1089 Kg/year Cephalosporin Antibiotic Production Plant From Corn Steep Liquor

BANGLADESH UNIVERSITY OF ENGINEERING & TECHNOLOGY
Design of 1089 kg/year Cephalosporin Antibiotic

Production Plant from Corn Steep liquor
Report
Submitted by
Mohammad Fokra Alam Chowdhury (1102007)
Oindrila Hossain (1102008)
Swaraj Podder Anik (1102010)
Antara Mazumder (1102058)
Supervisor
Dr. Shoeb Ahmed
Assistant Professor
Department of Chemical Engineering, BUET
ACKNOWLEDGEMENT
We would like to take this opportunity to convey our heartfelt appreciation to them whose blessing
and cooperation was important to bring this report in light. First we would like to pay our gratitude
to the Almighty Allah who made each attempt fruitful.
We wish to express our profound gratitude and indebtedness to our supervisor, Dr. Shoeb Ahmed,
Assistant Professor, Department of Chemical Engineering, BUET for his wonderful guidance,
encouragement and support from the beginning to the end of the design. It is a great pleasure to
thank him for his generous contribution to the conception and creation of the design dissertation.
We would like to thank all other teachers and staffs of Department of Chemical Engineering,
BUET. Last but not least, our sincere thanks to all our friends and seniors who have patiently
extended all sorts of help for accomplishing this undertaking.
i
TABLE OF CONTENTS
Acknowledgement………………………………………………………………… i
List of tables……………………………………………………………………...... iv
List of figures………………………………………………………………………… v
1. Process definition……………………………………………………………… 1-9

1.1 Project definition…………………………………………………………………….. 2
1.2 Process description…………………………………………………………………... 3-4
1.3 Design basis………………………………………………………………................. 4-7
1.3.1 Geological data……………………………………………………………………. 4-5
1.3.2 Climatic conditions………………………………………………………………... 5-6
1.3.3 Utility conditions………………………………………………………………….. 6-7
1.3.4 Raw materials……………………………………………………………………... 7
1.3.5 Solvents for extraction…………………………………………………………….. 7
1.4 Process selection…………………………………………………………………….. 7-9
2. Process diagrams………………………………………………………………. 10-12
2.1 Process Block Diagram……………………………………………………………… 11
2.2 Process Flow Diagram………………………………………………………………. 12
3. Material balance……………………………………………………………….. 13-28
4. Energy balance…………………………………………………………………. 29-36

5. Utility balance………………………………………………………………….. 37-40
6. Equipment list…………………………………………………………………... 41-44
6.1 Major equipment list………………………………………………………………... 42-44
6.2 List of plant auxiliaries, offsite units and package units……………………………. 44
7. Equipment sizing……………………………………………………………… 45-73
8. Individual equipment design………………………………….................... 74-135

8.1 Design of production fermenter………………………………………………. 75-86
8.1.1 Fermenter size calculation………………………………………………………... 76-77
8.1.2 Power calculation………………………………………………………………… 77-78
ii
8.1.3 Insulation thickness………………………………………………………………. 78
8.1.4 Mechanical design…………………………………………………………………. 78-82
8.1.5 Mechanical Drawing………………………………………………………………. 83-84
8.1.6 P & ID of fermenter……………………………………………………………….. 85
8.2 Design of decanter centrifuge…………………………………………………. 87-103
8.2.1 Centrifuge size calculation………………………………………………………… 87-89
8.2.2 Centrifugal force calculation………………………………………………………. 89
8.2.3 Settling velocity calculation……………………………………………………….. 90
8.2.4 Power calculation………………………………………………………………….. 90-92
8.2.5 Insulation thickness………………………………………………………………... 92
8.2.6 Mechanical design…………………………………………………………………. 92-98
8.2.7 Mechanical drawing……………………………………………………………….. 99-101
8.2.8 P & ID of centrifuge………………………………………………………………. 102
8.3 Design of crystallizer…………………………………………………................ 104-116
8.3.1 Crystallizer size calculation……………………………………………………….. 104-107
8.3.2 Power calculation………………………………………………………………….. 107-108
8.3.3 Cooling water calculation…………………………………………………………. 108-109
8.3.4 Mechanical design………………………………………………………………… 109-112
8.3.5 Mechanical drawing………………………………………………………………. 113-114
8.3.6 P & ID of crystallizer……………………………………………………………... 115
8.4 Design of direct heated rotary dryer……………………………………………... 117-139
8.4.1 Detailed design calculation………………………………………………………... 118-121
8.4.2 Power calculation…………………………………………………………………. 121-125
8.4.3 Mechanical design………………………………………………………………… 125-136
8.4.4 Mechanical drawing……………………………………………………………….. 137
8.4.5 P & ID of rotary dryer……………………………………………………………... 138
9. Plot plan…………………………………………………………………………... 140-141
10. Economic analysis…………………………………………………………… 142-151
iii
List of tables
Table 1.1.1: Raw Materials ……………………………………………………. 2
Table 3.1: Summary table of vacuum dryer balance…………………………... 14
Table 3.2: Summary table of crystallizer balance……………………………... 15
Table 3.3: Summary table of Mixer-2 balance………………………………… 16
Table 3.4: Summary table of centrifuge……………………………………….. 17
Table 3.5: Summary table of Mixer-1 balance………………………………… 19

Table 3.6: Summary table of 1st and 2nd extractor……………………………... 20
Table 3.7: Summary table of filtration unit……………………………………. 22
Table 3.8: Summary table of production fermenter…………………………… 24
Table 3.9: Summary table of seed fermenter………………………………….. 25
Table 3.10: Summary table of pre-seed fermenter…………………………….. 27
Table 6.1: List of plant auxiliaries, offsite and package units………………… 42-44
Table 6.2: List of plant auxiliaries, offsite and package units………………… 44
Table 8.4.1.1: Properties of substances………………………………………... 118
Table 8.4.1.2: Temperature…………………………………………………….. 118
Table 10.1: Table for equipment cost………………………………………….. 143-144
Table 10.2: Determination of total investment cost…………………………… 144-145
Table 10.3: Table for direct production cost…………………………………... 146
Table 10.4: Table10.4: Table for utility cost………………………………….. 146
Table 10.5: Calculation of Pay out period (with interest method)…………….. 151
iv
List of figures
Figure 1.4.1: Biosynthesis pathway of producing Cephalosporin C……………….. 8
Figure 2.1.1: Process block diagram………………………………………………… 11
Figure 2.2.1: Process flow diagram………………………………………………….. 12
Figure 8.1.5.1: Front sectional view of fermenter (with major dimensions)……….. 83
Figure 8.1.5.2: Top view of fermenter……………………………………………… 84
Figure 8.1.6.1: P & ID of fermenter………………………………………………... 85
Figure 8.2.7.1: The main operating part of a decanter centrifuge................................ 99
Figure 8.2.7.2: Dimension of a decanter centrifuge..................................................... 100
Figure 8.2.7.3: Saddle support of a decanter centrifuge............................................. 101
Figure 8.2.8.1: P & ID of centrifuge………………………………………………… 102
Figure 8.3.5.1: Front view of agitated batch crystallizer……………………………. 111
Figure 8.3.5.2: Baffle and impeller arrangement…………………………………… 112
Figure 8.3.6.1: P & ID of crystallizer………………………………………………... 113
Figure 8.4.3.1: Percentage of loaded area vs sine of angle θ………………………… 127
Figure 8.4.3.2: Saddle support sizes…………………………………………………. 135
Figure 8.4.4.1: Mechanical view of direct heated rotary dryer…………………….... 137
Figure 8.4.5.1: P & ID of direct heated rotary dryer………………………………... 138
Figure 9.1: Plot plan and plant layout……………………………………………….. 141
Figure 10.1: Cash flow diagram…………………………………………………….. 148
Figure 10.2: IRR analysis…………………………………………………………… 149
Figure 10.3: Cash flow diagram…………………………………………………….. 150
v
Chapter One
Process Definition
1
1.1 Project Definition
A Cephalosporin Antibiotic Production plant is to be set-up at Shibganj, Nawabganj in Bangladesh

with a capacity of 33 kg per cycle, 33 cycles per year corresponding to 1089 kg per year including
all offsite auxiliaries, utilities and support facilities.
Table 01: Raw Materials
Corn steep liquor, methionine 20%

Water 80%
Composition of corn steep liquor
Lactose (3.0-4.0%)
Glucose (0-0.5%)
Starch (1.5%)
Acetic acid (0.05%)
Glucose lactic acid (0.5%)
Phenylethylamine (0.05%)
Amino acids (0.5%)
Total solids (80-90%)
Total nitrogen (0.15-0.2%)
Products
95% Cephalosporin Sodium Salt (Antibiotics)
5% Water
2
1.2 Process Description
 From inoculum storage tank required amount of cephalosporium acremonium fungi and corn
steep liquor containing glucose, sucrose, methionine, ammonium salt and water etc. from
media storage tank are added to a mixer. Media is at 30⁰C. Media contains of 80 mole%
water and 20% other ingredients. Media before entering the fermenter is sterilized at 121⁰C
and cooled at 25-28⁰C. For sterilization 170⁰C steam is used. And cooling is done in two
steps. At the first cooler the temperature of the media decreases from 121⁰C to 70⁰C and in
the second cooler it is from 70⁰C to 25⁰C. Water is used as coolant.
 Then this mixture passes to preseed fermenter. A certain temperature (25-28⁰C) and pH (6-
7). are needed to maintain in fermenter. The media is about having pH 5-7. So, no base or
acid is needed to add in fermenter to maintain pH.
 The products from preseed fermenter pass to seed fermenter. Sterilized and cooled media is
also added to fermenter. Following the same procedure of sterilization and cooling the
required temperature (25-28⁰C) is maintained.
 Now the products of seed fermenter enter into production fermenter. All the conditions
maintained in seed fermenter are also maintained in production fermenter to get better yield.
The fermentation broth contains the desired protein with cells, debris, some media
ingredients and impurities. These insoluble cells, debris and impurities are needed to
separate. Filtration step is used in this purpose. After filtration some impurities also remains
with desired protein.
 Now the protein is needed to isolate from filtrate. For isolation of protein, extraction is used
in two stage. In first extractor, amylacetate solvent is used. Protein dissolved in filtrate is
transferred into amylacetate solvent. A stream containing protein and solvent is collected
separately and other stream containing water, media, undesired protein and desired protein
in solvent are sent to second extractor. Ether solution is used as solvent in second extractor.
Now the protein is transferred in ether solution.
 The first extractor outlet containing protein and solvent is mixed with second extractor outlet.
Sodium bicarbonate is also added to this solution. After that cephalosporin sodium salt is
produced but that is not pure.
 The mixed solution is then centrifuged to make the liquid portion separate. The separated
cephalosporin sodium salt is wet to some extent. Water is added to it in a mixer.
3
 This solution is sent to crystallizer to increase the purity of product and to give it a definite
shape. The crystallized product is 72.6% pure. It needs further purification.
 The crystals are about 10⁰C. But for drying the required temperature is 25⁰C. A heater is
used to make this temperature from 10⁰C to 25⁰C.
 To increase the purity of desired product drying step is used. By using ratary drying the final
product purity is increased to 95% from 72.6%.
1.3 Design Basis
1.3.1 Geological Data
a. Site characteristics
 Minimum water level: 22 m

 Maximum water level: 30 m
 Average depth for wells: 27 m
 During flood, maximum water level recorded is 10 ft above plant ground level
b. Soil type
The area of interest are formed by the deposition of three different materials, e.g. Piedmont
Alluvium, Tista Alluvium and Barind Tract.
Clay layer is either exposed at the surface or concealed under a thin soil layer less than one m
thick, formed from the weathering of the red clay. Due to the removal of the clayey materials, the
soil has become more sandy than the parent rock.
Surface area of standing water bodies, such as, haors, baors and beels excluding ponds and tanks
was surveyed by SPARRSO (1986). In the study area, there are 5 standing water bodies, beels and
blocked river channels. Total surface area of standing water bodies are 254 km (MPO, 1985).
c. Seismic condition
Moderate to large earthquake magnitudes are common in this region and will continue to occur as
long as the tectonic deformation continues. Where previous analysis based on instrumental
seismicity - may underestimate what might be expected from the Martin and Szeliga’s (2010)
4
historical earthquake catalogue, where there are two events located with earthquake magnitude
between 7.3 and 8.0 on 11 November 1842 and 22 June 1897, respectively.
1.3.2 Climatic conditions
a. Design conditions for equipment or facility
 Maximum dry bulb temperature: 39⁰C (in summer)

 Minimum dry bulb temperature: 6⁰C (in winter)
b. Design conditions for buildings: HVAC
 Maximum dry bulb temperature: 25⁰C (in summer)

 Maximum relative humidity(RH): 90 % (in summer)
 Minimum dry bulb temperature: 20⁰C (in winter)
 Maximum relative humidity(RH): 40%(in winter)
c. Meteorological conditions
 Ambient temperature
 Maximum: 38.8⁰C
 Minimum:7⁰C
 Average: 25⁰C
 Average monthly maximum: 28.8⁰C (in June)
 Average monthly minimum:17.4⁰C (in January)
 Sunshine: 7.9 hours (in November)
 Humidity
The highest annual humidity was at the year 1987(84) and the lowest was at the year
1981(49).
 Average relative humidity(RH): 57%

 Rainfall
The greater Dinajpur area has rainfall equivalent to 85 percent of annual rainfall in the
monsoon season between June and October and little rainfall in the dry season from
November to May the following year.
5
 Annual total rainfall: 2536 mm
 Maximum monthly:201mm (in July)
 Minimum monthly:3mm (January)
 Maximum daily:400mm
 Maximum intensity:8.07mm/15 min
 Barometric pressure
 Minimum pressure: 740 mmHg
 Design barometric pressure: 750 mmHg
 Wind
 Average daily wind speed: 7mph/6knots

 Wind direction
 Summer: South to South-East
 Winter: East to North- East
 Design wind velocity: 68 m/s
1.3.3 Utility conditions
a. Water
 Source: Ground water

 Temperature:25⁰C
 Design requirement of various water:
 Potable water: The bacteriological, physical and chemical requirements of WHO
must be fulfilled.
b. Electric power
440 V – 3 phase, 50 Hz for motors in the range of:
 230V-1 phase 50 Hz for motors 0.5 KW and below.

 120V-1 phase 50 Hz for instruments and control.
 Normal lighting:220 V-1 phase,50 Hz
6
c. Air
i. Instrument air
1. Pressure: 700kPa
2. Temperature: 25⁰C
3. Dew Point: 3⁰C
ii. Plant air
1. Pressure: 250kPa (abs)
2. Temperature: 28⁰C (Maximum)
Plant effluents and other waste disposal must meet the environmental regulations of the
government.
iii .Hot air
1. Temperature: 170⁰C
d. Steam
170⁰C saturated steam at 8 bar
121⁰C saturated steam at 2 bar
1.3.4 Raw Materials
Corn steep liquor, glucose, sucrose, ammonium salt, fungi.
1.3.5 Solvent for extraction
Amaylacetate and ether solution.
1.4 Process Selection
Available process for production of Cephalosporin-C.
7
 Biosynthesis process1
In presence of ACV synthase, LLD-ACV (L- α- aminodipoyl)- L- Cysteinyl-D- Valine is produced

from L- α- aminoadipic, L- cysteine and L- valine. After that Isopenicillin N is produced in
presence of Isopenicillin N synthase. Isopenicillin N is converted into Penicillin N by Isopenicillin
N Epimerase. Then DAOC/DAC synthase is used to make Desacetylcephalosporin C (DAC). In
presence of DAC acetyltransferase Cephalosporin C (CPC) is produced.
Figure 1.4.1: Biosynthesis pathway of producing Cephalosporin C.
1
Youjia Hu, “Genetic Engineering of Acremonium chrysogenum, the Cephalosporin C Producer”.
8
 Fermentation Process
In this process, the active pharmaceutical ingredient is produced by fermentation. By filtration

cells or insoluble is removed from fermentation broth. Extraction is used as primary isolation step
which increases desired product concentration. Centrifugation, crystallization and drying are used
as final polishing step.
Selected process: Cephalosporin Antibiotic from Corn Steep liquor by fermentation process.
9
Chapter Two
Process Diagrams
10
2.1 Process Block Diagram
Media +water Media +water Media +water
CA Inoculum CA Pre-seed CA Seed CA Production

fermente Media, water fermenter Media fermenter
r
Water CA
Media
Water
Cell Others
Impurity Filtration
API
Media
Water
First AA
extractor
Solvent NaHCO3 Cacetate solution
AA Media
C.NaHCO3 Cacetate Water
Centrifuge Mixer
Solvent Solvent Protein
Cacetate
Cacetate in ether Second Ether
extractor
C.NaHCO3 (powder)
Powder C.NaHCO3
Mixer Crystallizer Vacuum
dryer
Water
Water
Figure 2.1.1: Process Block Diagram of Cephalosporin Sodium Salt Production from Corn
Steep liquor.
11
2.2 Process Flow Diagram
12
Chapter Three
Material Balance
13
Basis : 33 Kg product/cycle (cephalosphorin acremonium) & 33 cycle/year.
Material balance on vacuum dryer

Table 3.1: Summary table of vacuum dryer balance
Stream Mass flow, Kg Components Composition (%)
Pure antibiotic 95
M1, product( C.NaHCO3) 34.48
impurities 5
M2, water vapor 17.30 water 100
Solid crystal 63.23

M3, C.NaHCO3 wet crystal in 51.78
the dryer
Mother liquor 36.27
M3 Kg C.NaHCO3
Wet crystal Vacuum dryer M1 Kg product (C.NaHCO3)
X1 solid crystal 95wt% pure cephalosporin

X2 mother liquor 5wt% impurities
M2 Kg water vapor
Overall balance:
M3=M2+M1
Or, M3=34.47+17.30
=51.78 Kg
Now, solid cephalosporin balance:
M3× X1=M1
X1=34.47/51.78
14
=0.6323
X2=1-0.6323
= 0.3627
Material balance on crystallizer

Table 3.2: Summary table of crystallizer balance
Composition,
Stream Mass flow, Kg Components
wt (%)
M3, product( C.NaHCO3 Pure crystal

33 100
wet crystal
51.78 powder 65
M4, outlet of mixer
Water 35
Water 95
M5, mother liquor 18.78
powder 5
Crystallizer M3 Kg C.NaHCO3
M4 kg, outlet of mixer Wet crystal
X3 powder
X4 water
M5 Kg mother liquor
M3=51.78 Kg
Assume efficiency of crystallizer be 98%

M4=M3+M5
Or, M4=33+18.78
15
= 51.78 Kg
Now,
Solid content balance
M4×X3×0.98=M3
M3
Or, X3= M4×0.98
33
= 51.78×0.95
=0.65
X4= 1- X3
Or, X4= 1-0.65
=0.35
Material balance on Mixer-2

Table 3.3: Summary table of Mixer-2 balance
Stream Mass flow , Kg Components Composition (%)
Solid
M6, outlet of centrifuge 33.5 100
51.78 powder 65
M4, outlet of mixer-2
Water 35
M7, water 18.28 water 100
16
M7 kg water
M4 Kg wet C.NaHCO3
M6, outlet of centrifuge
Mixer-2
65 wt% solid
35 wt% water
Overall balance
M6+M7=M4
Or, M6+M7= 51.78
Powder balance:
M4×0.65=M6
Or, M6= 0.65×51.78
= 33.5 Kg
M7= 18.28 Kg
Material balance on centrifuge

Table 3.4: Summary table of centrifuge
powder
M6, C.NaHCO3 33.5 100
3265.47 powder 1.04

M8, outlet of mixer-1
Waste 98.96
M9, Waste 3231.90 waste 100
17
M6 Kg wet C.NaHCO3
M8, outlet of mixer-1 Centrifuge
X5 powder
X6 Waste
M9 Kg waste
Assume, efficiency of the centrifuge = 98%

So, powder balance:
M6= 0.98×M8×X5
Or, M8×X5= 34.19 Kg
Overall balance,
M8=M6+M9
Or, M8- M9=33.5 Kg
Waste balance:
M8×X6=M9+0.02× M8×X5
Solving, we get
M8= 3265.47 Kg
M9= 3231.28 kg
X5= 0.0104
X6= 0.9896
18
Material balance on Mixer-1
Table 3.5: Summary table of Mixer-1 balance
powder 1.04
M8 Kg outlet of mixer-1 3265.47
waste 98.96
3236.34
M10, outlet of extractor Waste 100
M11, NaHCO3 29.13 NaHCO3 100
M11 kg water
M10 outlet of extractor M8 Kg outlet of mixer-1

Mixer-1
1.04 Wt% solid

98.96 wt% waste
Overall balance
M10+M11=M8
Or, M8+M11= 3265.47
Waste balance:
M8×0.9896=M10
Or, M10= 0.9896×3265.47
= 3236.34 Kg
M11= 3265.47-3236.34
19
= 29.13 Kg
Material balance on extractor

Table 3.5: Summary table of 1st and 2nd extractor
stream Mass flow, Kg component Composition (wt%)
M12, filtrate from 7665.28 API 5.02

filtration unit Solid waste 8.55
Water 86.43
M13, AA 2760
Pure solvent 100
M14, effluent from 2910.2 AA 0.9

first extractor
CA 0.1
M15, residue from 1st 7636.11 Solvent 8.66
extractor water 89.69
waste 0.79
CA 0.32
M16, ether 290.8 Pure solvent 100
M17, CA+ ether 326.22 Ether 0.9

CA 0.1
M18, residue 7571.89 Water 90.46
Waste 0.799
solvent 8.74
M10 Kg outlet 3236.34 CA 0.1
Others 0.9
20
M12 kg filtrate from M13 kg AA
Filtration unit M14 kg effluent from first extractor
First extractor
M15 kg residue from M10 Kg outlet (10wt% CA)

1st extractor
M16 kg ether Second extractor

M17 Kg CA+ ether
M18 kg residue
Assuming,
First extractor effluent CA composition=0.1
So, Second extractor effluent CA composition=0.1
Overall mass balance:
M12+ M16+ M13= M18+ M10
Or, M12+ M16+ M13- M18=3236.34
Now, composition of AA in first extractor effluent (M14) =0.9
Composition of ether in second extractor effluent (M17) =0.9
So, 0.9×M17=M16
And, 0.9×M14=M13
Overall balance in final outlet point,
M14 +M17=3236.34
21
Balance on first extractor:
M13+M12=M14+M15
Balance on second extractor:
M15+M16=M17+M18
Solvent AA balance: M14×0.9=M13
Solvent ether balance: M17×0.9=M16
Amount of waste disposed from 2nd extractor, M18=7571.89 Kg
Now, M13= 2760 kg
So, M15= 2910.12 Kg
And, M16= 290.8 Kg
So, M17 = 326.22 kg
Material balance on filtration

Table 3.7: Summary table of filtration unit
API 5.02
M12, filtrate 7665.98 Solid waste 8.55
Water 86.43
631.05 Cell 0.51
M19, filter cake(waste)
waste 0.49
CA
8.54
M20, flow from product
fermenter 8303.04 Water 79.77
Solid impurities 10.5
waste 1.19
22
M20 kg outlet of product
Fermenter M12 kg filtrate
Filtration unit
5.02wt% API
8.55wt% solid waste
86.43wt% water
M19 Kg filter cake
Overall mass balance:

M20= M12+M19
Or, M20-M19= 7665.98
Now, filter efficiency= 92%
Amount of solid cake removed from the filtration unit=631.05 Kg
Now, composition of cell and impurities are 51wt% and 49wt%
So, amount of cell=0.51×631.05
= 321.8355 kg
Amount of impurities in filter cake=0.49×631.05
= 309.2145 Kg
Amount of water in M20= 0.8643×7665.98

=6625.7 Kg
So, M20= 6625.7/0.7977
= 8303.04
Amount of CA in M20= 0.0854×8303.04
=709.08 Kg
Amount of solid impurities in M20 =0.105×8303.04
=871.82 Kg
23
Material balance on production fermenter
Table 3.8: Summary table of production fermenter
Stream Mass flow (kg) Components Composition (%)
CA 11.9
M 22, CA( cephalosporium Water 78.54
1111.25
acremonium) Waste 2.86
Media 6.7
Media 20
M21, media 7191.8
Water 80
CA 8.54
M20, outlet of product Media 10.5
8303.04
fermenter Waste 1.19
Water 79.77
M21 Kg Media
80wt% water
20wt%media
M22 Kg M20 Kg product

Production fermenter
Xc CA
Xm media
Xw Water
Xs waste
Balance
Overall mass balance: M22 + M21=8303.04
Water balance: M22 ×Xw+0.8×M21=8303.04×0.7977
Assume, yield=0.9
Yield equation: 0.8= (8303.04×0.0854-M22×Xc)/ (M22×Xm+0.8 M21-8303.04×0.105)
24
Waste balance: M22×Xs=8303.04×0.019
Media balance: M22×Xm+0.8×M21=8303.04×0.105
Mass fraction balance: Xs +Xc +Xm +Xw=1
Unknown: 6 (M22, M21, Xs, Xc, Xm, Xw)
Equation: 6
By solving, we get
M22=1111.25
M21=7191.8
Xc = 0.119
Xs =0.0286
Xw =0.7854
Xm =0.067
Material balance on seed fermenter

Table 3.9: Summary table of seed fermenter
CA 11.94
Water 78.33
M 22, outlet of seed fermenter 1111.25
Waste 2.86
Media 6.85
Media 20
M23, media 725.47
Water 80
CA 12.4
M24, outlet of pre-seed Media 10.5
385.77
Water 75.18
25
M23 Kg Media
80wt% water
20wt%media
M24 Kg M22 Kg product

Seed fermenter
Xc CA
Xm media
Xw Water
Xs waste
Balance
Overall mass balance: M24 + M23=1111.25
Water balance: M24 ×Xw+0.8×M23=1111.25×0.7833
Assume, yield=0.9
Yield equation: 0.9= (111.25×0.1194-M24×Xc)/ (M24×Xm+0.9 M23-1111.25×0.0685)
Waste balance: M24×Xs=1111.25×0.0286
Media balance: M24×Xm+0.8 M23=1111.25×0.0685
Mass fraction balance: Xs +Xc +Xm +Xw=1
Unknown: 6 (M24, M23, Xs, Xc, Xm,Xw)
Equation: 6
By solving, we get
M24=385.77
M23=725.47
Xc = 0.124
Xs =0.0967
Xw =0.7518
Xm =0.105
26
Material balance on pre-seed fermenter
Table 3.10: Summary table of pre-seed fermenter
CA 11.9
Water 78.54
M 26, inlet inoculum
Waste 2.86
Media 6.7
Media 20
M25, media 362.57
Water 80
CA 12.4
M24, outlet of pre-seed Media 9.7
385.77
Water 75.18
M25 Kg Media
80wt% water
20wt%media
M26 Kg inoculum M24 Kg outlet of pre-seed fermenter

Pre-seed fermenter
Balance
Mass balance in pre-seed fermenter:
M26 + M25 = M24
Water balance:
0.7518×M24=M25×0.8
Or, M25= 362.57 Kg
Amount of media in M25= 362.57×0.2
27
=72.5 Kg
Now, Let yield of the fermenter, Yx/s=0.7
So, Yx/s= (Xf-Xo)/ (So-Sf)
Or, Xo= Xf - Yx/s (So-Sf)
= 47.84-0.7× (72.5-37.41)
=23.2 Kg
So, amount of inoculum needed to produce 33 kg/cycle cephalosporin antibiotic is 23.2 Kg.
28
Chapter Four
Energy Balance
29
For sterilization
Media consists of 80% water and 20% solid media and solid media mostly consists of glucose.
Heat capacity of glucose is=1222 Jkg-1K-1
Heat capacity of water =4200 Jkg-1K-1
Cp,mix=(.80×4200+.2×1222)= 3604.4 Jkg-1K-1
Assumption: Steam is supplied in 170oC in the sterilizer and leave from the sterilizer in 110oC
At 170oC temperature the specific volume of superheated steam is =204.66 Kg/m3
At first the line has to be sterilized.
It has been assumed that total pipeline volume is 10% of total equipment volume (without sterilizer
and cooler).
Total pipeline volume is=(73.32×1.1)=80.652 m3
So amount of steam needed for sterilization= (204.66×80.652)
=16506 kg
Steam is supplied in 170oC and the heat of enthalpy at 170oC is =2618 J/Kg
30
Balance on sterilizer
Sterillizer-101 msteam kg steam at 170oC
362.57 kg media 362.57 kg media

at 30oC Sterilizer- 101 at 1210C
msteam kg steam at 110oC
we know that,
mmedia×Cpmix×delTmedia= msteam×Cp×delTsteam
 (362.57 ×3604×(121-30) =msteam× 2100×(110-170)
msteam= 943.73 Kg
The amount of heat released by steam=1.18×108 J
725.47 kg media 7 725.47 kg media

at 30oC Sterilizer-102 at 1210C
 (725.47 ×3604×(121-30) =msteam× 2100×(110-170)
msteam= 1888.31 Kg
31
The amount of heat released by steam =2.37×108 J
7191.8 kg media 7198.8 Kg media

at 30oC Sterilizer-103 at 1210C
 (7198.8 ×3604×(121-30) =msteam× 2100×(110-170)
msteam= 18737.67 Kg
The amount of heat released by steam=3.82×109 J
Balance on cooler
Assuming cooler will operate for 6 hours.
E-101
mcooling water kg at 25oC

at 121oC E-101 at 700C

mmedia×Cpmix×delTmedia= mcooling water×Cp×delTcooling water
 (362.57 ×3604×(70-121) J =mcooling water× 4200×(35-25)
Mcooling water= 1586.7 Kg
32
The amount of heat released by media=6.67×107 J=3085W
E-102

at 70oC E-102 at 260C
mmedia×Cpmix×delTmedia= mcooling water×Cp×delTcolling water
 (362.57 ×3604×(70-26) J =mcooling water× 4200×(35-25)
Mcooling water= 1368.93 Kg
The amount of heat released by media=5.74×107 J=2660 W
E-103

at 121oC E-103 at 700C
 (725.47 ×3604×(70-121) =mcooling water× 4200×(35-25)
Mcooling water= 3175 Kg
The amount of heat released by steam=1.33×108 J =6150 W
33
E-104

at 70oC E-104 at 260C
mcooling water kg steam at 35oC
mmedia×Cpmix×delTmedia= mcooling water×Cp×delTcoling water
 (725.47 ×3604×(26-70) =mcooling water× 4200×(35-25)
The amount of heat released by steam=1.15×108 J =5300 W
E-105

at 121oC E-105 at 700C

 (7191.8 ×3604×(70-121) =mcooling water × 4200×(35-25)
The amount of heat released steam=2.46×109 J =113500 W
34
E-106
7191.8 Kg media 7191.8 Kg media

at 70oC E-106 at 260C

 (7191.8 ×3604×(26-70) =mcooling water × 4200×(35-25)
Mcooling water= 27153.5Kg
The amount of heat released by steam=1.14×109 J=52750 W
Balance On Crystallizer
Crystallizer 101 normal water ,mnormal water at 25oC
51.78 Kg 51.78 kg
Cephalosprium Cephalosporium
Crystallizer-101
Acremonium Sodium Acremonium Sodium
Bicarbonate solution Bicarbonate solution
At 26oC At 12oC
normal water ,mnormal water at 31.63oC
The heat capacity of Cephalosporium Acreonium Sodium Bicarbonate solution is 1042 JKg-1K-1
mmedia×Csolution×delTmedia= mnormal water×Cp×delTcolling water
 (51.78 ×1042×(26-12) J =mnormal water× 4200×(31.63-25)
Mnormal water=31 Kg
35
The amount of heat released by Cephalosporium Acremonium Sodium Bicarbonate powder
=8.63×105 J
Balance On Heater
H 101
steam at 170oC
51.78 Kg 51.78 kg
H-101
At 12oC At 25oC
steam at 110oC
The heat capacity of Cephalosporium Acreonium Sodium Bicarbonate solution is 1042 JKg-1K-1
mmedia×Csolution×delTmedia= msteam×Cp×delTcolling water
 (51.78 ×1042×(25-12) =msteam× 2100×(110-170)
Msteam= 6.43 Kg
The amount of heat released by Cephalosporium Acremonium Sodium Bicarbonate

powder=8.1×105 J
=75 W
36
Chapter Five
Utility Balance
37
Cooling water balance
E-101 = 1586.7 Kg
E-102 =1368.93 Kg
E-103 = 3175Kg
E-104=2739 Kg
E-105=58627 Kg
E-106=27153.5 Kg
Total 94650 Kg amount cooling water is needed. This amount is sent to boiler at 35oC to produce
steam.
Energy balance at boiler
Total Process Steam required = 38075.71Kg
Steam for heating at heater =6.43 Kg
Total Steam required = 38082.14 Kg
Using a factor of 1.2
Rate of boiler feed water =38082 × 1.2 Kg
= 45698 Kg
Water flow rate 45698 Kg Water flow rate 45698 Kg

Boiler
Temperature=35oC Temperature 170oC
Pressure=1 atm Pressure =1 atm
Heat required, Q = 𝐹𝑠𝑡 × 𝐶𝑤 × (100 − 35) + 𝐿𝑣 × 𝐹𝑠𝑡 + 𝐹𝑠𝑡 × 𝐶𝑠𝑡 × (170 − 100)
38
= 2.96×106 KJ
Heating value of natural gas = 4884.6 KJ/kg
So amount of NG needed = 2.96× 106 / 4884.6
= 6.05×103 kg
Assuming 20% excess air is added to burn natural gas and the gas is burnt fully,
Hot gas in, m = 6051.43 + 0.20 ×6051.43
= 7261 kg
Hot air balance in Blower (including heater)
221.72 kW power input 431.622 hp
51.12 kg air/h Electric 51.12 Kg air/h 51.12 kg air/h

Heater Blower
25 ºC 170 ºC 170 ºC
Air flow rate through blower = 51.12 kg/h
Specific heat capacity of dry air = 1 kJ/kg-k
Temperature of inlet = 25 ºC
Outlet temperature = 170 ºC
Heat needed = 51.12×1 × (170 − 25)
= 7412.4 KJ/h
Assuming the efficiency of electric heater = 90%
7797412.4
The electric power needed to supply this amount of heat = 0.9
39
= 8236 kJ/h
=2.29 KW
Power calculation of blower
𝐶𝑃𝑀 ×𝑃𝑆𝐼
Power input into blower = 229 ×η
η = blower efficiency (assume 75 %)
𝐶𝑃𝑀= air flowrate in cubic feet per minute =23.306 Cubic feet per minute
PSI = pressure in psi unit (14.7 psi)
Thus Power input into blower = 2 hp
40
Chapter Six
Equipment List
41
6.1 MAJOR EQUIPMENT LIST
Table 6.1.1: List of Major Equipment and Vendors
Serial
List of major equipment Quantity List of vendors
number
MAXELL ENGINEERS
1 Tank (with stirrer) 1 VARUN AQUA
Hangzhou Kehao Machinery Co., Ltd.
Superior Tank Co., Inc.

Plas-Tanks Industries, Inc.
2 Tank (without stirrer) 1
Chemindustrial Systems Inc.
Fabricated Plastics Limited
Krishna Scientific Suppliers

Federal Equipment Co.
Pope Scientific Inc
3 Fermenter 3 B&P Process Equipment and Systems, LLC
ABEC Inc
S & B Process Systems
Michael Benalt Inc
Beckman Coulter
Eppendorf
4 Centrifuge 1 Hanil
NuAire
LabNet International
Mantra Filtration Products, Indore

5 Filter 1
Indo German Wire Screen Co.
42
Sophisticated Industrial Materials Analytic
Pvt. Ltd.
Shanghai Yuhua Instrument Equipment Co.

6 Liquid-liquid extractor 2
Zhangjiagang Stark Import & Export Co. Ltd.
Wuxi City Zhangjing Pressure Vessel

7 Mixer 5 Manufacture Co. Ltd.
Shanghai Zhuheng Industrial Co., Ltd.
Henan Blue Sail Trading Co. Ltd.

8 Crystallizer 1 Shanghai Yuhua Instrument Equipment Co.
Wenzhou Chinz Machinery Co. Ltd.
Prism Pharma Machinery

9 Rotary filter 1 Richard Engineering Works
Servo Enterprisess
Richard Engineering Works

Metal Craft Technologies
10 Vessel 8
Aum Industrial Seals
Aircon Handling Systems Private Ltd.
Henan Province Sitong Boiler Co., Ltd.

10 Boiler 2 Columbia Boiler
Fulton Boiler Works, Inc.
KAPSUN RESOURCES CORPORATION

11 Cooler 6 ROSHRI
Bhutani International Private Limited
Crystal Sugar Engineering Service

Astha Heat Tech
12 Heater 1 Mark Engineers
Wattco
Hotwatt
43
Newyork Blower Company
Dometrices,Inc
13 Blower 1 IAP
Jan-Air,Inc
Central Blower Co.
6.2 LIST OF PLANT AUXILIARIES, OFFSITE UNITS AND PACKAGE

UNITS
Table 6.2.1: List of plant auxiliaries, offsite and package units

Electrical And insulation system
Water treatment system

Plant Auxiliaries
Cephalosporium Acremonium storage tank
Control Room
Fire & safety
Guard room
Machine shop
Offsite units
Canteen
Loading/Unloading Point
Administrative unit
Process Control Package
Cogeneration power and steam plant
Water treatment plant

Package unit
Effluent treatment plant

Packaging unit
44
Chapter Seven
Equipment Sizing
45
Cephalosporium Acremonium Storage Tank
Total mass, 𝑚𝑜𝑢𝑡 = 23.21 kg
Density, 𝜌𝑜𝑢𝑡 = 1010 kg/𝑚3
𝑚3
Total volume, V= 23.10 kg× 1010 𝐾𝑔
= 0.023 𝑚3
Assuming, 75% of the total volume will be occupied
0.023
Total volume, 𝑉𝑡 = 𝑚3
0.75
= 0.03 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Diameter, D = 0.27 m
Length, L = 0.54 m
Media storage Tank
𝑚3
= 7.738 𝑚3
7.738
0.75
46
= 10.31 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Length, L = 3.75 m
Mixer Before Preseeed fermenter
Total mass flow rate, 𝑚𝑜𝑢𝑡 = 385.78 kg
Viscosity, 𝜇 = 9.2× 10−4 Pa-s
𝑚3
= 0.36 𝑚3
0.36
Total volume, 𝑉𝑡 = 0.75 𝑚3
=0.48 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Length, L = 1.34 m
Impeller Dimension
0.67
Impeller diameter, 𝐷𝑖 = = 0.223 m
3
47
Ideal space between impellers, 𝐻𝑖 = D = 0.67 m
0.75×𝐿
Number of impeller required, n = = 1.5
𝐷
So two impeller is required
And actual space between impellers, H= 0.6 m (as here n ≈ 2)
Power Calculation
Assumptions
 Six-blade turbine, 𝑲𝑻 = 1.65

 Turbine revolution, N= 10 rpm = 0.17 rev/s
𝐷𝑖 2 𝑁𝜌𝑜𝑢𝑡
𝑅𝑒 = 𝜇
0.2232 ×0.17×1070
= 9.2×10−4
= 9823
P = 𝐾𝑇 𝜌𝑖𝑛 𝑁 3 𝐷𝑖 5
= 1.65×1070×0.173 × 0.2235
= 0.005 W
For two turbines, power required =0.005 W ×2 W = 0.01 W
With 25% overdesign,
Power required, 𝑃𝑐𝑎𝑙 = 1.25× 0.01 W
= 0.0126 W
Assuming 10% gland loss and 20% transmission loss,
Total power required, 𝑃𝑡𝑜𝑡 = 1.3× 0.0126W
= 0.0164 W
48
Preseed Fermenter
𝑚3
= 0.36 𝑚3
0.36
=0.48 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Length, L = 1.34 m
Impeller Dimension
0.67
3
0.75×𝐿
𝐷
Power Calculation
Assumptions
49
𝑅𝑒 = 𝜇
0.2232 ×0.17×1070
= 9.2×10−4
= 9823
= 1.65×1070×0.173 × 0.2235
= 0.005 W
= 0.0126 W
= 0.0164 W
Mixer Before Seed fermenter
𝑚3
= 1.04 𝑚3
50
1.04
=1.38 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Length, L = 1.91 m
Impeller Dimension
0.95
3
0.75×𝐿
𝐷
Power Calculation
Assumptions

𝑅𝑒 = 𝜇
0.3162 ×0.17×1070
= 9.2×10−4
= 19743
= 1.65×1070×0.173 × 0.3165
= 0.027 W
51
= 0.068 W
= 0.088 W
Seed Fermenter
𝑚3
= 1.04 𝑚3
1.04
=1.38 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Length, L = 1.91 m
52
Impeller Dimension
0.95
3
0.75×𝐿
𝐷
Power Calculation
Assumptions

𝑅𝑒 = 𝜇
0.3162 ×0.17×1070
= 9.2×10−4
= 19743
= 1.65×1070×0.173 × 0.3165
= 0.027 W
= 0.068 W
= 0.088 W
53
Mixer After Seed Fermenter
𝑚3
= 7.76 𝑚3
1.047.76
0.75
=10.35 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Length, L = 3.75 m
Impeller Dimension
𝐷
Impeller diameter, 𝐷𝑖 = 3 = 0.623 m
0.75×𝐿
𝐷
Power Calculation
Assumptions
54
 Two baffles
𝑅𝑒 = 𝜇
0.6232 ×0.3333×1070
= 9.2×10−4
= 150631
= 1.65×1070×0.33333 × 0.6235
= 6.15 W
For two turbines, power required = 6.135 ×2 W = 12.31 W
Power required, 𝑃𝑐𝑎𝑙 = 1.25×12.27 W
= 15.38 W
Total power required, 𝑃𝑡𝑜𝑡 = 1.3×15.38 W
= 19.998 W
≈ 0.027 hp
Production Fermenter
𝑚3
55
= 7.76 𝑚3
1.047.76
0.75
=10.35 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Length, L = 3.75 m
Impeller Dimension
𝐷
0.75×𝐿
𝐷
Power Calculation
Assumptions

 Two baffles
𝑅𝑒 = 𝜇
0.6232 ×0.3333×1070
= 9.2×10−4
56
= 150631
= 1.65×1070×0.33333 × 0.6235
= 6.15 W
= 15.38 W
= 19.998 W
≈ 0.027 hp
Storage Vessel After Production Fermenter
𝑚3
= 7.76 𝑚3
1.047.76
0.75
=10.35 𝑚3
𝐿
Assuming, = 2
𝐷
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
57
Length, L = 3.75 m
Rotary drum filter

𝑚3
= 7.76 𝑚3
7.76
=10.35 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Length, L = 3.75 m
Debris Storage Vessel
𝑚3
= 0.56 𝑚3
0.56
=0.79 𝑚3
58
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Diameter, D = 0.8 m
Length, L = 1.6 m
First Extractor
𝑚3
= 11.6 𝑚3
11.6
=15.44 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Length, L = 4.28 m
Second Extractor
𝑚3
= 8.81 𝑚3
59
8.81
=11.74 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Length, L = 3.92 m
Amyl acetate Storage Vessel
Total mass, 𝑚𝑜𝑢𝑡 = 2760 kg
𝑚3
Total volume, V= 2760kg× 875 𝐾𝑔
= 3.15 𝑚3
3.15
=4.21 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Diameter, D = 1.4 m
Length, L = 2.8 m
Ether Storage Vessel
60
𝑚3
= 0.41 𝑚3
0.41
=0.55 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = 4
= 2
Diameter, D = 0.7 m
Length, L = 1.4 m
Mixer after second extractor
𝑚3
= 3.6 𝑚3
3.6
=4.8 𝑚3
𝐿
Assuming,𝐷 = 2
61
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Length, L = 2.9 m
Impeller Dimension
𝐷
0.75×𝐿
𝐷
Power Calculation
Assumptions

 Two baffles
𝑅𝑒 = 𝜇
0.482 ×0.3333×900
= 9.9×10−4
= 69811
= 1.65×900×0.33333 × 0.485
= 1.4 W
62
= 3.5 W
= 4.55 W
Centrifuge
Total mass, 𝑚 = 3265.47 kg
Density, 𝜌 = 900 kg/𝑚3
Let, Viscosity, 𝜇 = 9.9× 10−4 Pa-s
𝑚3
Total volume, V= 3265.47× 900 𝐾𝑔
= 3.6 𝑚3
Assuming, 80% of the total fermenter volume will be occupied
3.6
= 4.5 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
D = 1.42 m
Length L=2×D
= 2.84 m
Solvent Collection Vessel after Centrifuge
63
𝑚3
= 4.03 𝑚3
4.03
= 5.38 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Diameter, D = 1.5 m
Length, L = 3 m
Mixer after centrifuge
𝑚3
= 0.035 𝑚3
0.035
0.75
=0.046 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Diameter, D = 0.3 m
64
Length, L = 0.6 m
Impeller Dimension
𝐷
0.75×𝐿
𝐷
Power Calculation
Assumptions

 Two baffles
𝑅𝑒 = 𝜇
0.12 ×0.3333×1500
= 9.9×10−4
= 5050
= 1.65×1500×0.33333 × 0.15
= 0.0009 W
= 0.0023 W
65
= 0.003 W
Water Supply Vessel
𝑚3
= 0.01828 𝑚3
0.01828
0.75
=0.024 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Length, L = 0.5 m
Sodium Bicarbonate Storage Vessel
𝑚3
= 0.013 𝑚3
66
0.013
0.75
=0.018 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Length, L = 0.44 m
Crystallizer
𝑚3
= 0.035 𝑚3
0.035
0.75
=0.046 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Diameter, D = 0.3 m
Length, L = 0.6 m
Product Storage Vessel
Total mass, 𝑚𝑜𝑢𝑡 = 33 kg
67
𝑚3
Total volume, V= 33 kg× 1500 𝐾𝑔
= 0.022 𝑚3
0.022
0.75
=0.03 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = 4
= 2
Length, L = 0.52 m
E-101(counter current)
Th in=121oC, Th out=70oC,
Tc in =25oC ,Tc 0ut =35oC
LMTD= (𝑇ℎ,𝑖𝑛−𝑇𝑐,𝑜𝑢𝑡)−(𝑇ℎ,𝑜𝑢𝑡−𝑇𝑐,𝑖𝑛) oC= (121−35)−(70−25) oC = 63.3 oC

121−35
ln((𝑇ℎ,𝑖𝑛−𝑇𝑐,𝑜𝑢𝑡)/(𝑇ℎ,𝑜𝑢𝑡−𝑇𝑐,𝑖𝑛)) ln( )
70−25
For water gas cooler, Ud= 350-700 W/m2.oC (let=600 W/ m2.oC)
Q=U×A×LMTD
Q= 3085 W
(3085)
A=63.3×600= 0.08 m2
68
LMTD= (𝑇ℎ,𝑖𝑛−𝑇𝑐,𝑜𝑢𝑡)−(𝑇ℎ,𝑜𝑢𝑡−𝑇𝑐,𝑖𝑛) o = (70−35)−(26−25) o
C 70−35 C =9.56 oC
26−25
Q=U×A×LMTD
Q= 2660 W
(2660)
A=19.08×600=0.23 m2
LMTD= (𝑇ℎ,𝑖𝑛−𝑇𝑐,𝑜𝑢𝑡)−(𝑇ℎ,𝑜𝑢𝑡−𝑇𝑐,𝑖𝑛) oC= (121−35)−(70−25) oC =63.3 oC

121−35
70−25
Q=U×A×LMTD
Q= 6150 W
(6150)
A=63.3×600=0.16 m2

C 70−35 C =9.56 oC
26−25
Q=U×A×LMTD
Q= 5300W
69
(5300)
A=9.56×600= 0.92 m2
LMTD= (𝑇ℎ,𝑖𝑛−𝑇𝑐,𝑜𝑢𝑡)−(𝑇ℎ,𝑜𝑢𝑡−𝑇𝑐,𝑖𝑛) oC= (121−35)−(70−25) oC =63.3 oC

121−35
70−25
Q=U×A×LMTD
Q= 1.14×105 W
(1.14×105 )
A= = 2.98 m2
63.3×600

C 70−35 C =9.56 oC
26−25
Q=U×A×LMTD
Q= 0.525×105 W
(0.525×105)
A= = 9.15 m2
9.56×600
Product fermenter outlet pump

Assuming the efficiency of the pump is 60% and pressure drop ≈15 kPa
Pump inlet Pressure, P1 =101325 N/m2
Pump outlet Pressure, P2 = 202650 N/m2
Density, ρ = 1070 kg/m3
70
8303.04
Volumetric flow rate, = 1070×7200m3/s
= 0.001 m3/s
Required head (neglecting minor loss)
𝑃2−𝑃1
h= 𝜌×𝑔
202650 − 101325
= 1070×9.8
= 9.66 m
𝒉×𝒎𝒗𝟏 ×𝝆 ×𝒈
So, required power = 𝛈
𝟗.𝟔𝟔 × 𝟎.𝟎𝟎𝟏× 𝟏𝟎𝟕𝟎 × 𝟗.𝟖

=
𝟎.𝟔
= 168 W.
= 0.22 hp
First extractor outlet pump
Pump inlet Pressure, P1 =50662.5 N/m2
7695.79
Volumetric flow rate, = 900×14400 m3/s
= 0.00059 m3/s
𝑃2−𝑃1
h= 𝜌×𝑔
101325 − 50662.5
= 900×9.8
= 5.74 m
71
𝟓.𝟕𝟒× 𝟎.𝟎𝟎𝟎𝟓𝟗× 𝟗𝟎𝟎 × 𝟗.𝟖
= 𝟎.𝟔
= 49.7 W.
= 0.07 hp
Amyl Acetate Supply pump

2880.25
= 0.00045 m3/s
𝑃2−𝑃1
h= 𝜌×𝑔
202650 − 101325
= 875×9.8
= 11.8 m
𝟏𝟏.𝟖 × 𝟎.𝟎𝟎𝟎𝟒𝟓× 𝟖𝟕𝟓 × 𝟗.𝟖

= 𝟎.𝟔
= 76 W.
=0.1 hp
Ether Solution Supply pump

72
293.9
= 0.0001 m3/s
𝑃2−𝑃1
h= 𝜌×𝑔
202650 − 101325
= 715×9.8
= 14.46 m
𝟏𝟒.𝟒𝟔 × 𝟎.𝟎𝟎𝟎𝟏× 𝟕𝟏𝟑 × 𝟗.𝟖

=
𝟎.𝟔
= 99.28 W.
=0.13hp
73
Chapter Eight
Individual Equipment Design
74
8.1 Design of Production Fermenter
7191.8 Kg Media
80wt% water
20wt%media
1111.25 Kg 8303.05 Kg product

Production
fermenter
132.24 kg Cephalosporium Acremonium 709.08 kg Cephalosporium
74.46 kg media Acremonium(X)
872.78 kg Water 871.82 kg media
31.78 kg waste 6623.34 kg Water
98.81 waste
Assumptions
Working Day per year = 330 days
Hours per batch = 240 hr ~ 10 days
Fermenter operating time = 3 days per batch
Efficiency of biomass yield = 0.9
Now, Y X = 0.9 = (X-131.24)/ (74.46+0.2×7191.8-871.82)

S
→ X= 709.08 kg
75
8.1.1 Fermenter size calculation
𝑚3
Total volume, V= 8303.05 Kg× 1070 𝐾𝑔
=7.76 𝑚3
Assuming, 75% of the total fermenter volume will be occupied
7.76
= 10.35 𝑚3
𝐿
Assuming,𝐷 = 2
π𝐷 2 L π𝐷 3
𝑉𝑡 = =
4 2
Diameter of fermenter, D = 1.87 m
Length of fermenter, L = 3.745 ≈ 3.75 m
Impeller Dimension 2
𝐷
𝐷𝑖
Impeller length, 𝐿𝑖 = = 0.156 m
4
𝐷𝑖
Impeller width, W = = 0.125 m
5
Height of impeller above fermenter floor, E = 𝐷𝑖 = 0.623 m
𝐷
Width of baffle, J = 12 = 0.156 m
2
McCabe, Smith and Harriott “Unit Operations of Chemical Engineering”, 6th ed., McGraw Hill Book Company,2001.
Page -241
76
0.75×𝐿
𝐷
8.1.2 Power Calculation 3
Assumptions

 Two baffles
𝑅𝑒 = 𝜇
0.6232 ×0.3333×1070
= 9.2×10−4
= 150631
= 1.65×1070×0.33333 × 0.6235
= 6.15 W
= 15.38 W
3
McCabe, Smith and Harriott “Unit Operations of Chemical Engineering”, 6 th ed., McGraw Hill Book Company,2001.
Page -256
77
= 19.998 W
≈ 0.027 hp
8.1.3 Insulation Thickness

Thermal conductivity of insulation material (Brick), k = 0.6 W/mºC 4
Heat transfer co-efficient of air, h = 3 W/𝑚2 ºC
𝑘
Critical thickness of insulation, 𝑟𝑜 = ℎ
0.6
= 3
= 0.2 m ≈8 in
Here, thickness of insulation= 0.2 m
8.1.4 Mechanical Design
Vessel shell thickness
Type of vessel = Cylindrical
Internal diameter of the vessel, D = 1.87 m
Internal pressure due to liquid height = 𝜌 (h − 0.3)5
= 1070 × (3.75−0.3) kg/𝑚2
= 3691.50 kg/𝑚2
1
Internal pressure due to centrifugal force = 2 𝜌𝜔2 𝑟 2
= 209.14 kg/𝑚2
Design pressure, P = Total internal pressure× safety factor
= (3691.50+209.14)×1.2
3
Holman, J. P., “Heat Transfer” - SI Units, McGraw-Hill Education (India) Pvt Limited- 2002, Page -700.
5
Peter M.S., Timmerhaus K.D., Ronald E.W. “Plant Design and Economics for Chemical Engineers”, 5 th Edition.
78
= 0.47 kg/𝑐𝑚2
Material of construction, AISI SS 317
6
Joint efficiency, 𝐻𝐽 = 0.85 (Spot Welded)
Allowable stress, S = 750 kg/𝑐𝑚2
Permissible shear stress of shaft, 𝑓𝑠 = 550 kg/𝑐𝑚3
Corrosion allowance, 𝐶𝑐 = 3 mm
𝑃𝐷
Shell thickness, 𝑡𝑠 = 2 𝐻 𝑡𝑆+𝐶𝑐 7
𝑗
= 3.68 mm
Turbine shaft diameter
Power required, 𝑃𝑡𝑜𝑡 = 19.998 W
= 0.027 hp
ℎ𝑝×75×60 8
As 𝑇𝑐 = 2𝜋𝑁
= 0.96 kg-m
𝑇𝑚 = 1.5𝑇𝑐
= 1.44 kg-m
𝑇𝑚 ×100
𝑍𝑝 = 550
= 0.26 𝑐𝑚3
𝜋𝑑3
So = 0.26
16
Shaft diameter, d = 1.1 cm
6
Nicholas, T.”Tensile testing of materials at high rates of strain”, Exp. Mech., vol. 21, no. 5, pp. 177–185, May 1981.
7
Joshi, M. V. and Mahajani, V. V.;” Process Equipment Design”, 3 Edition, Macmillan India Limited-2000.
8
Harry Silla “Chemical Process Engineering Design and Economics”, 2003 Edition.
79
Feed Nozzle
Considering ρmV2 = 1000 kg/ms2 when the limit is <1500
𝜌𝑚 0.5 1070
4×𝑄𝑓×( ) 4×7.76×√( )
ρmV2 1000
Dn=√{ } = √{ = 2.84 mm
𝜋 3600×3.1416
Where, Qf = Feed Volumetric flowrate in m3/s
Skirt Design
Length of fermenter, L = 3.74 m
𝐷 𝐷
Volume of vessel wall, V = 2𝜋 ( + 𝐿) × 𝑡𝑠
2 2
1.87 1.87
= 2 × 3.1416 × ( + 3.75) × 0.00368
2 2
= 0.1𝑚3
Density of steel (AISI SS 317), 𝜌 = 8000 kg/𝑚3 9
Weight of vessel, 𝑊𝑣 = V 𝜌 + 𝑉𝑡 𝜌𝑜𝑢𝑡 = 0.1× 8000 + 10.35 × 1070
= 11880 kg
Let, safety factor = 1.2
So Maximum weight of the vessel, W = 𝑊𝑣 × 1.2
= 14256 kg
Assuming,
Diameter of skirt (Straight), d = 187 cm
Height of skirt, h = 1 m
Wind pressure, P = 128.5 kg/𝑚2
Permissible bearing pressure for concrete = 35 kg/𝑐𝑚2
9
Nicholas, T.; Tensile testing of materials at high rates of strain, Exp. Mech., vol. 21, no. 5, pp. 177–185, May 1981
80
𝑊
Stress due to dead weight, 𝑓𝑣 = 𝜋𝑑𝑡 10
14256
=3.1416×187×𝑡
24.27
= kg/𝑐𝑚2
𝑡
2 2×0.08×𝑊 11
Stress due to seismic load, 𝑓𝑠𝑏 = 3 × 𝜋𝑑2 𝑡
0.014
= kg/𝑐𝑚2
𝑡
24.27
Maximum tensile stress, 𝑓𝑡(m) = kg/𝑐𝑚2
𝑡
24.27
So t = ×3.68
750
= 0.12 mm
24.27
Maximum compressive stress, 𝑓𝑐(m) = kg/𝑐𝑚2
𝑡
Assuming 𝑓𝑐 permissible =31.1 kg/𝑐𝑚2
24.27
So t = ×3.68
31.1
= 2.87 mm
So the thickness of skirt = 2.87 mm
Let, bolt circle diameter = d + 20 cm
= 207 cm
Compressive stress between bearing plate and concrete foundation,
𝑊 3𝑘𝑃𝐻 2 12
𝑓𝑐 = +
𝐴 2𝑍
10
Joshi, M. V. and Mahajani, V. V.;” Process Equipment Design”, 3 Edition, Macmillan India Limited-2000, page-391.
11
Joshi, M. V. and Mahajani, V. V.;” Process Equipment Design”, 3 Edition, Macmillan India Limited-2000, page-393.
12
Joshi, M. V. and Mahajani, V. V.;” Process Equipment Design”, 3 Edition, Macmillan India Limited-2000, page-394
81
14256×4 3×0.7×128.5×4.752
=3.1416(2072 −1872 ) + 3.1416(2074 −1874 )
2
32×207
= 2.31 kg/𝑐𝑚2
6×2.31 102
Stress = ×
𝑡𝐵 2 2
694.18
= 𝑡𝐵 2
Permissible stress of bending = 800 kg/𝑐𝑚2
694.18
So 𝑡𝐵 2 =800×3.68
So 𝑡𝐵 =0.49 mm
Assuming 10 bolts
2.31 2072 −1872

Load on one anchor bolt, 𝑃𝑏𝑜𝑙𝑡 = ×
10 4
= 455.07
82
83
84
85
Specification Sheet
Identification: Item: Fermenter Date: 15/02/2017

By: ACI
Function: To produce Cephalosporin Antibiotic from Corn Steep Liquor
Operation: Batch
Type: Batch reactor ( non-jacketed and cylindrical with brick insulation)
Material Handled: Inlet Outlet
Quantity (kg) 8303 8303
Pressure (atm) 1 1
Temperature (ºC) 26 26
Design Data:
Tank Turbine
Height 3.75 m Impeller diameter 0.623 m
Diameter 1.87 m Impeller length 0.156 m
Shell thickness 3.68 mm Impeller width 0.125 m
Capacity safety factor 25% Impeller type Six-blade turbine
Capacity 10.35 𝒎𝟑 Speed 20 rpm
Operating pressure 1 atm Shaft diameter 1.1 cm
Operating Temperature 25 - 27 ºC Power required 0.03 hp
Material of construction: SS 317
Code AISI
Utilities: Not required
Tolerance: Rules of thumb and heuristics
Insulation:0.2 m (Brick) Skirt: 2.87 mm thick and 1 m height (AISI SS
317)
86
8.2 Design of Decanter Centrifuge
34.19 kg CNaHCO3 33.5 kg CNaHCO3

3231.25 kg solvent
Centrifuge
3231.94 kg solvent
8.2.1 Centrifuge size calculation

Let, Viscosity, 𝜇 = 9.9× 10−4 Pa-s
m3
Total volume, V= 3265.47×
900 Kg
= 3.6𝑚3
Assuming, 80% of the total centrifuge volume will be occupied
3.6 3
Total volume, 𝑉𝑡 = m
0.8
= 4.5𝑚3
L
Assuming, = 2
D
87
π𝐷2 L
𝑉𝑡 =
4
π𝐷3
=
2
D = 1.42 m
Length L=2×D
= 2.84 m
𝐷 13
r2 =
2
1.42
= m
2
= 0.71
𝑟1
= 0.7 14
𝑟2
R1 = 0.7 × r2
= 0.7 × 0.71
= 0.497 m
Flow rate calculation
Retention time, Tr = 3 hr
Vt
Volumetric flow rate Qc =
Tr
3.6
=
3 ×3600
= 0.00033 m3/s
Mass flow rate mf = Qc 𝜌
13
Alan Records, Ken Sutherland. Decanter Centrifuge Handbook. s.l. : Elsevier Advanced Technology, page-160
14
88
= 0.00033 × 990
= 0.33 kg/s
8.2.2 Centrifugal force calculation
The centrifugal force on a particle that is constrained to rotate in a circular path is given by
15
Fc = mr2
Where, Fc is the centrifugal force acting on the particle to maintain it in the circular path, r is the
radius of the path, m is the mass of the particle, and (omega) is the angular velocity of the
particle.
𝑣
Or, since =
𝑟
where v is the tangential velocity of the particle
𝑚𝑣 2
Fc =
𝑟
Rotational speeds are normally expressed in revolutions per minute, so that the above equation
can also be written, as
2𝜋𝑁
=
60
2×3.1416×1200
=
60
= 125.6664
2𝜋𝑁
Fc=mr( )2
60
2×3.1416×1200 2
= 3265.47 × 0.71 ×( )
60
15
89
= 3.66×108 N
8.2.3 Settling velocity calculation

µ= 9.9 × 10-4 Pa.s
p = 2200kg/m3
 = 900kg/m3
Dp = 16 × 10-6 m
𝐷𝑝2
Vt = (p- )g 16
18
(16 ×10−6 )2
= (2200 - 900) × 9.8
18 ×9.9 ×10−4
= 0.00018 m/s
8.2.4 Power calculation

The power consumed by the centrifuge is expressed as the following equation,
PT = (Pp + Pc+ PB) 17
Where, PT = Total power, W
Pp = Power required to generate centrifugal acceleration
Pc = Conveying power requirement

PB = Total Break power
Power required to generate centrifugal acceleration
Formula for power requirement for centrifugal force Pp = Qfp2r2 18
= 0.0003 × 990 × (125.6664)2 × (0.741)2

= 2833 W
16
17
18
90
Total conveying power
Total conveying torque was determined for a differential = 12 and gearbox ratio = 80 Total
conveying torque, Tc = 0.3 kN
Conveying power, Pc = Tc × N 19
2𝜋
= 0.3 × 1000 × 12 ×
60
= 377 W
Total braking power
Pinion speed, Sp = SB - N×RGB
SB = Rotation speed of the bowl, rpm

Sp = Rotation speed of the pinion, rpm
RGB = Gearbox ratio
Now, Sp = 1200 - 12×80 = 240 rpm

Tc
Pinion torque, TP =
RGB
300
=
80
= 3.75 Nm
2π 20
Braking power, PB = Tp× Sp×
60
2𝜋
= 3.75 × 240 ×
60
= 94.24 W
19
20
91
Total Power consumption, PT = 2833 + 377 + 94.24
= 3304.24 W
For frictional loss, considering a 80% of the efficiency
3304.24
PT =
0.80
= 4130.3 W
Total power consumption of the main motor, PT = 4.13 kW
8.2.5 Critical thickness of Insulation
Thermal conductivity of insulation material (carbon fiber), k = 0.55 W/mºC
Heat transfer co-efficient of air, h = 3 W/m2 ºC
𝑘 21
Critical thickness of insulation, ro =
ℎ
0.55
=
3
= 0.18 m
≈ 7.2 in
8.2.6 Mechanical design

Internal diameter of the vessel, Dt = 1.42 m
21
Holman, J. P., “Heat Transfer” - SI Units, McGraw-Hill Education (India) Pvt Limited- 2002, Page -700.
92
= 1420 mm
Internal pressure due to liquid height = ρ(h-0.3)g 22
= 900× (2.84-0.3)×9.81
= 22425.66 N/m2
Internal pressure due to centrifugal force = 0.5 ×  × r2 × 2
= 0.5 × 900 × (1.42)2 × (125.6664)2
= 1.43 × 107 N/m2
Safety factor = 1.2
Design pressure, P = Internal pressure × 1.2
= ( 22425.66 +1.43 × 107 ) × 1.2 N/m2
= 1.72 × 107 N/m2
r 𝑡
Now Tangential stress, s = × P + 2× × (r + )2 23
t 2
Here, tagential stress, s = 2.98 × 107N/m2
Pressure, P = 1.72 × 107 N/m2

1.42 𝑡
2.98 × 107 = × 1.72 × 107 + (125.6664)2×900 × (1.42 + )2
𝑡 2
t = 0.03m
= 30 mm
22
Peter M.S., Timmerhaus K.D., Ronald E.W. “Plant Design and Economics for Chemical Engineers”, 5th Edition
23
93
For a 20% over design, the bowl wall thickness = 30 x 1.2 mm
= 36 mm
Skirt Design
Saddle Support
Horizontal cylindrical vessels are supported on saddles. These are placed at two positions.
Material: Stainless Steel
Shell diameter = 1420 mm
D
R=
2
1420
=
2
= 710 mm
Length of shell,L= 2840 mm
Shell Thickness = Head Thickness = 36 mm
Tori-spherical Head- Crown radius = 1420 mm
knuckle radius,ro = 6% of diameter
= 0.6 × 1420 mm
= 85.2 mm
Total depth of head (H) = √(Doro/2)
= √(1420 x 85.2 /2)
= 245.95 mm
4H
Equivalent cylinder Length, L1 = L+
3
4×245.95
= 2840 +
3
= 3168 mm
94
D
Distance of saddle center line from shell end, A = 0.5 x
2
1420
= 0.5 × mm
2
= 355 mm
Diameter of centrifuge, D = 1.42 m
Length of centrifuge, L = 2.84 m
D D
Volume of vessel wall, V = 2π ( + L) × t s
2 2
1.42 1.42
= 2 × 3.1416 × ( + 2.84) × 0.03
2 2
= 0.475𝑚3
Density of steel (AISI SS 317), 𝜌 = 8000 kg/𝑚3 24
Weight of vessel, 𝑊𝑣 = V 𝜌 + 𝑉𝑡 𝜌𝑜𝑢𝑡
= 0.475× 8000 + 4.5× 900
= 7850.83 kg
So Maximum weight of the vessel, W = 𝑊𝑣 × 1.2
= 7850.83 × 1.2 kg
= 9421 kg
Longitudinal Bending Moment
WL1
Q=
2
24
Nicholas, T.; Tensile testing of materials at high rates of strain,Exp. Mech., vol. 21, no. 5, pp. 177–185, May 1981
95
9421 ×3168
=
2
= 14922 kg-m
A
(1− +(R2 − H2 )
1− L
2AL 25
M1 = QA 4H
1+ 3L
0.355
(1− +(0.7102 − 0.377592 )
1− 2.84
2×0.355×2.84
M1 = 14922 × 0.355 × 4×0.37759
1+ 3×2.84
= 1740.62 kg-m
Bending moment at center of the span
𝑄𝐿 1+2(𝑅2 − 𝐻 2 )/𝐿2 4𝐴
M2 = ×[ 4𝐻 − ]
4 1+ 3𝐿 𝐿
14922 ×2.84 1+2(0.7102 − 0.377592 )/2.842 4×0.355

M2 = ×[ 4×0.37759 − ]
4 1+ 3×2.84 2.84
= 4503 kg-m
Stresses in shell at the saddle
M1 26
At the topmost fibre of the cross section f1 =
k1 πR2 t
Let, assume k1=k2=1
25
http://www.sbioinformatics.com/design_thesis/Ammonium_Sulphate/Ammonium-2520Sulphate_Design-2520of-
2520Equipments.pdf
26
http://www.sbioinformatics.com/design_thesis/Terephthalic_acid/Terephthalic-
2520acid_Design-2520of-2520Equipments.pdf]
96
1740.62
=
π×0.7102 ×0.036
= 30530.5 kg/m2
The stresses are well within the permissible values.
M2
Stress in the shell at midpoint f2 =
k2 πR2 t
4503
=
π×0.7102 ×0.036
= 78982 kg/m2
Axial stress in the shell due to internal pressure
𝑃𝐷
Fp = 4𝑡
1×105 ×1.42
=
4×0.036
= 9.86 × 105 kg/cm2
f2 + fp = 883.48 kg/cm2
27
Support specification
135−110
A = 110 + 1.50−1.20 × (1.42 – 1.20)
= 138.33 mm
95−80
B = 80 + 1.50−1.20 × (1.42 – 1.20)
= 91 cm
C = 13 mm
D = 16 mm
37−33
E = 33 + × (1.42 – 1.20 )
1.50−1.20
27
M. V. Joshi and V. V. Mahajani, Process Equipment Design (3 Edition). Macmillan India Limited, 2000.
97
= 35.94 cm
58−45
F = 45 + 1.50−1.20 × (1.42 – 1.20 )
= 54.53 cm
G = 20 cm
H = 14 cm
Bolt diameter = 22 mm
98
8.2.7 Mechanical Drawing
2.8 4 m
Steam In
Steam Conveyer Feed
Out Hole
0.03 m
1.42 m Centrifuge
Feed
0.35 m
Solid Discharge
Liquid
Discharge
Figure 8.2.7.1 : The main operating part of a decanter centrifuge
99
Lc
Lk
r1
r2
Figure 8.2.7.2: Dimension of a decanter centrifuge
100
13 mm 13 mm
91 cm
16 mm
54.53 cm 35.94 cm 14 cm
138.33cm 20 cm
Figure 8.2.7.3 : Saddle support of a decanter centrifuge
101
8.2.8 P & ID
Figure 8.2.8.1: P & ID diagram of a decanter centrifuge
102
Specification sheet
Identification Item: Centrifuge Date: 11/02/2017
Function To remove solids from solution media
Operation: Batch
Parameters Inlet Outlet

Material
Handled Quantity (kg) 3265 kg 3265 kg
Pressure (psi) 14.7 14
Temperature(ºC) 30 35
Height 2.84 m Operating pressure 1 atm
Operating 30-35 ºC
Design Centrifuge Diameter 1.42 m
Data Temperature
Shell Capacity safety
30 mm 20%
thickness factor
Motor 1200
Speed Power required 5.54 hp
rpm
Material of AISI SS 316

construction
Code ASTM- UNS3160
Utilities Not required
Tolerance 20% of load
Insulation Noise cancelling
Remarks
Checked by
Date of
revision
103
8.3 Design of Agitated Batch Crystallizer
51.78 Kg feed from

Mixer 33 Kg pure crystal
Agitated batch crystallizer
65 wt% powder
35 wt% water
18.78 Kg mother liquor
0.95 Kg water/kg mother liquor
0.05 Kg solid/kg mother liquor
8.3.1 Crystallizer size calculation

Agitated batch crystallizer allows solid powder to increase its size and hence separate itself from
water. In our process a typical tank with agitator is used as a crystallizer. In this crystallizer,
Small particle grows and forms large crystal which is easily separated from mother liquor
contains few particles which are smaller than desired crystal.
Tank length and diameter determination
Total mass of the feed in the vessel, m= 51.78 Kg
Composition of feed= 65wt% powder and 35wt%water
Density of C.NaHCO3 powder= 900 Kg/ m3
Density of water= 1000 Kg/ m3
So, average density of feed, 𝜌 = 0.65×900+0.35×1000
=935 kg/m3
So, volume of feed, V=51.78/935
=0.055 m3
104
Assume, 50% of the vessel will be filled up by the feed.
So, volume of the tank=0.055/0.5
=0.1108 m3
28
Now, the vessel is cylindrical.
Let, diameter of the vessel be D and length of the tank be L
And also assume typical L/D ratio be 1.5
So, volume of the vessel, V=0.25×π×D2×L
=0.25×π×D2×1.5D
=0.375×π×D3
Or, 0.5×π×D3= 0.1108
3 0.1108
So, D= √
0.375×π
=0.455 m
=0.455×3.28 ft
=1.49 ft, equivalent to 1.5 ft
So, diameter of the tank, D= 18 inch
Length of the tank, L= 18×1.5
= 27 inch
29
Vessel cone at lower part with horizontal=15o
Impeller Dimensions
Impeller type:
28
McCabe, W. L., Smith, J., and Harriott, P., Unit Operations of Chemical Engineering, McGraw-Hill
Education-2005, 7th Edition, Page-244
29
Gregory P. Shankwitz, Richard K. Grenville, Kevin H. Tanner, Agitated vessel for producing a suspension of
solids,
105
Turbine type vertical blade
2
Impeller diameter, 𝐷𝑖 = 3 × 𝐷
2
= 3 × 18
= 12 inch
1
Blade width, w= 8 × 𝐷i
1
=12 × 12
=0.5 inch
1
Blade outer edge, Li= 6 × 𝐷i
1
=6 × 12
=2 inch
Distance between lower part of the vessel and impeller=0.5 inch
Ideal space between impellers, Hi=D=18 inch
0.5×𝐿
Number of impeller required= 𝐷
0.5×27
= 18
= 0.75≈1
So, 1 impeller is required.
Baffle design:
Number of baffles=4
Distance of baffle from side wall=0.5 inch
106
1
Baffle width, w=12 × 18
= 1.5 inch
Baffle position: four baffles equally spaced near sidewall.
8.3.2 Power calculation

30
Assumptions
 Six-blade turbine, 𝐾𝑇 = 1.65

 Four baffles
𝑅𝑒 = 𝜇
0.30482 ×0.33×935
= 9.9×10−4
= 28954
As, Re>10000, it is independent of Reynolds number
So, Np=KT= 1.65
𝑃
So, 𝑛3×𝐷5×𝜌=1.65
Or, P= 1.65× (0.33)3×935× (0.3048)5
=0.14585 W
= 0.2187 W
30
McCabe, W. L., Smith, J., and Harriott, P., Unit Operations of Chemical Engineering, McGraw-Hill
Education-2005, 7th Edition, Page-248
107
= 0.306 W
Turbine shaft diameter
Power required, 𝑃𝑡𝑜𝑡 = 0.14585 W
= 0.0002 hp
ℎ𝑝×75×60
As 𝑇𝑐 = 2𝜋𝑁
=0.007 kg-m
𝑇𝑚 = 1.5𝑇𝑐
= 0.01 kg-m
𝑇𝑚 ×100
𝑍𝑝 = 550
= 0.0019 𝑐𝑚3
𝜋𝑑3
So = 0.0019
16
Shaft diameter, d = 0.213 cm
= 1 inch
8.3.3 Cooling water calculation
51.78 Kg 51.78 kg
Crystallizer-101
At 26oC at 12oC
Normal water, mnormal water at 31.63oC
Cephalosporium Acremonium Sodium Bicarbonate solution:
108
The heat capacity of Cephalosporium Acremonium Sodium Bicarbonate is 1042JKg-1K-1
Mass=51.78 kg
Inlet temperature= 26oC
Outlet temperature= 12oC
Cooling water:
Inlet temperature= 25oC
Outlet temperature= 31oC
Heat capacity of water=4200JKg-1K-1
So,
mmedia× Csolution×delTmedia= mnormal water×Cp×delTcolling water
or, (51.78 ×1042×(26-12) J =mnormal water× 4200×(31.63-25)
Mnormal water=31 Kg
Now, crystallizer operating time=1 hour
Density of water=1000 kg/m3
31
So, volumetric flow rate of cooling water=1000
=0.031 m3/h
=31L/h
8.3.4 Mechanical Design
Internal diameter of the vessel, D = 0.4572 m
Internal pressure due to liquid height = 𝜌 ×h
= 935 × 0.6858×9.8 N/𝑚2
109
= 6283 N/𝑚2
1
Internal pressure due to centrifugal force = 2 𝜌𝜔2 𝑟 2
= 0.5×935× (0.33×2π)2× (0.1524)2×9.8 N/𝑚2
=457.47 N/m2
Design pressure, P = Total internal pressure× safety factor
= (6283+457.47) × 1.3
= 8762.61 N/m2
Material of construction, AISI SS 317
Joint efficiency, 𝐻𝐽 = 0.85 (spot Welded)
31
Corrosion allowance, 𝐶𝑐 = 3 mm
𝑃𝐷
Shell thickness, 𝑡𝑠 = 2 𝐻 𝑡𝑆+𝐶𝑐
𝑗
=3.3 mm
Skirt Design
Length of fermenter, L = 0.6858 m
𝐷 𝐷
Volume of vessel wall, V = 2𝜋 ( + 𝐿) × 𝑡𝑠
2 2
0.4572 0.4572
= 2 × 3.1416 × ( + 0.6858) × 0.0033
2 2
= 0.004𝑚3
32
Density of steel (AISI SS 317), 𝜌 = 8000 kg/𝑚3
31
Nicholas, T.; Tensile testing of materials at high rates of strain, Exp. Mech., vol. 21, no. 5, pp. 177–185,
May 1981.
32
Nicholas, T.; Tensile testing of materials at high rates of strain, Exp. Mech., vol. 21, no. 5, pp. 177–185,
May 1981
110
Weight of vessel, 𝑊𝑣 = V 𝜌 + 𝑉𝑡 𝜌𝑜𝑢𝑡 = 0.004× 8000 + 0.11 × 1070
= 150 kg
So Maximum weight of the vessel, W = 150 × 1.5
= 225 kg
Assuming,
Diameter of skirt (Straight), d = 45.72 cm
Height of skirt, h = 0.2 m
Permissible bearing pressure for concrete = 35 kg/𝑐𝑚2
33 𝑊
Stress due to dead weight, 𝑓𝑣 = 𝜋𝑑𝑡 34
225
=
3.1416×45.72×𝑡
1.566
= kg/𝑐𝑚2
𝑡
2 2×0.08×𝑊
Stress due to seismic load, 𝑓𝑠𝑏 = 3 × 𝜋𝑑2 𝑡
0.004
= kg/𝑐𝑚2
𝑡
1.566
Maximum tensile stress, 𝑓𝑡(m) = kg/𝑐𝑚2
𝑡
1.566
So t = ×3.3
750
= 0.07 mm
1.566
Maximum compressive stress, 𝑓𝑐(m) = kg/𝑐𝑚2
𝑡
33
Joshi, M. V. and Mahajani, V. V.;” Process Equipment Design”, 3 Edition, Macmillan India Limited-
2000, page-391.
111
Assuming 𝑓𝑐 permissible =31.1 kg/𝑐𝑚2
1.566
So t = ×3.68
31.1
= 0.18 mm
So the thickness of skirt = 0.18 mm
Let, bolt circle diameter = d + 20 cm
= 45.72+20
=65.72 cm
Compressive stress between bearing plate and concrete foundation,
𝑊 3𝑘𝑃𝐻 2
𝑓𝑐 = +
𝐴 2𝑍
225×4 3×0.7×128.5×4.752
=3.1416(65.722 −45.722 ) + 3.1416(65.724−45.724 )
2
32×65.72
= 0.27 kg/𝑐𝑚2
6×0.27 102
Stress = 2 ×
𝑡𝐵 2
82
=𝑡 2
𝐵
Permissible stress of bending = 800 kg/𝑐𝑚2
82
So 𝑡𝐵 2 =800×3.3
So 𝑡𝐵 =0.03 mm
Assuming 10 bolts
0.27 65.722 −45.722

Load on one anchor bolt, 𝑃𝑏𝑜𝑙𝑡 = ×
10 4
= 15 kg
112
8.3.5 Mechanical Drawing
Figure 8.3.5.1: Front view of agitated batch crystallizer
113
Figure 8.3.5.2: Baffle and impeller arrangement
114
8.3.6 P & ID
Figure 8.3.6.1: P & ID of crystallizer
115
Specification Sheet
Identification: Item: Crystallizer Date: 15/2/2016

By: ACI
Function: Increase size of cephalosporin sodium bicarbonate powder
Operation: Batch
Type: Batch agitated tank with cooling water jacket
Material Handled: Inlet Outlet
Quantity (kg) 51.78 33.0 ( crystal))
18.78 (liquid)
Pressure (atm) 1 1
Temperature (ºC) 26 12
Density (kg/m3) 935 1070 (crystal)

950 (liquid)
Design Data:
Tank Turbine
Type cylindrical Type vertical blade

Height 27 inch Impeller diameter 12 inch
Diameter 18 inch Impeller length 27 inch
Shell thickness 0.125 inch Impeller width 1 inch
Capacity safety factor 25% Impeller type Six-blade turbine
Capacity 0.11 ft3 Speed 20 rpm
Operating pressure 1-2 atm Shaft diameter 1 inch
Operating Temperature 10-30 ºC Power required 0.306 W
No of baffles: 4
Baffle thickness: 1 inch
Baffle width: 1.5 inch
Material SS 317
Code AISI
Skirt: Height: 8 inch Thickness: 1 inch
Tolerance: Rules of thumb and heuristics
116
117
Chapter Nine
Plot Plan and Plant Layout
140
Assembly point Road
Emergency
Ether
NaHCO3
Storage Storage Mixer
Tank
exit
Tank
Mosque Playground Housing

Future Expansion colony
First Second Centrifuge

Extractor Extractor
Crystallizer Parking
Product
Storage
Packing
Tank
AA Filtration
Unit Entry/Exit
Rotary
storage Unit Dryer
Tank
Health&
safety
Administrative Guard
Control Environment Building Room
Loading
Room
Unit
Product Intermediate
Seed
storage
Fermenter Mach
Fermenter
Tank Quality ine Canteen
Control shop
Media Generator
Pre-seed Storage
ETP Room
Servi
Inoculum Tank
Fermenter ce
Entr
y
Water Pump
Parking Boiler Treatment house
Chapter Ten
Economic Analysis
142
Equipment Cost
Table 10.1: Table for equipment cost

No. Name of Equipment Exponent Unit cost Cost (USD)
equipment number
1 TK-101 1 - 3500 3500
2 TK-102 1 - 27000 27000
3 MIX-101 1 0.6 2555 2555
4 MIX-102 1 0.6 4814 4814
5 MIX-103 1 0.6 16129 16129
6 MIX-104 1 0.6 10172 10172
7 MIX-105 1 0.6 625 625
8 F-101 1 - 12324 12324
9 F-102 1 - 23261 23261
10 F-103 1 - 77923 77923
11 ST-101 1 - 10000 10000
12 ST-102 1 - 15000 15000
13 ST-103 1 - 30000 30000
14 E-101 1 - 16800 16800
15 E-102 1 - 15600 15600
16 E-103 1 - 27900 27900
17 E-104 1 - 25800 25800
18 E-105 1 - 243900 243900
19 E-106 1 - 138700 138700
20 H-101 1 - 300 300
21 V-101 1 - 92700 92700
22 V-102 1 - 19900 19900
23 V-103 1 - 47700 47700
24 V-104 1 - 12300 12300
25 V-105 1 - 51200 51200
26 V-106 1 - 5500 5500
143
27 V-107 1 - 6100 6100
28 V-108 1 - 6300 6300
29 D-101 1 - 97517 97517
30 D-102 1 - 82539 82539
31 RVF-101 1 - 866900 866900
32 RD-101 1 - 102300 102300
33 CF-101 1 - 33300 33300
34 P-101 1 0.33 526 526
35 P-102 1 0.33 566 566
36 P-103 1 0.33 413 413
37 P-104 1 0.33 207 207
38 Blower 1 - 1704 1704
39 Boiler 2 - 202200 202200
40 Water 1 - 30000 30000
treatment
plant
41 ETP 1 - 20000 20000
42 HVAC 1 - 30000 30000
Total Equipment Cost = 2412175
Total Investment Cost
Table 10.2: Determination of total investment cost
Item % of Equipment cost Factor Cost (USD)
Purchased Equipment 100 1 2412175
Purchased Equipment Installation 20 0.2 482435
Instrumentation and Control 17 0.17 410069
144
Piping 35 0.35 844261
Electrical 10 0.1 241218
Building 18 0.18 434191
Yard Improvement 15 0.15 361826
Service Facilities 40 0.4 964870
Land 16 0.16 385948
Total Direct Plant Cost 271 2.71 6536994
Engineering & Supervision 30 0.3 723652
Construction Expenses 33 0.33 796017
Total Direct & Indirect Cost 334 3.34 8056664
Contractor’s Fee 18 0.18 434191
Contingency 35 0.35 844261
Fixed Capital Investment 387 3.87 9335117
Working Capital 70 0.7 1688522
Total Capital Investment 457 4.57 11023639
145
Estimation of product Cost
Manufacturing Cost
1. Direct Production Cost
Table 10.3: Table for direct production cost
Raw Material Cost per Kg(USD) Kg per year Cost per year (USD)
Corn steep liquor 15 273234 4098520

Cephalosporium 134.5 766 102973
Acremonium
Amyl Acetate 24.5 95048 2328682
Ether 4.5 9699 43644
Sodium Bicarbonate 0.2 961 192
Total raw material cost = $ 6574011
Operating labor cost (10% of raw material) = $657401
Supervision and clerical labor cost (5% of operating labor cost) = $ 32870
Utility
Table10.4: Table for utility cost
Equipment Operating Cost per Year

Boiler 3478
Pump 330
Blower 40
WTP 28410
ETP 37854
HVAC 20000
146
Total utility cost = $ 90112
Maintenance and repair cost (5% of Fixed Capital) = $466756
Operating Supplies (10% of Maintenance and repair) = $46676
Laboratory Charges (15% of Operating Supplies) = $7001

Total Direct product Cost = $ 7874827
2. Fixed Charges
Economic Life = 20 years
Fixed Capital Investment = $ 9335117
Salvage value = $933512
Depreciation per year = (9335117-933512)/20 = 420080
Insurance (0.1% of FCI) = $ 933512
3. Plant Overhead Cost

30% of Operating labor, supervision and maintenance cost = $ 207081
Total manufacturing Cost = $8808339
4. General Expanses
Administrative cost (10% of overhead cost) = $ 20708

Financing (3% of TCI) = $ 330709
Total Product Cost = $ 9159756
Gross Earning
Selling price of Cephalosporin Antibiotics = $ 12/gm
Annual selling = 1089 Kg
Annual revenue = $ 13068000
Profit before tax = $ 3488164
Income Tax (10%) = $ 348816
Profit after tax = $ 3139248
147
Depreciation = $420080
Net cash flow = $ 3559428
Financial Analysis
IRR Analysis
Rate of return after tax = 13 %
$ 933512 Salvage value

$ 3559428
1 2 18 19 20
$ 11023639
Figure 10.1: Cash Flow Diagram
148
Present Worth vs. interest rate
40000000
35000000
30000000
25000000
20000000
Present worth
15000000
10000000
5000000
0
0 10 20 30 40 50 60 70
-5000000
-10000000
Interest rate (%)
Figure 10.2: IRR analysis
From Figure 12, IRR = 32.26 %
As,
IRR>MARR(13%)
So, the project is economically feasible.
149
ERR Analysis
$ 933512 Salvage value

$ 3559428
1 2 18 19
20
$ 11023639
Figure 10.3: Cash flow diagram
If we consider MARR = 13% for our country
Present worth (PW) of all negative cash flow = $ 11023639

Future worth (FW) = 11023639 (1+i)20
3559428×(1.1320 −1)
Future worth of all positive cash flow = +933512
0.13
= 289057921
Now, 11023639 (1+i)20= 289057921
So, i= 17.74 %
ERR>MARR(13%)
So, the project is economically feasible.
150
Payout period
Table 10.5: Calculation of Pay out period (with interest method)
Cumulative PW (USD) Cumulative

Net cash flow PW (USD) PW (USD) MARR=13% PW (USD)
End of year
(USD) MARR=0% MARR = MARR=
0% 13%
0 -11023639 -11023639 -11023639 -11023639 -11023639
1 3559428 3559428 -7464211 3149936 -7873703
2 3559428 3559428 -3904783 2787554 -5086149
3 3559428 3559428 -345355 2466862 -2619287
4 3559428 3559428 3214073 2183064 -436223
5 3559428 3559428 6773501 1931915 1495692
6 3559428 3559428 10332929 1709659 3205251
7 3559428 3559428 13892357 1512973 4718324
So, Payout period without interest 4 years
And with interest 5 years
151
152

1089 Kg/year Cephalosporin Antibiotic Production Plant From Corn Steep Liquor

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1089 Kg/year Cephalosporin Antibiotic Production Plant From Corn Steep Liquor

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BANGLADESH UNIVERSITY OF ENGINEERING & TECHNOLOGY

Design of 1089 kg/year Cephalosporin Antibiotic

1. Process definition……………………………………………………………… 1-9

4. Energy balance…………………………………………………………………. 29-36

8. Individual equipment design………………………………….................... 74-135

Table 3.1: Summary table of vacuum dryer balance…………………………... 14

Table 3.2: Summary table of crystallizer balance……………………………... 15

Table 3.3: Summary table of Mixer-2 balance………………………………… 16

Table 3.4: Summary table of centrifuge……………………………………….. 17

Table 3.5: Summary table of Mixer-1 balance………………………………… 19

Table 8.4.1.1: Properties of substances………………………………………... 118

Table 8.4.1.2: Temperature…………………………………………………….. 118

Table 10.1: Table for equipment cost………………………………………….. 143-144

Table 10.2: Determination of total investment cost…………………………… 144-145

Table 10.3: Table for direct production cost…………………………………... 146

Table 10.4: Table10.4: Table for utility cost………………………………….. 146

A Cephalosporin Antibiotic Production plant is to be set-up at Shibganj, Nawabganj in Bangladesh

Table 01: Raw Materials

Corn steep liquor, methionine 20%

Composition of corn steep liquor

Acetic acid (0.05%)

Glucose lactic acid (0.5%)

Amino acids (0.5%)

Total solids (80-90%)

Total nitrogen (0.15-0.2%)

95% Cephalosporin Sodium Salt (Antibiotics)

1.3 Design Basis

1.3.1 Geological Data

 Minimum water level: 22 m

1.3.2 Climatic conditions

a. Design conditions for equipment or facility

 Maximum dry bulb temperature: 39⁰C (in summer)

b. Design conditions for buildings: HVAC

 Maximum dry bulb temperature: 25⁰C (in summer)

 Average relative humidity(RH): 57%

 Average daily wind speed: 7mph/6knots

1.3.3 Utility conditions

 Source: Ground water

440 V – 3 phase, 50 Hz for motors in the range of:

 230V-1 phase 50 Hz for motors 0.5 KW and below.

3. Dew Point: 3⁰C

ii. Plant air

1. Pressure: 250kPa (abs)

2. Temperature: 28⁰C (Maximum)

iii .Hot air

170⁰C saturated steam at 8 bar

121⁰C saturated steam at 2 bar

1.3.4 Raw Materials

Corn steep liquor, glucose, sucrose, ammonium salt, fungi.

1.3.5 Solvent for extraction

Amaylacetate and ether solution.

1.4 Process Selection

Available process for production of Cephalosporin-C.

In presence of ACV synthase, LLD-ACV (L- α- aminodipoyl)- L- Cysteinyl-D- Valine is produced

Figure 1.4.1: Biosynthesis pathway of producing Cephalosporin C.

In this process, the active pharmaceutical ingredient is produced by fermentation. By filtration

Media +water Media +water Media +water

CA Inoculum CA Pre-seed CA Seed CA Production

Material balance on vacuum dryer

Stream Mass flow, Kg Components Composition (%)

M2, water vapor 17.30 water 100

Solid crystal 63.23