University of San Carlos Department of Chemical Engineering

CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1

USC Chemical Engineering Student

Process Equipment Design 2017

D e p a r t m e n t o f Term/Academic Year:
Chemical Engineering First Semester AY 2017-2018
Talamban, Cebu City, Philippines 6000

PROJECT TITLE

A design project submitted in partial fulfillment of the requirements in the course

CHE 514N
Chemical Reactor and Process Equipment Design

Del Mar, Janus King S.M.

Maguikay, Dia Fatima P.
Torrefiel, John Christopher A.

October 2017
 University of San Carlos Department of Chemical Engineering
CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1

1 TABLE OF CONTENTS

2 1. The Design Problem............................................................................................................................................. 3

3 1.1. Statement of the design project .................................................................................................................... 3
4 1.2. Description of the process ............................................................................................................................ 3
5 1.3. Summary of the design task ......................................................................................................................... 4
6 2. Process definition ................................................................................................................................................. 5
7 2.1. Flow diagrams .............................................................................................................................................. 5
8 2.1.1. Input-output diagram............................................................................................................................ 5
9 2.1.2. Block flow diagram............................................................................................................................... 6
10 2.2. Basic assumptions ....................................................................................................................................... 6
11 2.2.1. Production capacity and feed/product specification ............................................................................. 6
12 2.2.2. Plant location, layout and operating hours ........................................................................................... 6
13 2.2.3. Battery limits ........................................................................................................................................ 6
14 2.2.4. Definition of incoming and outgoing streams ....................................................................................... 6
15 2.2.5. Economic margin ................................................................................................................................. 6
16 3. Chemical engineering design of process equipment ............................................................................................ 6
17 3.1. Equipment sizing .......................................................................................................................................... 6
18 3.2. Equipment configuration and operating scheme .......................................................................................... 7
19 3.3. Energy requirements and duties................................................................................................................... 7
20 4. Mechanical design of process equipment ............................................................................................................ 7
21 4.1. Materials of construction............................................................................................................................... 7
22 4.2. Fittings and connections ............................................................................................................................... 7
23 4.3. Equipment internals ...................................................................................................................................... 7
24 4.4. Loading and supports ................................................................................................................................... 7
25 4.5. Pumping requirements ................................................................................................................................. 7
26 4.6. Mechanical drawing of process equipment .................................................................................................. 7
27 5. Piping and instrumentation ................................................................................................................................... 7
28 5.1. Piping system ............................................................................................................................................... 7
29 5.2. Valves and meters ........................................................................................................................................ 7
30 5.3. Compressors and pumps ............................................................................................................................. 8
31 5.4. Control and instrumentation ......................................................................................................................... 8
32 6. Conclusions and recommendations ..................................................................................................................... 8
33 References..................................................................................................................................................................... 9
34 Appendices .................................................................................................................................................................. 10
35 A. Physical and Thermodynamic data .................................................................................................................... 10

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 University of San Carlos Department of Chemical Engineering
CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1

36 B. Kinetic and/or equilibrium data ........................................................................................................................... 10

37 C. Mass and energy balance calculation sheets ..................................................................................................... 10
38 D. Chemical engineering design calculation sheets ................................................................................................ 10
39 E. Mechanical design calculation sheets ................................................................................................................ 10
40
41

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 University of San Carlos Department of Chemical Engineering
CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1

42 1. The design problem

43
44 1.1. Statement of the design project
45
46 As a design firm, we have been task to design a rice bran processing plant catering to biodiesel production in order
47 to meet at least 10% of the Philippines local biodiesel demand by 2020 where the plant will be operated for 330 days
48 per year.
49
50 In order to achieve a viable raw material for biodiesel production, the rice bran oil going to the reactor contain atleast
51 only triglycerides and fatty acids. Lipids comprised about 18.3% of the total composition of the rice bran. Lipids is to
52 be extracted by using hexane as solvent to produce crude rice bran oil. Crude rice bran oil contains an abundant
53 amount of natural bioactive nutrients such as oryzanol and phytosterols with a balanced FFA content plus minimal
54 amounts of tocopherols and tocotrienols. Aside from nutrients, commercial crude rice bran oil usually contains 2-3%
55 wax and 1-2% phospholipids. Waxes and phospholipids are undesirable in the production since it may damage
56 production equipment and can cause interferences in reaction product analysis by gas chromatography. Hence, there
57 is a need for its removal to make biodiesel of higher purity.
58
59 Our team has been assigned to the physical refining step focusing in the removal of fat soluble impurities (e.g. wax
60 and gums) from crude rice bran oil. The degummed and dewaxed rice bran oil, containing a certain percentage of
61 free fatty acids, is then fed to a reactor where it is reacted with methanol to produce methyl esters.
62
63 1.2. Description of the process
64
65 The plant process is divided to 3 different sub-sections: i. upstream extraction and refining process, ii. biodiesel
66 production process, and iii. downstream recovery process. Rice bran is the raw material and is obtained as a
67 byproduct from polishing of rice grain. Rice bran is composed of 13.5% moisture, 13.2% protein, 18.3% lipids, 38.3%
68 sugar substance, 7.8% fiber, and 8.9% ash as reported by yujino et al (yujino, 1977). Oil produced from rice bran
69 have gotten attention since it has highly nutrient value due to a large amount of nutrients such as -oryzanol and
70 tocotrienol (vitamin E) which act as an antioxidant and lowers plasma cholesterol levels respectively.
71
72 Rice bran lipids are extracted with an aid of a solvent (usually hexane) in order to produce crude rice bran oil. Crude
73 rice bran oil extracted however is still not a viable biodiesel production raw material due to large amounts of waxes
74 and phospholipids. Crude rice bran oil is then further refined to remove fat-soluble impurities (e.g. wax and gums).
75 After removal of wax and gums, the oil is then sent to the biodiesel production process.

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 University of San Carlos Department of Chemical Engineering
CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1

76
77 The degummed and dewaxed rice bran usually containing a certain percentage of free fatty acids is then fed to a
78 reactor where it is reacted with methanol to produce methyl esters. Four (4) approaches is then considered to identify
79 the best method to do the reaction: i) Direct trans-esterification with a homogenous acid catalyst, ii) Direct trans-
80 esterification with heterogenous acid catalyst, iii) Heterogeneous acid catalyzed tran-esterification followed by either
81 homogenous base catalyzed trans-esterification or heterogeneous base catalyzed reaction. In the reactor.
82 triglycerides and fatty acids in the oil reacts with methanol to produce methyl esters, glycerol and water. A final
83 mixture of glycerol, methyl esters, methanol, and water is obtained. The mixture is then sent to the downstream
84 process.
85
86 The downstream process is responsible for further purification products and recovery of still usable methanol.
87 Methanol is first recovered from the mixture and recycled to the trans-esterification process. The mixture is then
88 separated to a crude methyl ester stream and a crude glycerol stream as by product. These two streams still contain
89 significant amounts of methanol that needs to be further recovered and recycled to the trans-esterification process. A
90 main product of fatty acid methyl ester and a glycerol byproduct is obtained.
91
92 1.3. Summary of the design task
93
94 It was a requirement to maximize product output of methyl esters that the rice bran oil going to the reactors should be
95 composed of at least triglycerides and free fatty acids. As mentioned above, crude rice bran oil aside from containing
96 nutrients also contain significant amount of impurities (e.g. wax and phospholipids). Phospholipids are to be removed
97 due to their strong emulsifying action. Phospholipids are mainly of two types: i. hydratable phospholipids (HPL) which
98 are composed of hydratable phosphatidylcholine (PC) and phosphatidylinositol (PI), and ii. non-hydratable
99 phospholipids (NHPL) which are calcium and magnesium salts of phosphatidic acid (PA) and
100 phosphatidylethanolamine (PE) (Hvolby 1971). HPL are removed mostly through water degumming while NPHL are
101 removed through addition of salt solutions, dilute acids or enzymes.
102
103 Our team has been assigned with the physical refining of extracted crude oils through degumming and dewaxing.
104 Degumming is the treatment of crude oils with water, dilute acids or enzymes to further remove phospholipids, waxes
105 and other impurities found within the oil (Sengar, 2014).
106
107 A novel process was introduced by rajam et al focusing entirely in degumming and dewaxing of crude rice bran oil.
108 The process involves addition of water to crude oils which exploits the HPLs affinity for water and the addition of salt
109 (calcium chloride) which causes a thermotropic phase transfer of NPHL and water to form liposomes with HPL which

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 University of San Carlos Department of Chemical Engineering
CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1

110 are then further separated by crystallization and centrifugation. The process was noted to have remove at least 80%
111 of the total wax content of the crude oil (Rajam, 2005).
112
113 The degumming process involves 4 steps: i. addition of water at 75C in a mixer, ii. addition of 6% wt/vol CaCl2
114 solution in a 2nd mixer, iii. crystallization from 75C to 20C, and iv. centrifugation to separate the oil from the
115 impurities. Some of the steps involve equipment that can readily be purchased except the crystallizer. Our paper then
116 focuses on designing a crystallizer equipment that can meet up with the specified 80% removal of the initial wax
117 content.
118
119 2. Process definition
120 Discuss in detail the major operations and process steps involved in the process assigned.
121 Include relevant process conditions and criteria of operation.
122
123 Pretreatment of feedstock. Xxxxxxxxxx
124
125 Extraction of lipids. Xxxxxxxxxx
126
127 Pretreatment of oil. Xxxxxxxxxx
128
129 (Trans)esterification reaction. Xxxxxxxxxx
130
131 Separation of methyl ester and glycerin. Xxxxxxxxxx
132
133 Recovery of Methanol. Xxxxxxxxxx
134
135 Subsection (Level 2) headers should be plain normal text and only the first letter of the first word should be capitalized (except for proper nouns).
136 Methodology or experimental procedures should be concise and brief, but should provide as much detail to allow verification and possible
137 reproduction of the work by other researchers. Sources from which the methodology was adopted should be cited.
138 Whenever possible, brand and model of the pieces of equipment used in accomplishing the research or experiment should be indicated. For
139 statistical analyses and graphics/artwork the software used should be indicated as well.

140
141 2.1. Flow diagrams
142 Sub-subsection (Level 3) headers should be ITALICIZED and only the first letter of the first word should be capitalized (except for proper nouns).

143 2.1.1. Input-output diagram

144
145
146
147 Figure 1. Input output diagram of the production of biodiesel from rice bran oil.
148

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 University of San Carlos Department of Chemical Engineering
CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1

149 For the input output diagram, it should be rendered using Microsoft Visio.
150 For Figures and other captions kindly use the tools provided in MS Word under the Reference tab.

151 2.1.2. Block flow diagram

152 Use CHE 514N FORM 1-1 Flow Sheet Template.vsdx
153 The block flow diagram should specify the flow rates and stream composition as well as the stream conditions, conversion and separation
154 efficiencies.
155 Calculation or data processing should be presented in the appendices using the prescribed calculation sheets (CHE 514N FORM 1-4 Calculation
156 Sheets Template).

157 2.2. Basic assumptions

158 Provide an overview of the process parameters adopted, feed and product specification, plant location, layout and operating hours, as well as the
159 battery limits of the design.

160 2.2.1. Production capacity and feed/product specification

161 Provide details of the feed and product specification, either based on the design demand or product standards.

162
163 2.2.2. Plant location, layout and operating hours
164 Provide a hypothetical plant location, layout (plot size and plan) and operating hours.

165
166 2.2.3. Battery limits
167 Articulate the scope of the design task and limitations.

168
169 2.2.4. Definition of incoming and outgoing streams
170 Define the streams in terms of the components in a given stream and its role in the process (Focus only in streams related to the process equipment
171 being designed.
172 (Tabulated) Summary of material flows or stream summary.

173 2.2.5. Economic margin

174 Provide a rough estimate of the allowable operating cost the process and/or process equipment.
175 This may be determined by determining the fraction of the gross revenue to that of the total sales of the main products (an economic margin of at
176 least 70 % is desirable but not absolutely necessary.)

177
178
179 3. Chemical engineering design of process equipment
180 Discuss in detail how the design of the process equipment was done and the key equations used in the design.
181 Calculation or data processing should be presented in the appendices using the prescribed calculation sheets (CHE 514N FORM 1-4 Calculation
182 Sheets Template).

183 3.1. Equipment sizing

184 Calculation or data processing should be presented in the appendices using the prescribed calculation sheets (CHE 514N FORM 1-4 Calculation
185 Sheets Template).

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 University of San Carlos Department of Chemical Engineering
CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1

186 3.2. Equipment configuration and operating scheme

187 Calculation or data processing should be presented in the appendices using the prescribed calculation sheets (CHE 514N FORM 1-4 Calculation
188 Sheets Template).

189 3.3. Energy requirements and duties

190 Calculation or data processing should be presented in the appendices using the prescribed calculation sheets (CHE 514N FORM 1-4 Calculation
191 Sheets Template).

192 4. Mechanical design of process equipment

193 Discuss in detail how the design of the process equipment was done and the key equations used in the design.
194 Calculation or data processing should be presented in the appendices using the prescribed calculation sheets (CHE 514N FORM 1-4 Calculation
195 Sheets Template).

196 4.1. Materials of construction

197 Discuss in detail and justify how the material selection was made and what material was chosen for later construction/fabrication.

198 4.2. Fittings and connections

199 Discuss in detail relevant fittings and connections needed for the process equipment designed.
200 Indicate size and type of fittings and connections necessary.

201 4.3. Equipment internals

202 Discuss in detail how the design of the process equipment internals was done and the key equations used in the design and selection.
203 Discuss in detail relevant equipment internals (packing, sieves, filters, mesh, impellers, baffles, feed distributor, diffusers, etc) needed for the process
204 equipment designed.
205 Indicate size and type of internals necessary.

206 4.4. Loading and supports

207 Detail the loading and assumption taken into consideration in the design of the vessel or process equipment support.

208 4.5. Pumping requirements

209 Provide a summary of the necessary accessory equipment and their specification.

210 4.6. Mechanical drawing of process equipment

211 Use CHE 514N FORM 1-1 Flow Sheet Template.vsdx
212 Use CHE 514N FORM 1-2 Equipment Specification Sheet.docx

213 4.7. Equipment Specification

214 Use CHE 514N FORM 1-1 Flow Sheet Template.vsdx
215 Calculation or data processing should be presented in the appendices using the prescribed calculation sheets (CHE 514N FORM 1-4 Calculation
216 Sheets Template).

217
218
219 5. Piping and instrumentation
220 Sample calculation or data processing should be presented in the appendices.

221 5.1. Piping system

222 Indicate the type of pipe, pipe diameters and estimate the total pipe lengths required.

223 5.2. Valves and meters

224 Discuss in detail relevant valves and meters needed for the process equipment designed.

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 University of San Carlos Department of Chemical Engineering
CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1

225 Justify how these were selected and chosen..

226 5.3. Compressors and pumps

227 Provide details and justification of the selected pumps and other accessory equipment used.

228 5.4. Control and instrumentation

229 Specify and indicate the necessary controls and instrumentation required in the operation of the process equipment designed.

230 5.5. Piping and instrumentation diagram

231 Use CHE 514N FORM 1-3 Piping and Instrumentation Diagram Template.vsdx

232
233
234 6. Conclusions and recommendations
235
236 Conclusions should be based on the interpretation(s) and discussions made in the previous section. The conclusions should be based on concrete
237 facts, providing answers to the design task or problem.
238 Recommendations should focus on how the current design may be improved or on the potential works which could be done to ease the design of the
239 process equipment.
240
241
242

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 University of San Carlos Department of Chemical Engineering
CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1

243 References
244 The references should be cited and the list should be generated through the aid of a citation manager (MENDELEY). For consistency the
245 Renewable and Sustainable Energy Review citation style should be adopted. Font size of 10 pts. and a line spacing of 1.
246
247 [1] Cholakov G, Toteva V, Nikolov R, Uzunova S, Yanev S. Extracts from coffee by-products as potential raw materials for fuel
248 additives and carbon adsorbents. Journal of Chemical Technology and Metallurgy. 2013:497-504.
249 [2] Margaritopoulou T, Roka L, Alexopoulou E, Christou M, Rigas S, Haralampidis K, et al. Biotechnology Towards Energy
250 Crops. Mol Biotechnol. 2016.
251 [3] Haile M. Integrated valorization of spent coffee grounds to biofuels. Biofuel Research Journal. 2014;2:65-9.
252 [4] Vardon DR, Moser BR, Zheng W, Witkin K, Evangelista RL, Strathmann TJ, et al. Complete utilization of spent coffee grounds
253 to produce biodiesel, bio-oil, and biochar. ACS Sustainable Chemistry & Engineering. 2013:1285- 94.
254 [5] Kwon EE, Jeon YY, Jeon YYJ. Sequential co-production of biodiesel and bioethanol with spent coffee grounds. Bioresource
255 Technology. 2013;136:475- 80.
256 [6] Mussatto SI, Machado EMS, Carneiro LM, Teixeira JA. Sugars metabolism and ethanol production by different yeast strains
257 from coffee industry wastes hydrolysates. Applied Energy. 2012;92:763-8.
258
259

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CHE 514N FORM-1-Undergraduate Equipment Design Report Template v2017-1

260 Appendices
261
262 Appendices should contain supplementary data and information relevant in the review of the research paper.
263 Sample calculation or data processing should be presented in the appendices.
264 Tables, Figures and Equations presented in the appendices should be numbered sequentially but should be distinct and not a
265 continuation of the labels found in the main text.
266
267 A. Physical and Thermodynamic data
268
269 B. Kinetic and/or equilibrium data
270
271 C. Mass and energy balance calculation sheets
272 Sample calculation or data processing should be presented in the appendices.

273
274 D. Chemical engineering design calculation sheets
275 Sample calculation or data processing should be presented in the appendices.
276
277 E. Mechanical design calculation sheets
278 Sample calculation or data processing should be presented in the appendices.
279

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