FYDP Sem 2

KKKB 4844BIOPROCESS PLANT DESIGN PROJECT II

Lim Kah HuayA132816Low Bee Chan A132764Sonia Dilip Patel A/P Dilip Kumar A133115Fatin Atikah Binti Kassim A132739Jamilah Binti Ahmad A133159Muhammad Khairil Azim bin Abdullah A133275

PRODUCTION OF BIOETHANOL FROM GLYCEROL USING Enterobacter aerogenes TISTR1468

Group KB4

2

CONTENT

1. Introduction2. Summary of Production3. List of improvement work4. Heat integration5. PFD after heat integration6. Piping and Instrumentation7. P&ID after HAZOP8. Detailed Unit & Mechanical Design9. Waste Management10. Process Hazard Analysis11. Plant Layout12. Conclusion

SUMMARY OF PRODUCTIONSpecifications Description

Product Bioethanol

Microorganism used Enterobacter aerogenes TSITR 1468

Processes involved • Micro-aerobic fermentation• Stripping• Binary Distillation• Extraction• Flash Vaporization

Production basis (per hour) 3676.47 kg

Bioethanol sale price (RM / kg) 3.04

Return on investment, ROI 0.25

Payback period, PBP 3.46 years

Net present value, NPV RM 10.37 million

Discounted cash flow rate of return, DCFRR 0.19

Site location Pengerang, Johor3

List of Improvement Work

4

CHAPTERS PROBLEM CORRECTION DONE

Chapter 3 - PFD • Size of bioreactors in series doesn’t shows its effectiveness in improving productivity of fermentation process

• Mass flow rate of medium from distillation column to condensers and reboilers are too big

• Stream tables lacks of data

• Bioreactors arrangement in parallel

• Re-calculation of mass balance

• Edited stream table data

Chapter 5 - Heat integration

Mistakes in inlet and outlet temperature

Corrected pinch analysis with heat recovery integrated in PFD

To be continued…

5


Chapter 6 – Piping and Instrumentation

• Control loops with electrical signal were not drawn correctly and some loops were not complete

• Relief valve for after HAZOP study was not done

• Mistakes in P&ID drawing

• Complete drawing of controllers for the entire plant

• Sizing calculated and type of valve determined

• Improved drawing with second layer of safety incorporated

Chapter 7 – Detailed Process Design

Design calculation had some mistake since inlet and outlet of stream changed

All the design calculation had been calculated and redesign for all unit

Chapter 8 - Mechanical Design

The calculation for the design and mechanical drawing are not complete

All the calculation design and drawing AUTOCAD is done

…continueList of Improvement Work

To be continued…

6


Chapter 10 – Production Hazard Analysis

HAZOP was incomplete and did not consider P&ID

HAZOP done after complete P&ID drawing

Chapter 11 – Site Location and Plant Layout

Plant layout need to reconstruct, details were not drawn out clearly and wrong arrangement of unit operations in plant layout

Completed plant layout drawing

List of Improvement Work…continue

7

Temperature interval start with 0KW

start with 5.915445 kW

107.5 0

105.5 0.004115 -0.004115 0.004115 5.91133

92.9 0.33933 -0.343445 0.33933 5.572

92.5 2.262 -2.605445 2.262 3.31

77.5 2.01 -4.615445 2.01 1.3

67.5 1.3 -5.915445 1.3 0

52.5 -0.4455 -5.469945 -0.4455 0.4455

29.5 0.0824 -5.552345 0.0824 0.3631E-103

HEAT INTEGRATION

PROCESS FLOW DIAGRAM after Heat integration

8

Relief System

Spring-loaded relief valve Gas leaks when pressure

reaches 92-95%

Bursting disc (rupture disc) ‘engineered weak spot’ Low cost, leak tight, instantaneous

response , reliable operation

9

DESIGN OF RELIEF VALVELocation Type Function A (mm2)

F-101 Spring-loaded To prevent the rupture of vessel due to overpressure during process and

sterilization

20 921.57

F-102 Spring-loaded To prevent rupture of vessel due to overpressure during process and

sterilization

18 673.24

F-103 Spring-loaded To prevent rupture of vessel due to overpressure during process and

sterilization

21 879.60

C-101 Spring-loaded To avoid damage to C-101 due to overpressure

17 614.22


16 392.17


15 670.20


17 986.11

10

11P&ID after HAZOP

DETAIL UNIT & MECHANICAL DESIGN

i. Seed Fermenter, F-101

ii. Stripping Column, C-01

iii. Binary Distillation Column, C-102

iv. Extractive Column, C-103

v. Flash Drum, C-104

vi. Cooling Tower

vii. Heat Exchanger, E-103

12

Dimension layout of impeller design

Axial hydrofoil with 3 blades Pitched-blade impellerSource: Lightnin 2013

Source: Hayward Gordon Ltd. 2013

Source: Geankoplis 2013

DETAILED DESIGNLim Kah Huay(A132816)

13Fermenter layoutSource: iGEM 2010

Detailed Design FermentersDesign Parameters F-101 F-102 & F-103

Tank diameter, Dt 1.91 m 3.50 m

Tank height, Ht 5.72 m 10.49 m

Working volume, V 16.35 m3 100.86 m3

Design of Cooling Jacket

Height of jacket 2 m 3.5 m

Spacing between jacket and vessel wall

50 mm 50 mm

Overall heat transfer coefficient, U

500.63 W/m.°C 201 W/m.°C

Pressure drop, ∆P 0.42 kPa 0.16 kPa

Design of Impeller

Type of impeller Axial flow 3 blades hydrofoil

Axial flow pitched-blade 45°impeller

Impeller diameter, Da 0.98 m 1.05 m

Depth of impeller in vessel, H

1.96 m 3.50 mTo be continued… 14

15

Design Parameters F-101 F-102 & F-103

Height of impeller above vessel floor, C 0.65 m 1.17 mImpeller width, W 0.20 m 0.13 mLength of impeller width, L 0.25 m 0.26 mDiameter of impeller base, Dd 0.65 m 0.70 mBaffle width, J 0.16 m 0.29 m

Power number, Np 0.3 1.6

Flow number, Nq 0.55 0.85

Impeller speed 0.10 rps 0.01 rps

Power, P 0.3057 W 0.0008 W

Sparger ring diameter, Ds 1.08 m 1.15 m

Sparger location above vessel floor, S 0.49 m 0.53 m

Mixing time, tT 6.67 s 2041.06 s

Circulation rate, Q 0.05 m3/s 0.29 m3/s

…Continue

Detailed Design Fermenters

16

MECHANICAL DESIGNSEED FERMENTER, F-101

Process Description Microaerobic continuous fermentation with an aeration rate of 0.5

vvm, medium consistently mixed by agitator. Glycerol and ammonium phosphate serve as raw material of carbon

and nitrogen source respectively Fermentation output consists of bioethanol and carbon dioxide

Material of Construction Carbon Steel SA 537

17

Design Specifications Details

Operating Pressure 1 atm (15 psia)

Operating Temperature 37°C (310 K)

Corrosion Allowance 2 mm

Vessel Layout Vertical

H/D ratio 3:1

Volume 16.35

Torispherical Head (Top and Bottom Design)

Crown radius, R (m) 1.81

Knuckle radius, a (m) 0.19

Distance from the center of the torus to the center of the torus tube, c (m)

0.76

Height from the base of the dome to the top, h (m) 0.38

Cylindrical Shell (Shell Design)

Height, (m) 4.96

Effective Length, L (m) 5.21

18

Vessel Parts Dimensions (mm)

Torispherical Top 5.72

Cylindrical Shell 8.89

Torispherical Bottom 5.72

Overall 11

Minimum Wall Thickness

Design of Cooling JacketDesign Parameters Details

Type Type 1 (confined entirely to the cylindrical shell)

Closure Type (b-2)

Material of Construction Carbon Steel SA537

Jacket Space 50 mm

Required minimum thickness of closure member as determined ()

0.91 mm

Nominal thickness of closure member ()

2.91 mm

Corner radius of torus closures 5.84 mm

19

Stresses Details

Longitudinal stress, (N/ 4.83

Circumferential stress, (N/ 9.66

Direct stress, (N/) 0.6324

Bending stress, (N/)

Primary stresses

upwind (N/) 6.53

downwind (N/) 4.40

Maximum allowable stress intensity, Δσ (N/)

5.26

Design stress, S (N/) 157

Critical buckling stress, (N/) 1361.54

Combined Loading

Design of Vessel Support

20

Design Parameters Details

Type of support Bracket support

Type of bracket Double gusset Type 1

Type of beam Wide-flange

Number of legs 4

Vertical load per support leg,

47 kN

Area of base plate required,

7.55

Standard wide flange beam leg type base plate

W6

21

Flanged Joint Design

Design Parameters Details

Type of flanged joint Welding neck flange

Flange faces Gasket between bolt circle

Outside diameter of flange (mm)

Stream 2&4 – 107.95Stream 3&5 – 152.4Stream 1&6 – 228.6

DISTILLATION COLUMN (C-101)SONIA DILIP PATEL (A133115)

C-101

D-101

H-101

BIOETHANOLBIOMASSWATER

55% Bioethanol45%Water

WASTEWATER TREATMENT/ STILLAGE

S14

S16

S18 S17

S20

S19

S21

Parameter Dimension

Column design Tray

Diameter, DT (m) 1.913

Height, H (m) 9.772

Tray spacing(m) 0.457

Number of actual stages 17

Design of plate Sieve plate

Plate spacing (m) 0.457

Downcomer area 0.2725m2

Active area 1.726m2

Holes area, 0.173m2

Number of holes 880522

MECHANICAL DESIGN OF C-101SONIA DILIP PATEL (A133115)

• Material usedSS-308

• Properties

Source : MIT Department of Civil and Environment 1999

Element Content (%)

Iron, Fe 66

Chromium, Cr 20

Nickel, Ni 11

Manganese, Mn 2.0

Silicon, Si 1.0

Carbon, C 0.080

Phosphorus, P 0.045

Sulfur, S 0.030

Properties Metric

Density 8 g/cm3

Tensile strength 585 MPa

Yield strength 240 MPa

Poisson’s ratio 0.27-0.30

23

• Design parameter for C-101Parameter Value (SI unit) Value (English unit)

Temperature, T 100 OC 212 OF

Operating pressure (gage), P0 101.325 kPa 15 psig

Height of vessel , H 9.3262 m 367.1732’’, 30.5978’

Inside diameter of vessel, Di 1.91 m 75.1969’’,6.6224’

Height of cylinder shell, Hcylinder 7.772 m 305.9843”, 25.4987’

Height of torispherical heads, Htoris 0.3688 m 14.5197”, 1.2100’

Torispherical head

, CA = 3.46 mm

24

• Combine loading

Primary Stress Value (N/mm2)

Longitudinal stress, 3.6226

Circumferential stress, 7.2453

Direct stress , -0.7885

Bending stress, 1.84 x

∑ σmax<σ c

0.7885 N mm−2<154.64 N mm− 2

( Δσ )max<Sdesign

4.4112 N mm− 2<138 N mm− 2

Criterion met. Design is satisfied.

25

Vessel Support Straight Cylindrical skirt.

σ s (tensile )=σbs− σ ws

σ s (compressive )=σ bs+σ ws

M s=26 647.7635 Nm

σ bs=0.0009252 N /mm2

σ ws (test )=2.9155 N /mm2

σ ws (operating )=1.9386 N /mm2

= -

=

σ s (tensile )≤ f s J sinθ

−1.9377 ≤132.32

σ s (compressive )<0.125 EY ( t s

Ds)sin θs

1.9395 ≤ 130.8901

Criterion satisfied, 2 mm CA added. Final skirt thickness = 12 mm

26

• Base ring and Anchor Belt Design

= 1934 mm Nb = 4 bolts M s=5974.56 Nm = = 10.79 mm

Bolt size = nominal diameter (BS 4190: 1967) Bolt used = M24 with root area = 353 mm2.

• Flanged Joint

Welding Neck Flange

27

28

DISTILLATION COLUMN (C-102)LOW BEE CHAN (A132764)

Parameter Dimension

Column design Tray

Diameter, DT (m) 1.524

Height, H (m) 26.50

Tray spacing(m) 0.46

Number of actual stages 53

Design of plate Sieve

Plate spacing (m) 0.457

Downcomer area (m2) 0.146

Active area (m2) 0.925

Holes area (m2) 0.0925

Number of holes 4720

29

Mechanical Design Of Stripping Column C-102LOW BEE CHAN A132764

Process Description:Purify ethanol-water mixture to form azeotrope with 95.63% ethanol and 4.37% water (by weight)

Material Selection:Austenitic Stainless Steel 304L

Design Specification:• External pressure vessel• Cylindrical shell• Torispherical heads

31

Minimum wall thickness (mm)

Top and bottom heads 5.08

Cylindrical shell 15.24

Overall(standard) 18

Primary Stresses (N/mm2)

Longitudinal Stress, σL 2.1447

Circumferential Stress, σh 4.2894

Direct Stress, σw 6.65

Bending Stress, σb ± 46.66

)

Elasticity Stability (N/mm2)

; No Buckling

CYLINDRICAL COLUMN DESIGN

31

VESSEL SUPPORT DESIGNResultant Stresses (N/mm2)

<

STRAIGHT SKIRT SUPPORT

Skirt thickness (mm) 20

Skirt height (mm) 2000

Base Ring and Anchor Bolt Design

Number of bolts 12

Actual width 220mm

Minimum thickness 50mm

M56 bolts (BS 4190: 1967)

32

FLANGE DESIGN

ParameterS26feed

S27top

S29refluxed

S31bottom

S32reboiled

Flow rate (kg/s) 0.4233 4.314 3.356 1.054 4.314

Density (kg/m3) 846.389 1.507 770.216 796.255 1.429

Optimum diameter 34.103 614.71 97.20 54.47 625.19

Nominal pipe size 50.8 660.4 101.6 101.6 660.4

Flange class 150 150 150 150 150

Outside flange diameter, O

152.4 831.85 228.6 228.6 831.85

Thickness of flange, Tf 17.526 63.5 22.352 22.352 63.5

Diameter of hub, X 77.724 708.152 134.874 134.874 708.152

Chamfer beginning diameter, A

60.452 609.6 114.3 114.3 609.6

Length through Hub, Y 61.976 127 74.676 74.676 127

Bore 52.578 355.6 102.362 102.362 355.6

Number of bolts 8 8 8 8 8

• Welding Neck Flange

33

DESIGN SUMMARY

Parameter Value

Operating temperature 100

Operating pressure (atm) 1

Material of construction Austenitic stainless steel Type 304L

Vessel internal diameter (m) 1.524

Vessel height (m) 2.65

Type of head and bottom Torispherical

Type of vessel Cylindrical

Vessel wall thickness (mm) 18

Stress analysis (N/mm2) (Δσ)max S < , (7.7128 < 137.89) [Safe]

Elastic stability (N/mm2) < σ , (1.0921< 70.09) [Safe]

Type of vessel support Straight conical skirt

Type of flanged joint Welding neck flange

Flange faces Gasket between bolt circle

Flange diameter (mm) 50.8, 101.6, 660.4

34

Specifications H-101 H-103Pitch pattern Square pitch Square pitchBrass, kw (W/m°C) 110 110Floating head Split-ring Split-ring Shell pass 1 1Tube pass 4 4Number of tubes, Nt 998 1596Outer diameter, do(m) 0.0381 0.0381Inner diameter, di(m) 0.0168 0.0168Length of tubes, l (m) 5 7Tube pitch, Pt (m) 0.0125 0.0125Heat transfer area, A (m2) 596.96 1336.46Shell inside diameter, Ds (m) 1.915 2.335Baffle spacing, lB(m) 0.036 0.036Baffle cut, (%) 45 45Tube side coefficient, hi(W/m2∆°C) 12473.48 11138.26Shell side coefficient, hs(W/m2∆°C) 3310.721 1053.628Overall coefficient, Uo(W/m2°C) 991.88 603.28Tube side pressure drop, ∆Pt(kPa) 78.83 44.67Shell side pressure drop, ∆Ps (kPa) 1.47 14.36

CONDENSER DESIGN

35

KETTLE REBOILER DESIGN

Specifications H-102 H-104

Pitch pattern Square pitch Square pitch

Carbon steel, kw (W/m.°C) 55 55

Number of U tubes 404 374

Outer diameter, do(m) 0.022 0.0381

Inner diameter, di(m) 0.01688 0.0168

Length of tubes, l (m) 5 4

Heat transfer area, A (m2) 158.78 94.09

Baffle spacing, lB (m) 0.036 0.036

Baffle cut (%) 45 45

Tube side coefficient, hi(W/m2∆°C) 736000 734000

Shell side coefficient, hnb (W/m2∆°C) 28137.52 28565.69

Overall coefficient, Uo (W/m2°C) 1444 1239.23

Tube side pressure drop, ∆Pt (kPa) 174.89 168.6

Shell side pressure drop, ∆Ps (kPa) 14.59 14.36

36

EXTRACTIVE DISTILLATION COLUMN (C-103)JAMILAH AHMAD (A133159)

Material Carbon steel 516

Actual no of stages 27

Diameter of the column (m) 4.68

Height of the column (m) 21.19

CONDENSER H-105

Cooling water flow rate 11409.8

Area required 3.531 m2

Outside diameter 19.05 mm

Inside diameter 14.83 mm

Length 5 m

Number of tube 12

Diameter of the bundle, Db 0.11 m

Shell-side coefficient 1030.137 W/m2oC

Tube-side coefficient 8982.51 W/m2oC

Overall heat transfer cofficient, Uo 649.99 W/m2oC

Total heat load (kW) 771

Area required 6.3

Shell side coefficient

Overall heat transfer coefficient (W/m2oC)

496

Pressure drop (kPa) 12.1

KETTLE REBOILER H-106

37

MECHANICAL DESIGN EXTRACTIVE COLUMN

JAMILAH AHMAD (A133159)

INTRODUCTION

• Wall thickness required for the vessel

• Pressure exerted by the outside force weather the vessel can withstand or not.

• Type of top & bottom and shell used for the vessel

• Type of vessel support to withstand the vessel.

38

EXTRACTIVE COLUMN

Parts Value/Description

Main Part:•Vessel height•Diameter•Shell height•Top & bottom height•Thickness•Type of shell•Type of head & bottom•Material

• 21.49 m• 4.68 m• 19.15 m• 1.17 m• 30 mm• Cylindrical• Torispherical• Carbon steel 516

Support•Type•Material•Height•Thickness

• Straight skirt• Carbon Steel• 1.219 m• 30 mm

Flanges• Type of flange • Welding neck

39

Detailed Design of Flash Drum C-104KHAIRIL AZIM (A133275)

Inlet (S41)

Vapour Outlet (S42)

Liquid Outlet (S43)

h=1.219m

Dv=0.366

Flash drum C-104 is used to separate the vapour and liquid. For design calculations it is normally assumed that the vapour and liquid are in equilibrium and the vessel is adiabatic

Condition Value

Temperature 100 oC

Pressure 1 atm

Density of Water 958.4 kg/m3

Vapour Density 1.422 kg/m3

From the calculation,•The diameter must be large enough•The high of vessel outlet above the gas inlet should be sufficient for liquid drops.•Liquid level will depend on hold up time necessary for smooth operations and control

hv=0.283 m3

The conclusion from the calculation,Minimum vessel diameter,Dv = 0.366 mLiquid depth required,hv = 0.238 m3Height of the tank,H = 1.219 m

Mechanical Design of Flash Drum C-104KHAIRIL AZIM (A133275)

Parts Value/Description

Main Part:•Height•Diameter•Thickness•MAWPvessel

1.219 m0.366 m3.5 mm1.714 kPa


Conical skirtPlain Carbon Steel0.25 m3.5 mm

Flanges•Feed•Liquid•Vapour

Welding neckWelding neckWelding neck

Design Summary of C-104

41

Properties Value

Cooling water flow rate (kg/h) 105458

Water inlet temperature (°C)

37

Water outlet temperature (°C)

28

Ambient wet bulb temperature (°C)

23.9

Tower characteristic, KaL/V

1.5

Minimum tower area (m2)

17

Height of cooling tower (m)

10.4Source : HarrisonCooling Tower 2002

DETAIL DESIGN OF COOLING TOWERFATIN ATIKAH (A132739)

42

DETAIL DESIGN OF HEAT EXCHANGERNumber of tube 43

Length tube 4 m

Shell-Side Pressure Drop 78.94 kPa

Tube-Side Pressure Drop 1.84 kPa

Shell-side coefficient 63.94 W/m2oC

Tube-side coefficient 661 W/m2oC

Overall heat transfer cofficient, Uo

549.47 W/m2oC

Shell and Tube Exchanger

FATIN ATIKAH (A132739)

43

MECHANICAL DESIGN FOR HEAT EXCHANGER (E-103) Parts Value/Description

Main Part:•Vessel length•Height vessel•Inner diameter•Outer diameter

4.0 m0.267 m0.016 m0.02 m


Saddle support Carbon Steel 0.8 m0.15 m

Flanges Welding neck

Shell and Tube Exchanger

Saddle support Welding neck flanges

FATIN ATIKAH (A132739)

44

Faculty of Engineering and Built Environment

Department of Chemical and Biochemical Engineering

Project Title:

Production of Bioethanol from Enterobacter aerogenes

TISTR1468 using Glycerol

Activated Sludge Wastewater Treatment Plant (WWTP)

Drawn by:

LOW BEE CHAN

Group Member:

Date:

Drawing no.

GRPKB4/C2H6O/PFD/01

Prepared by:

Group KB4

Checked by:

27 MARCH 2014

PROF. DR. SAHAID KALILDR NORLIZA ABDUL RAHMAN

LIM KAH HUAY (A 132816)

LOW BEE CHAN(A 132764)

SONIA DILIP PATEL A/P DILIP KUMAR (A 133115)

FATIN ATIKAH BINTI KASSIM (A132739)

JAMILAH BINTI AHMAD (A133159)

MUHAMMAD KHAIRIL AZIM BIN ABDULLAH (A133275)

Symbol:

1 Stream number

Major Streamline

T-101 Flocculation Tank T-103 Aeration Tank T-104 Secondary ClarifierT-102 Primary Clarifier A-101 Air Blower T-105 Sludge Storage Tank

Check Pond

Wastewater from production

plant

Air

Flocculants and Coagulant

T-101

T-102T-103

A-101

T-104

T-105

1

2 3

4

5

7

8

9

10

6

WASTEWATER MANAGEMENT

ACTIVATED SLUDGE WASTEWATER TREATMENT PLANT PROCESS FLOW DIAGRAM

Stream 1

Flowrate(m3/day) 892.99

S,BOD (mg/L) 362422.7

X, SS (mg/L) 16792.5Stream 8

Flowrate (m3/day) 0.47

S,BOD (mg/L) -

X, SS (mg/L) 5850.5

Stream 7


S,BOD (mg/L) -

X, SS (mg/L) 5850.5

Stream 6


S,BOD (mg/L) -

X, SS (mg/L) 5850.5

Stream 5


S,BOD (mg/L) 362422.7

X, SS (mg/L) 5940.5

Stream 4


S,BOD (mg/L) -

X, SS (mg/L) 11775.7

Stream 3


S,BOD (mg/L) 362422.7

X, SS (mg/L) 5016.8

Stream 2


S,BOD (mg/L) 362422.7

X, SS (mg/L) 16792.5

Stream 10


S,BOD (mg/L) 45

X, SS (mg/L) 90

Stream 9


S,BOD (mg/L) -

X, SS (mg/L) 12290.9

Flocculation tank

Sludge storage tank

Aeration tank

Secondary clarifier

Primary clarifier

46.51 m3

60 min

93.02 m3

SL: 40m3/m2.day

188. 06 m3

Length: 8.17 mWidth: 3.8 mHeight: 3m

93.02 m3

Length: 9.3 mWidth: 5 mHeight: 2 m

45

46

PLANT LAYOUT

Process Hazard Analysis

Components Hazardous Properties

Glycerol • Flammable• Explosion• Toxic

Ammonium phosphate • Toxic

Oxygen • Flammable• Toxic

Ethanol • Fire• Explosion• Toxic

Carbon dioxide • Explosion• Toxic

Nitrogen • Toxic

Hazard IdentificationLegal Acts Requirement1. Environmental Quality Act

(EQA) 19742. Occupational Safety and Health

Act (OSHA) 19943. Factory and Machinery Act

(FMA) 1967

Methods for PHA:1. HAZOP analysis2. FMEA

Set of organized and systematic assessments of the potential hazards associated with an industrial process. A PHA provides information intended to assist managers and employees in making decisions for improving safety and reducing the consequences of unwanted or unplanned releases of hazardous chemicals.

47

FMEA method- Systematic process to identify potential failures to fulfill the intended function, to identify possible failure and locate the failure impacts- Example of the method is shown in Seed Fermenter F-101

Component Failure mode Failure effects Symptom Safeguard ActionLevel control valve

Valve fails openValve fails closed

Fluid will exceed the level of storage tank causing overflow and rupture the tank

Liquid overflow None Schedule inspection and maintenance required

Pure glycerol valve

Valve fails open No glycerol in the tank. Product produce does not meet the specification.

The reaction is not complete

None Daily check

Temperature control valve

Valve fails open High temperature in the tank. It will effect product reaction

No cooling water is supply to the tank

Low level alarm Daily check

Process Hazard Analysis

48

Component Failure mode Failure effects Symptom Safeguard Action

Heat exchanger Tube failure High pressure and

could cause a cause

a major fire

Odors at the

cooling tower

None Daily check and

schedule

maintenance

Centrifugal pump Pump stop Loss of power

which cause

mechanical failure

Risk of upstream

process pump

damage due to

overpressure

None Preventive

maintenance

Temperature

control valve

Heater failure Electric device

failure. Loss of

electric power

May cause over

temperature which

will rupture the

wall

None Schedule

inspection and

maintenance

Condenser(Cooler) Power failure Unable to cool the

outlet stream

Very high

temperature is

flowing out

None Back-up power

supply generator

Level control valve Valve fails open

Valve fails closed

Fluid will exceed

the level of storage

tank causing

overflow and

rupture the tank

Liquid overflow None Schedule

inspection and

maintenance

required

- FMEA analysis for Distillation Column C-101

49

PROCESS HAZARD ANALYSIS

HAZOP Analysis

• HAZOP Analysis is to identify how a process deviation can be prevented or mitigate to minimize the potential hazard. Example of the analysis is in the distillation column.

Project name : Process Plant Design

Process : Bio ethanol production

Part : Distillation Column

Study node Process parameterDeviations

(guide words)Possible causes Possible consequence Action required

Stream 28 Flow NO Pipe broken or plugging

Loss of feed into column/not achieve into desired output.

Level decrease in distillation column.Off specification product.

1. Schedule inspection and maintene.an

LOW 1. Pipe partial plugged or leakage.

1. Level decrease in distillation column.

2. Off specification product.3. Back flow of material.

Install check valve.

HIGH 1. High pressure from source

1. Flooding in distillation column. 1. Install bypass line with manual valve.

Distillation column Level HIGH 1. Output pipe blockage.

Overpressure of reflux drum.Condensed liquid flow back to

distillation.

1. Install high level alarm2. Scheduling inspection

LOW Pipe partial clogged & leakage. Level decrease in the vessel The valve closed.Back flow of material.

1. Scheduling inspection2. Install valve.

Temperature HIGH 1. Low incoming flow from H-101 cause overheating.

Off specification product.

Install temperature sensor.

LOW 1. H-101 malfunction.2. High incoming flow through H-

101.

Low level inside reboiler.Off specification product.

1. Scheduling inspection2. Install temperature sensor.

50

CONCLUSION

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A high yield and potential for ethanol as fuel from Enterobacter aerogenes. Pengerang has been the best location judging from the coming development as Asia’s largest storage terminal.

Production rate of 3276 kg/hr and high demand in 2018 (projection) will leave a very stable economic growth for ethanol.

65% saving of energy through pinch and heat exchanger installation will further bloom the net profit.

Mechanical calculations and drawings for main utilities provide a clearer insight of the sizing and supports.

Safety has been of top consideration through FMEA and HAZOP performed. Layers of control aspect will further enhance the safety and continuous operation of ethanol plant.

Waste management has been of top priority and calculations from waste treatment plant designed is able to lower down pollutants to allowable limits.

Date post:	07-May-2015
Category:	Engineering
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