Heat Balance

Around Fermenter:
CO2 40°C

Feed 30°C Mash 40°C

For the calculation of heat to be removed in the fermenter

Reaction:
C6H12O6 2C2H5OH +2CO2
Formula used to calculate heat of Reaction
ΔH = mass of reactant * specific heat of products * temperature difference

Mass of reactant = 964610 kg

Specific heat of ethanol = 2.72 kj/kg C
Specific heat carbon dioxide = 0.844 kj/kg C
Temperature difference = 10°C
Now putting values in above formula
ΔH= 964610 × (2.72+0.844) ×10 = 34378700.4 kj
= 8216715.67 kcal
Heat of Reaction (ΔH) = 8216715.67 kcal/1000 gallon Alcohol
Density of ethanol=ρA=0.81 kg/ltr
1 gallon=3.78ltr
1000 gallon=3.78* 1000
=3780 ltr
Weight of Alcohol =3780* 0.810kg/ltr
3061.8 kg of Alcohol in 1000 gallons
Now for the heat of reaction in terms of kcal/ton
H=8216715.67 kcal/3061.81kg*1000kg/ton
H= 2683622.6 kcal/ton
Alcohol =190.8tons/day
Now
 For Heat released in the Reaction =2683622.6 *190.8
= 512035192 kcal/day
As the heat released during the fermentation reaction must be removed frequently to maintain the
temperature in the reactor to (35-40 C) the heat released will be used as heat to be removed.
Heat to be Removed = 512034589.2 kcal/day

To Remove this heat a Coolant (water ) is used in the Reactor for this Purpose

Q in = Q out
Q heat released = Q Coolant

Q=mCp∆T
512034589.2 = m* 0.99 kcal/kg°C*(40-30)
m= 51203459 kg
m= 51203.459 tons
Around Pre-heater:

Mash 60°C Mash 99°C

Heat in = mCp∆T
=4332 * 1000/24 Kg / hr * .97kcal/kg°C(99-60)
=6828315 kcal/hr
Q for steam =Msλs
Ms= Q /λs
=6828315 /519.45
= 13145.27 kg/hr( mass Flow rate of Steam )

Around Heat Exchanger:

Mash 40°C Mash 60°

Slope 79°C Slope 100°C

Cold Fluid
Heat in= mCp∆T
 =4332*1000/24 Kg / hr *.97 kcal/kg°C (60-40)
=3501700 kcal/hr
Hot Fluid
Outlet temp. of hot fluid
Q=mCp∆T
3501700 kcal/hr =4014*1000/24 Kg / hr*1kcal/kg°C(100-T)
T= 79.07oC
Around Stripper:
Top Product 92°C

Mash 99°C

Slope 99°C

Heat In
Heat in= mCp∆T
= 4332* 1000/24Kg / hr*.97kcal/kg°C(99-30)
=12080865 kcal/hr
Heat out= mCp∆T
=4014*1000/24 Kg / hr *1 kcal/kg°C (100-30)
=11707500 kcal/hr
Heat Out
Heat out=mCp∆T + mλ
=318*1000/24 Kg / hr *0.727 kcal/kg°C(92-30)+318*1000/24Kg / hr*521.4
=597230.5+6907225
=7504455.5kcak/hr
Heat to be provided by steam= (7504455.5 +11707500)-12080865
=7131090.5 kcal/hr
Around Condenser 1:

92°C

MA

Reflux ratio=0
Mv = MA
MA= 318ton/day

Top product contains 60% alcohol, so

Components Fraction Specific Heat Heat of Vaporization

Alcohol 0.6 0.581 204
Water 0.3735 0.99 374.41
Aldehyde 0.0243 0.269 12.82
Fusel oil 0.0026 0.768 1274

Cp mean=.6*.581+.3735*.99+.0243*.269+.0026*.768
=.727kcal/kg
Hl=mCp∆T
=1*.727kcal/kg°C*(92-30)
=45.074 kcal/kg
Hvap=45.074 +XH2Oλ+XC2H5OHλ+XF.Oλ+XAldehydeλ
=45.074 +139.845+122.4+3.31488+.3117
=310.94558kcal/kg
Hvap=318*1000/24Kg / hr*45.074 kcal/kg
=597230.5 kcal/hr
Hvap=318*1000/24Kg / hr*310.94558 kcal/kg
=4120028.935 kcal/hr
Duty =4120028.935 kcal/hr-597230.5 kcal/hr
= 3522798.435 kcal/hr
Mass of H2O required in condenser
mCp∆T= 3522798.435
m= 3522798.435kcal/hr/.99kcal/kg°C(40-30)
 m= 355838.2258kg/hr
m= 8540.11tons/day
Around Condenser 2:
82°C
30°C
40°C
MA

Reflux ratio =3:1

MB= 3MA
MV=MA+MB
MV=4MA
MA=200ton/day
=200*1000/24
=8333.3 kg/hr
XC2H5OH=.95
XH20= .05
Cp mean= .05*.99kcal/kg°C+.95*.93kcal/kg°C
= .933 kcal/kg
Hl= mCp∆T
=1*.933kcal/kg°C(82-30)
= 48.516 kcal/kg
Hvap=48.516 +XH20λ+XC2H5OHλ
=48.516 +18.75+193.8
= 261.066 kcal/kg
Duty=4*261.066 *8333.33
=8702196.579kcal/hr
Mass of water required in condenser
m= 8702196.579kcal/hr/.99kcal/kg°C(40-30)
m= 879009.7499kg/hr
m= 21096.23 tons/day