Preliminary Design of Vanillin Production Plant From Black Liquor
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Table of Content
Table of Content ...................................................................................................... i
CHAPTER 1 ........................................................................................................... 1
INTRODUCTION .................................................................................................. 1
1.1 Plant Development Background .............................................................. 1
1.2 Plant Development Goal ......................................................................... 7
1.3 Plant Development Analysis ................................................................... 8
1.3.1 Raw Material Analysis ...................................................................... 8
1.3.2 Location Analysis ........................................................................... 12
1.3.3 Market & Capacity Analysis .......................................................... 16
CHAPTER 2 ......................................................................................................... 23
PROCESS DESIGN .............................................................................................. 23
2.1 Process Technology Selection ................................................................ 23
2.2 Process Description ................................................................................ 26
2.2.1 Type Of Process .............................................................................. 26
2.2.2 BFD and Description ...................................................................... 30
2.2.3 PFD and Description ....................................................................... 32
CHAPTER 3 ......................................................................................................... 36
MASS AND ENERGY BALANCE ..................................................................... 36
3.1 Mass Balance .......................................................................................... 36
3.1.1 Overall Mass Balance ..................................................................... 36
3.1.2 Mass Balance Process Units ........................................................... 37
3.2 Energy Balance ...................................................................................... 40
CHAPTER 4 ......................................................................................................... 45
UTILITIES ............................................................................................................ 45
4.1 Water Utility ........................................................................................... 45
4.1.1 Water Utility Classification ............................................................ 45
4.2 Electric Utility ........................................................................................ 46
4.3 Steam Utility .......................................................................................... 48
BAB 5 ................................................................................................................... 49
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SIZING ................................................................................................................. 49
5.1 Vessel .......................................................................................................... 49
5.1.1 Black Liquor Storage Tank (S-101) ................................................ 49
5.1.2 Acidification Tank (V-101) ............................................................ 50
5.1.3 Acidification Tank (V-102) ............................................................ 51
5.1.4 Blending Tank (V-103) ................................................................... 53
5.1.5 Lignin Slurry Storage (S-102)......................................................... 54
5.1.6 Waste Storage (S-103) .................................................................... 55
5.1.7 H2SO4 Storage (S-104) ................................................................... 56
5.1.8 NaOH Storage (S-105) .................................................................... 57
5.2 Filtration ................................................................................................. 58
5.2.1 Plate and Frame Filter (PF-101)...................................................... 58
5.2.2 Plate and Frame Filter (PF-102)...................................................... 59
5.3 Pump ....................................................................................................... 60
5.3.1 Black Liquor Pump (P-101) ............................................................ 60
5.3.2 Black Liquor Acidification pump (P-102) ...................................... 60
5.3.3 Lignin Acidification Pump (P-103) ................................................ 61
5.3.4 Lignin Solution Pump (P-104) ........................................................ 62
5.3.5 Lignin Solution Pump (P-105) ........................................................ 63
5.3.6 Vanillin Slurry Pump (P-106) ......................................................... 63
5.3.7 Vanillin Solution Pump (P-107) ..................................................... 64
5.3.8 Water Pump (P-109) ....................................................................... 65
5.4 Conveyor ................................................................................................ 66
5.5 Bubble Column Reactor .............................................................................. 67
5.6 Ultrafiltration ............................................................................................... 68
5.7 Spray Dryer ................................................................................................. 69
5.8 Heat Exchanger .......................................................................................... 70
5.8.1 Heat Exchanger HE-101 ....................................................................... 70
5.8.2 Heat Exchanger HE-102 ....................................................................... 70
CHAPTER 6 ......................................................................................................... 71
PROCESS CONTROL ......................................................................................... 71
6.1 Process Control Instrumentation ............................................................ 71
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6.2 Process Control on Raw Material Storage Tank .................................... 71
6.3 Process Control on Heat Exchanger ....................................................... 72
6.4 Process Control on Reboiler ................................................................... 72
6.5 Process Control on Black Liquor Treatment Vessel .............................. 72
6.6 Process Control on Acidification Vessel and Lignin Solution Vessel ... 73
6.7 Process Control on Oxidation Reactor ................................................... 74
6.8 Process Control on Spray Dryer ............................................................. 76
CHAPTER 7 ......................................................................................................... 82
PLANT LAYOUT AND PIPING DESIGN ......................................................... 82
CHAPTER 8 ......................................................................................................... 86
HEALTH, SAFETY, AND ENVIRONMENT MANAGEMENT ....................... 86
8. 1 Health Aspects ........................................................................................ 87
8. 2 Safety Aspects ........................................................................................ 87
8.2.1 Hazard Identification and Risk Assessment (HIRA) ...................... 87
8.2.3 Hazard Operability Study (HAZOP) of Vanillin Plant....................... 94
8. 3. Environmental Aspects .......................................................................... 99
8. 3. 1. Liquid Waste ...................................................................................... 99
8. 3. 2. Solid Waste ........................................................................................ 99
8. 3. 3. Waste Gas .......................................................................................... 99
8. 4. Risk Management ................................................................................... 99
8.4.1. Personal Protection Equipment.......................................................... 100
8.4.2. Fire extinguisher ................................................................................ 105
8.4.3. MSDS (Material Safety Data Sheet).................................................. 107
8.5. Quality Control in Vanillin Plant ............................................................. 107
CHAPTER 9 ....................................................................................................... 108
ECONOMIC ANALYSIS .................................................................................. 108
9.1 Plant Cost Estimation ................................................................................ 108
9.2 Annual Operating Costs ....................................................................... 113
9.2.1 Raw Material Costs ....................................................................... 113
9.2.2 Operating Labor Costs ................................................................ 115
9.2.3 Utilities Costs ................................................................................ 116
9.2.4 Total Direct Costs ......................................................................... 117
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9.2.5 Total Fixed Costs .......................................................................... 117
9.2.6 Plant Overhead .............................................................................. 117
9.2.7 Total Manufacturing Cost ............................................................. 117
9.2.8 Expenses Cost ............................................................................... 118
9.2.9 Total Operating Cost ..................................................................... 118
9.3 Equity ................................................................................................... 119
9.4 Investment feasibility Analysis ............................................................ 120
9.5.1 Cash Flow ..................................................................................... 120
9.5.2 IRR ................................................................................................ 122
9.5.3 Net Present Value (NPV).................................................................... 124
9.5.4 Pay Back Period .................................................................................. 125
9.5.5Break Event Point (BEP) ..................................................................... 125
9.5.6 Sensitivity Analysis ............................................................................ 126
APPENDIX ......................................................................................................... 129
1. Vessel ....................................................................................................... 129
1.1 Black Liquor Storage Tank (S-101) ................................................. 129
1.2 Acidification Tank (V-101) ............................................................. 130
1.3 Acidification Tank (V-102) .............................................................. 132
1.4 Blending Tank ( V-103).................................................................... 133
1.5 Lignin Slurry Storage (S-102) .......................................................... 135
1.6 Waste Storage (S-103) ...................................................................... 137
1.7 H2SO4 Storage (S-104)..................................................................... 138
1.8 NaOH Storage (S-105) ..................................................................... 140
2. Plate and Frame Filter .............................................................................. 141
2.1 Plate and Frame Filter (PF-101) ....................................................... 141
2.2 Plate and Frame Filter (PF-102) ....................................................... 143
3 Pump ........................................................................................................ 144
3.1 Black Liquor Pump (P-101)&(P-102) .............................................. 144
3.2 Black Liquor Acidification Pump (P-102) ....................................... 146
3.3 Lignin Acidification Pump (P-103) .................................................. 148
3.4 Lignin Solution Pump (P-104) ......................................................... 150
3.5 Lignin Solution Pump (P-105) ......................................................... 152
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3.6 Vanillin Slurry Pump (P-106) ........................................................... 154
3.7 Vanillin Solution Pump (P-107) ....................................................... 156
3.8 Water Pump (P-108) ......................................................................... 158
4 Bubble Column Reactor ........................................................................... 161
5 Ultrafiltrasi ............................................................................................... 163
6 Spray Dryer .............................................................................................. 165
7. Material Safety Data Sheet (MSDS) ........................................................ 171
REFERENCE ...................................................................................................... 174
Preliminary Design of Vanillin Production Plant From Black Liquor
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CHAPTER 1
INTRODUCTION
1.1 Plant Development Background
Vanillin (4-hydroxy-3-methoxybenzaldehyde) is the major flavor
constituent of vanilla. This organic compound possesses the aldehydic, etheric and
phenolic functional groups, and its molecular formula is C8H8O3 corresponding to a
molecular weight of 152.15 (Washburn, 2003). The chemical structure and geometry
of vanillin are presented in Figure 1.1. Some relevant physical properties of vanillin
are shown in Table 1.1.
Figure 1.1. Chemical structure (a) and geometry (b) of vanillin molecule.
Vanillin occurs widely in nature, especially in the cured beans of the tropical
Vanilla orchids. It is the major component among about 200 other flavor compounds
found in these beans (Walton et al., 2003). Isolated vanillin occurs in the form of
white needle-like crystalline powder with a pleasant aromatic vanilla odor and an
intensively sweet taste, which are the main reasons for its widespread demand.
Table 1.1. Physical properties of vanillin.
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Vanillin has a wide range of applications in food industry as a flavor agent
and in perfumery as an additive. Other applications are as chemical precursor in
the pharmaceutical industry, ripening agent, antifoaming agent in lubrication oils,
brightener in zinc coating baths, vulcanization inhibitor, and starting material for
insecticides and herbicides (Mathias, 1993; Villar et al., 1997).
There are around 150 varieties of vanilla, but only two of them are grown
commercially – Bourbon and Tahitian vanilla (McGregor, 2005). Vanilla has it
origins on Mesoamerican Mexico, with this country dominating the world
production until the late 19th century. Since then, the focus of development was
shifted to the former French colonies, in particular Madagascar, Comoros,
Reunion and Tahiti. Nowadays, vanilla is grown on numerous countries, with data
from 2005 indicating that Madagascar was the largest producer, accounted for
around 60% of the world production, followed by Indonesia and China, with 23%
and 10%, respectively. Looking at the last 20 years, the vanilla production has
oscillated between 1200 and 4000 tonnes, with a world consumption varying from
1800 to 3000 tonnes (McGregor, 2005).
The natural vanilla market is characterized by very volatile prices.
Normally the price pattern of vanilla is made up of high peaks and prolonged
periods of relatively low prices. These prices have been particularly sensitive to
events affecting a single country – Madagascar. From 1989 to 1995, the vanilla
market was regulated by the Univanille cartel, an alliance of vanilla exporters.
The major buyers and producers, principally Madagascar, met annually to
determine demand and export pricing. In Figure 1.2 is schematically shown the
evolution on the market prices of natural vanilla, since the early 1990’s to the first
half of 2005.
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Figure 1.2. Evolution of natural vanilla prices since the early 1990’s to 2005 (Jaeger (2005)
Vanilla does not consist of vanillin alone, but contain several tens of
aromatic compounds. For example, the vanilla world trade in 2001 (2300 tonnes)
represents less than 50 tonnes of natural vanillin (Loeillet, 2003), which only
constitutes a yield around 2%. Historically, the production of vanillin was its
direct extraction from vanilla beans. However, according to the constantly
increasing markets, new chemicals routes were developed. Synthetic vanillin
became widely used and competition of markets is longstanding and turns more
fierce when prices of natural vanilla rockets.
Vanillin was first produced by Haarmann and Reimer in the late 1800’s,
using guaiacol from phenol. This was the main route for more than 40 years, until
it was discovered that vanillin could be produced from lignin present in the waste
liquor of pulp and paper industry. The commercial production of vanillin from
lignin started in 1937. This process become the dominant one for many years,
with 80% supply ratio of the synthetic vanillin market (Triumph Venture Capital,
2004). However, in the 1980’s some changes in the processes of pulp and paper
Preliminary Design of Vanillin Production Plant From Black Liquor
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industry led to a decrease in the available raw material required by the vanillin
plants. The traditional calcium sulphite pulping process produced huge amounts
of disposable effluents, that combined with the growing public awareness on
environmental issues were leading to unsustainable waste treatment costs. These
mills started to close, or were converted to new technology that allowed the
recycling of the waste liquors for chemical recovery and thus making these by-
products streams not available for vanillin production. Since 1993, only
Borregaard was producing vanillin from lignin. Nowadays the synthesis of
vanillin from guaiacol accounts for 85% of the world supply, with the remaining
15% being produced from lignin (Triumph Venture Capital, 2004b).
Commercial users can choose between natural vanilla (very expensive and
used only in niche markets), synthetic vanillin and artificial vanilla flavor (ethyl
vanillin). Synthetic vanillin is a cost effective alternative to vanilla and is
increasingly substituting the natural product. It not only substitutes vanilla, but
also supplements adulterated vanillin extracts. Global demand for synthetic
vanillin currently is around 16000 tonnes per year. But guaiacol is petroleum
derivatives and it has been limited. Natural "vanilla extract" is a mixture of
several hundred different compounds in addition to vanillin. Artificialvanilla
flavoring is a solution of pure vanillin, usually of synthetic origin. Because of the
scarcity and expense ofnatural vanilla extract, there has long been interest in the
synthetic preparation of its predominant component. The first commercial
synthesis of vanillin start with the more readily available natural compound
eugenol today, artificial vanillin is made from either guaiacol or from lignin, a
constituent of wood which is a byproduct of the pulp industry, Lignin based
artificial vanilla flavoring is alleged to have a richer flavor profile than oil based
flavoring; the difference is due to the presence of acetovanillone in the lignin-
derived product.
Rhodia SA dominates the world vanillin market using the catechol-
guaiacol process. Rhodia entered the USA vanillin market in 1986 with the
purchase of the Monsanto plant. This plant was subsequently closed down in
1991. In November 1993, Rhodia purchased the ITT Rayonier vanillin business
and immediately closed the plant. After that, their main target has been China.
Preliminary Design of Vanillin Production Plant From Black Liquor
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Borregaard (Norway), the second largest vanillin producer, is the only remaining
producer of lignin. The company also has guaiacol vanillin and ethyl vanillin
production capacity as it acquired Eurovanillin in 1995 (Triumph Venture Capital,
2004). Borregaard mainly supplies the European market and its lignin vanillin
production is almost exclusively for large costumers under long-term contracts.
Lignin based vanillin is in high demand in certain market sectors,
particularly the perfume industry, European chocolate manufacturers, and the
Japanese market, and as such tends to command a price premium. The price of
lignin vanillin is consistently maintained at about $1.00 to $2.00 per kg above that
of guaiacol based vanillin (Triumph Venture Capital, 2004b). The ethyl vanillin
price follows the same basic trend as the vanillin price. It is maintained at about
twice that of vanillin, but as it has about three times the flavour intensity of
vanillin there is a cost saving associated with substituting vanillin with ethyl
vanillin.
The main source of pure lignin is the pulp and paper industry, where
nowadays the Kraft process prevails with approximately 80% of the world
chemical pulp production (Ullmann’s Encyclopedia, 2003). A by-product stream
of this process, known as black liquor, contains typically 30 to 34% of lignin in
dry solid weight basis. This stream is burned to provide energy for mill
operations, and to facilitate the recovery of pulping chemicals. Due to the
complex energetic integration of the Kraft process, an expansion in the production
of pulp implies a revamp in the burners. An alternative plant design to the burners
revamp will be a utilization of the increased amount of black liquor in the
production of high-added value products and the elimination of a production
bottleneck at the recovery boiler (Axelsson et al., 2006). In this work, the focus is
on the production of synthetic vanillin from lignin obtained from black liquor.
A flow sheet of a process to produce synthetic vanillin from lignin in a
pulp and paper industrial unit is proposed in Figure 1.2. A portion of the by-
product stream, black liquor, is processed to extract lignin. This extraction can be
done by the traditional acidification/precipitation followed by separation, or using
an improved method similar to one developed by a Swedish group and known as
LignoBoost (Öhman et al., 2006). After obtaining purified lignin, the subsequent
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process is based on three main steps studied in LSRE. The first step consists on
the alkaline lignin oxidation in a bubble column reactor, which is the main subject
of this thesis. Then, the mixture obtained in the reaction passes through a
membrane ultrafiltration process where the bigger molecules of degraded lignin
are retained. Sodium vanillate (salt of vanillin) and other low molecular weight
species goes to the permeate stream (Zabkova, 2006). Finally, the permeate
containing smaller molecules and excess NaOH flows through a packed bed on
acid resin in H+ form, in order to convert the sodium vanillate into vanillin
(Zabkova et al., 2007). This ion exchange step is accompanied by neutralization
reaction resulting in a lower pH for the product exit stream.
In order to have a reference point for the results to achieve, it is important
to refer a study developed in South Africa that revealed a benchmark final vanillin
concentration was 4.2 g/l, for a production process based on Kraft black liquors
(Triumph Venture Capital, 2004a). A process which final product has a
concentration below this value should not be very competitive in the present
scenario of the synthetic vanillin market.
Figure 1.3. Flow sheet of a process for vanillin production integrated in a pulp and paper mill
(Zabkova, 2006).
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In the wide scope of the forestry activities the black liquor is obtained as a
by-product of the pulp and paper industry. For this reason, this work deals with
this industry. Pulp and paper industries are unquestionably of great relevance to
the Indonesia economy. In fact Badan Pusat Statistik (BPS) noted that pulp export
from January until September 2011 had increased by 72,37% from 1,05 juta tonne
to 1,81 million tonne. Indonesia take 9th
place in the world in pulp production.
The total of pulp industry is 13 units, where 6 units is in Sumatera. The
production capacity is for about 6,5 million tonne pulp per year.
Black liquor is the main raw material for vanillin making from lignin.
Black liquor is obtained from one of the biggest pulp and paper industry in
Indonesia that loctaing in Riau, PT Riau Andalan Pulp & Paper. The available
side product capacity of pulp is 4.920.000 m3/year. Because of the large side
production of black liquor, PT Riau Andalan concern to process the black liquor
beside to use it as fuel. Therefore, PT Riau Andalan Pulp & Paper decide to make
Vanillin Plant based on lignin that use black liquor as the raw material. By see the
ability of black liquor production and the excellence compared to China in
product shipping cost, the vanillin product from this plant can compete with
competitive price with good margin profit. Beside to fulfill the needs of vanillin
demand in Indonesia, the development of this plant will also create new job
opportunity, expand the vanillin export, and give contribution for local
communities. This is the first vanillin plant from lignin in Indonesia, it is expected
to increase confidence and independence of this nation to apply knowledge and
technology in real life.
1.2 Plant Development Goal
Market increase, raise in energy prices and high volatility in natural vanilla
prices are a strong driving force to have a deeper understanding of alternative
methods to produce vanillin. Vanillin obtained from lignin can employ a low-
value fuel to produce a high-added value and also represents a “green process”,
since it is biomass-based.
The guaiacol process to produce vanillin employs benzene obtained from a
non-renewable source (petroleum). Within this context, the objective of this plant
is to design the plant of vanillin production from lignin and its implementation in
Preliminary Design of Vanillin Production Plant From Black Liquor
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Indonesia. The source of lignin should be black liquor from pulp and paper
industries using the Kraft process. In this work it was used lignin from softwood
Pinus spp., kindly supplied by PT Riau Andalan Pulp and Paper. The target of
vanillin production per day is 4500 kg or 1750 ton per year.
Needs of vanillin in Indonesia until this plant design was done is still filled
with synthetic vanillin imported from China. This vanillin factory has a useful life
20 years. We assume that vanillin needs always grow every years according to
projections import data we have collected. Until 2022 the vanillin needs of
Indonesia is still below 1750 ton / year. That’s way until that year this plant can
fulfill all of vanillin needs in Indonesia. Otherwise, in 2035 vanillin needs of
Indonesia can reach 12000 ton / year, and we predict that there will be another
vanillin plant from lignin to fulfill needs of vanillin, but with keeping the best
quality of vanillin this plant won’t lose the customer.
1.3 Plant Development Analysis
1.3.1 Raw Material Analysis
Vanillin (4-hydroxy-3-methoxybenzaldehyde) is organoleptically the
characteristic aroma component of the cured vanilla pod, where it contributes to
about 2% (w/w) of the dry matter (Priefert, H., Rabenhorst, J., & Steinbüchel, A.,
2001). It is used in a broad range of flavors for foods, confectionery, and
beverages (approximately 60%), as a fragrance ingredient in perfumes and
cosmetics (approximately 33%), and for pharmaceuticals (approximately 7%).
From the annual consumption of the world flavor market, only about 0.2%
originates from botanical sources (Krings and Berger 1998). There are 2 types of
commercially available vanillin. The first one is a natural vanillin extracted from
the vanillin pods and the second type is a pure vanillin chemically synthesized
from various chemical substrates. The price of the chemically synthesized
“nature-identical” vanillin is very low (about US$15 kg–1), compared to the price
of cured vanilla pods [between US$30 kg–1 and US$120 kg–1 (actual price)],
which usually contain about 2% (w/w) vanillin. The high price of “natural”
vanillin is mainly due to the limited availability of vanilla pods depending on
climate-associated fluctuations of harvest yields, economical and political
Preliminary Design of Vanillin Production Plant From Black Liquor
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decisions, and last but not least to the labor-intensive cultivation, pollination,
harvesting and curing of vanilla pods.
Vanillin can be produced from phenolic compounds such as phenolic
stibenes, guaiacol, lignin, isoeugenol, eugenol, ferulic acid, vanillic acid, aromatic
amino acid, sugar beet pulp, wheat straw and biomass substances (Vaithanomsat,
P., & Apiwatanapiwat, W. , 2009). The main portion is produced by chemical
synthesis from guaiacol and lignin (Priefert, H., Rabenhorst, J., & Steinbüchel, A.,
2001).
1. Guaiacol
Guaiacol is one of the raw material to produce vanillin which is derived
from petroleum. Rhone-Poulenc is the World’s largest producer of vanillin and
ethyl vanillin with a $60m turnover in these two products. The company has
concentrated on the guaiacol route. Production facilities are situated in Saint Frons
(France), which has been in operation since 1978 and in Baton Rouge, Louisiana
(USA), which was commissioned over a two-year period ending in mid-1992.
Combined capacities for vanillin and ethyl vanillin are estimated to be 3 000t and
5 000t respectively. Ube Industries in Japan also use the guaiacol route to vanillin
and ethyl vanillin. The company recently expanded their 1 000t manufacturing
facility by 400t and are understood to produce more or less equal volumes of both
vanillin and ethyl vanillin.
Chinese producers are thought to produce only vanillin, mostly via the
guaiacol route (total capacity 2 000t). Rhodia acquired in 2000 the existing
business of the Chinese company Xuebao Fine Chemicals Co. Ltd, one of the
most recent vanillin plant at that time. Rhodia shares its experience in vanillin
manufacture about environmental problem, involved higher toxicity of the raw
materials (guaiacol), unfavourable ecobalance (3 to 5 more tars and COD -
Chemical Oxygen Demand, and 5 times more VOC - Volatile Organic
Compounds, 1/3 of which benzene), non compliance with environmental
standards, high health & safety risks and unacceptable standards for a flavor.
Therefore, many manufacturers are trying to produce vanillin with raw materials
that are environmentally friendly and renewable, likes lignin.
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2. Lignin
The term lignin is derived from the Latin word for wood lignum. Lignin is
a major constituent in structural cell walls of all higher vascular land plants. Its
polyphenolic structure is well known for its role in woody biomass to give
resistance to biological and chemical degradation. Lignin is third component
macromolecule of wood associated kovalen with cellulose and hemicellulose. At
this time and future, the application of lignin has prospect. Lignin commercially
can be used as binder, filler, surfactant, polymer product, disperser and others
chemical raw, especially benzene derivate.
Figure 1.4 Sustainable industrial wood biorefinery operated by Borregaard, Norway (2010).
Lignin is a renewable raw material that could potentially be used as a raw
material in the manufacture of vanillin. This sustainable resource is to be used
within the biobased economy which is expected in the years to come to gradually
take a larger share compared to the fossil-based economy. The biobased economy
is not just the implementation of innovative technologies using renewable
resources, but it will be a real transition with a broad and high impact on society
at different levels (Langeveld and Sanders 2010).
The use of lignin as a raw material has the advantage in terms of
availability of raw material is abundant, especially in Indonesia. Lignin is an
organic compound produced by woody plants and Indonesia are rich of it. One of
lignin source which has abundant availability in Indonesia are oil palm empty fruit
bunches (PEFB). At present and for the future, Indonesia is one of the largest
palm oil producing country in the world that automatically as well as the world's
largest producer of PEFB. However, in the manufacture of vanillin, PEFB
Preliminary Design of Vanillin Production Plant From Black Liquor
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ineffective if used as a raw material because of the process is not possible. Initial
pre-treatment to get lignin from PEFB not support passage of vanillin plant. This
is because the process of getting lignin is too complicated and a lot of equipment
needed. Moreover, until now there has been none of plant that utilizes PEFB as
raw materials in Indonesia.
Another alternative that can be used as raw material is black liquor. Black
liquor is the waste produced by the pulp and paper plant. Black liquor availability
is very abundant in Indonesia because Indonesia is one of the largest paper
producers in Southeast Asia. Therefore, black liquor can be used as renewable raw
materials in the vanillin manufacture. PT. Riau Andalan Pulp and Paper is a pulp
and paper plant that produced black liquor in Indonesia. The plant can produce
4.92 million tons of black liquor per year. 10% of black liquor produced by this
plant can support the needs of vanillin for 20 years.
Not only that, the processing of black liquor into lignin is much more economical
compared with the processing of PEFB into lignin.
Based on the explanation above, it was concluded that the raw materials
used to produce lignin vanillin was obtained from black liquor.
Table1.2 Analysis of Selection Raw Material
No Considerations Factor PEFB Black Liquor
1 Raw material
availability
5 4
2 Distance traveled raw
materials
5 5
3 Substances in the
material and the quality
of the products
4 3
4 Materials processing
efficiency
1 4
5 Material prices 4 5
Preliminary Design of Vanillin Production Plant From Black Liquor
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1.3.2 Location Analysis
1.3.2.1 Raw Material Availability Aspect
Raw material availability aspect is the most influence aspect to decide the
location of the plant that we want to build. Relating to this aspect, plant
construction must near with the source of raw material to minimize the
transportation cost and also avoid production obstacle due to raw material supply.
Main raw material of vanillin plant is black liquor as waste of pulp and paper
production plant.
In Indonesia, The biggest pulp and paper industry is Riau Andalan Paper
and Pulp (RAPP) with production capacity about two million tonnes a year. As
one of the largest integrated pulp and paper mill in the world, black liquor as the
waste production is so much, around 4.920.000 m3 a year. RAPP locates in
PangkalanKerinci village, Langgam sub-district, Pelalawan Regency, Riau,
Sumatra.
Based on black liquor availability, we choose to build our plant in
Pelalawan Regency, Riau near RAPP plant. Actually, the black liquor of this plant
is used to production methanol as renewable energy and reduced consumption of
fossil fuel for their plant. On the other side, total mass of black liquor that we need
per day is 1000.5 tonnes or just about 0.007% from the total black liquor waste
production per day from RAPP. Therefore, we sure that RAPP will give the black
liquor as our raw material plant.
Figure 1.5, 1.6, and 1.7 show the location of RAPP and also location of
vanillin plant that we want to build in Riau.
1.3.2.2 Utility Needs Availability Aspect
The utility needs for vanillin plant is water, electricity, and fuel. The water
need is obtained PDAM and Kampar Kiri River near the plant. Meanwhile energy
fuel resource is obtained from Pertamina RU II Dumai which is distributed
through piping.Te electricity need is obtained from PLTA.
Preliminary Design of Vanillin Production Plant From Black Liquor
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Figure 1.5. Location of raw material avaibility and plant building
Source: BadanKoordinasi Survey danPemetaanNasional, 2002
Figure 1.6. Location of raw material avaibility and plant building
Source : googlemap.com
Riau Andalan Pulp & Paper
(Sumber Black Liquor)
Vanillin Plant
Riau Andalan Pulp & Paper
(Sumber Black Liquor)
Vanillin Plant
Preliminary Design of Vanillin Production Plant From Black Liquor
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Figure 1.7. Location of raw material avaibility and plant building
Source : googlemap.com
1.3.2.3 Product Marketting Aspect
Our consumer is food companies especially milk, chocolate, and ice cream
industy. Most of that company locates in Cikarang industrial area.Some of the
biggest company are Unilever, Nestle, Diamond, and Campina.Vanillin product
will be distributed via land and sea transportation.Based on market place above,
vanillin plant in Pekanbaru, Riau is not too strategic because far from food
company target. We need more cost to distribute vanillin product. However, if we
compare with choosing to build vanillin plant near the market target, cost for
distribute vanillin product from Riau to Cikarang is lower than cost for deliver
raw material from riau to Cikarang.
Vanillin Plant
Riau Andalan Pulp & Paper
(Sumber Black Liquor)
Preliminary Design of Vanillin Production Plant From Black Liquor
15
1.3.2.4 Transportation Aspect
Transportation in our plant is need to support our process production plant,
mainly for supply the supporting material and distribution the vanillin to the target
marketing. From the figure 1.4.3, we can looked that our plant is near with east
main road Jambi-Riau. Our plant also near with the Kampar Kiri River. For, the
air transport, our plant is near with the Sultan SyarifKasim II Airport in
Pekanbaru. Therefore, from the transportation aspect, our plant location is
strategic.
1.3.2.5 Social and Environment Aspect
1. Geographic Aspect
Pelalawan regency is one of ten regency in Riau Province and
located at 00o46,24’ LU - 00
o24,34 LS dan 101
o 30,37’-103
o21,36’
BT.Pelalawan has area about 13.256,7 km2danborders to the following
area.
a. North : Siak regency
b. South :IndragiriHuluand Indragiri Hilirregency
c. West : Kampar danIndragiriHulurengency
d. East :Karimun, Kepulauan Riau province, Bengkalis regency
Pelalawan regency topography consist of lowland and hill, which
the lowland is about 93% from total area of Pelalawan Regency. Ground
characteristic from certain parts are organic ground and acidic with
brackish ground water. The humidity and temperature quite high. In
general, Pelalawan regency is suitable use for plant construction because
the ground structur is flat, not bumpy, and near with water resource.
2. Social Aspect
The number of residents in regency Pelalawan based on survey in
2009 (BPS, 2009) is 280.197, consist of 145.442 are men (51,54%) and
134.775 are women (48,46%). Majority residents are moslem (257.447
people) and the others are Protestan, Katolik, Hindu, and Budha.
3. Labor Aspect
The occupation of Pelalawan regency residents is quite diverse.
There are businessman, farmer, fisherman, labor, and others. The
Preliminary Design of Vanillin Production Plant From Black Liquor
16
availability of labor is quite big due to Riau province have many Industry
and residents. Therefore we can quite easily get the labor.
1.3.3 Market & Capacity Analysis
Vanillin is a versatile, well-established aroma chemical used mostly as a
flavourcompound. The total world market is estimated at 10,500 tons per annum.
Themajor applications are in the manufacture of chocolate and ice cream, with
smallerquantities used in baked goods and confectionery. Vanillin can also be
used as a fragrance and fixative in perfumes, cosmetics and other fragrance
mixtures. It is alsoused as a pharmaceutical intermediate.Commercial users can
choose between natural vanilla (very expensive and used onlyin niche markets),
nature-identical vanillin (guaiacol or lignin vanillin), and artificialvanilla flavour
(ethyl vanillin).
Figure 1.8 Vanillin Use for Flavour Market
Source : www.nedlac.org.za/media/5959/industry.pdf
Natural vanilla flavouring, produced from the pod of the vanilla orchid by
extraction of the aroma compounds with ethanol, constitutes less than 5% of the
world market. Natural vanilla contains both vanillin and a range ofother aroma
chemicals, which in total are responsible for the full flavour of true vanilla.
Natural vanilla is considerably more expensive than synthetic vanillin by afactor
of 10.
Synthetic vanillin is produced on a commercial scale using two distinct
technologies.Vanillin produced by the different process routes has different
flavour profiles.Consumer preference ultimately drives demand for the different
vanillin products. Incertain applications, particularly the perfume industry,
Preliminary Design of Vanillin Production Plant From Black Liquor
17
European chocolate manufacturers, and the Japanese market, lignin vanillin is
preferred over guaiacolvanillin. As is the case with most aroma chemicals used in
the flavour industry,companies are reluctant to change from current suppliers as
the organoleptic profilewill also change.
The world demand for vanillin in its major applications is as follows: The
world demand for vanillin in its major applications is as follows:
Table 1.3 Vanillin World Demand Applications
Source : www.nedlac.org.za/media/5959/industry.pdf
Vanillin is a mature market, and the market is growing steadily,
anticipated to be 2–3% over the next few years. Flavour and fragrance
applications continue to expandin line with demographics and increases with
disposable income. As a result, thegrowth in consumption of vanillin in flavour
and fragrance products is growing at 4%in developing nations, in comparison to
2% in developed regions.Vanillin for many years was used as an intermediate for
2,3,5-trimethoxybenzaldehyde, which itself is an intermediate for the drug
trimethoprim.This product is now however manufactured almost exclusively in
China using thecheaper gallic acid route. In the 1980’s the use of vanillin as a
pharmaceuticalintermediate in the production of drugs such as L-methyl dopa
declined. It has nowlevelled to approximately 10% of total vanillin demand. In
Europe, the use of vanillinas a pharmaceutical intermediate appears to be captive
to Rhodia. The globaldemand for vanillin is estimated as follows:
Preliminary Design of Vanillin Production Plant From Black Liquor
18
Tabel 1.4 World Demands for Vanillin
Source : www.nedlac.org.za/media/5959/industry.pdf
The high cost of production and natural vanillin causes the industries of
vanillin consumer (foods and drinks, pharmaceuticals, and perfumes) in Indonesia
prefer to choose using synthetic vanillin which is imported from other countries.
Based on literature that we have learned, there is several reasons Indonesia has to
import synthetic vanillin. Firstly, in agricultural areas that producing vanilla beans
such as Jawa Tengah, Jawa Timur, Bali, Nusa Tenggara Timur, Sulawesi Utara,
Lampung, and Sumatra are found the pest of vanillin called Busuk Batang Vanili
(BBV). It is the primary diseases and became one of problems in Indonesia’s
vanillin production since 1960 (Soetono 1962; Hadisutrisno et al. 1967; Risfaheri
et al. 1998). BBV has destroyed vanilla plants in production areas so it causes
loosing of billions of rupiahs every years. The loss that caused by BBV in 1991 is
predicted almost Rp 32 billions (Untung, 1992). The damage of vanillin plants
caused by BBV In Bali is almost 80% (Sedhana, 1996). The consequences are the
cost of vanillin natural is so much expensive and not sold in Indonesia’s markets
so the natural vanillin products is exported to many countries. In the other hand,
vanillin needs in Indonesia is fulfilled by synthetic vanillin product import that
much cheaper.
Literally, the good or bad market qualities from vanillin commodities, is
not only determined by the vanilla qualities. There is many things that determine
the vanillin quality markets, they are farmer, collector, wholesaler, processor,
importir and also the marketing models that used in market systems. This case
also causes synthetic vanilin cost that imported by Indonesia is so expensive. Price
of natural vanillin producton the marketis 3-4 times the price of synthetic vanillin. Price
Preliminary Design of Vanillin Production Plant From Black Liquor
19
of natural vanilla extract U.S.$ 30-60 per gallon, while the priceof synthetic vanillin
U.S.$10-15 pergallon(Schultz, 2005, referenced inMelawati2006).
Synthetic vanillin prodution is predicted about 3000 tonnes per year,
whereas the global market demand of synthetic vanillin reaches 3500 tonnes.
Along with the development of food and drink and pharmaceutical industries, the
demand of synthetic vanillin will always increase with velocity 8-9% per year
with the market target in USA 27 %, Eropa 45 %, Asia 21 % and others 7 %. For
saving the foreign exchange and decreasing the dependence of vanillin import, so
the production of synthetic vanillin with efficien process technology and high
quality product is needed. This indicates that the vanillin market in Indonesia is
big enough.
In the future, we predict that the interest of people in Indonesia for the
products such as ice cream, chocolate and the others semi-luxury foods FMCG
owns like Wall’s, Campina, Diamond, Nestle and others will increase too.
Moreover, today, the cake factories in big cities have increased so big. This case
is supported with three reasons. Firstly, the facts that the economic growth is
stable enough and will increase straightly. It will effect the amounts of middle
class people in Indonesia which has high purchasing power is increased too.
Finally, the semi-luxury food products that contains vanilla will be more
affordable and demand will increase continously. Secondly, the aggresiveness of
large FMCG campanies in Indonesia causes their volume increases continously.
As a result, demand forvanillaas one of theraw materialswould be even greater. The last
reasonis that Indonesiais havingstyle trendsof consumerismwhere the need forfood and
beverageis notanymorelimited tostaplefoods anddrinksbut also thesemi-luxury foods and
drinksthat tendimpulsive. Wetried tomap thelocation ofplant semi-luxuryfood and
beverage productsthat wil be our prospective customers. Someof these companiesare
listed in Table 1.5 below.
Preliminary Design of Vanillin Production Plant From Black Liquor
20
Table 1.5 FMCG Companies
No Companies Products
1 Wall's
Ice Creams : Magnum, Paddle Pop,
Vienetta, Cornetto, Buavita, etc
2 Campina
Ice Creams: Concerto, Hula-Hula,
Tropicana, Bazooka, etc
3 Diamond Ice Creams
4 PT IndoMeiji Diary Food Ice Creams
5 PT Ceres Chocolates
6 PT Cadbury Indonesia Chocolates
7 PT Nestlé Indonesia
Coffees (Nescafe), Milk (Milo,
Carnation), Candies (FOXS)
Needs of vanillin in Indonesia until this plant design was done is still filled
with synthetic vanillin imported from China. This vanillin factory has a useful life
20 years. We assumed that vanillin neededs always grow every years according to
projections import data we have collected. Thus the amount of vanila needed each
year until 2035 (according to the useful life on the plant) can be calculated.
Table 1.6 Vanillin Needs in Indonesia
Code Commodity 2007 2008 2009 2010 2011 Trend
291241 Vanillin (4-hydroxy-3-
methoxybenzaldehyde)
2,413.8 3,320.5
3,165.4
4,564.1
3,873
13.47
Preliminary Design of Vanillin Production Plant From Black Liquor
21
Figure 1.9 Curve Vanillin Needs in Indonesia
Prediction and calculation needs vanillin until 2035 are shown in Table 1.7
below.
Table 1.7 Value of Imported Vanillin in 2015-2035
Years
Indonesian
Imported
Vanillin (ton)
Years Indonesian Imported
Vanillin (ton)
2011 288 2023 1868
2012 336 2024 2183
2013 393 2025 2551
2014 459 2026 2981
2015 537 2027 3484
2016 627 2028 4072
2017 733 2029 4759
2018 857 2030 5562
2019 1001 2031 6501
2020 1170 2032 7597
2021 1367 2033 8879
2022 1598 2034 10377
2035 12128
Vanillin factory will be built in 2013-2015 and began operating in 2015.
The factory is designed to meet 53% requirement of vanilla in 2025. Because
production in 2015-2035 produced about 4.5 tons per day. Amount of excess vanillin
y = 4E-133e0.1559x R² = 0.8783 0
1000
2000
3000
4000
5000
6000
2006.5 2007 2007.5 2008 2008.5 2009 2009.5 2010 2010.5 2011 2011.5
Preliminary Design of Vanillin Production Plant From Black Liquor
22
which we produce will be exported to Australia so the factory will not be lossin the
beginning of the operation. The production capacity of the factory is shown in the table
1.8 below.
Table 1.8 Production Capacity 2015-2035
Years
Demand of
Vanillin in
Indonesia
(ton)
Plant
Production
Capacity (ton)
Excess of
Production (ton)
2013 393 Building Plant
2014 459 Building Plant
2015 537 1350 813
2016 627 1350 723
2017 733 1350 617
2018 857 1350 493
2019 1001 1350 349
2020 1170 1350 180
2021 1367 1350
2022 1598 1350
2023 1868 1350
2024 2183 1350
2025 2551 1350
2026 2981 1350
2027 3484 1350
2028 4072 1350
2029 4759 1350
2030 5562 1350
2031 6501 1350
2032 7597 1350
2033 8879 1350
2034 10377 1350
2035 12128 1350
Thus, the plant design for the production of synthetic vanillin from lignin can
bedone, because the assessment can be realized technically and financially
feasible. Feasibility is a projection that could change if the price of raw material
or product prices fluctuate, so it is recommended to do innovation processes to
reduce production costs and still prioritize the qualities of synthetic vanillin.
Preliminary Design of Vanillin Production Plant From Black Liquor
23
CHAPTER 2
PROCESS DESIGN
2.1 Process Technology Selection
In the manufacture of vanillin, a process that is needed is a method of
decision LignoBoost. Lignin from black liquor and high temperature oxidation
process in a reactor that will produce vanillin. In addition to the method above
methods, other ways that are often used in the making of the balck liquor lignin,
which Organosolv method using alcohol. Organosolv method is the technology
used to convert biomass into compounds lignosellulosic the compound cellulose,
lignin, and hemicellulose (Mosier et al., 2005). These technologies include
enzymatic fractionating by cellulases and chemical hydrolysis by hot water
treatment, steam explosion, ammonia fiber explosion, dilute or concentrated acid
hydrolysis, alkaline treatment and organosolv processes. While Organosolv
process itself means the use of ethanol in the pre-treatment process in biorefinery
useful to recover the desired multiple lignin products.
While LignoBoost is a method of making lignin extraction from black
liquor using a compact cake or pellets and products can be used for biofuels or
raw material for the chemical industry. LignoBoost works in conjunction with
evaporation. It all starts with being precipitated lignin from the black liquor by
lowering the pH with CO2. The precipitate is then dewatered using a filter press.
LignoBoost then overcomes conventional sodium filtering and separation
problems by redissolving the lignin in spent wash water and acid. The resulting
slurry is dewatered and washed once again, with acidified wash water, to produce
virtually pure lignin cakes. The lignin can be exported or, after the final drying, be
used as fuel in the lime kiln.
Preliminary Design of Vanillin Production Plant From Black Liquor
24
Figure 2.1 Proses Lignoboost
Table 2.1 Scoring Process of Lignin Production
Parameter
Retention
Time
(30%)
Process
Handling
(10%)
Cost
(40%)
Concentration
Obtained
(20%)
Total
Organosolv
Process 1 1 3 1 1.8
LignoBoost
Process 4 3 1 4 2.7
Retention time is the length of time used in the process of making lignin.
The greater nilainy, means less time spent in the process. Conversely, the more
time spent, indicating the smaller value given. In the references we get, the time
used to process more than one day Organosolv in a single batch. Meanwhile,
LignoBoost Process only requires 4 hours in a single batch.
Handling Process is how easy the process was done. In a reference point
that we get, Organosolv mixing process using the process at every stage of the
process used to be done so that the guard is large enough. Meanwhile, LignoBoost
Process conducted in a reactor so that maintenance is done not so great. Cost is
Preliminary Design of Vanillin Production Plant From Black Liquor
25
how inexpensive process. Process Organosolv use only simple tools are used so
the cost is not expensive. Otherways, LignoBoost Process using a mixing tank
used so the cost is very expensive. Obtained Concentration is how much product.
With a very high price, LignoBoost Process can use the tank so that the results can
be produced very much.
The next process is the process of making lignin into vanillin. In the
manufacture of vanillin tool used is oxidation reactor. Reactor oxidation can be
used in a continuous or batch mode. Continuous process is usually done to reduce
the area of the plant so that the plant will be used more efficiently. In contrast,
batch processes are used to meet the needs of the production of very large so the
existing plant will be larger wide area.
Table 2.2 Scoring process in Oxidation Reactor
Parameter
Process
Time
(30%)
Process
Handling
(10%)
Cost
(20%)
Concentration
Obtained
(30%)
Mass
Transfer
(10%)
Total
Batch
System 2 2 2 3 3 2.4
Continous
System 3 3 3 1 1 2.2
According to the tables above our team will choose is a batch process
Because of five parameters. Parameters that we choose is big factor in building a
plant. There are Process time, process handling, cost, consentration obatained, and
mass transfer. If the value of retention time is high, it means retention time of that
process happen in not a long time. Otherwise we if the retention time is low, it
means we need a long time in the process. In a batch system, process time need 12
hours a day. While in Continuous System, it takes time in one process can not be
calculated Because every second of BCR will produce.
If the value of the cost is high, it means the process is cheap and if low, it
means the process is expensive. Batch system is more expensive than continuous
process Because in batch system, the area will be very huge to cover capacity of
the plant. If the value of concentration obtained is high, it means we have a big
Preliminary Design of Vanillin Production Plant From Black Liquor
26
product in that process, and if low it means the product is small amount. Batch
system will produce until 0871 amounted to 0.7 g / L, while, for the continuous
process is 0.56 until 0.67 g / L. Mass transfer describe the amount of movement of
a substance that will the make the process efficient. High value is big mass
transfer, low mass transfer value is small. Batch system will result in a greater
mass transfer due to the mass of those who dwell in the reactor.
2.2 Process Description
2.2.1 Type Of Process
In vanillin production process, there are two primary stages to
producevanillin from black liquor. Black liquor contains typically 30 to 34% of
lignin in dry solid weight basis. Lignin should be extracted from black liquor with
LignoBosstprocess and continued with conversion of lignin to vanillin.
Figure 2.2 Diagram of vanillin production process
2.2.1.1 Lignin Extraction from Black Liquor
LignoBoost is a complete system that extracts ligninfrom Kraft black
liquor.LignoBoost works in conjunction with evaporation.In the LignoBoost
process, a stream of black liquor is taken from the black liquor evaporation plant
(Fig. 2.2), then lignin is precipitated by acidification (the preferred acid is CO2)
and filtered (“chamber press filter 1”, Fig. 2.2).Instead of washing lignin
immediately after filtration, as in traditional processes, the filter cake is re-
dispersed and acidified (“cake re-slurry”, Fig. 2.2). The resulting slurry is then
Preliminary Design of Vanillin Production Plant From Black Liquor
27
filtered and washed by means of displacement washing (“chamber press filter 2”,
Fig. 2.2). When the filter cake is re-dispersed in a liquid, at pH level and
temperature values approximately equal to those of the final washing liquor, the
concentration gradients during the washing stage will be low.
The change in the pH level, most of the change in ionic strength and any
change in lignin solubility will then take place in the slurry, and not in the filter
cake or in the filter medium during washing.The filtrate fromchamber press filter
2 (filtration, washingand dewatering stages) should be recycled tothe weak black
liquor. The resulting slurry is once again dewatered and washed, with acidified
wash water, to produce virtually pure lignin cakes.In some cases, thisfiltrate can
be also used for washing theunbleached or oxygen delignified pulp.The
LignoBoost process therefore makesit possible to extract lignin efficiently
fromthe black liquor in kraft mills. The majoradvantages, compared to the
previoustechnology, are the following:the filter area and the volume of
acidicwashing water can be kept at lowervalues, resulting in lower
investmentcosts,the addition of sulfuric acid can be alsokept at a lower level,
resulting in loweroperational costs,the yield of lignin is higher, the lignin has a
lower ash and carbohydrate content, the lignin has a higher content of dry solids.
Figure 2.3General layout of the LignoBoost lignin removal process (post-treatment,
drying and pulverizingare excluded)
2.2.1.2 Lignin Oxidation in Batch Process
Production of vanillin lignin based must be made in alkaline conditions.
Alkaline conditions is made to achieve a very high pH nearing pH 14, in addition
Preliminary Design of Vanillin Production Plant From Black Liquor
28
to high temperature conditions also are 1500C and 10 bar.The purpose of this
process is to break the bond position of alpha-and beta-carbon of fenilpropane and
breaking bonds in the carbon chain in the phenyl propane propanoid. Lignin
oxidation process in batch mode formed in a jacketed reactor with controlled
temperature and pressure. The reactor is under stirring and oxygen was fed to the
reactor.
LigninLingoboost outcome enter into a reactor that has a temperature
operating conditions of 1500C and pressure of 10 bar.Alkaline conditions created
by inserting NaOH pH 14 into reactor first. Then lignin lignoboost enter to the
input process. After that, the solution oxidaze with O2 gas 50% N2 50%.Lignin
reaction occurred with O2 being described at the beginning of the bond that ties
will occur. NaOH will react also with lignin to form Sodium Vanilate.Sodium
Vanilate is salt vanillin mixed with Na+ ions. In addition it also produced some of
the content of impurity content to be separated. Lignin is not transformed to
Sodium Vanilate 100% m.
2.2.1.3 Membrane Ultrafiltration Separation
In the filtration process, the tool used is membrane ultrafikasi.
Membraneultrafikasi used has a large cut-off membrane of 15 kDa, or about 1.6
nm and the pressure used is 0-4 bar. Vanillin has large molecules 152 Da MW,
making vanillin will pass with the existing pores.
This process begins with the entry of sodium vanilate and other impurities.
This process aims to separate Sodium vanilate with other impurities by using the
principle of molecular size difference. Sodiumvanilate is outflow and by product
is lignin and impurities. Lignin obtained from the by-product will in turn go back
to the oxidation tank to re reacted with O2.
2.2.1.4. Spray Dryer
Spray drying is a method of producing a dry powder from a liquid or
slurry by rapidly drying with a hot gas. This is the preferred method of drying of
many thermally-sensitive materials such as foods and pharmaceuticals. A
consistent particle size distribution is a reason for spray drying some industrial
products such as catalysts. Air is the heated drying medium; however, if the liquid
Preliminary Design of Vanillin Production Plant From Black Liquor
29
is a flammable solvent such as ethanol or the product is oxygen-sensitive
then nitrogen is used.
All spray dryers use some type of atomizer or spray nozzle to disperse the
liquid or slurry into a controlled drop size spray. The most common of these are
rotary disks and single-fluid high pressure swirl nozzles. Alternatively, for some
applications two-fluid or ultrasonic nozzles are used. Depending on the process
needs, drop sizes from 10 to 500 µm can be achieved with the appropriate
choices. The most common applications are in the 100 to 200 µm diameter range.
The dry powder is often free-flowing
The most common spray dryers are called single effect as there is only one
drying air on the top of the drying. In most cases the air is blown in co-current of
the sprayed liquid. The powders obtained with such type of dryers are fine with a
lot of dusts and a poor flowability. In order to reduce the dusts and increase the
flowability of the powders, there is since over 20 years a new generation of spray
dryers called multiple effect spray dryers. Instead of drying the liquid in one
stage, the drying is done through two steps: one at the top (as per single effect)
and one or an integrated static bed at the bottom of the chamber.
The fine powders generated by the first stage drying can be recycled in
continuous flow either at the top of the chamber (around the sprayed liquid) or at
the bottom inside the integrated fluidized bed. The drying of the powder can be
finalized on an external vibrating fluidized bed. The hot drying gas can be passed
as a co-current or counter-current flow to the atomiser direction. The co-current
flow enables the particles to have a lower residence time within the system and
the particle separator (typically a cyclone device) operates more efficiently. The
counter-current flow method enables a greater residence time of the particles in
the chamber and usually is paired with a fluidized bed system.
Preliminary Design of Vanillin Production Plant From Black Liquor
30
2.2.2 BFD and Description
Figure 2.4 Block Flow Diagram Vanillin Plant from Lignin
Lignin Extraction
(LignoBoost)Lignin Oxidation Filtration Drying
Black Liquor
NaOH
Vanillin +
OthersVanillin
Solution
Powdered
Vanillin
VANILLIN PLANT FROM LIGNIN
BLOCK FLOW DIAGRAM
Drawn By :
Checked By :
Revised By :
Darwing No. :
Date :
Date :
Without Scale A4
Note :
H2SO4
O2, N2 (50%,50%)
Lignin
CO2
Waste Liquor
Preliminary Design of Vanillin Production Plant From Black Liquor
31
Two main process in Vanillin Plant from Lignin is lignin extraction from
black liquor and vanillin oxidation from lignin itself. From this BFD the raw
material, which is black liquor is treated with acid. lignin is precipitated by
acidification (the preferred acid is CO2) and filtered. Instead of washing lignin
immediately after filtration, as in traditional processes, the filter cake is re-
dispersed and acidified (using H2SO4). The resulting slurry is then filtered and
washed by means of displacement washing.
After the slurry is filtered, the next process is blending with NaOH to
make a base condition of solution before entering bubble column reactor. In
bubble column reactor there will be oxidation reaction between lignin and oxygen.
It will result the vanillin solution and the other compounds. To get vanillin, this
solution must be separated using ultrafiltration, so the other compounds can be
impeded at filter, and the filtrate contains only vanillin. The vanillin solution from
ultrafiltration must be dried using spray dryer before it will be packed and
distributed.
Preliminary Design of Vanillin Production Plant From Black Liquor
32
2.2.3 PFD and Description
Black LiquorFrom pulp ind
CO2
H2SO4
P-109
P-107
PF-102
Water
NaOH
O2 and N2
P-104
Others
PowderVanillin
Air
Air
Water
1 2
3
4
6
8
7
9
11
10
13
14
P-101S-101
P-102V-101
F-101
P-103
PF-101
P-110
V-102
P-111 V-103
F-101
H-101
CS-101
H-102
UF-101
SD-101
P-101Black Liquor Pump
S-101BL Storage
P-102BL Pump
V-101BL Solid Treatment Vessel
P-103Slurry Pump
PF-101Plate & Frame Filter
P-104Slurry Pump
V-102Acidification Vessel
P-105Slurry Pump
P-106Slurry Pump
P-107Filtrate Pump
PF-102Plate & Frame Filter
SR-101Crusher
P-108Water Pump
V-103Lignin Solution Vessel
P-109H2SO4 Solution Pump
H-101Heat Exchanger
C-101O2 and N2 Compressor
CS-101Oxidation Reactor
UF-101Membrane Ultrafiltration
F-102Air Blower
H-102Heat Exchanger
SD-101Spray Dryer
N2
Steam
18
27
29
5
P-108
P-106
Water
P-107
21
16
22
23
H-103
B-101
P-111NaOH Pump
H-103Heat Exchanger
B-103Steam Reboiler
19
24
25
26
28
Alkali Sulfat +Liq Acid
Lean Liquor
12
VANILLIN PLANT FROM LIGNIN
PROCESS FLOW DIAGRAM
Drawn By :
Checked By
Revised By :
Drawing No :
Date :
Date :
Without Scale A4
Notes :
Group 6
P-105
C-101
C-102
15
17
20
30
V-104
Figure 2.5 Process Flow Diagram Vanillin Plant from Lignin
Preliminary Design of Vanillin Production Plant From Black Liquor
33
The main process of this plant consists of LignoBoost process which is the
lignin separation process from black liquor, and the core of this plant is vanillin
oxidation from lignin extract from LignoBoost process. The LignoBoost process
is started from black liquor solid separation from black liquor in V-101 until the
filtration process of black liquor solid so the lignin is separated from black liquor
solid. Otherwise the vanillin oxidation process is started while solid lignin
resulted by filtration F-102 entering the blending storage V-103 and NaOH is also
added in that storage, oxidation in bubble column reactor, ultrafiltration, until
drying process of vanillin to be vanillin powder in spray dryer.
From the PFD it can be seen that the black liquor from PT Riau Andalan
Pulp and Paper flowing through the pipe and pumped by P-101 pump to the black
liquor storage S-101. And then the black liquor is kept until the batch is started.
The black liquor than is pumped through P-102 pump to be precipitated in black
liquor treatment vessel V-101, CO2 is added to the storage. The slurry from V-101
is pumped to press chamber filter (Plate and frame) PF-101, and water is pumped
by P-108 as washing eluent in filtration. As the result, solid black liquor is
impeded above the filter as a cake. Then cake is brought using conveyor C-101 to
Acidification vessel V-102 to be re-dispersed so the lignin can be extracted. It
needs H2SO4 as an acid liquid at pH 4 to extract that lignin. When the filter cake
is re-dispersed in a liquid, at pH level and temperature values approximately equal
to those of the final washing liquor, the concentration gradients during the
washing stage will be low. The change in the pH level, most of the change in ionic
strength and any change in lignin solubility will then take place in the slurry, and
not in the filter cake or in the filter medium during washing. From V-102 the
extract is pumped by P-107 to press chamber filter (Plate and frame) PF-102, and
water is pumped by P-110 as washing eluent in filtration.
The lignin is in the cake then is brought to blending storage V-103 with
NaOH by conveyor C-102. In blending storage lignin is dissolved in NaOH before
it is added to bubble column reactor. NaOH will give a base condition as the
optimum condition in this reaction. Before entering bubble column reactor, the
lignin solution is pumped by P-105 pump. During the process, the lignin solution
is heated to increase the temperature through the heat exchanger HE-101, the heat
Preliminary Design of Vanillin Production Plant From Black Liquor
34
exchanger agent is steam from boiler B-101 at 220oC. The output temperature of
lignin slurry is 170oC and then it enter the bubble column reactor CS-101. The
operation condition of bubble column reactor itself is 170oC and 10 bar pressure.
In BCR lignin is reacted with O2 resulting vanillin and other compounds. The
reaction can be explained below.
Lignin oxidation : 0.5 L + 1.56 O2 V + 114 X
Vanillin oxidation : V + O2 D
Stoichiometry 1 Conversion 70%
Lignin Oxidation : 0.5 L + 1.56 O2 --> V + 114 X
Initial (mol) 2350.242 10781.25
Change (mol) -1645.17 -7332.75 4700.483
Remaining
(mol) 705.0725 3448.496 4700.483
Stoichiometry 2
Vanilin Oxidation : V + O2 --> Product
Initial (mol) 4700.483 3448.496
Change (mol) -3290.34 -3290.34 3290.338
Remaining
(mol) 1410.145 158.1582 3290.338
massa 500592.048 gram
0.50059205 ton
500.592048 kg
( )
( )
(
)
(
(
) )
(
)
(
(
) )
Where :
- A is Lignin
- B is Oxygen
- C is Vanillin
- D is Vanillin Acid Product
Preliminary Design of Vanillin Production Plant From Black Liquor
35
Rate Law :
(
)
(
)
The product from CS-101 is pumped using P-106 through HE-103 to
Ultrafiltration membrane UF-101. The filtrate then pumped to spray dryer SD-101
(80oC). In SD-101 the liquid vanillin is powdered with hot air after passing the
HE-102 at 120oC. Vanillin powder then is brought to packing building to be
packaged. The cake from UF-101 is pumped to waste storage.
Preliminary Design of Vanillin Production Plant From Black Liquor
36
CHAPTER 3
MASS AND ENERGY BALANCE
3.1 Mass Balance
3.1.1 Overall Mass Balance
Overall mass balance in this system is explained in table 3.1 below :
Table. 3.1 Mass Balance in Entire Process
OVERALL Input (ton) Output (ton)
FEED
Black Liquor 111.17 0
CO2 1.10 0
Water 14.54 22.98
H2SO4 0.88 0
NaOH 6.67 0
O2 0.16 0
N2 0.16 0.16
Waste
Lean liquor - 68.92
Liquid acid - 25.48
Alkali sulfat - 5.29
Filtrate cake - 10.14
Hot air 1.02 2.22
PRODUCT
Vanillin - 0.50
TOTAL 135.70 135.70
While the composition of the black liquor and its content found in Figure 3.2
Table. 3.2 Black Liquor Composition
Black Liquor Composition Total mass (ton)
Lignin (4.5%) 5
Water (8%) 8.89
Lean liquor (87,5%) 97.27
Preliminary Design of Vanillin Production Plant From Black Liquor
37
3.1.2 Mass Balance Process Units
Primary Process Description and Mass Balance in Every Process Units are
explained in the table below :
Table. 3.3 Mass Balance in Storage
STORAGE Input 1
(ton)
Output 2
(ton)
Lignin Alkali 10.01 10.01
Water 8.89 8.89
Lean liquor 92.27 92.27
TOTAL 111.17 111.17
Table. 3.4 Mass Balance in Acidification Process
ACIDIFICATION I Input 2
(ton)
Input 3
(ton)
Output 4
(ton)
Lignin Alkali 10.01 0 10.01
Water 8.89 0 8.44
Lean Liquor 92.27 0 92.27
CO2 0 1.10 0
Liquid Acid 0 0 1.55
111.17 1.10 112.27
TOTAL 112.27 112.27
Table. 3.5 Mass Balance in Filtration Process
FILTRATION I Input 4
(ton)
Input 5
(ton)
Output 6
(ton)
Output 7
(ton)
Lignin Alkali 10.01 0 10.01 0
Water 8.44 11.12 0 19.56
Lean Liquor 92.27 0 0 68.92
Liquid Acid 1.55 0 0 1.55
lean liquor solid 0 0 23.35 0
112.27 11.12 33.35 90.03
TOTAL 123.38 123.38
Preliminary Design of Vanillin Production Plant From Black Liquor
38
Table. 3.6 Mass Balance in Acidification Process
ACIDIFICATION II Input6
(ton)
Input 8
(ton)
Output 9
(ton)
Lignin Alkali 10.01 0 0
Lean liquor solid 23.35
0
H2SO4 0 0.88 0
Lignin 0 0 5
Alkali Sulfat 0 0 5.29
Liquid acid 0 0 23.93
33.35 0.88 34.23
TOTAL 34.23 34.23
Table. 3.7 Mass Balance in Filtration Process
FILTRATON II Input 9
(ton)
Input 10
(ton)
Output 11
(ton)
Output 12
(ton)
Lignin 5
5 0
Alkali sulfat 5.29 0 0 5.29
Liquid acid 23.93 0 0 23.93
Water 0 3.42 0 3.42
34.23 3.42 5.00 32.65
TOTAL 37.65 37.65
Table. 3.8 Mass Balance in Blending Process
BLENDING Input 11
(ton)
Input 13
(ton)
Output 14
(ton)
Lignin 5 0 0
NaOH 0 6.67 0
Lignin slurry 0 0 11.67
TOTAL 11.67 11.67
Preliminary Design of Vanillin Production Plant From Black Liquor
39
Table. 3.9 Mass Balance in Storage Lignin slurry
STORAGE Input 13
(ton)
Input 14
(ton)
Output 15
(ton)
Lignin 5 0 0
NaOH 0 6.67 0
Lignin slurry 0 0 11.67
TOTAL 11.67 11.67
Table. 3.10 Mass Balance in Oxidation Process
REACTOR
OXIDATION
Input 15
(ton)
Input 16
(ton)
Output 18
(ton)
Output 19
(ton)
Lignin slurry 11.67 0 0 0
N2 0 0.16 0 0.16
O2 0 0.16 0 0
Alkali Ligin Slurry 0 0 5.36 0
Water 0 0 1.20 0
Vanillin 0 0 0.50 0
Others 0 0 4.78 0
11.67 0.33 11.84 0.16
TOTAL 12.00 12.00
Table. 3.11 Mass Balance in Ultrafiltration Process
ULTRAFILTRATION
Input 18
(ton)
Output 20
(ton)
Output 21
(ton)
Vanillin 0.50 0.50 0
Alkali Lignin Slurry 5.36 0 0
water 1.20 1.20 0
Others 4.78 0 0
Filtrate Cake 0 0 10.14
11.84 1.70 10.14
TOTAL 11.84 11.84
Preliminary Design of Vanillin Production Plant From Black Liquor
40
Table. 3.12 Mass Balance in Drying Process
DRYING Input 20
(ton)
Input 26
(ton)
Output 28
(ton)
Output 29
(ton)
Vanillin 0.50 0 0 0
water 1.20 0 0 0
Hot Air 0 1.02 2.22 0
Vanillin Powder 0 0 0 0.50
1.70 1.02 2.22 0.50
TOTAL 2.72 2.72
3.2 Energy Balance
Table. 3.3.1 Mass Balance in Storage
STORAGE Input 1 (ton) Output 2(ton) Energy In
(Joule)
Energy Out
(Joule)
Lignin Alkali 10.01 10.01 0 0
Water 8.89 8.89 0 0
Lean liquor 92.27 92.27 0 0
TOTAL 111.17 111.17 0 0
Table. 3.3.2 Mass Balance in Acidification Process
ACIDIFICATION I Input 2 (ton) Input 3
(ton) Output 4 (ton) Energy In (Joule)
Energy Out
(Joule)
Lignin Alkali 10.01 0 10.01 0.00 0.00
Water 8.89 0 8.44 141.31 134.15
Lean Liquor 92.27 0 92.27 0.00 0.00
CO2 0 1.10 0 27.64
Liquid Acid 0 0 1.55
34.79
111.17 1.10 112.27
TOTAL 112.27 112.27 168.94 168.94
Preliminary Design of Vanillin Production Plant From Black Liquor
41
Table. 3.3.3 Mass Balance in Filtration Process
FILTRATION I Input 4
(ton)
Input 5
(ton)
Output 6
(ton) Output 7 (ton)
Energy In
(Joule)
Energy
Out
(Joule)
Lignin Alkali 10.01 0 10.01 0 0 0
Water 8.44 11.12 0 19.56 0 0
Lean Liquor 92.27 0 0 68.92 0 0
Liquid Acid 1.55 0 0 1.55 0 0
lean liquor solid 0 0 23.35 0 - -
TOTAL 112.27 11.12 33.35 90.03 0 0
TOTAL 123.38 123.38 0 0
Table. 3.3.4 Mass Balance in Acidification Process
ACIDIFICATION II Input6 (ton) Input 8
(ton)
Output 9
(ton)
Energy In
(Joule)
Energy Out
(Joule)
Lignin Alkali 10.01 0 0 49689.61 -
Lean liquor solid 23.35
0 - -
H2SO4 0 0.88 0 138.50 -
Lignin 0 0 5
24844.81
Alkali Sulfat 0 0 5.29
24494.23
Liquid acid 0 0 23.93
489.08
TOTAL 33.35 0.88 34.23 49828.12 49828.12
TOTAL 34.23 34.23 49828.12 49828.12
Preliminary Design of Vanillin Production Plant From Black Liquor
42
Table. 3.3.5 Mass Balance in Filtration Process
FILTRATON II Input 9
(ton)
Input 10
(ton)
Output 11
(ton)
Output 12
(ton)
Energy In
(Joule)
Energy Out
(Joule)
Lignin 5
5 0 0 0
Alkali sulfat 5.29 0 0 5.29 0 0
Liquid acid 23.93 0 0 23.93 0 0
Water 0 3.42 0 3.42 0 0
34.23 3.42 5.00 32.65 0 0
TOTAL 37.65 37.65
Table. 3.3.6 Mass Balance in Blending Process
BLENDING Input 11 (ton) Input 13
(ton)
Output 14
(ton)
Energy In
(Joule)
Energy Out
(Joule)
Lignin 5 0 0 0
NaOH 0 6.67 0 0
Lignin slurry 0 0 11.67
0
TOTAL 11.67 11.67 0
Table. 3.3.7 Mass Balance in Storage Lignin Slurry
STORAGE Input 11 (ton) Input 13
(ton)
Output 14
(ton)
Energy In
(Joule)
Energy Out
(Joule)
Lignin 5 0 0 0
NaOH 0 6.67 0 0
Lignin slurry 0 0 11.67
0
TOTAL 11.67 11.67 0
Preliminary Design of Vanillin Production Plant From Black Liquor
43
Table. 3.3.8 Mass Balance in Oxidation Process
REACTOR
OXIDATION
Input 15
(ton)
Input 16
(ton)
Output
18 (ton)
Output
19 (ton)
Energy In
(Joule)
Energy Out
(Joule)
Lignin slurry 11.67 0 0 0 57971.22 0
N2 0 0.16 0 0.16 0 0
O2 0 0.16 0 0 0 0
Alkali Ligin
Slurry 0 0 5.36 0
0.00 0
Water 0 0 1.20
Vanillin 0 0 0.50 0 0
Others 0 0 4.78 0 0
Total 11.67 0.33 11.84 0.16 57971.22 2811317971.22
TOTAL 12 12 57971.22 2811317971.22
Q masuk tambahan : 2811260000 J
Table. 3.3.9 Mass Balance in Ultrafiltration Process
ULTRAFILTRATION
Input 18 (ton)
Output 20
(ton)
Output 21
(ton)
Energy In
(Joule)
Energy
Out
(Joule)
Vanillin 0.50 0.50 0 0 0
Water 5.36 0 0 0 0
Alkali Lignin Slurry 1.20 1.20 0 0 0
Others 4.78 0 0 0 0
Filtrate Cake 0 0 10.14 0 0
11.84 1.70 10.14 0 0
TOTAL 11.84 11.84
Preliminary Design of Vanillin Production Plant From Black Liquor
44
Table. 3.3.10 Mass Balance in Drying Process
DRYING Input 20
(ton)
Input 26
(ton)
Output 28
(ton)
Output 29
(ton)
Energy In
(Joule)
Energy Out
(Joule)
Vanillin 0.50 0 0 0 - 4445.67
Hot Air 1.20 0 0 0 142800
Water 0 1.02 2.22 0 286850.67
Vanillin
Powder
0 0 0 0.50 0.00 0.00
1.70 1.02 2.22 0.50 142800 291296.34
TOTAL 2.72 2.72
Q masuk tambahan dari steam : 148496.34 J
So, Total of the heat steam that we need is = 2811408496.34 = 2811.41 MJ
Preliminary Design of Vanillin Production Plant From Black Liquor
45
CHAPTER 4
UTILITIES
4.1 Water Utility
Water availability system in this vanillin plant is really needed to support
the whole plant production. The water utility in this plant is needed as processes
water, water for equipment washing, domestic water availability and fire
extinguishing water. The water source design based on the water collection,
processing system efficiency and economical factor. The explanation about this
water utility consist as follows :
4.1.1 Water Utility Classification
4.1.1.1 Process Water
Process water that used in this plant is used to solute NaOH that will enter
oxidation reactor and for washer in filtration. In the whole process for this plant,
water is not too needed because water component in the main raw material (black
liquor) is 26% and the most of others materials is liquid solution. The water
process needs in this plant reach 123,40 m3 per day. The details about the needs of
water describes as follows :
Table 4.1 Total Process Water Needs in Plant
Unit Water (kg)
Filtration 1 11120
Filtration 2 3420
Blending 730
Total 15270
4.1.1.2 Domestic Water
This water is used to fulfill water needs for staff and other employers.
Domestic water include toilet facilities, drinking water, water for watering
gardens and many more. Assuming the total domestic water everyone is 100
litre/day. So, total water for domestic water if there is 100 persons in this plant is
10.000 litre/day.
Preliminary Design of Vanillin Production Plant From Black Liquor
46
4.1.1.3 Fire Extinguishing Water
Fire Extinguishing Water is used to extinguish fire if one day there is fire.
This water is reserved to be used anytime. The firefighting water used was water with
the low specs, but has under gone treatment first. The amount of water required for fire is
assumed to10,000 kg/day.
4.1.1.4 Total Water Requirements
Total water requirements needed for this plant per day covers the water needed
for process water, cooling water, water heater, boiler feed water, domestic water and fire
water. Total water requirement is shown in the table 5.1 below:
Table 4.2 Total Water Needs in Plant
Using water Total (Kg/day)
Processing Water 15270
Domestic water 10000
Fire Extinguishing Water 1000
Total 26270
4.1.1.5 Water Sources
Water supply to the plant will be taken from PT. Riau Andalan industrial area. PT
Riau Andalan independently manage all water providers to the needs of industries that
exist within the industry. Water supplied by PT Riau Andalan is considered clean enough
and qualify for use as water for industrial plants. So in the factory there is no clean water
management facilities further.
4.2 Electric Utility
As the plant in general, to run the equipment contained in the plant Vanillin,
energy required is not small. Equipment that requires a supply of energy, among others:
Pump
Agitator Mixing Tank
Electricity need for vanillin production in this vanillin plant can be seen in
the following table.
Preliminary Design of Vanillin Production Plant From Black Liquor
47
Table 4.3 Total Electricity Needs in Plant
Item No. Process unit Kwh/ day Kwh/year
V-101 Agitator CO2 precipitation tank 36.32 10897
V-102 Agitator H2SO4 precipitation tank 1.58 474.83
V-103 Agitator lignin slurry tank 0.09 26.68
P-101 Black liquor pump 19.31 5792.45
P-102 Black liquor pump 258.99 77696.04
P-103 CO2 precipitation pump 56.18 16854.27
P-104 Slurry pump 2.89 865.74
P-105 Slurry pump 0.53 157.70
P-106 Slurry pump 3.86 1157.32
P-107 Slurry pump 0.18 53.46
P-108 Water pump 14.19 258.08
P-109 H2SO4 precipitation pump 0.28 84.69
P-110 Water pump 10.38 3113.53
P-111 NaOH pump 1.78 533.65
C-101 Alkali lignin cake conveyor 7.44 2232
C-102 Black liquor solid conveyor 7.44 2232
C-103 Lignin solid conveyor 5.95 1785
C-104 Vanillin conveyor 5.95 1785
TOTAL 433.34 125999.44
Preliminary Design of Vanillin Production Plant From Black Liquor
48
Electricity need at vanillin plant is AC (accuired current) power type.
Total electricity needs for processes of this plant is equal to 433.34 kWh/day.
While the need support for lighting and other assumed 30% of the total energy is
130 kWh/day. So the total electricity need of vanillin plant is 125999.44
kWh/year.
Electrical power is largely used for two purposes primary. The first
necessity is requiring electrical power needs the production process. The second
purpose is to use electrical power production support facilities. Electricity used for
support facilities for the needs of lighting and air-conditioning (AC) in the office,
laboratories, workshops, as well as the control room, air supply (tap and clean),
water supply (and the net), and the sewage treatment plant.
4.3 Steam Utility
In this vanillin plant, steam utility is needed for heating the reactor through
the jacket. Reaction temperature needed in that process is 170oC. Based on
calculation, it is obtained that heat needed for reactor is 253.01 MJ per day.
It is assumed that steam needed is provided from diesel as fuels. Assuming
that efficiency from boiler is 40%. So, the diesel as fuels to produce steam in this
vanillin plant is :
m = 303 litre per day
Preliminary Design of Vanillin Production Plant From Black Liquor
49
BAB 5
SIZING
5.1 Vessel
5.1.1 Black Liquor Storage Tank (S-101)
STORAGE TANK
Identification: Item Black Liquor Storage Tank
Item no. S-101
No. required 3
Function: Storage black liquor to keep it from microorganism and algae
Operation: Discrete
Material
handled: Black Liquor
Composition
(%):
Black Liquor 100
Design data Capacity (kg) 333500
Feed quantity (m3/h) 326.57
Operating temperature (K) 333
Operating pressure (psi) 14.70
Storage Tank Specification
Type
Flat-bottomed cylindrical vessel
Material of construction Stainless steel 316
Diameter (m)
7.16
Height (m)
9.55
Thickness of shell (cm) 2.97
Thickness of Roof (cm) 2.97
Controls: S-101 for controlling Black liquor solution
Preliminary Design of Vanillin Production Plant From Black Liquor
50
5.1.2 Acidification Tank (V-101)
MIXER TANK
Identification: Item Mixer Tank
Item no. V-101
No. required 5
Function: To precipitation black liquor with CO2
Operation: Discrete
Material handled: Black Liquor slurry
Composition (%):
Black Liquor
Slurry
100
Design data Capacity (kg) 22230
Feed quantity (m3/h) 21.773
Operating temperature (K) 333
Residence time (h) 1
Operating pressure (psi) 14.7
Mixer Tank Specification
Type
Flat-bottom cylindrical vessel
Material of construction Stainless steel 316
Diameter(m)
2.90
Height (m)
3.87
Thickness of shell (cm) 2.12
Thickness of roof (cm) 2.12
Impeller Design
Type Flow turbine with 4 blades
Diameter (m) 1.16
Agitator space from based (m) 0.55
Blade width (m) 0.15
Impeller speed (rpm) 60
Power (kWh) 0.81
Controls: V-101 for precipitation black liquor slurry
Preliminary Design of Vanillin Production Plant From Black Liquor
51
5.1.3 Acidification Tank (V-102)
MIXER TANK
Identification: Item Mixer Tank
Item no. V-102 (A)
No. required 1
Function: Acidification process of black liquor slurry
Operation: Discrete
Material handled: Black Liquor slurry
Composition (%):
Black Liquor
Slurry
100
Design data Capacity (kg) 20540
Feed quantity (m3/h) 21.58
Operating temperature (K) 333
Residence time (h) 0.5
Operating pressure (psi) 14.7
Mixer Tank Specification
Type
Flat-bottom cylindrical vessel
Material of construction Stainless steel 316
Diameter(m)
2.30
Height (m)
3.06
Thickness of shell (cm) 2.06
Thickness of roof (cm) 2.06
Impeller Design
Type Flow turbine with 4 blades
Diameter (m) 0.92
Agitator space from based (m) 0.43
Blade width (m) 0.12
Impeller speed (rpm) 60
Power (kWh) 0.23
Controls: V-102 for precipitation black liquor slurry
Preliminary Design of Vanillin Production Plant From Black Liquor
52
MIXER TANK
Identification: Item Mixer Tank
Item no. V-102 (B)
No. required 1
Function: Acidification process of black liquor slurry
Operation: Discrete
Material handled: Black Liquor slurry
Composition (%):
Black Liquor
Slurry
100
Design data Capacity (kg) 13690
Feed quantity (m3/h) 14.38
Operating temperature (K) 333
Residence time (h) 0.5
Operating pressure (psi) 14.7
Mixer Tank Specification
Type
Flat-bottom cylindrical vessel
Material of construction Stainless steel 316
Diameter(m)
2.01
Height (m)
2.68
Thickness of shell (cm) 2.02
Thickness of roof (cm) 2.02
Impeller Design
Type Flow turbine with 4 blades
Diameter (m) 0.80
Agitator space from based
(m) 0.38
Blade width (m) 0.10
Impeller speed (rpm) 60
Power (kWh) 0.12
Controls: V-102 for precipitation black liquor slurry
Preliminary Design of Vanillin Production Plant From Black Liquor
53
5.1.4 Blending Tank (V-103)
MIXER TANK
Identification: Item Mixer Tank
Item no. V-103
No. required 1
Function: To make lignin slurry
Operation: Discrete
Material handled: Lignin slurry
Composition (%):
Lignin Slurry 100
Design data Capacity (kg) 150075
Feed quantity (m3/h) 6.89
Operating temperature (K) 333
Residence time (h) 0.167
Operating pressure (psi) 13.24
Mixer Tank Specification
Type
Flat-bottom cylindrical vessel
Material of construction Plate steels SA-283 grade C
Diameter(m)
4.53
Height (m)
6.04
Thickness of shell (cm) 0.70
Thickness of roof (cm) 0.70
Impeller Design
Type Flow turbine with 4 blades
Diameter (m) 1.81
Agitator space from based (m) 0.86
Blade width (m) 0.23
Impeller speed (rpm) 60
Power (kWh) 8.8
Controls: V-103 for make lignin slurry
Preliminary Design of Vanillin Production Plant From Black Liquor
54
5.1.5 Lignin Slurry Storage (S-102)
STORAGE TANK
Identification: Item Lignin Slurry Storage Tank
Item no. S-102
No. required 1
Function: Storage lignin slurry before enter to bubble column reactor
Operation: Discrete
Material handled: Black Liquor
Composition (%):
Lignin Slurry 100
Design data Capacity (kg) 11670
Feed quantity (m3/h) 6.43
Operating temperature (K) 333
Operating pressure (psi) 14.70
Storage Tank Specification
Type
Flat-bottomed cylindrical vessel
Material of construction Stainless steel 316
Diameter (m)
1.93
Height (m)
2.58
Thickness of shell (cm) 2.10
Thickness of Roof (cm) 2.10
Controls: S-102 for controlling lignin slurry
Preliminary Design of Vanillin Production Plant From Black Liquor
55
5.1.6 Waste Storage (S-103)
STORAGE TANK
Identification: Item Waste Storage Tank
Item no. S-103
No. required 2
Function: Waste storage from the process
Operation: Discrete
Material handled: Waste from process
Composition (%):
Waste 100
Design data Capacity (kg) 597670
Feed quantity (m3/h) 13.11
Operating temperature (K) 333
Operating pressure (psi) 14.70
Storage Tank Specification
Type
Flat-bottomed cylindrical vessel
Material of construction Carbon steel
Diameter (m)
7.07
Height (m)
9.43
Thickness of shell (cm) 3.63
Thickness of Roof (cm) 3.63
Controls: S-103 for controlling waste from process
Preliminary Design of Vanillin Production Plant From Black Liquor
56
5.1.7 H2SO4 Storage (S-104)
STORAGE TANK
Identification: Item H2SO4 Storage Tank
Item no. S-104
No. required 1
Function: Storage H2SO4 to keep it before enter to process
Operation: Discrete
Material handled: H2SO4
Composition (%):
H2SO4 100
Design data Capacity (kg) 47273.63
Feed quantity (m3/h) 25.69
Operating temperature (K) 333
Operating pressure (psi) 14.70
Storage Tank Specification
Type
Flat-bottomed cylindrical vessel
Material of construction Stainless steel 316
Diameter (m)
3.07
Height (m)
4.09
Thickness of shell (cm) 2.40
Thickness of Roof (cm) 2.40
Controls: S-103 for controlling H2SO4 from process
Preliminary Design of Vanillin Production Plant From Black Liquor
57
5.1.8 NaOH Storage (S-105)
STORAGE TANK
Identification: Item NaOH Storage Tank
Item no. S-105
No. required 1
Function: Storage NaOH to keep it before enter to process
Operation: Discrete
Material handled: NaOH
Composition (%):
NaOH 100
Design data Capacity (kg) 360180
Feed quantity (m3/h) 169.10
Operating temperature (K) 333
Operating pressure (psi) 14.70
Storage Tank Specification
Type
Flat-bottomed cylindrical vessel
Material of construction Stainless steel 316
Diameter (m)
5.75
Height (m)
7.67
Thickness of shell (cm) 2.70
Thickness of Roof (cm) 2.70
Controls: S-105 for controlling NaOH
Preliminary Design of Vanillin Production Plant From Black Liquor
58
5.2 Filtration
5.2.1 Plate and Frame Filter (PF-101)
Lignin Alkali Press Filter
Identification: Item Lignin Press Filter
Item no. PF-101
No. required 4
Function: To get lignin alkali solid and lean liquor solid, separate it
from lean liquor, liquid acid, and water.
Operation: batch
Material handled: Lignin slurry
Design data: Operating temperature (K) 303
Operating pressure (Pa) 7 x 105
Type
Vertical Plate
Airblow (VPA)
Material of construction Stainless steel 316
Effective filtration Area
(m2)
345
Filtration area with safety
factor 20% (m2)
414
Filter chamber size (m)
2.03 x 2.03
Number of chambers 50
L (m) 15.6
W (m) 4.25
H (m) 4.58
Weight empty (ton) 80
Total press filter required (item) 4
Total plates required 200
Preliminary Design of Vanillin Production Plant From Black Liquor
59
5.2.2 Plate and Frame Filter (PF-102)
Lignin Press Filter
Identification: Item Lignin Press Filter
Item no. PF-102
No. required 1
Function: To get solid lignin and separate it from alkali suphate, liquid
acid, and water.
Operation: batch
Material handled: Lignin slurry
Design data: Operating temperature (K) 303
Operating pressure (Pa) 7 x 105
Type
Vertical Plate
Airblow (VPA)
Material of construction Stainless steel 316
Effective filtration Area
(m2)
40.06
Filtration area with safety
factor 20% (m2)
48.08
Filter chamber size (m)
1.5 x 1.5
Number of chambers 24
L (m) 8.5
W (m) 3.8
H (m) 3.16
Weight empty (ton) 27.5
Total press filter required (item) 1
Total plates required 21
Preliminary Design of Vanillin Production Plant From Black Liquor
60
5.3 Pump
5.3.1 Black Liquor Pump (P-101)
Function : Pumping black liquor to acidification tank I
Type : Centrifugal pump
Number of Unit : 1 unit
No. Specification
1 Scope Double end-Vertical screw pump
2 Service condition Continuous process
3 Operating condition
Capacity (ton/h) 66.77
Suction pressure (Pa) 100,000
Power (kWh) 0.32
4 Liquid Properties
Liquid to be handled Black liqour
Viscosity (cp) 5.091
Temperature of liquid at inlet
(°C)
60
5 Material Stainles steel
5.3.2 Black Liquor Acidification pump (P-102)
Function : Pumping black liquor slurry from acidification tank to press
filter I
Type : Centrifugal pump
Number of Unit : 2 unit
No. Specification
1 Scope Centrifugal pump
2 Service condition Continuous process
3 Operating condition
Preliminary Design of Vanillin Production Plant From Black Liquor
61
Capacity (ton/h) 33.38
Suction pressure (Pa) 105,000
Power (kWh) 2.36
4 Liquid Properties
Liquid to be handled Black liqour
Viscosity (cp) 1.70
Temperature of liquid at inlet
(°C)
60
5 Material Stainles steel
5.3.3 Lignin Acidification Pump (P-103)
Function : Pumping sludge from acidification tank to filter press II
Type : Piston pump
Number of Unit : 1 unit
No. Specification
1 Scope Screw pump
2 Service condition Batch process
3 Operating condition
Capacity (ton/h) 61.68
Suction pressure (Pa) 105,000
Power (kWh) 2.56
4 Liquid Properties
Liquid to be handled Black liqour
Viscosity (cp) 1.3169
Temperature of liquid at inlet 60
Preliminary Design of Vanillin Production Plant From Black Liquor
62
(°C)
5 Material Stainles steel
5.3.4 Lignin Solution Pump (P-104)
Function : Pumping lignin slurry (lignin+water) from mixing tank to
storage
Type : Screw Pump
Number of Unit : 1 unit
No. Specification
1 Scope Screw pump
2 Service condition Batch process
3 Operating condition
Capacity (ton/h) 35.15
Suction pressure (Pa) 105,000
Power (kWh) 0.07
4 Liquid Properties
Liquid to be handled Lignin Solution
Viscosity (cp) 2.0801
Temperature of liquid at inlet
(°C)
60
5 Material Stainles steel
Preliminary Design of Vanillin Production Plant From Black Liquor
63
5.3.5 Lignin Solution Pump (P-105)
Function : Pumping lignin slurry (lignin+water) from storage to BCR
Type : Screw Pump
Number of Unit : 1 unit
No. Specification
1 Scope Screw pump
2 Service condition Batch process
3 Operating condition
Capacity (ton/h) 49.21
Suction pressure (Pa) 105,000
Power (kWh) 0.12
4 Liquid Properties
Liquid to be handled Lignin Solution
Viscosity (cp) 2.0801
Temperature of liquid at inlet
(°C)
60
5 Material Stainles steel
5.3.6 Vanillin Slurry Pump (P-106)
Function : Pumping Vanilin solution from BCR to Ultrafikasi
Type : Screw pump
Number of Unit : 1 unit
No. Specification
1 Scope Screw pump
2 Service condition Continous process
3 Operating condition
Capacity (ton/h) 4.87
Preliminary Design of Vanillin Production Plant From Black Liquor
64
Suction pressure (Pa) 200,000
Power (kWh) 0.32
4 Liquid Properties
Liquid to be handled Vanillin Solution
Viscosity (cp) 5.13
Temperature of liquid at inlet
(°C)
60
5 Material Stainles steel
5.3.7 Vanillin Solution Pump (P-107)
Function : Pumping Vanillin Solution to Spray Dryer
Type : Screw pump
Number of Unit : 1 unit
No. Specification
1 Scope Screw pump
2 Service condition Continous process
3 Operating condition
Capacity (ton/h) 0.85
Suction pressure (Pa) 105,000
Power (kWh) 0.03
4 Liquid Properties
Liquid to be handled Vanillin Slurry
Viscosity (cp) 1.65
Temperature of liquid at inlet
(°C)
60
5 Material Stainles steel
Preliminary Design of Vanillin Production Plant From Black Liquor
65
5.3.8 Water Pump (P-109)
Function : Pumping water from the reservoir to filtration Plate and Press
I
Type : Piston Pump
Number of Unit : 2 unit
No. Specification
1 Scope Piston Pump
2 Service condition Batch process
3 Operating condition
Capacity (ton/h) 3.34
Suction pressure (Pa) 105,000
Power (kWh) 0.26
4 Liquid Properties
Liquid to be handled Water
Viscosity (cp) 1.65
Temperature of liquid at inlet
(°C)
60
5 Material Carbon steel
Preliminary Design of Vanillin Production Plant From Black Liquor
66
5.4 Conveyor
Conveyor I and II
Function :To transfer filtrate from filtrasi to acidification II.
Type : horizontal belt conveyor
Material : Stainless steel
Operating Condition : - Temperature (T) = 300 C
- Pressure (P) = 1 atm
Conveyor I and II
Rate of material 6.67 ton/10 min 40.18 ton/h
Looseness factor 52.23 ton/h
Conveyor Capacity 54 ton/h
Spesifikasi
Width of Belt 18.00 inch 0.46 m
Area 0.02 m2
Normal Belt Speed 76.00 m/min 1.27 m/s
Maximum Belt Speed 107.00 m/min 1.78 m/s
Power 2.50 hp 1.86 kW
7.44 kWh/day
2,232.00 kWh/year
Number of Conveyor 2 pieces
Preliminary Design of Vanillin Production Plant From Black Liquor
67
Conveyor III
Function : Transfer of Cake of Filtration to mixer tank.
Type : horizontal conveyor belt
Material : Stainless steel
Operating conditions : Temperature (T) = 300C
Pressure (P) = 1 atm
5.5 Bubble Column Reactor
Equipment
Code CS-101
Operation Mode Batch
Operation
Temperature 170 oC
Pressure 10 Bar
Volume 25.52 m3
Retention Time 2 hours
Dimension
Height 4.48 M
Diameter 2.69 M
Thickness 6,44 mM
Multiple Ring Sparger
Diameter 3 mM
Number of
Holes 15
Material Stainless Steel 316
Preliminary Design of Vanillin Production Plant From Black Liquor
68
5.6 Ultrafiltration
Vanillin Solution Ultrafilter
Identification: Item Vanillin solution ultrafilter
Item no. UF-101
No. required 6
Function: Separate vanillin solution from lignin alkali solution after
oxidation
Operation: Continuous
Material handled: Lignin alkali and other by product
Design data: Operating temperature (oK) 353
Operating pressure (Psi) 30
Type
Hollow fiber membrane
Material of construction
Polyvinylidenefluoride
PVDF (for filter
membrane)
Effective filtration Area
(m2)
Filtration area with safety
factor (m2)
Available filter area (m2)
130
Number of fiber in each module 10000
L (m) 2.36
W (m) 0.34
D (m) 0.23
Membrane cut-off rating (kDa) 1
Total equipment required (item) 6
Preliminary Design of Vanillin Production Plant From Black Liquor
69
5.7 Spray Dryer
SPRAY DRYER
Identification: Item Spray Dryer
Item no. SD-101
No. required 2 (1 active, 1 stand by)
Function: Make vanillin powder from vanillin solution
Operation: Batch
Material handled: Vanillin Solution
Composition (%):
Vanillin solution 100
Design Data: Type Closed spray dryer
Material of construction Stainless steel
Atomizer Centrifugal Disc (Vane)
Volume (m3) 5.52
Height cylindrical (m) 1.47
Column Diameter (m) 2.45
Thickness (m) 0.0025
Volume Cone (m3) 4.05
Cone Angle (o) 20.57
Max Temp Operating (oC) 180
Max Press Operating (psi) 600
Power (hp) 116
Preliminary Design of Vanillin Production Plant From Black Liquor
70
5.8 Heat Exchanger
5.8.1 Heat Exchanger HE-101
5.8.2 Heat Exchanger HE-102
Tipe Shell and Tube
Jenis Countercurrent Floating Head
Heat transfer area, m2 273.50
Heat transfer coefficient, W/m2 0C 900
Agen pemanas Superheated steam 190oC
Laju alir pemanas, kg/hari 32000
Jumlah tube 218
Shell Side Tube Side
Material SS 304 SS304
Densitas, kg/m3 0.521 1060
Cp, 2.09 2.08
Temperature in, 0C 190 60
Temperature out, 0C 190 170
Tipe Shell and Tube
Jenis Countercurrent Floating Head
Heat transfer area, m2 202
Heat transfer coefficient, W/m2 0C 900
Agen pemanas Superheated steam 190oC
Laju alir pemanas, kg/hari 32000
Jumlah tube 161
Shell Side Tube Side
Material SS 304 SS304
Densitas, kg/m3 0.521 1.02
Cp, 2.09 1.00
Temperature in, 0C 190 25
Temperature out, 0C 190 120
Preliminary Design of Vanillin Production Plant From Black Liquor
71
CHAPTER 6
PROCESS CONTROL
6.1 Process Control Instrumentation
Process control system is absolutely necessary in a factory to control all
the variables such as temperature, pressure, level, and more so the process runs.
Some process control objective to be achieved are as follows:
a) Avoiding dangerous circumstances that may occur in the operation (safety)
b) Maintaining the quality of the resulting product
c) Keeping the equipment is working in a range of operating conditions
d) Keeping operations and various byproducts produced run in accordance with
environmental standards
e) Monitor and diagnose the operation
F) Keeping operations running optimally so keep the plant gains
At this plant a variety of variables controlled by using a variety of instruments that
are available at the P & ID. Here is an explanation of the control system in the
main equipment.
6.2 Process Control on Raw Material Storage Tank
Black liquor storage tank is connected to the acidification vessel. Yield
products from this vessel will greatly depend on the composition of the input to
the output reactor or storage tank. Flow rate control system of storage tanks
needed for the flow rate from the storage tank maintained.
The control system used to control the flow rate is bypass control system.
The process of controlling the flow rate of the tank using orifice meter as a sensor
to measure the flow rate output before entering the control valve. Flow rate
measurements made of the difference in pressure at P1 and P2.
The output of the orifice meter is then analyzed by the controller based on
set point. Then the controller controls the flow rate of the control valve (open
when the flow rate is too small and close when the flow rate is too large) to adjust
the flow rate to set point.
Preliminary Design of Vanillin Production Plant From Black Liquor
72
6.3 Process Control on Heat Exchanger
Process control in the heat exchanger also has a similar system of controls
for each heat exchanger. Controlled variable is the temperature of the main
product output heat exchanger. The parameters are controlled steam flow rate or
cooling water into the heat exchanger.
Temperature is one of the important variables to be controlled. Heat
exchangers are the main components that require temperature control. Heat
exchanger serves to exchange heat between the main product with steam / cooling
water. Controlling the temperature of the product is required to be maintained in
accordance with the main design.
The control system used for temperature control are feed back control
system. Process control using a thermocouple as a temperature sensor on the
output of main products in heat exchangers.
The output of the thermocouple is then analyzed by the controller based on
set point. Then the controller controls the flow rate of the flow control valve on
the pipe steam / cooling water before it enters the heat exchanger. Control valve
controlling the flow rate of steam / cooling water to adjust the flow rate of steam /
cooling water with a temperature set point to achieve the appropriate design.
6.4 Process Control on Reboiler
Process control more towards the boiler temperature control in steam
output. Boiler using diesel fuel to vaporize water into steam. Controlled variable
is the temperature of the steam output of the boiler. The parameters were
controlled flow rate of diesel fuel and water into the boiler. And also controlling
the pressure in boiler so it can result the high steam pressure needed.
6.5 Process Control on Black Liquor Treatment Vessel
Process control in black liquor treatment vessel is a control process that
involves more than one variable that needs to be controlled. Variables that are
controlled from the oxidation reactor is the flow rate, height, composition, and
pressure.
Height
The height is a variable that must be maintained during the lignin
separation from black liquor. The height of the fluid is maintained in order
Preliminary Design of Vanillin Production Plant From Black Liquor
73
not higher than the feed inlet and not too low. Sensors are deployed using
a floating sensor surface fluid in the vessel. The parameters are controlled
liquid flow rate at the outlet.
Pressure
The pressure in the black liquor treatment vessel is kept equal to or
slightly above atmospheric pressure. Excessive pressure can affect the
quality of the product and can also be dangerous when the reactor
exploded due to excess pressure. To prevent excess pressure of the reactor
is equipped with a relief valve to release the pressure in the reactor.
Controlled variable is the pressure inside the reactor. When the pressure
exceeds the set point, then the relief valve on the reactor will open thereby
releasing the pressure in the vessel.
Composition
The composition is a variable that can affect the production yield of the
reactor. The process of composition control over the direction of the
control fluid homogeneity in the vessel. Controlled variable is the
composition of the sample in the vessel. The parameters are speed
controlled agitator. Sensor compositions using gas liquid chromatography
(GLC). When the results of the GLC analysis are deviations from the set
point, the parameters changed by the addition of agitation speed of
stirring.
6.6 Process Control on Acidification Vessel and Lignin Solution Vessel
Process control in acidification and liginin solution vessel is a control
process that involves more than one variable that needs to be controlled. Variables
that are controlled from the oxidation reactor is the flow rate, height, composition,
and pressure.
Height
The height is a variable that must be maintained during the lignin
separation from black liquor. The height of the fluid is maintained in order
not higher than the feed inlet and not too low. Sensors are deployed using
a floating sensor surface fluid in the vessel. The parameters are controlled
liquid flow rate at the outlet.
Preliminary Design of Vanillin Production Plant From Black Liquor
74
Pressure
The pressure in the acidification vessel is kept equal to or slightly above
atmospheric pressure. Excessive pressure can affect the quality of the
product and can also be dangerous when the vessel exploded due to excess
pressure. To prevent excess pressure of the vessel is equipped with a relief
valve to release the pressure in the vessel. Controlled variable is the
pressure inside the reactor. When the pressure exceeds the set point, then
the relief valve on the reactor will open thereby releasing the pressure in
the vessel.
Composition
The composition is a variable that can affect the production yield of the
reactor. The process of composition control over the direction of the
control fluid homogeneity in the reactor. Controlled variable is the
composition of the sample in the reactor. The parameters are speed
controlled agitator. Sensor compositions using gas liquid chromatography
(GLC). When the results of the GLC analysis are deviations from the set
point, the parameters changed by the addition of agitation speed of
stirring.
6.7 Process Control on Oxidation Reactor
Process control in the manufacture of vanillin making oxidation reactor is
a control process that involves more than one variable that needs to be controlled.
Variables that are controlled from the oxidation reactor is the input flow rate,
height, composition, pressure and temperature.
Flow rate
The flow rate input is an important variable to be controlled in a reactor.
The flow rate input into the reactor can affect the composition in the
reactor that will also affect the yield of the reactor. In addition flow rate
can also affect the height of the liquid in the reactor. Sensors are used to
measure the flow rate is orificemeter. Flow rate is then controlled by the
controller input based on set point. Control the flow rate by the flow
control valve (FCV).
Preliminary Design of Vanillin Production Plant From Black Liquor
75
Height
The height is one important variable but often forgotten in BCR tank.
Sensor height is needed in order to know whether the height of the fluid is
sufficiently safe for the agitator to operate. The parameters that are
controlled from the control height is input flow rate into the reactor.
Height sensors are used to using sensors floating in the fluid surface. The
height of the fluid in the reactor is controlled by the controller based on set
point. Control the flow rate by the flow control valve (FCV) on the same
input stream as the flow rate control input.
Composition
The composition is a variable that can affect the production yield of the
reactor. The process of composition control over the direction of the
control fluid homogeneity in the reactor. Controlled variable is the
composition of the sample in the reactor. The parameter control is speed of
gas O2 through component in BCR. Sensor compositions using gas-liquid
chromatography (GLC). When the results of the GLC analysis are
deviations from the set point, the parameters changed by the addition of
flow rate O2 from gas sparger to BCR.
Pressure
Pressure is an important variable in the reactor. The pressure in the reactor
was kept at pressure of 10 bar above atmospheric pressure, but do not be
too excessive. It is intended that the oxidation of lignin into vanillin could
happen. Pressure changes can occur due to the continuous input reactor
and the reaction in the reactor. Excessive pressure can affect the quality of
the product and can also be dangerous when the reactor exploded because
excess pressure. To prevent excess pressure of the reactor is equipped with
a relief valve to release the pressure in the reactor. Controlled variable is
the pressure inside the reactor. When the pressure exceeds the set point,
then the relief valve on the reactor will open thereby releasing the pressure
in the reactor.
Preliminary Design of Vanillin Production Plant From Black Liquor
76
Temperature
Temperature is the most variable can change in the reactor. The process of
oxidation reaction produces heat which can change the temperature in the
reactor. The reaction in the reactor must be on guard at 170° C for the
reaction to occur and produce vanillin. To keep the temperature inside the
reactor is used jackets. The temperature sensor used is a thermocouple.
Controlled variable is the temperature in the reactor.
6.8 Process Control on Spray Dryer
Process control in the spray drayer is a control process that involves more
than one variable that needs to be controlled. Variables that are controlled from
the spray dryer is the input flow rate, composition, and pressure.
Flow rate
The flow rate input is an important variable to be controlled in a spray
dryer. The flow rate input can affect timing and composition amount.
Sensors are used to measure the flow rate is orificemeter. Flow rate is then
controlled by the controller input based on set point. Control the flow rate
by the flow control valve (FCV).
Composition
The composition is a variable that can affect the vanillin powder
production of spray dryer. The process of composition control is over the
direction of the contain of vanillin. Controlled variable is the composition
of the sample in the spray dryer. The parameters controlled is rate of
evaporation. Sensor compositions using gas-solid chromatography (GSC).
When the results of the GSC analysis are deviations from the set point, the
parameters changed by the addition of rate of hot air into spray dryer.
Pressure
Pressure is an important variable in the reactor. The pressure in spray
dryer was kept at atmospheric pressure or above atmospheric pressure, but
do not be too excessive. Pressure changes can occur due to the continuous
input to spray dryer. Excessive pressure can affect the quality of the
product and can also be dangerous when the spray dryer exploded because
excess pressure. To prevent excess pressure of the spray dryerr is equipped
Preliminary Design of Vanillin Production Plant From Black Liquor
77
with a relief valve to release the pressure in the reactor. Controlled
variable is the pressure inside. When the pressure exceeds the set point,
then the relief valve will open thereby releasing the pressure in the spray
dryer.
Preliminary Design of Vanillin Production Plant From Black Liquor
78
Water
Black Liquor
CO2
P-101
S-101
P-102 P-103
P-108
FT
101FIC
101
LT
101
FT
102
FIC
102
AT
101
AC
101
FT
103FIC
103
PT
101
PIC
101
P-14
FT
104FIC
104
FT
106
FIC
106
V-101
PF-101
To V-102
Lean Liquor
LT
102
S-101BL Storage
P-102BL Pump
V-101BL Solid Treatment
Vessel
F-101CO2 Fan
P-103Slurry Pump
PF-101Plate & Frame
Filter
P-105Water Pump
VANILLIN PLANT FROM LIGNIN
PIPING AND INSTRUMENTATION DIAGRAM
Drawn By :
Checked By
Revised By :
Drawing No :
Date :
Date :
Without Scale A4
Notes :
Group 6
V-19
Figure 6.1 Piping and Instrumentation Diagram - 1
Preliminary Design of Vanillin Production Plant From Black Liquor
79
P-107
AT
102
AC
102
PT
102
PIC
102
V-5P-4
FT
105FIC
105
V-102
PF-102
Alkali sulfat
LT
103
From PF-101
H2SO4
P-109
FIC
105
FT
105
NaoH
P-111
FIC
108
FT
108
AC
103
PT
103
PIC
103
AT
103
LT
104
P-104
FT
109
FC
109
V-103
Water
P-106
FIC
107
FT
107
TO V-104
V-102Acidification Vessel
P-105H2SO4 Pump
P-106H2SO4 Pump
P-107Lignin Slurry Pump
PF-102Plate & Frame Filter
P-108Water Pump
V-103Lignin Solution Vessel
P-109Lignin Solution Pump
VANILLIN PLANT FROM LIGNIN
PIPING AND INSTRUMENTATION DIAGRAM
Drawn By :
Checked By
Revised By :
Drawing No :
Date :
Date :
Without Scale A4
Notes :
Group 6
V-22
V-23
Figure 6.2 Piping and Instrumentation Diagram - 2
Preliminary Design of Vanillin Production Plant From Black Liquor
80
From P-109
CS-101
H-101
Air
F-102
O2 & N2B-101
P-112
FIC
115
FT
115
PT
105
PIC
105
FIC
114
FT
114
O2 & N2
TT
102
TIC
102
FT
114
FIC
104
TIC
101
TT
101
H-103
AT
104
AC
104
PT
106
PIC
106
P-106
FT
110
FIC
110
LT
105
H-102
To UF-101
TT
103
To SD-101
TIC
103
Steam
N2
H-101Heat Exchanger
C-101O2 and N2 Compressor
CS-101Oxidation Reactor
F-102Air Blower
H-102Heat Exchanger
P-112Water Pump
H-103Heat Exchanger
B-101Steam Reboiler
VANILLIN PLANT FROM LIGNIN
PIPING AND INSTRUMENTATION DIAGRAM
Drawn By :
Checked By
Revised By :
Drawing No :
Date :
Date :
Without Scale A4
Notes :
Group 6
FT
110
FIC
110
FT
110a
FIC
110a
P-30
AC
104
V-104P-105
P-33
PT
104
PIC
104
AT
104
LT
106
Figure 6.3 Piping and Instrumentation Diagram - 3
Preliminary Design of Vanillin Production Plant From Black Liquor
81
From H-102
PT
111
FIC
111
FT
112
FIC
112
P-111
From H-103
TIC
103
TT
104
Others
Air
Powder Vanillin
AT
105
PT
107
PIC
107
FT
114
FIC
114
AC
105
UF-101Membrane Ultrafiltration
SD-101Spray Dryer
P-111Filtrate Pump
VANILLIN PLANT FROM LIGNIN
PIPING AND INSTRUMENTATION DIAGRAM
Drawn By :
Checked By
Revised By :
Drawing No :
Date :
Date :
Without Scale A4
Notes :
Group 6
FT
113
FIC
113
Figure 6.4 Piping and Instrumentation Diagram - 4
Preliminary Design of Vanillin Production Plant From Black Liquor
82
CHAPTER 7
PLANT LAYOUT AND PIPING DESIGN
Vanillin plant is subsidiary of Riau Andalan Pulp & Paper. The location of our
plant is beside RAPP, in Langgam, Pelalawan Regency, Riau. Our Plant Must near with
RAPP because black liquor as vanillin plant raw material sourced from RAPP byproduct.
RAPP total land area in langgam is 10,100 Ha with the following boundaries area.
North : PT Mitra Unggul Pusaka (rubber)
East : PT Mitra Unggul Pusaka (rubber)
South : PT Siak Raya Timber
West : Rubber plantations
Figure 7.1. Location of vanillin plant building
Vanillin Plant
Riau Andalan Pulp & Paper
(Sumber Black Liquor)
Preliminary Design of Vanillin Production Plant From Black Liquor
83
Our vanillin plant is divided into several areas. The first area is the main
area of the factory, which is the production area adjacent to a black liqour storage
tank. Additionally, there are utility area at the back of the factory. For the
purposes of administration and personnel, there is a 3-storey office and other
facilities such as clinics, mosque, cafeteria, and athletic fields. For the power
source, there is an electric generator room adjacent to the living room
maintanance tools and fire safety.
Vanillin plant construction is based on safety considerations, ease of
distribution of raw materials, utilities, land availability, ease of marketing and
transportation of goods. Vanillin plant layout and process equipment layout can be
seen in the following figure.
Preliminary Design of Vanillin Production Plant From Black Liquor
84
Raw
Material
Storage
Labora-
torium
Control
Room
Product
Storage
70 m
Utility
room
OWNER PROJECT
GROUP 6
PLANT DESIGN
2012
SKALA
1 : 5
Project
MASTER PLANT OF VANILLIN PLANT
PICTURE
DESIGN LAYOUT OF VANILLIN PLANT
PICTURE NO:
PL 001/2012
NO.
Page
Total
Page
1
1
INFORMATION
Room or Area:
- Black Liquor storage tank
- Raw material storage
- Control Room
- Production Process Area
- laboratorium
- Utility Area
- Security Post
- Meeting point
- Fire Safety
- Maintenance Room
- Electric Generator Room
- Vehicle Parking Area
- Main Office
CHEMICAL ENGINEERING
DEPARTMENT
ENGINEERING FACULTY
UNIVERSITAS INDONESIA
155 m
125 m
Process Production Area
Black Liquor
Storage
wastewater
Storage
Security
post
Parking Area
clinic Mosque canteen
Meeting Point
Main
Office
Electric
generator
room
Maintenan-
ce room
Sport
Field
Fire
Station
65 m
50 m
30 m
Main Road Main Road
Truck Parking Area Truck Parking Area
Pedistrian road Pedistrian road
Pedistrian road
Pedistrian road
Figure 7.2. Design Layout of Vanillin Plant
Preliminary Design of Vanillin Production Plant From Black Liquor
85
7.16 m
2.9 m
4.25 m
15.6
m
15 m1.35 m
2.5 m
2.83 m
3.8 m
8.5 m
8 m1 m
1.86 m
4 m1.5 m
2.5 m
2.34 m
2.36 m
2 m
15 m
15 mRaw
Material
Storage
15 m
10 mLabora-
torium
Control
Room
15 m
10 m Product
Storage
15 m
15 m
30 m
65 m
70 m
15 m
10 mUtility
room
8.7 m
OWNER PROJECT
GROUP 6
PLANT DESIGN
2012
SKALA
1 : 5
Project
MASTER PLANT OF VANILLIN PLANT
PICTURE
DESIGN LAYOUT OF VANILLIN PLANT
EQUIPMENT PROCESS
PICTURE NO:
PL 002/2012
NO.
Page
Total
Page
1
1
INFORMATION
Equipment:
- Raw material storage tank
- Acidification Vessel 1
- Plate & Frame Filtration
- Belt Conveyor
- Elevator
- Acidification Vessel 2
- Solution lignin Vessel
- Heat Exchanger
- Ultrafiltration
- Spray Drying
- Wastewater tank
- Air tank
- Compressor
CHEMICAL ENGINEERING
DEPARTMENT
ENGINEERING FACULTY
UNIVERSITAS INDONESIA
160 m
125 m
Black
Liquor
Storage
Acidification
vessel 1Plate & Frame
filtration
Elevator,
acidification
vessel 2,
plate&frame
filtration
Vessel, storage, Heat
exchanger, reactor,
ultrafiltation, spray
drying
wastewater
Storage
Figure 7.3. Design Layout of Vanillin Plant Equipment Process
Preliminary Design of Vanillin Production Plant From Black Liquor
86
CHAPTER 8
HEALTH, SAFETY, AND ENVIRONMENT MANAGEMENT
Health, Safety, and Environment Program (HSE) is a standard for
industries in Indonesia in order to protect workers' rights. Safety and good health
can improve safety and morale for employees or labor in general. A sense of
safety and employee morale which is great significance for the improvement of
labor productivity is the key to the success of a company or factory. In order to
implement the good HSE program, in the factory applied some policies regarding
work place safety and health. The purpose of the HSE policy implementation
include :
1. Set a target of increasing annual health and safety and make sure
everything is fulfilled by conducting regular audits
2. Prevent personal injury and health risks for all people who are in the
factory
3. Develop, design, build, set up, operate and maintain the process, plant,
equipment, including disposal in accordance with company guidelines and
regulations on occupational safety and health, and document process
control methods are classified as hazardous
4. Provide and maintain a safe system of work and prepare all necessary
plans to tackle any kind of disturbance or damage
5. Ensure that all employees at the location of the company to realize
responsibility for occupational safety and health
6. Ensures staff provide guidance on occupational safety, health and
environmental issues receive adequate training
7. Involve all employees in the implementation of policies and procedures
using advice and training to facilitate the emergence of a sense of
involvement and responsibility
8. Ensuring and summarizes all the experience of occupational safety and
health hazards that are relevant and disseminate the conclusions for the
business as a whole
9. Reviewing periodically and health policy in line with central policy
Preliminary Design of Vanillin Production Plant From Black Liquor
87
8. 1 Health Aspects
Health factor is one of the main supporters milling operations. With good
health in the factory, all the factors supporting plant performance, especially the
employees will be more productive at work. To prevent disruption of the
environmental health aspects of plant it is necessary to consider what are the
factors that could potentially endanger the health aspects in plant environments.
Danger to the health aspects can be avoided by analyzing the potential hazards
affecting the environmental health aspects of the plant.
8. 2 Safety Aspects
Safety is a very important factor in a factory. Analysis of the factors of
potential harm occurred in this plant needs to be done so that we get the data and
considerations necessary for handling. Hazard Analysis is an analysis of the
composition of the dangers of a place that has the potential dangers.
Identify Adverse events leading to a hazard material
Mechanism analysis of opportunities possible unexpected events
The estimated magnitude of the dangers that may arise. Hazard analysis can
be divided into two, namely:
1. HIRA (Hazard Identification and Risk Assessment)
2. HAZOP (Hazard and Operability Study)
8.2.1 Hazard Identification and Risk Assessment (HIRA)
HIRA is the identification of risks to an activity. Hazard Identification and
Risk Assessment (Hazard Identification and Risk Assessment), analysis carried
out in daily activities and in the factory. In determining HIRA, there are several
steps that must be done. The stages are as follows:
Sorting activities to be carried out into smaller sub-activities and specific
Identify potential hazards for each sub-activity
Determination of the risks that might occur (hazard effects and the
possibilities)
Determining how to prevent and control the risk of harm
Conclusion potential hazards and risks involved for each activity
Conclusion to overall job
Risk = Hazard x Exchange Rate Possible Dangers
Preliminary Design of Vanillin Production Plant From Black Liquor
88
o Harmful effects are still composed of HIGH, MEDIUM and LOW
o The possible dangers consist of HIGH, MEDIUM and LOW
Table 8.1 Parameter in Counting Dangers Possibilities
PARAMETER HIGH MEDIUM LOW
Frequency of
harm
Each time the
work was done Once in 10-100
One time during
the job done
Frequency of
adverse
danger
Almost every
time the work is
done
Once in 10-100 Once in 100 or
more
Ability level
executive jobs
Without
experience,
never done
before work
Less experienced
Experienced,
have good
ability and often
do the work
Table 8.2 Parameter in Counting Danger Effects
PARAMETER HIGH MEDIUM LOW
Human
Resources
Death, disability,
body dysfunction,
severe injuries
Medium wounds,
the body can still
work
minor injuries
Asset
Damage to the
equipment,
production halted
The damage
causes decreased
production levels
Little damage,
does not affect
the production
of protection
tool
Protection
Tool
No protective
devices are in an
environment with
the presence of a
flammable
substance
Minimal
protection device
Tools available
with sufficient
protection,
installation of
insulated
Evacuation
time
availability
Less than 1 minute Between 1-30
minutes
More than 30
minutes
Preliminary Design of Vanillin Production Plant From Black Liquor
89
Table 8.5 Hazard Identification and Risk Assessment (HIRA)
Types of
Activities
Potential
Danger Dangers
Danger
Rate
Effects
Possible
Rate Risks Prevention and Management
Final
Risks
Pre-Operational Stage
Plant
Building
Falling from
Height
Permanent
Injuries Death H L M
Work on construction
activities in accordance with
SOP and using PPE safety
belt
L
Objects falling
from height
Moderate to
severe injuries M L M
Work on construction
activities in accordance with
SOP and using PPE safety
helmet
L
Tripped up by
construction
equipment
scattered
Mild to
moderate
injuries
M M M
Work on construction
activities in accordance with
SOP and using PPE safety
shoes
L
Installation
Tool
Falling or
pinched tool
Death and
organ
dysfunction
H M M Using PPE and safety belt L
Hit or tripped
work
equipment
Non-
permanent
injuries
M M M Checking the condition of the
tool to be used to start a job L
Preliminary Design of Vanillin Production Plant From Black Liquor
90
Electrical
installation
Electric shock
Death,
permanent
injury
H L M
Using rubber boots,
gloves and other tools
that are insulators
L
Fall at the
time of
installation of
the high
Death and
organ
dysfunction
H M M Using PPE and safety
belt L
Plant Operation Stage
Charging of
raw
materials in
tanks
Exposure to
chemicals
Irritation
and minor
injuries
L H M
Wearing PPE such as
gloves and masks when
filling the tank of raw
materials
L
Slip away due
to chemicals
Permanent
injuries and
death
H L M
Wearing PPE such as
gloves and masks when
filling the tank of raw
materials
L
The
operation
of the
process
Electric shock
at the pump
Permanent
injuries and
death
H L M
Perform regular checks
and maintenance of the
pump according to SOP
L
Preliminary Design of Vanillin Production Plant From Black Liquor
91
Exposure to
heat flow and
heat exchange
equipment
boiler
Injuries
caused by
the heat of
the skin
M M M
Workers doing the
work in accordance
with SOP
L
Exposure to
chemicals in a
leaky pipe
Irritation
and injury
by heat on
the skin.
M L M
Perform regular checks
on the piping system
and start planning a
better pipeline
L
Bumped by
pipelines &
reactors
Non-
permanent
minor
injuries
M L M
Workers work carefully
and in accordance with
SOP
L
Storage of
raw
materials /
product
Exposure to
chemicals
directly
Irritation
and minor
injuries
L M M
Carry out work in
accordance with the
SOP and training
employees periodically
L
Contamination
in the end
product
storage
Decline in
value and
product
quality
M M M
Implementation and
maintenance work as
per SOP tank
periodically
L
Preliminary Design of Vanillin Production Plant From Black Liquor
92
Factory Maintenance Stages
Maintenance
Process
Stumble and
fall
Non-
permanent
injuries to
permanent
M M M
Maintenance jobs done
mentati applicable
SOPs
L
Pinched or
scratched
appliance
Non-
permanent
injuries to
permanent
M M M Using PPE and safety
belt Obey SOP jobs L
Exposure to
chemicals
Irritation
and minor
injuries
L M M
Maintenance jobs done
mentati applicable
SOPs
L
Electric shock
on job-related
electrical
installation
Permanent
injuries to
farm
H L M
Perform maintenance
and replacement
electrical equipment
periodically and
perform maintenance
work on a regular basis
L
Treatment
Plant
Facilities
Falling from a
height
Permanent
injuries to
death
H L M
Perform maintenance
work in accordance
with the procedures and
PPE safety belt
L
Preliminary Design of Vanillin Production Plant From Black Liquor
93
Electric shock
Permanent
injuries to
death
H L M
Perform maintenance
and replacement
electrical equipment
periodically and
perform maintenance
work on a regular basis
L
Preliminary Design of Vanillin Production Plant From Black Liquor
94
8.2.3 Hazard Operability Study (HAZOP) of Vanillin Plant
Operation
Unit
Equipment
Code Parameter Deviation Causes Effects Prevention Control
Vessel
S-101
S-102
S-103
S-104
S-105
V-101
V-102
V-103
Flow rate
Less
Blocking of raw
material
supplies and not
suitable with the
equipment
capacity
Vessel doesn't
work
efficiently
Ensure that raw material
capacity must suitable
with equipment capacity
Flow
control (FC)
More
Raw material
capacity more
than machine
capacity
Vessel will be
damaged
easily
Installing controller
such as valve at the
input of reactor to adjust
raw material capacity
which entering the
equipments
Agitator
Velocity
Less Power resources
is low
Reaction
doesn't work
perfectly and
too long
Giving extra power such
as electrical power Flow
control (FC)
More
Agitator
velocity isn't
appropriate
Making bubble
in the agitating
process
Determine agitator
velocity value (rpm);
Controlling regularly
Pump
P-101
P-102
P-103
P-104
P-105
Flow rate No Blocking in
pump
Pump heat and
damaged
easily
Pump cleaning and
controlling regularly
Flow
control (FC)
Preliminary Design of Vanillin Production Plant From Black Liquor
95
P-106
P-107
P-108
P-109
P-110
P-111
Less Blocking or
leaking in pump Low supply
Pump cleaning and
controlling regularly,
installing valve and
flow indicator
More
Overload
stirring
performance
Pump
damaged
easily
Controlling regularly
Heat
Exchanger
H-101
Flow rate
Less Blocking or
leaking in HE
Supply will be
clogged Controlling regularly
Flow
control (FC)
More Input flow rate
increase
HE will be
damaged
easily
Controlling regularly
and installing valve in
HE input
Temperature
Less Steam supply
will decrease
Temperature
process will
increase too
long
Increasing steam to HE
Temperature
control (TC)
More Steam supply
will increase
Encrement of
temperature
will be
excessed
Decreasing steam to HE
H-102 Temperature
Less Steam supply
will decrease
Temperature
process will
increase too
long
Increasing steam to HE
Temperature
control (TC)
More Steam supply
will increase
Encrement of
temperature
will be excess
Decreasing steam to HE
HE-103 Flow rate Less Blocking or Supply will be Controlling regularly Flow
Preliminary Design of Vanillin Production Plant From Black Liquor
96
leaking in HE clogged control (FC)
More Input flow rate
increase
HE will be
damaged
easily
Controlling regularly
and installing valve in
HE input
Temperature Less Chilling water
supply increase
The
temperature
reduction will
be excess
Decreasing water supply
to HE
Temperature
control (TC)
More Chilling water
supply is less
Temperature
reduction
process will
too long
Increasing water supply
to HE
Boiler B-101 Flow rate
Less
Blocking or
leaking in
Boiler
Heating will
be blocked
Lean liquor flow rate
setting Flow
control (FC)
More
The result of
combustion
increase
Damaged
equipment Installing pressure valve
Bubble
column
reactor
CS-101 Flow rate
Less
Raw material
input is blocked
and unsuitable
with equipment
capacity
Reactor
doesn't work
efficiently
Ensure that raw material
capacity must suitable
with equipment capacity
Flow
control (FC)
More
Raw material
capacity more
than machine
capacity
reactor
damaged
easily and
liquid spilled
Installing controller
such as valve at the
input of reactor to adjust
raw material capacity
which entering the
equipments
Preliminary Design of Vanillin Production Plant From Black Liquor
97
Blower F-101 Flow rate
Less Low power
supply
Acidification
process doesn't
work
effectively
Giving extra power such
as electrical power Flow
control (FC)
More
Overload
stirring
performance
Blower/fan
damaged
easily
Controlling regularly
Plate and
Frame
Filtration
PF-101
PF-102 Flow rate
Less Blocking or
leaking in pump
Supply will be
decreased
Controlling pump and
flow regularly;
Installing flow rate
controller Flow rate
Control
More
Overload
stirring
performance in
pump
Filtration
process will
take time too
long
Controlling pump and
flow regularly;
Installing flow rate
controller
Conveyor
CON-101
CON-102
CON-103
CON-104
Belt Speed
Less Low driving
force
Materials
which will be
streamed from
one place to
another would
pile on
operations
Provide additional
power in the form of
electric power Flow
Control
(FC)
More Incorrectness set
point
Supply
products are
expected to be
the product
will be too big
Determining the value
of a new set point and
controlled on a regular
basis
Preliminary Design of Vanillin Production Plant From Black Liquor
98
Spray Drying SD-101
Temperature
of the Hot air
Less
Hot air
temperature
which use to
atomized is too
small
vanillin still
contain a
water
Increase temperature of
hot air
Temperature
Control
(TC)
More
Hot air
temperature
which use to
atomized is too
big
Vanillin may
participate
evaporate
Decrease flow rate and
temperature steam
Flow rate
input
Less Input flow rate
is too small
Decreases
debit fluid
Increasing the flow rate
input
Flow rate
Control
(LC) More Input flow rate
is too large
Flooding,
crystalization
cannot
maximum
running
Reducing the flow rate
input
Ultrafiltration UF-101 Flow rate
Less
Blocking of
material
supplies and not
suitable with the
equipment
capacity
Ultrafiltration
doesn't work
efficiently
Ensure that material
capacity must suitable
with equipment capacity
Flow
control (FC)
More
Raw material
capacity more
than machine
capacity
Ultrafiltration
will be
damaged
easily
Installing controller
such as valve at the
input of ultrafiltration to
adjust raw material
capacity which entering
the equipments
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8. 3. Environmental Aspects
An industrial process can have a negative impact on the environment if not handled
properly. The negative impact on the environment can affect the sustainability of
production and the local environment. In this section, we discuss some of the
environmental impacts that may result from the presence of the vanillin plant is that the
manufacturing process produces substances called residual waste. Based on his form, the
waste produced by the plant can be grouped into four types, namely:
8. 3. 1. Liquid Waste
Wastewater produced by this plant are lean liquor that will be recycled by PT Riau
Andalan Pulp and Paper and water which is reused for chilling water in heat exchanger.
8. 3. 2. Solid Waste
No solid waste is removed from the production process of this vanillin plant.
8. 3. 3. Waste Gas
Majority of the waste gas produced is CO2 emissions resulting from the generator.
8. 3. 4. Waste Sound (Noise)
Possible noise pollution generated by tools such as pumps and motors drive stirrer.
Noise can also be caused due to the damage to the mechanical system on the appliance. To
reduce the noise level equipment necessary regular maintenance schedule has been
determined. For workers who are diarea that generate noise should be equipped with ear
protection (ear plugs). Meanwhile, for tools that can generate noise can be added by means
of dampening noise.
Noise standards set by the minister of health is 60-70 dB, while the minister of labor
is a maximum of 85 dB for 8 hours. Expected kenisingan of indigo dye plant is not too
large because the pump used is not too large, as well as other tools.
8. 4. Risk Management
Risk Management aims to solve the problem even prevent accidents. A particular
effort is needed to reduce or eliminate potential risks. Risk is a condition where there is the
possibility of an accident or occupational disease because of the presence of a hazard. The
danger is of a material nature, administration of a tool, how to do a job or work
Vanillin Production from Lignin
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environment that can lead to property damage, occupational disease, or the loss of human
lives. To avoid the danger of necessary control components with potential risks such as
human factors, equipment and materials, as well as the methods and sources of danger.
Risk management system is a management process carried out with the intention of
minimizing the risk or the extent possible to avoid the risk altogether. In a risk management
system, which required the application of the hierarchy of control measures against the risk
of a hazard, with the following steps:
Elimination (eliminate the hazard)
Substitution (use raw materials more secure)
Engineering (redesign existing processes to make it more secure)
Administrative control (changing methods or procedures work in a more secure)
Personal protective equipment (using the appropriate protective equipment to isolate
the body from harm)
To meet risk management will require tools and backup facilities to prevent or
overcome danger danger that occurs in plants. The tools and means necessary including
body protective gear for employees, fire extinguishers, MSDS (Material Safety Data
Sheet), and Account Head Point (local assembled) for all employees if fire occurs.
8.4.1. Personal Protection Equipment
Equipment protection for employees is the main standard for a company to protect
its employees from the threat of disruption to the aspects of safety and health at work.
Based on the major needs in the field of personal protective equipment can be divided into:
a. General
Personal protective equipment as a minimum requirement to enter the plant,
ie safety helmet, googles, and safety shoes.
b. Special
Vanillin Production from Lignin
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PPE is used in accordance with the needs of employees in the workplace
each based on hazard and risk. For example: safety goggles, respirators, ear
protection, gloves, earplugs, etc. Here are some of the personal protective
equipment used in the factory:
a. Protective equipment fall
Fall protective equipment used in the petrochemical industry is the seat belt / safety
belt is one of safety for the protection of workers in performing work activities in high
places where workers are likely to fall. Things that need to be considered for fall
protection equipment, namely:
Safety belt used to be in high places over 4 ft, the rope should be tied firmly on
building / sustaining a capable Defence weight
Ensure seat belt component in a condition to be good
To keep the belt remains in good condition, the equipment belt should be cleaned
with hot water and soap, and stored away from the sun and ultaviolet very strong,
also the chemical that causes the fibers to become brittle and weak belt
Type of fall protection equipment consists of:
Belts or harnesses are equipped components stitching, buckles, D-rings, cuts and
abration
The rope is made up of components rot, proper hook and knots, frayed strands or
broker.
b. Respiratory protection
The usefulness of this protection tool, especially in an emergency, eg labor should
help others who suffer accidents / when must escape a sudden atmospheric air
composition changes such that endanger his soul / when should perform repairs
equipment in where very high levels of contaminants.
Respirator or air purifying respirator which serves to clean the air that has been
contaminated in the form of dust, gases, metal vapors, smoke and fog, and protect the
work force has been a breath of danger, composed of chem respirator (steam and gas
Vanillin Production from Lignin
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contaminants), mech filter respirators (dust, mist, vapor metallic, sour) and cartridge /
canister respirator (mixed gas / vapor with solid particles equipped with a filter).
Breathing apparatus (air supply respirator), which supplies clean air or oxygen to the
wearer. Respirator is not equipped with a filter or cartridge, but supplies the user with
compressed air / air cleaner / from an oxygen tank.
Figure 8.1. Respirator
c. Hand protection tool
To protect from possible dangers that occur, it is expected that workers in work
activities always wore gloves, which must be adjusted to the working conditions and in
the absence of injured / contamination of the hands. Various kinds of gloves according
to the types of hazards that must be prevented:
Asbestos gloves, leather, PVC should be used when heat is caused by the heat
generated in the factory work, eg welding gloves to be used must pass through the
wrist
Rubber gloves, made of synthetic material, vinyl as well as natural, to protect hands
from chemicals caustic acids, alkalis and various types of other solvents
Gloves canvas / leather, wear gloves of canvas or heavy cotton is typically used
when the main danger is very high heat caused by friction
Gloves with chrome leather or PVC material with special design, to reduce the
hazard when in contact with sharp objects
Vanillin Production from Lignin
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Figure 8.2. Gloves
d. The tool foot protector
Safety shoes should protect workers against accidents caused by heavy items falling
to the feet, protruding nails, liquid metal, and so on. The types of tools used: Protective
Footwear, used in good condition should provide some protection against the impact of
falling objects or punctures caused by sharp objects to be secure, end-coated steel in a
protective layer of skin shoes worn feet will not slip or high heels at least 3 / 8 inch, 1-1/2
inch maximum.
Figure 8.3. Safety Shoes
e. Eye protection
Use eye protection of workers flake delicate objects and spray chemicals that can
enter and cause irritation to the eyes or even injure the eyes. This tool can also protect your
Vanillin Production from Lignin
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eyes from impact workers against a hard object. For eye protection, personal protective
equipment supplied googles or safety glasses for workers.
Figure 8.4. Goggles
f. Ear protective devices
Ear protective devices commonly used in the area located the tools that may cause
loud noises such as compressors, pumps, steam generators, conveyors and other tools that
use motors for propulsion. For protection against ear every employee who deals with the
tools required to use earplug process provided by the company.
Figure 8.5. Earplugs
g. Protective equipment head
The tool used in the form of head protection safety helmet. This headwear is a
protective device that is used to protect the head from impact by hard objects while
working in the field.
h. The tool body armor
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Personal protective equipment such as protective clothing body safe. Clothing was
named coverall which serves to avoid the possibility of a leak or spill liquid products in
bulk, so it can protect the body and to avoid direct contact with the skin of workers. To
clean up the spill using absorbent material must be non-combustible inorganic. In addition,
protective clothing or clothing that workers should not be used that has a crease on the
bottom of his pants.
8.4.2. Fire extinguisher
Determining the type of fire extinguishers are provided to extinguish the fire and
fire prevention and control efforts tailored to the classification of fire, state buildings and
items that exist in the building. Classification of types of fires, as follows:
Types of fire extinguishers, among others:
a. Water type fire extinguishers, consists of two types:
Soda Acid
Water CO2
Fire extinguisher soda acid type is not used anymore because it is dangerous to
humans. Water type fire extinguisher was used to extinguish the fire Class-A and
has the following specifications:
Red tube.
Distance sprays to tubes 9 liters (12-15 kg) is 6 meters.
When usage is 1-2 minutes depending on the size of the tube
b. Fire extinguisher types of dry dust, consisting of three types:
BC-class Dry Dust
Fire Class - B and C
Class ABC dry dust
Fire Class - A, B and C
Dry Dust class D
Fire Class - D fire extinguishers dry dust types have the following specifications:
a. Light blue tube
b. Consists of chemicals such as:
Vanillin Production from Lignin
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o Sodium Bicarbonate (97%)
o Magnesium Stearate (1.5%)
o Magnesium Karbinat (1%)
o Tricalcium phosphate (0.5%)
c. Tube size 1-12 kg
d. Distance 9 liters spray tube is 4-6 meters
e. Long time usage depending on size, to the size of 14-16 kg is 15 seconds
c. Types of fire extinguishers carbon dioxide (CO2)
Extinguisher was used to extinguish the fire Class-B and C and has the
following specifications:
o black tube
o distance 4.5-8 kg spray tube is 2 meters
o spending time is 14 seconds
o gas CO2 in liquid tube.
o the level of development is 450:1
d. The type of fire extinguisher foam (foam), consists of three types:
o Scum Chemistry
o Self-Aspirating
o Non-Aspirating AFFF
The type of fire extinguisher foam or foam used to extinguish the fire classes A and
B. Specifications of this type extinguishers are:
o Creamy white colored tube
o Distance sprays to tubes 9 liters (14-16kg) is 4-5 meters
o The duration is 30 seconds spending
o The level of development is 1:8
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8.4.3. MSDS (Material Safety Data Sheet)
MSDS are data from material or plant material in the interests of health and safety.
Any material or chemicals present in the plant must have a MSDS which serves as the basis
for the use of (material handling). MSDS data serves to communicate and inform everyone
working with these materials so that they can use the material properly and act
appropriately if there is immediate danger. MSDS of some materials of this plant will be
showed in appendix.
8.5. Quality Control in Vanillin Plant
All the food people eat must be absolutely pure and clean. This is one of the most
important principles of the food industry. One decisive criterion here is that products leave
factory without any metal contaminations and other contaminants. Product manufacturers
and service industries have realized that competition in a global market require a continual
and committed effort towards the improvement of product and service quality.
Quality control process consists of raw materials, process, product and service.
Major factors in process that cause variability in quality of finished product are people,
equipment and methods or technologies employed in the process. Use of proper statistical
process control methods is vital for assurance of the product quality. Statistical quality
control comprises the following procedure:
– Finished product is measured
– Value of quality characteristics is used to provide feedback on how process can be
improved
– Sampling occurs for days or weeks
– Lot is either accepted or rejected based on information from sample
– This procedure provided slow feedback of information.
Recognizing the importance of quality control of food products, Government of
Indonesia has legalized the Act No. 7 of 1996 on food and our plant use it as regulation of
quality control. The Food Act is intended as a legal basis for the regulations, development,
and control on the production activities or process, the circulation, and trade of food. This
Act also provides a reference for various legislative regulations related to food, both
already in existence and to be established.
Vanillin Production from Lignin
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WCfeecontractorycontingencfacilitiesoffsitebuildingssiteTBM
WCTPITCI
CCCCCCC
CCC
CHAPTER 9
ECONOMIC ANALYSIS
This chapter gives the economic analysis of vanillin plant from lignin. The steps to analyze
the plant economic is explained below.
9.1 Plant Cost Estimation
For total Capital Investment estimation of vanillin plant, we use Guthrie method with the
following formula.
1. Total Bare Modul Cost (CTBM)
Total bare module cost can be calculated using the costs of bare module (CBM) from
each equipment manufacturer. Cost of bare module (CBM) for each equipment can be seen
in table 9.1 while total bare module cost (CTBM) can be seen in table 6.2.
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Table 9.1. Recapitulation CBM value for each equipment
Code Equipment Unit
Amount Cost $
Year
Basis
Cost Index
Year Basis
Cost Index in
2013
Cost in 2013
($) Source
P-101 BLACK LIQUOR PUMP 1 8,565.84 2007 525.4 587.88 9,584.48 sinnot,2009
P-102 BLACK LIQUOR ACIDIFICATION
PUMP 2 8,401.91 2007 525.4 587.88 18,802.11 sinnot,2009
P-103 LIGNIN ACIDIFICATION PUMP 1 8,485.19 2007 525.4 587.88 9,494.24 sinnot,2009
P-104 LIGNIN SOLUTION PUMP 1 7,836.77 2007 525.4 587.88 8,768.70 sinnot,2009
P-105 LIGNIN SOLUTION PUMP 1 8,168.08 2007 525.4 587.88 9,139.42 sinnot,2009
P-106 VANILLIN SOLUTION PUMP 1 7,076.06 2007 525.4 587.88 7,917.54 sinnot,2009
P-107 VANILLIN SLURRY PUMP 1 6,955.41 2007 525.4 587.88 7,782.54 sinnot,2009
P-108 WATER PUMP 2 7,092.47 2007 525.4 587.88 15,871.81 sinnot,2009
P-109 H2SO4 PUMP 1 7,005.95 2007 525.4 587.88 7,839.09 sinnot,2009
P-110 WATER PUMP 1 7,234.38 2007 525.4 587.88 8,094.69 sinnot,2009
P-111 NAOH PUMP 1 7,814.68 2007 525.4 587.88 8,743.99 sinnot,2009
S-101 BLACK LIQUOR STORAGE 3 2,646.54 2004 444.2 587.88 10,507.74 sinnot,2004
V-101 ACIDIFICATION VESSEL 5 885.85 2004 444.2 587.88 5,861.90 sinnot,2004
V-102 ACIDIFICATION VESSEL 2 (A) 1 586.39 2004 444.2 587.88 776.06 sinnot,2004
V-102 ACIDIFICATION VESSEL 2 (B) 1 1,892.34 2004 444.2 587.88 2,504.44 sinnot,2009
V-103 BLENDING VESSEL 1 996.13 2004 444.2 587.88 1,318.34 sinnot,2012
S-102 LIGNIN SLURRY STORAGE 1 93,131.21 2004 444.2 587.88 123,255.24 sinnot,2009
S-103 H2SO4 STORAGE 1 21,853.70 2004 444.2 587.88 28,922.45 sinnot,2012
S-104 NaOH STORAGE 1 10,708.90 2004 444.2 587.88 14,172.78 matche,2007
S-105 WASTE STORAGE 2 112,472.97 2004 444.2 587.88 297,706.49 sinnot,2004
PF-101 PLATE AND FRAME FILTRATION 4 215,362.25 2004 444.2 587.88 1,140,091.49 sinnot,2004
PF-102 PLATE AND FRAME FILTRATION 1 56,454.18 2004 444.2 587.88 74,714.73 sinnot,2004
E-101 HE 1 21,700.00 2007 525.4 615.40 25,417.17 Seider, 2003
E-102 HE 1 21,700.00 2007 525.4 615.40 25,417.17 Seider, 2003
E-103 HE 1 19,000.00 2007 525.4 615.40 22,254.66 Seider,2003
UF-101 ULTRAFILTRATION 2 70,834.40 2000 394.0 615.40 221,276.60 Seider, 2003
SD-101 SPRAY DRYING 1 32,269.54 2000 394.0 615.40 50,402.72 Seider, 2003
B-101 BOILER 1 17,032.24 2000 394.0 615.40 26,603.14 Seider, 2003
CS-101 BUBBLE COLUMN REACTOR 1 49,066.96 2004 444.2 587.88 64,938.06 sinnot, 2004
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Table 9.2. Recapitulation CTBM value
Code Equipment
FOB/unit
ammount
($)
Total
Module
Factor
Bare Modul
Cost ($)
P-101 BLACK LIQUOR PUMP
9,584.48 3.47
33,258.15
P-102
BLACK LIQUOR ACIDIFICATION
PUMP
18,802.11 3.47
65,243.33
P-103 LIGNIN ACIDIFICATION PUMP
9,494.24 3.47
32,945.02
P-104 LIGNIN SOLUTION PUMP
8,768.70 3.47
30,427.41
P-105 LIGNIN SOLUTION PUMP
9,139.42 3.47
31,713.78
P-106 VANILLIN SOLUTION PUMP
7,917.54 3.47
27,473.87
P-107 VANILLIN SLURRY PUMP
7,782.54 3.47
27,005.41
P-108 WATER PUMP
15,871.81 3.47
55,075.17
P-109 H2SO4 PUMP
7,839.09 3.47
27,201.64
P-110 WATER PUMP
8,094.69 3.47
28,088.57
P-111 NAOH PUMP
8,743.99 3.47
30,341.66
S-101 BLACK LIQUOR STORAGE
10,507.74 1.41
14,815.92
V-101 ACIDIFICATION VESSEL
5,861.90 4.2
24,619.97
V-102 ACIDIFICATION VESSEL 2 (A)
776.06 1.5
1,164.08
V-102 ACIDIFICATION VESSEL 2 (B)
2,504.44 1.47
3,681.52
V-103 BLENDING VESSEL
1,318.34 4.2
5,537.01
S-102 LIGNIN SLURRY STORAGE
123,255.24 1.47
181,185.20
S-103 H2SO4 STORAGE
28,922.45 4.2
121,474.31
S-104 NaOH STORAGE
14,172.78 3.37
47,762.27
S-105 WASTE STORAGE
297,706.49 1.5
446,559.73
PF-101 PLATE AND FRAME FILTRATION
1,140,091.49 3.47
3,956,117.46
PF-102 PLATE AND FRAME FILTRATION 3.37
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74,714.73 251,788.64
E-101 HE
25,417.17 1.5
38,125.75
E-102 HE
25,417.17 2.06
52,359.37
E-103 HE
22,254.66 3.37
74,998.21
UF-101 ULTRAFILTRATION
221,276.60 2.7
597,446.81
SD-101 SPRAY DRYING
50,402.72 2.7
136,087.36
B-101 BOILER
26,603.14 2.24
59,591.04
CS-101 BUBBLE COLUMN REACTOR
64,938.06 1.41
91,562.66
Total Bare Modul Cost ($)
6,493,651.30
- Csite cost calculation
( )
- Cbuilding cost calculation
( )
- Coffsite facilities cost calculation
( )
- Ccontingency cost calculation
- Ccontractor fee cost calculation
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- CWC cost calculation
( (
)
Therefore total capital investment of vanillin plant can be found with following equation.
(
)
(
)
Table 9.3. Total Cost Investment
Component Value in $
Total Bare Modul Cost (C TBM) ($) 6,493,651.30
Site Development Cost (C site) ($)
1,298,730.26
Building Cost (C building) ($)
1,298,730.26
Offsite Facilities Cost (C offsite facilities) ($)
15,000.00
Contingency ($)
974,047.70
Contractor fee ($)
194,809.54
Working Capital (C WC) ($)
2,182,403.43
Total Cost Investment ($)
14,306,866.92
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9.2 Annual Operating Costs
Annual operating costs are divided into two types; fixed and variable cost, this cost
will be issued during the plant operating. Some of the assumptions used for calculate the
operating costs are as follows:
1. Plant operating life is 20 years.
2. In 1 year, this plant operated for 300 days, 24 hours.
3. The production capacity is 100% since the plant operated.
4. Depreciation is 9%, inflation is 4%, and interest rate is 10% per year.
Operating costs are calculated by performing the following details:
9.2.1 Raw Material Costs
Raw material used in this plant consists of:
1. Black Liquor Costs
Black liquor is result of the paper mill waste. Black liquor obtained from Riau
Andalan Pulp and Paper mill without charge. It because PT. Riau Andalan Pulp and
Paper is owner of this plant.
Needs for a year : 200,100 tons/year
Raw material cost : $ 0 /tons
Raw material cost per year : 200,100 tons/year X $ 0 /tons
= $ 0 /year
2. Carbon Dioxide
Needs for a year : 1,500.30 m3/ year
Raw material cost : $ 2.04 /m3
Raw material cost per year : 1,500.30 m3/ year X $ 2.04 /m3
= $ 3,055.53 /year
3. Sulfuric Acid
Needs for a year : 2,362.50 tons/ year
Raw material cost : $ 412.83 /tons
Raw material cost per year : 2,362.50 tons/ year X $ 412.83 /tons
= $ 975,315.48 /year
4. Sodium Hydroxide
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Needs for a year : 450 tons/ year
Raw material cost : $ 1,767.78 /tons
Raw material cost per year : 450 tons/ year X $ 1,767.78 /tons
= $ 795,500.61 /year
5. Water
Needs for a year : 333,166.50 tons/ year
Raw material cost : $ 0.13 /tons
Raw material cost per year : 333,166.50 tons/ year X $ 0.13 /tons
= $ 44,604.48 /year
6. Air (O2 and N2)
Needs for a year : 612 m3/ year
Raw material cost : $ 3.16 /m3
Raw material cost per year : 612 m3/ year X $ 3.16 /m3
= $ 1,935.21 /year
Thus, the total direct material cost is $ 1,820,411.31 per year.
Table 9.4. Raw Material Cost per Year
Materials Amount Unit/batch Needs per
year
Cost in 2012
($)
Cost in
2015 ($)
Raw Material
Cost Per
Year ($)
Water 370.19 ton 333,166.50 0.12 0.13 44,604.48
CO2 1.67 m3 1,500.30 1.90 2.04 3,055.53
H2SO4 50.03 ton 45,022.50 385.14 412.83 975,315.48
NaOH 0.50 ton 450.00 1,649.20 1,767.78 795,500.61
Air (O2 and
N2) 0.68 m3 612.00 2.95 3.16 1,935.21
Total Raw Material Cost Per Year 1,820,411.31
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9.2.2 Operating Labor Costs
Table 9.5. Indirect Labor costs
Qualification Amount
Cost per
month ($)
Cost per
year ($)
Total cost
per year ($)
Commissioner 1 5000 60000 60000
President Director 1 3500 42000 42000
FINANCIAL
Financial Director 1 2000 24000 24000
Marketing Department Manager 1 1500 18000 18000
Marketing Department Staff 2 900 10800 21600
Financial Department Manager 1 1500 18000 18000
Financial Department Staff 2 900 10800 21600
Budgetary Department Manager 1 1500 18000 18000
Budgetary Department Staff 2 900 10800 21600
HUMAN RESOURCES
Human Resources Director 1 2000 24000 24000
Public Relation Manager 1 1500 18000 18000
Public Relation Staff 2 900 10800 21600
Personnel Manager 1 1500 18000 18000
Personnel Staff 2 900 10800 21600
Education & Training Manager 1 1500 18000 18000
Education & Training Staff 2 900 10800 21600
OPERATIONAL
Operational Director 1 3000 36000 36000
Engineering Manager 1 1800 21600 21600
Processing Manager 1 1800 21600 21600
HSE Manager 1 1800 21600 21600
Research & Development
Manager 1 1800 21600 21600
Research & Development Staff 3 1200 14400 43200
Fixed Cost of Indirect Labour 553,200.00
Variable Cost of Indirect Labour = 20% TIL 110,640.00
Total Indirect Labour 663,840.00
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Table 9.6. Direct Labor costs
Qualification Amount
Cost per
month ($)
Cost per
year ($)
Total cost
per year ($)
Supervisor 2 1500 450,000.00 900,000.00
Engineering Staff 3 1200 14400 43200
Processing Staff 3 1200 14400 43200
HSE Staff 3 1200 14400 43200
R&D Staff 3 1200 14400 43200
Fixed Cost of Direct Labour 172,800.00
Variable Cost of Direct Labour = 20% TDL 34,560.00
Total Direct Labour 207,360.00
Total Operating Labour (OL) 871,200.00
9.2.3 Utilities Costs
The table below explain the detail of the utilities cost needed per year.
Table 9.7. Total Utilities Cost per Year
Utilities Amount Unit Needs per
year
Cost in
2012 ($)
Cost in
2015 ($)
Utilities
Cost Per
Year ($)
Electricity 126129.44 kwh/year 126129.44 0.08 0.09 54432.38
Domestic Water 10.00 m3/day 3000.00 0.12 0.13 401.64
Fuel for Steam 210.43 L/batch 568161 1.10 1.18 669913.58
Total Utilities Cost Per Year 681131.08
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9.2.4 Total Direct Costs
Table 9.8. Total Direct Costs per Year
Total Raw Material Costs $ 1820411.31
Total Operating Labour (OL) $ 871200.00
Total Utilities Cost $ 681131.08
Maintanance Cost (10% Fc) $ 1212446.35
Direct Supervisory (20% Operating Labour) $ 174240.00
Operating Supplies (1%Fc) $ 121244.63
Laboratory Charges $ 87120.00
TOTAL DIRECT COST $ 4967793.37
9.2.5 Total Fixed Costs
Table 9.9. Total Fixed Cost
Fixed Cost
Local Taxes 3% Fc $ 363733.90
Insurance 1% Fc $ 121244.63
Total Fixed Cost $ 484978.54
9.2.6 Plant Overhead
( ) ( )
9.2.7 Total Manufacturing Cost
Table 9.10. Total Manufacturing Cost
Total direct cost $ 4967793.37
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Total Fixed Cost $ 484978.54
Plant Overhead $
Total Manufacturing Cost $ 6281542.17
9.2.8 Expenses Cost
Here, we can know value of TOC, with the estimating that total manufacturing cost is 85%
Total Operating cost. So, the value of TOC is :
We can get the expenses cost.
The details of expenses cost is in table 6.11
Table 9.11. Total Expenses Cost
EXPENSES COST
EXPENSES COST = 15% TOC $
Administrative Cost = 15% OL $ 130680.00
Financial Interest = 5% Fc $ 606223.17
Distribution&Selling + R&D = EC – (AC+FI) $ 371604.27
9.2.9 Total Operating Cost
So, total operating cost of this plant is
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9.3 Equity
The total investment from this vanillin plant is $ 14306866.92 (according to the
preliminary equation). The initial capital came from the plant 60% equity and 40% of the
bank loan.
Table 9.12. Source investment
Source investment % value Interest / year
Self investment 60% 8584120.15 5 %
Bank Loan 40% 5722746.77 10%
Table 9.13. Bank Source Equity
Year Bank Loan Interest
End Year
Payment Loan remaining
2014 5722747 0 0 0
2015 6295021 629502 0 6924524
2016 6924524 692452 2077357 5539619
2017 5539619 553962 1938867 4154714
2018 4154714 415471 1800376 2769809
2019 2769809 276981 1661886 1384905
2020 1384905 138490 1523395 0
Table 9.14. Self Investment Source Equity
Year
Investment
Loan Interest
End Year
Payment Loan Remaining
2014 8584120 0 0 0
2015 9442532 472127 0 9914659
2016 9914659 495733 2478665 7931727
2017 7931727 396586 2379518 5948795
2018 5948795 297440 2280372 3965864
2019 3965864 198293 2181225 1982932
2020 1982932 99147 2082078 0
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9.4 Investment feasibility Analysis
To determine a project feasible or not to do, it is necessary a feasibility analysis of
investment. Investment is called feasible if it gives more profit than the expected. Expected
minimum profit are commonly known as the MARR, while profits are calculated on the
investment feasibility analysis are known as the IRR. Some of the usual investment
parameters analyzed are given below.
9.5.1 Cash Flow
Cash flow can indicate fluctuations in income earned over the life of the plant
through net income. The calculation is by subtracting the cash inflow with cash flow out.
Calculations of cash inflow involving revenue after taxes cutting, depreciation, rest value of
equipment called the after-tax cash flow (ATCF). Meanwhile, out cash flow can be an
investment, cost, and loans. Calculations before and after tax cash flow is shown in Table
9.15 and is represented in the cash flow diagram in Figure 9.1
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Figure 9.1. Cash flow diagram
-15000000.00
-10000000.00
-5000000.00
0.00
5000000.00
10000000.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
After Tax Cash Flow
ATCF Total ATCF Bank ATCF Investor
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Table 9.15 shows the calculation of cash flow that calculated from the initial
construction plant. In early 2013, the construction of the plant is beganwhich an investment is
for the purchase of the entire instrument. Figure 6.1 shows that the largest investment
incurred in the first year. In 2013, the construction is still going on until the middle of 2014,
so it is still a cash flow investment. In 2015, our factory started operation.
9.5.2 IRR
To find out how IRR can be obtained from the cash flow in table 6.12 above, it can be
calculated that the number of trial IRR values PW = 0,
Table 9.16 IRR Calculation
NPV
PV Bank PV Investor PW
-5334763.94 -7929399.12 -14592249.73
-341252.11 -511878.16 -853130.27
-3605180.83 -5457383.83 -8237587.18
3268169.31 4992616.20 6825122.96
2952272.39 4551412.99 5635018.13
2666450.82 4148485.59 4651632.90
2407854.71 3780528.12 3839150.13
2173905.94 3444523.34 3167951.53
1962271.72 3137716.59 2613544.42
1770840.74 2857592.27 2155674.62
1597701.86 2601852.57 1777593.30
1441124.77 2368398.15 1465450.68
1299542.74 2155310.70 1207794.80
1171536.95 1960837.02 995156.86
1055822.43 1783374.61 819708.42
951235.31 1621458.53 674977.72
856721.38 1473749.51 555615.10
771325.68 1339023.03 457198.91
694183.17 1216159.45 376074.98
624510.20 1104134.97 309223.76
561596.91 1002013.39 254150.51
504800.24 908938.61 208794.37
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Based on the trial was obtained IRR = 20.35%. Then, to know the NPV value as one
component of determining the feasibility of the realization of the design, PW calculation with
i = MARR = 10%, at which NPV = PW.
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9.5.3 Net Present Value (NPV)
An investment is feasible to be implemented if the investment has a value
of NPV> 0. This value indicates that the value for money of the plant profit not
lower than the value of the money spent as an investment in the factory default.
Therefore all of the above ATCF then be calculated present value rate of 10%
MARR. Table 6.17 shows the calculation of our plant NPV.
Table 9.17 NPV Calculation
Year NPV
PV bank PV Investor
-1 -5334763.94 -7929399.12
0 -341252.11 -511878.16
1 -3605180.83 -5457383.83
2 3268169.31 4992616.20
3 2952272.39 4551412.99
4 2666450.82 4148485.59
5 2407854.71 3780528.12
6 2173905.94 3444523.34
7 1962271.72 3137716.59
8 1770840.74 2857592.27
9 1597701.86 2601852.57
10 1441124.77 2368398.15
11 1299542.74 2155310.70
12 1171536.95 1960837.02
13 1055822.43 1783374.61
14 951235.31 1621458.53
15 856721.38 1473749.51
16 771325.68 1339023.03
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17 694183.17 1216159.45
18 624510.20 1104134.97
19 561596.91 1002013.39
20 504800.24 908938.61
Total NPV 5143803.48 18242597.62
NPV total 23386401.11
From the table above we can see that the value of the plant NPV is greater than
zero.
9.5.4 Pay Back Period
The payback period can be determined where the number of cumulative
ATCF to year n is equal to zero. From table 6.15, payback period value is located
between 3 and 4 years because in year 3 the value of cumulative ATCF is
negative and in year 4 the value of cumulative ATCF is positive.
Table 9.18 Pay Back Period Calculation
Year Payback Bank Payback Self
investment
Payback overall
3 -1272777.01 -1909165.51 -3181942.52
4 2631173.64 3946760.46 6577934.10
PBP 3.33 3.33 3.33
From the table above, we using the interpolation, we get the payback period is
3,74 years. This shows that the construction of the plant is feasible to be realized.
9.5.5Break Event Point (BEP)
Break Event Point states where the total sales volume of income exactly
equal to the total cost, so the company does not make a profit nor suffer a loss.
Problems of Break event will appear in the company if it has a Variable Costs
and Fixed Costs. A company with a certain production volume may suffer a loss
Vanillin Production from Lignin
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of income due to sales is only able to cover variable costs and can only cover a
small portion fixed costs.
( ) ( )
( )
Where the variable cost is the total of raw material price, labour price, and plant
overhead. The data is gotten from table 6.15.
So, the BEP of this plant is 495,95 tonnes.
9.5.6 Sensitivity Analysis
Sensitivity for product price
Table 9.19. Sensitivity analysis for product price
Deviasi Price NPV
IRR
(%) PBP (tahun)
-0.20 14.40 -5658627.61 12.30 4.71
-0.10 16.20 8863886.75 16.58 3.86
-0.05 17.10 16125143.93 18.51 3.57
0.00 18.00 23386401.11 20.35 3.33
0.05 18.90 30647658.29 22.11 3.13
0.10 19.80 37908915.46 23.80 2.96
0.20 21.60 52431429.82 27.00 2.69
From the table above, we can see that if the price become cheaper, the
value of NPV, IRR and the payback period become lower. The payback period is
sensitive with deviation -20% or the price of vanillin $ 14.40 because the NPV
become a negative value although the PBP below 5 years and IRR still above 10%
(below MARR).
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Figure 9.2. Sensitivity analysis for product price
Sensitivity for Raw material price
Table 9.20. Sensitivity analysis for raw material cost effect
Deviasi Raw Material Cost NPV
IRR
(%) PBP (tahun)
0.00 1820411.31 23386401.11 20.35 3.33
0.05 1911431.87 21782327.30 19.94 3.38
0.10 2002452.44 20178253.37 19.51 3.44
0.20 2184493.57 16970105.67 18.66 3.57
0.50 2730616.96 7345662.59 16.03 4.02
From the table above, we can see that if the raw material cost
become higher, the value of NPV and IRR become smaller while payback
period lower. The payback period is sensitive with deviation 50% or raw
material cost $ 2730616.96.
y = 1E+08x + 2E+07 R² = 1
-10000000.00
0.00
10000000.00
20000000.00
30000000.00
40000000.00
50000000.00
60000000.00
-0.30 -0.20 -0.10 0.00 0.10 0.20 0.30
NP
V
PriceDeviation
Product Price Effect
Series1
Linear (Series1)
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Figure 9.3. Sensitivity analysis for raw material cost effect
y = -3E+07x + 2E+07 R² = 1
0.00
5000000.00
10000000.00
15000000.00
20000000.00
25000000.00
0.00 0.20 0.40 0.60
NP
V
Cost Deviation
Operational Cost Effect
Series1
Linear (Series1)
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APPENDIX
1. Vessel
1.1 Black Liquor Storage Tank (S-101)
Calculation
Storage tank functioning as a repository of black liquor that will be used
for the production of vanillin. To calculate the dimensions of the tank needs to
know the total volume of the tank. The total volume of the tank is calculation of
tank working volume and tank head space. In the design of storage tanks,
assumptions using are:
- Ratio of height to diameter of the tank is 4:3
- Tank working volume is 0.85 of the total volume of tank
- residence time is 1 hour.
Black liquor flow rate:
Tank working volume :
Diameter and height of the tank:
(
)
(
)
Where; D is diameter of the tank and H is height of the tank. From the
results of calculation and rounding up to 0.1 m, height and diameter of the
tank is obtained respectively 9.55 m and 7.16 m.
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Thickness of shell tank:
x (CA n)
P (psi) = Poperation (psi) + Pstatis + safety factor
= 14.7 psi + 21.8 psi + 20 psi
= 56.50
S = Allowable stress, for stainless steel 316 = 20000 psi
E = Joint efficiency = 0.85
CA= Corrosion Allowance = 0.001 m/year
n = equipment life = 20 years
( )
Roof thickness of the tank:
1.2 Acidification Tank (V-101)
Calculation
a. Tank Design
Mixer tank functioning as a tank to mix black liquor slurry with H2SO4. To
design mixer tank, the dimensions of the tank needs to know the total volume of
the tank. The total volume of the tank is calculation of tank working volume and
tank head space. In the design of storage tanks, the assumptions used are:
- Ratio of height to diameter of the tank is 4:3
- Tank working volume is 0.85 of the total volume of tank
- residence time is 1 hour.
Black liquor flow rate:
Tank working volume :
Vanillin Production from Lignin
131
Diameter and height of the tank:
(
)
(
)
Where; D is diameter of the tank and H is height of the tank. From the
results of calculation and rounding up to 0.1 m, height and diameter of the
tank is obtained respectively 3.87 m and 2.90 m.
Thickness of shell tank:
x (CA n)
P (psi) = Poperation (psi) + Pstatis + safety factor
= 14.7 psi + 4.78 psi + 20 psi
= 39.48
S = Allowable stress, for stainless steel 316 = 20000 psi
E = Joint efficiency = 0.85
CA= Corrosion Allowance = 0.001 m/year
n = equipment life = 20 years
( )
Roof thickness of the tank:
Vanillin Production from Lignin
132
b. Impeller Design
Calculated of impeller design are:
Diameter (Da) = 0.4 x 2.90 m = 1.16 m
Blade width (W) = 0.125 x 1.16 m = 0.15 m
Agitator space from based (E) = 0.167 x 3.29 m = 0.55 m
1.3 Acidification Tank (V-102)
Calculation
a. Tank Design
Mixer tank functioning as a tank to mix black liquor slurry with H2SO4. To
design mixer tank, the dimensions of the tank needs to know the total volume of
the tank. The total volume of the tank is calculation of tank working volume and
tank head space. In the design of storage tanks, the assumptions used are:
- Ratio of height to diameter of the tank is 4:3
- Tank working volume is 0.85 of the total volume of tank
- residence time is 0.5 hour.
Black liquor flow rate:
Tank working volume :
Diameter and height of the tank:
(
)
(
)
Vanillin Production from Lignin
133
Where; D is diameter of the tank and H is height of the tank. From the
results of calculation and rounding up to 0.1 m, height and diameter of the
tank is obtained respectively 3.06 m and 2.30 m.
Thickness of shell tank:
x (CA n)
P (psi) = Poperation (psi) + Pstatis + safety factor
= 14.7 psi + 7.05 psi + 20 psi
= 41.75
S = Allowable stress, for stainless steel 316 = 20000 psi
E = Joint efficiency = 0.85
CA= Corrosion Allowance = 0.001 m/year
n = equipment life = 20 years
( )
Roof thickness of the tank:
b. Impeller Design
Calculated of impeller design are:
Diameter (Da) = 0.4 x 2.30 m = 0.92 m
Blade width (W) = 0.125 x 0.92 m = 0.12 m
Agitator space from based (E) = 0.167 x 2.60 m = 0.43 m
1.4 Blending Tank ( V-103)
Calculation
Vanillin Production from Lignin
134
c. Tank Design
Mixer tank functioning as a tank to mix black liquor slurry with H2SO4. To
design mixer tank, the dimensions of the tank needs to know the total volume of
the tank. The total volume of the tank is calculation of tank working volume and
tank head space. In the design of storage tanks, the assumptions used are:
- Ratio of height to diameter of the tank is 4:3
- Tank working volume is 0.85 of the total volume of tank
- residence time is 10 minute.
Black liquor flow rate:
Tank working volume :
Diameter and height of the tank:
(
)
(
)
Where; D is diameter of the tank and H is height of the tank. From the
results of calculation and rounding up to 0.1 m, height and diameter of the
tank is obtained respectively 2.04 m and 1.54 m.
Thickness of shell tank:
x (CA n)
P (psi) = Poperation (psi) + Pstatis + safety factor
Vanillin Production from Lignin
135
= 14.7 psi + 4.49 psi + 20 psi
= 39.19
S = Allowable stress, for stainless steel 316 = 20000 psi
E = Joint efficiency = 0.85
CA= Corrosion Allowance = 0.001 m/year
n = equipment life = 20 years
( )
Roof thickness of the tank:
c. Impeller Design
Calculated of impeller design are:
Diameter (Da) = 0.4 x 1.54 m = 0.61 m
Blade width (W) = 0.125 x 0.61 m = 0.08 m
Agitator space from based (E) = 0.167 x 1.74 m = 0.29 m
1.5 Lignin Slurry Storage (S-102)
Calculation
Storage tank functioning as a repository of alkali lignin slurry before enter
to bubble column reactor. To calculate the dimensions of the tank needs to know
the total volume of the tank. The total volume of the tank is calculation of tank
working volume and tank head space. In the design of storage tanks, assumptions
using are:
- Ratio of height to diameter of the tank is 4:3
- Tank working volume is 0.85 of the total volume of tank
- residence time is 1 hour.
Black liquor flow rate:
Vanillin Production from Lignin
136
Tank working volume :
Diameter and height of the tank:
(
)
(
)
Where; D is diameter of the tank and H is height of the tank. From the
results of calculation and rounding up to 0.1 m, height and diameter of the
tank is obtained respectively 2.58 m and 1.93 m.
Thickness of shell tank:
x (CA n)
P (psi) = Poperation (psi) + Pstatis + safety factor
= 14.7 psi + 5.65 psi + 20 psi
= 40.35
S = Allowable stress, for stainless steel 316 = 20000 psi
E = Joint efficiency = 0.85
CA= Corrosion Allowance = 0.001 m/year
n = equipment life = 20 years
( )
Roof thickness of the tank:
Vanillin Production from Lignin
137
1.6 Waste Storage (S-103)
Calculation
Storage tank functioning as a repository of waste from vanillin production
process. To calculate the dimensions of the tank needs to know the total volume
of the tank. The total volume of the tank is calculation of tank working volume
and tank head space. In the design of storage tanks, assumptions using are:
- Ratio of height to diameter of the tank is 4:3
- Tank working volume is 0.85 of the total volume of tank
- residence time is 1 hour.
Black liquor flow rate:
Tank working volume :
Diameter and height of the tank:
(
)
(
)
Where; D is diameter of the tank and H is height of the tank. From the
results of calculation and rounding up to 0.1 m, height and diameter of the
tank is obtained respectively 9.43 m and 7.07 m.
Thickness of shell tank:
Vanillin Production from Lignin
138
x (CA n)
P (psi) = Poperation (psi) + Pstatis + safety factor
= 14.7 psi + 21.6 psi + 20 psi
= 56.34
S = Allowable stress, for stainless steel 316 = 20000 psi
E = Joint efficiency = 0.85
CA= Corrosion Allowance = 0.001 m/year
n = equipment life = 20 years
( )
Roof thickness of the tank:
1.7 H2SO4 Storage (S-104)
Calculation
Storage tank functioning as a repository of H2SO4 before used in vanillin
production process. To calculate the dimensions of the tank needs to know the
total volume of the tank. The total volume of the tank is calculation of tank
working volume and tank head space. In the design of storage tanks, assumptions
using are:
- Ratio of height to diameter of the tank is 4:3
- Tank working volume is 0.85 of the total volume of tank
- residence time is 1 hour.
Black liquor flow rate:
Tank working volume :
Vanillin Production from Lignin
139
Diameter and height of the tank:
(
)
(
)
Where; D is diameter of the tank and H is height of the tank. From the
results of calculation and rounding up to 0.1 m, height and diameter of the
tank is obtained respectively 4.09 m and 3.07 m.
Thickness of shell tank:
x (CA n)
P (psi) = Poperation (psi) + Pstatis + safety factor
= 14.7 psi + 9.09 psi + 20 psi
= 43.79 psi
S = Allowable stress, for stainless steel 316 = 20000 psi
E = Joint efficiency = 0.85
CA= Corrosion Allowance = 0.001 m/year
n = equipment life = 20 years
( )
Roof thickness of the tank:
Vanillin Production from Lignin
140
1.8 NaOH Storage (S-105)
Calculation
Storage tank functioning as a repository of NaOH before used in vanillin
production process. To calculate the dimensions of the tank needs to know the
total volume of the tank. The total volume of the tank is calculation of tank
working volume and tank head space. In the design of storage tanks, assumptions
using are:
- Ratio of height to diameter of the tank is 4:3
- Tank working volume is 0.85 of the total volume of tank
- residence time is 1 hour.
Black liquor flow rate:
Tank working volume :
Diameter and height of the tank:
(
)
(
)
Where; D is diameter of the tank and H is height of the tank. From the
results of calculation and rounding up to 0.1 m, height and diameter of the
tank is obtained respectively 7.67 m and 5.75 m.
Thickness of shell tank:
x (CA n)
P (psi) = Poperation (psi) + Pstatis + safety factor
Vanillin Production from Lignin
141
= 14.7 psi + 19.72 psi + 20 psi
= 54.42 psi
S = Allowable stress, for stainless steel 316 = 20000 psi
E = Joint efficiency = 0.85
CA= Corrosion Allowance = 0.001 m/year
n = equipment life = 20 years
( )
Roof thickness of the tank:
2. Plate and Frame Filter
2.1 Plate and Frame Filter (PF-101)
Sizing Calculation :
1. Component mass and volume
Component input mass
(ton) output
mass (ton)
Density
(ton/m3)
input volume
(m3)/ batch
output volum
(m3)/ batch
Lignin Alkali 2 2 1.3 1.54 1.54
Water 3.91 3.91 1 3.91 3.91
Lean Liquor 18.45 13.78 1 18.45 13.78
Liquid Acid 0.31 0.31 1 0.31 0.31
lean liquor solid 0 4.67 1 0 4.67
Total 24.68 24.68 13.35 24.22 24.22
Total Mass
Filtrate
18.01
Total
VolumFiltrat 18.01
Total Mass
Cake
6.67
2. Filtrate density
( )
( )
3. Cake density
Vanillin Production from Lignin
142
( )
( )
4. Thickness of cake (L)
Estimated thickness of cake is = 0.06 m
5. Estimated cake porosity
Cake porosity ( ) of black liquor with pH 9 at 30°C = 0.7
6. Dry solid per unit area ( )
( )
( )
kg/m2
7. Effective filtration area (A)
m2
8. Safety factor = 20%
9. Filtration area (A)
( )
10.In this design, we use press filter with the filter area 2 x 2 m (4 m2) and
have 50 chambers. So, total press filter that we need for this process is:
And total minimum plate required is:
Vanillin Production from Lignin
143
2.2 Plate and Frame Filter (PF-102)
Sizing Calculation:
1. Component of lignin Slurry
Component input
mass (ton)
output
mass
(ton)
Density
(ton/m3)
input
volume (m3)/
batch
output
volum (m3)/
batch
Lignin 5 5 1.3 3.85 3.85
alkali sulfate 5.29 5.29 2.66 1.99 1.99
Liquid Acid 23.93 23.93 1 23.93 23.93
water 3.42 3.42 1 3.42 3.42
total 37.64 37.64 33.18 33.18
total mass filtrate
32.64
Volume
filtrate 29.34
total mass cake
2.5
2. Filtrate density
3. Cake density
4. Thickness of cake (L)
Estimated thickness of cake is = 0.06 m
5. Estimated cake porosity
Cake porosity ( ) of black liquor with pH 3 at 30°C = 0.33
6. Dry solid per unit area ( )
( )
( )
kg/m2
Vanillin Production from Lignin
144
7. Effective filtration area (A)
m2
8. Safety factor = 20%
9. Filtration area (A)
( )
10.In this design, we use press filter with the filter area 1.5 x 1.5 m (2.25 m2)
and have 24 chambers. So, total press filter that we need for this process
is:
And total minimum plate required is:
3 Pump
3.1 Black Liquor Pump (P-101)&(P-102)
Operation Condition :
Psuction= 100,000 Pa
Pdischarge= 105,000 Pa
T = 600 C
Mass Rate = 66.77 ton/h
Density = 1818.2kg/m3
Liquid Viskosity = 5.09 cP
Pump design :
( ) ( ) (Timmerhaus, 2004)
Vanillin Production from Lignin
145
From tabel A.3 buku Noel de Nevers (1991), we choose pipe with spesification:
Nominal Measure: 6 inch
Schedule number : 40
Inner Diameter (ID) : 6.065in
Outer Diameter (OD) : 6.625 in
Inside sectional area : 28.9 inch2
Velocity,
Reynold Number:
(aliran turbulen)
To get the value of the friction factor, used 6:10 on the book charts Noel de
Nevers (1991), in which the first note ε / D. To pipe the design of this plant, used
types of commercial steel. From table 6.2 on the book Noel de Nevers (1991), is
known for stainless steel pipes , value ε = 0,000046 m.
So, value ε/D = 0.0029
From 6:10 charts Noel de Nevers book (1991), the value of the friction factor (f) =
0,0034
Assumption of friction loss in the pipe is relatively the same.
Friction loss :
Number of
Velocity
Equivalent pipe
diameter
Tank outlet 0.5 25
Tank inlet 1 50
Vanillin Production from Lignin
146
Gate valve 0.3 15
4 elbow 9 450
Total 10.8 540
Extra Length of Pipe:
Total Length
Pressure Drop
Pressure Drop = 4381.08 N/m2
Head : 3.87 m
Pressure Differences : 5000 N/m2
Efficiency
Eff = 82.77%
From Energy Balance, So we can get,
W : 43.08 J/kg
Power : 0.32 kWh/operation
3.2 Black Liquor Acidification Pump (P-102)
Operation Condition :
Psuction= 105,000 Pa
Vanillin Production from Lignin
147
Pdischarge= 700,000 Pa
T = 600 C
Mass Rate = 33.38 ton/h
Density = 1020kg/m3
Liquid Viskosity = 1.7 cP
Pump design :
( ) ( ) (Timmerhaus, 2004)
From tabel A.3 buku Noel de Nevers (1991), we choose pipe with spesification:
Nominal Measure: 6 inch
Schedule number : 40
Inner Diameter (ID) : 6.065in
Outer Diameter (OD) : 6.625 in
Inside sectional area : 28.9 inch2
Velocity,
Reynold Number:
(Turbulen Stream)
To get the value of the friction factor, used 6:10 on the book charts Noel de
Nevers (1991), in which the first note ε / D. To pipe the design of this plant, used
types of commercial steel. From table 6.2 on the book Noel de Nevers (1991), is
known for stainless steel pipes , value ε = 0,000046 m.
So, value ε/D = 0.0029
From 6:10 charts Noel de Nevers book (1991), the value of the friction factor (f) =
0,0034
Assumption of friction loss in the pipe is relatively the same.
Vanillin Production from Lignin
148
Friction loss :
Number of
Velocity
Equivalent pipe
diameter
Tank outlet 0.5 25
Tank inlet 1 50
Gate valvle 0.3 15
4 elbow 6 300
Total 7.8 390
Extra Length of Pipe:
Total Length
Pressure Drop
Pressure Drop = 1271.13 N/m2
Head : 4.58 m
Pressure Differences : 595,000 N/m2
Efficiency
Eff = 82.49%
From Energy Balance, So we can get,
W : 629.46 J/kg
Power :2.35 kWh/operation
3.3 Lignin Acidification Pump (P-103)
Operation Condition :
Psuction= 105,000 Pa
Pdischarge= 700,000 Pa
T = 600 C
Vanillin Production from Lignin
149
Mass Rate = 61.68 ton/h
Density = 1774.71kg/m3
Liquid Viskosity = 1.32 cP
Pump design :
( ) ( ) (Timmerhaus, 2004)
From tabel A.3 buku Noel de Nevers (1991), we choose pipe with spesification:
Nominal Measure: 6 inch
Schedule number : 40
Inner Diameter (ID) : 6.065in
Outer Diameter (OD) : 6.625 in
Inside sectional area : 28.9 inch2
Velocity,
Reynold Number:
(Turbulen Stream)
To get the value of the friction factor, used 6:10 on the book charts Noel de
Nevers (1991), in which the first note ε / D. To pipe the design of this plant, used
types of commercial steel. From table 6.2 on the book Noel de Nevers (1991), is
known for stainless steel pipes , value ε = 0,000046 m.
So, value ε/D = 0.0029
From 6:10 charts Noel de Nevers book (1991), the value of the friction factor (f) =
0,0034
Assumption of friction loss in the pipe is relatively the same.
Friction loss :
Number of
Velocity
Equivalent pipe
diameter
Vanillin Production from Lignin
150
Tank outlet 0.5 25
Tank inlet 1 50
Gate valvle 0.3 15
4 elbow 9 450
Total 10.8 540
Extra Length of Pipe:
Total Length
Pressure Drop
Pressure Drop = 3601.57 N/m2
Head : 3.16 m
Pressure Differences : 595,000 N/m2
Efficiency
Eff = 81.98%
From Energy Balance, So we can get,
W : 368.26 J/kg
Power : 2.56 kWh/operation
3.4 Lignin Solution Pump (P-104)
Operation Condition :
Psuction= 105,000 Pa
Pdischarge= 105,000 Pa
T = 600 C
Mass Rate = 35.15 ton/h
Density = 1814.6kg/m3
Vanillin Production from Lignin
151
Liquid Viskosity = 2.08cP
Pump design :
( ) ( ) (Timmerhaus, 2004)
From tabel A.3 buku Noel de Nevers (1991), we choose pipe with spesification:
Nominal Measure: 4inch
Schedule number : 40
Inner Diameter (ID) : 4.026in
Outer Diameter (OD) : 4.5 in
Inside sectional area : 28.9 inch2
Velocity,
Reynold Number:
(Turbulen Stream)
To get the value of the friction factor, used 6:10 on the book charts Noel de
Nevers (1991), in which the first note ε / D. To pipe the design of this plant, used
types of commercial steel. From table 6.2 on the book Noel de Nevers (1991), is
known for stainless steel pipes , value ε = 0,000046 m.
So, value ε/D = 0.0044
From 6:10 charts Noel de Nevers book (1991), the value of the friction factor (f) =
0,0035
Assumption of friction loss in the pipe is relatively the same.
Friction loss :
Number of
Velocity
Equivalent pipe
diameter
Tank outlet 0.5 25
Tank inlet 1 50
Gate valvle 0.3 15
Vanillin Production from Lignin
152
4 elbow 3 150
Total 4.8 240
Extra Length of Pipe:
Total Length
Pressure Drop
Pressure Drop = 3165.23 N/m2
Head : 3.12 m
Pressure Differences : 0 N/m2
Efficiency
Eff = 79.83 %
From Energy Balance, So we can get,
W : 32.32 J/kg
Power : 0.06 kWh/operation
3.5 Lignin Solution Pump (P-105)
Operation Condition :
Psuction= 105,000 Pa
Pdischarge= 105,000 Pa
T = 600 C
Mass Rate = 49.21 ton/h
Density = 1814.6kg/m3
Liquid Viskosity = 2.08cP
Vanillin Production from Lignin
153
Pump design :
( ) ( ) (Timmerhaus, 2004)
From tabel A.3 buku Noel de Nevers (1991), we choose pipe with spesification:
Nominal Measure: 6 inch
Schedule number : 40
Inner Diameter (ID) : 6.625in
Outer Diameter (OD) : 6.065 in
Inside sectional area : 28.9 inch2
Velocity,
Reynold Number:
(Turbulen Stream)
To get the value of the friction factor, used 6:10 on the book charts Noel de
Nevers (1991), in which the first note ε / D. To pipe the design of this plant, used
types of commercial steel. From table 6.2 on the book Noel de Nevers (1991), is
known for stainless steel pipes , value ε = 0,000046 m.
So, value ε/D = 0.0044
From 6:10 charts Noel de Nevers book (1991), the value of the friction factor (f) =
0,0035
Assumption of friction loss in the pipe is relatively the same.
Friction loss :
Number of
Velocity
Equivalent pipe
diameter
Tank outlet 0.5 25
Tank inlet 1 50
Gate valvle 0.3 15
4 elbow 3 150
Total 4.8 240
Vanillin Production from Lignin
154
Extra Length of Pipe:
Total Length
Pressure Drop
Pressure Drop = 1129.98 N/m2
Head : 4.48 m
Pressure Differences : 0 N/m2
Efficiency
Eff = 81.32 %
From Energy Balance, So we can get,
W : 44.53 J/kg
Power : 0.12 kWh/operation
3.6 Vanillin Slurry Pump (P-106)
Operation Condition :
Psuction= 105,000 Pa
Pdischarge= 200,000 Pa
T = 600 C
Mass Rate = 4.87 ton/h
Density = 1609kg/m3
Liquid Viskosity = 5.13cP
Pump design :
Vanillin Production from Lignin
155
( ) ( ) (Timmerhaus, 2004)
From tabel A.3 buku Noel de Nevers (1991), we choose pipe with spesification:
Nominal Measure: 1.5inch
Schedule number : 40
Inner Diameter (ID) : 1.9in
Outer Diameter (OD) : 1.61 in
Inside sectional area : 2.04 inch2
Velocity,
Reynold Number:
(Turbulen Stream)
To get the value of the friction factor, used 6:10 on the book charts Noel de
Nevers (1991), in which the first note ε / D. To pipe the design of this plant, used
types of commercial steel. From table 6.2 on the book Noel de Nevers (1991), is
known for stainless steel pipes , value ε = 0,000046 m.
So, value ε/D = 0.0011
From 6:10 charts Noel de Nevers book (1991), the value of the friction factor (f) =
0,0055
Assumption of friction loss in the pipe is relatively the same.
Friction loss :
Number of
Velocity
Equivalent pipe
diameter
Tank outlet 0.5 25
Tank inlet 1 50
Gate valvle 0.3 15
4 elbow 3 150
Total 4.8 240
Extra Length of Pipe:
Vanillin Production from Lignin
156
Total Length
Pressure Drop
Pressure Drop = 52,223 N/m2
Head : 0.34 m
Pressure Differences : 95,000 N/m2
Efficiency
Eff = 79.73 %
From Energy Balance, So we can get,
W : 94.83 J/kg
Power : 0.32 kWh/operation
3.7 Vanillin Solution Pump (P-107)
Operation Condition :
Psuction= 105,000 Pa
Pdischarge= 150,000 Pa
T = 600 C
Mass Rate = 0.85 ton/h
Density = 1015.67kg/m3
Liquid Viskosity = 1.65cP
Pump design :
( ) ( ) (Timmerhaus, 2004)
Vanillin Production from Lignin
157
From tabel A.3 buku Noel de Nevers (1991), we choose pipe with spesification:
Nominal Measure: 1.5 inch
Schedule number : 40
Inner Diameter (ID) : 1.9in
Outer Diameter (OD) : 1.61 in
Inside sectional area : 2.04 inch2
Velocity,
Reynold Number:
(Turbulen Stream)
To get the value of the friction factor, used 6:10 on the book charts Noel de
Nevers (1991), in which the first note ε / D. To pipe the design of this plant, used
types of commercial steel. From table 6.2 on the book Noel de Nevers (1991), is
known for stainless steel pipes , value ε = 0,000046 m.
So, value ε/D = 0.0011
From 6:10 charts Noel de Nevers book (1991), the value of the friction factor (f) =
0,0055
Assumption of friction loss in the pipe is relatively the same.
Friction loss :
Number of
Velocity
Equivalent pipe
diameter
Tank outlet 0.5 25
Tank inlet 1 50
Gate valvle 0.3 15
4 elbow 3 150
Total 4.8 240
Extra Length of Pipe:
Total Length
Vanillin Production from Lignin
158
Pressure Drop
Pressure Drop = 52,223 N/m2
Head : 0.34 m
Pressure Differences : 45,000 N/m2
Efficiency
Eff = 79.69 %
From Energy Balance, So we can get,
W : 50.12 J/kg
Power : 0.029 kWh/operation
3.8 Water Pump (P-108)
Operation Condition :
Psuction= 105,000 Pa
Pdischarge= 700,000 Pa
T = 600 C
Mass Rate = 3.33 ton/h
Density = 1000kg/m3
Liquid Viskosity = 0.89cP
Pump design :
( ) ( ) (Timmerhaus, 2004)
From tabel A.3 buku Noel de Nevers (1991), we choose pipe with spesification:
Nominal Measure: 1.5 inch
Schedule number : 40
Vanillin Production from Lignin
159
Inner Diameter (ID) : 1.9in
Outer Diameter (OD) : 1.61 in
Inside sectional area : 2.04 inch2
Velocity,
Reynold Number:
(Turbulen Stream)
To get the value of the friction factor, used 6:10 on the book charts Noel de
Nevers (1991), in which the first note ε / D. To pipe the design of this plant, used
types of commercial steel. From table 6.2 on the book Noel de Nevers (1991), is
known for stainless steel pipes , value ε = 0,000046 m.
So, value ε/D = 0.0011
From 6:10 charts Noel de Nevers book (1991), the value of the friction factor (f) =
0,005
Assumption of friction loss in the pipe is relatively the same.
Friction loss :
Number of
Velocity
Equivalent pipe
diameter
Tank outlet 0.5 25
Tank inlet 1 50
Gate valvle 0.3 15
4 elbow 6 300
Total 7.8 390
Extra Length of Pipe:
Total Length
Pressure Drop
Vanillin Production from Lignin
160
Pressure Drop = 91.87 N/m2
Head : 4.58 m
Pressure Differences : 595,000 N/m2
Efficiency
Eff = 76.51 %
From Energy Balance, So we can get,
W : 639.97 J/kg
Power : 0.25 kWh/operation
Tank working volume :
Diameter and height of the reactor:
(
)
(
)
Where; D is diameter of the tank and H is height of the tank.From the
results of calculation and rounding up to 0.1 m, height and diameter of the
tank is obtained respectively 1.89 m and 1.134 m.
Thick walls of the tank:
Vanillin Production from Lignin
161
P (psig) = P operation (psia) + Pstatis + safety factor
= 159,7 psia + 14.7 psia + 25 psia
= 199,4 psia
= 184,7 psig
S = Allowable stress, for Stainless Steel 316 = 74500 psig
E = Joint efficiency = 0.8 (Walas, 1988)
R = D/2 = 0,8465 m = 33,32 in
Corrosive factor = 0.15 in
4 Bubble Column Reactor
Stoichiometry 1 Conversion 70%
Lignin Oxidation : 0.5 L + 1.56 O2 --> V + 114 X
Initial (mol) 2350.242 10781.25
Change (mol) -1645.17 -7332.75 4700.483
Remaining
(mol) 705.0725 3448.496 4700.483
Stoichiometry 2
Vanilin Oxidation : V + O2 --> Product
Initial (mol) 4700.483 3448.496
Change (mol) -3290.34 -3290.34 3290.338
Remaining
(mol) 1410.145 158.1582 3290.338
massa 500592.048 gram
Vanillin Production from Lignin
162
0.50059205 ton
500.592048 kg
Reactor Volume = 25.51 m3
Reactor functioning as a tank to mix and react lignin slurry with oxygen in
alkaline condition. To design bubble column reactor, the dimensions of the reactor
needs to know the total volume of the reactor. In the design of reactor, the
assumptions used are:
- Ratio of height to diameter of the bubble column reactor is 5:3
- residence time is 2 hour.
Diameter and height of the reactor:
(
)
(
)
Where; D is diameter of the tank and H is height of the tank. From the results of
calculation and rounding up to 0.1 m, height and diameter of the tank is obtained
respectively 4.48 m and 2.69 m.
Thickness of shell tank:
x (CA n)
Vanillin Production from Lignin
163
P (psi) = Poperation (psi) + Pstatis + safety factor
= 145 psi + 6787 psi + 20 psi
= 174.84
S = Allowable stress, for stainless steel 316 = 20000 psi
E = Joint efficiency = 0.85
CA= Corrosion Allowance = 0.001 m/year
n = equipment life = 20 years
( )
Roof thickness of the tank:
5 Ultrafiltrasi
Sizing Calculation :
Component mass and volume
Component Input mass
(ton)
Output
mass (ton)
Density
(ton/m3)
Input
volume
(m3)/
batch
Output
volume
(m3)/
batch
Vanillin 0.500 0.500 1.05 0.476 0.476
Alkali Lignin Slurry 5.360 0.000 1.22 4.393 0
Water 1.200 1.200 1 1.200 1.200
Vanillin Production from Lignin
164
Others 4.780 0.000 1 4.780 0
Filtrate Cake 0.000 10.140 1.3 0 7.800
Total 11.840 11.840 10.849 9.476
total mass filtrate 1.700 volum
filtrat
1.676
Filtrate density
( )
( )
3. Cake density
( )
( )
4. Thickness of cake (L)
Estimated thickness of cake is = 0.03 m
5. Estimated cake porosity
Cake porosity ( ) of product = 0.2
6. Dry solid per unit area ( )
( )
( )
kg/m2
7. Effective filtration area (A)
Vanillin Production from Lignin
165
m2
8. Safety factor = 20%
9. Filtration area (A)
( )
10.In this design, we use hollow fiber ultrafiltration with the filter area 190 m2 and
have 10000 fibers per module. So, filter that we need for this process is:
6 Spray Dryer
Surface moisture is removed in about 5 sec, and most drying is completed in less
than 60 sec. Parallel flow of air and stock is most common. Atomizing nozzles
have openings 0.012-0.15 in. and operate at pressures of 300-4000 psi. Atomizing
spray wheels rotate at speeds to 20,000rpm with peripheral speeds of 250-600
ft/sec. With nozzles, the length to diameter ratio of the dryer is 4-5; with spray
wheels, the ratio is 0.5-1.0. For the final design, the experts say, pilot tests in a
unit of 2 m dia should be made.
Diameter of particle,
= 55,65 μm
T air inlet = 120oC
T air oulet = 110oC
T feed inlet = 80oC
T feed outlet = 90oC
Vanillin Production from Lignin
166
Design aspect include : Atomizer : its type & design, flow rate of the heated inlet
air, settling velocity, solid & Gas operating velocity, chamber Diameter, residence
time, design of Conical bottom.
Atomizer : Centrifugal disk atomization is particularly advantageous for
atomizing suspensions and pastes that erode and plug nozzle. Type of Disk
atomizer (Vane, Kesner, Pin) Ref. patent US20040139625. Diameter of the disk
atomizer 5-45 cm. Rotational speed 33.000 rpm, peripheral speed 6000 m/min.
Mean particle size 55 micron.
Feed Rate = 730 kg/hr = 24 lb/min
Peripheral speed is got from Herring and Marshal chart (peripheral speed vs.
mean particle diameter, with feed rate as parameter). On interpolation we get 473
ft/s (v =8952 m/min).
Disk Selection
Disk selected = B-1, with diameter 0,59 ft. Vane height= 0,406 ft, vane length = 1
ft, number of vanes = 60.
Rotational speed (N) =
N = 473 * 60 = 15800 rpm
So, power consumption of atomizer can be calcaulated below
( )
Vanillin Production from Lignin
167
Spray Chamber design
Vanillin Production from Lignin
168
X1 = 0.015, X2 = 0.003
Y1 = 0.01317 (by psychometric chart at given DB & WB) humidity air
HL1= 112.2 kJ/kg of dry solid, HL2= 121.68 kJ/kg of dry solid
H1= 134.29 kJ/kg dry air
Simultaneously solving mass balance and enthalpy balance eq (1) and (2) we get
Y2= 0.0206
Evaporation rate of water = (0.015-0.003)*1500 kg/hr = 18 kg
Assumed chamber efficiency is 70%, therefore net evaporation rate of water is
18/0.7 =25.71 kg water /hr.
Moisture removed per kg of dry air = (0.0206-0.01317)=0.00743 kg water per kg
of dry air.
Gs = 25.71/0.00743 = 3460 kg/hr.
After this we must calculate humid volume
Vanillin Production from Lignin
169
Humid volume inlet (Vin) = 0.283 m3/kg dry air
Humid volume outlet (Vout) = 0.281 m3/ kg dry air
Vavg = (Vin + Vout)/2 = 0.282 m3 / kg dry air
Assume Dp = 100 micron
And then we calculate operating velocity. The operating velocity in the case of
non-dusting spray dryer is taken as two times the settling velocity of the drop.
Settling velocity didapatkan berdasarkan perhitungan adalah sebesar 0.25 m/s.
Stoke’s law is applicable if Re < 2. So we must check the reynold number
So we can get operating velocity, va= 2vs = 2*0.25 = 0.5 m/s
Column Area: ( )
= 3.1 m2
Vanillin Production from Lignin
170
Column diameter : √
= 1,974 m, for safety, assuming 15 % safety
factor, Dc = 2.1 m.
Residence time : √
Time required to evaporate moisture from droplet :
Өp = 0.00969 sec, Өp < td, design is acceptable
Chamber is a cylindrical with a conical bottom
Total volume of chamber (Vt) = Gs*Vav*td = 5.2 m3
Minimum height of cylindrical portion (hmin) = vs*Өp = 0.00068 m
Recommended height of cylindrical portion (hcyl) = 0.6 *Dc = 1.47 m
Volume Cone =
= 3.1 m3
Height of cone (hcone) =
m
Cone angle : tan(a/2) = Dc/2hcone
a = 20.57 degree
Thickness of chamber : tmin = (Dc+100)/1000 = 0.11 inch
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7. Material Safety Data Sheet (MSDS)
1. Black Liquor
Properties Information
Molecular Weight (g/mol) Not available
Melting Point (0C) Not available
Boiling Point (0C) Variable
Form Slurry
Odor rotten egg odor
pH Typical Range 10-12
Color Black liquid
Solubility Soluble in cold and hot water
Flammability
Not flammable, will burn at very
high temperatures
Materials to avoid Aluminum and acids. Contact with
acids and oxidizing agents can
result in release of potentially lethal
concentrations of hydrogen sulfide
(H2S) gas
Corrosivity Corrosive with aluminum
Toxic effect Causes eye and skin irritation and
corrosion; respiratory airways
irritation if ingested in large
amounts : digestive tract irritation
and corrosion,
vomiting, diarrhea, and death
(possible)
Handling Do not contact with eyes, skin,
and clothing. Do not be inhaled
Do not contact with the acid
Storage Keep away from acids and
aluminum
Personal protective equipment Gloves, respirator, eye protection,
goggles and footwear
Spill procedures Open ventilation and insulation use
Vanillin Production from Lignin
172
a shovel to dispose of spill
2. H2SO4
Properties Information
Molecular Weight (g/mol) 98
Melting Point (0C) 10.36
Boiling Point (0C) 100
Form Liquid
Odor Odorless
pH Typical Range 2-3
Color Transparent
Solubility Soluble in cold and hot water
Flammability Easy to flammable
Materials to avoid Organic material, metal, acids, and
alkali
Corrosivity Corrosive with aluminum, stainless
steel (304,316), not corrosive with
glass
Toxic effect Causes eye irritation and burn if
contact with skin.
Handling Do not contact with eyes, skin,
and clothing.
Storage Keep in closed container, cool, and
good ventilated
Personal protective equipment Gloves, respirator, eye protection,
goggles and footwear
Spill procedures Spare with soil, sand, and not
flammable material
Vanillin Production from Lignin
173
3. NaOH
Properties Information
Molecular Weight (g/mol) 40
Melting Point (0C) 323
Boiling Point (0C) 1388
Form Solid
Odor Odorless
pH 13.5 (Basic)
Color White
Solubility Easily soluble in cold water
Flammability Not flammable
Materials to avoid Aluminum
Corrosivity Very caustic to aluminum and other
metals in presence of moisture.
Toxic effect Causes damage to the following
organs: lungs
Handling Do not contact with eyes, skin,
and clothing.
Storage Keep in closed container and cool
Personal protective equipment Gloves, respirator, eye protection,
goggles and footwear
Spill procedures Insulation use a shovel to dispose of
spill
Vanillin Production from Lignin
174
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lignin/vanillin mixture by using tubular ceramic ultrafiltration membranes.
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Araújo, j. D., grande, c. A., & rodrigues, a. E. (2010). Vanillin production from
lignin oxidation in a batch reactor. Chemical engineering research and
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Heradewi. (2007). Isolasi lignin dari lindi hitam proses pemasakan organosolv
serat tandan kosong kelapa sawit (tkks). Bogor: institut pertanian bogor.
Jo, j. D., grande, c. A., & rodrigues, a. E. (2009). Structured packed bubble
column reactor for continuous production of vanillin from kraft lignin
oxidation. Journal of catalysis today , s330-335.
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Priefert, h., rabenhorst, j., & steinbüchel, a. (2001). Biotechnological production
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