUIREMENT 1.62 KW
EQUIPMENT FIGURE
101
PUMP
IDENTIFICATION
FUNCTION Transfer fluid from fermentation tank to centrifuge
NO. OF EQUIPMENT 1
MATERIAL HANDLED Xylose, ammonium lactate, water, biomass
EQUIPMENT DESIGN
CAPACITY 2.06 m3
37oC 67oC
SHAFT WORK 1964.9 J/Kg
POWER INPUT 2316.77 KW
EQUIPMENT FIGURE
102
CENTRIFUGE
IDENTIFICATION
EQUIPMENT CODE CF-201
FUNCTION Remove biomass
NO. OF EQUIPMENT 1
MATERIAL HANDLED Biomass, xylose, ammonium lactate, water
EQUIPMENT DESIGN
37oC 67oC
100 Kpa 110Kpa
CAPACITY 0.36 m
MATERIAL OF Stainless steel 316 (SA-240)
CONSTRUCTION
EQUIPMENT FIGURE
103
PUMP
IDENTIFICATION
FUNCTION Transfer liquid from centrifuge to reactor
NO. OF EQUIPMENT 1
MATERIAL HANDLED Xylose, ammonium lactate, water
EQUIPMENT DESIGN
CAPACITY 0.53 m3
37oC 67oC
SHAFT WORK 1964.9 J/Kg
104
EQUIPMENT FIGURE
ESTERIFICATION REACTOR
IDENTIFICATION
EQUIPMENT CODE ER-201
FUNCTION Provide operating conditions for esterification
NO. OF EQUIPMENT 1
MATERIAL HANDLED Butanol, water, Xylose, ammonium lactate, butyl lactate,
ammonium hydroxide
EQUIPMENT DESIGN
105
CAPACITY 2.11 m3
LENGTH 1.75 m
THICKNESS 0.00918 m
MASS 2035.8 Kg
o
80 C 110oC
26.66 Kpa 29.33 Kpa
MATERIAL OF High-alloy stainless steel 304 (SA-240)
CONSTRUCTION
EQUIPMENT FIGURE
HEAT EXCHANGER
IDENTIFICATION
106
FUNCTION Cool liquid
NO. OF EQUIPMENT 1
MATERIAL HANDLED Xylose, Water, Butyl lactate
EQUIPMENT DESIGN
HEAT TRANSFER AREA 1.68 m2
FLOW RATE 708.58 kg/hr
TEMPERATURE INNER TUBE OUTER TUBE
INLET: 80OC INLET: 15 OC
O
OUTLET: 37 C OUTLET: 23 OC
CONSTRUCTION
LENGTH 4.9 m
DIAMETER 0.0254 m
EQUIPMENT FIGURE
107
EXTRACTION COLUMN
IDENTIFICATION
EQUIPMENT CODE EX-201
FUNCTION Remove Xylose
NO. OF EQUIPMENT 1
MATERIAL HANDLED Butanol, water, xylose, butyl lactate
EQUIPMENT DESIGN
CAPACITY 1.093 m3
LENGTH 2.49 m
THICKNESS 9.53 mm
37 OC 67 OC
150 Kpa 325 Kpa
MATERIAL OF Stainless steel type 316
CONSTRUCTION
EQUIPMENT FIGURE
108
PUMP
IDENTIFICATION
FUNCTION Transfer liquid from extraction column to reactor
NO. OF EQUIPMENT 1
MATERIAL HANDLED Water, butyl lactate
EQUIPMENT DESIGN
CAPACITY 0.48 m3
37 OC 67 OC
SHAFT WORK 1967.84J/Kg
POWER INPUT 651.625 W
EQUIPMENT FIGURE
109
HYDROLYSIS REACTOR
IDENTIFICATION
EQUIPMENT CODE HR-201
FUNCTION Convert butyl lactate to lactic acid
NO. OF EQUIPMENT 1
MATERIAL HANDLED Butly lactate, water, lactic acid, butanol
EQUIPMENT DESIGN
CAPACITY 2.12 m3
LENGTH 0.99 m
THICKNESS 0.0115 m
100 OC 130 OC
466.095 Kpa 512.7 Kpa
MATERIAL OF High -alloy stainless steel 304 (SA-240)
CONSTRUCTION
EQUIPMENT FIGURE
110
111
EVAPORATOR
IDENTIFICATION
EQUIPMENT CODE EC-201
FUNCTION Remove water
NO. OF EQUIPMENT 1
MATERIAL HANDLED Water, lactic acid
EQUIPMENT DESIGN
CAPACITY 21.82 m3
LENGTH 6.29 m
THICKNESS 9.67 mm
EC-201 = 89oC EC-201 = 119oC
MATERIAL OF Carbon steel 316 SA-240

CONSTRUCTION
CORROSION ALLOWANCE 9mm
EQUIPMENT FIGURE
112
PUMP
IDENTIFICATION
FUNCTION Transfer liquid in evaporator
NO. OF EQUIPMENT 1
MATERIAL HANDLED Lactic acid, water
EQUIPMENT DESIGN
CAPACITY 0.118 m3
o
37 C 67 oC
SHAFT WORK 4929.4J/Kg
EQUIPMENT FIGURE
113
HEAT EXCHANGER
IDENTIFICATION
FUNCTION 1
NO. OF EQUIPMENT Cool water
MATERIAL HANDLED water
EQUIPMENT DESIGN
HEAT TRANSFER AREA 1.54 m2
FLOW RATE 130.12 Kg/hr
TEMPERATURE INNER OUTER
O
INLET: 89 C INLET: 25OC
O
OUTLET: 37 C OUTLET: 35OC
CONSTRUCTION
LENGTH 4.9 m
DIAMETER 0.0254 m
EQUIPMENT FIGURE
114
FERMENTATION
SECTION
115
116
POLYMERIZATION
SECTION
117
118
APPENDICES
119
MATERIAL
BALANCE
120
Section 1: Pre-treatment
Balance in M-101
Components Inlet Outlet
[1] [2] [3]
Dextrose 1191.63 1191.63
Xylose 708.40 708.40
Lignin 450.34 450.34
Water 179.63 10094.70 10274.33
Sulfuric Acid 25.30 25.30
TOTAL 2530 10120 12650
Basis: 2530 kg/hr @ Stream [1]
Assumptions:
 Initial % composition: Dextrose = 47.1% , Xylose = 28% , Lignin = 17.8%
Reference: Silva et al., 2013
 % sulfuric acid used = 1
Reference: Tan et al., 2013
121
 Acid step hydro module = 4
Reference: Vila et al., 2012
𝐼𝑛𝑝𝑢𝑡 = 𝑂𝑢𝑡𝑝𝑢𝑡
𝑆𝑡𝑟𝑒𝑎𝑚 [1] + 𝑆𝑡𝑟𝑒𝑎𝑚 [2] = 𝑆𝑡𝑟𝑒𝑎𝑚[3]
𝑆𝑡𝑟𝑒𝑎𝑚 [1] = 𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 + 𝑋𝑦𝑙𝑜𝑠𝑒 + 𝐿𝑖𝑔𝑛𝑖𝑛 + 𝑊𝑎𝑡𝑒𝑟
𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [1] = 𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑐𝑜𝑚𝑝𝑜𝑠𝑖𝑡𝑖𝑜𝑛 𝑜𝑓 𝑑𝑒𝑥𝑡𝑟𝑜𝑠𝑒 𝑥 𝑡𝑜𝑡𝑎𝑙 𝑓𝑒𝑒𝑑
𝑘𝑔
𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [1] = (0.471)(2530) = 1191.63
ℎ𝑟
𝑋𝑦𝑙𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [1] = 𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑐𝑜𝑚𝑝𝑜𝑠𝑖𝑡𝑖𝑜𝑛 𝑜𝑓 𝑥𝑦𝑙𝑜𝑠𝑒 𝑥 𝑡𝑜𝑡𝑎𝑙 𝑓𝑒𝑒𝑑
𝑘𝑔
𝑋𝑦𝑙𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [1] = (0.28)(2530) = 708.40
ℎ𝑟
𝐿𝑖𝑔𝑛𝑖𝑛 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [1] = 𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑐𝑜𝑚𝑝𝑜𝑠𝑖𝑡𝑖𝑜𝑛 𝑜𝑓 𝑙𝑖𝑔𝑛𝑖𝑛 𝑥 𝑡𝑜𝑡𝑎𝑙 𝑓𝑒𝑒𝑑
𝑘𝑔
𝐿𝑖𝑔𝑛𝑖𝑛 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [1] = (0.178)(2530) = 450.34
ℎ𝑟
𝑆𝑡𝑟𝑒𝑎𝑚 [2] = 𝑊𝑎𝑡𝑒𝑟 + 𝑆𝑢𝑙𝑓𝑢𝑟𝑖𝑐 𝐴𝑐𝑖𝑑
𝑆𝑢𝑙𝑓𝑢𝑟𝑖𝑐 𝐴𝑐𝑖𝑑 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [2] = 𝑆𝑡𝑟𝑒𝑎𝑚 [1] 𝑥 1%
kg
𝑆𝑢𝑙𝑓𝑢𝑟𝑖𝑐 𝐴𝑐𝑖𝑑 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [2] = 2530 𝑥 0.01 = 25.30
hr
𝑘𝑔
𝑆𝑢𝑙𝑓𝑢𝑟𝑖𝑐 𝐴𝑐𝑖𝑑 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [2] = 25.30
ℎ𝑟
𝑊𝑎𝑡𝑒𝑟 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [2] = (𝑆𝑡𝑟𝑒𝑎𝑚 [1]𝑥 𝐴𝑐𝑖𝑑 𝑠𝑡𝑒𝑝 ℎ𝑦𝑑𝑟𝑜𝑚𝑜𝑑𝑢𝑙𝑒) − 𝑆𝑢𝑙𝑓𝑢𝑟𝑖𝑐 𝐴𝑐𝑖𝑑
𝑘𝑔 𝑘𝑔
𝑊𝑎𝑡𝑒𝑟 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [2] = (2530 ) (4) − 25.30
ℎ𝑟 ℎ𝑟
𝑘𝑔
𝑊𝑎𝑡𝑒𝑟 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [2] = 10094.70
ℎ𝑟
𝑆𝑡𝑟𝑒𝑎𝑚 [2] = 𝑊𝑎𝑡𝑒𝑟 + 𝑆𝑢𝑙𝑓𝑢𝑟𝑖𝑐 𝐴𝑐𝑖𝑑
122
𝑘𝑔 𝑘𝑔
𝑆𝑡𝑟𝑒𝑎𝑚 [2] = 10094.70 + 25.30
ℎ𝑟 ℎ𝑟
𝑘𝑔
𝑆𝑡𝑟𝑒𝑎𝑚 [2] = 10120
ℎ𝑟
𝑆𝑡𝑟𝑒𝑎𝑚 [3] = 𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 + 𝑋𝑦𝑙𝑜𝑠𝑒 + 𝐿𝑖𝑔𝑛𝑖𝑛 + 𝑊𝑎𝑡𝑒𝑟 + 𝑆𝑢𝑙𝑓𝑢𝑟𝑖𝑐 𝐴𝑐𝑖𝑑
𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [3] = 𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [1]
𝑋𝑦𝑙𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [3] = 𝑋𝑦𝑙𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [1]
𝐿𝑖𝑔𝑛𝑖𝑛 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [3] = 𝐿𝑖𝑔𝑛𝑖𝑛 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [1]
𝑆𝑢𝑙𝑓𝑢𝑟𝑖𝑐 𝐴𝑐𝑖𝑑 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [3] = 𝑆𝑢𝑙𝑓𝑢𝑟𝑖𝑐 𝐴𝑐𝑖𝑑 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [2]
𝑘𝑔
𝑊𝑎𝑡𝑒𝑟 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [3] = 10274.33
ℎ𝑟
𝑘𝑔 𝑘𝑔 𝑘𝑔 𝑘𝑔 𝑘𝑔
𝑆𝑡𝑟𝑒𝑎𝑚 [3] = 1191.63 + 708.40 + 450.34 + 10274.33 + 25.30
ℎ𝑟 ℎ𝑟 ℎ𝑟 ℎ𝑟 ℎ𝑟
𝑘𝑔
𝑆𝑡𝑟𝑒𝑎𝑚 [3] = 12650
ℎ𝑟
𝑘𝑔 𝑘𝑔 𝑘𝑔
2530 + 10120 = 12650
ℎ𝑟 ℎ𝑟 ℎ𝑟
𝑘𝑔 𝑘𝑔
12650 ≡ 12650
ℎ𝑟 ℎ𝑟
123
Balance in R-101
Reference: Danon et al., 2013
[4] [5] [11]
Dextrose 1191.63 1154.69
Xylose 708.40 670.15
Lignin 450.34 400.35
Water 10274.33 9232.55
Sulfuric Acid 25.30
Furfural 1192.26
TOTAL 12650 1192.26 11457.74
Assumptions:
 Reactor Operating Temperature = 175℃
Reference: Valekar et al.,2010
124
 % Recovery (Furfural) = 9.425%
Reference: Riera et al., 1990
 % Recoveries: Dextrose = 96.9, Xylose = 94.6, Lignin = 88.9
Reference: Cao et al., 2009
𝑆𝑡𝑟𝑒𝑎𝑚 [4] = 𝑆𝑡𝑟𝑒𝑎𝑚[5] + 𝑆𝑡𝑟𝑒𝑎𝑚 [11]
𝐼𝑛𝑙𝑒𝑡 𝑆𝑡𝑟𝑒𝑎𝑚 [4] = 𝑂𝑢𝑡𝑙𝑒𝑡 𝑆𝑡𝑟𝑒𝑎𝑚 [3]
𝑆𝑡𝑟𝑒𝑎𝑚 [4] = 𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 + 𝑋𝑦𝑙𝑜𝑠𝑒 + 𝐿𝑖𝑔𝑛𝑖𝑛 + 𝑊𝑎𝑡𝑒𝑟 + 𝑆𝑢𝑙𝑓𝑢𝑟𝑖𝑐 𝐴𝑐𝑖𝑑
𝑘𝑔 𝑘𝑔 𝑘𝑔 𝑘𝑔 𝑘𝑔
𝑆𝑡𝑟𝑒𝑎𝑚 [4] = 1191.63 + 708.40 + 450.34 + 10274.33 + 25.30
ℎ𝑟 ℎ𝑟 ℎ𝑟 ℎ𝑟 ℎ𝑟
𝑘𝑔
𝑆𝑡𝑟𝑒𝑎𝑚 [4] = 12650
ℎ𝑟
𝑆𝑡𝑟𝑒𝑎𝑚 [5] = 𝐹𝑢𝑟𝑓𝑢𝑟𝑎𝑙 = 𝑆𝑡𝑟𝑒𝑎𝑚 [4] 𝑥 % 𝑟𝑒𝑐𝑜𝑣𝑒𝑟𝑦
𝑘𝑔
𝑆𝑡𝑟𝑒𝑎𝑚 [5] = (0.09425)(12650) = 1192.26
ℎ𝑟
𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [11] = 𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [4] 𝑥 % 𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦
𝑘𝑔
𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [11] = (1191.63 ) (0.969)
ℎ𝑟
𝑘𝑔
𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [11] = 1154.69
ℎ𝑟
𝑋𝑦𝑙𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [11] = 𝑋𝑦𝑙𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [4] 𝑥 % 𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦
𝑘𝑔
𝑋𝑦𝑙𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [11] = (708.40 ) (0.946)
ℎ𝑟
𝑘𝑔
𝑋𝑦𝑙𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [11] = 670.15
ℎ𝑟
125
𝐿𝑖𝑔𝑛𝑖𝑛 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [11] = 𝐿𝑖𝑔𝑛𝑖𝑛 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [4] 𝑥 % 𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦
𝑘𝑔
𝐿𝑖𝑔𝑛𝑖𝑛 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [11] = (450.34 ) (0.889)
ℎ𝑟
𝑘𝑔
𝐿𝑖𝑔𝑛𝑖𝑛 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [11] = 400.35
ℎ𝑟
𝑊𝑎𝑡𝑒𝑟 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [11] = 9232.55
𝑘𝑔 𝑘𝑔 𝑘𝑔 𝑘𝑔
𝑆𝑡𝑟𝑒𝑎𝑚 [11] = 1154.69 + 670.15 + 400.35 + 9232.55
ℎ𝑟 ℎ𝑟 ℎ𝑟 ℎ𝑟
𝑘𝑔
𝑆𝑡𝑟𝑒𝑎𝑚 [11] = 11457.74
ℎ𝑟
12650 = 1192.26 + 11457.74
𝑘𝑔 𝑘𝑔
12650 ≡ 12650
ℎ𝑟 ℎ𝑟
126
Balance in F-101
[15] [16] [17]
Dextrose 1154.69 216.74 937.95
Xylose 670.15 134.03 536.12
Lignin 400.35 316.28 400.14
Water 9232.55 6091.88 2824.60
TOTAL 11457.74 6758.92 4698.82
Assumptions:
 % Recovery (Dextrose) = 81.23%
Reference: Aboagye et al., 2017
 % Recovery (Xylose) = 80%
Reference: Sievers et al., 2017
 % Recovery (Lignin) = 21%
𝑆𝑡𝑟𝑒𝑎𝑚 [15] = 𝑆𝑡𝑟𝑒𝑎𝑚 [16] + 𝑆𝑡𝑟𝑒𝑎𝑚 [17]
127
𝐼𝑛𝑙𝑒𝑡 𝑆𝑡𝑟𝑒𝑎𝑚 [15] = 𝑂𝑢𝑡𝑙𝑒𝑡 𝑆𝑡𝑟𝑒𝑎𝑚 [11]
𝑆𝑡𝑟𝑒𝑎𝑚 [15] = 1154.69 + 670.15 + 400.35 + 9232.55
𝑘𝑔
𝑆𝑡𝑟𝑒𝑎𝑚 [15] = 11457.74
ℎ𝑟
𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [17] = 𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [15] 𝑥 % 𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦
𝑘𝑔
𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [17] = (1154.69 ) (0.8123)
ℎ𝑟
kg
𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [17] = 937.95
hr
𝑋𝑦𝑙𝑜𝑠𝑒 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [17] = 𝑋𝑦𝑙𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [15] 𝑥 % 𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦
𝑘𝑔
𝑋𝑦𝑙𝑜𝑠𝑒 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [17] = (670.15 ) (0.80)
ℎ𝑟
kg
𝑋𝑦𝑙𝑜𝑠𝑒 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [17] = 536.12
hr
𝐿𝑖𝑔𝑛𝑖𝑛 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [17] = 𝐿𝑖𝑔𝑛𝑖𝑛 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [15] 𝑥 % 𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦
𝑘𝑔
𝐿𝑖𝑔𝑛𝑖𝑛 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [17] = (400.35 ) (0.21)
ℎ𝑟
kg
𝐿𝑖𝑔𝑛𝑖𝑛 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [17] = 400.14
hr
kg
𝑊𝑎𝑡𝑒𝑟 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [17] = 2824.60
hr
𝑆𝑡𝑟𝑒𝑎𝑚 [17] = 937.95 + 536.12 + 400.14 + 2824.60
kg
𝑆𝑡𝑟𝑒𝑎𝑚 [17] = 4698.82
hr
128
𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [16] = 𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [15] 𝑥 (1 − % 𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦)
𝑘𝑔
𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [16] = (1154.69 ) (1 − 0.8123)
ℎ𝑟
kg
hr
𝑋𝑦𝑙𝑜𝑠𝑒 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [16] = 𝑋𝑦𝑙𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [15] 𝑥 (1 − % 𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦)
𝑘𝑔
𝑋𝑦𝑙𝑜𝑠𝑒 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [16] = (670.15 ) (1 − 0.80)
ℎ𝑟
kg
hr
𝐿𝑖𝑔𝑛𝑖𝑛 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [16] = 𝐿𝑖𝑔𝑛𝑖𝑛 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [15] 𝑥 (1 − % 𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦)
𝑘𝑔
𝐿𝑖𝑔𝑛𝑖𝑛 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [16] = (400.35 ) (1 − 0.21)
ℎ𝑟
kg
hr
kg
hr
𝑘𝑔 𝑘𝑔 kg 𝑘𝑔 𝑘𝑔
𝑆𝑡𝑟𝑒𝑎𝑚 [16] = 216.74 + 134.03 + 316.28 + 6091.88
ℎ𝑟 ℎ𝑟 hr ℎ𝑟 ℎ𝑟
kg
𝑆𝑡𝑟𝑒𝑎𝑚 [16] = 6758.92
hr
11457.74 = 6758.92 + 4698.82
ℎ𝑟 ℎ𝑟 ℎ𝑟
𝑘𝑔 𝑘𝑔
11457.74 ≡ 11457.74
ℎ𝑟 ℎ𝑟
129
Balance at M-102
[17] [19] [27] [20]
Dextrose 937.95 937.95
Xylose 536.12 536.12
Lignin 400.14 400.14
Water 2824.60 4252.44 7077.05
Ethanol 21.17 3778.88 3800.05
NaOH 140.96 140.96
TOTAL 4698.82 4414.57 3778.88 12892.28
Assumptions:
 Ethanol used = 0.45%
 NaOH used = 3%
Reference: Fialho, 2015
𝑆𝑡𝑟𝑒𝑎𝑚 [17] + 𝑆𝑡𝑟𝑒𝑎𝑚[19] + 𝑆𝑡𝑟𝑒𝑎𝑚[27] = 𝑆𝑡𝑟𝑒𝑎𝑚 [20]
130
𝑆𝑡𝑟𝑒𝑎𝑚 [17] = 937.95 + 536.12 + 400.14 + 2824.60
𝑘𝑔
𝑆𝑡𝑟𝑒𝑎𝑚 [17] = 4698.82
ℎ𝑟
𝑆𝑡𝑟𝑒𝑎𝑚 [19] = 𝑊𝑎𝑡𝑒𝑟 + 𝐸𝑡ℎ𝑎𝑛𝑜𝑙 + 𝑁𝑎𝑂𝐻
𝐸𝑡ℎ𝑎𝑛𝑜𝑙 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [19] = 𝑆𝑡𝑟𝑒𝑎𝑚 [17] 𝑥 0.45%
𝑘𝑔
𝐸𝑡ℎ𝑎𝑛𝑜𝑙 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [19] = (4698.82 ) (0.45)
ℎ𝑟
kg
𝐸𝑡ℎ𝑎𝑛𝑜𝑙 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [19] = 21.17
hr
𝑁𝑎𝑂𝐻 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [19] = 𝑆𝑡𝑟𝑒𝑎𝑚 [17] 𝑥 3%
𝑘𝑔
𝑁𝑎𝑂𝐻 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [19] = (4698.82 ) (0.03)
ℎ𝑟
kg
𝑁𝑎𝑂𝐻 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [19] = 140.96
hr
kg
𝑊𝑎𝑡𝑒𝑟 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [19] = 4252.44
hr
kg kg 𝑘𝑔
Stream [19] = 21.17 + 140.96 + 4252.44
hr hr ℎ𝑟
kg
Stream [19] = 4414.57
hr
kg
hr
𝑆𝑡𝑟𝑒𝑎𝑚 [20] = 𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 + 𝑋𝑦𝑙𝑜𝑠𝑒 + 𝐿𝑖𝑔𝑛𝑖𝑛 + 𝑊𝑎𝑡𝑒𝑟 + 𝐸𝑡ℎ𝑎𝑛𝑜𝑙 + 𝑁𝑎𝑂𝐻
𝑘𝑔
ℎ𝑟
𝑘𝑔
ℎ𝑟
𝑘𝑔
ℎ𝑟
131
𝐸𝑡ℎ𝑎𝑛𝑜𝑙 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [20] = 𝐸𝑡ℎ𝑎𝑛𝑜𝑙 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [19] + 𝐸𝑡ℎ𝑎𝑛𝑜𝑙 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [27]
𝑘𝑔
𝐸𝑡ℎ𝑎𝑛𝑜𝑙 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [20] = 21.17 + 3778.88
ℎ𝑟
𝑘𝑔
ℎ𝑟
kg
𝑁𝑎𝑂𝐻 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [20] = 140.96
hr
kg
𝑊𝑎𝑡𝑒𝑟 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [20] = 7077.05
hr
𝑘𝑔 𝑘𝑔 kg kg kg kg
𝑆𝑡𝑟𝑒𝑎𝑚 [20] = 937.95 + 536.12 + 400.14 + 3800.05 + 140.96 + 7077.05
ℎ𝑟 ℎ𝑟 hr hr hr hr
kg
𝑆𝑡𝑟𝑒𝑎𝑚 [20] = 12892.28
hr
𝑆𝑡𝑟𝑒𝑎𝑚 [17] + 𝑆𝑡𝑟𝑒𝑎𝑚[19] + 𝑆𝑡𝑟𝑒𝑎𝑚[27] = 𝑆𝑡𝑟𝑒𝑎𝑚 [20]
𝑘𝑔 kg kg kg
4698.82 + 4414.57 + 3778.88 = 12892.28
ℎ𝑟 hr hr hr
𝑘𝑔 𝑘𝑔
12892.28 ≡ 12892.28
ℎ𝑟 ℎ𝑟
132
Balance in R-102
[21] [22] [30] [26]
Dextrose 937.95 740.98
Xylose 536.12 423.53
Lignin 400.14 316.11
Water 7077.05 7598.13
Ethanol 3800.05 3800.05 13.46
NaOH 140.96
TOTAL 12892.28 3800.05 9078.76 13.46
Assumptions:
 % Recovery from delignification process = 79%
Reference: Fialho, 2015
𝑆𝑡𝑟𝑒𝑎𝑚 [21] = 𝑆𝑡𝑟𝑒𝑎𝑚 [22] + 𝑆𝑡𝑟𝑒𝑎𝑚 [30] + 𝑃𝑢𝑟𝑔𝑒 (𝑆𝑡𝑟𝑒𝑎𝑚 [26])
133
𝐼𝑛𝑙𝑒𝑡 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [21] = 𝑂𝑢𝑡𝑙𝑒𝑡 𝑆𝑡𝑟𝑒𝑎𝑚 [20]
𝐼𝑛𝑙𝑒𝑡 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [21] = 𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 + 𝑋𝑦𝑙𝑜𝑠𝑒 + 𝐿𝑖𝑔𝑛𝑖𝑛 + 𝑊𝑎𝑡𝑒𝑟 + 𝐸𝑡ℎ𝑎𝑛𝑜𝑙 + 𝑁𝑎𝑂𝐻
𝑘𝑔 kg kg kg kg kg
𝑆𝑡𝑟𝑒𝑎𝑚 [21] = 937.95 + 536.12 + 400.14 + 7077.05 + 3800.05 + 140.96
ℎ𝑟 hr hr hr hr hr
kg
𝑆𝑡𝑟𝑒𝑎𝑚 [21] = 12892.28
hr
𝐸𝑡ℎ𝑎𝑛𝑜𝑙 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [22] = 𝐸𝑡ℎ𝑎𝑛𝑜𝑙 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [21]
kg
hr
Dextrose @ Stream [30] = Dextrose @ Stream [21] 𝑥 79%
kg
Dextrose @ Stream [30] = (937.95 ) (0.79)
hr
kg
Dextrose @ Stream [30] = 740.98
hr
Xylose @ Stream [30] = Xylose @ Stream [21] 𝑥 79%
kg
Xylose @ Stream [30] = (536.12 ) (0.79)
hr
kg
Xylose @ Stream [30] = 423.53
hr
Lignin @ Stream [30] = Lignin @ Stream [21] 𝑥 79%
kg
Lignin @ Stream [30] = (400.14 ) (0.79)
hr
kg
Lignin @ Stream [30] = 316.11
hr
kg
Water @ Stream [30] = 7598.13
hr
𝑆𝑡𝑟𝑒𝑎𝑚 [30] = Dextrose + Xylose + Lignin + Water
kg kg kg kg
𝑆𝑡𝑟𝑒𝑎𝑚 [30] = 740.98 + 423.53 + 316.11 + 7598.13
hr hr hr hr
134
kg
𝑆𝑡𝑟𝑒𝑎𝑚 [30] = 9078.76
hr
𝑃𝑢𝑟𝑔𝑒 = 𝐸𝑡ℎ𝑎𝑛𝑜𝑙 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [21] − 𝐸𝑡ℎ𝑎𝑛𝑜𝑙 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [27]
𝑘𝑔 kg
𝑃𝑢𝑟𝑔𝑒 = 3800.05 − 3778.88
ℎ𝑟 hr
kg
𝑃𝑢𝑟𝑔𝑒 = 13.46
hr
𝑆𝑡𝑟𝑒𝑎𝑚 [21] = 𝑆𝑡𝑟𝑒𝑎𝑚 [22] + 𝑆𝑡𝑟𝑒𝑎𝑚 [30] + 𝑃𝑢𝑟𝑔𝑒 (𝑆𝑡𝑟𝑒𝑎𝑚 [26])
kg kg kg kg
12892.28 = 3800.05 + 9078.76 + 13.46
hr hr hr hr
𝑘𝑔 𝑘𝑔
12892.28 ≡ 12892.28
ℎ𝑟 ℎ𝑟
135
Balance in F-102
[33] [34] [35]
Dextrose 740.98 139.08 601.90
Xylose 423.53 84.71 338.83
Lignin 316.11 249.73 66.38
Water 7598.13 4882.04 2716.09
TOTAL 9078.76 5355.56 3723.20
Assumptions:
 % Recovery (Lignin) = 21%
 Reference: Sievers et al., 2017
𝐼𝑛𝑙𝑒𝑡 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [33] = 𝑂𝑢𝑡𝑙𝑒𝑡 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [30]
136
𝑘𝑔 kg kg kg
𝑆𝑡𝑟𝑒𝑎𝑚 [33] = 740.98 + 423.53 + 316.11 + 7598.13
ℎ𝑟 hr hr hr
kg
𝑆𝑡𝑟𝑒𝑎𝑚 [33] = 9078.76
hr
kg
hr
kg
hr
kg
𝑋𝑦𝑙𝑜𝑠𝑒 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [35] = (423.53 ) (0.80)
hr
kg
hr
𝐿𝑖𝑔𝑛𝑖𝑛 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [35] = 𝐿𝑖𝑔𝑛𝑖𝑛 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [33] 𝑥 % 𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦
𝑘𝑔
𝐿𝑖𝑔𝑛𝑖𝑛 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [35] = (316.11 ) (0.21)
ℎ𝑟
kg
hr
kg
hr
𝑆𝑡𝑟𝑒𝑎𝑚 [35] = 601.90 + 338.83 + 66.38 + 2716.09
kg
𝑆𝑡𝑟𝑒𝑎𝑚 [35] = 3723.20
hr
137
kg
hr
kg
hr
kg
𝑋𝑦𝑙𝑜𝑠𝑒 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [34] = (423.53 ) (1 − 0.80)
hr
kg
hr
𝑘𝑔
𝐿𝑖𝑔𝑛𝑖𝑛 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [34] = (316.11 ) (1 − 0.21)
ℎ𝑟
kg
hr
kg
hr
𝑆𝑡𝑟𝑒𝑎𝑚 [34] = 139.08 + 84.71 + 249.73 + 4882.04
kg
𝑆𝑡𝑟𝑒𝑎𝑚 [34] = 5355.56
hr
𝑘𝑔 kg 𝑘𝑔
9078.76 = 5355.56 + 3723.20
ℎ𝑟 hr ℎ𝑟
𝑘𝑔 𝑘𝑔
9078.76 ≡ 9078.76
ℎ𝑟 ℎ𝑟
138
Balance in R-103
[35] [36] [37]
Dextrose 601.90 541.71
Xylose 338.83 304.94
Lignin 66.38 59.75
Water 2716.09 2343.77 5160.57
TOTAL 3723.20 2343.77 6066.97
Assumptions:
 30 FPU cellulose/g in 48 hours
 90% enzymatic cellulose conversion
Reference: Berson et al., 2009
𝑆𝑡𝑟𝑒𝑎𝑚 [35] + 𝑆𝑡𝑟𝑒𝑎𝑚 [36] = 𝑆𝑡𝑟𝑒𝑎𝑚 [37]
kg kg kg kg
𝑆𝑡𝑟𝑒𝑎𝑚 [35] = 601.90 + 338.83 + 66.38 + 2716.09
hr hr hr hr
139
kg
𝑆𝑡𝑟𝑒𝑎𝑚 [35] = 3723.20
hr
kg
𝑊𝑎𝑡𝑒𝑟 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [36] = 2343.77
hr
𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [37] = 𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [35] 𝑥 % 𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦
kg
𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [37] = (601.90 ) (0.90)
hr
kg
hr
𝑋𝑦𝑙𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [37] = 𝑋𝑦𝑙𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [35] 𝑥 % 𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦
kg
𝑋𝑦𝑙𝑜𝑠𝑒 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [37] = (338.83 ) (0.90)
hr
kg
hr
𝐿𝑖𝑔𝑛𝑖𝑛 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [37] = 𝐿𝑖𝑔𝑛𝑖𝑛 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [35] 𝑥 % 𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦
kg
𝐿𝑖𝑔𝑛𝑖𝑛 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [37] = (66.38 ) (0.90)
hr
kg
hr
kg
𝑊𝑎𝑡𝑒𝑟 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [37] = 5160.57
hr
kg
𝑆𝑡𝑟𝑒𝑎𝑚 [37] = 6066.97
hr
𝑆𝑡𝑟𝑒𝑎𝑚 [35] + 𝑆𝑡𝑟𝑒𝑎𝑚 [36] = 𝑆𝑡𝑟𝑒𝑎𝑚 [37]
kg kg kg
3723.20 + 2343.77 = 6066.97
hr hr hr
140
kg kg
6066.97 ≡ 6066.97
hr hr
Balance in F-103
[38] [39] [40]
Dextrose 541.71 101.68 440.03
Xylose 304.94 60.99 243.95
Lignin 59.75 47.20
Water 5160.57 3369.04 1804.08
TOTAL 6066.97 3578.91 2488.06
Assumptions:
 All lignin were consumed.
141
𝐼𝑛𝑙𝑒𝑡 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [38] = 𝑂𝑢𝑡𝑙𝑒𝑡 @ 𝑆𝑡𝑟𝑒𝑎𝑚 [37]
𝑘𝑔 kg kg kg
𝑆𝑡𝑟𝑒𝑎𝑚 [38] = 541.71 + 304.94 + 59.75 + 5160.57
ℎ𝑟 hr hr hr
kg
𝑆𝑡𝑟𝑒𝑎𝑚 [38] = 6066.97
hr
𝑆𝑡𝑟𝑒𝑎𝑚 [40] = 𝐷𝑒𝑥𝑡𝑟𝑜𝑠𝑒 + 𝑋𝑦𝑙𝑜𝑠𝑒 + 𝑊𝑎𝑡𝑒𝑟
𝑘𝑔
ℎ𝑟
kg
hr
𝑘𝑔
𝑋𝑦𝑙𝑜𝑠𝑒 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [40] = (304.94 ) (0.8123)
ℎ𝑟
kg
hr
kg
hr
kg kg kg
𝑆𝑡𝑟𝑒𝑎𝑚 [40] = 440.03 + 243.95 + 1804.08
hr hr hr
kg
𝑆𝑡𝑟𝑒𝑎𝑚 [40] = 2488.06
hr
kg
hr
kg
hr
142
kg
𝑋𝑦𝑙𝑜𝑠𝑒 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [39] = (304.94 ) (1 − 0.80)
hr
kg
hr
𝑘𝑔
𝐿𝑖𝑔𝑛𝑖𝑛 𝑖𝑛 𝑆𝑡𝑟𝑒𝑎𝑚 [39] = (59.75 ) (1 − 0.21)
ℎ𝑟
kg
hr
kg
hr
𝑆𝑡𝑟𝑒𝑎𝑚 [39] = 101.68 + 60.99 + 47.20 + 3369.04
kg
𝑆𝑡𝑟𝑒𝑎𝑚 [39] = 3578.91
hr
kg kg 𝑘𝑔
6066.97 = 3578.91 + 2488.06
hr hr ℎ𝑟
kg kg
6066.97 ≡ 6066.97
hr hr
143
Balance at HT-101
[40] [41]
Dextrose 440.03 440.03
Xylose 243.95 243.95
Water 1804.08 1804.08
TOTAL 2488.06 2488.06
Assumption: No losses
𝑆𝑡𝑟𝑒𝑎𝑚 [40] = 𝑆𝑡𝑟𝑒𝑎𝑚 [41]
kg kg kg
𝑆𝑡𝑟𝑒𝑎𝑚 [40] = 440.03 + 243.95 + 1804.08
hr hr hr
𝑘𝑔
𝑆𝑡𝑟𝑒𝑎𝑚 [40] = 2488.06
ℎ𝑟
kg kg kg
𝑆𝑡𝑟𝑒𝑎𝑚 [41] = 440.03 + 243.95 + 1804.08
hr hr hr
𝑘𝑔
𝑆𝑡𝑟𝑒𝑎𝑚 [41] = 2488.06
ℎ𝑟
𝑘𝑔 𝑘𝑔
2488.06 ≡ 2488.06
ℎ𝑟 ℎ𝑟
144
Section 2: Fermentation Process
MIXER (M-201)
ST-201
Biomass
[44]
M-201
[43]
[45]
[43] [44] [45]
Dextrose 440.03 - 440.03
Xylose 243.95 - 243.95
Water 1804.08 7598.13
Biomass - 870.82 870.82
TOTAL 2488.06 870.82 3358.88
𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 = 𝑀𝑎𝑠𝑠 𝐼𝑁
𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 = ∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠 𝑖𝑛 [45] + ∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠 [46]
∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑖𝑛 [45] = 𝑀𝑎𝑠𝑠 𝐶6 𝐻12 𝑂6 + 𝑀𝑎𝑠𝑠 𝐶5 𝐻10 𝑂5 + 𝑀𝑎𝑠𝑠 𝐻2 𝑂
∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑖𝑛 [45] = 440.03 𝐾𝑔 + 243.95 𝐾𝑔 + 1804.08 𝐾𝑔
145
∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑖𝑛 [45] = 𝟐𝟒𝟖𝟖. 𝟎𝟔 𝑲𝒈
∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑖𝑛 [46] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠
∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑖𝑛 [46] = 𝟖𝟕𝟎. 𝟖𝟐 𝑲𝒈
𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 = 𝑀𝑎𝑠𝑠 𝑠𝑡𝑟𝑒𝑎𝑚 [47]
𝑀𝑎𝑠𝑠 𝑠𝑡𝑟𝑒𝑎𝑚 [47] = 2488.06 𝐾𝑔 + 870.82 𝐾𝑔
𝑀𝑎𝑠𝑠 𝑠𝑡𝑟𝑒𝑎𝑚 [47] = 𝟑𝟑𝟓𝟖. 𝟖𝟖 𝑲𝒈
146
FERMENTATION (BR-201)
ST-202
Ammonia
[46]
BR-201
[45] [48]
[47]
[45] [46] [47] [48]
Dextrose 440.03 - - -
Xylose 243.95 - - 243.95
Water 1804.07 - - 205.61
Biomass 870.82 - - 1016.91
Ammonia - 90.55 - -
Ammonium Lactate - - - 231.39
147
CO2 - - 84.65 -
TOTAL 3358.88 90.55 84.65 1697.87
Assumptions:
 100 % conversion of Dextrose.
 All carbon Dioxide are released.
 All Inoculum are consumed.
 All Ammonia are consumed.
 No fermentation of Xylose involved.
References :
 Ammonium lactate production by Lactobacillus lactis BME5-18M in pH-controlled fed-

batch fermentations (DongMei, et.al, 2003)
 1000 TPD Production Of PLA (Polylactic Acid) by Abbas et al.  
Overall Reaction:
1.13 𝐶6 𝐻12 𝑂6 + 0.93 𝑂2 + 1.46 𝑁𝐻3 + 𝑁𝐻4 𝑂𝐻
→ 2.92 𝐶𝐻1.75 𝑂0.15 𝑁0.15 + 0.89 𝐶𝑂2 + 4.45 𝐻2 𝑂 + 𝑁𝐻4 𝐶3 𝐻5 𝑂3
𝑁𝐻4 𝐶3 𝐻5 𝑂3 / H2O = 0.2247
𝑁𝐻4 𝐶3 𝐻5 𝑂3/ CO2 = 1.1236
𝑁𝐻4 𝐶3 𝐻5 𝑂3/Biomass = 0.3425
𝑁𝐻4 𝐶3 𝐻5 𝑂3/ 𝑁𝐻4 𝑂𝐻 = 0.6849
148
𝑁𝐻4 𝐶3 𝐻5 𝑂3/ NH3 = 0.6849
𝑁𝐻4 𝐶3 𝐻5 𝑂3/ O2 = 1.0753
𝑁𝐻4 𝐶3 𝐻5 𝑂3 / 𝐶6 𝐻12 𝑂6 = 0.8849
Molecular Weight:
𝑁𝐻4 𝐶3 𝐻5 𝑂3 = 107. 06 Kg / Kmol
𝐶𝑂2 = 44.01 Kg / Kmol
Biomass = 23.15 Kg / Kmol
𝑁𝐻4 𝑂𝐻= 35.04 Kg / Kmol
𝑁𝐻3 = 17.03 Kg / Kmol
𝑂2 = 31.998 Kg / Kmol
𝐶6 𝐻12 𝑂6 = 180.156 Kg / Kmol
𝐻2 𝑂 = 18.01 Kg / Kmol
𝑚𝑎𝑠𝑠 𝑜𝑓 𝐶6 𝐻12 𝑂6 𝑁𝐻4 𝐶3 𝐻5 𝑂3 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡

𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 = ×
𝑚𝑜𝑙𝑎𝑟 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐶6 𝐻12 𝑂6 𝐶6 𝐻12 𝑂6 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡
440.03 𝐾𝑔 0.8849
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 = ×
𝐾𝑔 1
180. 156
𝐾𝑚𝑜𝑙
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 = 𝟐. 𝟏𝟔 𝑲𝒎𝒐𝒍𝒆𝒔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 = 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 × 𝑚𝑜𝑙𝑎𝑟 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3
149
𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 = 2.16 𝐾𝑚𝑜𝑙𝑒𝑠 × 107.06
𝐾𝑚𝑜𝑙
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 = 𝟐𝟑𝟏. 𝟑𝟗 𝑲𝒈
𝐵𝑖𝑜𝑚𝑎𝑠𝑠 𝑐𝑜𝑒𝑓𝑓𝑖𝑒𝑛𝑡
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 = 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 ×
𝑁𝐻4 𝐶3 𝐻5 𝑂3 𝑐𝑜𝑒𝑓𝑓𝑖𝑒𝑛𝑡
1
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 = 2.16 𝐾𝑚𝑜𝑙𝑒𝑠 ×
0.3425
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 = 𝟔. 𝟑 𝑲𝒎𝒐𝒍𝒆𝒔
𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 = 𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 + 𝐹𝑜𝑟𝑚𝑒𝑑 𝐵𝑖𝑜𝑚𝑎𝑠𝑠
𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 = 37.61 𝐾𝑚𝑜𝑙𝑒𝑠 + 6.3 𝐾𝑚𝑜𝑙𝑒𝑠
𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 = 𝟒𝟑. 𝟗𝟏𝑲𝒎𝒐𝒍𝒆𝒔
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 + 𝑀𝑜𝑙𝑎𝑟 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠
𝐾𝑔
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 = 43. 91 𝑘𝑚𝑜𝑙𝑒𝑠 × 23.15
𝐾𝑚𝑜𝑙𝑒𝑠
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 = 𝟏𝟎𝟏𝟔. 𝟗𝟏 𝑲𝒈 𝒐𝒇 𝑩𝒊𝒐𝒎𝒂𝒔𝒔
𝐻2 𝑂 𝑐𝑜𝑒𝑓𝑓𝑖𝑒𝑛𝑡
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 ×
1
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 = 2.16 𝐾𝑚𝑜𝑙𝑒𝑠 ×
0.2247
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 = 𝟗. 𝟔𝟏 𝑲𝒎𝒐𝒍𝒆𝒔
𝑁𝐻3 𝑐𝑜𝑒𝑓𝑓𝑖𝑒𝑛𝑡
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻3 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 ×
150
1
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻3 = 2.16 𝐾𝑚𝑜𝑙𝑒𝑠 ×
0.6849
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻3 = 𝟑. 𝟏𝟓 𝑲𝒎𝒐𝒍𝒆𝒔
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻 = 𝑀𝑜𝑙𝑒𝑠 𝑁𝐻4 𝐶3 𝐻5 𝑂3 = 2.16 𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑜𝑙𝑒 𝑜𝑓 𝑁𝐻3 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻 = 2.16 𝐾𝑚𝑜𝑙𝑒𝑠
𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻3 = 2.16 𝐾𝑚𝑜𝑙𝑒𝑠 + 3.15 𝐾𝑚𝑜𝑙𝑒𝑠
𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻3 = 𝟓. 𝟑𝟏 𝑲𝒎𝒐𝒍𝒆𝒔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻3 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻3 × 𝑀𝑜𝑙𝑎𝑟 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻3
𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻3 = 5.31 𝐾𝑚𝑜𝑙𝑒𝑠 × 17.03
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑵𝑯𝟑 = 𝟗𝟎. 𝟓𝟓 𝑲𝒈
𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑓𝑜𝑟𝑚𝑒𝑑 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑓𝑜𝑟𝑚𝑒𝑑 − 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑
𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑓𝑜𝑟𝑚𝑒𝑑 = 9. 61 𝐾𝑚𝑜𝑙𝑒𝑠 − 2.16 𝐾𝑚𝑜𝑙𝑒𝑠
𝑇𝑜𝑡𝑎𝑙 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑓𝑜𝑟𝑚𝑒𝑑 = 𝟕. 𝟒𝟓 𝑲𝒎𝒐𝒍𝒆𝒔
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝑓𝑜𝑟𝑚𝑒𝑑 = 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 × 𝑚𝑜𝑙𝑎𝑟 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂
𝐾𝑔
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝑓𝑜𝑟𝑚𝑒𝑑 = 7.45 × 18.01
𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝑓𝑜𝑟𝑚𝑒𝑑 = 𝟏𝟑𝟒. 𝟏𝟕 𝑲𝒈
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝐼𝑁 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝑓𝑜𝑟𝑚𝑒𝑑
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 = 1804. 07 𝐾𝑔 + 134.17 𝐾𝑔
151
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 = 𝟏𝟗𝟑𝟖. 𝟑𝟖 𝑲𝒈
𝐶𝑂2 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶𝑂2 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 ×
𝑁𝐻4 𝐶3 𝐻5 𝑂3 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡
1
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶𝑂2 = 2.16 𝐾𝑚𝑜𝑙𝑒𝑠 ×
1.1236
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶𝑂2 = 𝟏. 𝟗𝟐 𝑲𝒎𝒐𝒍𝒆𝒔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑂2 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶𝑂2 × 𝑀𝑜𝑙𝑎𝑟 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐶𝑂2
𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑂2 = 1.92 𝐾𝑚𝑜𝑙𝑒𝑠 × 44.01
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑂2 = 𝟖𝟒. 𝟔𝟓 𝑲𝒈
𝑂2 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡
𝑀𝑜𝑙𝑒 𝑜𝑓 𝑂2 = 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3 ×
𝑁𝐻4 𝐶3 𝐻5 𝑂3 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡
1
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓𝑂2 = 2.16 𝐾𝑚𝑜𝑙𝑒𝑠 ×
1.0753
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑂2 = 𝟐 𝑲𝒎𝒐𝒍𝒆𝒔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑂2 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑂2 × 𝑀𝑜𝑙𝑎𝑟 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑂2
𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑂2 = 2 𝐾𝑚𝑜𝑙𝑒𝑠 + 32
𝐾𝑚𝑜𝑙𝑒
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑂2 = 𝟔𝟒 𝑲𝒈
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [47] = ∑ 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠
152
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [47]
= 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶6 𝐻12 𝑂6 + 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠
+ 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶5 𝐻10 𝑂5
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [47] = 440.03 𝐾𝑔 + 243.95 𝐾𝑔 + 1804.07 𝐾𝑔 + 870.82 𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [47] =3358.88 Kg
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [48] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻3
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [48] = 𝟗𝟎. 𝟓𝟓 𝑲𝒈
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [50] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑂2
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [50] = 𝟖𝟒. 𝟔𝟓 𝑲𝒈
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [49]
= 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶5 𝐻10 𝑂5 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐵𝑖𝑜𝑚𝑎𝑠𝑠
+ 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑪𝟓 𝑯𝟏𝟎 𝑶𝟓
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [49] = 243.95 𝐾𝑔 + 1938.38 𝐾𝑔 + 1016.91 𝐾𝑔 + 231.39 𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [49] = 𝟑𝟒𝟑𝟎. 𝟔𝟓 𝑲𝒈
CENTRIFUGE (CF-201)
153
CF-201
[49] [51]
[50]
Wastewater
Treatment
Facility
[49] [50] [51]
Water 1938.38 96.91 1841.46
Biomass 1016.91 1016.91 -
Ammonium Lactate 231.39 11.56 219.82
Xylose 243.95 12.19 231.75
TOTAL 3430.65 1137.59 2293.05
Assumptions:
 All Biomass is removed.
 Assume 5% losses
𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 = 𝑀𝑎𝑠𝑠𝑠 𝐼𝑁
𝑀𝑎𝑠𝑠 𝑠𝑡𝑟𝑒𝑎𝑚 [53] = 𝑀𝑎𝑠𝑠 𝑡𝑟𝑒𝑎𝑚 [52] + 𝑀𝑎𝑠𝑠 𝑠𝑡𝑟𝑒𝑎𝑚 [50]
𝑀𝑎𝑠𝑠 𝑠𝑡𝑟𝑒𝑎𝑚 [50] = ∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠 𝐼𝑁
154
𝑀𝑎𝑠𝑠 𝑠𝑡𝑟𝑒𝑎𝑚 [50] = 𝑀𝑎𝑠𝑠 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 + 𝑀𝑎𝑠𝑠 𝑁𝐻4 𝐶3 𝐻5 𝑂3 + 𝑀𝑎𝑠𝑠 𝑪𝟓 𝑯𝟏𝟎 𝑶𝟓
𝑀𝑎𝑠𝑠 𝑠𝑡𝑟𝑒𝑎𝑚 [50] = 2423.95 𝐾𝑔 + 1938.38 𝐾𝑔 + 1016.91 𝐾𝑔 + 231.39 𝐾𝑔
𝑀𝑎𝑠𝑠 𝑠𝑡𝑒𝑒𝑎𝑚 [50] = 𝟑𝟒𝟑𝟎. 𝟔𝟓 𝑲𝒈
𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 𝑠𝑡𝑟𝑒𝑎𝑚 [52] = ∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠 𝑜𝑓 𝑠𝑡𝑟𝑒𝑎𝑚 [52]
𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 𝑠𝑡𝑟𝑒𝑎𝑚 [52]
= 𝑀𝑎𝑠𝑠 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝐵𝑖𝑜𝑚𝑎𝑠𝑠 + 𝑀𝑎𝑠𝑠 𝑁𝐻4 𝐶3 𝐻5 𝑂3 + 𝑀𝑎𝑠𝑠 𝑪𝟓 𝑯𝟏𝟎 𝑶𝟓
𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 𝑠𝑡𝑟𝑒𝑎𝑚 [52] = 12.19 Kg + 96.91 Kg + 1016.91 Kg+ 11.56 Kg
𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 𝑠𝑡𝑟𝑒𝑎𝑚 [52] = 𝟏𝟏𝟑𝟕. 𝟓𝟗 𝑲𝒈
𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 𝑠𝑡𝑟𝑒𝑎𝑚 [53] = ∑ 𝑀𝑎𝑠𝑠 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠 𝑜𝑓 𝑠𝑡𝑟𝑒𝑎𝑚 [53]
𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 𝑠𝑡𝑟𝑒𝑎𝑚 [53] = 𝑀𝑎𝑠𝑠 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝑁𝐻4 𝐶3 𝐻5 𝑂3 + 𝑀𝑎𝑠𝑠 𝑪𝟓 𝑯𝟏𝟎 𝑶𝟓
𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 𝑠𝑡𝑟𝑒𝑎𝑚 [53] = 231.75 𝐾𝑔 + 1841.46 𝐾𝑔 + 219.82 𝐾𝑔
𝑀𝑎𝑠𝑠 𝑂𝑈𝑇 𝑠𝑡𝑟𝑒𝑎𝑚 [53] = 𝟐𝟐𝟗𝟑. 𝟎𝟓 𝑲𝒈
155
ESTERIFICATION (ER-201)
ST-203
Butanol
[53]
ER-201
[52] [55]
[54]
Wastewater
Treatment
Facility
[52] [53] [54] [55]

Water 1841.46 - - 1822.97
Xylose 231.75 - - 231.75
Ammonium 219.82 - - -
Lactate
Butyl Lactate - - - 299.98
Butanol - 249.15 49.83 -
Ammonium - - 71.94 -
Hydroxide
TOTAL 2293.05 249.15 121.77 2354.72
Assumptions:
 All Ammonium Lactate is converted to Butyl Lactate
 Excess Butanol is fed to the reactor
156
 Water and Xylose are inert
References:
 Extraction and purification of lactic acid from fermentation broth by esterification and
hydrolysis method (Sakata, et al., 2006)
Reaction:
𝐶3 𝐻9 𝑂3 𝑁 + 𝐶4 𝐻10 𝑂 → 𝐶7 𝐻14 𝑂3 + 𝐻2 𝑂 + 𝑁𝐻3
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶3 𝐻9 𝑂3 𝑁
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶3 𝐻9 𝑂3 𝑁
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶3 𝐻9 𝑂3 𝑁 =
𝑀𝑜𝑙𝑎𝑟 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶3 𝐻9 𝑂3 𝑁
1 𝐾𝑚𝑜𝑙𝑒
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶3 𝐻9 𝑂3 𝑁 = 299.98 𝐾𝑔 ×
107.06 𝐾𝑔
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶3 𝐻9 𝑂3 𝑁 = 2.02 𝐾𝑚𝑜𝑙𝑒s
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 × 𝑀𝑜𝑙𝑎𝑟 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3
𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠 × 146.1
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 = 𝟐𝟗𝟗. 𝟗𝟖 𝑲𝒈
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝑂𝑈𝑇 = 𝑀𝑜𝑙𝑒𝑠 𝐶4 𝐻10 𝑂 𝐼𝑁 − 𝑀𝑜𝑙𝑒𝑠 𝐶4 𝐻10 𝑂 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 𝐺𝑒𝑛𝑒𝑟𝑎𝑡𝑒𝑑
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠
157
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑏𝑢𝑡𝑎𝑛𝑜𝑙 𝑛𝑒𝑒𝑑𝑒𝑑 ∗ 1.2
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝐼𝑁 =
𝑀𝑜𝑙𝑎𝑟 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐵𝑢𝑡𝑎𝑛𝑜𝑙
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 = 249.15 𝐾𝑔 ×
74.1 𝐾𝑔
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝐼𝑁 = 3.36 𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝑂𝑈𝑇 = 3.36 𝐾𝑚𝑜𝑙𝑒𝑠 × 0.2
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝑂𝑈𝑇 = 0.2 𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝑂𝑈𝑇 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝑂𝑈𝑇 × 𝑀𝑜𝑙𝑎𝑟 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂
𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝑂𝑈𝑇 = 0.67 𝐾𝑚𝑜𝑙𝑒𝑠 × 74.1
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝑂𝑈𝑇 = 𝟒𝟗. 𝟖𝟑 𝑲𝒈
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻3 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝐶3 𝐻5 𝑂3
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻3 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻 𝑂𝑈𝑇 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻3
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻 × 𝑀𝑜𝑙𝑒𝑐𝑢𝑙𝑎𝑟 𝑤𝑒𝑖𝑔ℎ𝑡 𝑁𝐻4 𝑂𝐻
𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠 × 35.04
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻 = 𝟕𝟏. 𝟗𝟒 𝑲𝒈
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐼𝑁 − 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑
158
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐼𝑁 = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝐼𝑁 × 𝑀𝑜𝑙𝑎𝑟 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐼𝑁 = 1841.46 𝐾𝑔 ×
18.01 𝐾𝑔
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐼𝑁 = 102. 24 𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻 ×
𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻
1𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠 ×
2 𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 = 1.01 𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 = 102.24 𝐾𝑚𝑜𝑙𝑒𝑠 − 1.01 𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑂𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 = 101. 22 𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 × 𝑀𝑜𝑙𝑎𝑟 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂
𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 = 101.22 𝐾𝑚𝑜𝑙𝑒𝑠 × 18.01
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 = 𝟏𝟖𝟐𝟐. 𝟗𝟕 𝑲𝒈
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [54] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶3 𝐻9 𝑂3 𝑁 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑪𝟓 𝑯𝟏𝟎 𝑶𝟓
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [54] = 231.75 𝐾𝑔 + 1841.46 𝐾𝑔 + 219.82 𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [54] = 𝟐𝟐𝟗𝟑. 𝟎𝟓 𝑲𝒈
159
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [55] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [55] = 𝟐𝟒𝟗. 𝟏𝟓 𝑲𝒈
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [56] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑁𝐻4 𝑂𝐻
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [56] = 49.83 𝐾𝑔 + 71.94 𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [56] = 𝟏𝟐𝟏. 𝟕𝟕 𝑲𝒈
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [57] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑪𝟓 𝑯𝟏𝟎 𝑶𝟓
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [57] = 231.75 𝐾𝑔 + 1822.97 𝐾𝑔 + 299.98 𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [57] = 𝟐𝟑𝟓𝟒. 𝟕𝟐 𝑲𝒈
Extraction Column (EX-201)
160
ST-203
Butanol
[59]
[58]
EX-201
[60]
Wastewater [61]
Treatment
Facility

[58] [59] [60] [61]
Water 1822.97 - - 1822.97
Xylose 231.75 - 231.75 -
Butyl Lactate 299.98 - - 299.98
Butanol - 695.27 695.27 -
TOTAL 2354.72 695.27 927.02 2122.96
Assumptions:
 No Butyl lactate is lost in the operation
 Excess Butanol is fed.
 All Xylose in the mixture are removed
References:
 1000 TPD Production Of PLA (Polylactic Acid) by Abbas et al.  
161
𝑀𝑎𝑠𝑠 𝐼𝑁 = 𝑀𝑎𝑠𝑠 𝑂𝑈𝑇
𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [57] = ∑ 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠
𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [57] = 𝑀𝑎𝑠𝑠 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝐶5 𝐻10 𝑂5 + 𝑀𝑎𝑠𝑠 𝐶7 𝐻14 𝑂3
𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [57] = 231.75 𝐾𝑔 + 1822.97 𝐾𝑔 + 299.98 𝐾𝑔
𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [57] = 𝟐𝟑𝟓𝟒. 𝟕𝟐 𝑲𝒈
𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [58] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂
𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [58] = 𝟔𝟗𝟓. 𝟐𝟕 𝑲𝒈
𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [59] = ∑ 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠
𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [59] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶5 𝐻10 𝑂5
𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [59] = 231.75 𝐾𝑔 + 695.27 𝐾𝑔
𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [59] = 𝟗𝟐𝟕. 𝟎𝟐 𝑲𝒈
𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [60] = ∑ 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠
𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [60] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶5 𝐻10 𝑂5
𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [60] = 1822.97 𝐾𝑔 + 299.98 𝐾𝑔
𝑀𝑎𝑠𝑠 𝑆𝑡𝑟𝑒𝑎𝑚 [60] = 𝟐𝟏𝟐𝟐. 𝟗𝟔 𝑲𝒈
162
Hydrolysis (HR-201)
[62]
[64] HR-201
[63]
Butanol
Storage Tank
Component Inlet Outlet

[62] [63] [64]
Water 1822.97 - 1785.99
Butyl Lactate 299.98 - -
Lactic Acid - - 184.96
Butanol - 152.14 -
TOTAL 2122.96 152.14 1970.96
Assumptions:
 All butanol formed is released
 All Butyl Lactate is consumed to form Lactic Acid
163
 All catalyst is recycled after the process
References:
 Extraction and purification of lactic acid from fermentation broth by esterification and
hydrolysis method (Sakata, et al., 2006)
Reaction:
𝐶7 𝐻14 𝑂3 + 𝐻2 𝑂 → 𝐶3 𝐻6 𝑂3 + 𝐶4 𝐻10 𝑂
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑 =
𝑚𝑜𝑙𝑎𝑟 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3
299.98 𝐾𝑔
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 =
𝐾𝑔
146.1
𝑀𝑂𝑙𝑒𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶3 𝐻6 𝑂3 𝑓𝑜𝑟𝑚𝑒𝑑 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3 𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶3 𝐻6 𝑂3 𝑓𝑜𝑟𝑚𝑒𝑑 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶3 𝐻6 𝑂3 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶3 𝐻6 𝑂3 × 𝑚𝑜𝑙𝑎𝑟 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐶3 𝐻6 𝑂3
𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶3 𝐻6 𝑂3 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠 × 90.08
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶3 𝐻6 𝑂3 = 𝟏𝟖𝟒. 𝟗𝟔 𝑲𝒈
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐼𝑁 − 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝐼𝑁
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐼𝑁 =
𝑀𝑜𝑙𝑎𝑟 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂
164
1822.97 𝐾𝑔
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐼𝑁 =
𝐾𝑔
18.01
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝐼𝑁 = 101.21 𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐿𝑎𝑐𝑡𝑖𝑐 𝑎𝑐𝑖𝑑 𝑓𝑜𝑟𝑚𝑒𝑑
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 = 101. 21 𝐾𝑚𝑜𝑙𝑒𝑠 − 2.02 𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 = 99.16 𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 × 𝑀𝑜𝑙𝑎𝑟 𝑚𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂
𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 = 99.16 𝐾𝑚𝑜𝑙𝑒𝑠 × 18.01
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 𝑂𝑈𝑇 = 𝟏𝟕𝟖𝟓. 𝟗𝟗 𝑲𝒈
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 𝑂𝑈𝑇 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶3 𝐻6 𝑂3 𝑓𝑜𝑟𝑚𝑒𝑑
𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 = 𝑀𝑜𝑙𝑒𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 × 𝑀𝑜𝑙𝑎𝑟 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂
𝐾𝑔
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 = 2.02 𝐾𝑚𝑜𝑙𝑒𝑠 × 74.1
𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂 = 𝟏𝟓𝟐. 𝟏𝟒 𝑲𝒈
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [61] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶7 𝐻14 𝑂3
165
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [61] = 𝟐𝟏𝟐𝟐. 𝟗𝟔 𝑲𝒈
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [62] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶4 𝐻10 𝑂
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [62] = 𝟏𝟓𝟐. 𝟏𝟒 𝑲𝒈
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [63] = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐻2 𝑂 + 𝑀𝑎𝑠𝑠 𝑜𝑓 𝐶3 𝐻6 𝑂3
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑆𝑡𝑟𝑒𝑎𝑚 [63] = 𝟏𝟗𝟕𝟎. 𝟗𝟔 𝑲𝒈
Evaporator (EC-201)
[67]
To Water EC-201 [64]
Storage Tank
[66] [65]
[71]
Component Inlet Outlet

[64] [67] [71]
Water 139.86 130.12 9.73
166
Lactic Acid 184.96 - 184.96
TOTAL 324.82 130.12 194.70
Assumptions:
 95% Lactic Acid concentration after single effect evaporation
 No Lactic Acid losses
Reference:
 Principles of Transport Processes and Separation Processes (Geankoplis, 2003)
H2O at stream 71:
𝐿𝑎𝑐𝑡𝑖𝑐 𝑎𝑐𝑖𝑑 ∗ (𝐿𝑎𝑐𝑡𝑖𝑐 𝐴𝑐𝑖𝑑 − 𝑎𝑐𝑞𝑢𝑒𝑜𝑢𝑠 𝐿𝐴 𝑐𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑖𝑜𝑛)

𝐻2 O at stream 71 =
𝑎𝑐𝑞𝑢𝑒𝑜𝑢𝑠 𝐿𝐴 𝑐𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑖𝑜𝑛
184.96 ∗ (1 − 0.95)
𝐻2 O at Stream [71] =
0.95
𝑘𝑔
𝐻2 O at Stream [71] = 9.73
ℎ𝑟
𝑘𝑔 𝑘𝑔
Stream [71] = 184.96 + 9.73
ℎ𝑟 ℎ𝑟
𝑘𝑔
Stream [71] = 194.70
ℎ𝑟
Stream [64] = Stream [67] + Stream [71]
𝑘𝑔 𝑘𝑔
Stream [67] = 324.82 − 194.70
ℎ𝑟 ℎ𝑟
167
𝑘𝑔
Stream [67] = 130.12
ℎ𝑟
168
Section 3: Polymerization Process
169
ENERGY BALANCE
170
Mixer M-101
Assumptions:
● No reaction takes place
● Qgain = Qloss
● Constant pressure operations
● Inlet temperature = 25℃
● Outlet temperature = 30℃
Components kg kJ
𝑚̇, 𝐶𝑝,
hr kg ∙ K
Dextrose 1191.63 1.21
Xylose 708.40 1.67
Lignin 450.34 1.10
Water 10274.33 4.12
Sulfuric Acid 25.30 11.34
𝐹𝑜𝑟 𝑑𝑒𝑥𝑡𝑟𝑜𝑠𝑒:
𝑄 = 𝑚̇𝐶𝑝 ∆T
kg kJ kJ
Q = 1191.63 (1.21 ) (30 − 25)K = 7209.36
hr kg ∙ K hr
𝐹𝑜𝑟 𝑥𝑦𝑙𝑜𝑠𝑒:
kg kJ kJ
Q = 708.40 (1.67 ) (30 − 25)K = 5915.14
hr kg ∙ K hr
𝐹𝑜𝑟 𝑙𝑖𝑔𝑛𝑖𝑛:
171
kg kJ kJ
Q = 450.34 (1.10 ) (30 − 25)K = 2476.87
hr kg ∙ K hr
𝐹𝑜𝑟 𝑤𝑎𝑡𝑒𝑟:
kg kJ kJ
Q = 10274.33 (4.12 ) (30 − 25)K = 211651.20
hr kg ∙ K hr
𝐹𝑜𝑟 𝑠𝑢𝑙𝑓𝑢𝑟𝑖𝑐 𝑎𝑐𝑖𝑑:
kg kJ kJ
Q = 25.30 (11.34 ) (30 − 25)K = 1434.51
hr kg ∙ K hr
kJ kJ kJ kJ kJ
𝑄𝑡𝑜𝑡𝑎𝑙 = 7209.36 + 5915.14 + 2476.87 + 211651.20 + 1434.51
hr hr hr hr hr
kJ
𝑄𝑡𝑜𝑡𝑎𝑙 = 228687.08
hr
172
Pump P-101
Assumptions:
 Incompressible fluid flow
 Heat transfer is negligible
 No change in pressure
 The height is considered to be 10 m.
 100 m friction head
Mechanical Energy Balance
∆𝑃 ∆𝑢2 𝑔 𝑔
𝑊𝑠 = + + ∆𝑧 + 𝐹
𝜌 2𝑔𝑐 𝑔𝑐 𝑔𝑐
Pressure Drop:
∆𝑃
=0
𝜌
Kinetic Energy
∆𝑢2
=0
2𝑔𝑐
Potential Energy
𝑚
𝑔 9.8 2
𝑠
∆𝑧 = (10 𝑚) ( 𝑘𝑔∙𝑚)
𝑔𝑐 1 𝑁∙𝑠2
𝑔 J
∆𝑧 = 98
𝑔𝑐 kg
Friction
𝑔
𝐹=𝑓
𝑔𝑐
𝑚
9.8
𝐹 = (100 𝑚) ( 𝑠2 )
1 𝑘𝑔∙𝑚
𝑁∙𝑠2
J
𝐹 = 980
kg
173
Work
𝑔
𝑊𝑠 = 0 + 0 + ∆𝑧 +𝐹
𝑔𝑐
J J
Ws = 98 + 980
kg kg
J
𝑊𝑠 = 1078
kg
Power Requirement
𝑃 = 𝑚̇𝑊𝑠
kg J
P = (12650 ) (1078 )
hr kg
J 1 hr
P = 13636700 ( )
hr 3600 s
kg
P = 3787.97 W = 13460.29
hr
174
Reactor R-101
Assumptions:
● Constant heat capacities
● Negligible heat loss to the surroundings
● Qgain = Qloss
kg kJ
Components 𝑚̇, 𝐶𝑝,
hr kg ∙ K
Dextrose 1154.69 1.21
Xylose 670.15 1.67
Lignin 400.35 1.10
Water 9232.55 4.12
Furfural 1192.26 1.69
Reference: NIST Standard Reference Database 69: NIST Chemistry WebBook
kg kJ kJ
Q = 1154.69 (1.21 ) (195 − 165)K = 41915.25
hr kg ∙ K hr
kg kJ kJ
Q = 670.15 (1.67 ) (195 − 165)K = 33574.52
hr kg ∙ K hr
kg kJ kJ
Q = 400.35 (1.10 ) (195 − 165)K = 13211.55
hr kg ∙ K hr
175
kg kJ kJ
Q = 9232.55 (4.12 ) (195 − 165)K = 1141143.18
hr kg ∙ K hr
𝐹𝑜𝑟 𝑓𝑢𝑟𝑓𝑢𝑟𝑎𝑙:
kg kJ kJ
Q = 1192.26 (1.69 ) (195 − 165)K = 60447.58
hr kg ∙ K hr
kJ kJ kJ kJ kJ
𝑄𝑡𝑜𝑡𝑎𝑙 = 41915.25 + 33574.52 + 13211.55 + 1141143.18 + 60447.58
hr hr hr hr hr
𝑘𝐽
𝑄𝑡𝑜𝑡𝑎𝑙 = 1290292.08
ℎ𝑟
176
Heat Exchanger HE-101
Assumptions:
● Qgain = Qloss
Component Flow Rate Heat Capacity
𝑘𝑔 kJ
Furfural 1192.26 ℎ𝑟 1.69 kg∙K
kg kJ
Water 9232.55 hr 4.12
kg∙K
𝐹𝑜𝑟 𝑓𝑢𝑟𝑓𝑢𝑟𝑎𝑙:
𝑘𝑔 kJ
𝑄 = (1192.26 ) (1.69 ) (25 − 80)𝐾
ℎ𝑟 kg ∙ K
𝑘𝐽
𝑄 = −110820.567
ℎ𝑟
𝑘𝑔 kJ
𝑄 = (9232.55 ) (4.12 ) (25 − 80)𝐾
ℎ𝑟 kg ∙ K
𝑘𝐽
𝑄 = −2092095.83
ℎ𝑟
𝑄𝑡𝑜𝑡𝑎𝑙 = −30.78 𝑘𝑊 + (−58.11 𝑘𝑊)
𝑄𝑡𝑜𝑡𝑎𝑙 = −88.89 𝑘𝑊
177
Pump P-102
Assumptions:
 Constant pipe diameter
𝑊𝑠 = + + ∆𝑧 + 𝐹
Pressure Drop
∆𝑃
=0
𝜌
Kinetic Energy
∆𝑢2
=0
2𝑔𝑐
Potential Energy
𝑚
𝑔 9.8 2
𝑠
∆𝑧 = (10 𝑚) ( 𝑘𝑔∙𝑚)
𝑔 𝐽
∆𝑧 = 98
𝑔𝑐 𝑘𝑔
Friction
𝑔
𝐹=𝑓
𝑔𝑐
𝑚
9.8
𝐹 = (100 𝑚) ( 𝑠2)
1 𝑘𝑔∙𝑚
𝑁∙𝑠2
𝐽
𝐹 = 980
𝑘𝑔
178
Work
𝑔
𝑊𝑠 = 0 + 0 + ∆𝑧 +𝐹
𝑔𝑐
𝐽 𝐽
𝑊𝑠 = 98 + 980
𝑘𝑔 𝑘𝑔
𝐽
𝑊𝑠 = 1078
𝑘𝑔
Power Requirement
𝑘𝑔 𝐽
𝑃 = (11457.7375 ) (1078 )
ℎ𝑟 𝑘𝑔
𝐽 1 ℎ𝑟
𝑃 = 12351441.03 ( )
ℎ𝑟 3600 𝑠
𝑘𝐽
𝑃 = 3430.96 𝑊 = 12351.46
ℎ𝑟
179
Assumptions:
● Qgain = Qloss
kg kJ
hr kg ∙ K
Dextrose 1154.69 1.21
Xylose 670.15 1.67
Lignin 400.35 1.10
Water 9232.55 4.12
kg kJ kJ
Q = 1154.69 (1.21 ) (60 − 175)K = − 160675.11
hr kg ∙ K hr
kg kJ kJ
Q = 670.15 (1.67 ) (60 − 175)K = − 128702.31
hr kg ∙ K hr
kg kJ kJ
Q = 400.35 (1.10 ) (60 − 175)K = −5064427.50
hr kg ∙ K hr
180
kg kJ kJ
Q = 9232.55 (4.12 ) (60 − 175)K = −4374382.19
hr kg ∙ K hr
kJ kJ kJ kJ
𝑄𝑡𝑜𝑡𝑎𝑙 = − 160675.11 + (− 128702.31 ) + (−5064427.50 ) + (−4374382.19 )
hr hr hr hr
𝑘𝐽
𝑄𝑡𝑜𝑡𝑎𝑙 = −9728187.11
ℎ𝑟
181
Mixer M-102
Assumptions:
● No reaction takes place
● Constant pressure operations
● Qgain = Qloss
kg kJ
hr kg ∙ K
Dextrose 937.95 1.21
Xylose 536.12 1.67
Lignin 400.14 1.10
Water 7077.05 4.12
Ethanol 3800.05 2.33
NaOH 140.96 2.18
kg kJ kJ
Q = 937.95 (1.21 ) (80 − 60)K = 22698.39
hr kg ∙ K hr
kg kJ kJ
Q = 536.12 (1.67 ) (80 − 60)K = 17906.41
hr kg ∙ K hr
kg kJ kJ
Q = 400.14 (1.10 ) (80 − 60)K = 8803.08
hr kg ∙ K hr
182
kg kJ kJ
Q = 7077.05 (4.12 ) (80 − 60)K = 583148.92
hr kg ∙ K hr
𝐹𝑜𝑟 𝑒𝑡ℎ𝑎𝑛𝑜𝑙:
kg kJ kJ
Q = 3800.05 (2.33 ) (80 − 60)K = 177082.33
hr kg ∙ K hr
𝐹𝑜𝑟 𝑁𝑎𝑂𝐻:
kg kJ kJ
Q = 140.96 (2.18 ) (80 − 60)K = 6145.86
hr kg ∙ K hr
𝑘𝐽
𝑄𝑡𝑜𝑡𝑎𝑙 = (22698.39 + 17906.41 + 8803.08 + 583148.92 + 177082.33 + 6145.86)
ℎ𝑟
𝑘𝐽
𝑄𝑡𝑜𝑡𝑎𝑙 = 815784.99
ℎ𝑟
183
Pump P-103
Assumptions:
𝑊𝑠 = + + ∆𝑧 + 𝐹
Pressure Drop
∆𝑃
=0
𝜌
Kinetic Energy
∆𝑢2
=0
2𝑔𝑐
Potential Energy
𝑔 9.8 𝑠𝑚2
∆𝑧 = (10 𝑚)( 𝑘𝑔∙𝑚)
𝑔𝑐 1 2 𝑁∙𝑠
𝑔 𝐽
∆𝑧 = 98 𝑘𝑔
𝑔𝑐
Friction
𝑔
𝐹=𝑓
𝑔𝑐
9.8 𝑠𝑚2
𝐹 = (100 𝑚) ( )
1 𝑘𝑔∙𝑚
𝑁∙𝑠2
𝐽
𝐹 = 980 𝑘𝑔
184
Work
𝑔
𝑊𝑠 = 0 + 0 + ∆𝑧 +𝐹
𝑔𝑐
𝐽 𝐽
𝑊𝑠 = 98 𝑘𝑔 + 980 𝑘𝑔
𝐽
𝑊𝑠 = 1078 𝑘𝑔
Power Requirement
𝑘𝑔 𝐽
𝑃 = (12892.27686 ℎ𝑟 ) (1078 𝑘𝑔)
𝐽 1 ℎ𝑟
𝑃 = 13897874.46 ℎ𝑟 ( )
3600 𝑠
𝑘𝐽
𝑃 = 3860.52 𝑊 = 13897.87 ℎ𝑟
185
Reactor R-102
Assumptions:
● Qgain = Qloss
kg kJ
hr kg ∙ K
Xylose 423.53 1.67
Lignin 316.11 1.10
Water 7598.13 4.12
Ethanol 3813.51 2.33
kg kJ kJ
Q = 740.98 (1.21 ) (185 − 60)K = 112073.23
hr kg ∙ K hr
kg kJ kJ
Q = 423.53 (1.67 ) (185 − 60)K = 88411.89
hr kg ∙ K hr
kg kJ kJ
Q = 316.11 (1.10 ) (185 − 60)K = 43465.12
hr kg ∙ K hr
186
kg kJ kJ
Q = 7598.13 (4.12 ) (185 − 60)K = 3913036.95
hr kg ∙ K hr
kJ kJ
Q = 3813.51 (2.33 ) (185 − 60)K = 1110684.79
kg ∙ K hr
kJ
𝑄𝑡𝑜𝑡𝑎𝑙 = (112073.23 + 88411.89 + 43465.12 + 3913036.95 + 1110684.79)
hr
kJ
𝑄𝑡𝑜𝑡𝑎𝑙 = 5267671.98
hr
187
Assumptions:
● Qgain = Qloss
kg kJ
hr kg ∙ K
Xylose 423.53 1.67
Lignin 316.11 1.10
Water 7598.13 4.12
Ethanol 3813.51 2.33
kg kJ kJ
Q = 740.98 (1.21 ) (80 − 25)K = 49312.22
hr kg ∙ K hr
kg kJ kJ
Q = 423.53 (1.67 ) (80 − 25)K = 38901.23
hr kg ∙ K hr
kg kJ kJ
Q = 316.11 (1.10 ) (80 − 25)K = 19124.65
hr kg ∙ K hr
188
kg kJ kJ
Q = 7598.13 (4.12 ) (80 − 25)K = 1721736.26
hr kg ∙ K ℎ𝑟
kg kJ 𝑘𝐽
Q = 3813.51 (2.33 ) (80 − 25)K = 488701.31
hr kg ∙ K ℎ𝑟
kJ kJ kJ kJ 𝑘𝐽
𝑄𝑡𝑜𝑡𝑎𝑙 = 49312.22 + 38901.23 + 19124.65 + 1721736.26 + 488701.31
hr hr hr ℎ𝑟 ℎ𝑟
𝑘𝐽
𝑄𝑡𝑜𝑡𝑎𝑙 = 2317775.67
ℎ𝑟
189
Assumptions:
● Qgain = Qloss
kg kJ
hr kg ∙ K
Xylose 423.53 1.67
Lignin 316.11 1.10
Water 7598.13 4.12
Ethanol 3813.51 2.33
kg kJ kJ
Q = 740.98 (1.21 ) (85 − 185)K = −89658.58
hr kg ∙ K hr
kg kJ kJ
Q = 423.53 (1.67 ) (85 − 185)K = −70729.51
hr kg ∙ K hr
kg kJ kJ
Q = 316.11 (1.10 ) (85 − 185)K = −34772.1
hr kg ∙ K hr
190
kg kJ kJ
Q = 7598.13 (4.12 ) (85 − 185)K = −3130429.56
hr kg ∙ K hr
kJ kJ
Q = 3813.51 (2.33 ) (85 − 185)K = −888547.83
kg ∙ K hr
𝑘𝐽
𝑄𝑡𝑜𝑡𝑎𝑙 = [−89658.58 + (−70729.51) + (−34772.1) + (−3130429.56) + (−888547.83)]
ℎ𝑟
𝑘𝐽
𝑄𝑡𝑜𝑡𝑎𝑙 = −4214137.58
ℎ𝑟
191
Reactor R-103
Assumptions:
● Qgain = Qloss
kg kJ
hr kg ∙ K
Xylose 304.94 1.67
Lignin 59.75 1.10
Water 5160.57 4.12
kg kJ kJ
Q = 541.71 (1.21 ) (80 − 55)K = 16386.73
hr kg ∙ K hr
kg kJ kJ
Q = 304.94 (1.67 ) (80 − 55)K = 12731.24
hr kg ∙ K hr
kg kJ kJ
Q = 59.75 (1.10 ) (80 − 55)K = 1643.12
hr kg ∙ K hr
192
kg kJ kJ
Q = 5160.57 (4.12 ) (80 − 55)K = 531538.71
hr kg ∙ K hr
kJ kJ kJ kJ
𝑄𝑡𝑜𝑡𝑎𝑙 = 16386.73 + 12731.24 + 1643.12 + 531538.71
hr hr hr hr
𝑘𝐽
𝑄𝑡𝑜𝑡𝑎𝑙 = 562299.80
ℎ𝑟
193
Pump P-104
Assumptions:
 The height is considered to be 10m.
𝑊𝑠 = + + ∆𝑧 + 𝐹
Pressure Drop
∆𝑃
=0
𝜌
Kinetic Energy
∆𝑢2
=0
2𝑔𝑐
Potential Energy
𝑚
𝑔 9.8 2
𝑠
∆𝑧 = (10 𝑚) ( 𝑘𝑔∙𝑚)
𝑔 𝐽
∆𝑧 = 98
𝑔𝑐 𝑘𝑔
Friction
𝑔
𝐹=𝑓
𝑔𝑐
𝑚
9.8
𝐹 = (100 𝑚) ( 𝑠2 )
1 𝑘𝑔∙𝑚
𝑁∙𝑠2
𝐽
𝐹 = 980
𝑘𝑔
194
Work
𝑔
𝑊𝑠 = 0 + 0 + ∆𝑧 +𝐹
𝑔𝑐
𝐽 𝐽
𝑊𝑠 = 98 + 980
𝑘𝑔 𝑘𝑔
𝐽
𝑊𝑠 = 1078
𝑘𝑔
Power Requirement
𝑘𝑔 𝐽
𝑃 = (6066.97 ) (1078 )
ℎ𝑟 𝑘𝑔
𝐽 1 ℎ𝑟
𝑃 = 6540193.66 ( )
ℎ𝑟 3600 𝑠
𝑘𝐽
𝑃 = 1816.72 𝑊 = 6540.19
ℎ𝑟
195
Pump P-105
Assumptions:
 The height is considered to be 10m.
𝑊𝑠 = + + ∆𝑧 + 𝐹
Pressure Drop
∆𝑃
=0
𝜌
Kinetic Energy
∆𝑢2
=0
2𝑔𝑐
Potential Energy
𝑚
𝑔 9.8 2
𝑠
∆𝑧 = (10 𝑚) ( 𝑘𝑔∙𝑚)
𝑔 𝐽
∆𝑧 = 98
𝑔𝑐 𝑘𝑔
Friction
𝑔
𝐹=𝑓
𝑔𝑐
𝑚
9.8
𝐹 = (100 𝑚) ( 𝑠2)
1 𝑘𝑔∙𝑚
𝑁∙𝑠2
𝐽
𝐹 = 980
𝑘𝑔
196
Work
𝑔
𝑊𝑠 = 0 + 0 + ∆𝑧 +𝐹
𝑔𝑐
𝐽 𝐽
𝑊𝑠 = 98 + 980
𝑘𝑔 𝑘𝑔
𝐽
𝑊𝑠 = 1078
𝑘𝑔
Power Requirement
𝑘𝑔 𝐽
𝑃 = (2488.0645 ) (1078 )
ℎ𝑟 𝑘𝑔
𝐽 1 ℎ𝑟
𝑃 = 2682133.531 ( )
ℎ𝑟 3600 𝑠
𝑘𝐽
𝑃 = 745.04 𝑊 = 2682.144
ℎ𝑟
197
FERMENTATION (BR-201)
Assumptions:
 The process is at steady-state.
 There is no heat transfer in the surroundings.
 The operating condition is 37 degrees Celsius.
 The feed temperature is 25 degrees Celsius.
INPUT  The
m, Cp, mCp, KJ/hr-K

Kg/hr KJ / Kg-K
Dextrose 440.03 1.21 532.44
Ammonia 90.55 2.2 199.21
Water 1804.07 4.19 7559.09
Biomass 870.82 1.29 1123.36
Xylose 243.95 1.67 407.40
Oxygen 64.32 0.92 59.17
Total 9880.68
product temperature 37 degrees Celsius.
 The energy is conserved inside the fermenter.
𝑚𝐻𝐼𝑁 = 𝑚𝐶𝑝,𝐼𝑁 (𝑇1 − 𝑇𝑟𝑒𝑓 )
∑ 𝑚 𝐶𝑝,𝐼𝑁 = 440.03 (1.21) + 90.55(2.2) + 1804.07 (4.19) + 870(1.29) + 243.95(1.67)
+ 64.32(0.92)
198
OUTPUT
m, Kg/hr Cp, KJ / Kg-K mCp
Ammonium Lactate 231.39 1.61 372.55
Water 205.61 4.19 861.51
Biomass 1016.91 1.29 1311.82
Xylose 243.95 1.67 407.40
CO2 64.32 0.84 54.03
Total 3007.31
𝑲𝑱
∑ 𝑚 𝐶𝑝,𝐼𝑁 = 𝟗𝟖𝟖𝟎. 𝟔𝟖
𝒉𝒓 − 𝑲
𝑚𝐻𝑂𝑈𝑇 = 𝑚𝐶𝑝,𝑂𝑈𝑇 (𝑇1 − 𝑇𝑟𝑒𝑓 )
∑ 𝑚 𝐶𝑝,𝑂𝑈𝑇 = 231.39 (1.61) + 205.61 (4.19) + 1016.91 (1.29) + 243.95(1.67) + 64.32(0.84)
𝑲𝑱
∑ 𝑚 𝐶𝑝,𝑂𝑈𝑇 = 𝟑𝟎𝟎𝟕. 𝟑𝟏
𝒉𝒓 − 𝑲
REACTANTS
Components Molar Mass Moles nHf mHf
Kg/Kmol Kmol KJ/mol KJ/Kg
Dextrose 90.08 1 -1262 -14009.76
Ammonium Hydroxide 35.04 2 -336.7 -19218.03
Total -33227.80
PRODUCTS
Ammonium 107.06 2 -688.28 -12857.83
Lactate
Water 18.02 2 -285.8 -31720.31
Total -44578.14
199
𝐻𝑅𝑋𝑁 = ∑ 𝑛𝐻𝑓,𝑝𝑟𝑜𝑑𝑢𝑐𝑡 − ∑ 𝑛𝐻𝑓,𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡
1000 1000
∑ 𝑛𝐻𝑓,𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = [−688.28 × × 2] + [−285.8 × × 2]
107.06 18.02
𝐾𝐽
∑ 𝑛𝐻𝑓,𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = − 44578.14
𝐾𝑔
1000 1000
∑ 𝑛𝐻𝑓,𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡𝑠 = [−1262 × × 1] + [−336.7 × × 2]
90.08 18.02
𝐾𝐽
∑ 𝑛𝐻𝑓,𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = − 33227.80
𝐾𝑔
𝐾𝐽 𝐾𝐽
𝐻𝑅𝑋𝑁 = −44578.14 − (−33227.80 )
𝐾𝑔 𝐾𝑔
𝐾𝐽
𝐻𝑅𝑋𝑁 = −11350.34
𝐾𝑔
𝐾𝑔 𝐾𝐽
𝑚𝐻𝑅𝑋𝑁 = 231.39 (= −11350.34 )
ℎ𝑟 𝐾𝑔
𝐾𝐽
𝑚𝐻𝑅𝑋𝑁 = −2626429.9
ℎ𝑟
𝑄 = 𝑚𝐻𝑂𝑈𝑇 − 𝑚𝐻𝐼𝑁 + 𝑚𝐻𝑂𝑈𝑇
𝑄 = 𝑚𝐶𝑝,𝑂𝑈𝑇 (𝑇2 − 𝑇𝑟𝑒𝑓 ) − 𝑚𝐶𝑝,𝐼𝑁 (𝑇1 − 𝑇𝑟𝑒𝑓 ) + 𝑚𝐻𝑂𝑈𝑇
𝐾𝐽 𝐾𝐽 𝐾𝐽
𝑄 = 3007.31 (25 − 25)𝐾 − 9880.68 (37 − 25)𝐾 + (−2626429.9 )
ℎ𝑟 − 𝐾 ℎ𝑟 − 𝐾 ℎ𝑟
𝐾𝐽
𝑄 = −2744998
ℎ𝑟
200
Pump (P-201)
Assumptions:
 Negligible heat transfer to surroundings
 Constant pressure operations
 Solution goes into pump by gravity transferred 0.5 m to CF-201
 200 m Friction head
+ + ∆𝑧 ( ) + 𝐹 ( ) = 𝑊
Pressure Drop
∆𝑃
=0
𝜌
Kinetic Energy
∆𝑢2
=0
2𝑔𝑐
Potential Energy
𝑚
𝑔 9.8 2 𝐽
𝑠
∆𝑧 ( ) = (0.5𝑚) ( 𝑘𝑔∙𝑚) = 4.9
𝑔𝑐 1 2 𝑘𝑔
𝑁∙𝑠
Friction
𝑔
𝐹 = 𝑓( )
𝑔𝑐
201
𝑚
9.8
𝑠 2 ) = 1960 𝐽
𝐹 = (200𝑚)𝑥 ( 𝑘𝑔∙𝑚
1 2 𝑘𝑔
𝑁∙𝑠
Work
𝑔 𝑔
𝑊 = ∆𝑧 ( ) + 𝐹 ( )
𝑔𝑐 𝑔𝑐
𝐽 𝐽 𝐽
𝑊 = 1960 + 4.9 = 1964.9
Power requirement:
𝑃 = 𝑚̇𝑊
𝑘𝑔 𝐽
𝑃 = (1697.87 )(1964.9 )
ℎ𝑟 𝑘𝑔
𝐽
𝑃 = 3336144.76 = 926.71 𝑊
ℎ𝑟
202
Pump (P-202)
Assumptions:
 Solution goes into pump by gravity transferred 0.5 m to ER-201
+ + ∆𝑧 ( ) + 𝐹 ( ) = 𝑊
Pressure Drop
∆𝑃
=0
𝜌
Kinetic Energy
∆𝑢2
=0
2𝑔𝑐
Potential Energy
𝑚
𝑔 9.8 2 𝐽
𝑠
∆𝑧 ( ) = (0.5𝑚) ( 𝑘𝑔∙𝑚) = 4.9
𝑁∙𝑠
Friction
𝑔
𝐹 = 𝑓( )
𝑔𝑐
203
𝑚
9.8
𝑠 2 ) = 1960 𝐽
𝐹 = (200𝑚)𝑥 ( 𝑘𝑔∙𝑚
1 2 𝑘𝑔
𝑁∙𝑠
Work
𝑔 𝑔
𝑊 = ∆𝑧 ( ) + 𝐹 ( )
𝑔𝑐 𝑔𝑐
𝐽 𝐽 𝐽
𝑊 = 1960 + 4.9 = 1964.9
Power requirement:
𝑃 = 𝑚̇𝑊
𝑘𝑔 𝐽
𝑃 = (646.91 )(1964.9 )
ℎ𝑟 𝑘𝑔
𝐽
𝑃 = 1271113.46 = 353.09 𝑊
ℎ𝑟
204
ESTERIFICATION (ER-201)
Assumptions:
 The process is at steady-state.
 There is no heat transfer to the surrounding.
 The operating temperature is 80 degrees Celsius.
 The entering feed is 37 degrees Celsius.
 The energy is conserved inside the reactor.
INPUT
Components m, Cp, mCp,
kg/hr KJ / Kg-K
KJ/hr-K
Ammonium 219.82 1.61 353.92
Lactate
Water 195.32 4.19 818.43
Xylose 231.75 1.67 387.03
Butanol 249.15 2.49 620.40
Total 2179.79
𝑚𝐻𝐼𝑁 = 𝑚𝐶𝑝,𝐼𝑁 (𝑇1 − 𝑇𝑟𝑒𝑓 )
∑ 𝑚 𝐶𝑝,𝐼𝑁 = 219.82(1.61) + 195.32 (4.19) + 231.75 (1.67) + 249.15(2.49)
𝑲𝑱
∑ 𝑚 𝐶𝑝,𝐼𝑁 = 𝟐𝟏𝟕𝟗. 𝟕𝟗
𝒉𝒓 − 𝑲
OUTPUT
Components m, Cp, mCp,
kg/hr KJ / Kg K
KJ/ hr-K
Butyl Lactate 299.98 1.97 590.98
Water 176.83 4.19 740.96
Xylose 231.75 1.67 387.03
Butanol 49.83 2.49 124.08
205
Ammonium 6.219 1.61 10.01
Hydroxide
Total 1853.06
𝑚𝐻𝑂𝑈𝑇 = 𝑚𝐶𝑝,𝑂𝑈𝑇 (𝑇1 − 𝑇𝑟𝑒𝑓 )
∑ 𝑚 𝐶𝑝,𝑂𝑈𝑇 = 299.98 (1.97) + 176.82(4.19) + 231.75 (1.67) + 49.83 (2.49) + 6.21(1.61)
𝑲𝑱
∑ 𝑚 𝐶𝑝,𝑂𝑈𝑇 = 𝟏𝟖𝟓𝟑. 𝟎𝟔
𝒉𝒓 − 𝑲
REACTANTS
Ammonium Lactate 107.06 1 -688.28 -6428.91
Butanol 74.1 1 -274.43 -3703.5
Total -10132.42
PRODUCTS
Butyl Lactate 146.1 1 -401.78 -2750.03
Water 18.02 1 -285.8 -15860.15
Ammonia 17.03 1 -45.9 -2695.24
Total -21305.433
𝐻𝑅𝑋𝑁 = ∑ 𝑛𝐻𝑓,𝑝𝑟𝑜𝑑𝑢𝑐𝑡 − ∑ 𝑛𝐻𝑓,𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡
1000 1000 1000

∑ 𝑛𝐻𝑓,𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = [−401.78 × × 1] + [−285.8 × × 1] + [−45.9 × × 1]
146.1 18.02 17.03
𝐾𝐽
∑ 𝑛𝐻𝑓,𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = − 21305.43
𝐾𝑔
1000 1000
∑ 𝑛𝐻𝑓,𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡𝑠 = [−688.28 × × 1] + [−274.43 × × 1]
107.06 74.1
𝐾𝐽
∑ 𝑛𝐻𝑓,𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = − 10132.42
𝐾𝑔
206
𝐾𝐽 𝐾𝐽
𝐻𝑅𝑋𝑁 = −21305.43 − (−10132.42 )
𝐾𝑔 𝐾𝑔
𝐾𝐽
𝐻𝑅𝑋𝑁 = −11173
𝐾𝑔
𝐾𝑔 𝐾𝐽
𝑚𝐻𝑅𝑋𝑁 = 299.98 (−11173 )
ℎ𝑟 𝐾𝑔
𝐾𝐽
𝑚𝐻𝑅𝑋𝑁 = −3351764
ℎ𝑟
𝑄 = 𝑚𝐻𝑂𝑈𝑇 − 𝑚𝐻𝐼𝑁 + 𝑚𝐻𝑂𝑈𝑇
𝑄 = 𝑚𝐶𝑝,𝑂𝑈𝑇 (𝑇2 − 𝑇𝑟𝑒𝑓 ) − 𝑚𝐶𝑝,𝐼𝑁 (𝑇1 − 𝑇𝑟𝑒𝑓 ) + 𝑚𝐻𝑂𝑈𝑇
𝐾𝐽 𝐾𝐽 𝐾𝐽
𝑄 = 1853.06 (80 − 25)𝐾 − 2179.79 (37 − 25)𝐾 + (−3351764 )
ℎ𝑟 − 𝐾 ℎ𝑟 − 𝐾 ℎ𝑟
𝐾𝐽
𝑄 = −328206.01
ℎ𝑟
207
HEAT EXCHANGER (HE-201)
Assumptions:
 Constant heat capacities
 Negligible heat loss to the surroundings
 𝑄𝑔𝑎𝑖𝑛 = 𝑄𝑙𝑜𝑠𝑠
 Inlet Temperature = 80°C
 Outlet Temperature = 37°C
m, Cp,
Components
kg/hr KJ / Kg K
Butyl Lactate 299.98 1.97
Water 176.83 4.19
Xylose 231.75 1.67
Total 708.58
Inlet Outlet
Th 80°C 37°C
Tc 15°C 23°C
𝑘𝐽 𝑘𝐽 𝑘𝐽
𝐶𝑝 = (0.42) (1.97 ) + (0.25) (4.19 ) + (0.33)(1.67 )
𝑘𝑔 ∙ 𝐾 𝑘𝑔 ∙ 𝐾 𝑘𝑔 ∙ 𝐾
𝑘𝐽
𝐶𝑝 = 2.43
𝑘𝑔 ∙ 𝐾
(80 − 15) − (37 − 23)

∆𝑇𝑙𝑚 =
80 − 15
ln ( )
37 − 23
∆𝑇𝑙𝑚 = 33.22 𝐾
𝑄 = 𝑚𝐶𝑝Δ𝑇
𝑘𝐽
𝑄 = (708.58𝑘𝑔) (2.43 ) (33.22 𝐾)
𝑘𝑔 ∙ 𝐾
𝑄 = 57199.84 𝑘𝐽
208
Mass of water used:
𝑘𝐽
57199.84 𝑘𝐽 = (𝑚) (4.18 ) (23 − 15)𝐾
𝑘𝑔 ∙ 𝐾
𝑚 = 1710.52 𝑘𝑔
209
Pump (P-203)
Assumptions:
 Solution goes into pump by gravity transferred 0.8 m to HR-201
+ + ∆𝑧 ( ) + 𝐹 ( ) = 𝑊
Pressure Drop
∆𝑃
=0
𝜌
Kinetic Energy
∆𝑢2
=0
2𝑔𝑐
Potential Energy
𝑚
𝑔 9.8 2
𝑠 ) = 7.84 𝐽
∆𝑧 ( ) = (0.8𝑚) ( 𝑘𝑔∙𝑚
𝑁∙𝑠
Friction
𝑔
𝐹 = 𝑓( )
𝑔𝑐
210
𝑚
9.8
𝑠 2 ) = 1960 𝐽
𝐹 = (200𝑚)𝑥 ( 𝑘𝑔∙𝑚
1 2 𝑘𝑔
𝑁∙𝑠
Work
𝑔 𝑔
𝑊 = ∆𝑧 ( ) + 𝐹 ( )
𝑔𝑐 𝑔𝑐
𝐽 𝐽 𝐽
𝑊 = 1960 + 7.84 = 1967.84
Power requirement:
𝑃 = 𝑚̇𝑊
𝑘𝑔 𝐽
𝑃 = (476.83 )(1967.84 )
ℎ𝑟 𝑘𝑔
𝐽
𝑃 = 938325.15 = 260.65 𝑊
ℎ𝑟
211
Hydrolysis (HR-201)
Assumptions:
 The operating temperature is 100°C
 The feed temperature is 37°C
m, Cp,
Components
kg/hr KJ / Kg K
Butyl Lactate 299.98 1.97
Water 176.83 4.19
Total 708.58
For Butyl Lactate:
𝑘𝐽
𝑄 = 𝑚𝜆 = (299.99 𝑘𝑔) (323.84 ) = 97148.76 𝑘𝐽
𝑘𝑔
For Water:
𝑘𝐽
𝑄 = (176.83 𝑘𝑔) (4.19 ) (100 − 37)𝐾
𝑘𝑔 ∙ 𝐾
𝑄 = 46677.82 𝑘𝐽
𝑄𝑇𝑜𝑡𝑎𝑙 = 97148.76 𝑘𝐽 + 46677.82 𝑘𝐽

𝑄𝑇𝑜𝑡𝑎𝑙 = 143826.58 𝑘𝐽
212
Evaporator (EC-201)
Assumptions:
 The process is at steady-state
 The energy is conserved inside the evaporator
 Boiling Point Rise (BPR) Equation = 5.32x, where x is the mass fraction of lactic acid
in the solution
𝑊
 Overall heat transfer coefficient of 900 𝑚2 ∙𝐾
Reference:
 An economic evaluation of the fermentative production of lactic acid from wheat
flour. (Akerberg & Zacchi, 2000)
m, Cp,
Components
kg/hr KJ / Kg K
Lactic Acid 184.96 2.37
Water 139.86 4.19
Total 324.82
𝐹ℎ𝐹 + 𝑆𝜆𝑠 = 𝐿ℎ𝐿 + 𝑉𝐻𝑉
For F:
ℎ𝐹 = 𝐶𝑝Δ𝑇
𝑘𝐽 𝑘𝐽
𝐶𝑝 = (0.57) (2.37 ) + (0.43) (4.19 )
𝑘𝑔 ∙ 𝐾 𝑘𝑔 ∙ 𝐾
𝑘𝐽
𝐶𝑝 = 3.15
𝑘𝑔 ∙ 𝐾
𝑘𝐽
ℎ𝐹 = (3.15 )(100 𝐾)
𝑘𝑔 ∙ 𝐾
𝑘𝐽
ℎ𝐹 = 315
𝑘𝑔
For L:
213
𝐵𝑃𝑅 = 5.32𝑥
𝐵𝑃𝑅 = 5.32(0.95)
𝐵𝑃𝑅 = 5.054 ℃
𝑇𝐿 = 𝑇𝑉 = 89℃ + 5.054 ℃ = 94.054℃
ℎ𝐿 = 𝐶𝑝Δ𝑇
𝑘𝐽
ℎ𝐹 = (3.15 )(94.054 𝐾)
𝑘𝑔 ∙ 𝐾
𝑘𝐽
ℎ𝐿 = 296.27
𝑘𝑔
For V:
𝑇𝑉 = 94.054℃
From PHB Table 2-305
𝑘𝐽 1000 𝑚𝑜𝑙 1 𝑘𝑚𝑜𝑙 𝑘𝐽

𝐻𝑉 = 48.03 𝑥 𝑥 = 2668.3
𝑚𝑜𝑙 1 𝑘𝑚𝑜𝑙 18𝑘𝑔 𝑘𝑔
For S:
𝑇𝑆 = 121.1℃ = 394.15𝐾
From PHB Table 2-305
𝑘𝐽
ℎ𝑆 = 9.15
𝑚𝑜𝑙
𝑘𝐽
𝐻𝑆 = 48.77
𝑚𝑜𝑙
𝑘𝐽 𝑘𝐽 𝑘𝐽
𝜆𝑠 = 48.77 𝑚𝑜𝑙
− 9.15 𝑚𝑜𝑙
= 39.62 𝑚𝑜𝑙
𝑘𝐽 1000 𝑚𝑜𝑙 1 𝑘𝑚𝑜𝑙 𝑘𝐽

𝜆𝑠 = 39.62 𝑥 𝑥 = 2201.11
𝑚𝑜𝑙 1 𝑘𝑚𝑜𝑙 18𝑘𝑔 𝑘𝑔
214
𝑘𝐽 𝑘𝐽
(324.82 𝑘𝑔) (315 ) + 𝑆 (2201.11 )
𝑘𝑔 𝑘𝑔
𝑘𝐽 𝑘𝐽
= (194.7 𝑘𝑔) (296.27 ) + (130.12 𝑘𝑔) ( 2668.3 )
𝑘𝑔 𝑘𝑔
𝑆 = 137.46 𝑘𝑔
215
HEAT EXCHANGER (HE-202)
Assumptions:
 Constant heat capacities
 𝑄𝑔𝑎𝑖𝑛 = 𝑄𝑙𝑜𝑠𝑠
 Inlet Temperature = 89°C
 Outlet Temperature = 25°C
m, Cp,
Components
kg/hr KJ / Kg K
Water 130.12 4.19
Inlet Outlet
Th 89°C 37°C
Tc 25°C 35°C
𝑘𝐽
𝑄 = (130.12𝑘𝑔) (4.19 ) (89 − 37)𝐾
𝑘𝑔 ∙ 𝐾
𝑄 = 28350.55 𝑘𝐽
Mass of water used:
𝑘𝐽
28350.55 𝑘𝐽 = (𝑚) (4.19 ) (35 − 25)𝐾
𝑘𝑔 ∙ 𝐾
𝑚 = 676.624 𝑘𝑔
216
Pump (P-204)
Assumptions:
 Solution goes into pump by gravity transferred 3 m to HE-301
+ + ∆𝑧 ( ) + 𝐹 ( ) = 𝑊
Pressure Drop
∆𝑃
=0
𝜌
Kinetic Energy
∆𝑢2
=0
2𝑔𝑐
Potential Energy
𝑚
𝑔 9.8 2 𝐽
𝑠
∆𝑧 ( ) = (3 𝑚) ( 𝑘𝑔∙𝑚) = 29.4
𝑁∙𝑠
Friction
𝑔
𝐹 = 𝑓( )
𝑔𝑐
217
𝑚
9.8
𝑠 2 ) = 4900 𝐽
𝐹 = (500𝑚)𝑥 ( 𝑘𝑔∙𝑚
1 2 𝑘𝑔
𝑁∙𝑠
Work
𝑔 𝑔
𝑊 = ∆𝑧 ( ) + 𝐹 ( )
𝑔𝑐 𝑔𝑐
𝐽 𝐽 𝐽
𝑊 = 4900 + 29.4 = 4929.4
Power requirement:
𝑃 = 𝑚̇𝑊
𝑘𝑔 𝐽
𝑃 = (194.70 )(4929.4 )
ℎ𝑟 𝑘𝑔
𝐽
𝑃 = 959754.18 = 266.60 𝑊
ℎ𝑟
218
Mixer (M-201)
Heuristics:
 Optimum length-to-diameter ratio is 3
 Corrosion allowance is 9 mm.
 Design temperature is 30 degrees Celsius above operating temperature.
 Design pressure is 10% above operating pressure.
 10% freeboard.
 The mixer diameter is three times the turbine impeller diameter and impeller level
above bottom.
 Mild agitation with an impeller at superficial velocities of 0.03 m/s to 0.06 m/s.
Component Mass Flow Rate Density Kg/m3
Dextrose 440.03 1540
Xylose 243.95 1520
Water 1804.07 1000
Biomass 870.82 574.713
TOTAL 3348.87 4634.7
Operating Temperature = 25 oC = 298 K
Design Temperature = 298 K + 30 K
Design Temperature = 328 K
Operating Pressure = 101.325 Kpa
219
Design Pressure = 101.325 Kpa (1.1)
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 0.1205 (1540) + 0.0735 (1520) + 0.5435 (1000) + 0.2623 ( 574.7)
𝐾𝑔
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 991.72
𝑚3
𝐾𝑔 𝑑𝑎𝑦 12 ℎ𝑟
𝑚 3348.87 ℎ𝑟 (1 𝑐𝑦𝑐𝑙𝑒)( 𝑑𝑎𝑦 )
𝑉𝑓𝑒𝑒𝑑 = =
𝜌 𝐾𝑔
991.72 3
𝑚
𝑉𝑓𝑒𝑒𝑑 = 40.52 𝑚3
Volume of the reactor
𝑉 = 𝑉𝑓𝑒𝑒𝑑 (1.1)
𝑉 = 40.52 (1.1)
𝑉 = 44.57 𝑚3
Inside Diameter,
𝜋 2
𝑉= 𝐷 𝐿
4 𝑖
3𝜋 3
𝑉= 𝐷
4 𝑖
3𝜋 3
44.57 𝑚3 = 𝐷
4 𝑖
𝐷𝐼 = 2.67 𝑚
Length,
𝐿 = 3𝐷𝐼
𝐿 = 3 (2.67)
220
𝐿 = 7.98 𝑚
Parameter
Corrosion Allowance Corrosive Streams 𝐶𝑐 = 0.009 𝑚
(m)
Maximum Allowance Carbon Steel 𝑆 = 94500 𝐾𝑝𝑎
Stress (Kpa)
Efficiency of Joints Fully Radiographed 𝐸𝑗 = 0.85
double-welded butt
joint
𝑃𝑟𝑖
𝑡= + 𝐶𝑐
𝑆𝐸𝑗 − 0.6𝑃
7.98
111.45 𝐾𝑝𝑎( 2 )
𝑡= + 0.009𝑚
94500 𝐾𝑝𝑎(0.85) − 0.6(111.45 𝐾𝑝𝑎)
𝑡 = 0.0145 𝑚
𝐷𝑜 = 2 (𝑟𝑖 − 𝑡)
7.98
𝐷𝑜 = 2 ( − 0.0145)
2
𝐷𝑜 = 8 𝑚
221
External Volume
𝜋 2
𝑉= 𝐷 𝐿
4 𝑖
𝜋
𝑉= 2.672 (8)
4
𝑉 = 44.84 𝑚3
Volume Steel
𝑉𝑆𝑡𝑒𝑒𝑙 = 𝑉𝑒𝑥𝑡𝑒𝑟𝑛𝑎𝑙 − 𝑉𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙
𝑉𝑆𝑡𝑒𝑒𝑙 = 44.84 𝑚3 − 44.57 𝑚3
𝑉𝑆𝑡𝑒𝑒𝑙 = 0.27 𝑚3
Mass of Mixer
𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 𝑉𝑠𝑡𝑒𝑒𝑙 × 𝜌𝑠𝑡𝑒𝑒𝑙
𝑘𝑔
𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 0.27 𝑚3 × 7830
𝑚3
𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 2114.1 𝐾𝑔
Diameter Impeller
𝐷𝐼
𝐷𝑇𝐼 =
3
2.66
𝐷𝑇𝐼 =
3
𝐷𝑇𝐼 = 0.88 𝑚
Impeller level above bottom
𝐷𝐼
𝐻𝐼 =
3
222
2.66
𝐻𝐼 =
3
𝐻𝐼 = 0.88 𝑚
Impeller blade width
𝐷𝐼
𝑊𝐼 =
15
2.66
𝑊𝐼 =
15
𝑊𝐼 = 0.177 𝑚
For Homogenizing mixture
𝑚
𝑁 = 0.038
𝑠
Wall baffles (thickness)
𝐷𝑖
𝑡𝑏𝑎𝑓𝑓𝑙𝑒𝑠 =
10
2.66
10
𝑡𝑏𝑎𝑓𝑓𝑙𝑒𝑠 = 0.266 𝑚
Speed of Impeller
𝑚
𝑁 = 0.038
𝑠
Reynolds Number
2
𝐷𝑇𝐼 𝑛𝜌
𝑅𝑒 =
𝜇
223
1
(0.88)2 ((0.308)(
0.88 ))(991.72)
( )
𝑅𝑒 = 2
8.9 × 10−4
𝑅𝑒 = 604035.48
5
𝑃 = 𝐾𝑡 𝑛3 𝐷𝑇𝐼 𝜌
1 3
𝑃 = (5.75)((0.038)( ) (0.88)2 (991.72)
0.88
( )
2
𝑃 = 15.5 𝑘𝑊
224
225
EQUIPMENT
SIZING
CALCULATIONS
226
Storage Tank ST-101
Heuristics:
 An addition of 30℃ to the operating temperature to get the design temperature
 10% additional pressure for determining the design pressure
 Length-to-diameter ratio is equal to 3.
 70% fill capacity
 0.0038 m corrosion allowance for noncorrosive streams
 6 hours residence time
Component Mass flow rate (kg/hr) Density (kg/m3)
Dextrose 1191.63 1540
Xylose 708.40 1520
Lignin 450.34 1340
Water 179.63 1000
Total 2530 5400
Design Temperature
𝑇𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 = 25 ℃
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 25 ℃ + 30 ℃
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 55 ℃
Design Pressure
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)𝑃𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(101.325 𝑘𝑃𝑎)
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = 111.458 𝑘𝑃𝑎
227
Volume
𝑚̇
𝑉̇ =
𝜌
(2530 𝑘𝑔
ℎ𝑟
)
𝑉̇ = 𝑘𝑔
(5400 𝑚 3)
𝑚 3
𝑉̇ = 0.47 ℎ𝑟
𝑉
𝜏=
𝑉̇
𝑚3
𝑉 = 6 ℎ𝑟 (0.47 ℎ𝑟
)
𝑉 = 2.82 𝑚3
Dimensions of the tank
At 70% fill capacity
2.82 𝑚3 𝑑
𝑉= = 4.03 = 𝜋( )2 (3𝑑)
0.70 2
𝑑 = 1.20 𝑚
ℎ = 3.59 𝑚
Wall thickness
𝑃𝑟𝑖
𝑡=( ) + 𝐶𝑐
For titanium, S = 108,500
For fully radiographed double welded-butt joints, Ej= 1.0
1.20
(111.458 − 101.325) 𝑘𝑃𝑎( 2 )𝑚
𝑡=( ) + 0.0038
(108500)(1.0) − 0.6(111.458 − 101.325)
𝑡 = 3.86 × 10−3 𝑚 = 3.86 𝑚𝑚
228
Conveyor Belt CB-101
Heuristics:
 Standard width is 0.61 m for solids with fine particles
 Inclination is less than the repose angle, where the maximum repose angle is 30°
 1.5 m/s conveying speed with a maximum capacity bulk capacity of up to 2 m3/s
 Actual power requirement is 10-20% higher to account for power losses in the drive gear and
motor
 C1 = 1.0 to account for the power required to move and empty belt conveyor
Dextrose 1191.63 1540
Xylose 708.40 1520
Lignin 450.34 1340
Water 179.63 1000
Total 2530 5400
Design Temperature
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 25 ℃ + 30 ℃
Design Pressure
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(101.325 𝑘𝑃𝑎)
Volumetric flow rate of corn
𝑚̇
𝑉̇ =
𝜌
229
𝑘𝑔 𝑚3
𝑉̇ = (2530 ℎ𝑟 )( )
5400 𝑘𝑔
𝑚3 1 ℎ𝑟
𝑉̇ = 0.47 ℎ𝑟 ( )
3600 𝑠
𝑚 3
𝑉̇ = 0.000306 𝑠
𝐷 = 0.61 𝑚
𝐿 = 15 𝑚
𝑚2
𝑣𝑐𝑜𝑛𝑣𝑒𝑦𝑜𝑟 = 1.52 𝑠
For a 6m conveyor lift,
∆𝑍 = 𝐿𝑡𝑎𝑛𝜃
6 = 15𝑡𝑎𝑛𝜃
𝜃 = 21.8°
𝑟𝑒𝑝𝑜𝑠𝑒 𝑎𝑛𝑔𝑙𝑒 = 20°
𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 113.4 𝑘𝑔/𝑠
Actual conveyor belt
𝐿
𝐿𝑎 =
𝑐𝑜𝑠𝜃
15
𝐿𝑎 =
cos(21.8°)
𝐿𝑎 = 16.16 𝑚
Power requirement
𝑃 = 𝑃𝑒𝑚𝑝𝑡𝑦 + 𝑃ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 + 𝑃𝑣𝑒𝑟𝑡𝑖𝑐𝑎𝑙
𝐿
𝑃 = 𝐶1 𝑉𝐵𝑆 + 0.0295 (0.4 + ) 𝑚̇ + 0.00969∆𝑍𝑚̇
91.42
𝑠 𝑚 18 𝑚 𝑘𝑔 𝑘𝑔
𝑃 = (1 𝑘𝑊 ∙ 𝑚) (1.52 𝑠 ) + 0.0295 (0.4 + ) (0.703 𝑠 ) + 0.00969(6 𝑚)(0.703 𝑠 )
91.42
𝑃 = 1.57 𝑘𝑊
Assuming actual power requirement is 15% higher due to losses,
𝑃 = (1.15)(1.57 𝑘𝑊) = 1.81 𝑘𝑊
230
Mixer M-101
Heuristics:
 An addition of 30 ℃ to the operating temperature to get the design temperature
 Height-to-diameter ratio is equal to 1.
 0.009 m corrosion allowance for corrosive streams
Component Mass flow rate kg/hr Density kg/m3 Weight fraction
Dextrose 1191.63 1540 0.0942
Xylose 708.4 1520 0.056
Lignin 450.34 1340 0.0356
Water 10274.33 1000 0.8122
Sulfuric Acid 25.3 1840 0.002
Total 12650 7240 1
Design Temperature
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 60 ℃ + 30 ℃
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 90℃
Design Pressure
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(101 𝑘𝑃𝑎)
Volume
𝑚̇
𝑉=
𝜌𝑎𝑣𝑒
231
𝜌𝑎𝑣𝑒 = (1540)(0.0942) + (1520)(0.056) + (1340)(0.0356) + (1000)(0.8122)
+ (1840)(0.002)
𝑘𝑔
𝜌𝑎𝑣𝑒 = 1093.73 𝑚3
(12650 𝑘𝑔
ℎ𝑟
)
𝑉= 𝑘𝑔
(1093.73 𝑚 3)
𝑉 = 11.57 𝑚3
For 70% filling capacity,
(11.57 𝑚3 )
𝑉=
(0.7)
𝑑
𝑉 = 16.52 𝑚3 = 𝜋( )2 (𝑑)
2
𝑑 = ℎ = 2.76 𝑚
Wall thickness
𝑃𝑟𝑖
𝑡=( ) + 𝐶𝑐
For high tensile steel, S= 137900
2.76
(111.458 − 101.325) 𝑘𝑃𝑎( 2 )𝑚
𝑡=( ) + 0.009
(137900)(1.0) − 0.6(111.457 − 101.325)
𝑡 = 9.1 × 10−3 𝑚 = 9.1 𝑚𝑚
Impeller
Heuristics:
 The impeller diameter is 90% of the tank diameter
 The ratio of height to diameter is 1
 The ratio of width to diameter is 1
 5% clearance for tank diameter
 The solution is mixed at 1 m/s
232
 1.0 joint efficiency
 25 min residence time
Diameter and Height of the impeller
𝐷𝐼 = 0.90(𝑑)
𝐷𝐼 = 0.90(2.76 𝑚)
𝐷𝐼 = 𝐻𝐼 = 2.48 𝑚
At 5% clearance,
𝐶 = 0.05(𝑑)
𝐶 = 0.05(2.76 𝑚)
𝐶 = 0.14 𝑚
𝑊𝐼
= 1.0
𝐷𝐼
𝑊𝐼 = (0.1)(2.76𝑚)
𝑊𝐼 = 0.276 𝑚
Impeller rotational speed
𝑚 1 1 𝑟𝑒𝑣 60 𝑠
𝑁𝑠 = 1.0 𝑠 [ ]( )( )
1(2.48 𝑚) 2𝜋𝑟𝑎𝑑 1 𝑚𝑖𝑛
𝑁𝑠 = 3.85 𝑟𝑝𝑚
Power Requirement
1 ℎ𝑟 𝑘𝑔 𝑚3 1 𝑘𝑊
𝑃 = 25 min ( ) (12650 ℎ𝑟 ) ( )( 3 )
60 𝑚𝑖𝑛 1093.73 𝑘𝑔 𝑚
𝑃 = 4.82 𝑘𝑊
233
Pump P-101
Heuristics:
 Efficiency is 80%
 Capacity range is 0.5-20000 m3/h
Dextrose 1191.63 1540
Xylose 708.40 1520
Lignin 450.34 1340
Water 10274.33 1000
Total 12650 5400
Pump volumetric flow rate
𝑚̇
𝑉̇ =
𝜌
(12650 𝑘𝑔
ℎ𝑟
)
𝑉̇ = 𝑘𝑔
(5400 𝑚 3)
𝑚 3
𝑉̇ = 2.34 ℎ𝑟
Discharge head
Output power, Pout (from energy balance) = 3787.97 𝑊 = 13460.29 ℎ𝑟

𝑘𝐽
𝑃𝑜𝑢𝑡
𝐻=
𝑚̇𝑔
𝑘𝐽 1 ℎ𝑟 1000 𝐽
(13460.29 ℎ𝑟 )(3600 𝑠)( )
1 𝑘𝐽
𝐻=
(12650 𝑘𝑔 𝑚
× 1 ℎ𝑟 )(9.8 2 )
ℎ𝑟 3600 𝑠 𝑠
𝐻 = 108.58 𝑚
Input power
𝑃𝑜𝑢𝑡
𝑃𝑖𝑛 =
𝜀
234
𝑘𝐽
(13460.29 ℎ𝑟 )
𝑃𝑖𝑛 =
0.8
𝑃𝑖𝑛 = 16825.36 𝑊
235
Reactor R-101
Heuristics:
 70 hours per cycle
 10% freeboard
 Turbine impeller diameter and impeller level above bottom is 1/3 mixer diameter
 Impeller blade width is 1/15 the mixer diameter
 Mild agitation with an impeller at superficial velocities of 0.03 m/s to 0.06 m/s
Mass flow rate Volumetric flow

Component Density kg/m3 Weight fraction
kg/hr rate m3/day
Dextrose 1191.63 1540 0.0942 18.57
Xylose 708.4 1520 0.056 11.19
Lignin 450.34 1340 0.0356 8.07
Water 10274.33 1000 0.8122 246.58
Sulfuric acid 25.3 1840 0.002 0.33
Total 12650 7240 1 284.74
Design Temperature
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 175 ℃ + 30 ℃
Design Pressure
236
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(911.925 𝑘𝑃𝑎)
Basis: 1 cycle
𝑚̇
𝑉=
𝜌𝑎𝑣𝑒
𝜌𝑎𝑣𝑒 = (1540)(0.0942) + (1520)(0.056) + (1340)(0.0356) + (1000)(0.8122)
+ (1840)(0.002)
𝑘𝑔
𝜌𝑎𝑣𝑒 = 1093.73 𝑚3
70 ℎ𝑜𝑢𝑟𝑠
(12650 𝑘𝑔 )( )
ℎ𝑟 𝑐𝑦𝑐𝑙𝑒
𝑉= 𝑘𝑔
(1093.73 𝑚 3)
𝑉 = 809.61 𝑚3
Consider a 10% freeboard,
𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 = (809.61 𝑚3 )(1.1)
𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 = 890.571 𝑚3
Assuming that L=3Di,
𝜋𝐷𝑖2 (3𝐷𝑖 )
𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 =
4
𝜋𝐷𝑖3
4
3 4𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙
𝐷𝑖 = √
3𝜋
3 4(890.571)
𝐷𝑖 = √
3𝜋
𝐷𝑖 = 7.23 𝑚
Length
𝐿 = 3𝐷𝑖
𝐿 = 3(7.23 𝑚)
𝐿 = 21.69 𝑚
237
Wall thickness
𝑃𝑟𝑖
𝑡=( ) + 𝐶𝑐
For carbon steel, S= 94500 kPa
7.23
(1003.12 − 911.925) 𝑘𝑃𝑎( 2 )𝑚
𝑡=( ) + 0.009
(94500)(1.0) − 0.6(1003.12 − 911.925)
𝑡 = 0.0125 𝑚 = 12.49 𝑚𝑚
Outside diameter
𝐷𝑜 = 2(𝑟𝑖 + 𝑡)
7.23
𝐷𝑜 = 2 ( + (0.0125))
2
𝐷𝑜 = 7.26 𝑚
External volume
𝜋𝐷𝑜2 (𝐿)
𝑉𝑒𝑥𝑡𝑒𝑟𝑛𝑎𝑙 =
4
𝜋(7.26)2 (21.69)
4
𝑉𝑒𝑥𝑡𝑒𝑟𝑛𝑎𝑙 = 897.89 𝑚3
Volume of steel
𝑉𝑠𝑡𝑒𝑒𝑙 = 𝑉𝑒𝑥𝑡𝑒𝑟𝑛𝑎𝑙 − 𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙
𝑉𝑠𝑡𝑒𝑒𝑙 = 897.89 − 890.571
𝑉𝑠𝑡𝑒𝑒𝑙 = 7.32 𝑚3
Mass of the tank
𝑚𝑡𝑎𝑛𝑘 = 𝑉𝑠𝑡𝑒𝑒𝑙 𝜌𝑠𝑡𝑒𝑒𝑙
𝑘𝑔
𝑚𝑡𝑎𝑛𝑘 = (7.32 𝑚3 ) (7830 𝑚3 )
𝑚𝑡𝑎𝑛𝑘 = 57315.6 𝑘𝑔
238
Heuristics:
 For S&T heat exchanger, 0.0254 m outer diameter and 4.9 m long
 Qgain=Qloss
 The design pressure is 10% above the operating pressure.
 Use the overall heat transfer coefficient 1875 W/m2-K (Hot fluid to cold fluid)
Tin Tout
Hot Fluid 175℃ 85℃
Cold Fluid 25℃ 80℃
Design Pressure:
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(101.325 𝑘𝑃𝑎)
Heat transfer area
𝑄
𝐴=
𝑈∆𝑇𝐿𝑀
(𝑇1 − 𝑡2 ) − (𝑇2 − 𝑡1 ) (175 − 80) − (85 − 25)

∆𝑇𝐿𝑀 = =
(𝑇 − 𝑡2 ) (175 − 80)
ln ( 1 ) ln ( )
(𝑇2 − 𝑡1 ) (85 − 25)
∆𝑇𝐿𝑀 = 76.16℃
𝑘𝐽 1000 𝐽
(611.92)
𝑠 × 1 𝑘𝐽
𝐴=
(1875 W/m2 − K)(76.16)
𝐴 = 4.29 𝑚2
Number of tubes (Assume negligible pipe thickness Pshellside ~ Ptube side)
𝐴
𝑛=
𝜋𝐷𝐿
4.29 𝑚2
𝑛=
𝜋(0.0254)(4.9)
239
𝑛 = 14 𝑡𝑢𝑏𝑒𝑠
By interpolation from table 14-9 (Timmerhaus),
𝐷𝑠ℎ𝑒𝑙𝑙 = 0.203 𝑚
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠 = 𝑓𝑜𝑢𝑟 𝑝𝑎𝑠𝑠
0.0254 𝑚, 𝑠𝑞𝑢𝑎𝑟𝑒 𝑝𝑖𝑡𝑐ℎ
Wall thickness
𝑃𝑟𝑖
𝑡=( ) + 𝐶𝑐
𝐼𝐷𝑠ℎ𝑒𝑙𝑙
𝑟𝑖 = = 0.1015 𝑚
2
For noncorrosive streams, Cc = 0.0038
(111.458 − 101.325) 𝑘𝑃𝑎 × (0.1015)𝑚

𝑡=( ) + 0.0038
(94500)(1.0) − 0.6(111.458 − 101.325)
𝑡 = 0.0038 𝑚 = 3.80 𝑚𝑚
Outside Diameter
𝐷𝑜 = 2(𝑟𝑖 + 𝑡)
0.203
= 2( + 0.0038)
2
= 0.2106 𝑚
240
Storage Tank ST-102
Heuristics:
Furfural 1192.2625 1160
Total 1192.2625 1160
Design Temperature
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 25 ℃ + 30 ℃
Design Pressure
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(101.325 𝑘𝑃𝑎)
Volume
𝑚̇
𝑉̇ =
𝜌
(1192.2625 𝑘𝑔
ℎ𝑟
)
𝑉̇ = 𝑘𝑔
(1160 𝑚 3)
𝑚 3
𝑉̇ = 1.03 ℎ𝑟
241
𝑉
𝜏=
𝑉̇
𝑚3
𝑉 = 6 ℎ𝑟 (1.03 ℎ𝑟
)
𝑉 = 6.17 𝑚3
At 70% fill capacity,
6.17 𝑚3 𝑑
𝑉= = 8.81 = 𝜋( )2 (3𝑑)
0.70 2
𝑑 = 1.55 𝑚
ℎ = 4.66
Wall thickness
𝑃𝑟𝑖
𝑡=( ) + 𝐶𝑐
For titanium, S= 108,500
1.55
(111.458 − 101.325) 𝑘𝑃𝑎( 2 )𝑚
𝑡=( ) + 0.0038
(108500)(1.0) − 0.6(111.325 − 101.325)
𝑡 = 3.87 × 10−3 𝑚 = 3.87 𝑚𝑚
242
Heuristics:
 Qgain=Qloss
 Use the overall heat transfer coefficient 1875 W/m2-K (Hot fluid to cold fluid)
Tin Tout
Design Pressure:
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(101.325 𝑘𝑃𝑎)
Heat transfer area
𝑄
𝐴=
𝑈∆𝑇𝐿𝑀
(𝑇1 − 𝑡2 ) − (𝑇2 − 𝑡1 ) (175 − 60) − (60 − 25)

∆𝑇𝐿𝑀 = =
(𝑇 − 𝑡2 ) (175 − 60)
ln ( 1 ) ln ( )
(𝑇2 − 𝑡1 ) (60 − 25)
∆𝑇𝐿𝑀 = 71.02℃
𝑘𝐽 1000 𝐽
2702.27 𝑠 ×
1 𝑘𝐽
𝐴=
(1875 W/m2 − K)(71.02)
𝐴 = 20.29 𝑚2
Number of tubes
𝐴
𝑛=
𝜋𝐷𝐿
243
20.29 𝑚2
𝑛=
𝜋(0.019)(4.9)
𝐷𝑖,𝑠ℎ𝑒𝑙𝑙 = 0.264 𝑚
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠 = 𝑜𝑛𝑒 𝑝𝑎𝑠𝑠
0.019 𝑚, 𝑡𝑟𝑖𝑎𝑛𝑔𝑢𝑙𝑎𝑟 𝑝𝑖𝑡𝑐ℎ
Wall thickness
𝑃𝑟𝑖
𝑡=( ) + 𝐶𝑐
𝑟𝑖 = = 0.132 𝑚
2
(111.458 − 101.325) 𝑘𝑃𝑎 × (0.132)𝑚

𝑡=( ) + 0.0038
(94500)(1.0) − 0.6(111.458 − 101.325)
𝑡 = 0.0038 𝑚 = 3.80 𝑚𝑚
Outside Diameter
𝐷𝑜 = 2(𝑟𝑖 + 𝑡)
0.264
= 2( + 0.0038)
2
= 0.2716 𝑚
244
Pump P-102
Heuristics:
Dextrose 1154.69 1540
Xylose 670.15 1520
Lignin 400.35 1340
Water 9232.55 1000
Total 11457.74 5400
𝑚̇
𝑉̇ =
𝜌
(11457.74 𝑘𝑔
ℎ𝑟
)
𝑉̇ = 𝑘𝑔
(5400 𝑚 3)
𝑚 3
𝑉̇ = 2.12 ℎ𝑟
Discharge head

𝑘𝐽
𝑃𝑜𝑢𝑡
𝐻=
𝑚̇𝑔
𝑘𝐽 1 ℎ𝑟 1000 𝐽
(12351.46 )(
ℎ𝑟 3600 𝑠
)( )
1 𝑘𝐽
𝐻=
(11457.7375 𝑘𝑔 𝑚
× 1 ℎ𝑟 )(9.8 2 )
ℎ𝑟 3600 𝑠 𝑠
𝐻 = 110 𝑚
Input power
𝑃𝑜𝑢𝑡
𝑃𝑖𝑛 =
𝜀
245
𝑘𝐽
(12351.46 ℎ𝑟 )
𝑃𝑖𝑛 =
0.8
𝑃𝑖𝑛 = 15439.325 𝑊
246
Filter F-101
Heuristics:
 10% freeboard
 Length to diameter ratio is 1
Dextrose 937.95 1540 0.1996
Xylose 536.12 1520 0.114
Lignin 400.14 1340 0.085
Water 2824.6 1000 0.601
Total 4698.82 5400 1
Basis: 1 cycle
𝑚̇
𝑉=
𝜌𝑎𝑣𝑒
𝜌𝑎𝑣𝑒 = (1540)(0.1996) + (1520)(0.114) + (1340)(0.085) + (1000)(0.601)

𝑘𝑔
𝜌𝑎𝑣𝑒 = 1195.56 𝑚3
(4698.82 𝑘𝑔
ℎ𝑟
)
𝑉= 𝑘𝑔
(1195.56 𝑚 3)
𝑉 = 3.93 𝑚3
Consider a 10% freeboard
𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 = (3.93 𝑚3 )(1.1)
Assuming Li/Di = 1
𝜋𝐷𝑖2 (𝐿)
4
247
𝐷𝑖 = √
𝜋
3 4(4.323)
𝐷𝑖 = √
𝜋
𝐷𝑖 = 𝐿𝑖 = 1.77 𝑚
For stainless steel type 316, S= 128900 kPa
𝑃𝑟𝑖
𝑡=( ) + 𝐶𝑐
1.77
(110 − 100) 𝑘𝑃𝑎( 2 )𝑚
𝑡=( ) + 0.0038
(128900)(1.0) − 0.6(110 − 100)
𝑡 = 3.87 × 10−3 𝑚 = 3.87 𝑚𝑚
Outside diameter
𝐷𝑜 = 2(𝑟𝑖 + 𝑡)
1.77
𝐷𝑜 = 2 ( + (0.00387))
2
𝐷𝑜 = 1.78 𝑚
External volume
4
𝜋(1.78)2 (1.77)
4
Volume of steel
𝑉𝑠𝑡𝑒𝑒𝑙 = 4.40 − 4.323
Mass of the tank
248
𝑘𝑔
𝑚𝑡𝑎𝑛𝑘 = (0.077 𝑚3 ) (7830 𝑚3 )
𝑚𝑡𝑎𝑛𝑘 = 602.91 𝑘𝑔
Area of the filtering surface
𝜋𝐷𝑖2
𝐴=
4
𝜋(1.77)2
𝐴=
4
𝐴 = 2.46 𝑚2
249
Heuristics:
motor
Xylose 536.12 1520
Lignin 400.14 1340
Water 2824.6 1000
Total 4698.82 5400
Design Temperature
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 25 ℃ + 30 ℃
Design Pressure
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(101.325 𝑘𝑃𝑎)
𝑚̇
𝑉̇ =
𝜌
250
𝑘𝑔 𝑚3
𝑉̇ = (4698.82 ℎ𝑟 )( )
5400 𝑘𝑔
𝑚3 1 ℎ𝑟
𝑉̇ = 0.87 ℎ𝑟 ( )
3600 𝑠
𝑚 3
𝑉̇ = 0.000242 𝑠
𝐷 = 0.61 𝑚
𝐿 = 15 𝑚
𝑚2
𝜃 = 21.8°
𝐿
𝐿𝑎 =
𝑐𝑜𝑠𝜃
15
𝐿𝑎 =
cos(21.8°)
𝐿𝑎 = 16.16 𝑚
Power requirement
𝐿
𝑃 = 𝐶1 𝑉𝐵𝑆 + 0.0295 (0.4 + ) 𝑚̇ + 0.00969∆𝑍𝑚̇
91.42
𝑃 = (1 𝑘𝑊 ∙ 𝑚) (1.52 𝑠 ) + 0.0295 (0.4 + ) (1.305 𝑠 ) + 0.00969(6 𝑚)(1.305 𝑠 )
91.42
𝑃 = 1.619 𝑘𝑊
Assuming actual power requirement is 15% higher due to losses
𝑃 = (1.15)(1.619 𝑘𝑊) = 1.86 𝑘𝑊
251
Mixer M-102
Heuristics:
 Height-to-diameter ratio is equal to 1.
Dextrose 937.95 1540 0.0728
Xylose 536.12 1520 0.0416
Lignin 400.14 1340 0.031
Water 7077.05 1000 0.5489
Ethanol 3800.05 789 0.2948
NaOH 140.96 2130 0.011
Total 12892.28 8319 1
Design Temperature
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 60 ℃ + 30 ℃
Design Pressure
252
Volume
𝑚̇
𝑉=
𝜌𝑎𝑣𝑒
𝜌𝑎𝑣𝑒 = (1540)(0.0728) + (1520)(0.0416) + (1340)(0.031) + (1000)(0.5489)
+ (789)(0.2948) + (2130)(0.011)
𝑘𝑔
𝜌𝑎𝑣𝑒 = 1021.81 𝑚3
(12892.28 𝑘𝑔
ℎ𝑟
)
𝑉= 𝑘𝑔
(1021.81 𝑚 3)
𝑉 = 12.62 𝑚3
For 70% filling capacity,
(12.62 𝑚3 )
𝑉=
(0.7)
𝑑
𝑉 = 18.03 𝑚3 = 𝜋( )2 (𝑑)
2
𝑑 = ℎ = 2.84 𝑚
Wall thickness
𝑃𝑟𝑖
𝑡=( ) + 𝐶𝑐
For high tensile steel, S= 137900
2.84
(111 − 101) 𝑘𝑃𝑎( 2 )𝑚
𝑡=( ) + 0.009
(137900)(1.0) − 0.6(111 − 101)
𝑡 = 9.1 × 10−3 𝑚 = 9.1 𝑚𝑚
Impeller
Heuristics:
 The impeller diameter is 90% of the tank diameter
 The ratio of height to diameter is 1
 The ratio of width to diameter is 1
 5% clearance for tank diameter
253
 The solution is mixed at 1 m/s
 1.0 joint efficiency
 25 min residence time
Diameter and Height of the impeller
𝐷𝐼 = 0.90(𝑑)
𝐷𝐼 = 0.90(2.84 𝑚)
𝐷𝐼 = 𝐻𝐼 = 2.56 𝑚
At 5% clearance,
𝐶 = 0.05(𝑑)
𝐶 = 0.05(2.84 𝑚)
𝐶 = 0.14 𝑚
𝑊𝐼
= 1.0
𝐷𝐼
𝑊𝐼 = (0.1)(2.84𝑚)
𝑊𝐼 = 0.284 𝑚
Impeller rotational speed
𝑚 1 1 𝑟𝑒𝑣 60 𝑠
𝑁𝑠 = 1.0 𝑠 [ ]( )( )
1(2.84 𝑚) 2𝜋𝑟𝑎𝑑 1 𝑚𝑖𝑛
𝑁𝑠 = 3.36 𝑟𝑝𝑚
Power Requirement
1 ℎ𝑟 𝑘𝑔 𝑚3 1 𝑘𝑊
𝑃 = 25 min ( ) (12892.28 ℎ𝑟 ) ( )( 3 )
60 𝑚𝑖𝑛 1021.81 𝑘𝑔 𝑚
𝑃 = 5.26 𝑘𝑊
254
Pump P-103
Heuristics:
Xylose 536.12 1520
Lignin 400.14 1340
Water 7077.05 1000
Ethanol 3800.05 800
NaOH 140.96 2130
Total 3723.2 8330
𝑚̇
𝑉̇ =
𝜌
(3723.2 𝑘𝑔
ℎ𝑟
)
𝑉̇ = 𝑘𝑔
(8330 𝑚 3)
𝑚 3
𝑉̇ = 0.45 ℎ𝑟
Discharge head

𝑘𝐽
𝑃𝑜𝑢𝑡
𝐻=
𝑚̇𝑔
𝑘𝐽 1 ℎ𝑟 1000 𝐽
(13897.87 )(
ℎ𝑟 3600 𝑠
)( )
1 𝑘𝐽
𝐻=
(3723.2 𝑘𝑔 𝑚
× 1 ℎ𝑟 )(9.8 2 )
ℎ𝑟 3600 𝑠 𝑠
𝐻 = 380.1 𝑚
255
Input power
𝑃𝑜𝑢𝑡
𝑃𝑖𝑛 =
𝜀
𝑘𝐽
(13897.87 ℎ𝑟 )
𝑃𝑖𝑛 =
0.8
𝑃𝑖𝑛 = 17372.34 𝑊
256
Reactor R-102
Heuristics:
 10% freeboard
Component Mass flow rate Density kg/m3 Weight fraction Volumetric flow
kg/hr rate m3/day
Dextrose 937.95 1540 0.0728 14.62
Xylose 536.12 1520 0.0416 8.47
Lignin 400.14 1340 0.0310 7.17
Water 7077.05 1000 0.5489 169.85
Ethanol 3800.05 800 0.2948 114.00
NaOH 140.96 2130 0.011 1.59
Total 12892.28 8330 1 315.7
Design Temperature
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 150 ℃ + 30 ℃
257
Design Pressure
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = 121 𝑘𝑃𝑎
Basis: 1 cycle
𝑚̇
𝑉=
𝜌𝑎𝑣𝑒
𝜌𝑎𝑣𝑒 = (1540)(0.0728) + (1520)(0.0416) + (1340)(0.0310) + (1000)(0.5489)
+ (800)(0.2948) + (2130)(0.011)
𝑘𝑔
𝜌𝑎𝑣𝑒 = 1025.05 𝑚3
(12892.28 𝑘𝑔 )( )
𝑉= 𝑘𝑔
(1025.05 𝑚 3)
𝑉 = 880.41 𝑚3
𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 = (880.41 𝑚3 )(1.1)
4
𝜋𝐷𝑖3
4
𝐷𝑖 = √
3𝜋
3 4(968.45)
𝐷𝑖 = √
3𝜋
𝐷𝑖 = 7.44 𝑚
Length
𝐿 = 3𝐷𝑖
258
𝐿 = 3(7.44 𝑚)
𝐿 = 22.31 𝑚
Wall thickness
𝑃𝑟𝑖
𝑡=( ) + 𝐶𝑐
7.44
(1003.12 − 911.925) 𝑘𝑃𝑎( )𝑚
𝑡=( 2 ) + 0.009
(94500)(1.0) − 0.6(1003.12 − 911.925)
𝑡 = 0.0126 𝑚 = 12.6 𝑚𝑚
Outside diameter
𝐷𝑜 = 2(𝑟𝑖 + 𝑡)
7.44
𝐷𝑜 = 2 ( + (0.0126))
2
𝐷𝑜 = 7.47 𝑚
External volume
4
𝜋(7.47)2 (22.31)
4
Volume of steel
𝑉𝑠𝑡𝑒𝑒𝑙 = 977.76 − 968.45
Mass of the tank
𝑘𝑔
𝑚𝑡𝑎𝑛𝑘 = (9.31 𝑚3 ) (7830 𝑚3 ) = 72868.9 𝑘𝑔
259
Heuristics:
 Qgain=Qloss
 Heat transfer coefficients for liquid to liquid is 1875 W/m2-K
Tin Tout
Design Pressure
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(101.325 𝑘𝑃𝑎)
Heat transfer area
𝑄
𝐴=
𝑈∆𝑇𝐿𝑀
(𝑇1 − 𝑡2 ) − (𝑇2 − 𝑡1 ) (180 − 80) − (85 − 25)

∆𝑇𝐿𝑀 = =
(𝑇 − 𝑡2 ) (180 − 80)
ln ( 1 ) ln ( )
(𝑇2 − 𝑡1 ) (85 − 25)
∆𝑇𝐿𝑀 = 78.30℃
𝑘𝐽 1000 𝐽
643.83 𝑠 ×
1 𝑘𝐽
𝐴=
(1875 W/m2 − K)(78.30)
𝐴 = 4.39 𝑚2
Number of tubes
𝐴
𝑛=
𝜋𝐷𝐿
260
4.39 𝑚2
𝑛=
𝜋(0.019)(4.9)
Wall thickness
𝑃𝑟𝑖
𝑡=( ) + 𝐶𝑐
𝑟𝑖 = = 0.1015 𝑚
2
(111.458 − 101.325) 𝑘𝑃𝑎 × (0.1015)𝑚

𝑡=( ) + 0.0038
(94500)(1.0) − 0.6(111.458 − 101.325)
𝑡 = 0.0038 𝑚 = 3.80 𝑚𝑚
Outside Diameter
𝐷𝑜 = 2(𝑟𝑖 + 𝑡)
0.203
= 2( + 0.0038)
2
= 0.2106 𝑚
261
Storage Tank ST-103
Heuristics:
Ethanol 13.46 800
Total 13.46 800
Design Temperature
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 25 ℃ + 30 ℃
Design Pressure
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(101.325 𝑘𝑃𝑎)
Volume
𝑚̇
𝑉̇ =
𝜌
(13.46 𝑘𝑔
ℎ𝑟
)
𝑉̇ = 𝑘𝑔
(800 𝑚 3)
𝑚 3
𝑉̇ = 0.017 ℎ𝑟
262
𝑉
𝜏=
𝑉̇
𝑚3
𝑉 = 6 ℎ𝑟 (0.017 ℎ𝑟
)
𝑉 = 0.1 𝑚3
At 70% fill capacity,
0.1 𝑚3 𝑑
𝑉= = 0.14 = 𝜋( )2 (3𝑑)
0.70 2
𝑑 = 0.39 𝑚
ℎ = 1.17 𝑚
Wall thickness
𝑃𝑟𝑖
𝑡=( ) + 𝐶𝑐
0.39
(110 − 100) 𝑘𝑃𝑎( 2 )𝑚
𝑡=( ) + 0.009
(108500)(1.0) − 0.6(110 − 100)
𝑡 = 9.02 × 10−3 𝑚 = 9.02 𝑚𝑚
263
Heuristics:
 Qgain=Qloss
 Heat transfer coefficients for liquid to liquid is 1875 W/m2-K
Tin Tout
Design Pressure
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(101.325 𝑘𝑃𝑎)
Heat transfer area
𝑄
𝐴=
𝑈∆𝑇𝐿𝑀
(𝑇1 − 𝑡2 ) − (𝑇2 − 𝑡1 ) (185 − 85) − (90 − 25)

∆𝑇𝐿𝑀 = =
(𝑇 − 𝑡2 ) (185 − 85)
ln ( 1 ) ln ( )
(𝑇2 − 𝑡1 ) (90 − 25)
∆𝑇𝐿𝑀 = 81.25℃
𝑘𝐽 1000 𝐽
1170.59 𝑠 ×
1 𝑘𝐽
𝐴=
(1875 W/m2 − K)(81.25)
𝐴 = 7.68 𝑚2
Number of tubes
𝐴
𝑛=
𝜋𝐷𝐿
7.68 𝑚2
𝑛=
𝜋(0.019)(4.9)
264
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠 = 𝑡𝑤𝑜 𝑝𝑎𝑠𝑠
Wall thickness
𝑃𝑟𝑖
𝑡=( ) + 𝐶𝑐
𝑟𝑖 = = 0.1015 𝑚
2
(111.458 − 101.325) 𝑘𝑃𝑎 × (0.1015)𝑚

𝑡=( ) + 0.0038
(94500)(1.0) − 0.6(111.458 − 101.325)
𝑡 = 0.0038 𝑚 = 3.80 𝑚𝑚
Outside Diameter
𝐷𝑜 = 2(𝑟𝑖 + 𝑡)
0.203
= 2( + 0.0038)
2
= 0.2106 𝑚
265
Filter F-102
Heuristics:
 10% freeboard
Dextrose 601.9 1540 0.1617
Xylose 338.83 1520 0.091
Lignin 66.38 1340 0.018
Water 2716.09 1000 0.730
Total 3723.2 5400 1
Basis: 1 cycle
𝑚̇
𝑉=
𝜌𝑎𝑣𝑒
𝜌𝑎𝑣𝑒 = (1540)(0.1617) + (1520)(0.091) + (1340)(0.018) + (1000)(0.730)

𝑘𝑔
𝜌𝑎𝑣𝑒 = 1141.46 𝑚3
(3723.2 𝑘𝑔
ℎ𝑟
)
𝑉= 𝑘𝑔
(1141.46 𝑚 3)
𝑉 = 3.26 𝑚3
𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 = (3.26 𝑚3 )(1.1)
Assuming Li/Di = 1
266
4
𝐷𝑖 = √
𝜋
3 4(3.59)
𝐷𝑖 = √
𝜋
𝐷𝑖 = 𝐿𝑖 = 1.66 𝑚
𝑃𝑟𝑖
𝑡=( ) + 𝐶𝑐
1.66
(110 − 100) 𝑘𝑃𝑎( 2 )𝑚
𝑡=( ) + 0.0038
(128900)(1.0) − 0.6(110 − 100)
𝑡 = 3.86 × 10−3 𝑚 = 3.86 𝑚𝑚
Outside diameter
𝐷𝑜 = 2(𝑟𝑖 + 𝑡)
1.66
𝐷𝑜 = 2 ( + (0.00386))
2
𝐷𝑜 = 1.67 𝑚
External volume
4
𝜋(1.67)2 (1.66)
4
Volume of steel
𝑉𝑠𝑡𝑒𝑒𝑙 = 3.64 − 3.59
267
Mass of the tank
𝑘𝑔
𝑚𝑡𝑎𝑛𝑘 = (0.046 𝑚3 ) (7830 𝑚3 )
𝜋𝐷𝑖2
𝐴=
4
𝜋(1.66)2
𝐴=
4
𝐴 = 2.16 𝑚2
268
Heuristics:
motor
Dextrose 601.9 1540
Xylose 338.83 1520
Lignin 66.38 1340
Water 2716.09 1000
Total 3723.2 5400
Design Temperature
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 25 ℃ + 30 ℃
Design Pressure
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(101.325 𝑘𝑃𝑎)
269
𝑚̇
𝑉̇ =
𝜌
𝑚3
̇𝑉 = (3723.2 𝑘𝑔)( )
ℎ𝑟 5400 𝑘𝑔
𝑚3 1 ℎ𝑟
𝑉̇ = 0.69 ℎ𝑟 ( )
3600 𝑠
𝑚 3
𝑉̇ = 0.000192 𝑠
𝐷 = 0.61 𝑚
𝐿 = 15 𝑚
𝑚2
𝜃 = 21.8°
𝐿
𝐿𝑎 =
𝑐𝑜𝑠𝜃
15
𝐿𝑎 =
cos(21.8°)
𝐿𝑎 = 16.16 𝑚
Power requirement
𝐿
𝑃 = 𝐶1 𝑉𝐵𝑆 + 0.0295 (0.4 + ) 𝑚̇ + 0.00969∆𝑍𝑚̇
91.42
𝑃 = (1 𝑘𝑊 ∙ 𝑚) (1.52 𝑠 ) + 0.0295 (0.4 + ) (1.03 𝑠 ) + 0.00969(6 𝑚)(1.03 𝑠 )
91.42
𝑃 = 1.59 𝑘𝑊
270
Assuming actual power requirement is 15% higher due to losses,
𝑃 = (1.15)(1.59 𝑘𝑊)
𝑃 = 1.83 𝑘𝑊
271
Reactor R-103
Heuristics:
 An addition of 30℃ to the operating temperature to get the design temperature
 10% freeboard
Mass flow rate Volumetric flow

Component Density kg/m3 Weight fraction
kg/hr rate m3/day
Dextrose 601.9 1540 0.1617 9.38
Xylose 338.83 1520 0.091 5.35
Lignin 66.38 1340 0.0178 1.19
Water 2716.09 1000 0.730 65.19
Total 3723.2 8330 1 81.11
Design Temperature
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 55 ℃ + 30 ℃
Design Pressure
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(101.325 𝑘𝑃𝑎)
272
Basis: 1 cycle
𝑚̇
𝑉=
𝜌𝑎𝑣𝑒
𝜌𝑎𝑣𝑒 = (1540)(0.1617) + (1520)(0.091) + (1340)(0.0178) + (1000)(0.730)
𝑘𝑔
𝜌𝑎𝑣𝑒 = 1141.19 𝑚3
(3723.2 𝑘𝑔 )( )
𝑉= 𝑘𝑔
(1141.19 𝑚 3)
𝑉 = 228.38 𝑚3
𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 = (228.38 𝑚3 )(1.1)
4
𝜋𝐷𝑖3
4
𝐷𝑖 = √
3𝜋
3 4(251.22)
𝐷𝑖 = √
3𝜋
𝐷𝑖 = 4.74 𝑚
Length
𝐿 = 3𝐷𝑖
𝐿 = 3(4.74 𝑚)
𝐿 = 14.23 𝑚
Wall thickness
𝑃𝑟𝑖
𝑡=( ) + 𝐶𝑐
273
4.74
(111 − 110) 𝑘𝑃𝑎( 2 )𝑚
𝑡=( ) + 0.009
(94500)(1.0) − 0.6(111 − 110)
𝑡 = 0.00903 𝑚 = 9.03 𝑚𝑚
Outside diameter
𝐷𝑜 = 2(𝑟𝑖 + 𝑡)
4.74
𝐷𝑜 = 2 ( + (0.00903))
2
𝐷𝑜 = 4.76 𝑚
External volume
4
𝜋(4.76)2 (14.23)
4
Volume of steel
𝑉𝑠𝑡𝑒𝑒𝑙 = 253.23 − 251.22
Mass of the tank
𝑘𝑔
𝑚𝑡𝑎𝑛𝑘 = (2.006 𝑚3 ) (7830 𝑚3 )
𝑚𝑡𝑎𝑛𝑘 = 15708.77 𝑘𝑔
274
Pump P-104
Heuristics:
Xylose 304.94 1520
Lignin 59.75 1340
Water 5160.57 1000
Total 6066.97 5400
𝑚̇
𝑉̇ =
𝜌
(6066.97 𝑘𝑔
ℎ𝑟
)
𝑉̇ = 𝑘𝑔
(5400 𝑚 3)
𝑚 3
𝑉̇ = 1.12 ℎ𝑟
Discharge head

𝑘𝐽
𝑃𝑜𝑢𝑡
𝐻=
𝑚̇𝑔
𝑘𝐽 1 ℎ𝑟 1000 𝐽
(6540.19 ℎ𝑟 )(3600 𝑠)( )
1 𝑘𝐽
𝐻=
(6066.97 𝑘𝑔 𝑚
× 1 ℎ𝑟 )(9.8 2 )
ℎ𝑟 3600 𝑠 𝑠
𝐻 = 110 𝑚
Input power
𝑃𝑜𝑢𝑡
𝑃𝑖𝑛 =
𝜀
275
𝑘𝐽
(6540.19ℎ𝑟 )
𝑃𝑖𝑛 =
0.8
𝑃𝑖𝑛 = 8175.24 𝑊
276
Filter F-103
Heuristics:
 10% freeboard
Dextrose 440.03 1540 0.1769
Xylose 243.95 1520 0.098
Water 1804.08 1000 0.725
Total 2488.06 5400 1
Basis: 1 cycle
𝑚̇
𝑉=
𝜌𝑎𝑣𝑒
𝜌𝑎𝑣𝑒 = (1540)(0.1769) + (1520)(0.098) + (1000)(0.725)

𝑘𝑔
𝜌𝑎𝑣𝑒 = 1146.39 𝑚3
(2488.06 𝑘𝑔
ℎ𝑟
)
𝑉= 𝑘𝑔
(1146.39 𝑚 3)
𝑉 = 2.17 𝑚3
𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 = (2.17 𝑚3 )(1.1)
Assuming Li/Di = 1,
4
277
𝐷𝑖 = √
𝜋
3 4(2.39)
𝐷𝑖 = √
𝜋
𝐷𝑖 = 𝐿𝑖 = 1.45 𝑚
𝑃𝑟𝑖
𝑡=( ) + 𝐶𝑐
1.45
(111 − 101) 𝑘𝑃𝑎( 2 )𝑚
𝑡=( ) + 0.0038
(128900)(1.0) − 0.6(111 − 101)
𝑡 = 3.86 × 10−3 𝑚 = 3.86 𝑚𝑚
Outside diameter
𝐷𝑜 = 2(𝑟𝑖 + 𝑡)
1.45
𝐷𝑜 = 2 ( + (0.00386))
2
𝐷𝑜 = 1.46 𝑚
External volume
4
𝜋(1.46)2 (1.45)
4
Volume of steel
𝑉𝑠𝑡𝑒𝑒𝑙 = 2.43 − 2.39
278
Mass of the tank
𝑘𝑔
𝑚𝑡𝑎𝑛𝑘 = (0.038 𝑚3 ) (7830 𝑚3 )
𝜋𝐷𝑖2
𝐴=
4
𝜋(1.45)2
𝐴=
4
𝐴 = 1.65 𝑚2
279
Heuristics:
motor
Xylose 60.99 1520
Lignin 47.200 1340
Water 3369.04 1000
Total 3578.91 5400
Design Temperature
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 25 ℃ + 30 ℃
Design Pressure
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(101.325 𝑘𝑃𝑎)
𝑚̇
𝑉̇ =
𝜌
280
𝑘𝑔 𝑚3
𝑉̇ = (3578.91 ℎ𝑟 )( )
5400 𝑘𝑔
𝑚3 1 ℎ𝑟
𝑉̇ = 0.66 ℎ𝑟 ( )
3600 𝑠
𝑚 3
𝑉̇ = 0.000184 𝑠
𝐷 = 0.61 𝑚
𝐿 = 15 𝑚
𝑚2
𝜃 = 21.8°
𝐿
𝐿𝑎 =
𝑐𝑜𝑠𝜃
15
𝐿𝑎 =
cos(21.8°)
𝐿𝑎 = 16.16 𝑚
Power requirement
𝐿
𝑃 = 𝐶1 𝑉𝐵𝑆 + 0.0295 (0.4 + ) 𝑚̇ + 0.00969∆𝑍𝑚̇
91.42
𝑃 = (1 𝑘𝑊 ∙ 𝑚) (1.52 𝑠 ) + 0.0295 (0.4 + ) (0.99 𝑠 ) + 0.00969(6 𝑚)(0.99 𝑠 )
91.42
𝑃 = 1.59 𝑘𝑊
Assuming actual power requirement is 15% higher due to losses
𝑃 = (1.15)(1.59 𝑘𝑊) = 1.83 𝑘𝑊
281
Holding Tank HT-101
Heuristics:
 0.0038 corrosion allowance for noncorrosive conditions
 10% freeboard
Component Mass flow rate Density kg/m3 Weight fraction
(kg/hr)
Dextrose 440.03 1540 0.1769
Xylose 243.95 1520 0.098
Water 1804.08 1000 0.7251
Total 2488.06 4060 12.514
Design Temperature
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 25 ℃ + 30 ℃
Design Pressure
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(101.325 𝑘𝑃𝑎)
Volumetric flow rate
𝑚̇
𝑉=
𝜌𝑎𝑣𝑒
𝜌𝑎𝑣𝑒 = (1540)(0.1769) + (1520)(0.098) + (1000)(0.7251)
282
𝑘𝑔
𝜌𝑎𝑣𝑒 = 1146.49 𝑚3
(2488.06 𝑘𝑔 )( )
𝑉= 𝑘𝑔
(1146.49 𝑚 3)
𝑉 = 151.91 𝑚3
𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 = (151.91 𝑚3 )(1.1)
4
𝜋𝐷𝑖3
4
𝐷𝑖 = √
3𝜋
3 4(167.1)
𝐷𝑖 = √
3𝜋
𝐷𝑖 = 4.14 𝑚
Length
𝐿 = 3𝐷𝑖
𝐿 = 3(4.14 𝑚) = 12.42 𝑚
Wall thickness
𝑃𝑟𝑖
𝑡=( ) + 𝐶𝑐
4.14
(111 − 101) 𝑘𝑃𝑎( 2 )𝑚
𝑡=( ) + 0.0038
(108500)(1.0) − 0.6(111 − 101)
283
𝑡 = 4.0 × 10−3 𝑚 = 4.0 𝑚𝑚
Outside diameter
𝐷𝑜 = 2(𝑟𝑖 + 𝑡)
4.14
𝐷𝑜 = 2 ( + (0.004))
2
𝐷𝑜 = 4.148 𝑚
External volume
4
𝜋(4.148)2 (12.42)
4
Volume of steel
𝑉𝑠𝑡𝑒𝑒𝑙 = 167.84 − 167.10
Mass of the tank
𝑘𝑔
𝑚𝑡𝑎𝑛𝑘 = (0.737 𝑚3 ) (7830 𝑚3 )
𝑚𝑡𝑎𝑛𝑘 = 5774.54 𝑘𝑔
284
Pump P-105
Heuristics:
Xylose 240.95 1520
Water 1804.08 1000
Total 2488.06 4060
𝑚̇
𝑉̇ =
𝜌
(2488.06 𝑘𝑔
ℎ𝑟
)
𝑉̇ = 𝑘𝑔
(4060 𝑚 3)
𝑚 3
𝑉̇ = 0.61 ℎ𝑟
Discharge head

𝑘𝐽
𝑃𝑜𝑢𝑡
𝐻=
𝑚̇𝑔
𝑘𝐽 1 ℎ𝑟 1000 𝐽
(2682.144 ℎ𝑟 )(3600 𝑠)( )
1 𝑘𝐽
𝐻=
(2488.06 𝑘𝑔 𝑚
× 1 ℎ𝑟 )(9.8 2 )
ℎ𝑟 3600 𝑠 𝑠
𝐻 = 110 𝑚
Input power
𝑃𝑜𝑢𝑡
𝑃𝑖𝑛 =
𝜀
𝑘𝐽
(2682.144 ℎ𝑟 )
𝑃𝑖𝑛 = = 3.35 𝑘𝑊
0.8
285
Fermentation tank (BR-201)
Heuristics considered:
 Design temperature is set 30 degrees Celsius above the operating temperature.
 Volume of industrial scale bioreactor ranges from 0.5m3 to 2.5m3
 70% fill capacity; 30% free space.
 The equipment is cylindrical.
 Height-to-diameter ratio is 1
 Based on literature residence time is about 12 hours.
 Design pressure is 10% above the operating pressure.
Operating conditions:
286
Xylose 243.95 1520
Water 1804.07 1000
Biomass 870.82 574.713
TOTAL 3348.87 4634.7
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 0.1205 (1540) + 0.0735 (1520) + 0.5435 (1000) + 0.2623 ( 574.7)
𝐾𝑔
𝑚3
Volume of the feed
𝐾𝑔 𝑑𝑎𝑦 12 ℎ𝑟
𝑚 3348.87 ℎ𝑟 (1 𝑐𝑦𝑐𝑙𝑒)( 𝑑𝑎𝑦 )
𝑉𝑓𝑒𝑒𝑑 = =
𝜌 𝐾𝑔
991.72 3
𝑚
𝑉𝑓𝑒𝑒𝑑 = 40.52 𝑚3
Volume of the reactor
𝑉 = 𝑉𝑓𝑒𝑒𝑑 (1.3)
𝑉 = 40.52 (1.3)
𝑉 = 52.67
Number of Fermenter per cycle
- Usual Volume of Industrial Scale bioreactor: 11 m3
Number of fermenter per cycle = V/VUSUAL
Number of fermenter per cycle = 52.67 / 11
287
Number of fermenter per cycle= 4.78 = 5 Fermenters per cycle
Inside Diameter
𝜋 2
𝑉= 𝐷 𝐿
4 𝑖
𝜋 3
𝑉= 𝐷
4 𝑖
𝜋 3
11 𝑚3 = 𝐷
4 𝑖
𝐷𝐼 = 2.41 𝑚
Internal Volume
- Assume 70% fill capacity
𝑉
𝑉𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 =
0.7
11
𝑉𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 =
0.7
𝑉𝐼𝑛𝑡𝑒𝑟𝑛𝑎𝑙 = 15. 71 𝑚3
Length
𝜋 2
𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 = 𝐷 𝐿
4 𝑖
𝜋
15.71 = (2.41)2 𝐿
4
𝐿 = 3.44 𝑚
288
Thickness
Parameter
(m)
Maximum Allowance Carbon Steel 𝑆 = 94500 𝐾𝑝𝑎
Stress (Kpa)
Efficiency of Joints Fully Radiographed 𝐸𝑗 = 1
double-welded butt
joint
Design equation for cylindrical shells:
𝑃𝑟𝑖
𝑡= + 𝐶𝑐
2.41
111.45 𝐾𝑝𝑎( 2 )
𝑡= + 0.009𝑚
94500 𝐾𝑝𝑎(1) − 0.6(111.45 𝐾𝑝𝑎)
𝑡 = 0.01 𝑚
𝐷𝑜 = 2 (𝑟𝑖 − 𝑡)
2.41
𝐷𝑜 = 2 ( − 0.01)
2
𝐷𝑜 = 2.43 𝑚
External Volume
𝜋 2
𝑉= 𝐷 𝐿
4 𝑖
𝜋
𝑉= 2.432 (3.44)
4
289
𝑉 = 15.95 𝑚3
Volume Steel
𝑉𝑆𝑡𝑒𝑒𝑙 = 15.95 𝑚3 − 15. 71 𝑚3
Mass of Fermentation tank
𝑘𝑔
𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 0.24 𝑚3 × 7830
𝑚3
Diameter of Impeller
𝐷𝑖
𝐷𝑇𝐼 =
3
2.41
𝐷𝑇𝐼 =
3
𝐷𝑇𝐼 = 0.8033 𝑚
Impeller level above bottom
𝐷𝑖
𝐻𝐼 =
3
2.41
𝐻𝐼 =
3
𝐻𝐼 = 0.8033 𝑚
290
Impeller blade width
𝐷𝑖
𝑊𝐼 =
15
2.41
𝑊𝐼 =
3
𝑊𝐼 = 0.8033 𝑚
Speed of Impeller
𝑚
𝑁 = 0.038
𝑠
Wall baffles (thickness)
𝐷𝑖
10
2.41
10
𝑡𝑏𝑎𝑓𝑓𝑙𝑒𝑠 = 0.241 𝑚
Reynolds Number
2
𝐷𝑇𝐼 𝑛𝜌
𝑅𝑒 =
𝜇
1
(0.8024)2 ((0.308)(
0.8024 ))(991.72)
( 2 )
𝑅𝑒 =
8.9 × 10−4
𝑅𝑒 = 552006.75
5
𝑃 = 𝐾𝑡 𝑛3 𝐷𝑇𝐼 𝜌
1
𝑃 = (5.75)((0.038)( )3 (0.8033)2 (991.72)
0.8024
( )
2
291
𝑃 = 1.62 𝑘𝑊
292
Pump (P-201)
Heuristics:
 Centrifugal pump with 40% efficiency
Xylose 243.95 1520
Water 205.61 997
Biomass 1016.91 574.713
Ammonium Lactate 231.40 1054
Total 1697.87
Volumetric Flow Rate
𝑚̇
𝑉̇ =
𝜌
̇ 𝑘𝑔
1697.87
𝑉̇ = ℎ𝑟
(0.14) (1520 3 ) + (0.12) (997 3 ) + (0.60) (574.713 3 ) + (0.14) (1054 3 )
𝑚 𝑚 𝑚 𝑚
𝑚3
= 2.06
ℎ𝑟
Head
𝑃
𝐻=
𝑚𝑔
𝐽
𝑃 = 179702.56
ℎ𝑟
𝐽
3336144.76
𝐻= ℎ𝑟
̇ 𝑘𝑔 𝑚
(1697.87 ℎ𝑟 ) (9.8 2 )
𝑠
293
𝐻 = 200.5 𝑚
For Centrifugal Pump
𝑃𝑜𝑢𝑡
𝑃𝑖𝑛 =
𝜀
926.71 𝑊
𝑃𝑖𝑛 =
0.4
𝑃𝑖𝑛 = 2316.77 𝑊
294
Centrifuge (CF-201)
 Design Pressure is 10% higher than operating pressure
 Optical length -to-diameter ratio is 1
 10% freeboard
Xylose 205.61 1520
Water 1016.91 1000
Biomass 239.31 574.713
TOTAL 1705.78 4634.7
Operating Pressure = 100 Kpa
Design Pressure = 100 Kpa (1.1)
Design Pressure = 110 Kpa
295
𝑚𝑎𝑠𝑠
𝑉=
𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑑𝑒𝑛𝑠𝑖𝑡𝑦
1705.78 𝐾𝑔
𝑉=
𝐾𝑔
4634.7 3
𝑚
𝑉 = 0.36 𝑚3
Volume internal (10% Freeboard)
𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 = 1.1 𝑉
𝑉𝑖𝑛𝑡𝑒𝑟𝑛𝑎𝑙 = 1.1 (0.36)
Inside Diameter and Length
𝜋 2
𝑉= 𝐷 𝐿
4 𝑖
𝜋 2
𝑉= 𝐷 𝐷
4 𝑖 𝑖
𝜋 2
0.4 = 𝐷 𝐷
4 𝑖 𝑖
𝐷𝑖 = 0.8 𝑚
𝐿 = 0.8 𝑚
Thickness
Parameter
(m)
296
Maximum Allowance Stainless 316 steel 𝑆 = 119086.09 𝐾𝑝𝑎
Stress (Kpa) (SA-240)
double-welded butt
joint
𝑃𝑟𝑖
𝑡= + 𝐶𝑐
0.8
110 𝐾𝑝𝑎( 2 )
𝑡= + 0.009𝑚
119086.09 𝐾𝑝𝑎(1) − 0.6(110 𝐾𝑝𝑎)
𝑡 = 0.00937 𝑚
Outside Diameter
𝐷𝑜 = 2 (𝑟𝑖 + 𝑡)
0.8
𝐷𝑜 = 2 (( ) + 0.00937)
2
𝐷𝑜 = 0.8187 𝑚
External Volume
𝜋 2
𝑉= 𝐷 𝐿
4 𝑖
𝜋
𝑉= (0.8187)2 (0.8)
4
𝑉 = 0.42 𝑚3
Volume of steel
297
𝑉𝑆𝑡𝑒𝑒𝑙 = 0.42 𝑚3 − 0.4𝑚3
Mass of steel
𝑘𝑔
𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 0.02 𝑚3 × 7883
𝑚3
𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 157.66 𝑘𝑔
298
Pump (P-202)
Heuristics:
Water 195.33 997
Xylose 231.76 1520
Total 646.91
𝑚̇
𝑉̇ =
𝜌
̇ 𝑘𝑔
646.91 𝑚3
𝑉̇ = ℎ𝑟 = 0.53
𝑘𝑔 𝑘𝑔 𝑘𝑔 ℎ𝑟
(0.36) (1520 3 ) + (0.30) (997 3 ) + (0.34) (1054 3 )
𝑚 𝑚 𝑚
Head
𝑃
𝐻=
𝑚𝑔
𝐽
𝑃 = 1271113.46
ℎ𝑟
𝐽
1271113.46
𝐻= ℎ𝑟
𝑘𝑔 𝑚
(646.91 ) (9.8 2 )
ℎ𝑟 𝑠
𝐻 = 200.5 𝑚
299
𝑃𝑜𝑢𝑡
𝑃𝑖𝑛 =
𝜀
353.09 𝑊
𝑃𝑖𝑛 =
0.4
𝑃𝑖𝑛 = 882.725 𝑊
300
Esterification Reactor (ER-201)
 Volume of industrial scale bioreactor ranges from 0.5m3 to 2.5m3
 70% fill capacity; 30% free space.
 The equipment is cylindrical.
 Height-to-diameter ratio is 1
 Based on literature residence time is about 12 hours.
301
Xylose 231.75 1520
Water 195.32 1000
Butanol 249.15 810
TOTAL 896.04 4384
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 0.2586 (1520) + 0.2179 (1000) + 0.2453 (1054) + 0.2780 ( 810)
𝐾𝑔
𝑚3
3 /𝑅𝑇
𝐾 = 2.2602 (𝑇 0.3498 )(𝑒 −9.91 𝑥10 )
𝐽
𝑅 = 8.314 𝑚𝑜𝑙 𝐾 𝑇 = 80𝑜 𝐶 +273 = 353 K
3 /(8.314)353
𝑘 = 2.2602 (3530.3498 )(𝑒 −9.91 𝑥10 )
𝑘 = 0.601 𝑚𝑖𝑛−1
𝑘 = 865.44 𝑑𝑎𝑦 −1
𝐹𝐴
𝑣𝑜 =
𝐶𝐴
25.55
𝐶𝐴 =
𝑣𝑜
𝐾𝑚𝑜𝑙𝑒 𝐾𝑔 1
𝑣𝑜 = (25.55 ) (90.73 )( )
ℎ𝑟 𝑘𝑚𝑜𝑙 1094. 𝐾𝑔
𝑚 3
𝑚3
𝑣𝑜 = 2.11
ℎ𝑟
302
𝐾𝑚𝑜𝑙𝑒
25.55
𝐶𝐴 = ℎ𝑟
𝑚3
2.11
ℎ𝑟
𝐶𝐴 = 12.1 𝑘𝑚𝑜𝑙/𝑚3
30.87
𝑉𝐶𝑆𝑇𝑅 =
(0.601)(12.1)
𝑉𝐶𝑆𝑇𝑅 = 4.24 𝑚3
4.24 𝑚3
𝑅𝑒𝑠𝑖𝑑𝑒𝑛𝑐𝑒 𝑡𝑖𝑚𝑒 = 𝜏 =
𝑚3
2.11
ℎ𝑟
𝜏 = 2ℎ𝑟𝑠 = 120 𝑚𝑖𝑛𝑠
Diameter and Length
𝜋 2
𝑉= 𝐷 𝐿
4 𝑖
𝜋 2
𝑉= 𝐷 𝐷
4 𝑖 𝑖
𝜋 2
4.24 = 𝐷 𝐷
4 𝑖 𝑖
𝐷𝑖 = 1.75 𝑚
𝐿 = 1.75 𝑚
Thickness of tank
- Using the equation for vessels at atmosphere pressure:
𝑃𝑟𝑖
𝑡= + 𝐶𝑐
303
Parameter
(m)
Maximum Allowance High-alloy steel 𝑆 = 111666.67 𝐾𝑝𝑎
Stress (Kpa) Stainless 304
(SA-240)
double-welded butt
joint
1.75
23.33 ( 2 )
𝑡= + 0.009
23.33 (1) − 0.6(23.33)
𝑡 = 0.00918 𝑚
Outside Diameter
𝐷𝑜 = 2 (𝑟𝑖 + 𝑡)
1.75
𝐷𝑜 = 2 (( ) + 0.00918)
2
𝐷𝑜 = 1.76𝑚
External Volume
𝜋 2
𝑉= 𝐷 𝐿
4 𝑖
𝜋
𝑉= (1.76)2 (1.75)
4
𝑉 = 4.25 𝑚3
Volume of steel
304
𝑉𝑆𝑡𝑒𝑒𝑙 = 4.5 𝑚3 − 4.24𝑚3
Mass of steel
𝑘𝑔
𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 0.26 𝑚3 × 7830
𝑚3
𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 2035. 8 𝐾𝑔
305
Heat Exchanger (HE-201)
Heuristics:
 The flow is counter current with feed at the tube side and water at the shell side
𝑊
 Heat transfer coefficient water to liquid: 285 𝑚2 ∙𝐾
 Outer diameter is 0.0254m and the length is 4.9m
Temperature Conditions
Inlet Outlet
Th 80°C 37°C
Tc 15°C 23°C
Design Pressure:
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(101.325 𝑘𝑃𝑎)
Heat Transfer Area
𝑄
𝐴=
𝑈∆𝑇
(80 − 15) − (37 − 23)

∆𝑇𝑙𝑚 =
80 − 15
ln (37 − 23)
∆𝑇𝑙𝑚 = 33.22 𝐾
15888.84𝑊
𝐴=
𝑊
(285 2 )(33.22 𝐾)
𝑚 ∙𝐾
𝐴 = 1.68 𝑚2
306
Number of tubes
𝐴
𝑛=
𝜋𝐷𝐿
1.68 𝑚2
𝑛=
𝜋(0.0254)(4.9)
𝑛 = 4.29 𝑡𝑢𝑏𝑒𝑠 ~ 4 𝑡𝑢𝑏𝑒𝑠
307
Extraction Column (EX-201)
Heuristics:
 The design temperature is 30℃ higher than the operating temperature
 The design pressure is 10% over than the maximum operating pressure or 70 to 175
kPa higher whichever is greater
 100% extraction stage efficiency
 Height-to-diameter tank ratio of 3
 9mm corrosion allowance
 Actual velocity is 85% of flooding velocity
Assumptions:
 Single stage extraction column
 Slope of equilibrium line is 1
Design Temperature
𝑇𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 = 37℃
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 𝑇𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 + 30℃
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 37℃ + 30℃
Design Pressure
𝑃𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 = 150 𝑘𝑃𝑎
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = 𝑃𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 + 175 𝑘𝑃𝑎
308
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = 150 𝑘𝑃𝑎 + 175 𝑘𝑃𝑎
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = 325 𝑘𝑃𝑎
Xylose 231.76 - 1520
Water 176.84 176.84 997
Butyl Lactate 299.99 299.99 980
Total 708.58 476.83
Mixture Density
For inlet streams:
𝑀𝐷 = (0.33)(1520) + (0.25)(997) + (0.42)(980)
𝑘𝑔
𝑀𝐷 = 1162.45
𝑚3
For outlet streams:
𝑀𝐷 = (0.37)(997) + (0.63)(980)
𝑘𝑔
𝑀𝐷 = 986.29
𝑚3
Volume
𝑀𝑎𝑠𝑠 𝑇𝑜𝑡𝑎𝑙
𝑉=
𝑀𝑖𝑥𝑡𝑢𝑟𝑒 𝐷𝑒𝑛𝑠𝑖𝑡𝑦
708.58 476.83
𝑉= +
1162.45 986.29
𝑉 = 1.093𝑚3
309
Dimension
For 80% filling capacity:
1.093 𝑑
𝑉= = 1.36625 = 𝜋( )2 (3𝑑)
0.8 2
𝑑 = 0.83 𝑚
ℎ = 2.49 𝑚
Wall thickness
𝑃𝑟𝑖
𝑡= + 𝐶𝑐
𝑆 = 137,900 (𝑆𝑡𝑎𝑖𝑛𝑙𝑒𝑠𝑠 𝑠𝑡𝑒𝑒𝑙 𝑡𝑦𝑝𝑒 316)
𝐸𝑗 = 1.0 (𝐹𝑢𝑙𝑙𝑦 𝑟𝑎𝑑𝑖𝑜𝑔𝑟𝑎𝑝ℎ𝑒𝑑 𝑑𝑜𝑢𝑏𝑙𝑒 − 𝑤𝑒𝑙𝑑𝑒𝑑 𝑏𝑢𝑡𝑡 𝑗𝑜𝑖𝑛𝑡𝑠)
0.83
(325 − 150)𝑘𝑃𝑎( 2 )𝑚
𝑡= + 0.009 𝑚
(137900)(1) − 0.6(325 − 150)𝑘𝑃𝑎
1000𝑚𝑚
𝑡 = 9.53𝑥10−3 𝑚 ( )
1𝑚
𝑡 = 9.53 𝑚𝑚
310
Pump (P-203)
Heuristics:
Water 176.84 997
Butyl Lactate 299.99 980
Total 476.83
𝑚̇
𝑉̇ =
𝜌
̇ 𝑘𝑔
476.834 𝑚3
̇𝑉 = ℎ𝑟 = 0.483
𝑘𝑔 𝑘𝑔 ℎ𝑟
(0.37) (997 3 ) + (0.63)(980 3 )
𝑚 𝑚
Head
𝑃
𝐻=
𝑚𝑔
𝐽
𝑃 = 938325.15
ℎ𝑟
𝐽
938325.15
𝐻= ℎ𝑟
𝑘𝑔 𝑚
(476.83 ) (9.8 2 )
ℎ𝑟 𝑠
𝐻 = 200.8 𝑚
311
𝑃𝑜𝑢𝑡
𝑃𝑖𝑛 =
𝜀
260.65 𝑊
𝑃𝑖𝑛 =
0.4
𝑃𝑖𝑛 = 651.625 𝑊
312
Hydrolysis Reactor (HR-201)
Heuristics:
 Design equation is based on the principle of PFR.
 Height-to Diameter ratio is about 1.
Butyl Lactate 299.98 980
Water 1822.97 1000
TOTAL 2122.95 1980
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 0.8586 (1000) + 0.1413 (980)
𝐾𝑔
𝑚3
313
To solve for the volumetric flow rate Q:
𝑚
𝑣𝑜 =
𝜌
𝐾𝑔
2122.95
𝑣𝑜 = ℎ𝑟
𝑘𝑔
997.07 3
𝑚
𝑚3
𝑣𝑜 = 2.12
ℎ𝑟
𝑚𝑜𝑙
𝑥𝑖 𝑣𝑜 𝐶𝐴𝑜 = 2.05
ℎ𝑟
𝑚3 𝑚𝑜𝑙
0.1413 (2.12 )𝐶𝐴𝑜 = 2.05
ℎ𝑟 ℎ𝑟
𝑚𝑜𝑙
𝐶𝐴𝑜 = 6.84
𝑚3
Reaction rate constant:
3 /𝑅𝑇
𝐾 = 2.2602 (𝑇 0.3498 )(𝑒 −9.91 𝑥10 )
𝐽
𝑅 = 8.314 𝑇 = 100𝑜 𝐶 +273 = 403 K
𝑚𝑜𝑙 𝐾
3 /(8.314)403
𝑘 = 2.2602 (4030.3498 )(𝑒 −9.91 𝑥10 )
𝑘 = 0.957 𝑚𝑖𝑛−1
𝑘 = 3445.5 𝑑𝑎𝑦 −1
𝑥
𝐶𝐴𝑜 𝑣𝑜 𝑑𝑥
𝑉𝑃𝐹𝑅 = ∫ −
0 𝑟𝐴
𝑚𝑜𝑙 𝑚3
0.99 6.84 3 (2.12 ) 𝑑𝑥
𝑚 ℎ𝑟
𝑉𝑃𝐹𝑅 = ∫ −
0 57.42 𝑚3
(2.12 )(1 − 𝑥)
ℎ𝑟 ℎ𝑟
𝑉𝑃𝐹𝑅 = 0.55 𝑚3
314
For 70% filling capacity
𝑉
𝑉2 =
0.7
0.55 𝑚3
𝑉2 =
0.7
𝑉2 = 0.78 𝑚3
Diameter and length
𝜋 2
𝑉= 𝐷 𝐿
4 𝑖
𝜋 2
𝑉= 𝐷 𝐷
4 𝑖 𝑖
𝜋 2
0.78 = 𝐷 𝐷
4 𝑖 𝑖
𝐷𝑖 = 0.99 𝑚
𝐿 = 0.99 𝑚
Thickness of tank
- Using the equation for vessels at atmosphere pressure:
𝑃𝑟𝑖
𝑡= + 𝐶𝑐
Parameter
(m)
Maximum Allowance High-alloy steel 𝑆 = 99853.5 𝐾𝑝𝑎
Stress (Kpa) Stainless 304
315
(SA-240)
double-welded butt
joint
0.99
512.7 ( 2 )
𝑡= + 0.009
99853.5 (1) − 0.6(512.7)
𝑡 = 0.0115 𝑚
Outside Diameter
𝐷𝑜 = 2 (𝑟𝑖 + 𝑡)
0.99
𝐷𝑜 = 2 (( ) + 0.00918)
2
𝐷𝑜 = 1.01𝑚
External Volume
𝜋 2
𝑉= 𝐷 𝐿
4 𝑖
𝜋
𝑉= (1.01)2 (0.99)
4
𝑉 = 0.79 𝑚3
Volume of steel
𝑉𝑆𝑡𝑒𝑒𝑙 = 0.79 𝑚3 − 0.78𝑚3
316
Mass of steel
𝑘𝑔
𝑚𝑎𝑠𝑠𝑡𝑎𝑛𝑘 = 0.01 𝑚3 × 7830
𝑚3
317
Evaporator (EC-201)
Heuristics:
 The diameter of the tube is between 19-63 mm and its length is between 12-30 ft
 The design pressure is 10% greater than the maximum operating pressure
 The design temperature is 30℃ higher than the operating temperature
 Length-to-diameter tank ratio of 3
 9mm corrosion allowance
 Working stress is one-fourth of ultimate strength of material
Assumptions:
𝑊
 Assume overall heat transfer coefficient, U= 900 𝑚2∙𝐾
Design Temperature
𝑇𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 = 89℃
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 𝑇𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 + 30℃
𝑇𝑑𝑒𝑠𝑖𝑔𝑛 = 89℃ + 30℃
Design Pressure
𝑃𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 = 67.824 𝑘𝑃𝑎
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = 𝑃𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 + 𝑃𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 (0.1)
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = 67.824 𝑘𝑃𝑎(1.1)
318
Heat Transfer Area
𝑄
𝐴=
𝑈∆𝑇
𝑘𝐽 1000𝐽 1 ℎ𝑟
137.46 𝑘𝑔 (2201.11 )( )( )
𝑘𝑔 1 𝑘𝐽 3600 𝑠
𝐴=
𝑊
(900 )(121.1 − 94.054)𝐾
𝑚2∙𝐾
𝐴 = 3.45 𝑚2
Dimension
𝜋𝐷 2
𝐴 = 3.45 𝑚2 =
4
𝐷 = 2.10 𝑚
𝐻 = 6.29 𝑚
Volume
𝜋𝐷 2 𝐻
𝑉=
4
𝜋𝐷 2 (3𝐷) 3
𝑉= = 𝜋𝐷 3
4 4
𝑉 = 21.82 𝑚3
Wall thickness
𝑃𝑟𝑖
𝑡= + 𝐶𝑐
𝑆 = 117760 (𝑆𝐴 − 240 𝐺𝑟𝑎𝑑𝑒 316)
𝐸𝑗 = 1.0 (𝐹𝑢𝑙𝑙𝑦 𝑟𝑎𝑑𝑖𝑜𝑔𝑟𝑎𝑝ℎ𝑒𝑑 𝑑𝑜𝑢𝑏𝑙𝑒 − 𝑤𝑒𝑙𝑑𝑒𝑑 𝑏𝑢𝑡𝑡 𝑗𝑜𝑖𝑛𝑡𝑠)
2.1
(74.6064)𝑘𝑃𝑎( 2 )𝑚
𝑡= + 0.009 𝑚
(117760)(1) − 0.6(74.6064)𝑘𝑃𝑎
319
1000𝑚𝑚
𝑡 = 9.665𝑥10−3 𝑚 ( )
1𝑚
𝑡 = 9.67 𝑚𝑚
320
Pump (P-204)
Heuristics:
Water 9.73 997
Lactic Acid 184.96 1206
Total 194.69
𝑚̇
𝑉̇ =
𝜌
𝑘𝑔
194.69 𝑚3
𝑉̇ = ℎ𝑟 = 0.118
𝑘𝑔 𝑘𝑔 ℎ𝑟
(0.5) (997 ) + (0.95)(1206 3 )
𝑚3 𝑚
Head
𝑃
𝐻=
𝑚𝑔
𝐽
𝑃 = 959754.18
ℎ𝑟
𝐽
959754.18
𝐻= ℎ𝑟
𝑘𝑔 𝑚
(194.69 ) (9.8 2 )
ℎ𝑟 𝑠
𝐻 = 503.03 𝑚
321
𝑃𝑜𝑢𝑡
𝑃𝑖𝑛 =
𝜀
266.60 𝑊
𝑃𝑖𝑛 =
0.4
𝑃𝑖𝑛 = 666.5 𝑊
322
Heat Exchanger (HE-202)
Heuristics:
 The flow is counter current with feed at the tube side and water at the shell side
𝑊
 Heat transfer coefficient water to liquid: 285 𝑚2∙𝐾
 Outer diameter is 0.0254m and the length is 4.9m
Temperature Conditions
Inlet Outlet
Th 89°C 37°C
Tc 25°C 35°C
Design Pressure:
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (1.1)(101.325 𝑘𝑃𝑎)
Heat Transfer Area
𝑄
𝐴=
𝑈𝐹∆𝑇
(89 − 25) − (25 − 50)

∆𝑇𝑙𝑚 =
89 − 25
ln ( )
25 − 50
∆𝑇𝑙𝑚 = 17.89 𝐾
7875.15 𝑊
𝐴=
𝑊
(285 2 )(17.89 𝐾)
𝑚 ∙𝐾
𝐴 = 1.54 𝑚2
323
Number of tubes
𝐴
𝑛=
𝜋𝐷𝐿
1.54 𝑚2
𝑛=
𝜋(0.0254)(4.9)
𝑛 = 3.93 𝑡𝑢𝑏𝑒𝑠 ~ 4 𝑡𝑢𝑏𝑒𝑠
324
325
References
[1] D. Aboagye, N. Banadda, R. Kambugu, J. Seay, N. Kiggundu, A. Zziwa, I. Kabenge,

Glucose recovery from different corn stover fractions using dilute acid and alkaline
pretreatment techniques, (2017) 1–11. doi:10.1186/s41610-017-0044-1.
[2] G. Cao, N. Ren, A. Wang, D. Lee, W. Guo, B. Liu, Acid hydrolysis of corn stover for
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MAPÚA UNIVERSITY

School of Chemical, Biological, Materials Engineering and Sciences

PANGASINAN POLYLACTIC ACID PLANT

Asuncion, Jose Daniel G.

A Plant Design Report Submitted in Partial Fulfillment of the

Dr. Rhoda B. Leron

“PANGASINAN POLYLACTIC ACID PLANT” prepared by Jose Daniel G. Asuncion, Ivan

Dr. Rhoda B. Leron

(CHE181-1D) for the Degree of Bachelor of Science in Chemical.

Dr. Alvin R. Caparanga

Dr. Alvin R. Caparanga

Prof. Rhoda B. Leron

Asuncion, Jose Daniel D. Bagumba, Ivan Harold P.

Garcia, Gwenneth P. Nagayo, Juan Augustus A.

Panghulan, Ann Justine B. Soller, Alexis I.

manufactured by Pangasinan PLA Producers (Triple P) is located in Binalonan, Pangasinan. The

putting up polylactic acid producing plants.

processes, especially fermentation process, generate an abundant amount of wastewater. The

the production of numerous products. In the Philippines, industries such as automotive,

releasing any toxic material.

(a) Less amount of energy is needed for the production,

(b) Less amount of greenhouse gases is released during the production,

of PPIA’s goals, which serves as the foundation for this project.

and the waste generated would be minimized.

Polylactic acid, also known as PLA, is a biodegradable thermoplastic produced from

Table 1.1 Properties of PLA

Density (g/cm3) 1.21 – 1.43

Melting point (°C) 150-160

Tensile Strength (MPa) 50

Modulus of Elasticity (MPa) 3500

which is then reshaped for intended purposes.

Additionally, PLA being a bioplastic, it is environmentally viable as it is generally easier

to decomposed as to other plastics. With an industrial composting facility present, decomposition

an edge to other plastics produced.

many applications such as solid waste disposal problems.

Figure 1.1 Per Capita Consumption of Plastic Materials in 2015

capacity is expected to increase in 2022.

Figure 1.2 Global production capacities of bioplastics

properties that can be of great replacement for PS (polystyrene) and PP (polypropylene).

Figure 1.3 Global PLA application market, 2013

PLA in the Philippines

accessibility to raw materials.

because of its availability of resources.

2016, it gradually increased on the following year.

Figure 1.5 PLA Supply in the Philippines

Figure 1.6 PLA Demand in the Philippines

between the supply and demand of polylactic acid in the Philippines.

Figure 1.7 Projected supply and demand

𝑃𝑙𝑎𝑛𝑡 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 1.2589 𝐾𝑖𝑙𝑜 𝑇𝑜𝑛𝑠 𝑝𝑒𝑟 𝑦𝑒𝑎𝑟

Environmental Assessment and Waste Management Plan

be wastewater and solid waste generation.

these emissions continue to rise during the plant operation.

Generation of wastewater accumulates during construction and operation phase. For

be discharged without treatment.

installation will be double/triple-checked to prevent leakage when on operational phase. 6-

months maintenance will be implemented to ensure the quality of pipes.

Flora and Fauna

Operating Temperature = 25oC