Beruflich Dokumente
Kultur Dokumente
Submitted by
SULTAN AL AHMARI (428102729)
MUBARAK AL QAHTANI (428102448)
ALI AL GHAMDI (428102690)
ZIYAD AL SAKRAN (428102060)
Supervised by
Prof. MOURAD BOUMAZA
Dr. MOHAMED KAMEL HADJ-KALI
ACKNOWLEDGEMENT
First of all, we would like to show our great thanks to our
supervisors in this project Prof. Mourad and Dr. Mohamed Kamel
for their help during all this semester to gain a good project. Also,
we want to thank the entire employees of the Chemical
Engineering Department for their efforts during the last 5 years and
we will not forget any moment with anyone. Finally, we want to
thank our parents and family members who supported us during
this semester.
EXECUTIVE SUMMARY
The objective of this project is to carry out a design of plant that produces 300
ton/day of sugar from sugar beet.
The carbonation process using sugar-beet has several benefits and
advantages in comparison to the one using sugar cane. In addition to the
main product (white sugar), the sugar-beet factories produce molasses and
pulp which are used to prepare feed for cows and sheep.
The plant consists of 15 main units. Five units have been fully designed,
namely:
The Continuous Stirred Tank Reactor (CSTR) ,
The Rotary Drum Filter,
The Multiple Effect Evaporator,
The Natural Draft Cooling Tower
The Rotary Drum Dryer
The remaining units have been sized.
As the sugar process requires an large quantity of water, we have also
studied the water treatment and recycling part to minimize the water
consumption.
A hazard and operability (HAZOP) analysis both with the environmental and
safety have also been covered in this project.
The economical study has shown that this project requires a capital cost of
$98 million and about 3 years payback period to retain the total capital
investment.
II
TABLE OF CONTENTS
Chapter 1. Introduction
............................................................. 3
.................................................. 29
Overview. ........................................................................................... 53
7.2
7.3
7.4
7.5
7.6
Overview: ...................................................................................... 67
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.11
9.12
9.13
9.14
LIST OF TABLES
Table 1.1 Annual Consumption of Sugar in The World .......... 4
Table 1.2 Sucrose Properties .. .................................................................... 8
Table 3.1 The Materials of Process.. ............................................... 15
Table 5.1 Reactor Design . .................................................................. 32
Table 5.2 Filter Design ........................................................................... 34
Table 5.3 Evaporator Design .................................................................. 39
Table 5.4 Dryer Design . . ....................................................................... 42
Table 5.5 Cooling Tower Design ............................................................. 44
Table 6.1 Sizing of Mixer. .......................................................................... 45
Table 6.2 Sizing of Diffuser ........................................................................ 46
Table 6.3 Sizing of Heater. ......................................................................... 47
Table 6.4 Sizing of Lime Unit . .................................................................... 48
Table 6.5 Sizing of Clarifier ........................................................................ 48
Table 6.6 Sizing of Heater. ........................................................................ 49
Table 6.7 Sizing of Cooler .. ...................................................................... 51
Table 6.8 Sizing of Centrifuge. .................................................................. 51
Table 7.1 Mass Balance of Washing Water Recycling. ............................. 53
Table 7.2 Mass Balance of Diffusion Tower water recycling...................... 55
Table 7.3 Mass Balance Evaporator Water Recycling. ............................. 55
Table 8.1 HAZOP of Reactor . ............................................................. 59
Table 8.2 HAZOP of Cooling Tower ........................................................... 60
Table 8.3 HAZOP of Evaporator ................................................................. 61
Table 8.4 HAZOP of Dryer......................................................................... 62
Table 8.5 MSDS of Sugar Factory .. ........................................................... 65
Table 9.1 Control Overview. ...................................................................... 74
Table 10.1 Total Capital Investment ....................................................... 82
Table 10.2 Raw Material.. .................................................. 83
Table 10.3 Total Production Cost.. ............................................................. 84
Table 10.4 Calculations of Total Production Cost ....................................... 85
Table 10.5 Summary for Economics Calculation ...87
VI
LIST OF FIGURES
Figure 1.1 Beet and Cane Distribution in The World .............. 4
Figure 1.2 The Relationship Between Solubility and Temperature .. ............ 8
Figure 2.1 Block Diagram of Process............................................... 12
Figure 2.2 Flow Sheet of Process ....................................................... 13
Figure 5.1 Reactor Design ..................................................................... 29
Figure 5.2 Rotary Drum Filter ................................................................. 33
Figure 5.3 Multiple Effect Evaporator . . .................................................. 35
Figure 5.4 Rotary Drum Dryer .. .............................................................. 40
Figure 5.5 Natural Draft Cooling Tower. ..................................................... 42
Figure 7.1 Diagram of Water Recycling and Treatment ... .......................... 53
Figure 7.2 Diagram of Washing Water Recycling. ...................................... 54
Figure 7.3 Diagram of Diffusion Tower Water Recycling . .......................... 55
Figure 7.4 Diagram of Evaporator Water Recycling. .................................. 55
Figure 7.5 Diagram of Cooling Water Recycling From Cooling Tower........ 56
Figure 9.1 Control Flow Sheet .. ................................................................. 67
Figure 9.2 Diffusion Tower Control . ........................................................... 68
Figure 9.3 Mixer Control ... ......................................................................... 68
Figure 9.4 Heater1 Control . ....................................................................... 69
Figure 9.5 Liming Control. .......................................................................... 69
Figure 9.6 Clarifier Control.......................................................................... 70
Figure 9.7 Heater2 Control. ........................................................................ 70
Figure 9.8 Filter Control. ............................................................................. 70
Figure 9.9 Evaporator Control. ................................................................... 71
Figure 9.10 Sulfitation Control. ................................................................... 71
Figure 9.11 Crysallizer Control. .................................................................. 71
Figure 9.12 Cooler Control. ........................................................................ 72
Figure 9.13 Cenrifuge Control. ................................................................... 72
Figure 9.14 Dryer Control. .......................................................................... 72
Figure 9.15 Cooling Tower Control. ............................................................ 73
VII
NOMENACLATURE
Purity
Temperature
DS
Dry substance
CP
Heat Capacity
Density
Latent Heat
Enthalpy
Amount of heat
Tlm
Volume
ha
hb
Conversion of reaction
Xa
Initial moisture
Xb
Final moisture
Diameter
Length
Time
Concentration
Submergence fraction
Cake resistance
Viscosity
Pressure drop
Compressibility coefficient
VIII
Chapter 1. Introduction
1.1 Overview
"Beet and cane are almost similar in sugar content (beet typically contains
18% and cane about 15%), but are dissimilar in the amount of non sugars
(beet juice contains about 2.5% and cane juice about 5%) and fiber (beet
contains about 5% and cane about 10%). The composition differences require
different methods to produce sugar from beet or cane. The differences in
farming, composition, and processing of these crops are sufficient to justify
two separate industries:
Beet-sugar industry
Cane-sugar industry
During the last century, both industries have grown considerably. World sugar
production has increased from approximately 10 million tons in 1900 to about
160 million tons in 2012.
There are over 500 beet-sugar factories in the world. About 40% of the
worlds sugar production is from beet, and 60% is from cane. The climates of
most sugar-producing countries are suitable for growing either beet (in
moderately cold areas) or cane (in tropical areas). In only a few countries
(United States, Iran, Spain, Egypt, and Pakistan), the growing conditions are
suitable for both crops. Sugar from sugarbeet is produced in about 50
countries worldwide, in North America(United States and Canada), South
America (Chile), Asian, North Africa (Morocco and Egypt)countries, and most
of Europe.
Sugar technologists often use an old statement regarding a sugar factorys
goal: The sugar factory does not make sugar; it separates non sugars. But
this is only half a picture because todays beet-sugar factory cannot survive if
it doesnt aim for the following:
- To produce sugar with the highest efficiency.
- To produce molasses with the lowest possible purity.
- To be responsive to the natural environment with its wastes."[1]
3
Country
India
European Union
China
Brazil
United States
Other
Total
23,500
16,760
14,500
11,650
9,473
76,604
152,487
22,500
17,400
14,300
11,800
9,861
77,915
153,776
23,500
17,800
14,000
12,000
10,086
78,717
156,103
25,500
17,800
14,400
11,500
10,251
80,751
160,202
26,500
17,800
14,900
11,700
10,364
81,750
163,014
"Today, the annual consumption is running at about 160 million tons and is
expanding at a rate of about 2 million tons per year. The European Union,
Brazil and India are the top three producers and together account for some
40% of the annual production. However most sugar is consumed within the
country of production and only approximately 25% is traded internationally.
Sugar cane is cultivated in over 100 countries and the amount of sugar from
sugar cane is approximately 6 times higher than of beet sugar."[8]
"The word sugar comes from the Indian "sarkara". The chemical name of
sugar is "sucrose" in English and "saccharose" in some European languages.
Sugar (sucrose, C12H22O11) is one of the families of sugars (saccharides). All
sugars belong to a larger group, known as carbohydrates (sugars, starches,
and dietary fibers). The term sugar substitutes refers to all natural and
4
synthetic (artificial) sugars other than sucrose. All sweet-taste sugars and
sugar substitutes are known to us as sweeteners.
Sucrose (sugar), glucose (dextrose), and fructose (levulose) are examples of
sweet-tasting sugars. The quantity of hydroxyl groups (OH) in molecules of
sugars contributes to their sweetness. However, not all sugars are sweet in
taste. In general, sugars with at least two hydroxyl groups (OH) in their
molecules are sweet. About 50 compounds have a sweet taste.
Sugar in its market-quality form is white and crystalline (granulated) with a
sweet taste. It is used in the kitchen, as an ingredient in sugar-added food
products (e.g., soft drinks and confectioneries), and in production of nonfood
products (e.g., detergents and ethanol). Sugar is considered as:
one of the worlds purest food products (99.95% sucrose; water is the main
remainder).
One of the most natural foods used by humans for centuries without proven
health risk.
One of the most purified organic compounds in the world and one of the
lowest priced food products."[1]
C6H12O6 + 6 O2
C12H22O11 + H2O
Chemical Formula
C12H22O11
Density (Kg/m3)
1587.1
Melting point ( C)
185
SUCROSE SOLUBILITY
"Sucrose is highly soluble in water. The reason for its high solubility is that
sucrose contains eight free hydroxyl groups (OH) of which at least five can
attach to other molecules depending on the molecule reactivity.
When sucrose is dissolved in water, each sucrose molecule can form at least
five hydrogen bonds with water molecules. As the concentration of the
solution increases, no more free water molecules are left in the solution for
hydrogen bonding and the solution becomes saturated.
Solubility increases with increasing temperature."[1]
"The specific heat of pure and impure sucrose solutions decreases when their
concentration and temperature are increased. You can calculate the specific
heat of pure and impure sucrose solutions by using equation (1.1) :
CP = 4.187 DS (0.0297 4.6 105 P ) + 7.5 105 DS T (1.1)
DS: Dry substance content (for pure sucrose solutions, DS = S)
T: Temperature (C)
P: Purity (for pure solutions, P = 100)"[1]
"The specific enthalpy (in kJ/kg) of pure and impure sucrose solutions using
equation (1.2) :
H = T {4.187 DS ( 0.0297 4.6 105 P ) +3.75 105 DS T} (1.2)
DS: Dry substance content (for pure sucrose solutions, DS = S)
T: Temperature (C)
P: Purity (for pure solutions, P = 100)"[1]
1.4.3 Sucrochemistry:
"Sucrochemistry is the study of using sucrose as a raw material for production
of other products.
Many sucrose-based products are available on the market, such as the
following:
BIOETHANOL
of the future. Because of a recent steady increase of oil price, every country
tries to reduce its dependence on oil-based fuel. In the United States, a
program called 25/25 aims to get 25% of its energy from renewable resources
(e.g., ethanol, solar, and wind) by the year 2025. Ethanol produced from
sugarcane and corn plays an important role in this program.
Bioethanol is produced in countries such as Brazil, the United States (ethanol
is produced from corn), India, Pakistan, and some European countries. It is
mixed up to 85% with gasoline as a blend of fuel for most cars, or it is used
without mixing in specially designed cars. Bioethanol consumption counts for
2.5% of the world gasoline use In the world, Brazil leads sugar and ethanol
production, both of which come from sugarcane.
In Brazil, ethanol is produced from sugarcane juice, molasses, or mix of both
with an expected production of about 17.5 million m3 in 2005/2006 campaign.
As a result, Brazil became an energy-independent nation and its sugar
surplus was reduced. Ethanol produced in Brazil costs less than U.S. ethanol
produced from corn.
European countries have become interested in ethanol production from sugar
beet. France produces 125000 m3 ethanol a year from sugar beet, wheat, and
maize.
DEXTRAN
10
CARBOHYDRATES:
MONOSACCHARIDES:
DISACCHARIDES:
OLIGOSACCHARIDES:
Oligosaccharides (from the Latin oligo meaning a few) consist of three to six
monosaccharides.
Example: Stachyose, Raffinose .
POLYSACCHARIDES:
11
12
2.2
14
4
Diffusion
Tower
7
2
Mixer
Liming
3
8
14
13
11
Evaporator
10
Filter
Clarifier
12
15
17
Sulfitation
16
Crystallizer
18
19
Centrifuge
20
21
25
24
23
Storage
Dryer
22
26
13
In flow sheet, we have 15 main units of the process, (Mixer, Diffusion Tower,
Heater1, Reactor, Clarifier, Heater2, Filter, Evaporator, Tank, Crystallizer,
Cooler1, Centrifuge, Dryer, Cooler2 and Storage).
2.3
Figure (2.2) shows the sliced beet (cossettes) in stream 1 enters a mixer, and
the diffusion juice in stream 3 will be mixed with cossettes , after mixing
operation the thin juice (cossettes + diffusion juice) in stream 2 enters the
diffusion tower and the mass transfer operation will be between (thin juice in
stream 2 and the condensate water coming from evaporator in stream 14) ,
the pulp will exit as stream 4 , and the juice returns to the mixer and exits ,
then it is heated from 30 OC to 88 OC before entering the liming unit (stream 6)
. In liming unit there are two steps : The first is the addition Milk of Lime (MOL)
Ca(OH)2 to remove the impurities in juice after mixing operation. The second
is Carbonation Process (Adding CO2) to precipitate CaO from juice. Stream 8
(thin juice + precipitated CaO) enter clarifier to remove CaO precipitated in
Carbonation Process. Then the clarifying juice (Stream 10) is heated to 92OC
before entering the filter to remove non sugars (increasing purity of sucrose in
dry substance from 88% to 92%). The thin juice in previous units has (15%
dry substance and 85% water). In evaporation unit the concentration of dry
substance will be increased to 70% , water 30% in stream 15 with
temperature about 95OC before adding SO2 to decolorize it from impurities
with thick juice. Then, the thick juice in stream 16 enters the crystallizer to
form the crystals of sugar and the dry substance here will be 93% and 7%
water. Then the wet crystals will be cooled to 75OC before entering the
centrifuge unit (stream 19) which separate the crystals from molasses by
centrifuging force. The molasses here (stream 20) is available as a product for
selling and the wet crystals (stream 21) will enter the dryer and leave it with
100% sucrose and 0% water before cooling to 30OC (stream 24). The product
(white sugar) now is available in storage (silos) at 30OC with 100% sugar but
different shape (granulated sugar in stream 25 and powder of sugar in stream
26).
14
The aim of this chapter is to carry out the mass balance calculation about the
giving flow sheet in Fig.(2.2).
The general equation of mass balance calculation will be considered as
follows: [2]
=
(3.1)
Name
Species
Symbol
Water
H2O
Sugar
C12H22O12
Non Sugar
Mg,Ca,.
NS
- The amount of Beet entering to the process after washing and slicing
(Cossetts) is 3554 ton/day (by backward mass balance).
- Factory works 180 days.
- m1= 148083 kg/h (the amount of beet)
- m4= 29616 kg/h (the amount of pulp)
- m7= 5574 kg/h (the amount of lime added to the reactor)
- m20 = 19737 kg/h (the amount of molasses produced)
15
3.2
Water
14
1
Beet
Overall mass
balance of
Diffusion
(C12H22O12)
Juice diff.
XDS = 0.15
Xw = 0.85
Pulp
Xp= 0.2 on beet
=
Overall M.B. :
m1+ m14= m4 + m5 m1+ 3845.87= m4 + 6689.05
m4=0.2m1
m1+3845.87= 0.2m1 + 6689.05
0.8m1=6689.05-3845.87
m1=3554 ton/day = 148083.33 kg/h
m4= (0.2)(3554)=710.8 ton/day = 29616.67 kg/h
Component M.B. :
STREAM 5 :
m5DS = 0.15 (6689.05) = 1003.36 ton/day =41806.67 kg/h
m5S = 1003.36 (0.88) = 883 ton/day = 36791.67 kg/h
m5NS = 1003.36 (0.12) = 120.36 ton/day = 5015 kg/h
m5w = 0.85 (6689.05) = 5685.7 ton/day = 236904.2 kg/h
16
Stream
Water(kg/h)
Sugar(kg/h)
Non Sugar(kg/h)
226567.5
35184.6
4797.9
333005.34
52427.5
7149.17
236904.2
36791.67
5015
Water(kg/h)
Sugar(kg/h)
Non Sugar(kg/h)
226567.5
35184.6
4797.9
333005.34
52427.5
7149.17
14
160244.8
Stream
Water(kg/h)
Sugar(kg/h)
Non Sugar(kg/h)
236904.2
36791.7
5015
236904.2
36791.7
5015
Liming Unit 4 : Liming is the step of purification where lime is added to the
juice .
Stream
Water(kg/h)
Sugar(kg/h)
Non Sugar(kg/h)
236904.2
36791.7
5015
241641.9
37525.4
5117.1
17
Clarifier Unit 5 : In this unit the lime will be separated from juice .
Stream
Water(kg/h)
Sugar(kg/h)
Non Sugar(kg/h)
241641.8958
37525.4
5117.1
21321.375
9380.6167
1279.175
10
181233.95
28144.7833
3837.925
Stream
Water(kg/h)
Sugar(kg/h)
Non Sugar(kg/h)
10
181233.95
28144.7833
3837.925
11
181233.95
28144.7833
3837.925
Stream
Water(kg/h)
Sugar(kg/h)
Non Sugar(kg/h)
11
181233.95
28144.8
3837.925
12
7878.4
1390.3125
13
173355.7
28144.8
2447.375
Evaporator Unit 8 : In this unit the dry substance increased from 15 to 70.
Stream
Water(kg/h)
Sugar(kg/h)
Non Sugar(kg/h)
13
173355.7
28144.8
2447.375
14
160244.8
15
13110.9
28144.8
2447.375
18
Stream
Water(kg/h)
Sugar(kg/h)
Non Sugar(kg/h)
15
13110.9
28144.8
2447.375
16
13110.9
28144.8
2447.375
Water(kg/h)
Sugar(kg/h)
Non Sugar(kg/h)
16
13110.9
28144.8
2447.375
17
10809.4
18
2301.6
28144.8
2447.375
Cooler Unit 11: In this unit the juice will be cooled from 100 to 75 oC .
Stream
Water(kg/h)
Sugar(kg/h)
Non Sugar(kg/h)
18
2301.5625
28144.8125
2447.375
19
2301.5625
28144.8125
2447.375
Centrifuge Unit 12: In this unit,the sugar crystals are separated from molasses
.
Stream
Water(kg/h)
Sugar(kg/h)
Non Sugar(kg/h)
19
2302.56
28144.33
2447.33
20
1184.25
9831.74
854.933
21
657.5
12500
19
Dryer Unit 13 : In this unit , the wet crystal entered the dryer and leave it as
dry crystal ( W= 0% , S = 100% )
Stream
Water(kg/h)
Sugar(kg/h)
Non Sugar(kg/h)
21
657.5
12500
22
657.5
23
12500
Stream
Water(kg/h)
Sugar(kg/h)
Non Sugar(kg/h)
23
12500
24
12500
Stream
Water(kg/h)
Sugar(kg/h)
Non Sugar(kg/h)
24
12500
25
6250
26
6250
20
(4.1)
(4.2)
4-1
Heat Capacities :
21
Mixer Unit 1
2
Beet
T= 25oC
H1
(C12H22O12)
T= 65oC
H3
Mixer
(C12H22O12)
T= 70oC
H4
5
(C12H22O12)
T= 35oC
H5
Water @ 25oC
CPdT =
[75.4*10-3] [65-25]
22
H3W =
CPdT =
[75.4*10-3] [70-25]
CPdT =
[75.4*10-3] [30-25]
23
Heater Unit 3
Temperature(T)
Total Enthalpy(HT)
(OC)
(KJ/KgoC)
(KJ/h)
30
3.835
6548876.93
88
3.905
72801444.38
Streams
Diffuser Unit 2
Temperature(T)
Total Enthalpy(HT)
(OC)
(KJ/KgoC)
(KJ/h)
65
3.8775
385827720.8
70
3.88
74039921.63
70
3.88
2174126.11
14
90
43622136.58
Streams
Liming Unit 4
Temperature(T)
Total Enthalpy(HT)
(OC)
(KJ/KgoC)
(KJ/h)
88
3.905
72801444.38
40
100989.46
88
3.905
74260150.38
Streams
24
Clarifier Unit 5
Temperature(T)
Total Enthalpy(HT)
(OC)
(KJ/KgoC)
(KJ/h)
88
3.905
74260150.38
88
2.87
14621985.76
10
88
3.905
55695000.60
Streams
Heater Unit 6
Temperature(T)
Total Enthalpy(HT)
(OC)
(KJ/KgoC)
(KJ/h)
10
88
3.905
55695000.60
11
92
3.908
59237619.49
Streams
25
Filter Unit 7
Temperature(T)
Total Enthalpy(HT)
(OC)
(KJ/KgoC)
(KJ/h)
11
92
3.908
59237619.49
12
92
3.908
2575166.572
13
92
3.908
56663384.47
Streams
Evaporator Unit 8
Temperature(T)
Total Enthalpy(HT)
(OC)
(KJ/KgoC)
(KJ/h)
13
92
3.908
56663384.47
14
100
----
50343572.05
15
95
2.985
10236656.06
Streams
26
Crystallizer Unit 10
Temperature(T)
Total Enthalpy(HT)
(OC)
(KJ/KgoC)
(KJ/h)
16
95
2.985
10236656.06
17
100
------
81494833.33
18
100
2.43
12809018.75
Streams
Cooler Unit 11
Temperature(T)
Total Enthalpy(HT)
(OC)
(KJ/KgoC)
(KJ/h)
18
100
2.43
12809018.75
19
75
2.39
8478162.50
Streams
27
Centrifuge Unit 12
Temperature(T)
Total Enthalpy(HT)
(OC)
(KJ/KgoC)
(KJ/h)
19
75
2.39
555362
20
60
2.175
1412539.78
21
60
-----
949354.23
Streams
Dryer Unit 13
Temperature(T)
Total Enthalpy(HT)
(OC)
(KJ/KgoC)
(KJ/h)
21
60
----
949354.23
22
65
----
110167.78
23
65
----
927000
Streams
KJ/h))
Temperature(T)
Total Enthalpy(HT)
(OC)
(KJ/KgoC)
(KJ/h)
23
65
----
927000
24
30
----
106195.31
Streams
(5.1)
Assumptions :
- Operating at steady state and the reactor is isothermal .
- Negligible heat resistance between the pellets and gas.
- The pressure drop along the reactor is negligible.
B= C12H22O11.CaO
C12H22O11
XB=0.98
T=88oC
P=2 atm
Reactor
A=CO2
CaCO3
XA=0.02
Figure 5.1 Reactor Design
29
- A is limiting of reaction .
To calculate the volume of reactor, the equation (5.2) shown is :[3]
(5.2)
The percentage of CO2 in the carbonation gas entering the carbonation tank
(CO2)IN to CO2 in the gas leaving the tank (CO2)OUT , It can be calculated by
the following formula :[1]
X=
10000
(5.3)
X=
10000 = 0.8
(5.4)
Where:
=
= yAo
(5.5)
=1+1-1-1=0
(5.6)
30
= 0
0=
0=
( .
( .
(5.7)
=
(
= 0.98/0.02= 49
(5.8)
(5.9)
Kinetic :[3]
=
(5.10)
31
FBo=
.
(
5.2
Temperature (T)
88oC
Pressure (P)
2atm
Concentration of A (CA)
0.27 mol/m3
Concentration of B (CB)
65.07 mol/m3
activation energy , E
50000 J/mol
frequency factor, A
3.29 105
0.0192 S-1
Number of Reactors
42.23 m3
Filtration is the process of separating solid particles from a liquid by the force
of the pressure difference on both sides of the filter medium (a porous
material). The filter residue is the solid that remains on the filter medium
(nonsugars), and filtrate (thin juice) is the liquid that passes through the filter
medium and is collected during filtration. There are many types of filters , we
will use Rotary Drum Filter in our project because the amount of cake on filter
is very big with time , and the rotary drum can stand this large amounts.
Type : Rotary drum filter (continuous filtration).
32
The general relation to specify the total area of rotary drum filter "with
constant pressure drop" :[5]
=(
(5.11)
Assumptions :
- The pressure drop will be constant in rotary drum filter , P = 103.42 KPa
- The cake resistance (0 = 2.7 x 1010 m/kg)
- The compressibility coefficient of the cake (s = 0.29)
- The cycle time (Tc = 4 minutes = 4 x 60 = 240 second)
- The submergence fraction (f = A/AT = 0.4)
The total area of filter can be calculated using equation (5.12) :[5]
(5.12)
33
103.4214 KPa
2.7*1010 m/Kg
0.29
40 % (0.4)
67.7 m2
3m
7.2 m
27.08 m2
34
5.3
35
C , the
(5.13)[4]
36
(5.14)[4]
V1 = 203947.9167 L1
V2 = L1 L2
V3 = L2 43703.126
Effect (1) : FCp1(TF 0) + S s1 = L1Cp2(T1 0)+ V1H1
203947.9167 (3.83) (92) + S (2014.98) = L1 (3.71) (165.169) +
(203947.9167 L1) (2764.6624)
Effect (2) : L1Cp2(T1 0) + V1 s2 = L2Cp3(T2 0)+ V2H2
L1 (3.71) (165.169) + (203947.9167 L1) (2066.16) = L2 (3.45) (141.241) +
(L1 L2) (2737.208)
Effect (3) : L2Cp3(T2 0) + V2 s3 = L3Cp4(T3 0)+ V3H3
L2 (3.45) (141.241) + (L1 L2) (2143) = 43703.126 (2.54) (99.3) +
(57461.5182) (2676.186)
Solving equation for effects (2) and (3) simultaneously :
L1 = 155188.6455 Kg/h ,
V1 = 48759.2712 Kg/h
L2 = 101164.6418 Kg/h ,
V2 = 54024.0037 Kg/h
L3 = 43703.126 Kg/h
, V3 = 57461.5182 Kg/h
38
STEP 5 : The heat required of each effect and area can be calculated as
follows : [4]
=
(5.15)
(5.16)
78430.489 Kg/h
43.898*106 W
27.984*106 W
32.159*106 W
947.76 m2
640.36 m2
717.60 m2
95 OC
180 OC
39
5.4
Drying is the process of removing a liquid (usually water) from a wet solid
substance by the use of heat (usually hot air). The concentration difference
between the heating medium and the solid substance under drying is the
driving force (cause) of drying, which evaporates the water in the substance.
In normal operations, if the sugar entering the dryer has a moisture content
below 1% and is at about 60C, its heat provides sufficient energy to reduce
the moisture to about 0.00%. Most of the water in wet sugar is on the surface
of the crystals in the form of a saturated sucrose solution with high purity (very
close to 100%) and high concentration (about 90%). The wet sugar is dried
and cooled in the sugar dryer to a moisture content of about 0.00% and a
temperature below 30C. The sugar loses more moisture and cools during
transportation from the dryer to the silo or in the packing station. The dryer
used is rotary drum because the efficiency is higher than other types.
Type : Rotary drum dryer.
Assumption :
Mass velocity of dry air (G) = 2000 Kg/m2.h
Temperature of entering air (Thb) = 126.7C
Temperature of exiting air (Tha) = 70C
The amount of mass entering the dryer (m) = 13157.5 Kg/h
Initial moisture (Xa) = 0.05 , Final moisture (Xb) = 0 , G = 2000 Kg/m2.h
Tsa = 60C , Tsb = 65C , Thb = 126.7C , Tha = 70C , Csb = 0.57 kJ/Kg.C
Rate of mass transfer : mv = m(Xa Xb) = 657.875 Kg/h , hb = 0.01
40
The heat duty was found from energy balance : Q = 87813.55 kJ/h
The flow rate of entering air is found from heat balance :[5]
(1
(1
= 2717.087
(5.17)
= 0.01
= .
(5.18)
= .
(5.19)
=(
= .
(5.20)
=
=
(5.21)
.
.
.
41
13157.5 Kg/h
0.05
2000 Kg/m2.h
87813.55 kJ/h
5.5
.
.
.
Cooling towers are heat removal devices used to transfer process waste heat
to the atmosphere. Cooling towers make use of evaporation whereby some of
the water is evaporated into a moving air stream and subsequently
discharged into the atmosphere. As a result, the remainder of the water is
cooled down significantly.
The chosen cooling tower type that is natural draft cooling tower.
42
Assumption :
Temperature of entering water (t1) = 40 oC
Temperature of exiting water (t2) = 25 oC
Temperature of entering air (t1) = 20 oC
Temperature of exiting air (t2) = 38 oC
Overall heat transfer coefficient (U) = 650 w/m2.K
The heat duty was found from energy balance : Q = - 820804.69 kJ/h
Design equation:
(5.22)[5]
Where :
U: overall heat transfer coefficient (w/m2.K).
A: surface area for cooler (m2).
Tln: log mean temperature difference.
43
Tln =
Tout Tin
, Tout= (40-30)= 10oC, Tin= (65-25)= 40oC
Tout
ln
Tin
13091 Kg/h
45373.39 Kg/h
- 820804.69 kJ/h
650 w/m2.K
21.64oC
16.21 m2
44
.
.
= 5.73 m3/min
(6.1)[4]
V = 5.73* ( 15 ) = 85.95 m3
The volume is big , then will dived to three tanks (28.65 m3 per tank)
Table 6.1 Mixer Sizing
Diameter of one tank (D)
2.5 m
5. 85 m
15 minutes
5.73 m3/min
Number of tanks
28.65 m3
45
.
.
= 6.033 m3/min
V = 6.033* ( 50 ) = 301.65 m3
Table 6.2 Diffusion Tower Sizing
Diameter (D)
5.44 m
High (H)
13 m
50 minutes
6.033 m3/min
310.65 m3
46
Tlm =
(6.2)
Tout Tin
T
ln out
Tin
(6.3)
700 W/m2.OC
139.83 OC
66252567.46 KJ/h
188 m2
47
= 4.26 m3/min
V = 4.26 * ( 15 ) = 64 m3
3m
High (H)
9m
15 minutes
4.26 m3/min
64 m3
= 4.34 m3/min
V = 4.34 * ( 20 ) = 86.8 m3
Table 6.5 Clarifier Sizing
Diameter (D)
2.5 m
High (H)
11 m
20 minutes
4.34 m3/min
86.8 m3
48
=
Tlm =
Tout Tin
, Tout = (100-92)= 8oC ,Tin=(130-88)= 42oC
T
ln out
Tin
700 W/m2.OC
20.5 OC
3542618.875 KJ/h
68.56 m2
49
Volume required =
volume required=
= 31.11 m3
=
Tlm =
Tout Tin
, Tout = (75-50)= 25oC ,Tin=(100-25)= 75oC
Tout
ln
Tin
650 W/m2.OC
45.5 OC
1203015.6 w
40.7 m2
Model
TITAN 2400
1.4
Capacity (Kg)
2413
Length (m)
6.299
Diameter (m)
1.981
51
= 11 .4
(6.4)[5]
52
Overview:
Water recycling is used on four units in this project : washing ,diffusion tower ,
evaporation and cooling tower.
The objectives of this operation is to reduce water consumption to reduce
costs and preserve the natural resources .
53
7.2
In this plant ,we need one ton of water to clean two ton of beet . Most of this
water is supplied by various in-factory sources such as condensate,
condenser water, and wastewater treatment system.
Stream
Water(ton/day)
Beet(ton/day)
Mud(ton/day)
3554
396
2370
3554
7900
396
5530
2370
396
1659
711
396
54
7.3
The pulp exiting from diffuser has 90% water and 10% solid . We need to
compress the pulp to extract the water in it. After that drain the pulp to be sold
as food for animals.
10
12
11
7.4
Stream
Water(ton/day)
Pulp(ton/day)
639.72
71.08
10
511.78
11
127.94
71.08
12
71.08
Diffusion
Tower
13
Evaporator
Stream
Water(ton/day)
13
3845.875
55
56
7.6
Water Treatment :
Chlorination :
57
HAZOP
58
8.1.1 Reactor
Table 8.1 HAZOP of Reactor
Unit
Guide Word
No
Reverse
Deviation Causes
No flow
cooling
Reverse
Flow
More of
More
cooling
flow
As well as
Reactor
product
in
Coils
Reactor
Other than
-Another
material
besides
cooling
water
-Cooling
water valve
Malfunction
- Failure of
water
source
resulting in
backward
flow
- Control
valve
failure,
operator fails
to take
action
on alarm
- More
pressure in
reactor
Consequences Action
- Temperature
-Install high
increase in
temperature
reactor
alarm (TAH)
- Less cooling,
possible
runaway
reaction
- Too much
cooling,
reactor cool
- Off-spec
product
-May be cooling
-Water
inefffective
source
and
Contaminated
effect on the
reaction
- Install check
valve
Instruct
operators on
Procedures
- Check
maintenance
procedures
and
schedules
-If less
cooling, TAH
will
detect. If
detected,
isolate
water source.
Back up
water source?
59
Unit
Guide Word
No
Less
Less cooling
flow
More
More cooling
flow
- Reverse
process fluid
Flow
- Output of
Process fluid
temperature
too low
Reverse
Reverse
cooling
Flow
- Failure of
process fluid
inlet
Valve
- Product off
set
Other than
Cooling
tower
Action
- Install
Temperature
indicator
before and
after the
process
fluid line
Install TAH
- Installation
of flow meter
- Install
Temperature
indicator
before and
after
process fluid
line
Install TAL
- Install
check valve
(whether it
is crucial
have to
check)
- Proper
maintenance
and
operator
alert
60
8.1.3 Evaporator
Unit
Guide Word
No
Less
Less steam
- Pipe
leakage
- Process fluid
temperature low
Evaporator More
More steam
flow
- Reverse
process fluid
Flow
- Output of Process
fluid
temperature too high
Reverse
process fluid
Flow
- Failure of
process fluid
inlet
Valve
Reverse
Action
- Install
Temperature
indicator
before and
after the
process
fluid line
Install TAL
- Installation
of flow meter
- Install
Temperature
indicator
before and
after
process fluid
line
Install TAH
- Install
check valve
61
8.1.4 Dryer
Rotary
drum
dryer
Guide Word
No
Deviation
No hot Air
flow
Causes
- Failure of
inlet hot air
valve to
open
Consequences
- Process fluid
temperature is
not
Increased
accordingly
Less
- Pipe
leakage
- Process fluid
temperature
low
More
- Reverse
process fluid
flow
- Output of
Process fluid
temperature
too high
Reverse
Reverse
process fluid
Flow
- Failure of
process fluid
inlet
valve
- Product off
set
Action
-Install
Temperature
indicator
Before and
after the
process
fluid line
Install TAL
- Installation
of flow meter
-Install
Temperature
indicator
before and
after
process fluid
line
Install TAH
- Install
check valve
62
8.2
Environmental
"We are dependent on water and air in every minute of our life. Thus , it is the
responsibility of every one of us to not degrade the natural environment with
solid, liquid, and air pollutants. The systems for treatment of wastewater and
solid wastes for reuse and to release safe enivroment . The beet-sugar factory
produces more waste products than sugar, pulp, and molasses combined. If
beet-sugar producers are not diligent in caring and disposing of waste
products, the wastes can pollute the natural environment significantly. It
makes good business sense for producers to reduce pollution and comply
with all legally required actions and limitations with regard to the creation,
storage, treatment, and disposal of pollutants, wastes, and hazardous
compounds. Not doing so invites costly enforcement actions by the
governments and lawsuits by citizens. If comprehensive pollution reduction is
approached correctly, sugar producers not only be environmentally safe but
also can generate considerable cost savings."[1]
63
64
8.2.3 Safety :
Table 8.5 MSDS for Sugar Factory *
- First aid measures :
of
symptoms
running
persist,
water.
seek
If
medical
attention.
Skin: Wash thoroughly with soap and
water.
Inhaled: Remove to fresh air.
Advice
to
Doctor:
symptomatically.
Treat
People
with
- Extinguishing Media :
- Handling :
can
yield
carbon
in
an
explosion.
These
confined
space
during fermentation.
- Storage:
- Personal protection:
- Chemical Stability:
Stable.
- Toxicity Data :
Non-toxic .
- Health Effects:
MSDS : Material Safety Data Sheet for (white sugar pulp molasses)
66
Overview :
67
9.3
Mixer Control :
Figure 9.3
Mixer Control
68
9.4
Heater(1) Control :
9.5
Liming Control :
69
9.6
Clarifier Control :
9.7
Heater(2) Control :
9.8
Filter Control :
70
9.9
Evaporator Control :
9.11
Crystallizer Control :
71
9.12
Cooler Control :
9.13
Centrifuge Control :
9.14
Dryer Control :
72
9.15
73
Equipment
Manipulated
Controlled
Action
Variables
Variables
Diffusion Tower
Flow rate
Control Valve ( B1 )
Mixer
Flow rate
Control Valve ( B2 )
Liming
Flow rate
Control Valve ( B4 )
Exit composition
Clarifier
Flow rate
Filter
Flow rate
Control Valve ( B8 )
Evaporator
Flow rate
Control Valve ( B8 )
Temperature
Sulfitation
Flow rate
Crystallizer
Flow rate
Temperature
Centrifuge
Flow rate
Dryer
Temperature
Cooling Tower
St.22Flow rate
Temperature
Heater (1)
Temperature
Control Valve ( B3 )
Heater (2)
St.11Flow rate
Temperature
Control Valve ( B7 )
Cooler
Temperature
74
(10.1)
Reactor 2 = $ 627,900
Clarifier = $ 389,900
Heater = $ 32,200
Filter = $ 380,800
1st Evaporator = $ 3,253,000
2nd Evaporator = $ 2,489,700
3rd Evaporator = $ 2,690,800
Crystallizer = $ 152,300
Sulfitation Tank = $ 36300
Cooler 1 = $ 205,100
Centrifuge = $ 203,500
Dryer = $ 519,400
Cooler 2 = $ 79,300
Storages = $ 321,600
Total purchased equipment = $ 12,699,800
Cost index at 2007 = 525
Cost index at 2012 = 580
Cost of equipment in KSA in 2012 =
(10.2)[7]
(2007
Location factor = 1.4 "because the plant location in KSA"
Diffuser
Pressure
atm
Volume
310.65
m3
Material
Carbon steel
76
Static Mixer :
Pressure
Atm
Volume
85.95
m3
Material
Carbon steel
Pressure
Atm
Area
175.5
m2
Material
Carbon steel
Pressure
atm
Volume
84.46
m3
Material
Stainless steel
atm
Volume
64
m3
Material
Carbon steel
Dorr rake
Pressure
atm
Diameter
2.5
Material
Carbon steel
77
Heater 2 :
Type
Pressure
atm
Area
68.56
m2
Material
Carbon steel
Pressure
atm
Area
67.7
m2
Material
Carbon steel
Pressure
atm
Area
947.79
m2
Material
Stainless steel
st
Evaporator 2 :
Type
Pressure
atm
Area
640.36
m2
Material
Stainless steel
78
Evaporator 3 :
Type
Pressure
atm
Area
717.6
m2
Material
Stainless steel
Batch
Pressure
atm
Volume
31.11
m3
Material
Carbon steel
Sulfitation Tank :
Pressure
atm
Volume
32.4
m3
Material
Carbon steel
Pressure
atm
Area
293.7
m2
Material
Carbon steel
79
Centrifuge :
Type
Vertical , Batch
Pressure
atm
Diameter
1.981
Material
Carbon steel
Rotary drum
m2
89.87
Material
Stainless steel
Pressure
atm
Area
17.55
m2
Material
Carbon steel
Silos
Number
12
Pressure
atm
Volume
115.45
m3/silos
Material
Carbon steel
80
(10.3)
(10.4)
81
Item
Cost Capital %
Cost ($)
Direct Costs
Purchased equipments cost
100
19,544,453
39
7,622,337
26
5,081,558
Piping (installed)
31
6,058,780
10
1,954,445
29
5,667,891
Yard improvement
12
2,345,334
Service facilities
55
10,749,449
302
59,024,247
32
6,254,225
Construction expenses
34
6,645,114
Contractor's fee
19
3,713,446
Contingency
37
7,231,448
Legal expenses
781,778
126
24,626,011
FCI $
428
83,650,258
75
14,658,340
503
98,308,598
82
(10.5)
Raw Material
Cost ($/ton)
ton/year
$/year
41
711,000
29,151,786
0.267
1,422,000
379,200
CO2
11
24,562
270,182
SO2
2.12
180
381.6
80
24,080
1,926,400
Beet
Water
Lime (CaCO3)
31,727,164
83
Item
Cost capital %
Cost ($)
MANUFACTURE COST
Direct Production Cost (DPC)
Raw Material
31,727,164
31,727,164
10% TPC
0.1 TPC
10% OL
0.01 TPC
Utilities
10% TPC
0.1 TPC
4% FCI
3,346,010
Operation Supplies
0.5% FCI
418,251
Laboratory Supplies
10% OL
0.01 TPC
3% TPC
0.03 TPC
11,711,036
Depreciation
10% FCI
8,365,026
Local Taxes
---
---
Insurance
0.4% FCI
3,346,010
6% TPC
0.06 TPC
GENERAL EXPENSES
Administration Cost
2 % TPC
0.02 TPC
5% TPC
0.05 TPC
5% TPC
0.05 TPC
84
Item
Cost ($)
56,194,259
Raw Material
31,727,164
31,727,164
10% TPC
8,281,134
10% OL
828,113
Utilities
10% TPC
8,281,134
4% FCI
3,346,010
Operation Supplies
0.5% FCI
418,251
Laboratory Supplies
10% OL
828,113
3% TPC
2,484,340
11,711,036
Depreciation
10% FCI
8,365,026
Local Taxes
---
---
Insurance
0.4% FCI
3,346,010
4,968,680
2 % TPC
1,656,227
5% TPC
4,140,567
5% TPC
4,140,567
82,811,335
85
100 (10.6)
100 = 59.89 %
Payback Period =
(10.7)[7]
Payback Period =
= 1.46
Payback Period =
.
(
= 2.92
86
$ 98,308,598
$ 83,650,285
$ 14,658,340
$ 82,811,335
Rate of Return
29.95 %
Payback Period
2.92 Year
87
88
REFERENCES :
Books :
[1] Mosen Asadi (2007). Beet-Sugar Handbook.
89
Websites :
[8] http://www.food-info.net/uk/products/sugar/history.htm
[9]http://www.agmrc.org/commodities__products/grains__oilseeds/sugarcane
profile.cfm
[10] (http://blog.ub.ac.id/spiritgumilang/2012/10/05/single-multiple-effectevaporator/)
[11] www.westernstates.com/centrifuge
[12] http://ar.scribd.com/doc/6749495/Sugar-Safety
[13] www.klmtechgroup.com
[14] www.matche.com/equipment
90
APPENDICES
APPENDIX A : MASS BALANCE
A.1 Diffusion balance
Water
14
beet
(C12H22O12)
Juice diff.
XDS = 0.15
Xw = 0.85
Diffusion
5
1
4
Pulp
Xp= 0.2 onbeet
Overall M.B. :
m1+ m14= m4 + m5 m1+ 3845.87= m4 + 6689.05
m4=0.2m1
m1+3845.87= 0.2m1 + 6689.05
0.8m1=6689.05-3845.87
m1=3554 ton/day = 148083.33 kg/h
m4= (0.2)(3554)=710.8 ton/day = 29616.67 kg/h
Component M.B. :
STREAM 5 :
m5DS = 0.15 (6689.05) = 1003.36 ton/day =41806.67 kg/h
m5S = 1003.36 (0.88) = 883 ton/day = 36791.67 kg/h
m5NS = 1003.36 (0.12) = 120.36 ton/day = 5015 kg/h
m5w = 0.85 (6689.05) = 5685.7 ton/day = 236904.2 kg/h
91
XDS = 0.15
Xw = 0.85
Mixer
Beet
Beet
1
+
0.8 juice (on
beet)
Juice diff.
(C12H22O12)
XDS = 0.15
Xw = 0.85
92
At (88%) purity
STREAM (3) :
m3 = 9532.25 ton/day =397177.1 kg/h
m3DS = 9532.25 (0.15) = 1429.84 ton/day = 59576.67 kg/h (88% S, 12% NS)
m3S = 1429.84 (0.88) = 1258.26 ton/day = 52427.5 kg/h
m3NS = 1429.84 (0.12) = 171.58 ton/day = 7149.17 kg/h
STREAM (5) :
m5DS = 6689.05 (0.15) = 1003.36 ton/day = 41806.67 kg/h (88% S, 12% NS)
m5S = 1003.36 (0.88) = 883 ton/day = 36791.67 kg/h
m5NS = 1003.36 (0.12) = 120.36 ton/day = 5015 kg/h
m5W = 0.85 (6689.05) = 5685.7 ton/day = 236904.2 kg/h
STREAM (2)
m2DS = 6397.2 (0.15) = 959.58 ton/day = 39982.5 kg/h
m2W = 6397.2(0.85) = 5437.62 ton/day = 226567.5kg/h
93
Water
Beet
+
0.8 juice
14
(on beet)
4
diffuser
Juice tower
(C12H22O12)
Pulp
Xp= 0.2
onbeet
XDS = 0.15
Xw = 0.85
Overall M.B. :
STREAM (2)
m2DS = 6397.2 (0.15) = 959.58 ton/day = 39982.5 kg/h
m2W = 6397.2(0.85) = 5437.62 ton/day = 226567.5kg/h
STREAM (3) :
m3 = 9532.25 ton/day =397177.1 kg/h
m3DS = 9532.25 (0.15) = 1429.84 ton/day = 59576.67 kg/h (88% S, 12% NS)
m3S = 1429.84 (0.88) = 1258.26 ton/day = 52427.5 kg/h
m3NS = 1429.84 (0.12) = 171.58 ton/day = 7149.17 kg/h
STREAM(4):
m4=710.8 ton/day = 29616.67 kg/h
STREAM(14):
m14=3845.87 ton/day =160244.58 kg/h
94
7
6
(C12H22O12)
XDS = 0.15
Xw = 0.85
8
Liming
(C12H22O12)
XDS = 0.15
Xw = 0.85
(Purity = 88 %)
Overall M.B. :
m6+ m7 = m8 m6+ m7 = 6822.83 m6 +0.02 m6 = 6822.83
1.02m6 = 6822.83
m6 = 6689.05 ton/day = 278710.42 kg/h
m6DS = 6689.05 (0.15) =1003.36 ton/day = 41806.67 kg/h(88% S,12% NS)
m6S = 1003.36 (0.88) = 883 ton/day = 36791.67 kg/h
m6NS = 1003.36 (0.12) = 120.36 ton/day = 5015 kg/h
m6W = 0.85 (6689.05) = 5685.7 ton/day = 236904.2 kg/h
At (STREAM 7) Hence, the amount of milk of lime can be calculated as
follows :
m 7 = m 8 m6
95
(C12H22O12)
XDS = 0.15
Xw = 0.85
CLARIFIER
10
(C12H22O12)
XDS = 0.15
Xw = 0.85
9
Slurry (Mud)
XDS = 0.7
XW = 0.3
96
(C12H22O12)
XDS = 0.15
Xw = 0.85
11
FILTER
13
(C12H22O12)
XDS = 0.15
Xw = 0.85
12
REJECT
XDS = 0.15
Xw = 0.85
97
98
VAPOR
XDS = 0.0
Xw = 1.0
14
(C12H22O12)
XDS = 0.15
Xw = 0.85
13
15
Evaporator
(C12H22O12)
XDS = 0.7
Xw = 0.3
(Purity = 92 %)
Overall M.B. :
m13 = m14 + m15 m13 = m14 + 1048.875 m14 = m13 1048.875
Component M.B. :
For water : (STREAM 13)
0.85 m13 = (m13 1048.875) + 0.3(1048.875)
-0.15 m13 = -734.2125
m13 = 4894.75 ton/day = 203947.9167 kg/h
m13DS = 4894.75 (0.15) = 734.2125 ton/day = 30592.1875 kg/h (92% S, 8%
NS)
m13S = 734.2125 (0.92) = 675.4755 ton/day = 28144.8125 kg/h
m13NS = 734.2125 (0.08) = 58.737 ton/day = 2447.375 kg/h
m13W = 0.85 (4894.75) = 4160.5375 ton/day = 173355.7292 kg/h
At (STREAM 14) XDS = 0 and XW = 1.0
Hence, the amount of water vaporized during evaporation can be calculated
as follows :
m14 = m13 m15
= 4894.75 1048.875 = 3845.875 ton/day = 160244.7917 kg/h
99
SO2
(C12H22O12)
XDS = 0.7
Xw = 0.3
15
16
SULFITATION
(C12H22O12)
XDS = 0.7
Xw = 03
(Purity = 92 %)
Overall M.B. :
m15= m16 1048.875 ton/day (43703.125 Kg/h)
Component M.B. :
(STREAM 15 = STREAM 16)
0.7 m16 = m16DS = m15DS = 43703.125(0.7) = 30592.1875 Kg/h
m15S = m16S = 30592.1875 (0.92) = 28144.8125 kg/h
m15NS = m16NS = 30592.1875 (0.08) = 2447.375 kg/h
0.3m16 = m16W = m15W = 0.3 (43703.125) = 13110.9375 kg/h
100
17
(C12H22O12)
XDS = 0.7
Xw = 0.3
H2O
16
18
CRYSTALLIZER
(C12H22O12)
XDS = 0.93
Xw = 0.07
(Purity = 92 %)
Overall M.B. :
m16 = m17 + m18 m16 = m17 + 798.45 ton/ day (32893.75 Kg/hr)
m17 = m16 32893.75
Component M.B. :
( STREAM 16)
mT = 43703.125=
m16DS = 43703.125(0.7) = 30592.1875 Kg/h
m16S = 30592.1875 (0.92) = 28144.8125 kg/h
m16NS = 30592.1875 (0.08) = 2447.375 kg/h
m16W = 0.3 (43703.125) = 13110.9375 kg/h
( STREAM 18)
m18= 32893.75 Kg/hr
m18DS = m16DS = 30592.1875 Kg/h
m18S = m16S = 28144.8125 kg
m18NS = m16NS = 2447.375 kg/h
m18W = m18 - m18DS = 2301.5625 Kg/hr
m17 (Only water):
m17W= 43703.125 - 32893.75 = 10809.375 Kg/hr
101
(C12H22O12)
XDS = 0.93
Xw = 0.07
(C12H22O12)
XDS = 0.93
Xw = 0.07
COOLER
(C12H22O12)
XDS = 0.93
Xw = 0.07
19
20
CENTRIFUGE
Other
processes
XDS = 0.94
Xw = 0.06
21
(C12H22O12)
XDS = 0.95
XW = 0.05
Component M.B. :
STREAM 19 :
m19DS = 0.93 (789.45) = 734.2 ton/day = 30591.7 kg/h
m19S = 0.92 (734.2) = 675.46 ton/day = 28144.33 kg/h
m19NS = 0.08 (734.2) = 58.736 ton/day = 2447.33 kg/h
m19w = 0.07 (789.45) = 55.26 ton/day = 2302.56 kg/h
STREAM 20 :
m20DS = 0.94 (473.7) = 445.278 ton/day = 18553.25 kg/h
m20w = 0.06 (473.7) = 28.422 ton/day = 1184.25 kg/h
STREAM 21 :
m21DS = 0.95 (315.78) = 300 ton/day = 12500 kg/h
m21W = 0.05 (315.78) = 15.78 ton/day = 657.5 kg/h
103
(C12H22O12)
XDS = 0.95
Xw = 0.05
21
DRYER
23
(C12H22O12)
XDS = 1
Xw = 0.00
22
WATER
XDS = 0.00
Xw = 1
104
(C12H22O12)
25
24
XDS = 1
STORAGE
STOREHOUSE
XDS = 0.5
Xw = 0.00
Xw = 0.00
26
SPECIALTY
SUGARS
XDS = 0.5
Xw = 0.00
DS= Dry substance (100% S , 0% NS)
W = Water
(Purity = 100 %)
Overall M.B. :
m26 = 150 ton/day = 6250 kg/h
m24 = m25 + m26 m24 = m25 + 150
0.5m24 = 150 m24 = 300 ton/day = 12500 kg/h
m25 = 300 150 = 150 ton/day = 6250 kg/h
105
mixer
(C12H22O12)
T= 65oC
H2
3
(C12H22O12)
T= 70oC
H3
5
(C12H22O12)
T= 35oC
H5
Water @ 25oC
CPdT =
[75.4*10-3] [65-25]
106
H3 = H3DS + H3W
H3DS = m3DS CpDS T
CPDS at 70oC (90% purity)(15%DS) = 3.88 kJ/kg.oC (From App D.1)
H3DS = (1429.84*103)(3.88)(70-25) = 249650064 kJ/day = 10402086 kJ/h
H3W =
CPdT =
[75.4*10-3] [70-25]
CPdT =
[75.4*10-3] [30-25]
107
(C12H22O12)
T= 30oC
H5
(C12H22O12)
T= 88oC
H6
CPdT =
[75.4*10-3] [88-25]
108
water
T=90oC
H14
Beet+(C12H22O12)
T=65oC
H2
Diffuser
(C12H22O12)
T=70oC
H3
(C12H22O12)
T=70oC
H4
CPdT =
[75.4*10-3] [90-25]
CPdT =
[75.4*10-3] [70-25]
109
(C12H22O12)
T=88oC
H6
8
liming
(C12H22O12)
T=88oC
H8
H7 =
CPdT =
[89.5*10-3] [40-25]
110
(C12H22O12)
T= 88oC
H8
CLARIFIER
10
(C12H22O12)
T= 88oC
H10
9
SLURRY
T= 88oC
H9
Water @ 25oC
H8 = H8DS + H8W
H8DS = m8DS CpDS T
CPDS at 88oC (90% purity)(15%DS) = 3.905 kJ/kg.oC (From App D.1)
H8DS = (1023.42*103)(3.905)(88-25) = 251776671.3 kJ/day = 10490694.64
kJ/h
H8W =
CPdT =
[75.4*10-3] [88-25]
CPdT =
[75.4*10-3] [88-25]
111
CPdT =
[75.4*10-3] [88-25]
112
10
(C12H22O12)
T= 88oC
H10
11
(C12H22O12)
T= 92oC
H11
.90
(92 90
(
(
( .92 .90
(100 90
=3.908
CPDS at 92oC (90% purity)(15%DS) = 3.908 kJ/kg.oC
H11DS = (767.568*103)(3.908)(92-25) = 200976934.8 kJ/day = 8374038.952
kJ/h
H11W =
CPdT =
[75.4*10-3] [92-25]
113
11
(C12H22O12)
T=92oC
H11
FILTER
13
(C12H22O12)
T=92oC
H13
12
REJECT
T=92oC
H12
H11 = 1421702868 kJ/day = 59237619.49 kJ/h
H12 = H12DS + H12W
H12DS = m12DS CpDS T
CPDS at 92oC (90% purity)(15%DS) = 3.908 kJ/kg.oC
(By Interpolation in
previous page)
H12DS = (33.368*103)(3.908)(92-25) =8736943.648 kJ/day = 364039.3187 kJ/h
H12W =
CPdT =
[75.4*10-3] [92-25]
CPdT =
[75.4*10-3] [92-25]
114
14
(C12H22O12)
T=92oC
H13
13
15
Evaporator
(C12H22O12)
T=95oC
H15
CPdT =
[75.4*10-3] [100-25]
CPdT =
[75.4*10-3] [95-25]
115
Water
T=100oC
H17
(C12H22O12)
T=95oC
H16
CRYSTALLIZER
(C12H22O12)
T=100oC
H18
CPdT =
3844418.229 kJ/h
H16T = 245679745.4 kJ/day = 10236656.06 kJ/h
H17W=
CpdT =
= 3395618.055 kJ/h
CPDS at 100oC (90% purity)(90%DS) = 2.43 kJ/kg.oC (From App A.4)
H18DS = (734.2*103)(2.43)(100-25) = 133807950 kJ/day = 5575331.25 kJ/h
H18W=
CpdT =
= 7233687.5 kJ/h
H18T= 12809018.75 kJ/h
Q = Hout - Hin = (H18 + H17) (H16)
Q = 5967980.745 kJ/h
116
COOLER
(C12H22O12)
T=75oC
H19
CpdT =
= 7233687.5 kJ/h
H18T= 12809018.75 kJ/h
CpDS at 75
CpdT =
= 482245.83 kJ/h
H19T= 8478162.497 kJ/h
Q = Hout - Hin = (H19) (H18)
Q = - 4330856.253 kJ/h
117
(C12H22O12)
T= 75oC
H19
CENTRIFUGE
19
20
Other processes
T= 60oC
H20
21
(C12H22O12)
T= 60oC
H21
Water @ 25oC
=
= 2. 6
(
(7 70
(
(
(2.42 2. 6
(80 70
=2.39
118
CPdT =
[75.4*10-3] [75-25]
CPdT =
[75.4*10-3] [60-25]
C) we find CPDST(100%
CPdT =
[75.4*10-3] [60-25]
119
(C12H22O12)
T= 60oC
H21
DRYER
21
23
(C12H22O12)
T= 65oC
H23
22
WATER
T= 65oC
H22
Water @ 25oC
C) we find CPDST(100%
CPdT =
[75.4*10-3] [60-25]
120
H22 = H22W
CPW at 65oC (0%DS) = 3.016 kJ/mol .oC
H22W =
CPdT =
[75.4*10-3] [65-25]
(From
equation)
H23DS = H23 = (300*103)(74.16) = 22248000 kJ/day = 927000 kJ/h
Q = Hout - Hin = (H22 + H23) (H21)
Q = 2107525.207 kJ/day = 87813.55 kJ/h
121
(C12H22O12)
T= 65oC
H23
23
COOLER
24
(C12H22O12)
T= 30oC
H24
H23 = H23DS
H23DS = m23DS CpDS T
CPDST from (25 65) (100% purity)(100%DS) = 74.16 kJ/kg
(From
equation)
H23DS = (300*103)(74.16) = 22248000 kJ/day = 927000 kJ/h
H24 = H24DS
H24DS = m24DS CpDS T
CPDST from (25 30) (100% purity)(100%DS) = 8.5 kJ/kg (From equation)
H24DS = (300*103)(8.5) = 2548687.5 kJ/day = 106195.31 kJ/h
Q = Hout - Hin = (H24 H23)
Q = -19699312.5 kJ/day = - 820804.69 kJ/h
122
123
124
125
D.2) Density :
126