Beruflich Dokumente
Kultur Dokumente
Report Assignment 1
GROUP 17
GROUP PERSONNEL:
Ahmad Jamal (1506746342)
Andreas Emil S. (1506746260)
Anissa Clarita (1506746374)
Dionisius Parsaoran W (1506746071)
Muhammad Fachri L. (1506717992)
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conversion uses the process of gasification, producing syngas (H2 and C) and then
reassembling them to alcohol. Biochemical conversion is chosen because the
process has been developed and widely used in the industry, the operating condition
is much more sustainable than thermochemical process, and the cost is more
reasonable. The biochemical path undergoes pretreatment, hydrolysis,
fermentation, distillation, and dehydration.
Alkali pretreatment is chosen because it requires lower temperatures and
pressures than other pretreatment technologies. Enzymatic hydrolysis is chosen
because the process is simple, by using bacterial and fungi as biocatalyst, and the
cost is relatively cheaper than acid hydrolysis because chemical compounds are
relatively expensive. The fermentation process will be operated in batch reactor
with Saccharomyces as its yeast. For each kilogram of glucose, 470 grams of
ethanol can be produced, representing a yield of 92% of theoretical maximum. The
fermentation temperature will be 33oC. Ethanol from fermentation process is
recovered by distillation with temperature of at least 95oC.
The mass and energy balance calculation were done by using simulation in
both SuperPro and UniSim. Alternately, we did simulation that combine both
simulators. SuperPro was used because of its advantages which can proceed and
provide bio-solid material properties such as biomass, whereas UniSim cannot.
Based on the simulation, the sugar and ethanol that can be produced is 48000 tonne
and 14100 tonne per year, respectively, converted from 350,000 of sugarcane feed.
This ethanol-furfural production may reduce national ethanol needs. The
operational conditions - in the simulators - are obtained from many sources such as
paper, book, and trial-error to get the highest ethanol yield. The purity of ethanol is
93.6%. The production conversion efficiency is 17.93%, and the total energy
required per hour for the plant is 38,960 kWand the energy required to produce
sugar and bioethanol is 2,482.26 kW
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3.1.5 Extractor ........................................................................................... 54
3.1.6 Sulphitation Process ......................................................................... 55
3.1.7 Heater 1 ............................................................................................ 56
3.1.8 Evaporator 1 ..................................................................................... 57
3.1.9 Evaporator 2 ..................................................................................... 59
3.1.10 Evaporator 3 ..................................................................................... 61
3.1.11 Evaporator 4 ..................................................................................... 63
3.1.12 Evaporator 5 ..................................................................................... 65
3.1.13 Crystalization Process ...................................................................... 67
3.1.14 Centrifugator 1 ................................................................................. 69
3.1.15 Heater 2 ............................................................................................ 71
3.1.16 Rotary Drying .................................................................................. 72
3.1.17 Sterilization Process ......................................................................... 74
3.1.18 Cooler ............................................................................................... 75
3.1.19 Hydrolysis Process ........................................................................... 76
3.1.20 Mixer ................................................................................................ 79
3.1.21 Fermentation Process ....................................................................... 81
3.1.22 Centrigugator 2 ................................................................................ 83
3.1.23 Distillation Coloumn ........................................................................ 85
3.2. Energy Balance ..................................................................................... 87
3.3. Product Conversion Efficiency............................................................ 87
3.4. Product Yield ........................................................................................ 88
3.5. Energy Consumption of Unit Product ................................................ 88
CHAPTER IV CONCLUSION.......................................................................... 89
REFERENCES .................................................................................................... 90
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LIST OF FIGURES
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LIST OF TABLES
1.1. Background
As the growth of Indonesia’s industrial sector each year tends to increase,
the need for industrial raw materials will also rise. One of the most valuable feed
stock in chemical industry is ethanol because it has numerous applications for the
production of parfume, medicines, alcoholic beverages and dye. Ethanol, an organic
compound with the formula C2H6O, is mainly used as a solvent in the production
of food coloring.
The high need for ethanol in Indonesia is not currently fully supported by
the government or private companies. This causes Indonesia to import the material
from other countries. Whereas ethanol can be produced through fermentation
derived from biomass. Biomass-based ethanol plants have by-products namely
sugar. The sugar is produced in the stage of changing biomass to glucose. Hence, it
is a necessity to establish a manufacture of ethanol here in Indonesia.
Ethanol can be produced from bagasse, sweet potato, sugar cane, corn,
sorghum, beetroot, grass, and poplar. The source of ethanol which is quite potential
to be developed in Indonesia is sugar cane. Because it has long been known by
Indonesian farmers, the development of sugar cane to be processed into ethanol raw
materials is not too difficult. Sugar cane as a raw material for the sugar industry is
one of the plantation commodities which has a strategic role in the economy in
Indonesia. With an area of about 458.26 thousand hectares, the sugar industry made
from sugar cane is one of the sources of income for thousands of sugar cane farmers
and workers in the sugar industry. Sugar is also one of the basic needs for most
people and a relatively cheap source of calories. The increase in sugar consumption
in Indonesia from year to year provides wide opportunities for increasing the
production capacity of sugar mills. In addition, the amount of sugar production in
the country is currently felt unable to meet the needs of sugar in Indonesia. With
this step, the price of sugar cane will become stable so as to provide sufficient
profits for farmers.
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using familiar methods, such as fermentation, and it can be distributed using the
same petrol forecourts and transportation systems as before.
Ethanol can be produced from biomass by the hydrolysis and sugar
fermentation processes. Biomass wastes contain a complex mixture of carbohydrate
polymers from the plant cell walls known as cellulose, hemi cellulose and lignin.
In order to produce sugars from the biomass, the biomass is pre-treated with acids
or enzymes in order to reduce the size of the feedstock and to open up the plant
structure. The cellulose and the hemi cellulose portions are broken down
(hydrolysis) by enzymes or dilute acids into sucrose sugar that is then fermented
into ethanol. The lignin which is also present in the biomass is normally used as a
fuel for the ethanol production plants boilers. There are three principle methods of
extracting sugars from biomass. These are concentrated acid hydrolysis, dilute acid
hydrolysis and enzymatic hydrolysis.
The Arkanol process works by adding 70-77% sulphuric acid to the biomass
that has been dried to a 10% moisture content. The acid is added in the ratio of 1.25
acid to 1 biomass and the temperature is controlled to 50C. Water is then added to
dilute the acid to 20-30% and the mixture is again heated to 100C for 1 hour. The
gel produced from this mixture is then pressed to release an acid sugar mixture and
a chromatographic column is used to separate the acid and sugar mixture.
The dilute acid hydrolysis process is one of the oldest, simplest and most
efficient methods of producing ethanol from biomass. Dilute acid is used to
hydrolyse the biomass to sucrose. The first stage uses 0.7% sulphuric acid at 190C
to hydrolyse the hemi cellulose present in the biomass. The second stage is
optimized to yield the more resistant cellulose fraction. This is achieved by using
0.4% sulphuric acid at 215oC.The liquid hydrolates are then neutralized and
recovered from the process.
Instead of using acid to hydrolyse the biomass into sucrose, we can use
enzymes to break down the biomass in a similar way. However this process is very
expensive and is still in its early stages of development.
The hydrolysis process breaks down the cellulose part of the biomass or
corn into sugar solutions that can then be fermented into ethanol. Yeast is added to
the solution, which is then heated. The yeast contains an enzyme called invertase,
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which acts as a catalyst and helps to convert the sucrose sugars into glucose and
fructose (both C6H12O6). The chemical reaction is shown below:
The fructose and glucose sugars then react with another enzyme called zymase,
which is also contained in the yeast to produce ethanol and carbon dioxide. The
chemical reaction is shown below:
The ethanol, which is produced from the fermentation process, still contains
a significant quantity of water, which must be removed. This is achieved by using
the fractional distillation process. The distillation process works by boiling the
water and ethanol mixture. Since ethanol has a lower boiling point (78.3oC)
compared to that of water (100oC), the ethanol turns into the vapor state before the
water and can be condensed and separated.
1.3. Raw Material Selection
Sugar and ethanol can be produced from various raw materials, with the
most common one being the first generation of bioethanol produced from feed
stock. The second generation of bioethanol, produced from biomass, will be
considered as well. The considerations for raw material selection are based on some
criterias shown in Table 1.1.
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The average
Sugarcane to ethanol
Sugar: 120-160 production is 23-
Sugar content: 7- Lignocellulose to
kg/ton 27% of the total
12%, Ethanol Sugar: 21-39%.
Sugarcane to corn stover mass.
Yield produced directly Sugar to Ethanol:
Ethanol: 74 The ethanol is
from juice: 3000 42% from the
l/ton, Molasse produced from
L/ha sugar yielded.
to Ethanol: the hydrolysis of
256.78 l/ton glucose and
xylose.
Cost of
IDR 500,000 - IDR IDR IDR 220,000-
Raw
700,000/tonne 1,500,000/tonne 700,000/tonne 500,000/tonne
Material
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Each potential raw material is scored and multiplied by a weight for each
criteria to determine the raw material which will be used. Based on the analysis, the
scoring table is shown below in Table 1.2.
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container lacking oxygen it will produce ethanol (alcohol). Humans have been
isolating this process since the beginning of history. The yeast helps in the
rising of bread with it’s other by-product carbon dioxide. The gas that is
produce inside the dough causes it to rise and expand. Both of these processes
use the haploid of this yeast for this process. In industry they isolate one strain,
either a or ά, of the haploid to keep them from undergoing mating. (Madigan,
457) In the baker’s yeast they have a strain were the production of carbon
dioxide is more prevalent then ethanol and vice versa for brewing. Another
importance is that “live yeast supplementation to early lactating dairy goats
significantly increased milk production”. (Stella, A.V.;1)
1.5. Market and Capacity Analysis
1.5.1. Market Segmentation
The development of sugar imports during 2012-2016 was quite fluctuating.
In 2012-2013, the total weight of sugar imports experienced an increase of around
21.86 percent, while in 2014 it decreased by 12.26 percent. In 2014 the weight of
Indonesia's sugar imports reached 2.93 million tons with an import value of US $
1.31 billion. In 2015 the weight of sugar imports increased by around 14.87 percent
or to 3.37 million tons with a value of US $ 1.25 billion. In 2016 the weight of
imported sugar experienced a significant increase to 4.75 million tons or an increase
of around 40.83 percent and its value reached US $ 2.08 billion.
The lack of domestic sugar supply requires Indonesia to import sugar from
various countries. The government urges and supprots the idea of the use of
bioethanol as an alternative for conventinal fuel, as a plan fo r the future. Although
one of the problem is the produced ethanol is only being used as a foodstock and
the rest would be transported for export purposes, if the ethanol produced want to
be used as a fuel then the fuel grade must be enhanced to about 99.5% fuel grade
(Rinaldy Dalimi, DEN member 2017). This thing will make the fuel become so
expensive. As for the market segmentation of Ethanol, we are assuming that it will
be sold domestically, in Indonesia. Although, the production capacity has been
constantly increasing over the last years, but it is still insufficient to meet the full
demand.
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Raw Production
Producer Location
Material (kL/year)
PT. Molindo
Molasses Malang
Raya 30000
PT. Energi Agro
Molasses Mojokerto
Nusantara 30000
Total Production 60000
(Source: Kompas, 2014)
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From the table we know that current ethanol production each year in
Indonesia is around 60000 kL/year. Based on Indonesia biofuels annual report
2017, we found that ethanol demand is always increasing in these few years as well
as for the future demand. The demand projection of ethanol can be seen in the table
below.
Bioethanol Demand
Year
(KL/year)
2009 314.333
2010 323.994
2011 333.714
2012 434.725
2013 354.073
2014 364.658
2015 375.598
2016 386.866
2017 398.472
2018 410.426
2019 422.739
2020 435.421
2021 448.483
2022 461.938
2023 475.795
2024 490.07
2025 504.772
2026 519.915
2027 535.513
(Source: BPPT, 2016)
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Composition Mass%
Sucrose 13.85%
Water 69.35%
Bagasse 15.14%
Redicing sugars 0.59%
(Source: Pina, 2015)
With 1 tonne bagasse we can produce 27% ethanol. So the amount of
ethanol can be produced is 14,307 tonne per year, with a small addition of the
bioethanol from molasses yielded from the sugar production.
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CHAPTER II
PROCESS SELECTION
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juice is sent to a screen, where a fraction of the fibers dragged with the juice are
removed and recycled to the second mill for recovery of sugars. Usually, juice from
the first mill is sent to sugar production because it contains higher sugar purity,
while juice obtained in the second mill (called mixed juice) is diverted for ethanol
production.
Mills and other equipment in the cane preparation are usually driven by
steam turbines, which require more energy as steam than electric energy in efficient
electric engines. Diffusers can also be used in juice extraction with increased sugar
recovery and less energy consumption than the milling tandem (Palacios-Bereche,
2014).
2.2.2. Juice Treatment for Producing Sugar
The juice treatment for sugar production begins with the screening and the
sulphitation process in order to remove some colour components of juice. Then the
juice is heated first at 105oC.
Juice treatment for sugar production is ideally comprised by the same steps
as the juice treatment for ethanol production for production of raw sugar (VHP –
very high polarization, or VVHP – very very high polarization). However, more
CaO is necessary for sugar production in comparison with ethanol. CaO consumtion
is 0.5 kg/ton cane. In the production of white sugar, SO2 must be added in order to
decrease the color of the syrup in a process called sulphitation. Sucrose contain in
filter cake is 2% and moisture contain in filter cake is 70%.
2.2.3. Concentration of Sugarcane Juice
The concentration of treated juice for sugar also takes place in a multiple-
effect evaporation system of 5 effects until sucrose content of 55.4% (syrup). The
evaporator is arranged in series at a pressure of 1.69 bar, 1.31 bar, 0.93 bar, 0.54
bar and 0.16 bar. Vapour bleedings with different pressures and temperatures
resulting from the concentration process are used to cover heat demands in other
parts of the plant. For this case, without consider the heat integration, vapour
bleedings of first effect are used for heating in juice treatment and for heating the
vacuum pans in crystallization step.
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2.0% depending on the type of sugar produced, then cooled and stored prior to
distribution.
2.3. Alternative Processes for Bioethanol Production
In biomass conversion, there are few processes to convert biomass into
energy according to its product, as shown in Figure 2.2.
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Figure 2.4. Conceptual Flow Diagram of Gasification based Biomass to Fuel System
(Source: Puettmann et. al, 2011)
a. Feed Handling and Preparation
The biomass feed stock is dried to 10 wt% moisture using hot flue gases
from the char combustor and tar reformer catalyst regenerator.
b. Gasification
Biomass is indirectly gasified. Heat for the gasification reactions is supplied
by circulating synthetic olivine sand that is pre-heated in a char combustor and fed
to the gasifier. Steam is injected into the gasifier to stabilize the flow of biomass
and olivine through the gasifier. Gasification temperature is typically >850oC.
Within the gasifier, biomass thermally deconstructs to a mixture of syngas
components (CO, H2, CO2, CH4, etc), tars, and solid char containing residual
carbon from the biomass and coke deposited on the olivine. Cyclones at the exit of
the gasifier separate the char and olivine from the syngas. The solids flow to the
char combustors where the char is burned in air in a fluidized bed, resulting in
olivine temperatures greater than 982oC. The hot olivine and residual ash is carried
out of the combustor by the combustion gases and separated using a pair of
cyclones.
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c. Gas Cleanup
Syngas cleanup is defined as reforming of tars, methane, and other
hydrocarbons followed by cooling, quench, and scrubbing of the syngas for
downstream operations. The water gas shift reaction also occurs in the reformer.
Tars, methane, and light hydrocarbons are reformed to syngas in a circulating,
fluidized, solid catalyst system that resembles a small-scale fluid catalytic cracker
(FCC), complete with reforming and regeneration operations in separate beds. The
syngas is reacted with tar reforming catalyst in an entrained flow. The catalyst is
then separated from the effluent syngas in a cyclone. From the cyclone, the spent
catalyst flows to the catalyst regenerator.
The hot catalyst is separated from the combustion flue gas in the regenerator
cyclone and flows back to the tar reformer reactor to provide the energy necessary
for the reforming reactions. Additional syngas and unreacted gases from the
methanol synthesis reactor may also be combusted to provide all the heat necessary
for the endothermic reforming reactions. The hot reformed syngas is cooled
through heat exchange with other process streams and scrubbed with water to
remove persistent impurities such as particulates, ammonia, halides, and
recalcitrant tars. Scrubber water is purged and treated continuously in an on-site
wastewater treatment facility.
d. Syngas Compression
Cooled low pressure syngas enters a six-stage centrifugal compressor
system where the pressure is increased to approximately 3,000 psi (207 bar). The
pressurized syngas is fed to the tube sides of two vertical tubular reactors (shell
and tube type) operating in parallel.
e. Alcohol Synthesis
A sulfide-type mixed alcohol catalyst is packed within the tube of the
reactor, which is oriented in a down-flow configuration. Reactions at above 300oC
convert a portion of the syngas to oxygenate and hydrocarbon products. Heat from
the reactions is removed by the steam generation in the shell side of the tubular
reactor. The reactor effluent consisting of mixed alcohols, gaseous by-products,
and unconverted syngas is cooled through heat exchange with other process
streams As the reactor effluent cools, alcohols and water are condensed and sent to
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Waste treatment
Waste treatment may be directly discared, recycled, or processed as materials
in process based on Human Safety Environment
Each criterion will have a percentage that will be used to evaluate the
qualifying process. Both biochemical and thermochemical processes are compared
and then scoring with a matrix of scoring described below:
1 = worst
2 = worse
3 = acceptable
4 = better
5 = best
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Figure 2.5 Schematic diagram of the jacketed reactor system for lime pretreatment under
nonoxidative (N2 supply) and oxidative (air supply) conditions.
(Source: Rapello, 2011)
The enzymatic hydrolysis of lime-treated biomass is affected by structural
features resulting from the treatment. These are the extents of acetylation,
lignification, and crystallization. Lime pretreatment removes amorphous
substances (e.g., lignin and hemicellulose), which increases the crystallinity index.
Chang et al. reported correlations between enzymatic digestibility and three
structural factors: lignin content, crystallinity, and acetyl content. They concluded
that (1) extensive delignification is sufficient to obtain high digestibility regardless
of acetyl content and crystallinity, (2) delignification and deacetylation remove
parallel barriers to enzymatic hydrolysis; and (3) crystallinity significantly affects
initial hydrolysis rates but has less of an effect on ultimate sugar yields. These
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results indicate that an effective lignocellulose treatment process should remove all
of the acetyl groups and reduce the lignin content to about 10% in the treated
biomass. Therefore, alkaline pretreatment can play a significant role in exposing
the cellulose to enzyme hydrolysis.
Lignin removal increases enzyme effectiveness by eliminating
nonproductive adsorption sites and by increasing access to cellulose and
hemicellulose. Kim et al. pretreated corn stover with excess calcium hydroxide [0.5
g of Ca(OH)2/g of raw biomass] in nonoxidative (in the presence of nitrogen) and
oxidative (in the presence of air) conditions at 25, 35, 45, and 55 °C. The enzymatic
digestibility of lime-treated corn stover was affected by the change of structural
features such as acetylation, lignification, and crystallization resulting from the
treatment. Extensive delignification required oxidative treatment and additional
consumption of lime [up to 0.17 g of Ca(OH)2/g of biomass]. Deacetylation reached
a plateau within 1 week, and there were no significant differences between
nonoxidative and oxidative conditions at 55 °C; both conditions removed
approximately 90% of the acetyl groups in 1 week at all temperatures studied.
Delignification highly depended on temperature and the presence of oxygen. Lignin
and hemicellulose were selectively removed or solubilized, but cellulose was not
affected by lime pretreatment at mild temperatures (25-55 °C). The degree of
crystallinity increased slightly with delignification (from 43% to 60%) because
amorphous components such as lignin and hemicellulose were removed. Lee et al.
reported that the rate of enzymatic hydrolysis depends on enzyme adsorption and
the effectiveness of the adsorbed enzymes, instead of the diffusive mass transfer of
enzyme. Lignin removal increases enzyme effectiveness by eliminating
nonproductive adsorption sites and by increasing access to cellulose and
hemicellulose. Kong et al. reported that alkalis remove acetyl groups from
hemicellulose (mainly xylan), thereby reducing the steric hindrance of hydrolytic
enzymes and greatly enhancing carbohydrate digestibility. They concluded that the
sugar yield in enzymatic hydrolysis is directly associated with acetyl group content.
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2.5.2. Hydrolysis
2.5.2.1. Acid Hydrolysis
Acid hydrolysis of surplus cellulosic materials, such as bagasse, into
fermentation sugars offers enormous opportunity worldwide to add incremental
value to farming operations and displace expensive, imported, polluting oil fuel
products. Arkenol has developed and patented a strong acid hydrolysis process
which can economically convert cellulose into ethanol for transportation fuel.
Acid hydrolysis of cellulose into glucose by sultiric acid was first noted by
Bracormet in 1819. Since then numerous investigators have developed processes
attempting to cost effectively convert the cellulose and hemicellulose fraction of
plant matter into sugar for various purposes, primarily fermentation. Arkenol was
established in 1991 to extrapolate the basic research its affiliate company, an
independent power developer, had done in seeking to devise a thermal user business
for its cogeneration power plants.
Arkenol has now patented an acid hydrolysis process which economically
converts cellulose and hemicellulose into sugar for fermentation into ethanol.
Alternative methods have various uneconomic characteristics which preclude their
application in today’s petrochemical age except in non-market based economies of
war time or political isolation. The key Arkenol improvements to regain economic
competitiveness with petroleum are:
1. High solids, high concentration hydrolysis of minimally prepared feed stock to
yield high sugar concentration of above 15%. This is achieved without energy
use for hydrolysate drying nor sugar drying. The results of this improvement
are reduction in the energy and capital equipment needed to grind the feedstock
and then the achievement of 8% ethanol in the fermentation beer with
consequent distillation energy consumption typical of the best grain to ethanol
fermentation plants.
2. Separation of the hydrolysate liquor into pure acid and sugar streams for
product recovery and acid recycling. Purities are better than 98% and
concentrations are maintained high for both fractions of interest, 15% sugar
and 25% acid, which facilitates their efficient use.
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been of the most interest in such studies as it is inexpensive and effective. Dilute
H2SO4 has been used to commercially manufacture furfural from cellulosic
materials.74,75 Dilute H2SO4 is mixed with biomass to hydrolyze hemicellulose to
xylose and other sugars and then continues to break xylose down to form furfural.
The dilute H2SO4 pretreatment can achieve high reaction rates and
significantly improve cellulose hydrolysis. Dilute acid effectively removes and
recovers most of the hemicellulose as dissolved sugars, and glucose yields from
cellulose increase with hemicellulose removal to almost 100% for complete
hemicellulose hydrolysis. Hemicellulose is removed when H2SO4 is added and this
enhances digestibility of cellulose in the residual solids. High temperature in the
dilute-acid treatment is favorable for cellulose hydrolysis. Recently developed
dilute-acid hydrolysis processes use less severe conditions and achieve high xylan
to xylose conversion yields. Achieving high xylan to xylose conversion yields is
necessary to achieve favorable overall process economics because xylan accounts
for up to onethird of the total carbohydrate in many lignocellulosic materials.
Two types of dilute-acid pretreatment processes are typically used: a high-
temperature (T > 160 °C), continuous-flow process for low solids loadings (weight
of substrate/weight of reaction mixture ) 5-10%) and a low-temperature (T < 160
°C), batch process for high solids loadings (10-40%) The most widely used and
tested approaches are based on dilute sulfuric acid. However, nitric acid,
hydrochloric acid, and phosphoric acid have also been tested. Numerous plant
materia1s have been examined, including legume byproducts; reed canary grass;
corn (husks, cobs, and stover); mixed hardwood (10% map1e and 90% birch); and
hardwood bark from aspen, poplar, and sweet gum. Thompson et al. used dilute
H2SO4 to pretreat mixed hardwood and observed that the crystallinity index,
although not a function of pretreatment temperature, still increased as a
consequence of pretreatment. The removal of amorphous cellulose fractions,
leaving a more crystalline fraction behind, could explain this observation.
Addition of very dilute sulfuric acid (about 0.1% versus the 0.7-3.0% typical
for batch dilute-acid technology) in a flow through reactor configuration is effective
at acid levels lower than 0.1%. Despite achieving excellent hemicellulose sugar
yields and highly digestible cellulose with low acid loadings, the equipment
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Table 2.5 Selected bacterial and fungi strains for glycosyl hydrase production
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Acid Enzymatic
Criteria
Hydolysis Hydrolysis
Maturity 0 0
Product Conversion 1 -1
Capacity 1 -1
Treatment Process -1 1
Simplicity -1 1
Capital Expenditure -1 1
Operational Expenditure -1 1
Total -2 2
Based on the criteria above, hydrolysis process that choose as the treatment
before the fermentation is enzymatic hydrolysis. There are several benefits to use
enzymatic hydrolysis. Below shown the benefits of using enzymatic hydrolysis.
Basic treatment process. The treatment that suitable for using enzymatic
hydrolysis is liming the cellulose.
The process is simple because using bacterial and fungi as biocatalyst
Cost relatively cheaper than acid hydrolysis because chemical compounds
relatively expensive.
2.5.3. Fermentation
Ethanol fermentation is a biological process in which sugars are converted
by microorganisms to produce ethanol and CO2. The microorganism most
commonly used in fermentation process is the yeast, among the yeast,
Saccharomyces cerevisiae is the preferred choice for ethanol fermentation. This
yeast can grow on both simple sugars, such as glucose, and on the disaccharide
sucrose. S. cerevisiae has high resistance to ethanol, consumes significant amount
of substrate in adverse conditions, and shows high resistance to inhibitors present
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The input stream would be glucose, yeast, and water. The output stream is ethanol
and water. Output stream then will be centrifuged to recover yeast cells.
Parameter Value
Temperature 33oC
pH 4.5
Residence Time 20 h
2.5.4. Distillation
The recovery of ethanol from fermented media is predominantly performed
by distillation. Distillation refers to separation of mixtures of two or more chemicals
on basis of volatility difference, which is the ratio of the partial pressure to the mole
fraction in the liquid.
In order to produce fuel ethanol, wine must be purified to at least 95oC;
centrifuged wine is purified in the distillation and rectification columns, producing
hydrous (around9 3wt%) ethanol. The most common configuration of the
distillation columns is illustrated in Figure 2.6. Wine is fed at the top of column A1,
located between columns D and A. At the top of column D, volatile compounds are
removed, while vinasse which containsmostly water is obtained at the bottom of
column A.Ethanol-rich streams (phlegms) containing around 50wt% ethanol are
obtained at columns D and A. This first set of columns is called distillation. The
second set, comprised by columns B and B1, is named rectification. Phlegms are
fed to these columns, and the rest of the water is removed at the bottom of column
B1, while hydrated ethanol is produced at the top of column B.
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Figure 2.7. Simplified scheme of the distillation process for production of hydrated ethanol
(Source: Rapello, 2011)
Vinasse is used to pre-heat wine in the heat exchanger. Wine is also pre-
heated by heate xchange with ethanol vapor from the top of column B (Econdenser)
before it is fed into column A1 Vinasse is used in fertirrigation of the sugarcane
fields, promoting nutrients (mostly potassium) recycle. Fusel oil, a mixture of
organic compounds which has isoamyl-alcohol as its main component, is produced
as a side stream of columns B–B1.
This configuration of the distillation columns presents relatively high steam
consumption. Multiple effect operation of the distillation columns and production
of wine of higher ethanol content are some options to reduce steam consumption in
distillation.
2.5.5. Ethanol Dehydration
In order to be used in a mixture with gasoline in gasoline-driven engines,
ethanol must be concentrated to 99.3 wt%, at least. This purity must be
accomplished by means of alternative purification systems, since ethanol and water
form an azeotrope with ethanol concentration od around 95 wt%. the most common
dehydration systems used are azeotropic distillation with cyclohexane, extractive
distillation with monoethyleneglycol and adsorption on molecular sieves.
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Figure 2.8. Block Flow Diagram of Sugar and Ethanol Production from Sugarcane
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Figure 2.9. PFD of Sugar Production
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Figure 2.10. PFD of Bioethanol Production
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CHAPTER III
MASS AND ENERGY BALANCE
From process flow diagram in the previous chapter, mass balance energy
balance for this plant, mass balance and the energy balance is calculated for a day.
SuperPro Designer software is used as the simulation software. SuperPro Designer
is chosen to be the simulators of our plant because it defines biomass as its material
stream and proceed material. The SuperPro simulation is shown in Figure 3.1 to
Figure 3.5.
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Figure 3.4 SuperPro Simulation for Sugar Productio
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Figure 3.5 SuperPro Simulation for Bioethanol Productio
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3.1.2 Grinder 1
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3.1.3 Grinder 2
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3.1.4 Mills
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3.1.5 Extractor
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3.1.7 Heater 1
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3.1.8 Evaporator 1
Input Stream
Composition Molecular Weight (kg/kgmol) S-111
% Mass kg/hr % Mole kgmol/hr
Ash 200 0 0 0 0
Celulose 162,14 0 0 0 0
Glucose 180,157 0,704040216 490,41788 0,084102 2,72216944
Hemicellulose 132,12 0 0 0 0
KCl 74,543 0 0 0 0
Lignin 122,49 0 0 0 0
Sucrose 342,299 16,52704583 11512,352 1,039085 33,6324441
Sulfur Dioxide 64,059 0 0 0 0
Water 18,015 82,76891396 57654,8817 98,87681 3200,382
Total 100 69657,6515 100 3236,73661
Total Mass in Each Stream 69657,65152
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3.1.9 Evaporator 2
Input Stream
Composition Molecular Weight (kg/kgmol) S-113
% Mass kg/hr % Mole kgmol/hr
Ash 200 0 0 0 0
Celulose 162,14 0 0 0 0
Glucose 180,157 0,936605734 490,41788 0,119571 2,72216944
Hemicellulose 132,12 0 0 0 0
KCl 74,543 0 0 0 0
Lignin 122,49 0 0 0 0
Sucrose 342,299 21,98642285 11512,352 1,477296 33,6324441
Sulfur Dioxide 64,059 0 0 0 0
Water 18,015 77,07697141 40358,4172 98,40313 2240,2674
Total 100 52361,187 100 2276,62201
Total Mass in Each Stream 52361,18702
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3.1.10 Evaporator 3
Input Stream
Composition Molecular Weight (kg/kgmol) S-115
% Mass kg/hr % Mole kgmol/hr
Ash 200 0 0 0 0
Celulose 162,14 0 0 0 0
Glucose 180,157 1,218318675 490,41788 0,169654 2,72216944
Hemicellulose 132,12 0 0 0 0
KCl 74,543 0 0 0 0
Lignin 122,49 0 0 0 0
Sucrose 342,299 28,59951481 11512,352 2,096078 33,6324441
Sulfur Dioxide 64,059 0 0 0 0
Water 18,015 70,18216652 28250,892 97,73427 1568,18718
Total 100 40253,6619 100 1604,54179
Total Mass in Each Stream 40253,66188
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3.1.11 Evaporator 4
Input Stream
Composition Molecular Weight (kg/kgmol) S-117
% Mass kg/hr % Mole kgmol/hr
Ash 200 0 0 0 0
Celulose 162,14 0 0 0 0
Glucose 180,157 1,54324311 490,41788 0,240032 2,72216944
Hemicellulose 132,12 0 0 0 0
KCl 74,543 0 0 0 0
Lignin 122,49 0 0 0 0
Sucrose 342,299 36,22697828 11512,352 2,9656 33,6324441
Sulfur Dioxide 64,059 0 0 0 0
Water 18,015 62,22977861 19775,6244 96,79437 1097,73102
Total 100 31778,3943 100 1134,08564
Total Mass in Each Stream 31778,39427
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3.1.12 Evaporator 5
Input Stream
Composition Molecular Weight (kg/kgmol) S-119
% Mass kg/hr % Mole kgmol/hr
Ash 200 0 0 0 0
Celulose 162,14 0 0 0 0
Glucose 180,157 2,054696291 490,41788 0,391683 2,72216944
Hemicellulose 132,12 0 0 0 0
KCl 74,543 0 0 0 0
Lignin 122,49 0 0 0 0
Sucrose 342,299 48,23312506 11512,352 4,839248 33,6324441
Sulfur Dioxide 64,059 0 0 0 0
Water 18,015 49,71217865 11865,3746 94,76907 658,638614
Total 100 23868,1445 100 694,993228
Total Mass in Each Stream 23868,14451
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Table 3.14 Mass Balance for Crystalization Process for Input Stream
Input Stream
Composition Molecular Weight (kg/kgmol) S-121
% Mass kg/hr % Mole kgmol/hr
Ash 200 0 0 0 0
Celulose 162,14 0 0 0 0
Glucose 180,157 2,346294865 490,41788 0,513294 2,72216944
Hemicellulose 132,12 0 0 0 0
KCl 74,543 0 0 0 0
Lignin 122,49 0 0 0 0
Sucrose 342,299 55,07827805 11512,352 6,341753 33,6324441
Sulfur Dioxide 64,059 0 0 0 0
Water 18,015 42,57542708 8899,03098 93,14495 493,978961
Total 100 20901,8008 100 530,333574
Total Mass in Each Stream 20901,80085
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Table 3.15 Mass Balance for Crystalization Process for Output Stream
Output Stream
Molecular Weight
Composition S-123 S-122
(kg/kgmol)
% Mass kg/hr % Mole kgmol/hr % Mass kg/hr % Mole kgmol/hr
Ash 200 0 0 0 0 0 0 0 0
Celulose 162,14 3,9398205 490,41788 6,80637472 2,72216944 0 0 0 0
Glucose 180,157 0 0 0 0 0 0 0 0
Hemicellulose 132,12 0 0 0 0 0 0 0 0
KCl 74,543 0 0 0 0 0 0 0 0
Lignin 122,49 95,7027233 11912,8084 87,01802598 34,8023465 0 0 0 0
Sucrose 342,299 0 0 0 0 0 0 0 0
Sulfur
Dioxide 64,059 0,35745618 44,49515 6,175599304 2,46989453 100 8454,07943 100 469,280013
Water 18,015 100 12447,7214 100 39,9944104 100 8454,07943 100 469,280013
Total 20901,80085
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3.1.14 Centrifugator 1
Input Stream
Composition Molecular Weight (kg/kgmol) S-123
% Mass kg/hr % Mole kgmol/hr
Ash 200 0 0 0 0
Celulose 162,14 0 0 0 0
Glucose 180,157 2,346294865 490,41788 6,806375 2,72216944
Hemicellulose 132,12 0 0 0 0
KCl 74,543 0 0 0 0
Lignin 122,49 0 0 0 0
Sucrose 342,299 56,9941723 11912,8084 87,01803 34,8023465
Sulfur Dioxide 64,059 0 0 0 0
Water 18,015 0,212877112 44,49515 6,175599 2,46989453
Total 59,55334428 12447,7214 100 39,9944104
Total Mass in Each Stream 12447,72142
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Output Stream
Molecular Weight
Composition Sugar S-123
(kg/kgmol)
% Mass kg/hr % Mole kgmol/hr % Mass kg/hr % Mole kgmol/hr
Ash 200 0 0 0 0 0 0 0 0
Celulose 162,14 0 0 0 0 0 0 0 0
Glucose 180,157 0 490,41788 6,80637472 2,72216944 100 490,41788 100 2,72216944
Hemicellulose 132,12 0 0 0 0 0 0 0 0
KCl 74,543 0 0 0 0 0 0 0 0
Lignin 122,49 0 0 0 0 0 0 0 0
Sucrose 342,299 99,6279 11912,8084 87,01802598 34,8023465 0 0 0 0
Sulfur Dioxide 64,059 0 0 0 0 0 0 0 0
Water 18,015 0,3721 44,49515 6,175599304 2,46989453 0 0 0 0
Total 100 12447,7214 100 39,9944104 100 490,41788 100 2,72216944
Total Mass in Each
Stream 12447,72142
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3.1.15 Heater 2
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Table 3.16 Mass Balance for Rotary Drying for Input Stream
Input Stream
Molecular Weight
Composition Hot Dry Air Sugar
(kg/kgmol)
% Mass kg/hr % Mole kgmol/hr % Mass kg/hr % Mole kgmol/hr
Nitrogen 28,013 76,7 170,63892 99,97341 6,09141898 0 0 0 0
Oxygen 31.999 23,3 51,83686 0,026587 0,00161995 0 0 0 0
Ash 200 0 0 0 0 0 0 0 0
Celulose 162,14 0 0 0 0 0 0 0 0
Glucose 180,157 0 0 0 0 0 0 0 0
Hemicellulose 132,12 0 0 0 0 0 0 0 0
KCl 74,543 0 0 0 0 0 0 0 0
Lignin 122,49 0 0 0 0 0 0 0 0
Sucrose 342,299 0 0 0 0 99,6279 11912,8084 93,37336724 34,8023465
Sulfur Dioxide 64,059 0 0 0 0 0 0 0 0
Water 18,015 0 0 0 0 0,3721 44,49515 6,626632761 2,46989453
Total 100 222,47578 100 6,09303894 100 11957,3035 100 37,272241
Total Mass in Each Stream 12179,77932
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Table 3.16 Mass Balance for Rotary Drying for Output Stream
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3.1.18 Cooler
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Table 3.19 Mass Balance for Hydrolysis Process: Input Stream (1)
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Table 3.19 Mass Balance for Hydrolysis Process: Input Stream (2)
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3.1.20 Mixer
Input Stream
Molecular Weight
Composition Glucose 30.45% Sterilized Molasses
(kg/kgmol)
% Mass kg/hr % Mole kgmol/hr % Mass kg/hr % Mole kgmol/hr
Nitrogen 28,013 0 0 0 0 0 0 0 0
Oxygen 31.999 0 0 0 0 0 0 0 0
Ash 200 0,6037 93,62126 0,17142 0,4681063 0 0 0 0
Celulose 162,14 2,133 330,78927 0,747098 2,04014598 0 0 0 0
Glucose 180,157 30,4546 4722,85347 9,599959 26,2152093 100 490,41788 100 2,72216944
Hemicellulose 132,12 9,389 1456,02926 4,035688 11,0205061 0 0 0 0
KCl 74,543 1,1284 174,993 0,859666 2,34754437 0 0 0 0
Lignin 122,49 17,7726 2756,13975 8,2398 22,5009368 0 0 0 0
Sucrose 342,299 3,9071 11912,8084 12,74455 34,8023465 0 0 0 0
Sulfur Dioxide 64,059 0 605,91326 3,463748 9,45867497 0 0 0 0
Water 18,015 16,5966 2573,77631 52,31817 142,868516 0 0 0 0
Calcium Hydroxide 74,095 0,0645 10 0,049423 0,13496187 0 0 0 0
Carbon Oxide 44,01 0 0 0 0 0 0 0 0
Xylose 132 17,602 2729,68977 7,572781 20,679468 0 0 0 0
CaCO3 100,087 0,3484 54,03172 0,197691 0,53984753 0 0 0 0
Total 99,9999 27420,6455 100 273,076263 100 490,41788 100 2,72216944
Total Mass in Each Stream 27911,06334
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Output Stream
Composition Molecular Weight (kg/kgmol) Ca(OH)2
% Mass kg/hr % Mole kgmol/hr
Nitrogen 28,013 0 0 0 0
Oxygen 31.999 0 0 0 0
Ash 200 0,5852 93,62126 0,22071301 0,4681063
Celulose 162,14 2,0677 330,78927 0,9619327 2,04014598
Glucose 180,157 32,5865 5213,27135 13,644029 28,9373788
Hemicellulose 132,12 9,1012 1456,02926 5,1961895 11,0205061
KCl 74,543 1,0938 174,993 1,10687162 2,34754437
Lignin 122,49 17,2278 2756,13975 10,6092344 22,5009368
Sucrose 342,299 3,7874 605,91326 0,83461901 1,77012863
Sulfur Dioxide 64,059 0 0 0 0
Water 18,015 16,0879 2573,77631 67,362776 142,868516
Calcium Hydroxide 74,095 0,0625 10 0,06363478 0,13496187
Carbon Oxide 44,01 0 0 0 0
Xylose 132 17,0624 2729,68977 9,75040835 20,679468
CaCO3 100,087 0,3377 54,03172 0,25453914 0,53984753
Total 100,0001 15998,255 100 212,088224
Total Mass in Each Stream 15998,25495
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Table 3.21 Mass Balance for Fermentation Process for Input Stream
Input Stream
Molecular Weight
Composition S-131 Nitrogen
(kg/kgmol)
% Mass kg/hr % Mole kgmol/hr % Mass kg/hr % Mole kgmol/hr
Nitrogen 28,013 0 0 0 0 100 70508,8909 100 2517,00606
Oxygen 31.999 0 0 0 0 0 0 0 0
Ash 200 0,6037 93,62126 0,200639 0,4681063 0 0 0 0
Celulose 162,14 2,0677 330,78927 0,874445 2,04014598 0 0 0 0
Glucose 180,157 32,5865 5213,27135 12,4031 28,9373788 0 0 0 0
Hemicellulose 132,12 9,1012 1456,02926 4,723596 11,0205061 0 0 0 0
KCl 74,543 1,0938 174,993 1,006202 2,34754437 0 0 0 0
Lignin 122,49 17,2278 2756,13975 9,644325 22,5009368 0 0 0 0
Sucrose 342,299 3,7874 605,91326 0,75871 1,77012863 0 0 0 0
Sulfur Dioxide 64,059 0 0 0 0 0 0 0 0
Water 18,015 16,0879 2573,77631 61,23613 142,868516 0 0 0 0
Calcium Hydroxide 74,095 0,0625 10 0,057847 0,13496187 0 0 0 0
Carbon Oxide 44,01 0 0 0 0 0 0 0 0
Xylose 132 17,0624 2729,68977 8,863609 20,679468 0 0 0 0
CaCO3 100,087 0,3377 54,03172 0,231389 0,53984753 0 0 0 0
Ethyl Alcohol 46,049 0 0 0 0 0 0 0 0
Total 100 15998,255 100 233,30754 100 70508,8909 100 2517,00606
Total Mass in Each Stream 86507,14582
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Table 3.21 Mass Balance for Fermentation Process for Output Stream
Output Stream
Molecular Weight
Composition CO2 Vent Product
(kg/kgmol)
% Mass kg/hr % Mole kgmol/hr % Mass kg/hr % Mole kgmol/hr
Nitrogen 28,013 58,354 70508,8909 68,7631956 2517,00606 0 0 0 0
Oxygen 31.999 0 0 0 0 0 0 0 0
Ash 200 0 0 0 0 0,129 468,10628 0,016785746 2,3405314
Celulose 162,14 0 0 0 0 0,5622 2040,14597 0,090239621 12,5826198
Glucose 180,157 0 0 0 0 0,3987 1446,86894 0,05759758 8,03115583
Hemicellulose 132,12 0 0 0 0 3,0369 11020,50604 0,598217563 83,4128523
KCl 74,543 0 0 0 0 0,6469 2347,54437 0,225856779 31,4924858
Lignin 122,49 0 0 0 0 6,2006 22500,93682 1,317425766 183,696112
Sucrose 342,299 0 0 0 0 0,4878 1770,12864 0,037087314 5,17129364
Sulfur Dioxide 64,059 0 0 0 0 0 0 0 0
Water 18,015 0 0 0 0 67,5019 244951,5632 97,51515968 13597,0893
Calcium Hydroxide 74,095 0 0 0 0 0,0372 134,96187 0,013063164 1,82147068
Carbon Oxide 44,01 42,646 50320,6425 31,2368044 1143,3911 0 0 0 0
Xylose 132 0 0 0 0 0,4559 1654,35744 0,089883837 12,5330109
CaCO3 100,087 0 0 0 0 0,1488 539,84749 0,038682951 5,39378231
Ethyl Alcohol 46,049 0 0 0 0 20,394 74006,13024
Total 100 120829,533 100 3660,39717 99,9999 362881,0973 100 13943,5646
Total Mass in Each
Stream 483710,6306
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3.1.22 Centrigugator 2
Input Stream
Composition Molecular Weight (kg/kgmol) Product
% Mass kg/hr % Mole kgmol/hr
Nitrogen 28,013 0 0 0 0
Oxygen 31.999 0 0 0 0
Ash 200 0,129 468,10628 0,015051 2,3405314
Celulose 162,14 0,5622 2040,14597 0,080914 12,5826198
Glucose 180,157 0,3987 1446,86894 0,051645 8,03115583
Hemicellulose 132,12 3,0369 11020,506 0,536394 83,4128523
KCl 74,543 0,6469 2347,54437 0,202515 31,4924858
Lignin 122,49 6,2006 22500,9368 1,181274 183,696112
Sucrose 342,299 0,4878 1770,12864 0,033254 5,17129364
Sulfur Dioxide 64,059 0 0 0 0
Water 18,015 67,5019 244951,563 87,43726 13597,0893
Calcium Hydroxide 74,095 0,0372 134,96187 0,011713 1,82147068
Carbon Oxide 44,01 0 0 0 0
Xylose 132 0,4559 1654,35744 0,080595 12,5330109
CaCO3 100,087 0,1488 539,84749 0,034685 5,39378231
Ethyl Alcohol 46,049 20,394 74006,1302 10,3347 1607,11699
Total 100 362881,097 100 15550,6816
Total Mass in Each Stream 362881,0973
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Output Stream
Molecular Weight
Composition Light Phase Heavy Phase
(kg/kgmol)
% Mass kg/hr % Mole kgmol/hr % Mass kg/hr % Mole kgmol/hr
Nitrogen 28,013 0 0 0 0 0 0 0 0
Oxygen 31.999 0 0 0 0 0 0 0 0
Ash 200 0 0 0 0 1,0657 468,10628 0,67552616 2,3405314
Celulose 162,14 0 0 0 0 4,6448 2040,14597 3,63160642 12,5826198
Glucose 180,157 0 0 0 0 3,2941 1446,86894 2,31795902 8,03115583
Hemicellulose 132,12 0 0 0 0 25,0903 11020,506 24,0746883 83,4128523
KCl 74,543 0 0 0 0 5,3446 2347,54437 9,08938803 31,4924858
Lignin 122,49 0 0 0 0 51,2277 22500,9368 53,0185282 183,696112
Sucrose 342,299 0 0 0 0 4,03 1770,12864 1,49254317 5,17129364
Sulfur Dioxide 64,059 0 0 0 0 0 0 0 0
Water 18,015 76,7975 244951,563 89,42978698 13597,0893 0 0 0 0
Calcium Hydroxide 74,095 0 0 0 0 0,3073 134,96187 0,52571442 1,82147068
Carbon Oxide 44,01 0 0 0 0 0 0 0 0
Xylose 132 0 0 0 0 3,7665 1654,35744 3,61728826 12,5330109
CaCO3 100,087 0 0 0 0 1,2291 539,84749 1,55675804 5,39378231
Ethyl Alcohol 46,049 23,2025 74006,1302 10,57021302 1607,11699 0 0 0 0
Total 100 318957,693 100 15204,2063 100,0001 43923,4039 100 346,475315
Total Mass in Each
Stream 318957,6934
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Table 3.23 Mass Balance for Distillation Coloumn for Inlet Stream
Input Stream
Composition Molecular Weight (kg/kgmol) Product
% Mass kg/hr % Mole kgmol/hr
Nitrogen 28,013 0 0 0 0
Oxygen 31.999 0 0 0 0
Ash 200 1,0657 468,10628 0,015051 2,3405314
Celulose 162,14 4,6448 2040,14597 0,080914 12,5826198
Glucose 180,157 3,2941 1446,86894 0,051645 8,03115583
Hemicellulose 132,12 25,0903 11020,506 0,536394 83,4128523
KCl 74,543 5,3446 2347,54437 0,202515 31,4924858
Lignin 122,49 51,2277 22500,9368 1,181274 183,696112
Sucrose 342,299 4,03 1770,12864 0,033254 5,17129364
Sulfur Dioxide 64,059 0 0 0 0
Water 18,015 0 0 0 0
Calcium Hydroxide 74,095 0,3073 134,96187 0,011713 1,82147068
Carbon Oxide 44,01 0 0 0 0
Xylose 132 3,7665 1654,35744 0,080595 12,5330109
CaCO3 100,087 1,2291 539,84749 0,034685 5,39378231
Ethyl Alcohol 46,049 0 0 0 0
Total 100 43923,4039 2,228039 346,475315
Total Mass in Each Stream 43923,40386
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Table 3.23 Mass Balance for Distillation Coloumn for Outlet Stream
Output Stream
Molecular Weight
Composition Ethanol 93.6% Water 99.3%
(kg/kgmol)
% Mass kg/hr % Mole kgmol/hr % Mass kg/hr % Mole kgmol/hr
Nitrogen 28,013 0 0 0 0 0 0 0 0
Oxygen 31.999 0 0 0 0 0 0 0 0
Ash 200 0 0 0 0 0 0 0 0
Celulose 162,14 0 0 0 0 0 0 0 0
Glucose 180,157 0 0 0 0 0 0 0 0
Hemicellulose 132,12 0 0 0 0 0 0 0 0
KCl 74,543 0 0 0 0 0 0 0 0
Lignin 122,49 0 0 0 0 0 0 0 0
Sucrose 342,299 0 0 0 0 0 0 0 0
Sulfur Dioxide 64,059 0 0 0 0 0 0 0 0
Water 18,015 6,3275 4899,03126 14,72409796 271,941785 99,3872 240052,532 99,7593648 13325,1475
Calcium Hydroxide 74,095 0 0 0 0 0 0 0 0
Carbon Oxide 44,01 0 0 0 0 0 0 0 0
Xylose 132 0 0 0 0 0 0 0 0
CaCO3 100,087 0 0 0 0 0 0 0 0
Ethyl Alcohol 46,049 93,6725 72526,0076 0 1574,97465 0,6128 1480,1226 0,24063519 32,1423397
Total 100 77425,0389 14,72409796 1846,91643 100 241532,654 100 13357,2898
Total Mass in Each
Stream 318957,6934
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3.2. Energy Balance
Table 3.24 Overall Energy Balance
Energy In Energy Out
Equipment Requirenment
(kWh/h) (kWh/h)
Washing 3007,836 3007,858 -0,022
Grinding 1 2248,344 2681,609 -433,265
Grinding 2 2681,609 3028,221 -346,612
Milling 3028,221 2248,244 779,977
Extraction 2248,534 1648,634 599,9
Sulphitation 1179,136 1779,136 -600
Pump 1779,136 1779,922 -0,786
Heating HX-
1179,922 6974,215 -5794,293
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Extraction 1 6974,215 16351,433 -9377,218
Extraction 2 2994,405 10064,336 -7069,931
Extraction 3 926,315 8121,048 -7194,733
Extraction 4 1578,763 7334,521 -5755,758
Extraction 5 1194,448 3269,156 -2074,708
Crystallization 966,628 1348,104 -381,476
Centrifugation 367,309 391,455 -24,146
Rotary Dryer 374,019 106,512 267,507
Sterilization 23,705 35,177 -11,472
Cooler 35,177 8,659 26,518
Hydrolysis 487,194 564,102 -76,908
Mixer 373,964 373,964 0
Fermentation 388,256 603,529 -215,273
Centrifuge 423,458 452,226 -28,768
Distilation 294,079 1543,115 -1249,036
TOTAL 34754,673 73715,176 -38960,503
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η = 17.93%
3.4. Product Yield
Yield based on sugar and bioethanol, respectively is:
12,11875 𝑡𝑜𝑛/ℎ
𝑌𝑖𝑒𝑙𝑑𝑏𝑎𝑠𝑒𝑑 𝑜𝑛 𝑠𝑢𝑔𝑎𝑟 = × 100% = 13.85%
87,5 𝑡𝑜𝑛/ℎ
3,576825𝑡𝑜𝑛/ℎ
𝑌𝑖𝑒𝑙𝑑𝑏𝑎𝑠𝑒𝑑 𝑜𝑛 𝑏𝑖𝑜𝑒𝑡ℎ𝑎𝑛𝑜𝑙 = × 100% = 4.09%
87,5 𝑡𝑜𝑛/ℎ
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CHAPTER IV
CONCLUSION
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REFERENCES
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