University of San Carlos – Department Department of Chemical Engineering CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1
USC Chemical Engineering Student Process Equipment Design 2017 D e p a r t m e n t o f Chemical Engineering
Term/Academic Year: First Semester AY 2017-2018
Talamban, Cebu City, Philippines 6000
PROJECT TITLE
A design project submitted submitted in partial fulfillment of the requirements requirements in the course course
CHE 514N Chemical Reactor and Process Equipment Design
Del Mar, Janus King S.M. Maguikay, Dia Fatima P. Torrefiel, John Christopher A.
October 2017
University of San Carlos – Department of Chemical Engineering CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1
TABLE OF CONTENTS
1 2
1.
The Design Problem.............................................................................................................................................3
3
1.1.
Statement of the design project .................................................................................................................... 3
4
1.2.
Description of the process ............................................................................................................................3
5
1.3.
Summary of the design task .........................................................................................................................4
6
2.
7
Process definition ................................................................................................................................................. 5 2.1.
Flow diagrams .............................................................................................................................................. 5
8
2.1.1.
Input-output diagram............................................................................................................................5
9
2.1.2.
Block flow diagram...............................................................................................................................6
10
2.2.
Basic assumptions .......................................................................................................................................6
11
2.2.1.
Production capacity and feed/product specification.............................................................................6
12
2.2.2.
Plant location, layout and operating hours ...........................................................................................6
13
2.2.3.
Battery limits ........................................................................................................................................6
14
2.2.4.
Definition of incoming and outgoing streams ....................................................................................... 6
15
2.2.5.
Economic margin ................................................................................................................................. 6
16
3.
Chemical engineering design of process equipment ............................................................................................6
17
3.1.
Equipment sizing ..........................................................................................................................................6
18
3.2.
Equipment configuration and operating scheme ..........................................................................................7
19
3.3.
Energy requirements and duties................................................................................................................... 7
20
4.
Mechanical design of process equipment ............................................................................................................7
21
4.1.
Materials of construction...............................................................................................................................7
22
4.2.
Fittings and connections...............................................................................................................................7
23
4.3.
Equipment internals......................................................................................................................................7
24
4.4.
Loading and supports ................................................................................................................................... 7
25
4.5.
Pumping requirements ................................................................................................................................. 7
26
4.6.
Mechanical drawing of process equipment ..................................................................................................7
27
5.
Piping and instrumentation ................................................................................................................................... 7
28
5.1.
Piping system ............................................................................................................................................... 7
29
5.2.
Valves and meters........................................................................................................................................7
30
5.3.
Compressors and pumps .............................................................................................................................8
31
5.4.
Control and instrumentation .........................................................................................................................8
32
6.
33
References..................................................................................................................................................................... 9
34
Appendices ..................................................................................................................................................................10
35
A.
Conclusions and recommendations ..................................................................................................................... 8
Physical and Thermodynamic data .................................................................................................................... 10
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University of San Carlos – Department of Chemical Engineering CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1
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B.
Kinetic and/or equilibrium data ...........................................................................................................................10
37
C.
Mass and energy balance calculation sheets..................................................................................................... 10
38
D.
Chemical engineering design calculation sheets................................................................................................10
39
E.
Mechanical design calculation sheets ................................................................................................................ 10
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University of San Carlos – Department of Chemical Engineering CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1
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1.
43 44
1.1. Statement of the design project
The design problem
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As a design firm, we have been task to design a rice bran processing plant catering to biodiesel production in order
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to meet at least 10% of the Philippines’ local biodiesel demand by 2020 where the plant will be operated for 330 days
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per year.
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In order to achieve a viable raw material for biodiesel production, the rice bran oil going to the reactor contain atleast
51
only triglycerides and fatty acids. Lipids comprised about 18.3% of the total composition of the rice bran. Lipids is to
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be extracted by using hexane as solvent to produce crude rice bran oil. Crude rice bran oil contains an abundant
53
amount of natural bioactive nutrients such as oryzanol and phytosterols with a balanced FFA content plus minimal
54
amounts of tocopherols and tocotrienols. Aside from nutrients, commercial crude rice bran oil usually contains 2-3%
55
wax and 1-2% phospholipids. Waxes and phospholipids are undesirable in the production since it may damage
56
production equipment and can cause interferences in reaction product analysis by gas chromatography. Hence, there
57
is a need for its removal to make biodiesel of higher purity.
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Our team has been assigned to the physical refining step focusing in the removal of fat soluble impurities (e.g. wax
60
and gums) from crude rice bran oil. The degummed and dewaxed rice bran oil, containing a certain percentage of
61
free fatty acids, is then fed to a reactor where it is reacted with methanol to produce methyl esters.
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1.2. Description of the process
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The plant process is divided to 3 different sub-sections: i. upstream extraction and refining process, ii. biodiesel
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production process, and iii. downstream recovery process. Rice bran is the raw material and is obtained as a
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byproduct from polishing of rice grain. Rice bran is composed of 13.5% moisture, 13.2% protein, 18.3% lipids, 38.3%
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sugar substance, 7.8% fiber, and 8.9% ash as reported by yujino et al (yujino, 1977). Oil produced from rice bran
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have gotten attention since it has highly nutrient value due to a large amount of nutrients such as γ -oryzanol and
70
tocotrienol (vitamin E) which act as an antioxidant and lowers plasma cholesterol levels respectively.
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Rice bran lipids are extracted with an aid of a solvent (usually hexane) in order to produce crude rice bran oil. Crude
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rice bran oil extracted however is still not a viable biodiesel production raw material due to large amounts of waxes
74
and phospholipids. Crude rice bran oil is then further refined to remove fat-soluble impurities (e.g. wax and gums).
75
After removal of wax and gums, the oil is then sent to the biodiesel production process.
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University of San Carlos – Department of Chemical Engineering CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1
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The degummed and dewaxed rice bran usually containing a certain percentage of free fatty acids is then fed to a
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reactor where it is reacted with methanol to produce methyl esters. Four (4) approaches is then considered to identify
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the best method to do the reaction: i) Direct trans-esterification with a homogenous acid catalyst, ii) Direct trans-
80
esterification with heterogenous acid catalyst, iii) Heterogeneous acid catalyzed tran-esterification followed by either
81
homogenous base catalyzed trans-esterification or heterogeneous base catalyzed reaction. In the reactor.
82
triglycerides and fatty acids in the oil reacts with methanol to produce methyl esters, glycerol and water. A final
83
mixture of glycerol, methyl esters, methanol, and water is obtained. The mixture is then sent to the downstream
84
process.
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The downstream process is responsible for further purification products and recovery of still usable methanol.
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Methanol is first recovered from the mixture and recycled to the trans-esterification process. The mixture is then
88
separated to a crude methyl ester stream and a crude glycerol stream as by product. These two streams still contain
89
significant amounts of methanol that needs to be further recovered and recycled to the trans-esterification process. A
90
main product of fatty acid methyl ester and a glycerol byproduct is obtained.
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1.3. Summary of the design task
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It was a requirement to maximize product output of methyl esters that the rice bran o il going to the reactors should be
95
composed of at least triglycerides and free fatty acids. As mentioned above, crude rice bran oil aside from containing
96
nutrients also contain significant amount of impurities (e.g. wax and phospholipids). Phospholipids are to be removed
97
due to their strong emulsifying action. Phospholipids are mainly of two types: i. hydratable phospholipids (HPL) which
98
are composed of hydratable phosphatidylcholine (PC) and phosphatidylinositol (PI), and ii. non-hydratable
99
phospholipids (NHPL) which are calcium and magnesium salts of phosphatidic acid (PA) and
100
phosphatidylethanolamine (PE) (Hvolby 1971). HPL are removed mostly through water degumming while NPHL are
101
removed through addition of salt solutions, dilute acids or enzymes.
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Our team has been assigned with the physical refining of extracted crude oils through degumming and dewaxing.
104
Degumming is the treatment of crude oils with water, dilute acids or enzymes to further remove phospholipids, waxes
105
and other impurities found within the oil (Sengar, 2014).
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A novel process was introduced by rajam et al focusing entirely in degumming and dewaxing of crude rice bran oil.
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The process involves addition of water to crude oils which exploits the HPL’s affinity for water and the addition of salt
109
(calcium chloride) which causes a thermotropic phase transfer of NPHL and water to form liposomes with HPL which
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University of San Carlos – Department of Chemical Engineering CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1
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are then further separated by crystallization and centrifugation. The process was noted to have remove at least 80%
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of the total wax content of the crude oil (Rajam, 2005).
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The degumming process involves 4 steps: i. addition of water at 75˚C in a mixer, ii. addition of 6% wt/vol CaCl2
114
solution in a 2nd mixer, iii. crystallization from 75˚C to 20˚C, and iv. centrifugation to separate the oil from the
115
impurities. Some of the steps involve equipment that can readily be purchased except the crystallizer. Our paper then
116
focuses on designing a crystallizer equipment that can meet up with the specified 80% removal of the initial wax
117
content.
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2.
Process definition
Discuss in detail the major operations and pro cess steps involved in the pro cess assigned.
Include relevant process conditions and criteria of operation.
Pretreatment of feedstock. Xxxxxxxxxx
Extraction of lipids. Xxxxxxxxxx
Pretreatment of oil. Xxxxxxxxxx
(Trans)esterification reaction. Xxxxxxxxxx
Separation of methyl ester and glycerin. Xxxxxxxxxx
Recovery of Methanol. Xxxxxxxxxx
Subsection (Level 2) headers should be plain normal text and only the first letter of the first word should be capitalized (except for proper nouns).
Methodology or experimental procedures should be concise and brief, but should provide as much detail to allow verification and possible reproduction of the work by other researchers. Sources from which the methodology was adopted should be cited.
Whenever possible, brand and model of the pieces of equipment used in accomplishing the research or experiment should be indicated. For statistical analyses and graphics/artwork the software used should be indicated as well.
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2.1. Flow diagrams
Sub-subsection (Level 3) headers should be ITALICIZED and only the first letter of the first word should be capitalized (except fo r proper nouns).
2.1.1. Input-output diagram
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Figure 1. Input – output diagram of the production of biodiesel from rice bran oil.
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University of San Carlos – Department of Chemical Engineering CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1
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For Figures and other captions kindly u se the tools provided in MS Word under the Reference tab.
Use CHE 514N FORM 1-1 Flow Sheet Template.vsdx
The block flow diagram should specify the flow rates and stream composition as well as the stream conditions, conversion and separation efficiencies.
Calculation or data processing should be presented in the appendices using the prescribed calculation sheets (CHE 514N FORM 1 -4 Calculation Sheets Template).
2.2. Basic assumptions
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For the input – output diagram, it should be rendered using Microsoft Visio.
2.1.2. Block flow diagram
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Provide an overview of the process parameters adopted, feed and product specification, plant location, layout and operating hours, as well as the battery limits of the design.
2.2.1. Production capacity and feed/product specification
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Provide details of the feed and product specification, either based on the design demand or product standards.
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2.2.2. Plant location, layout and operating hours
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Provide a hypothetical plant location, layout (plot size and plan) and operating hours.
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2.2.3. Battery limits
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Articulate the scope of the design task and limitations.
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2.2.4. Definition of incoming and outgoing streams
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Define the streams in terms of the components in a given stream and its role in the proce ss (Focus only in streams related to the process equipment being designed.
(Tabulated) Summary of material flows or stream summary.
2.2.5. Economic margin
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Provide a rough estimate of the allowable operating cost the proce ss and/or process equipment.
This may be determined by determining the fraction of the gross revenue to that of the total sales of the main products (an economic margin of at least 70 % is desirable but not absolutely necessary.)
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3.
Chemical engineering design of process equipment
Discuss in detail how the design of the process equipment was done a nd the key equations used in the design.
Calculation or data processing should be presented in the appendices using the prescribed calculation sheets (CHE 514N FORM 1 -4 Calculation Sheets Template).
3.1. Equipment sizing
Calculation or data processing should be p resented in the appendices using the prescribed calculation sheets (CHE 514N FORM 1-4 Calculation Sheets Template).
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University of San Carlos – Department of Chemical Engineering CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1
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3.2. Equipment configuration and operating scheme
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Sheets Template).
3.3. Energy requirements and duties
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4.
Discuss in detail and justify how the material selection was made and what material was chosen for later construction/fabrication.
Discuss in detail relevant fittings and connections needed for the process equipment designed.
Indicate size and type of fittings and connections necessary.
Discuss in detail how the design of the process equipment internals was done and the key equations used in the design and selection.
Discuss in detail relevant equipment internals (packing, sieves, filters, mesh, impellers, baffles, feed distributor, diffusers, etc) needed for the process equipment designed.
Indicate size and type of internals necessary.
4.4. Loading and supports
Detail the loading and assumption taken into consideration in the design of the vessel or process equipment support.
4.5. Pumping requirements
Provide a summary of the necessary a ccessory equipment and their specification.
4.6. Mechanical drawing of process equipment
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Calculation or data processing should be presented in the appendices using the prescribed calculation sheets (CHE 514N FORM 1-4 Calculation
4.3. Equipment internals
209 210
4.2. Fittings and connections
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Discuss in detail how the design of the process equipment was done and the key equations used in the design.
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4.1. Materials of construction
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Mechanical design of process equipment
Sheets Template).
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Calculation or data processing should be presented in the appendices using the prescribed calculation sheets (CHE 514N FORM 1 -4 Calculation Sheets Template).
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Calculation or data processing should be presented in the appendices using the prescribed calculation sheets (CHE 514N FORM 1-4 Calculation
Use CHE 514N FORM 1-1 Flow Sheet Template.vsdx
Use CHE 514N FORM 1-2 Equipment Specification Sheet.docx
4.7. Equipment Specification
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Use CHE 514N FORM 1-1 Flow Sheet Template.vsdx
Calculation or data processing should be presented in the appendices using the prescribed calculation sheets (CHE 514N FORM 1 -4 Calculation Sheets Template).
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5.
Piping and instrumentation
Sample calculation or data processing should be presented in the appendices.
5.1. Piping system
Indicate the type of pipe, pipe diameters and estimate the total pipe lengths required.
5.2. Valves and meters
Discuss in detail relevant valves and meters needed for the process equipment designed.
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University of San Carlos – Department of Chemical Engineering CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1
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5.3. Compressors and pumps
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Specify and indicate the necessary controls and instrumentation required in the operation of the process equipment designed.
5.5. Piping and instrumentation diagram
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Provide details and justification of the selected pumps and other acce ssory equipment used.
5.4. Control and instrumentation
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Justify how these were selected and ch osen..
6.
Use CHE 514N FORM 1-3 Piping and Instrumentation Diagram Template.vsdx
Conclusions and recommendations
Conclusions should be based on the interpretation(s) and discussions made in the previous section. The conclusions should be based on concrete facts, providing answers to the design task or problem. Recommendations should focus on how the current design may be improved or on the potential works which could b e done to ease the design of the process equipment.
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University of San Carlos – Department of Chemical Engineering CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1
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References
The references should be cited and the list should be generated through the aid of a citation manager (MENDELEY). For consistency the Renewable and Sustainable Energy Review citation style should be adopted. Font size of 10 pts. and a line spacing of 1.
[1] Cholakov G, Toteva V, Nikolov R, Uzunova S, Yanev S. Extracts from coffee by-products as potential raw materials for fuel additives and carbon adsorbents. Journal of Chemical Technology and Metallurgy. 2013:497-504. [2] Margaritopoulou T, Roka L, Alexopoulou E, Christou M, Rigas S, Haralampidis K, et al. Biotechnology Towards Energy Crops. Mol Biotechnol. 2016. [3] Haile M. Integrated valorization of spent coffee grounds to biofuels. Biofuel Research Journal. 2014;2:65-9. [4] Vardon DR, Moser BR, Zheng W, Witkin K, Evangelista RL, Strathmann TJ, et al. Complete utilization of spent coffee grounds to produce biodiesel, bio-oil, and biochar. ACS Sustainable Chemistry & Engineering. 2013:1285- 94. [5] Kwon EE, Jeon YY, Jeon YYJ. Sequential co-production of biodiesel and bioethanol with spent coffee grounds. Bioresource Technology. 2013;136:475- 80. [6] Mussatto SI, Machado EMS, Carneiro LM, Teixeira JA. Sugars metabolism and ethanol production by different yeast strains from coffee industry wastes hydrolysates. Applied Energy. 2012;92:763-8.
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University of San Carlos – Department of Chemical Engineering CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1
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Appendices
Appendices should contain supplementary data and information relevant in the review of the research paper.
Sample calculation or data processing should be presented in the appendices.
Tables, Figures and Equations presented in the appendices should be numbered sequentially but should be distinct and not a continuation of the labels found in the main text.
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A. Physical and Thermodynamic data
268 269
B. Kinetic and/or equilibrium data
270 271
C. Mass and energy balance calculation sheets
272
273 274
D. Chemical engineering design calculation sheets
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Sample calculation or data processing should be presented in the appendices.
Sample calculation or data processing should be presented in the appendices.
E. Mechanical design calculation sheets
Sample calculation or data processing should be presented in the appendices.
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