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Where
= angular velocity
R = radius of rotation
Acceleration due to gravity is g
G-level is centrifugal acceleration G, measured in multiples of earth gravity, g
Taking speed of rotation of the centrifuge to be N rev/min and D to be the diameter of
the centrifuge, the above equation can be written as
Stokes law is used to determine the settling velocity. It is given by
48
Where
vtg= settling velocity under gravitational conditions
d = particle size (diameter)
s = density of the particle
= density of the fluid
= viscosity of the surrounding fluid
Under centrifugal conditions, the equation becomes
Where
= angular velocity
r = radius of rotation
In a disk centrifuge (illustrated in figure 1.6), the continuous phase containing the solid
or liquid particles to be separated flows from the outside of the disc stack, with radius r1
to the inside discharge opening with radius r2.
Assuming that the lighter liquid is evenly divided between the spaces formed by the
discs, the flow in each disc space is
Where
n = number of disks
= angular velocity
g = gravitational acceleration
49
r1 = outer radius of disk stack
r2 = inner radius of disk stack
= conical half angle
The sigma value is related to the volumetric flow rate as shown below
The radius of the interphase between the heavy phase and the light phase is given by
the following equation
Where
rs= radius of the interphase of the 2 phases
ri = radius of the outlet of the light phase
R = radius of the bowl
Q1 = volumetric rate of feed for the light phase
Q2 = volumetric rate of feed for the heavy phase
From the equation (8), the retention time
R
t necessary to give adequate separation of
the liquids with the assumption that it solely depends on densities and interfacial
tension is expressed as:
Where
V = the volumetric hold-up of liquid in the bowl
Q = the total volumetric flow rate
DATA
Basis 1 hour
Total feed rate = 783 kg/hr. = 0.2175 kg/s
Mass flow rate of light phase = 781 kg/hr. = 0.2169 kg/s
Mass flow rate of heavy phase = 2 kg/hr. =5.5*10
-4
kg/s
50
Density of light phase (virgin oil) = 914 kg/m
3
Density of heavy phase (water) = 1000 kg /m
3
Volumetric flow rate of light phase (Q1)= 2.373 x 10
-4
m
3
/s
Volumetric flow rate of heavy phase (Q2) = 5.5 x 10
-7
m
3
/s
Volumetric flow rate of feed = 2.378 x 10
-4
m
3
/s
Viscosity of water (at 30
o
C) = 7.974 x 10
-4
Ns/m
2
Viscosity of oil (light phase) = 0.0643 Ns/m
2
Particle size is assumed to be 1m
7.0.4 CHEMICAL DESIGN
The speed of a centrifuge ranges between 4500 and 8000 revolutions per minute
(Encyclopedia of Chemical Processing and Design Vol. 7, Mc Ketta). A value of 7000
revolutions per minute was chosen, high enough to reduce retention time and low
enough to reduce energy consumption.
7.0.4.1 Bowl diameter
Using equation 3 with G/g = 15000 (Perrys Chemical Engineers Handbook 8
th
ed) and N
= 7000 rpm
Centrifuges come in standard sizes with the largest size being of diameter 0.6m (Kirk
Othmer, Encyclopedia of Chemical Technology, 3
rd
Edition, Vol. 5). Therefore D =
0.548m and R = 0.274m
7.0.4.2 Disk diameter
Disk diameter is the diameter of the bowl
Therefore, the outer radius of the disk is
7.0.4.3 Terminal velocity
Substituting our values into equation 4, we get
51
7.0.4.5 Sigma value
It is obtained from equation 7. A factor has to be included for practical values of the flow
rate, Q. For most disk centrifuges, the factor is 0.45(Perrys Chemical Engineering
Handbook 7
th
ed).
7.0.4.6 Number of discs
The number of discs is obtained empirically from tabulated values (Perrys Chemical
Engineers Handbook).
(x10
4
ft
2
) Number of discs
1.1 33
10.84 N
21.5 107
Taking the lowest value in the range then
7.0.4.7 Inner radius of the discs
The conical half angle of a disk centrifuge ranges between 35 and 50 therefore we
chose a value of 35.
The angular velocity is given by
The inner disc radius is obtained from substituting values into equation 6
7.0.4.8 Radius of the interphase
This is calculated using equation (8)
52
For efficient separation rs > r2 as is our case.
7.4.0.9 Disc length
7.4.0.9 Bowl axial height
The aspect ratio (height to diameter) of a centrifuge should be low enough in order to
achieve the required separation. A value that is less than 0.4 is preferred. We selected
0.25.
7.4.0.10 Disc spacing
Disc spacing is calculated using the following equation.
l
b
0.206m
0.15m
35
o
53
7.4.0.11Disc perforations
Disc perforations are placed in order to create channels through which the liquid will
pass through. The diameter of the perforations vary from 6mm to 12.75mm.We
therefore choose a diameter, 0.010m (10mm) and the number of perforations per disc,
8.
Location of the perforations is half the disc length
The area of the perforation is given by
7.4.0.12 Centrifugal force
This is calculated by using the following equation
G/g is in the required range for disc centrifuges (300-16000).
7.4.0.13 Centrifugal settling velocity
The settling velocity under centrifugal forces is given by
7.4.0.14 Retention time
This is calculated using equation 9
Where
Therefore
7.4.0.15 The centrifugal pressure
This is the pressure exerted by the fluids on the walls of the centrifuge machine. It is
calculated as
54
Where
Pc = pressure inside the centrifuge
f = density of the fluid
7.4.0.16 Power consumption
The total power P, used to drive a given centrifuge may be considered to be made up of:
- The power needed to overcome the weight of the bowl, P1
- The power required to overcome the weight of the liquid mixture in the bowl
and friction in the bearings, P2
- The power needed to accelerate a liquid stream of Q and discharge at r, P3
The correlations used are as follows:
i. Power needed to overcome the weight of the bowl is given by:
Where mb is the mass of the bowl given by:
W is the linear or peripheral velocity and is given as
Therefore
ii. Power required to overcome the weight if the liquid mixture in the bowl and
friction in the bearings is obtained using the following equation
55
Where
G is the total weight of the liquid and the bowl
is the co-efficient of friction bearings equal to 0.2
WW is the velocity of the shaft
Therefore
iii. Power needed to accelerate a liquid stream of Q and discharge at r, is given
by:
Taking r = r2 is 0.13m
The total power required to operate the centrifuge is given
The power supplied from the motor is 1.1 times this value
56
7.0.5 MECHANICAL DESIGN
It shall involve:
- The stresses involved
- The vibration problem
- The material of construction
- The thickness of the centrifuge shell
7.0.5.1 Stresses involved
Rotation of a cylindrical object such as an empty centrifuge bowl creates a stress in the
bowl shell wall called self stress.
Assuming that the thickness of the wall is small with respect to its radius from the axis
of rotation, the self-stress is given by the following equation
Where
s = Self stress (N/m
2
)
= Angular velocity (rad/s)
R = Radius of the bowl (m)
m = density of the material of construction of the shell (kg/m
3
)
The material in the centrifuge also causes a pressure on the walls of the bowl and
therefore exerts an additional pressure. This stress is given by
Where
= Average density of the solids and liquids inside the bowl (kg/m
3
)
= Thickness of the bowl wall (m)
The total stress is therefore given as
57
According to Mcketta, Encyclopedia of Chemical and Processing Design, commercial
centrifuges are designed so that self-stress is in the range of 45-65% of the total stress.
We chose self-stress to be about 55%, therefore total stress will be obtained as
7.0.5.2 Material of construction
Centrifuge bowls are made of almost every machine-able alloy of reasonably high
strength. Preference is given to those alloys having 1% elongation to minimize the risk
of cracking at stress concentration points. Hence, the shell will be made from stainless
steel type 316.
The stationary parts, that is, casings and feed, rinse and discharge lines that are
stationary and light stressed may be constructed of any suitable, rigid, corrosion-
resistant material such as carbon steel.
Wear-resistant material such as Tungsten and ceramic carbide are often used to protect
the bare metal surfaces in high wear areas of the centrifuge.
Frames that are in contact with the external environment will be made of structural
steel.
7.0.5.3 Vibration problem
In the design of any high-speed rotating machinery, attention must be paid to the
phenomenon of critical speed. This is the speed at which the frequency of rotation
matches the natural frequency of the rotating part. At this speed, any vibration induced
by slight unbalance in the rotor is strongly reinforced, resulting in large deflections, high
stresses and even failure of the equipment.
The critical speed of simple shapes may be calculated from the moment of inertia but
with complex elements such as a loaded centrifuge, it is best found by test.
Nearly all centrifuges operate at speeds well above the primary critical speed and
therefore must pass through this speed during acceleration and deceleration. To permit
them to do so safely, some degree of damping in their mounting must be provided. This
may result from:
- The design of the spindle or driveshaft alone
- Spring-loading of the spindle bearing nearest to the rotor
- Elastic loading of the suspension
- A combination of the above
Smaller and medium-sized centrifuges of the cream separator and bottle centrifuge
design are frequently mounted on elastic cushions.
58
7.0.5.4 Thickness of the centrifuge shell
The thickness of the centrifuge shell is calculated from the equation of stress due to the
contents given by
Therefore
Where
= Thickness of the centrifuge shell
7.0.6 SUMMARY OF CENTRIFUGAL
Table 5.4: SUMMARY OF CENTRIFUGAL
PROPERTY SPECIFICATION
Total feed 0.2175 kg/s
Number of revolutions 7000 rpm
Shell diameter 0.548 m
Disc diameter 0.411 m
Particle settling velocity 5.24410
-8
m/s
Angular velocity 733.04 rad/s
Number of discs 50
Conical half angle 35
Radius of discharge 0.125 m
Radius of interface 0.27 m
Disc length 0.10 m
59
Disc spacing 0.00109 m
Bowl axial length 0.11
Number of perforations per disc 8
Area of disc perforation 7.854410
-5
m
2
Centrifugal settling velocity 7.75510
-4
m/s
Retention time 86.14 s
Power 23.281 W
Stress 575.789 MN/m
2
Thickness of shell 0.0098 m
Material of construction Stainless steel type 316
60
7.1 Design of a wipe film evaporator by JOAKIM KISUA PIUS CPE/09/08
The process by which any substance is converted from a liquid state into, and carried off
in, vapor, as, the evaporation of water ,ether is called evaporation .The transformation
of a portion of a fluid into vapor, in order to obtain the fixed matter or target material
contained in a state of greater consistence. That which is evaporated (vapor).
Equipment used in the process of boiling a liquid in order to reduce its volume is called
an evaporator.
7.1.1 Functions of an evaporator
The main function of an evaporator is to concentrate a solution or to recover a solvent.
The evaporator design consists of three principle elements: heat transfer, vapor-liquid
separation and efficient utilization of energy. For evaporators to be efficient, the
equipment selected and used must be able to accomplish several things.
1. Transfer large amounts of heat to the solution with a minimum amount of
metallic surface area. This requirement, more than all other factors, determines
the type, size, and cost of the evaporator system.
2. Achieve the specified separation of liquid and vapor and do it with the simplest
devices available. Separation may be important for several reasons: value of the
product that would otherwise be lost, pollution, fouling and corrosion of the
equipment downstream with which the vapor is contacted.
3. Make efficient use of available energy. This may take several forms. Evaporator
performance often is rated on the basis of steam economy, pounds of solvent
evaporated per pound of steam used. Heat is required to raise the feed
temperature from its initial value to that of the boiling liquid, to provide the
energy required to separate liquid solvent from the feed, and vaporize the
solvent or to vaporize the target matter from the liquid feed. The greatest
increase in energy economy is achieved by reusing the vaporized solvent as a
heating medium. Energy efficiency may be increased by exchanging heat
between the entering feed and the leaving residues or condensate. When this
method is used each evaporator is known as an effect.
4. Meet the conditions imposed by the liquid being evaporated or by the solution
being concentrated. Factors that must be considered include;
Product quality
61
Salting and scaling
Corrosion
Foaming
Product degradation
Hold up
The need for special types of construction
7.1.2 DESIGN METHODOLOGY OF WIPED FILM EVAPORATOR
The first criterion that a wiped film evaporator should satisfy is that the fulfillment of
the process requirements. The design specifications may contain all the necessary
detailed information on flow rates of streams: pressure drop limitation for both
streams; temperature; size; length and other design constraints such as cost, type of
materials, and arrangement of different components. The wiped film evaporator design
provides missing information based on experiences, judgment, and the requirements of
the process.
Based on the problem specifications, the evaporator construction type, flow
arrangement, surface or core geometry, and materials must be selected.in the selection
of wiped film evaporator, the evaporating pressures and temperature levels,
maintenance requirements, reliability, safety, availability and manufacturability of
surfaces and cost must be considered.
Thermal design of wiped film evaporator may be classified as sizing(design problem) or
rating(performance analysis).in the sizing problem, the surface area and evaporator
dimensions are to be determined; inputs to the sizing problem are flow rates, inlet
temperature, outlet temperature, surface geometries, pressure drop limitations, and
thermo physical properties of process thermal fluid and materials.
In the rating problem, evaporator configuration is selected by approximate sizing.
Therefore, inputs to the rating problem evaporator surface geometry and dimensions,
fluid flow rates, inlet temperature and pressure drop limitations.
The fluid outlet temperature, total heat transferred and pressure drop for both streams
through the evaporator are to be calculated in the rating (performance analysis).if the
rating gives acceptable performance with pressure drop in both streams, this
evaporator configuration may be considered a solution to the problem.it is often
62
possible to find a number of variant configurations that will meet these requirements;
the choice must be made on other criteria, usually cost of evaporator.
Rating is a the computational process (hand method or computer method) by which one
determines the thermal performance and pressure drops for two streams in the
evaporator
The selection criterion is that the evaporator must withstand the service conditions of
the plant environment. Therefore after thermal design analysis, mechanical design is
conducted, which includes the calculation of tubes, shell, and arrangements, the
evaporator must resist corrosion by the service and process streams and by the
environment; this is mostly a matter of proper material selection. A proper design of the
inlet and outlet nozzles, connections and supporting material.
Manifolds are to be made. Thermal stress calculation must be performed under steady
state and transmit process conditions. The additional important factor that should be
considered and checked in the design is flow vibration, and the level of velocities to
minimize fouling and erosion.
Another criterion is the maintenance requirement. The configuration and placement of
the evaporator must be properly chosen to permit cleaning as required and placement
of tubes, gaskets, and any other components that are especially vulnerable to corrosion,
erosion, and vibration or aging.
There may be limitation on evaporator diameter, length, and weight, or tube, matrix,
core specifications due to size requirements. Lifting and servicing capabilities and
availability of replacement tubes and gaskets.
After the mechanical design is completed, the final cost analysis to arrive at an optimum
solution must be considered.
An overall optimum design, in general, is the one that meets the performance
requirements at a minimum cost.
7.1.3 Wiped Film Evaporator Principle
The wiped film evaporator (WFE), also known as an agitated thin-film evaporator
(ATFE) is a device often used to purify liquids with viscosities up to 105 poise, to
63
separate temperature sensitive mixtures, or in general to provide short residence times
in heated zones. Unfortunately, the heat and mass transfer mechanisms involved in
wiped film evaporators are poorly understood. Users of the technology must rely on
equipment vendors experience for guidance.
Wiped film evaporators are designed to spread a thin layer or film of liquid on one side
of a metallic wall, with heat being supplied to the other side. The unique feature of this
equipment is not the film itself, but rather the mechanical wiping device for producing
and agitating the film. This mechanical concept permits the processing of high-viscosity
liquids, liquids with suspended solids, or situations requiring liquid rates too small to
keep the thermal surface of a falling film evaporator uniformly wet.
Most wiped film evaporators are vertical cylinders where the feed material is
distributed to the inner surface. As the liquid flows downward, axially arranged blades
or roller wipers distribute the liquid as a thin film, which is constantly mixed. This type
of equipment can operate at very low pressure and provides minimum pressure drop.
Thin film evaporation is applied in heat exchangers called thin film or thin layer
evaporators. Actually thin film evaporators may be considered as heat and mass
exchangers, since molecules from liquid phase are transferred to gas phase during the
process of vaporization and the movement of molecules from gas phase to liquid phase
is probable during the process of condensation.
These kinds of devices are most commonly applied in chemical, pharmaceuticals and
food industries. Vertical thin-film evaporators are characterized by small pressure drop
and short residence time of the phases in the apparatus, which means also that there is
short contact time of the liquid with the hot surface of the evaporator wall. These
features of the evaporator cause that it is applied for the concentration of heat sensitive
liquid solutions especially with high viscosity.
Because of the low value of pressure drop during gas flow inside the evaporator the
boiling temperature of liquid, which is evaporated, depends only on its composition and
does not depend on liquid position in the evaporator, which is of great importance in
case of evaporation at low pressure.
64
Wiped film evaporators constitute a vertical cylinder heated from the outside, inside of
which liquid flows off gravitationally on the heated surface. During that flow
vaporization of liquid takes place.
There are many interdependent factors that must be considered while designing and
optimizing an evaporator.
1. Heat and mass transfer analysis
2. Passes
3. Mechanical design
i. Shell thickness
ii. Tubing thickness
iii. Installation thickness
iv. Overall dimensions
v. All components material selection
4. Analysis
i. Material properties
ii. FEM and FEA stress analysis
iii. CED
iv. HMT analysis
v. F.O.S[Factor of safety]
7.1.4 Thermal Design Calculations
Important equations
Total heat load = sensible heat + latent heat
(
Agitator power
65
66
7.1.5 Calculations
(
67
7.1.5.1 Log mean temperature difference (LMTD) method
68
}
Proper design, plus the cleanliness of the heating medium system and the cleaning effect
of the agitated thin-film evaporator rotor, generally allows neglecting the fouling
factors. (Scale up William. B. Glover thin-film evaporators)
Depending on the velocity criterion internal diameter
The table below shows wiped film evaporator standard dimensions used with respect to
the area of the evaporation surface. To determine the optimum dimensions of your
design you can interpolate or extrapolate using the standard dimensions and be able to
obtain the optimum dimensions for your design intend as will be shown in the main
design.
69
Evaporator
surface
area (m
2
)
Dimensions(mm)
A B C D E F Nominal
Diameter
G
0.1 220 135 505 230 240 880 150
0.4 375 236 890 380 860 2070 300
0.8 375 212 1425 1230 840 2500 300
1.2 375 212 1850 1230 1020 3100 900
2.3 1000 325 2027 810 720 3100 900
4.75 1000 325 2885 1660 720 5370 900
7.2 1000 325 3740 2500 1300 5370 900
9.5 1000 325 4587 3360 1645 6560 900
16.2 1650 525 4825 3340 1600 7490 1500
7.1.6 MECHANICAL DESIGN
The material of construction is SS304 (stainless steel304) and its properties are as
under:
7.1.7 AGITATOR DESIGN
Agitation in wiped film evaporators is effected by rotary blades.
7.1.7.1 Number of blade calculations
For effective agitation at the process flow rates and effective heat transfer height the
best blade size is as under:
Effective Heat Transfer Height: 4300-500mm (required for high vacuum model)
=2500mm
70
The blades are welded at
The total number of blades:
The blades maintain a close clearance of around from the inner tube
wall.
7.1.7.2
Taking outside diameter of tubes to be , then the number entrainment tubes can
be determined.
7.1.7.3
To determine the approximate jacket diameter it is a batch condition is assumed.
7.1.7.4
Where:
71
Therefore,
7.1.7.5 Jacket thickness
The jacket thickness is taken to be 19mm.
7.1.7.6 Feed nozzle
Assuming that the feed velocity is 1.5m/s, the diameter of the feed nozzle can be
calculated as under.
14.19mm
7.1.7.7 Design temperature
The maximum allowable stress for this design is evaluated at 300
0
C.this includes due
allowance for predicting the vessel wall temperature. According to principles of
chemical engineering design, the maximum design temperature should be the
temperature at which the maximum allowable stress is evaluated which in this case is
300
0
C.
72
7.1.7.8 Design pressure
The wiped film molecular evaporator operates at an internal pressure 0f
Weight loads
The major source of dead weight loads in this design is:
The vessel shell
The vessel fittings: nozzles
Internal fittings
For stainless steel vessels the dead weight is calculated as under:
Where,
This can be taken as;
73
7.1.8 Design summary
THERMAL DESIGN MECHANICAL DESIGN
Feed flow rate Number of blades 40
Thermic fluid flow
rate
Blade height 250mm
Heat transfer
effectiveness
0.86 Blade width 70mm
Rate of heat transfer 125.25kW/s Blade thickness 12mm
Welding angle of blades
Heat transfer
coefficient
Number of entrainment
tubes
88
Film thickness Shell internal diameter 900mm
Residence time Seconds Shell thickness 9.28mm
Jacket internal diameter 1000mm
Height of the jacket 2.7mm
Design temperature
Design internal pressure
Design external pressure 3.3 bar
Weight loads 9.018N
74
CHAPTER 8
8.0 PROCESS CONTROL AND INSTRUMENTATION
8.1 Introduction
A chemical plant is an arrangement of processing units integrated with each other in a
systematic and rational manner with an overall objective is to convert certain raw materials
(input feedstock) into desired products using available sources of energy, in the most
economical way.
During its operation, a chemical plant must uphold the requirements of general techniques
as proposed by the designers as well as economic and social conditions responsibilities in
the ever-changing external influences. To ensure these requirements are upheld to the later,
the control and instrumentations of a chemical process plant is put in place for the
following reasons;
- Safe plant operation - This is a major requirement that reduces incidences of
accidents as well as to contribute to maximization of production. The controls
aim;
o To keep the process variables within known safe operating limits.
o To detect dangerous situations as they develop and to provide alarms and
automatic shut-down systems.
o To provide interlocks and alarms to prevent dangerous operating
procedures.
- Production rate:
o To achieve the design product output.
- Product quality
o To maintain the product composition within the specified quality
standards.
- Cost:
o To operate at the lowest production cost, commensurate with the other
objectives.
- Environmental regulations
o To comply with the regulation specifications on the condition of the
waste released to the surrounding
- Operating conditions
o To maintain optimum operating conditions for all the equipment
75
8.2 Objectives of process control and instrumentation
The main objectives of process instrumentation and control schemes are outline below
- To suppress the influence of external disturbances,
- To ensure the stability of a chemical process
- To optimize the performance of a chemical process
8.3 Classification of process variables
The process instrumentation and controls and designed based on the chemical variables
which are broadly grouped into two categories;
I. Input variables these are those variables resulting from the influence of
the surrounding on a chemical process
II. Output variables these are those variables results from the influence of the
process on the surroundings
Types of process variables
Controlled variables (CVs): these are those process variables that are controlled the
desired values. The desired value of a controlled variable is regard as its set point. They
include temperature inter alia.
Manipulated variables (MVs): these are those process variables that are regulated,
manipulated or adjusted in order to keep the controlled variables at or near their set
points. They include flow rate among others.
Disturbance variables (DVs): these are those process variables that affect the controlled
variables but can never be adjusted. These variables result from the changes in the
operating environment of the process.
The specifications of the process variables are very important during the development
of a control system. The selection of the process should therefore be based on the
knowledge, experience and the control objectives.
8.4 Control principles
The control principles are the techniques used to monitor and control the behavior of a
process variable for example temperature within a unit operation being carried out.
They include;
Automatic control there is an automatic measurement and adjustment of process
control on a continuous basis
Manual control this is where an operator reads the process variables periodically and
adjusts when the variables towards set values when the variables are deviating from the
set points/values. Manual controls are used when critical applications, where major
upsets are unlikely to occur, where any process conditions occur slowly and in small
increments, and where a minimum of operations attention is required. Operators may
76
also control the process manually by closing or opening the valves at the directions
from the control room. However, with availability of reliable low-cost controllers, most
users opt for automatic mode
Categories of controllers
The controllers are categorized depending on the actuating medium;
I. Electrical controllers- it uses electric power to actuating the final control
element. These types of controllers have wide range of application in the
modern process industries. Electronic controllers can be classified according
to the type of signals they receive from the primary element, as self-operated
controllers and Relay-operated controllers.
II. Pneumatic controllers- they are commonly used in industrial processes due
to their explosion-proof characteristics as well as their simplicity and
maintenance.
III. Hydraulic controllers- they provide control to liquid medium so as to
provide an output which is a function of an input error signal.
Control of unit operation in the production of pharmaceutical avocado jelly
from avocado pear
Level controller (LC)
Level controllers are used to check the level of liquid at the mixer, storage tank 1 and
storage tank 2 so as to avoid overflow as well as avoid emptiness of these equipment so
that the continuous operation is maintained. Liquid levels may affect the pressure and
rate of flow in and out of the vessels hence the quality may be affected. Level
measurements include;
- Direct measurement- sight glasses, float type, hook-type indicator.
- Indirect measurement- hydrostatic pressure type, pressure type, pressure
gauge. Air bellows, air purge system, liquid system and electrical methods.
As for this plant, sight glasses and manual opening of valves are used.
Temperature controller (TC)
Temperature control is important for separation and reaction processes, and
temperature must be maintained within limits to ensure safe and reliable operation of
process equipment. Various thermal sensitive instruments are used to regulate this
parameter; they may be thermostats, thermocouples or digital thermometers. In this
process, shell and tube heat exchanger as well as wiped film molecular evaporator use
temperature control. Virgin oil is heated in the heat exchanger from 25
O
C to 150
O
C by
the heavy phase oil from the evaporator. Temperature controller here ensures that the
temperature of around 150
O
C is achieved by the virgin oil otherwise it would indicate
77
that either the heat exchanger or the evaporator has a malfunctioning. As for the case of
the evaporator, the temperature is maintained at 210
o
C and this is ensured by the
steam.
Pressure controller (PC)
Pressure control is necessary for most systems handling vapor or gas and it is used in
this unit operation at the evaporator. The pressure measurement method used in this
project is electrical pressure transducer which uses elastic primary sensing elements
such as the Bourdon tube, bellows and diaphragm. Pressure controller is only used at
the wiped film evaporator to maintain the pressure between 10
-3
10
-2
mmHg within
the evaporator since the pressure is very essential and sensitive in this unit operation.
Programmable Logic Control (PLC)
This is an automated system used for vessels that have a specified retention time. It
measures the duration in the vessel and the level simultaneously and presents it
digitally. Any changes in the set points are indicated immediately and can either be
manually controlled or automatically altered. In this processing plant, it is used at the
mixer and centrifugal sedimentation tank where retention time is very important
during their respective operations.
Alarms, Safety Trips and Interlocks
Alarms are used to alert operators of serious and potentially hazardous deviations in
process conditions. Key instruments are fitted with switches and relays to operate
audible and visual alarms on the control panels and annunciator panels. The instrument
is fitted with a trip system to take action automatically to avert the hazard such as
shutting down pumps, closing valves, operating emergency systems. The basic
components of an automatic trip system are:
- A sensor to monitor the control variable and provide an output signal when a
preset value is exceeded ( the instrument)
- A link to transfer the signal to the actuator, usually consisting of a system of
pneumatic or electric relays.
- An actuator to carry out the required action; close or open valve, switch off a
motor.
78
Illustration of process controls around the wiped film molecular evaporator
79
CHAPTER NINE
9.0 ECONOMIC AND PROFITABILITY ANALYSIS
9.1 INTRODUCTION
The project objective is to produce pharmaceutical jelly from avocado pear. However it
will be illogical to produce the jelly without any profit reaps from the investment.
Therefore, the project will be viable if it is going to generate profit so as to ensure
sustainability as well as the plant should be able to return the capital invested on the
project over a certain period of time. This chapter focuses on the economic viability of
the production of pharmaceutical jelly from avocado pear fruit.
The determination and analysis of profits obtainable from the investment of capital and
the choice of the best investment among several alternatives are the major objectives of
an analysis. The primary purpose of the establishment of chemical industries is to make
profit. The processes which are chosen to manufacture the desired products are those
which are believed to offer the best profit to the producer. The major objectives for
economic analysis include:
- To determine whether the project is feasible at the prevailing economic
conditions.
- To compare the designed process to alternative processes and gauge its
attractiveness over others.
A capital investment is required for any industrial process, and determination of the
necessary investment is an important part of a plant-design project. The total
investment for any process consists of fixed-capital investment for physical equipment
and facilities in the plant plus working capital which must be available to pay salaries,
keep raw materials and products on hand, and handle other special items requiring a
direct cash outlay. Thus, in an analysis of costs in industrial processes, capital-
investment costs, manufacturing costs, and general expenses including income taxes
must be taken into consideration.
9.2 Economic Evaluations
For economic evaluation, the following factors are put into account.
Fixed Capital Investment (FCI)
This is the capital necessary for acquisition of manufacturing and plant facilities. It
includes;
- Manufacturing FCI - represents the capital necessary for the installed process
equipment with all auxiliaries that are needed for complete process operation. It
includes expenses for piping, instruments, insulation, foundations, and site
preparation.
80
- Non-manufacturing FCI represents fixed capital required for construction
overhead and for all plant components that are not directly related to the
process operation. It includes; land, processing buildings, administrative, and
other offices, warehouses, laboratories, transportation, shipping, and receiving
facilities, utility and waste-disposal facilities, shops, and other permanent parts
of the plant.
Working Capital (WC)
This is the capital needed to operate the plant, it includes;
- Raw material and supplies carried in stock
- Finished product in stock and semi-finished goods in the process of manufacture.
- Accounts receivable
- Cash-in-hand for monthly payments of operating expenses like salaries, wages
and raw materials.
- Accounts payable.
- Taxes payable.
Working capital has been taken as 15% of the total capital investment.
Total product cost
This is the cost involved in the manufacture of goods. It is divided into:
- Direct cost
- Raw material cost
- Utilities cost
- Operating labor
- Direct supervisory and clerical labor
- Maintenance and repair
- Laboratory charges
- Fixed cost
These are costs not affected by the level of production and include
- Depreciation
- Local taxes and insurances
- Plant overhead costs
- Rent
- General expenses
These are costs associated with management and administrative activities not directly
related to the manufacturing process. They include:
- Administration cost
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- Ware housing
- Distribution and marketing costs
- Research and development on separation of unsaponifable fraction from the
avocado oil in the wiped film molecular evaporator.
Profitability Analysis
The methods available for profitability analyses are:
- Discounted Cash Flow Rate of Return based on full life performance.
- Payback Period.
- Net present worth.
- Rate of return on investment.
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Table: Purchased equipment cost
Equipment
C S N Base year
cost
Current cost Quantity Total Cost
$
De-stoning machine 10000 5 1 17000.00
Peeling machine 8000 4.5 1 16500.00
High speed grinder 2000 4.99 0.35 3510.47 4628.91 1 25000.00
Mixer 3000 1.331 0.5 3461.07 4563.77 1 4563.77
Storage tank 1 2400 1.577 0.6 3154.35 4159.33 1 4159.33
Storage tank 2 2400 1.139 0.6 2594.93 3421.67 1 3421.67
Storage tank 3 2400 0.17 0.6 828.86 1092.93 1 1092.93
Storage tank 4 2400 0.969 0.6 2355.08 3105.41 1 3105.41
Tri-canter 0.5 - - 50750 1 50750.00
Centrifuge 8000 0.548 1.0 1 16900.00
Shell and tube heat
exchanger
- 24.856 1 12187.328 14287.666 1 14287.66
Wiped film molecular
evaporator
- 3.4 - 140,000 1 140,000.00
Condenser 8000 - - 1 8000.00
Conveyors 1900 4.00 0.75 1900 6115.63 1 6115.63
Bucket elevators - - - - 15750 2 31500.00
Pumps - 0.2337 1.2 3308.39 3378.55 4 17819.82
- - - 5500 3 16500.00
Total Purchased
Equipment Cost(I
E
)
361506.22
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9.2.1 Estimation of fixed capital investment
Fixed capital cost estimates
Direct costs % Purchased Equipment cost Cost($)
Purchased Equipment cost 100 361506.22
Equipment Delivery cost 10 36150.622
Delivered Equipment Cost(ID)
397656.842
% Delivered Equipment cost Cost($)
Purchased Equipment Installation 50 198828.42
Insulation 10 39765.68
Instrumentation and Control 9 35789.12
Piping 70 278359.79
Electrical Installation 12 47718.21
Yard Improvement 10 39765.68
Service Facilities Installed 60 238594.10
Land 20 79531.37
Total Direct Costs
958352.37
Indirect Costs % of Fixed Capital Investment Cost($)
Engineering and Supervision(20%OL)
104,202
Contractor's cost 4 82,265.42
Contingencies 8 164,530.84
Startup expense 10 205,663.55
Construction cost 7 143,964.49
Total Indirect costs
596,424.297
Total FCI($)
2,056,635.51
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9.2.2 Total capital investment estimates
Total capital cost estimates
% of TCI Cost($)
Total FCI 80 2,056,635.51
Working Capital (20 % of FCI) 20 411,327.102
Total Capital Investment($) 2,467,962.61
9.2.3 Total product cost
This is the cost involved in the manufacture of goods and sale of products. It can be
estimated on one of the three bases:
- Daily basis
- Unit-of-product basis
- Annual basis
The annual basis is chosen for the calculation of the total product cost because it
smoothes the effect of seasonal variations.
TPC is divided into:
Direct production costs
- Raw material cost
- Utilities cost
- Operating labor
- Direct supervisory and clerical labor
- Maintenance and repair
- Laboratory charges
Fixed charges
These are costs not affected by the level of production and include
- Depreciation
- Local taxes and insurances
- Plant overhead costs
- Rent
General expenses
These are costs associated with management and administrative activities not directly
related to the manufacturing process. They include:
- Administration cost
- Ware housing
- Distribution and marketing costs
- Research and development
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9.2.4 Raw materials cost estimates
Annual raw materials cost estimates
Name of Material Price,
$/tonne
Annual Amount,
tonne/yr
Annual raw materials cost,
$/yr
Avocado pear fruit 137.25 50000 6,862,745.10
Total annual cost($) 6,862,745.10
9.2.5 Annual utilities cost estimates
9.2.6 Depreciation
Depreciation is calculated using the declining balance method. The table below gives
the depreciation values for all the years, including the salvage value
Where:
87
9.2.7 Operating labor cost estimates
Annual operating labor cost estimates
Department Job description Number Monthly pay($) Annual pay ($)
Administration General Manager 1 4000 48,000
Human Resource
Manager
1 2500 30,000
Marketing manager 1 2500 30,000
Procurement
officer
1 2000 24,000
Clerk 1 295 3,550
Secretary 2 320 7680
Receptionist 2 200 4,800
Helper 2 150 3,600
Accounting Finance manager 1 2500 30,000
Clerk 1 295 3,550
Accountant 1 1100 13,200
Secretary 1 320 3,840
Sales and marketing Sales
representative
1 1,000 12,000
Clerk 1 295 3,550
Secretary 1 320 3,840
Production Production
manager
1 2250 27,000
Engineers 2 1200 28,800
Technicians 6 500 36,000
Supervisors 6 600 43200
Operators 15 350 63,000
Casual workers 15 170 30,600
Quality control Chemists 6 500 36,000
Support staff Chief security
officer
1 700 8400
Cafeteria staff 2 200 4800
Guards 6 200 14,400
Driver/messenger 2 300 7,200
Total Operating Labor costs ($) 521,010
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TOTAL PRODUCT COST ESTIMATES
Direct Product Costs Factor
Raw Material
6,862,745.10
Operating Labor costs
521,010
Utilities
160,417.58
Maintenance(3 % of FCI) 0.050 102,831.78
Laboratory charges(10 % of OL) 0.100 52,101
Operating Supplies(0.5% of FCI) 0.005 10,283.18
Total Direct Costs 7,709,388.64
Fixed Charges
Depreciation( Vs=5 % of FCI) 0.05 108,879.50
Property Taxes(2% of FCI) 0.02000 41,132.71
Insurance(1 % of FCI) 0.01000 205,663.55
Total Fixed Charge 355,675.71
General Expenses
Plant Overhead Costs(7 % of TPC) 0.070 670,520.38
Administrative Costs(3 % of TPC) 0.030 287,365.88
Distribution and Marketing(2 % of TPC) 0.020 191,577.25
Research and Development(2% of TPC) 0.020 191,577.25
Financing(7% of TCI) 0.070 172,757.45
Total 1,513,798.21
Total Product Cost($) 9,578,862.56
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9.2.8 Annual Cash Flow Analysis
Annual Sales
Avocado pharmaceutical jelly (light phase from wiped film molecular evaporator) is the
main product. The triglyceride rich fraction is will be sold to refining companies for
further processing. The table below shows the annual sales from the main product and
the by products;
Annual sales from products
Name of
Material
Price, $/ton Annual Amount,
tons/yr.
Annual value of product,
$/yr.
Pharmaceutical
product
10000 843.48 8,434,800
Triglyceride
concentrate
710 4779.72 3,393,601.20
Total annual value of products 11,828,401.20
Definitions:
197,437.09
The following assumptions are made:
- Income tax is charged at 30% of the gross profit
- The production capacity in the first year is only 70%
- All the products are sold.
The table below shows annual cash flows for the entire plant life.
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Annual cash flow
Year Plant
capacity
Annual sales USD Annual TPC Annual dep Gross income Net income Annual cash
flow
Cumulative cash
flow
0 0.00 0 0 0 0 0 0 -2,467,963
1 0.70 8,279,881 7,350,000 205,664 526,780 326,604 532,267 -1,935,695
2 0.80 9,462,721 8,400,000 185,097 680,187 421,716 606,813 -1,328,882
3 0.90 10,645,561 9,450,000 166,587 831,537 515,553 682,140 -646,742
4 1.00 11,828,401 10,500,000 149,929 981,035 608,242 758,171 111,428
5 1.00 11,828,401 10,500,000 134,936 996,028 617,538 752,473 863,902
6 1.00 11,828,401 10,500,000 121,442 1,009,522 625,904 747,346 1,611,248
7 1.00 11,828,401 10,500,000 109,298 1,021,666 633,433 742,731 2,353,979
8 1.00 11,828,401 10,500,000 98,368 1,032,596 640,209 738,578 3,092,556
9 1.00 11,828,401 10,500,000 88,531 1,042,433 646,308 734,840 3,827,396
10 1.00 11,828,401 10,500,000 79,678 1,051,286 651,797 731,475 4,558,871
11 1.00 11,828,401 10,500,000 71,710 1,059,254 656,737 728,448 5,287,319
12 1.00 11,828,401 10,500,000 64,539 1,066,425 661,183 725,723 6,013,042
13 1.00 11,828,401 10,500,000 58,085 1,072,879 665,185 723,270 6,736,312
14 1.00 11,828,401 10,500,000 52,277 1,078,687 668,786 721,063 7,457,375
15 1.00 11,828,401 10,500,000 47,049 1,083,915 672,027 719,076 8,176,452
Totals 134,843,774 151,200,000 1,633,192 14,534,228 9,011,222 10,644,414 43,710,597
Averag
e
108,879 600,748
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9.2.9 Cumulative cash flow analysis
-4000000
-2000000
0
2000000
4000000
6000000
8000000
-4 -2 0 2 4 6 8 10 12 14
c
u
m
u
l
a
t
i
v
e
c
a
s
h
f
l
o
w
Year
Cumulative cash flow curve
cumulative cash flow
Break -even point
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9.2.10 Profitability Analysis
Profitability analysis is a measure of the attractiveness of the project. Absolute profit is of little
significance; instead the rate of return on invested capital is to be looked into.
The methods used to analyze the profitability of this design project are:
- Rate of return on investment
- Discounted cash flow based on full life performance
- Pay out period
Rate of return on investment
Rate of return (ROR), which is evaluated as given below;
Payout period
The payback period is defined as the minimum length of time theoretically necessary to recover
the original capital investment in the form of cash flow to the project based on total income
minus all costs except depreciation.
Discounted cash flow rate of return
This method of approach for a profitability takes into account the time value of money and is
based on the amount of the investment that is unreturned at the end of each year during the
estimated life of the project.
A trial-and-error procedure is used to establish a rate of return which can be applied to yearly
cash flow so that the original investment is reduced to zero (or to salvage and land value plus
working capital investment) during the project life.
( )
( )
( )
|
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.
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+
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=
15
15
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1
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Where:
93
Using excel, the DCFROR was established to be 25% as shown in the table below. For a
project to be viable, DCFROR should be at least 5 % more than the bank lending rate.
For an Initial investment of $ the DCFROR is therefore or
Estimating the Bank Lending Rate (BLR) to be approximately 18%, the difference
between the DCFROR and the bank lending rate is an indication that the venture
is very profitable.
94
Trial for i=20% Trial for i=22% Trial for i=24% Trial for i=25%
1+i 1.200 1+i 1.220 1+i 1.240 1+i 1.3
YEAR CASH FLOW 1/(1+i)n P.W 1/(1+i)n P.W 1/(1+i)n P.W 1/(1+i)n P.W
0.0 2,467,963.6
1.0 532,267.3 0.8 443,556.1 0.81967 436,284.7 0.80645 429,247.8 0.80000 425,813.8
2.0 606,812.9 0.7 421,397.9 0.67186 407,694.8 0.65036 394,649.4 0.64000 388,360.3
3.0 682,140.1 0.6 394,757.0 0.55071 375,659.3 0.52449 357,773.8 0.51200 349,255.7
4.0 758,170.7 0.5 365,630.1 0.45140 342,237.5 0.42297 320,686.2 0.40960 310,546.7
5.0 752,473.4 0.4 302,402.2 0.37000 278,414.6 0.34111 256,674.5 0.32768 246,570.5
6.0 747,345.8 0.3 250,284.6 0.30328 226,653.6 0.27509 205,585.0 0.26214 195,912.2
7.0 742,731.0 0.3 207,282.6 0.24859 184,634.5 0.22184 164,770.6 0.20972 155,762.0
8.0 738,577.7 0.2 171,769.6 0.20376 150,493.4 0.17891 132,136.5 0.16777 123,912.8
9.0 734,839.7 0.2 142,416.9 0.16702 122,731.0 0.14428 106,022.4 0.13422 98,628.5
10.0 731,475.5 0.2 118,137.4 0.13690 100,138.6 0.11635 85,110.5 0.10737 78,541.6
11.0 728,447.7 0.1 98,040.3 0.11221 81,741.1 0.09383 68,353.4 0.08590 62,573.2
12.0 725,722.7 0.1 81,394.6 0.09198 66,750.2 0.07567 54,917.5 0.06872 49,871.3
13.0 723,270.2 0.1 67,599.6 0.07539 54,528.4 0.06103 44,138.6 0.05498 39,762.2
14.0 721,063.0 0.1 56,161.1 0.06180 44,559.0 0.04921 35,487.0 0.04398 31,712.7
15.0 719,076.5 0.1 46,672.0 0.05065 36,423.2 0.03969 28,539.7 0.03518 25,300.3
Total 13,112,377.7 3,167,501.9 2,908,943.7 2,684,092.8 2,582,523.7
RATIO 1.283448 1.17868 1.08757 1.04642
Discounted Cash Flow Rate of Return (DCFROR) table
95
9.2.11 Break-Even Point (BEP) Analysis
This is the point at which the total sales and the total cost of production are equal. It marks the
production rate below which the plant is operating at a loss and must therefore be exceeded.
The BEP is calculated as:
Where:
The break-even point (
). The table below shows a detailed breakdown of how Total Production Cost
and Sales Revenue vary with the variable output quantities between production rates of 0
tonnes/year and 6,000 tonnes /year.
Break-even point analysis table
Units(tonnes/year) Total sales Total product cost
0 0 1869473.72
500 1051750 2424603.72
1000 2103500 2979733.72
1500 3155250 3534863.72
2000 4207000 4089993.72
2500 5258750 4645123.72
3000 6310500 5200253.72
3500 7362250 5755383.72
4000 8414000 6310513.72
4500 9465750 6865643.72
5000 10517500 7420773.72
5500 11569250 7975903.72
6000 12621000 8531033.72
96
Break-Even point analysis chart
0.00
2,000,000.00
4,000,000.00
6,000,000.00
8,000,000.00
10,000,000.00
12,000,000.00
0 2000 4000 6000 8000
T
o
t
a
l
s
a
l
e
s
a
n
d
t
o
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r
o
d
u
c
t
c
o
s
t
i
n
U
S
d
o
l
l
a
r
s
Tonnes per year
BREAK-EVEN ALALYSIS CHART
Total
sales
Break-Even point
profit zone
loss zone
97
CHAPTER 10
10.0 SAFETY AND ENVIRONMENT IMPACT ASSESSMENT
10.1 INTRODUCTION
Safety, health and environmental issues are very important in any processing plants and
need to be well addressed by outlining precautious guidelines and plans to guide both
the employees and any other persons within the vicinity of the plant area. With well
guidelines in place, the management is assured of minimal occurrence of accidents
which may result in the loss of lives and property as well as environmental pollution. It
is a duty and responsibility that is expected of any organizational management and if
any accident occurs in the light of deliberate violation of rules and guidelines set forth
by the management, someone is expected to take the responsibility. The management is
therefore expected to uphold their duties of protecting the employees welfares as well
as the environment by providing them with resources and skills to avoid and confront
any accidents.
The natures of errors that can occur in a plant are hereby outline below;
- Planning stage
- Designing stage
- Construction stage
- Operation stage
- Maintenance stage
- Repairing stage
- Shutdown stage
The errors which can culminate to accidents at most cases occur or can be avoided at
operators levels. Operator error is inevitable in the system design and the operator like
any other process input in a processing plant has a certain capacity. When the demand
on the operator exceeds his/her capacity, the result will be failure or error due to
negligence. If the system cannot tolerate occasional randomness in his/her response,
the result will be an error. In this view, operator error is a significant contribution to the
safety related incidents and therefore the recommended number of operators to
operate a machine is fundamental for such errors to be averted. In spite having well
trained personnel to operate the plant machines, automation of the plant is also
paramount as it helps in detecting and locating any malfunction making the
confrontation of the situation easier to deal with.
As mentioned, the environmental pollution is of a great concern and any release of toxic
substances to the environment is hazardous to the environment and the people within
the plant areas as well as the people living around the plant area. Environmental
analysis involves the following;
98
- Determining which substance can be released and where
- Determining the rate of release, and total amount release
- Determining the extent of dispersion, spread and hold up that might occur
- Determining the mode of transfer to humans, animals and plants and any
indirect pathway
- Determining the toxicity of substances to humans, animals and plants
Environmental accidents have a long term effects since it is not always possible to carry
out a perfect clean-up operations. The emergency plans in place to combat the release of
toxic substances involve choosing the best techniques at each stage for limiting
environmental consequences.
In the first stage of an environmental accident, release may be limited by shutting down,
by bounding and retaining walls, by holdup ponds. In the third stage when dispersion
had begun, various clean-up methods can be used to limit the risk such as removal of
soil, boom towing and skimming, absorption and pumping. At the fourth stage, the effect
of damage limitations methods, such as special ventilation in housing, water purification
methods etc. need to be taken into account.
10.2 SAFETY
Safety as a concept and practice has evolved from a plain sense approach of eliminating
agents of injury to a more complex and a reliable control of harm to human beings,
animal and plants. Safety is therefore becoming an increasingly important activity in the
chemical industry. A crucial aspect in design of chemical plants is safety. Chemical
process safety refers to the applications of the technology and management practices;
- To prevent accidents in the plant.
- To reduce potential for accidents
Process safety management (PSM) systems are only as effect as the day-to-day ability of
the organization to rigorously execute system requirements correctly every time. This
is because any failure to correctly execute a duty may lead to injurious incidents.
Therefore any processing company or any other company has legal and moral
obligations towards the health of its employees and the environment at large. The
magnitude of safety factors are directed by the economic or market considerations,
accuracy of the design data and calculations, potential changes in the operating
performance and the background information available. The occupation Safety
Safety is a fundamental aspect in the design of chemical plants. The occupations Safety
and Health Act of 1970 aimed at ensuring that every worker was safe and that working
conditions were favorable and bearable. A safety review entails evaluation of
environmental parameters that have been altered by industrial operations. Two
approaches shall be employed to implement approved safety processes:
- Through administrative controls and
99
- By engineering methods
Administrative controls mainly involve regulating the amount of time a worker is
exposed to certain unhealthy environment with the aim of reducing risk. Engineering
methods involve technical solutions within the design of the process to deal with
identified problems. On the overall, process safety of the industry is considered under
the following titles:
Identification and assessment of the hazards
Control of the hazards
Control of the process
Limitation of any loss
The potential health hazard to an individual by material used in any chemical process is
a function of the inherent toxicity of the material and the frequency and duration of
exposure. The designer must therefore be aware of these hazards and ensure through
the application of sound engineering practice that the risks are reduced to acceptable
levels. The necessity to anticipate potential problems so as to avoid them or to reduce
their effect requires thorough appraisal of an environmentally significant action before
it is taken. The formalization of this concept is embodied in the environmental impact
assessment. The main areas that involve safety considerations in this plant include:
- Vibration problems
- Spillage of solvents and their effects
- Accidents
- Pressure buildup in mixers and storage tank.
- Exposure to fumes and vapor from the solvents used.
10.3 ADMINISTRATIVE CONTROLS
Housekeeping: The factory must always be kept clean and neat. Trenches, stored
materials, products storage tanks, machines and any other structures that may cause
danger in the factory shall be clearly marked off.
Spillages: any spillages should be identified, contained and collected accordingly.
Hygiene: all persons should access lavatory, washrooms and changing rooms. All meals
must be taken within the designated areas.
Industrial behaviors: all the industrial workers are expected to uphold the industrial
safety precautions as they are outlined in the safety guidelines. Failure to follow them
has penalties and therefore all relevant individuals are expected to have utmost
responsibility to do so. Drinking alcohol or use of illegal drugs is prohibited within the
companys premises.
100
Safety campaigns: safety campaigns are necessary to create sufficient awareness
regarding safety requirements. Safety attires provided are strictly expected to be worn
during hours of operations.
Accidents: all accidents should be reported to the relevant section managers and
eventually so that they can be investigated and handled with propriety.
Technical facilities: it shall be required that all personnel working technical facilities
undergo an introductory period to their respective facilities so that they are well
conversant to their functioning
10.4 ENGINEERING SAFETY CONTROL
Engineering safety controls involve technical solutions within the design process that
deals with identified problem.
Ventilation: it is a requirement that buildings are well ventilated to allow fresh air to
remove odor or dilute any gas leakage. When an inflammable gas leaks, it concentration
increases drastically and when there is a fire, then it causes fire to escalate. It is
therefore in this view that ventilation is necessary. Inaccessible areas must be fitted
with hoods, ducts and other air cleaning devices. Fans should be placed downstream of
the air-cleaning device to handle clean air.
Isolation: risk control by isolation or containment will be used for the highly volatile
and toxic materials. All acids in the factory, prior to use, have to be kept in containment
stores to avoid any contamination by fumes, vapors or spillages. It shall be required that
those rooms and containers be clearly labeled. This shall apply to all chemicals used in
the laboratory and outside the laboratory.
Location of flammable material: Flammable materials should be located in areas as
remote as possible, to reduce the risk of fire spreading to other areas.
Explosion in equipment: Explosions in digesters, evaporators, distillation columns and
any other pressure equipment can be avoided by regular inspection of the equipment to
prevent mechanical failure through thermal vibrations, corrosion and stresses.
Spillages: Spillage should be avoided and whenever it happens. The amount of risk
from spillages can be reduced by isolating the failure-prone sections of the plant
installation. Water system should be readily available to wash out any spillage.
Detectors and sensors: Fire detectors and sensors will be installed all over the plant. A
sensor after receiving the fire signal should fire the suppression (often water and
Bromo-chloromethane) at a speed not less than 200m/sec.
Vent: For all pressurized vessels including tanks, columns etc, vent systems must be
installed to protect the vessel from rupturing; the vent is designed so that at a given
pressure, relief device will release to regulate the pressure.
101
Storage: All chemical storage vessels shall be regularly inspected to avoid leakages
Spacing: There should be a minimum of 5m distance between vessels and pipeline, and
between vessels and building wall.
Labeling: All containers holding chemicals should be correctly labeled and warnings
appended according to their risk potential, all areas should be marked accordingly to
avoid cases of controllable accidents.
Control valves: There should be remote control valves to isolate equipment and areas
of the plant in case of an emergency. Whenever two pipes, a pipe and equipment, or two
equipments are connected, the equipment should be earthed and connected by a wire
connection.
Sprinkling system: There should be an automatic sprinkling system to put out the fire.
10.5 DEVELOPMENT OF A SAFETY AND HEALTH PROGRAM
The development of a safety and health program with a minimum of;
- 45 hours initial instruction of site,
- Days instruction on site and,
- Hour annual refresher training course.
The first two conditions shall apply to any newly hired worker. The third condition shall
apply to all workers, both old and new. It shall be a requirement for each worker to have
the following items within the factory premises;
- Gas masks for protection from fume inhalation especially from the heated
solvents
- Hand gloves - for solvents and raw materials.
- Goggles - for protection against mists and fumes.
- Protective clothing this will consist of overalls and dust coats to be cleaned
twice a week.
- Protect shoes safety boots with special uppers to prevent injury from falling
objects and a special rubber sole to prevent falling or sliding.
- Ear plugs to prevent damage due to vibrations or noise caused by nearby
equipment
- Safety helmet mandatory inside the factory
10.6 HAZARD COMMUNICATION
Hazard communication shall consist of;
- Container labeling, identification and hazards warning.
- A Material, Safety Data Sheet (MSDS) shall be obtained for all chemicals being
used within the factory.
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- All workers within special areas such as the lab must be introduced to all the
chemicals being used in the area of interest and advised accordingly.
- There should be special First Aid emergency plans in case of poisoning of any
kind in the laboratory and the whole factory.
MSDSs must address health and physical hazards in the workplace. They must contain
both toxicological and ecological data as well as fire and reactivity hazards posed by the
chemicals. No data should be omitted from MSDSs.
10.7 ENVIRONMENTAL IMPACT ASSESSMENT (EIA)
Introduction
Environmental impact assessment is a process of identifying, predicting, evaluating and
mitigating the biophysical, social, and other relevant effects of development proposals
prior to major decisions being taken and commitments made. It is a process, set down
as a repeatable series of steps to be taken, to allow the environmental consequences of a
proposed development to be assessed.
Purpose of EIA
The purpose of the assessment is to ensure that decision-makers consider
environmental impacts before deciding whether to proceed with new projects. EIA is
intended to identify the Environmental, Social and Economic impacts of a proposed
development prior to decision making.
This means that it is easy to identify:
- The most environmentally suitable option at an early stage.
- The Best Practicable Environmental Option.
- Alternative processes.
The objectives of EIA are to provide:
- Baseline information about the environment, social and economic conditions in
the project area.
- Information on potential impact of the project and the characteristics of the
impacts, magnitude, distribution who will be the affected group and their
duration
- Information on potential mitigation measures to minimize the impact including
mitigation costs.
- To assess the best alternative project at most benefit and least costs in terms of
financial, social and environment. In addition to alternative location of the
project, project design or project management may also be considered.
- Basic information for formulating environmental management plan
- To ensure compliance with environmental legislation.
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10.8 ENVIRONMENTAL IMPACT AND MITIGATION MEASURES
Environmental issues associated with the operation of an extraction of pharmaceutical
jelly from avocado pear oil plant include:
- Solid waste and by-products
- Wastewater effluents
- Emissions to air
- Noise
- Energy consumption and Management
- Socio-economic Impacts
Solid Wastes and By-products
The production of pharmaceutical jelly from avocado pear oil yields a significant
quantity of solid wastes which should be well managed for economic purposes.
The de-stoning processing and peeling machine yield significant solid wastes. The seeds
and peels are the waste solid products resulting from these two processes. Seeds can be
used by interested companies to extract oil from them or be crashed and used to
improve the fertility of agricultural soil. On the other hand, the peels can also be ground
and use to improve agricultural soil fertility. Their soil improving ability is based on the
fact that they are able to decompose in the soil therefore they dont pose any threat to
the environment.
At the three phase decanting and centrifugal processes result with solid wastes which is
in these cases are cakes and fine solid particles respectively. The cake which is in the
slurry which enters the three phase decanter is removed as a cake in solid phase while
the solid particles which are removed from the centrifuge results from the solid
particles which wont have be completely removed in the oil from the decanter. The
solid particles from the decanter can be disposed off and can be also used to improve
soil fertility. For the solid particles which are drawn from the centrifuge, it is disposed
off in form of oil-solid mixture and the mixture is channeled to waste water treatment
section.
Wastewater Effluents
The principal factors which determine the nature of effluents from this plant and on
which strict controls will be placed by the responsible authority i.e. NEMA are:
- Oil
- Suspended solids.
- Toxicity.
- Biological oxygen demand.
- Temperature
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Recommended measures for the prevention and control of process wastewater include
the following:
- Oil in the sludge and water effluent coming from the decanter has to be
eliminated before these wastes are disposed to the environment. The solids
particles in the washing water (water for washing avocado fruits) are separated
from the water in the clarifier before the water is recycled for reuse.
- Suspended solids can be removed by settling at centrifuge
- For effluents which are highly toxic, the toxicity levels may be reduced by
dilution or chemical treatment.
- The oxygen concentration in a water course must be maintained at a level
sufficient to support aquatic life and therefore it is important to measure the
BOD though standard tests which can then be reduced by activated sludge
processes before discharging the wastewater.
- The products and byproducts temperature has to be significantly reduced before
these materials are taken to the storage tanks. The heavy phase from the
molecular evaporator comes with significant high temperature which is used to
preheat the virgin oil before it delivered to the evaporator in the shell and tube
heat exchanger. The heavy phase oil is able to increase the temperature of the oil
to 150
o
C while the temperature of the heavy oil itself is reduced to 60
o
C. This
temperature of the heavy phase is further reduced to temperature of 25
o
C in the
water cooler while the temperatures of the product (light phase of the
evaporator) is reduced to 25
o
C other water cooler before it is finally pumped to
the storage tank. Other source of heat in the plant is also from the boilers where
steam is being generated. For this matter, the boilers should be operated with
the required procedures being followed to the later.
Emissions to air
The main emission to air in this plant is dust. The dust results from the fresh avocado
pear fruits during the offloading of the raw materials which if unchecked will be harmful
to the staff and also the environment.
Recommended management techniques to prevent and control dust include:
- Ensuring that the offloading of the raw materials should be done in designated
place so that the dust does not affect whose who are not involved in the
offloading.
Noise
Noise can cause a serious nuisance in the neighborhood of a process plant. Care needs to
be taken when selecting and specifying equipment such as compressors, generators,
boilers among other noisy plant units. In this plant the main source of noise is the plant
is from the utility section where generators provide the source of energy throughout the
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plant. Such equipment should be fitted with silencers or the process be done in a sound
proofed enclosed area. This noise can also be controlled by siting this equipment as far
as practicable away from the site boundary. Vendors specifications should be checked
to ensure that equipment complies with statutory noise levels; both for the protection of
employees, as well as for noise pollution considerations.
Energy Consumption and Management
The production of pharmaceutical jelly from avocado pear oil requires a significant
amount of energy therefore energy management is very essential for efficient operation
of the plant.
Various unit operations such as evaporator require heating and so consume energy.
This heating is done by use of steam which is generated in boilers.
For the purpose of energy conservation, the heat in the heavy phase oil from the
evaporator is significant is used to preheat oil before it is being delivered to the
evaporator for the separation. This reduces the cost of preheating which could be
instead incurred in the heating of the oil.
Socio-economic Impact
The plant will be put up in an area human settlement and so there may be displacement
of the locals and hence negatively impacting the immediate society. This may initially
result in an outcry from the local community.
On the other hand the building of the plant in this area will bring about great economic
gains for the local community. Employment will be created and this will increase the
standards of living of the locals. The plant will also bring about development in the area
in terms of improved transport networks, increase in the settlement in area around the
plant culminating to rapid development of businesses in the area. The transportation
section will eventually develop significantly due transportation of the raw materials to
the plant. Agricultural section will also develop significantly because the farmers will be
motivated to plant avocado pear fruits since there will be a ready matter for their
produce.
10.9 LEGISLATION
This refers to the rules and regulations that govern environmental management and
safety and should be adhered to by all process industries.
The legislations enforced in chemical and process industries include:
- Work Injuries and Benefits Act(WIBA)
- Occupational Health and Safety Act(OHSA)
- Environmental Management and Coordination Act(EMCA)
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Work Injuries and Benefits Act (WIBA)
This Act provides for compensation of employees for work related injuries and diseases
contracted in the course of their employment. It applies to all employees except those in
the armed forces i.e. private and public sector. It defines clearly who employer is, who
employee is and dependants to employee i.e. family.
Some of the provisions in this Act include:
- This Act requires an employer to obtain and maintain an insurance policy with
an insurer approved by the Ministry of labour to cater for any liabilities
employer may incur under the Act to any of his employees. Penalty; 100,000 or 3
months imprisonment.
- Every employer must register with the Director of Occupational Health and
Safety Services.(DOHSS)
- The employer must keep records of; earnings and other prescribed particulars
of all employees. He must produce those records on demand to the DOHSS for
inspection and he must retain these records for at least 6 years.
- The employer must notify the DOHSS if he is winding up the organization so as
to address any pending claims and compensation.
Occupational Health and Safety Act (OHSA)
This legislation is intended to ensure that every employee has safe working
environment. The Act establishes Occupational safety and health standards to be
adhered to in work places. It also establishes the National Council for Occupational
Health Services and Directorate of Occupational Health and Safety Services (DOHSS).
Some of the provisions of this Act include:
- Inspection of all work places
- Maintenance of accurate records of employee exposure to potential toxic
material or harmful physical agents and to have access to such records by
employees and inspectors.
- Maintenance of accurate records of any toxic or harmful material whose levels
exceed those prescribed by an applicable standard.
- It provides for the right of employees to be informed of any violations by
employers, sited by inspectors of work places.
Environmental Management and Coordination Act (EMCA)
In Kenya regulations and policies regarding the environment are regulated by National
Environmental Management Agency(NEMA).These regulations include the
Environmental Management And Co-ordination Act (EMCA) of 1999.This legislation is a
critical component for sustainable environmental management in that it establishes
national environmental principles and provides guidance and coherence to good
107
environmental management. It further deals with cross-sectorial issues such as overall
environmental policy formulation, environmental planning, protection and
conservation, environmental impact assessment, environmental audit and monitoring,
environmental quality standard, environmental protection orders, Institutional co-
ordination and conflict resolution.
10.10 HAZARD AND OPERABILITY ANALYSIS (HAZOP)
Introduction
A hazard and operability study is a procedure for the systematic, critical, examination of the
operability of a process. When applied to a process design or an operating plant, it indicates
potential hazards that may arise from deviations from the intended design conditions.
The HAZOP process is based on the principle that a team approach to hazard analysis will
identify more problems than when individuals working separately combine results.
Hazard - any operation that could possibly cause a catastrophic release of toxic, flammable or
explosive chemicals or any action that could result in injury to personnel.
Operability - any operation inside the design envelope that would cause a shutdown that could
possibly lead to a violation of environmental, health or safety regulations or negatively impact
profitability.
Purpose of HAZOP
HAZOP is carried out for the following reasons:
HAZOP identifies potential hazards, failures and operability problems.
It encourages creativity in design concept evaluation.
Its use results in fewer commissioning and operational problems and better informed
personnel, thus confirming overall cost effectiveness improvement.
Necessary changes to a system for eliminating or reducing the probability of operating
deviations are suggested by the analytical procedure.
HAZOP provides a necessary management tool and bonus in so far that it demonstrates
to insurers and inspectors evidence of comprehensive thoroughness.
HAZOP reports are an integral part of plant and safety records and are also applicable to
design changes and plant modifications, thereby containing accountability for
equipment and its associated human interface throughout the operating lifetime.
HAZOP Process
The HAZOP process is undertaken in the following procedure:
1. Divide the system into sections (i.e., reactor, storage)
2. Choose a study node (i.e., line, vessel, pump, operating instruction)
3. Describe the design intent
4. Select a process parameter
5. Apply a guide-word
6. Determine cause(s)
7. Evaluate consequences/problems
108
8. Recommend action: What? When? Who?
9. Record information
10. Repeat procedure (from step 2)
HAZOP concepts
a) Node
A node is a specific location in the process in which (the deviations of) the design/process intent
are evaluated.
Examples might be: separators, heat exchangers, scrubbers, pumps, compressors, and
interconnecting pipes with equipment.
b) Design Intent
The design intent is a description of how the process is expected to behave at the node; this is
qualitatively described as an activity (e.g., feed, reaction, sedimentation) and/or quantitatively
in the process parameters, like temperature, flow rate, pressure, composition, etc.
c) Deviation
A deviation is a way in which the process conditions may depart from their design/process
intent.
d) Parameter
The relevant parameter for the condition(s) of the process (e.g. pressure, temperature,
composition).
e) Guideword
A short word to create the imagination of a deviation of the design/process intent. The most
commonly used set of guide-words is: no, more, less, as well as, part of, other than, and reverse.
The guidewords are applied, in turn, to all the parameters, in order to identify unexpected and
yet credible deviations from the design/process intent.
Guide-word + Parameter Deviation
f) Cause
The reason(s) why the deviation could occur are many. Several causes may be identified for one
deviation. It is often recommended to start with the causes that may result in the worst possible
consequence.
g) Consequence
The results of the deviation, in case it occurs. Consequences may both comprise process hazards
and operability problems, like plant shut-down or reduced quality of the product.
h) Safeguard
These are facilities that help to reduce the occurrence frequency of the deviation or to mitigate
its consequences.
A sample HAZOP analysis
109
A HAZOP analysis of heat exchanger is carried with the exit stream as the node. It is represented
in the table below.
Inlet stream Outlet stream
Heat exchanger
110
Study node: Heat Exchanger Exit
Deviation Causes Consequences Safeguard Action required Assigned to
Less temperature - Decreased flow of heavy
phase oil
- Fouling in the heat
exchanger tubes
- Valve stuck in half-closed
position
- Increased flow rate of
material
- Lower outlet temperature
- More energy requirements in
evaporator
- Conducting temperature
profiles for heat exchanger to
monitor desired temperature.
- Regular inspection and
maintenance of heat exchanger.
-Monitoring of material flow
rates.
-Regular maintenance and
inspection of valves and sensors
- Install sensors to monitor
material and heavy phase oil
flow rates
-Install low temperature alarms
- Repair/replace
malfunctioning sensors
and valves.
- Clean tubes
-bypass heat exchanger
increase thermic fluid
flow rate in the
evaporator.
Process
engineer
More temperature -Temperature control
failure
-Increased flow of heavy
phase oil.
- Increased temperature of
heavy phase oil from the
evaporator
-Less flow rate of virgin
- High energy consumption.
- Conducting temperature
profiles for heat exchanger to
monitor desired temperature.
-Monitoring of material and
heavy phase oil flow rate.
-Regular maintenance and
inspection of valves and sensors
- Install sensors to monitor
- Repair/replace
malfunctioning sensors
and valves.
- Maintenance of alarm
systems
Process
engineer
Table: HAZOP Analysis of Heat Exchanger
111
avocado oil. material and heavy phase oil
flow rates
-Install high temperature alarms
-No flow - No material in storage
tanks
- Bursting of material
delivery pipe
- Valve stuck in close
position
- Failure of feed pump
- Blockage of pipes
- No heat exchange occurs
- Overheating of heat exchanger
tubes leading to damage.
- Installing level indicators in the
material storage tank
- Installing alarms to detect low
material levels
- Regular maintenance of pumps
and valves
- High strength materials used
for pipes
- Repair/replace
burst/leaking pipes
- Regular maintenance
of valves
- Maintenance of feed
pumps
- Removal of blockages
from pipes
Operator
Less flow
- Leakages from feed pipe
- Blockages in feed pipe
- Valve stuck in half-closed
position
-Blockages in exit pipes
Flow control failure
-Affects subsequent processes
-High temperatures of the exit
stream if it is caused by less
flow of material.
-Overheating of plates.
-Regular maintenance of pipes
-Regular checks of flow control
systems
-Maintenance of pumps and
valves
-Installing alarms to detect less
flow.
- High strength materials used
for pipes
-Repair/replace
burst/leaking pipes
- Regular maintenance
of valves
- Maintenance of feed
pumps
- Removal of blockages
from pipes
Operator
More flow -Flow control failure
-Valves stuck in open
-Increased pressure in the heat
exchanger
-Regular inspection of flow
control systems.
- Regular maintenance
of valves
Operator
112
position
-Low temperature of the exit
stream
-Insufficient heat exchange
-Higher energy consumption in
subsequent processes
-Installing alarms to detect more
flow.
Regular maintenance
of flow controllers
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CHAPTER 11
11.0 PLANT LOCATION AND LAYOUT
11.1 INTRODUCTION
The setting and location of a plant has a very huge impact on the profitability of the
enterprise and the capability for future expansion. There are several factors that influence
the location of a specific plant. The location for our avocado oil processing plant is Athi
River in Machakos county, Nairobi province. The following factors explain the choice of our
site.
RAW MATERIAL
The availability and accessibility of raw material is a key to the sitting of any plant. Athi
River is in a centralized position to allow us to access the eastern avocado market, the
central avocado market and the rift valley market due to its proximity to all producers and
also a good road network. Locating the plant in this area will ensure reduced transport
costs and easy access to the farmers.
AVAILABILITY OF LABOUR
This strategic location of the plant opens us to a huge labor resource. Nairobi being the
capital city allows us access to both skilled and unskilled labor for training. Skilled
construction labor will be outsourced or contracted from within.
UTILITIES
The production of avocado oil and its processing to meet market requirements requires
water for washing and for general process use. Athi River and Nairobi River being near will
sustain us with sufficient supply of water.
Electrical power is a very key utility for any processing industry. The power required in
running the plant will be supplied from the national grid by Kenya Power and lighting
company.
CONSUMER MARKET
The sitting of this plant opens us to a huge market for our products. The final product
which is a concentrate of the unsaponifiale fraction of avocado oil which is rich in sterols,
tocopherols, vitamin E and beta-sistosterol can be sold in bulky to the cosmetic and
pharmaceutical industries. The heavy phase oil(byproduct) which is rich in esterified
sterols can be sold in bulk to oil refining industries for further processing and stabilization
115
such as Olivado, Pwani oil. The plant therefore has an adequate market for its products and
byproducts.
ENVIRONMENTAL IMPACT AND EFFLUENT DISPOSAL
This plant poses no threat to the environment due to minimal emissions and the waste
water is recycled and its oil content tested before discharge. The solid waste from this plant
which includes the peels, pits and the cake from the decanter has been incorporated in our
waste management programme were we are considering selling the peels and the cake to
farmers for use as fertilizer and the pits can be sold to interested buyers for mechanical oil
extraction hence no severe frestrictions to waste disposal with regard to this location.
LOCAL COMMUNITY
The proposed plant must be acceptable by the local community. This plant can be located
close to the people because it does not pose a risk to the local community owing to the
short process involved, minimal use of chemicals and minimal effluent. This plant will be
located at Athi River just close to the centre. This will ensure access to social amenities like
hospitals, recreational facilities and schools thus making it easier to accommodate our
employees for efficient production.
LAND
In Machakos County and particularly Athi River, there is sufficient land for the location of
the proposed plant and room for future expansion. This area being within the urban setting
lacks idle land and thus leasing will be way convenient for the construction of the plant.
POLITICAL AND STRATEGIC CONSIDERATION
Following the recent devolution of power, bringing finished goods closer to the people,
creating job opportunities for the locals and creating market for farmers will be hailed as a
very ingenious and resourceful move. The proposed plant being in Machakos county will
benefit from government incentives, tax wavers and security.
11.2 SITE LAYOUT
The process units and ancillary buildings should be laid out to give the most economical
movement of materials, machinery and personnel around the site. Hazardous process
buildings must be located at a safe distance from the other buildings. The layout of the
infrastructure should allow room for future expansion. In addition to the main process
buildings, the following units and service units are required on site:
- Raw material storage facilities, products storage tank farm and warehouses
- Maintenance workshops
116
- Maintenance stores and operating supplies
- Process control labs
- Effluent disposal unit
- Administrative offices
- Canteens and other amenities
- Car parks
FACTORS CONSIDERED
The following factors are to e considered in sitting a plant and laying down the plant:
- The layout of the processing units should be such that it allows flow of materials
through the various production stages, from the raw material to the finished
products tanks with ease.
- The arrangement of principle ancillary buildings such as the administration block,
laboratories and process control rooms should minimize time spent by personnel
moving from one building to the other. These buildings where large numbers of
personnel will be should be located away from hazardous processes and upstream
of the prevailing wind.
- The sitting of the main processing buildings will help determine the sitting of plant
roads, pipe alleys and drainage lines.
- Storage units should be placed within a close proximity to the process units they
serve.
117
11.3 PLANT LAYOUT
Pipe Bridge
Road
Wind
Car
Park
Workshop
Administration
Offices
Fire
Assembly
Point
Canteen
E
x
p
a
n
s
i
o
n
Laboratory Control
Room
Plant area
Product
Warehouse
Raw material
Reception
Waste
Water
Treatment
Utilities
Product
Loading
Bay
Security
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CHAPTER 12
12.0 CONCLUSION AND RECOMMENDATIONS
The introduction of avocado oil in the Kenyan market will go a long way in boosting the
economy. This will be attained through creation of a market for avocado farmers who for
long have been lacking a sustainable market for their farm outputs, creation of employment
and improved health.
The cold press process involves minimal number of stages and energy consumption thus
making the process very economically viable with a high rate of return. The main challenge
in this process is minimizing the local heating effects resulting from prolonged exposure of
the oil to heat. This has been achieved by use of a short path molecular distiller. Minimal
information has been provided on the wiped film molecular distiller but the practical
aspect of it has been proven on an industrial scale.
The three phase separation technology used in this process is new in the market but it has
been put to practical use recently and has worked well. This technology has proven very
efficient in our process and thus it choice instead of two phase separation process.
This process has very minimal to no negative impact on the environment and also
minimizes the energy consumed. The waste from this process is easily manageable and fits
well within our waste management programme. This technology is effective and requires
minimal modification to perfect and optimization. If incentives are given to attract
investors, tax wavers and sufficient financing of the county governments, then the
economic viability we are talking about will be a reality.
119
REFERENCES
Bailey, AE, 1951. Industrial oil and Fat Products. 881.
S. B. Wepukhulu, J.K. Njuguna, M.W. Kamau, B.K. Chegeh, 2005. Assessment of Avocado
in Embu, Kirirnyaga and Muranga Districts of Kenya.
K.A. Finau, 2007. Literature Review of Avocado Oil for Technological Purpose. SROS
publishers.
Couper, Penney, Fair and Wals, 2008. Chemical Process Equipment; Selection and
Design
J.M. Coulson and J.F. Richard, 2005. Chemical Engineering Design, Vol. 6, Fourth Edition,
Elsevier Publishers.
Gavin Towler and Ray Sinnott, 2008. Chemical Engineering Design Principles, Practice
and Economics of Plant and process, design Elsevier publishers
McCabe,W.L., and Smith, J.C., Unit Operations of Chemical Engineering, p.418,Mc-
Graw-Hill,New York, 1950.
Freeze, H.L., and Glover,W.B, Mechanically Agitated Thin-Film Evaporator,Chem.
Eng..Prog., Vol.75,No. 1, p.53, January 1979.
Jacinto Lopez-Toledo, Heat and Mass Transfer Characteristics of a Wiped Film
Evaporator The University of Texas at Austin
Janusz Dziak, Mass and Heat Transfer during Thin Film Evaporation of Liquid solution
Wroclaw University of Technology, Poland.
MIT International Journal of Mechanical Engineering Vol. 2, No. 2, Aug. 2012, pp. (105-
108)
The Indian Journal of Technical Education (Futuristic Trends in MECHANICAL
ENGINEERING)
Pfaudler- Wiped Film Evaporators (Pfaudler Engineered systems)
http://www.wxhysh.com/products/prod9.htm
http://www.dalalengineering.com/wiped_fim_evaporator.aspx
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APPENDICES
Appendix A: Data
Table A-1: specific heat capacities of key components
Compound Cp(Kj/kg.K)
Sterols (tocopherols,sistosterols)the light fractions 2.33
Triglyceride and esterified sterols 3.20
Virgin avocado oil 3.01
Appendix B: Detailed Sample Mass Balances
Average weight of one avocado=600g=S1
Average weight of flesh=432g
Average weight of skin=50g
Average weight of seed=118g
Light phase is between 8 15% of the original oil
Raw material, 50,000 tons per year.
Taking a basis of 4999 kg of avocado pears per hour
300 working days a year.
24 hour operation
Heavy phase is between 85 92% of the original oil weight of avocados =6944kg/hr. =S1
Average weight of flesh=4999kg/hr.
Average weight of skins=580kg/hr.
Average weight of seed=1365kg/hr.
Mass of virgin oil from various researches using cold press {13-22%}
Ratio of avocado flesh to water in the mixer =1:2.2
Average percentage of oil content= (13 + 22)/2 = 17.5% = 17.5%
121
Therefore average oil content in avocado pulp is 0.175 x 4999= 868kg/hr.
Water in an avocado pulp (70 80%) assumed %= (70+80)/2=75%
Overall mass balance
Mass in = mass out
Stream 3(kg/hr.) = stream 4 (kg/hr.) +stream 5 (kg/hr.)
Component mass balance
Mass in (S3) = 5579 kg/hr.
Mass out (S4) = peels 580 kg/hr.
Mass out (S5) = 5579-580 =4999 kg/hr. (pulp)
Table B-2: Summary of mass balance around peeler machine
INLET STREAMS OUTLET STREAM
Streams Components Mass
(kgs)
Streams Components Mass (kgs)
S3 Pulps 4999 S4 Skins 580
Skins 580 S5 Pulps 4999
TOTAL
5579 TOTAL
5579
Appendix C: Sample energy balance calculation
i. Heat Exchanger or pre-heater.
This unit is used to the raise the temperature of the virgin avocado oil from 25C to 150C
by using triglyceride rich fraction of avocado oil at 1.1 bars from the evaporator.
Sensible heat loss to the environment is assumed to 0.04%.
A schematic of the unit is shown in the diagram below.
122
The amount of energy required to effect temperature rise is given by the expression below.
Where,
Accounting for sensible heat loss (QL)
The total energy to be supplied by the latent heat of vaporization of triglycerides at 1.1
bars is given by;
Heat Exchanger
Heavy fraction oil in
(210.00C)
663.85kg/hr.
273.10 kg/hr
Virgin Avocado oil
(150C)
781kg/hr.
10000.00 kg/hr
Virgin Avocado oil (25C)
781.00 kg/hr.
Oil out (60.00C)
663.85 kg/hr.
Q
L
123
Mass flow rate of triglyceride rich fraction required is calculated as,
Where
Appendix D: Equipment Sizing Calculations
i. Avocado slurry tanks
This equipment is used for mixing of avocado pulp and water to attain the required
consistency and to lower the viscosity of the pulp for easy pumping. The chosen design is a
cylindrical tank fitted with a Rushton 6 blade agitator.
Assumptions
- The tank should be way full.
- The height to diameter ratio chosen is
- A basis of 1 hour is taken
124
- 10 minute residence time is assumed
The mixing in the tank should be severe to ensure complete mixing of water and pulp to
achieve the required consistency. To effectively carry this out, an agitator with 4 baffles is
selected.