Succinic Acid Production Plant

PLANT DESIGN AND ECONOMICS

(CHE 604)

GROUP PROJECT:

SUCCINIC ACID PRODUCTION PLANT

GROUP NUMBER : GROUP 3

GROUP MEMBERS: MOHD ADIB BIN MOHD NOR (2010438828)

MUHAMMAD BIN AJMI (2010823606)

ABDUL FAIZ SAIFUL BIN ABD RAZAK (2010427046) NUR HAZLINA BINTI ABD GHANI (2010481158) NUR SUHADA BINTI MUSTAFAR (2010221172) NOR EKANADIRAH BINTI ABDUL RAHMAN (2011817088) NUR SUHAILI BINTI MUHAMAD PUJI (2011270636)

NORAFIQAH BINTI AZMAN (2010872226)

TABLE OF CONTENT

CONTENT

PAGE

Introduction

3

Process Description

6

Equipment Design

15

Economic Analysis

48

Environmental Considerations

75

Plant Layout

95

Summary & Conclusion

98

References

99

Appendixes

100

This plant has been designed to produce succinic acid and focused on all aspects that are important for the production of succinic acid. The plant is located at Bukit Minyak Free Industrial Zone, Penang and this report will explain thoroughly on the details about the variation of methods, process selection, the reaction being generated and the description on the production of succinic acid based on 1000 kg of raw material supplied. Basically, this project had chosen the fermentation of Anaerobiospirillum succiniciproducens as the method of operation. This reaction will consume 100% pure carbon dioxide gas at 39 0_{C and absolute pressure of 1.013} bars. Product specification has been carried out and the result obtained at the end of the process is purified succinic acid. The environmental impact assessment, ways to control the pollution, the characteristics and the behaviour of the populace surrounding are also discussed in this report. This plant considers full safety of overall plant operations starting from the handling of raw materials until the recovery of final product. The product will be sold to local and foreign markets and being used as a raw material for other manufacturing purposes.

1.1 Product Description

Succinic acid is a white, odorless solid which categorized under dicarbolxylic acid and diprotic acid group. Succinic acid has a chemical formula of C4H6O4 and molecular weight of 118.088 g/mol. Before this chemical is named as succinic acid, it is known as butanedioic acid. Succinic acid is under organic acid family and has a melting point of 185-188 C. This chemical is soluble⁰ in water, ehanol and diethyl ether while it is insoluble in chloroform and methylene chloride. Succinic acid could be applied in many different fields, such as chemical, food and medicine industry. In chemical industry, succinic acid is used in the productions of spray paint, dyes, ion exchange resin, pesticide and many more. In medicine industry, this chemical is used in the synthesis of sedative, diuretic, vitamin, contraceptive and cancer drugs. It is also used in foods as seasoning of wine, candy, feed, buffer, and a neutralizing agent.

1.2 Methods of Manufacturing Succinic Acid

Succinic acid can be manufactured by hydrogenation of maleic acid, maleic anhydride, or fumaric acid. This process produces good yields of succinic acid. Chemical compound 1, 4-Butanediol can be oxidized to succinic acid in several ways. One of the means is by oxidizing 1, 4-Butanediol with oxygen gas in an aqueous solution of an alkaline-earth hydroxide at 90-110 ⁰C in the presence of Pd-C component. The second way is by ozonolysis of 1, 4-Butanediol in aqueous acetic acid or by applying the third way which is by reacting 1, 4-Butanediol with N2O4 at low temperature.

Succinic acid can also be obtained by phase-transfer-catalyzed reaction of 2-haloacetates, electrolytic dimerization of bromoacetic acid or ester, oxidation of 3-cyanopropanal, and fermentation of n-alkanes. Besides, succinic acid can also be derived from the fermentation of ammonium tartrate.

1.3 The Environmental and Exposure Effect of Succinic Acid

Succinic acid is a component of almost all plant and animal tissues as it is a normal secondary metabolite and involves in Kreb's cycle. If this chemical released into the atmosphere, succinic acid may exist in both the particle and vapor phases in the ambient atmosphere. Therefore, vapor-phase succinic acid will be degraded in the atmosphere by reaction with photochemically-produced hydroxyl radicals that has an estimated half-life of about 6 days. Particle phase succinic acid will be physically removed from the atmosphere by wet and dry deposition. If succinic acid is exposed to soil, the succinic acid is expected to have very high mobility in soil while if released into water, succinic acid may not adsorb the suspended solids and sediments present in the water. Besides, the potential for exposure of succinic acid into aquatic organisms is low.

Therefore, hydrolysis will not result in crucial environmental effect since this compound lacks functional group that hydrolyzes under environmental conditions. Occupational exposure to succinic acid may occur through inhalation and dermal contact with this chemical at workplaces where succinic acid is produced or applied. Based on data from Hazardous Substance Data Bank (HSDB), the data indicates that the general population may be exposed to succinic acid via inhalation of ambient air, ingestion of food and drinking water, and dermal contact with products containing succinic acid.

1.4 Exposure Standard and Regulations

This information is obtained from HDSB where these regulations are set by United States Food and Drug Administration (FDA).

 Substance added directly to human food affirmed as generally recognized as safe (GRAS).

 Succinic acid used as a general purpose food additive in animal drugs, feeds, and related products is generally recognized as safe when used in accordance with good manufacturing or feeding practice.

 Succinic acid is a food additive permitted for direct addition to food for human

consumption, as long as the quantity of the substance added to food does not exceed the amount reasonably required to accomplish its intended physical, nutritive, or other technical effect in food, and any substance intended for use in or on food is of

2. PROCESS DESCRIPTION

The process start with the medium containing dextrose and corn liquor is charge into the reactor. Inside this reactor it is mix with the water and also nutrients. The solution is mix to make sure that the media is homogenized. After that, it is transfer out from the reactor to the heat sterilization to make sure that the media is no contaminated by other organisms. In this process as shown from the process design, we can see that the fermentation broth A.

succiniciproducens is grown in a seed fermentor with a temperature of 39o_{C and pressure 1 bar} together with a medium containing dextrose, corn liquor, tryptophan, sodium ions, sodium carbonate and also carbon dioxide to produce succinate and also water. The byproduct and unreacted material from this seed fermentation is pump to the waste treatment for further treatment before dispose into the environment.

Figure 1: Diagram of Media Preparation and Inoculums Development

The succinate and also water then enter the fermentation reactor where in this reactor the calcium oxide and carbon dioxide is charge in to produce calcium succinate. The calcium oxide is used as to neutralize the product which allowing the calcium succinate to precipitate. The stream 12 which contain calcium succinate, succinate and water enter the filtration process by

using microfiltration to removes the succinate. Inside the mircofiltration the filtrate is heated to 80o_{C to precipitate additional calcium succinate.}

Figure 2: Diagram of Filtration Process

The desired succinic acid product is recovered from the precipitated calcium succinate by acidification with sulfuric acid. In this process, gypsum or calcium sulfate is produce as the byproduct. This accidification of the calcium succinate is accomplished by slurrying the calcium succinate with water then with sulfuric acid to precipitate the calcium sulfate followed by a careful neutralization of the acid with calcium hydroxide.

Figure 3: Diagram of Acidification Process, Slurry Tank and Cation Exchanger

After that, the process will enter the plate and frame filtration to removes the calcium sulfate from the succinic acid. The filtrate will contain only succinic acid, calcium succinate and also

hydroxide and also hydrochloric acid is charge in the equipment to get the final product of succinic acid.

2.1

PROCESS DETAILS

1.

Feed Stream

Stream 1: 900 kg/batch fermentation broth

Stream 2, 18, and 27: 100 kg/batch water

Stream 3: 0.01 kg/batch nutrients

Stream 6: 100 kg/ batch microorganisms

Stream 7: 3018 kg/batch Carbon Dioxide

Stream 10: 10 kg/batch Calcium Oxide

Stream 21: 100 kg/ batch Sulfuric Acid

Stream 23: 148.5 kg/batch Calcium Hydroxide

Stream 31: 191.34 kg/batch Sodium Hydroxide

Stream 30: 99.47 kg/batch Hydrochloric Acid

Stream 33: 210.82 kg/batch Succinic Acid

2.

Equipments

1. Seed Fermentation (SFR-101)

: Ferment the media to produce succinate

2. Fermentation (FR-101)

: Do the fermentation process to produce calcium

succinate

3. Microfiltration (MF-101)

: To filter the calcium succinate from succinate

4. Vessel Procedure (R-101)

: To slurrying the calcium succinate with water

(R-102)

: Slurrying and precipitate the calcium succinate

with sulfuric acid

(R-103)

: Media preparation

5. Neutralization (V-101)

: Neutralize the acidic condition

6. P&F Filtration (PFF-101)

: To remove gypsum/calcium sulfate

7. Ion Exchange (INX-101)

: To recover purified succinic acid

8. Heat Sterilization (ST-101)

: To sterilize the media before inoculation

9. Fluid Flow ( PP-102)

: Pump the fluid.

( PM-101,102,103)

10. Mixing (MX-101)

: Mix the by-product.

11. Gate Valve ( GTV- 101,102)

: To prevent backflow.

3. EQUIPMENT DESIGN 3.1 CHEMICAL DESIGN

In order to develop a commercially succinic acid by the batch fermentation, several important fermentation and product purification criteria need to be accomplished. The fermentation of succinic acid should be able to produce higher yield production concentration by using inexpensive raw material and nutrients .The fermentation broth contains cells, proteins and unwanted materials. The efficient recovery and purification need to be considered for the production of higher concentration of succinic acid.

3.1.1 Material Balance

The material balance is fundamental to the control of processing, particularly in the control yield of the products. It is an important part in the process design. The first material balances are determined in the exploratory stages of a new process that improved during the pilot plant experiments. During the succinic acid production A.succiniproducens, were conducted in a low cost media that contain carbohydrates; dextrose (C6H12O6), other nutrients, such as corn steep liquor; trytophan (C11H12N2O2) and water are used as a raw material with basis of raw material of succinic acid production is 1000 Kg/batch. The carbon dioxide is supply to ensure that the process in the anaerobically fermentation process.

The law of conservation of mass leads to what is called a mass or a material balance:

Mass In = Mass Out + Mass Stored

Raw Materials = Products + Wastes + Stored Materials

Table 3.1.1 below provides a summary of the overall material balances and figure 3.1.1 is the process flow diagram of our plant in producing succinic acid. Our final product will be the succinic acid. From the table below, dextrose will represent the fermentable carbohydrates in molasses. These quantities of these compounds depend on the chemistry of the recovery process and cannot be reduced without changing the recovery technology. The large amount of

Table 3.1 Summary of the overall material balance

COMPONENT INITIAL INPUT OUTPUT FINAL OUT-IN A. succiniprodu 0.00 100.00 1.00 0.00 -99.000 Ca Hydroxide 0.00 148.50 49.50 0.00 -99.000 Calcium succina 0.00 0.00 6.98 0.00 6.98 CaOxide 0.00 10.00 10.00 0.00 0.00 Carb. Dioxide 0.00 6164.92 5921.86 1.06 -242.000 CaSO4 0.00 0.00 214.31 0.00 214.31 Corn Liquor 0.00 585.00 35.00 0.00 _550.000 -Dextrose 0.00 315.00 216.00 0.00 -99.000 Hydrochloric ac 0.00 99.47 99.47 0.00 0.00 Na2CO3 0.00 0.00 0.00 0.00 0.00 Nitrogen 6.24 0.00 2.78 3.46 0.00 Oxygen 1.89 0.00 0.85 1.05 0.00 Sodium Hydroxide 0.00 191.34 191.34 0.00 0.00 Sodium ions 0.00 0.01 0.01 0.00 0.00 Succinate 0.00 0.00 4.40 0.00 4.40 Succinic Acid 0.00 0.00 214.31 0.00 214.31 Sulfuric Acid 0.00 100.00 1.00 0.00 _99.000 -Tryptophan 0.00 0.00 0.00 0.00 0.00 Water 0.00 1792.06 2540.06 0.00 748.00 TOTAL 8.13 9506.29 9508.85 5.57 0.00

3.1.2 Chemical Reaction

a) Seed Fermentaion P-2 / SFR-10

A chemical reaction occurs in the process fermentation is the inoculum development.For this unit procedures, the fermentation process of this invention is carried out at a temperature between about 25˚C and about 45˚C (Datta, Glassner et al. 1992). The optimum growth of the

A. succinicproducens organism is about 39˚C (Datta, Glassner et al. 1992).The fermentation of

this process is carried out under anaerobic conditions in a medium which has been strelized before by heat.In this reaction A.succiniproducens will act as Reaction-Limiting Components and we extent to achieved 99.00% from this reaction. The pH in this fermentor is adjusted to to 6.4 by adding 3M Na2CO3 (Datta, Glassner et al. 1992).The overall stream seed fermentation mass is shown below:

Table 3.2 The summary stream for the seed fermentation reactor.

Stream Table 4 6 7 8(a) 9 11(a)

INLET OUTLET

Temperature (˚c) 25 25 25 39 20 39

Pressure (bar) 10.116 1.013 1.013 1.014 1.013 0.579

Vapor fraction 0 3 3 3 19 3

Mass flowrate (kg/batch) 1000.011 100 3081.723 252 2841.15 1090 Volumetric Flowrate (L/batch) 1002.219 100.532 1713134 254.28 1553493 1101.454

Component Flowrates (kg/batch)

Corn liquor 585 - - 35 - -dextrose 315 - - 216 - -A.succinicproducen - 100 - 1 - -Water 100 - - - - 650 Sodium ion 0.0077 - - - 0.0077 -Trytophan 0.0011 - - - 0.0011 -Na2co3 0.0022 - - - 0.0022 -Carbon Dioxide - - 3081.723 - 2839.141 -Nitrogen - - - - 1.53269 -Oxygen - - - - 0.46529 -Succinate - - - 440

Mass Balance at SuperPro

18 A. Succiniproducens + 44 Carbon Dioxide + 100 Corn Liquor + 18 Dextrose → 80 Succinate + 100 Water.

Calculated Mass Balance

Corn liquor+ Dextrose+ Biomass + Na+ _{+ Trytophan + Na}

2CO3 + Co2 + water Na+ + Trytophan + Na2CO3 + CO2 + N2 + O2 + H2O+ Succinate + Corn liquor + Dextrose+ Biomass

585 kg/batch + 315 kg/batch + 100 kg/batch + 0.0077 kg/batch + 0.0011kg/batch+

0.0022g/batch+ 3081.723 kg/batch +100 kg/batch 0.0077 kg/batch + 0.0011 kg/batch + 0.0022 kg/batch + 2839.141 kg/batch + 1.53269 kg/batch + 0.46529kg/batch +650 kg/batch + 440 kg/batch+35 kg/batch +216 kg/batch + 1 kg/batch

Mass In = Mass Out

b) Fermentation P-1 / FR-10

A.succiniciproducens fermentations of carbohydrate (dextrose) were conducted in batch

fermentors.For this unit procedures, succinate will act as Reaction-Limiting Components and we extent to achieved 99.00% from this reaction. In this process carbohydrate that containing substrate is fermented with succinate.Table 3.1.2.1 shows the summary stream for the fermentor reactor.

Table 3.3 The summary stream for the fermentation reactor.

Stream Table 11(b) 13 10 12(a) 14

INLET OUTLET

Temperature (˚c) 39.01 25 25 39 20

Pressure (bar) 1.529 1.013 1.013 1.014 1.013

Vapor fraction 3 3 3 3 19

Mass flowrate (kg/batch) 1090

3083.19 4 10 1090 3094.34 2 Volumetric Flowrate (L/batch) 1101.45 8 1713952 3.448 1101.45 4 1690594

Component Flowrates (kg/batch)

Water 650 - - 650 -Nitrogen - - - - 1.24916 Oxygen - - - - 0.37922 Carbon Dioxide -3083.19 4 - -3082.71 4 Carbon Oxide - - 10 - 10 Calcium succinate - - - 435.6 -Succinate 440 - - 4.4

-Mass Balance at SuperPro

The fermentation mass stoichiometry (reaction) is as shown below: 56.00 Succinate → 56.00 Calcium Succinate

Calculated Mass Balance

Water + Succinate+ CO2 + CO Water + Calcium Succinate+ Succinate+N2 + O2 + CO2 + CO

650 kg/batch + 440 kg/batch + 3083.194 kg/batch + 10 kg/batch

650 kg/batch + 435.6 kg/batch + 4.4 kg/batch +1.24916 kg/batch + 0.37922 kg/batch + 3082.714 kg/batch +10 kg /batch

mass in = mass out

4182.94 kg/batch 4184.3438 kg/batch

* The mass balance is not equal maybe due to the presence of side reaction inside the reactor

c) Vessel Procedure P-5 / R-102

The desired succinic acid product is recovered from the precipitated calcium succinate by the acidification with the sulphuric acid followed by filtration to remove the calcium sulfate which precipitate.The fermentation mass stoichiometry (reaction) is as shown below:

Table 3.4 The summary stream for the vessel reactor (acidification process).

Mass Balance at SuperPro

100.00 Calcium Succinate → 50.00 CaSO4 Succinic Acid

For this unit procedures, calcium succinate will act as Reaction-Limiting Components and the extent to achieve is 99.00% from this reaction.

Stream Table 20 21 22

INLET OUTLET

Temperature (˚c) 37.81 25 37.45

Pressure (bar) 10.605 1.013 4.319

Vapor fraction 3 3 3

Mass flowrate (kg/batch) 1178.99 100 1278.99

Volumetric Flowrate (L/batch) 1190.856 54.687 1046.394 Component Flowrates (kg/batch)

succinic acid - 214.3091

Water 746.0422 - 746.0422

CaSO4 - - 214.3091

Sulphuric acid 100 100

Calculated Mass Balance

Water + Calcium succinate + Sulphuric acid → Succinic acid + Water + CaSO4 + Calcium succinate + Sulphuric acid

746.0422 kg/batch + 432.9477 kg/batch + 100 kg/batch → 214.3091 kg/batch + 746.0422 kg/batch + 4.3294 kg/batch + 100 kg/batch + 214.3091 kg/batch

mass in = mass out

d) NEUTRALIZATION PROCESS P-7 / V-101

Adding excess of sulfuric acid in the (P-5/R-102) vessel procedure is followed by the neutralization of the excess acid with 148.5 kg/batch calcium hydroxide. Thus ,the stream, than goes to the filtration at (P-6/PFF-101) to filtrate any unwanted succinic acid at the filter cake with the 100 kg/batch of hot water .The succinic acid aqueous also contain some cation and anions ,thus its use ion exchanger to stabilize the charge ions without removing the succinic acid .The succinic acid production in the ion-exchange (P-9/INX) is 210.819 kg/batch with the volumetric flow is 152.826 L/batch.The fermentation mass stoichiometry (reaction) in the neutralization process is as shown below:

Table 3.5 The summary stream for the vessel reactor (Neutralization process)

Stream Table 22 23 24 25

INLET OUTLET

Temperature (˚c) 37.45 25 35.68 25

Pressure (bar) 4.319 1.013 1.013 1.013

Vapor fraction 3 3 3 0

Mass flowrate (kg/batch) 1278.99 148.5 1427.49 0 Volumetric Flowrate (L/batch) 1046.39 4 63747 1212.55 4 0

Component Flowrates (kg/batch) succinic acid 214.309 1 -214.309 1 -Water 746.042 2 -944.042 2 -Calcium succinate 4.3294 - 4.32948 Succinate - - - -Sulphuric acid 100 - 1 -CaSO4 214.309 1 -214.309 1 -Calcium Hydroxide - 148.95 49.5

-Mass Balance at SuperPro

Calculated Mass Balance

Succinic acid + water + Calcium Succinate + Sulphuric Acid + CaSO4 + Calcium Hydroxide

Succinic Acid + Water + Calcium Succinate + Sulphuric Acid + CaSO4 + Calcium Hydroxide

214.3091 kg/batch + 746.0422 kg/batch + 4.3294 kg/batch + 100 kg/batch + 214.3091 kg/batch + 148.95 → 214.3091 kg/batch + 944.0422 kg/batch + 4.32948 kg/batch + 1 kg/batch +

214.3091 kg/batch + 49.5 kg/batch

mass in = mass out

3.2 MECHANICAL DESIGN OF EQUIPMENTS 3.2.1 Introduction

This chapter covers the mechanical design of the succinic plant production. The purpose of this chapter is to detail out the design information of major equipment used in the bioproduction of succinic acid. The summary of the design information of the equipment are tabulated. They include the parameter of equipment sizing and mechanical design of major equipment.

3.2.2 Mechanical Design of Fermentor Sample Calculation

3.2.2.1 Design Pressure

The seed fermentor will designed based on maximum operating pressure. The design pressure that will be used is in 5%-10% range above the maximum operating pressure. For safety purpose, the design pressure 10% above the maximum operating pressure was used. The process flow was designed using SuperPro Designer and equipment report stated that the design pressure that was used for fermentor is 1.52 bar.

Pdesign = 1.52 bar X 0.1N/mm2 = 0.152 N/mm2 1 bar

3.2.2.2 Design Temperature

The design temperature of the equipment depends on the temperature of the material used in the process. The design temperature is chosen 10% above the maximum operating temperature to avoid spurious operation during minor process upsets and for safety reasons.

Operating temperature = 39°C Design temperature = 1.1 x 39°C

3.2.2.3 Material Used

The material of construction of the fermentor was chosen to be Stainless Steel 316 (SS316). The chemical composition of SS316 includes 16% chromium, 10% nickel and 2% molybdenum (Anderson, 2012).The construction of fermentor should implemented the usage of materials that is anti-corrosive as the metal part in fermentor will corrode due to the varying pH levels and salinity of medium contained in the fermentor for long-term usage (Manjady, 2013). SS316 gives better overall resistant corrosion in chloride environment compared to other stainless steel material used for bioreactor construction (Atlas Steels Australia, 2013). In addition, SS316 also a heat resistance material and it can withstand high temperature condition especially during sterilization process.

3.2.2.4 Maximum Allowable Stress

Table 3.2: Mechanical properties of material used for reactor’s construction (Sinnott&Towler,2009). Design temperature = 42.9°C X 9/5 + 32 = 109.22°F Based on Table 3.2, using interpolation;

Maximum allowable stress at 109.22°F = 19.80ksi X 6.8948 N/mm2 = 136.52 N/mm2 1ksi

At 42.9°C, the maximum allowable stress is 136.52 N/mm2

The joint efficiency that is chosen was 1.0. The type of welds used for this joint efficiency is double-welded butt joints. This joint efficiency is selected because the strength of the joint will be as strong as the virgin plate and the risks can be reduce as any possible defects are cutting out and reconstructed (Sinnott&Towler, 2009).

3.2.2.6 Corrosion Allowance

Corrosion allowance is defined as the additional thickness of metal added to allow for material lost by corrosion, erosion or scaling (Sinnott&Towler, 2009). The estimation of corrosion allowances cannot be specified for all conditions as corrosion itself is a complex phenomenon. Moreover, corrosion allowances may also be neglected if there is past experience regarding the same design of reactor that proves or shown no corrosion that occurred.

For this fermentor, there is no corrosion allowance that will be used as Stainless Steel 316 has superior corrosion resistance.

3.2.2.7 Minimum Wall Thickness

The determination of minimum wall thickness is essential as it will clarify whether the reactor can withstand its own weight and the weight of additional loads. For a cylindrical shell, the minimum wall thickness that is required to withstand the internal pressure during the production of succinic acid can be calculated using the following equation:

From ASME BPV Code Sect. VIII D.I. Part UG-27; tdesign =

Pi x Di

2 fJ−1.2 Pi

Where; t = Thickness (mm)

f = Maximum Allowable Stress (N/mm2₎ J =Joint Efficiency

Di = Diameter (mm) Pi = Internal Pressure (N/ mm2₎

t =

_{2 fJ−1.2 Pi}

Pi x Di

t =

(

0.152 N /mm2 )(840 mm)

2

(

136.52

N

mm 2

)

(1.0)−1.2(

0.152 N

mm 2

)

= 0.468 mm Wall thickness = 0.468 mm~1mm

A much thicker wall is needed at the base of the vessel to enable the vessel to tolerate wind and dead-weight loads. As a trial, the column is divided into five equal sections and the wall thickness is increased by 1mm as the section further downwards as shown in Figure 3.2.

Figure 3.2: Cross sectional view of design vessel. tavg = (1+2+3+4+5)mm = 3mm

5 3.2.2.8 Heads and Closures

The ends of cylindrical vessels are closed by heads as shown in Table 3.3. According to Sinnott&Towler (2009), there are four principals types of heads used in industry. There are:

 Flat plates and formed flat heads  Hemispherical heads

 Ellipsoidal heads  Torispherical heads

The standard torispherical heads was chosen to be used as the head of the fermentor as it is the most commonly used closure for equipment that operating at pressure less than 15bar. This

1.0mm

2.0mm

3.0mm

4.0mm

5.0mm

process only used operating pressure of 1.52bar. The minimum thickness of torispherical head was calculated as follows:

Flat plates and formed flat heads Hemispherical heads Ellipsoidal heads Torispherical heads Diagram

Uses  Covers for manways  The channel

covers of heat exchangers

Head closure for high pressure vessels Shape ‘Flange-only’ heads Domed head, Optimum thickness ratio = 7/17 Domed head, Major and minor axis ratio = 2:1

Domed head, Knuckle to crown radius ratio > 0.06

Strength Require thick plates for high pressures or large diameter reactor.  The strongest shape  Capable of withstand twice the pressure of a torispherical head of the same thickness Capable of withstand the pressure above 15bar. Capable of resisting pressure up to 15bar.

Price Cheapest Expensive Cheaper than

hemispherical heads

Cheap yet the price will increased as the increase of operating pressure.

Minimum

thickness

_t=De

√

CPi

fJ

t=

PiDi

4 f −1.2 Pi

t=

PiDi

2 fJ−0.2 Pi

t=

PiRcCs

2 fJ+Pi(Cs−0.2)

Rcc

Rk

Table 3.3: Comparison of head types (Sinnott&Towler, 2009) Rc = Di = 840mm Rk = 6% of Rc = 6/100 X 840mm = 50.4mm Cs = ¼ (3 + √(Rc/Rk)) = ¼ [ 3+ √(840mm/50.4mm)] = 1.77

t=

PiRcCs

2 fJ+Pi (Cs−0.2)

t=

(

0.152 N

mm 2

)(840 mm)(1.77)

2(136.52 N /mm 2)(1.0)+(

0.152 N

mm2

)(1.77−0.2)

t=0.83 mm

*Flat plates and formed flat heads;C= a design constant, depends on the edge constraint; De= nominal plate diameter (L); f= maximum allowable stress (ML-1_T-2_{); J= joint efficiency;} Hemispherical Heads& Ellipsoidal Heads: Pi= internal pressure(ML-1_T-2_{); Di= internal} diameter (L);Torispherical Heads; Rc= crown radius(L); Cs= stress concentration factor for torispherical heads=1/4(3+√Rc/Rk)

Figure 3.3: Torispherical heads (Types of Vessel Head, 2013).

The height of the dome is equal to the crown radius. Therefore, Height of dome = 840mm

Total height of fermentor = Height of cylindrical vessel + 2(Height of dome) = 2.51m + 2(0.84m)

= 4.19m

3.2.2.10 Weight loads

According to Sinnott&Towler (2009), there are five major sources of loads. They are: 1. Pressure

2. Dead weight of vessel and contents 3. Wind

4. Earthquake

5. External loads due to piping and attached equipment

However, this process will neglect one source of loads that is earthquake. Earthquake loads can be neglected as there is no earthquake ever occurs in Malaysia.

3.2.2.10.1 Dead weight of vessel

Vessel weight

According to Sinnott&Towler (2009), the approximate weight of cylindrical vessel with domed heads for steel vessel can be calculated by using equation as stated below;

Wv = 240 CvDm(Hv + 0.8Dm)t

Where; Wv = Total weight of shell, excluding internal fittings

Cv = A factor to account for the weight of nozzles, manways, internal supports, etc; which can be taken as

= 1.08 for vessels with few internal fittings = 1.15 for distillation columns, or similar vessels. Dm = Mean diameter of the vessel = (Di + (t X 10-3)(m)

Dm = Di + (t X 10-3) = 840mm + 3mm = 843mm = 0.843m Wv = 240 CvDm(Hv + 0.8Dm)t

= 240 (1.15)(0.843m)[2.51m + 0.8(0.843m)](3X10-3_m) = 2.22kN

Weight of insulation material Insulation material = Mineral Wool Density = 130 kg/m3 Thickness = 50mm (assume)

Volume of insulation material = п X 0.84m X 2.51m X (50X10-3_{m) = 0.33m}3 Load due to weight of insulation material = ρVg

= (130kg/m3_)(0.33m3_)(9.81m/s2_{) = 0.42kN} 1000

The total weight of insulation material needs to be double to cater for insulation fittings. Total load due to weight of insulation material = 0.42kN X 2 = 0.84kN

Total dead weight of the vessel = Vessel weight + Total load due to weight of insulation material = (2.22 + 0.84)kN

= 3.06kN

3.2.2.10.2 Wind load

The local wind speed at Bukit Minyak Industrial Zone, Penang is 15mph (24.14km/h). Area of the vessel that projected to wind = 2 r h = 2 (0.42m)(2.51m) = 6.62mᴫ ᴫ 2 Wind pressure, Psf=( ½ x ρair x v2wind x Cd)/A

= [½ x 1.25kg/m3 _{x (6.706m/s)}2 _{x 0.8]} 13.25m2

= 1.70N/m2

Mean diameter of vessel = 0.84m + 2(0.003m + 0.05m) = 0.946m Loading per linear meters, Fw = 1.70N/m2 x 0.946m

= 1.61 N/m Bending moment at the bottom of the vessel; Mx = Fw Hv2/2 = [1.61N/m x (2.51m)2]/2 = 5.07N.m 3.2.2.10.3 Analysis of stress Circumferential stress 2 2 / 77 . 12 ) 5 ( 2 ) 840 )( / 152 . 0 ( 2 mm N mm mm mm N t PD_i h   



Longitudinal stress t PD_i L  ₄  = 2 2

/

38

.

6

)

5

(

4

)

840

)(

/

152

.

0

(

mm

N

mm

mm

mm

N



Dead weight stress

w



= t t D W i v ) (   = 2 3

/

23

.

0

5

)

5

840

(

10

06

.

3

mm

N

mm

mm

mm

N









σwis a compressive stress and has a negative magnitude.

Bending stress

σh=6.152 N/mm2 σh=6.152 N/mm2 12.77N/mm2 12.77N/mm2 σh=6.148 N/mm2 σh=6.148 N/mm2 12.77N/mm2 12.77N/mm2 2 4 9

₂

5

0

.

0018

/

840

10

18

.

1

5070

2

mm

N

mm

mm

mm

Nmm

t

D

I

M

_i b













_



















_







I = /64 (Dᴫ o4-Di4) = /64 [850 ᴫ 4_-8404_{] mm}4_{= 1.18x10}9_mm4 2 2

/

1518

.

6

/

)

0018

.

0

)

23

.

0

(

38

.

6

(

mm

N

mm

N

b w L























Resultant longitudinal stress Upwind stress 2 2

/

1482

.

6

/

)

0018

.

0

)

23

.

0

(

38

.

6

(

mm

N

mm

N

b w L























Downwind stress

Upwind stress = (12.77 – 6.152)N/mm2 _{Downwind stress = (12.77 – 6.148)N/mm}2 = 6.618N/mm2 _{= 6.622N/mm}2

Criteria 1

The maximum allowable design stress for SS316 at 42.9°C is 136.52N/mm2_{. Both upwind and} downwind stresses are below the maximum allowable stress for SS316 material. Therefore, it is safe to specify the wall thickness to be 5mm for the bottom-most part of the vessel.

2 4 4

₁₁₇

_.

₆₅

_/

850

5

10

2

10

2

N

mm

mm

mm

D

t

o cbs

































Critical bending stress, σcbs

2 2

₀

_..

₂₃₁₈

_/

/

)

0018

.

0

23

.

0

(

N

mm

N

mm

b w















Maximum compressive stress

Therefore, maximum compressive stress is less than the critical bending stress. The column will NOT buckle under wind load and dead loads.

3.2.2.10.3 Vessel support

According to Sinnott &Towler (2009), the notable criteria that must be observe in order to choose the method to support the vessel are size, shape and weight of the vessel; the design temperature and pressure; the location and arrangement of the vessel and internal and external fittings and the accessories of the vessel. Normally, saddle support is used for horizontal vessel while skirt support is suitable to be used for vertical vessel. The design of the thickness of the skirt must be sufficient to ensure that the skirt is able to withstand the dead-weight loads and bending moment with the exclusion of vessel pressure that subjected to the vessel. For the design of fermentor in this process, the material of construction of the skirt material is plain carbon steel using straight skirt support for the vessel.

3.2.2.11 Properties of skirt support Type: Straight skirt support (s = 90) Material of construction: Plain carbon steel Conditions: Ambient temperature and pressure

Maximum Allowable Design Stress (plain carbon steel) = 130 N/mm2 Modulus of elasticity, E = 200,000 N/mm2

Refer to Figure 13.23(Sinnott&Towler, 2009), by interpolation; Skirt support height = 0.60m

As a first trial, the skirt thickness was taken as the same as the bottom section of the vessel, 11mm.

Bending moment at the base of the skirt

Nm m m N Wx Mx (1.62 / )(2.51 0.60) 7.83 2 1 2 1 2 _{ } 2 2 _ 

The maximum dead weight of vessel

Weight of water in vessel =

kN s m m kg m m) 2.51 1000 / 9.81 / 13.65 84 . 0 ( 4 2 3 2_{   }  

The maximum dead weight of vessel = (3.06+ 13.65)kN = 16.71kN

Bending stress in the skirt, bs =

s sR sR s x D t t D M ) ( 4   =

)

840

)(

5

)(

5

840

(

)

10

83

.

7

(

4

3

mm

mm

mm

mm

Nmm







= 0.0028N/mm2

Dead weight stress in skirt, σ ws SR sR total ws

t

t

Ds

W

test

)

(

)

(









mm

mm

mm

N

5

)

5

840

(

10

71

.

16

3









= 1.26N/mm² SR sR v ws

t

t

Ds

W

operating

)

(

)

(











mm mm



mm N 5 5 840 10 06 . 3 3     = 0.23N/mm² σs(compression) = σbs + σws(test) = 0.0028N/mm2+1.26N/mm2 = 1.2628N/mm2 σs(tensile) = σbs -σws(operating) = 0.0028N/mm2-0.23N/mm2 = -0.2272N/mm2

The skirt thickness should not exceed the following design criteria: Assume J=1; Criteria 1 s (tensile) < fJ sin s 0.2272N/mm2_{< 130 (1)( sin 90)} 0.2272N/mm2_{< 130 N/mm}2 Criteria 2 s (compression) < 0.125 E (tsR/ Ds) sin  1.2628N/mm2_{< 0.125(200,000N/mm}2_{)(5mm/840mm)(sin 90°)}

It is observed that both criteria are met. The design thickness of the skirt support is 5mm.

3.2.2.12 Agitator design

Agitation provides mixing of the phases in the reactor to keep the cells in perfect homogenous condition for the microbes to grow and produced desired products (Sakshat Virtual Labs, 2013). These conditions are met by providing bulk fluid and gas phase mixing, air dispersion, better oxygen transfer and heat transfer as well as uniform environment inside the vessel (Design of Fermenter and Kinetics, n.d.). The comparisons between different types of impeller are shown in Table 3.4.

Table 3.4: Comparison between different types of impeller (Mirro&Voll, 2009)

Impeller Rushton Impellers Pitch-blade Impeller Gentle Marine-blade Impellers

Diagram

Blades Flat and set vertically

along agitation shaft Flat and set at 45°

Leading face- flat/concave Back sides- convex Types of

flow Unidirectional radial flow

Simultaneous axial and

Oxygen mass transfer

rate

Low High High but lower than

pitch-blade impeller Cells Not shear-sensitive Shear-sensitive cells Shear-sensitive cells Example

of cells Yeast, bacteria, fungi

Filamentous bacteria and fungi

Filamentous bacteria and fungi

The type of impeller chosen to be used for this fermentor is pitch-blade impeller because it create better mixing inside the vessel and the mixing process that occur will not damage the cells.

On the other hand, baffles are essentials as they can prevent vortexing inside the vessel. The existence of vortex inside the vessel may create unfavourable operating conditions as it may change the center of gravity of the system thus increase the power consumption of the process (Sakshat Virtual Labs, 2013). Baffle width is one-tenth the tank diameter. In addition, the positions of the baffles are offset from the wall at a distance equal to one-sixth the baffle width because of the presence of heat transfer jacket that is water jacket (Mixing and Agitation, n.d.).Furthermore, the position baffles from the tangent line at the bottom of liquid level also extended to one half of impeller diameter.

Figure 3.4: The dimentions of vessel. H=Height of liquid level, Dt= Tank diameter, d=Impeller diameter (Mixing and Agitation, n.d.).

m

m

D

_t

28

.

0

3

84

.

0

3







Impeller diameter

m

m

H

42

.

0

6

51

.

2

6







Impeller height above vessel floor

m

m

D

_impeller

07

.

0

4

28

.

0

4







Length of impeller blade

m

m

D

_impeller

056

.

0

5

28

.

0

5







Width of impeller blade Number of impellers = 3

Number of impeller blades = 4

Distance between 2 consecutive impellers = 0.28m

m

m

D

_k

084

.

0

10

84

.

0

10

tan

_

_



Width of baffle

m

m

W

_buffle

0084

.

0

10

084

.

0

6







Position of baffles from wall

m

m

W

_buffle

042

.

0

2

084

.

0

2







Position of baffles from tangent line of bottom floor

3.2.2.13 Cooling jacket design

Jacket provides the circulation of water of constant temperature to maintain the temperature inside bioreactor. The maintaining of temperature is done through indirect contact method. The effective maintaining of temperature inside bioreactor is achieved by providing adequate heat transfer area at the contact area of jacket and the desired water temperature is constantly circulated throughout the process (Sakshat Virtual Labs, 2013). There are three types of jackets that are commonly used in industry. They are spiral baffle jacket, half pipe coil jacket and dimple jacket. The comparison between these jackets is shown in Table 3.5.

Table 3.5: Comparison of jackets used in bioreactor (Reactor (CSTR) Design Steps and Calculations, n.d.)

Types of

Diagram

Cost Less expensive Expensive Expensive but cheaper

than half coil jacket Heat transfer

rate High High Low

Pressure Up to 10 bar Up to 70 bar Up to 20 bar

The type of jacket that is used in this fermentor design is spiral baffle jacket because it is

cheaper compared to the other types of jackets and it gives low pressure drop. Furthermore, the heat transfer rate using this jacket is high thus, the desired temperature inside the fermentor can be controlled effectively.

MECHANICAL DESIGN SPECIFICATION SHEET FERMENTOR

Identification:Fermentation process Item No : P1/FR-101

No. Required: 1

Function: To grow A.succiniproducens at its exponential phase by supplying adequate nutrients and optimum conditions for the growth of the microorganisms inside the fermentor to harvest desired products at the end of the batch process that is succinic acid.

Operating Condition Temperature = 39C

Pressure = 1.52 bar Volume = 1381.11L

Specification Types of Reactor = Fermentor

Material construction = Stainless Steel 316 Vessel diameter = 0.84 m

Vessel length = 2.51 m

Domed head = Torispherical heads Vessel Support Type = Skirt Dimen sions (m) mm V Y C E J G t2 t1 Bolt diam Bolt holes 0.60 0.15 0.74 0.31 0.245 0.095 8.8 5.4 20 25

Figure 3.5: Dimension for skirt support (Sinnott&Towler, 2009).

3.2.3 Heat Sterilization Specification

MECHANICAL DESIGN SPECIFICATION SHEET HEAT STERILIZATION

Identification: Heat sterilization Item No : P-19/ST-101 No. Required: 1

Function: To sterilize the media for fermentation process in fermentor. Operating condition Temperature Throughput 140 °C 334.07 L/h Specification Material of Construction Tube length Tube diameter Stainless steel 316 18.66 m 0.98 cm

3.2.4 Seed Fermentor Specification

MECHANICAL DESIGN SPECIFICATION SHEET SEED FERMENTOR

Identification: Inoculum development Item No : P-2/SFR-101

No. Required: 1

Function: To grow A.succiniproducensto the density near the end of their exponential phase. Operation: Batch Mechanical Design Material of Construction Vessel Temperature Vessel Pressure Vessel Diameter Total Height Vessel Volume

Average wall thickness Type of insulation Domed head type Thickness of head Total height of fermentor Dead weight of vessel: Dead weight of Vessel Weight of insulation Total dead weight Wind load: Bending moment Analysis of stress: Cicumferential stress Longitudinal stress Stainless Steel 316 39 0_C 1.52 bar 0.90 m 2.69 m 1,694.67 L 3 mm Mineral wool Torispherical 0.89 mm 4.49 m 2.55kN 0.38kN 3.51kN 6.19N.m 13.68 N/mm2 6.84 N/mm2

Type of skirt

Material of construction Skirt thickness

Skirt height

Straight (Ɵs=90°) Plain carbon steel 5 mm

0.63 m

Agitator specifications Types of impeller

Impeller diameter

Impeller height above vessel floor Length of impeller blade

Width of impeller blade Number of impellers Number of impeller blades

Distance between 2 consecutive impellers Width of baffles

Position of baffle from wall

Position of baffle from tangent line of bottom floor Pitch-blade impeller 0.30 m 0.45 m 0.075 m 0.06 m 3 4 0.30 m 0.09 m 0.015 m 0.045 m 3.2.4 Microfiltration Specification

MECHANICAL DESIGN SPECIFICATION SHEET MICROFILTRATION

Identification: Microfiltration Item No : P-3/MF-101 No. Required: 1

Function: To remove precipitated succinate from slurry. Specification

Material of Construction Size (Capacity)

Number of available cartridge slots

Stainless steel 316 13.63 m2

3.2.5 Vessel Procedure Specification

MECHANICAL DESIGN SPECIFICATION SHEET VESSEL PROCEDURE

Identification: Vessel Procedure Item No : P-5/R-102 No. Required: 1

Function: To recover desired succinic acid product by acidification process by addition of sulfuric acid.

Operation: Batch Mechanical Design Material of Construction Vessel Temperature Vessel Pressure Vessel Diameter Total Height Vessel Volume

Average wall thickness Type of insulation Domed head type Thickness of head Total height of fermentor Dead weight of vessel: Dead weight of Vessel Weight of insulation Total dead weight Wind load: Bending moment Analysis of stress: Cicumferential stress Stainless Steel 316 39 0_C 1.52 bar 0.89 m 2.22 m 1,384.15 L 3 mm Mineral wool Torispherical 0.876 mm 4.00 m 2.17kN 0.80 kN 2.97 kN 4.16N.m 13.53 N/mm2

Vessel support: Type of skirt Material of construction Skirt thickness Skirt height Straight (Ɵs=90°) Plain carbon steel 5 mm

0.625 m

Agitator specifications Types of impeller

Impeller diameter

Impeller height above vessel floor Length of impeller blade

Width of impeller blade Number of impellers Number of impeller blades

Distance between 2 consecutive impellers Width of baffles

Position of baffle from wall

Position of baffle from tangent line of bottom floor Pitch-blade impeller 0.30 m 0.37 m 0.075 m 0.06 m 3 4 0.30 m 0.089 m 0.015 m 0.0445 m 3.2.6 Neutralizer Specification

MECHANICAL DESIGN SPECIFICATION SHEET NEUTRALIZER

Identification: Neutralization Item No : P-7/V-101 No. Required: 1

Function: To neutralize excess sulfuric acid.

Operating condition Pressure Temperature 1.52 bar 25 °C Specification Material of Construction Volume Diameter Height Carbon steel 581.33 L 0.67 m 1.67 m

3.2.7 P&F Filtration Specification

MECHANICAL DESIGN SPECIFICATION SHEET P&F FILTRATION

Identification: Plate and Frame Filtration Item No : P-6/PFF-101

No. Required: 1

Function:

Specification Material of Construction

Filter area Stainless steel 3161.25 m2

3.2.8 Ion Exchange Specification

MECHANICAL DESIGN SPECIFICATION SHEET ION EXCHANGE

Identification: Ion exchange Item No : P-9/INX-101 No. Required: 1

Function: To stabilize charged ions without removing succinic acid product. Specification Bed height Column height Column diameter Bed volume Column volume 4.00 m 8.00 m 3.87 m 47, 146.35 L 94, 292.69 L

4.1 Introduction

Economic analysis is one parts of the production in order to estimate the economic feasibility. Succinic acid has a wide range of applications in areas such as pharmaceutical, food and agricultural and chemical industries. Presently a major share of succinic acid is derived from petroleum feedstock. Based on the worldwide price index of succinic acid, refer to the demand of world it has been mentioned that the global succinic acid market going to reach 144.7 thousand tons by 2015, according to New Report by global industry analysts. The objective is to perform economic analysis to estimate whether that the cost of production is profitable or loss regarding to world profit. [San Jose, CA (Vocus) August 18, 2010]

4.2 Estimation of Capital Cost

Capital cost is the cost associated with the construction of a new plant or modification to an existing chemical manufacturing plant.

4.2.1 Module Costing Technique

Module costing technique is a common technique used to estimate the cost of a new chemical plant and for making preliminary cost estimation. Deviation from these base conditions are handled by using multiplying factors that depend on the following:

 Specific equipment type  Specific system pressure

 Specific materials of construction

Bare module cost is the sum of the direct and indirect costs:

C

BM

=

C

Po

F

BM

Where CBM = bare module equipment cost: direct and indirect FBM = bare module cost factor

log

(

¿¿

10 A )

2

C

p 0

=

K

1

+

K

2

log

10

A+K

3

¿

Where: K1, K2, K3 can be obtained from appendix table A.1 of Analysis, Synthesis and Design of Chemical Processes, Second Edition by Richard Turton, Richard C. Bailie,Wallace B.Whiting, Joseph A.Shaeiwitz, pg 916

A is the capacity (kW or m3 _{or m}2₎

4.2.2 Pressure Factors for Process Vessels

F

P , vessel

=

(

P+1) D

2 [850−0.6 ( P+1)]

+

0.00315

0.0063

For vessel > 0.0063 m

If FP, vessel is less than 1 (corresponding to t vessel < 0.0063 m), then FP, vessel = 1. For pressure less than -0.5 barg, FP, vessel = 1.25. This equation is strictly true for case when thickness of the vessel wall is less than ¼ D, vessel in the range D= 0.3 to 0.4.

4.2.3 Pressure Factors for other Process Equipment

log

10

F

P

=

C

1

+

C

2

log

10

P+C

3

(log

10

P)

2

Bare Module and Material Factors for Heat Exchangers, Process Vessels and Pumps

C

BM

=

C

Po

F

BM

=

C

OP

(

B

1

+

B

2

F

M

F

P

)

The value of the constants B1 and B2 are given in Table A.4. in Appendix A in Analysis, Synthesis, and Design of Chemical Processes, Third Edition, Richard Turton. Table A.5 shows the Equation for Bare Module Cost for Equipment Not covered by Table A.3 and A.4.

C

₂

=

C

₁

I

2

I

1

Where: C = Purchased cost I = cost index

CTM = 1.18

∑

i=1 n C_{BM ,i} Sample calculation:-Reactor Diameter = 0.88 m Height = 2.19 m

Material = Stainless steel (SS316) Pressure = 1.0 bar = 0.0 barg Purchased Equipment Cost, C0

p From Table A.1,

Equipment Type Equipment Description K1 K2 K3 Capacity, Units Min Size Max Size Reactor Jacketed agitated 4.1052 -0.4680 -0.0005 Volume, m3 0.1 35 Volume = (π /4) D2 _H = (π /4) x (0.88)2 _{x (2.19)} = 1.33 m3 = 1.4 m3

log10 Cp0 = K1 + K2 log10 A + K3 (log10 A)2

= 4.1052 - 0.4680 (log10 1.4) - 0.0005 (log10 1.4)2 = 4.14

= $13800

From Table A.3

Equipment type Equipment Description Bare Module factor, FM

Reactor Jacketed agitator 3.1

Bare Module Cost, CBM

CBM = C0pFBM = $13800 (7.892) = $108382.5462 C1 = CBM = $108400 C2 = C1 (I2/I1) = $108400 (575.4/394) = $158282.5307 C2 =$158300

Fixed capital investment, CTM

CTM = 1.18

∑

i=1 n

C

_{BM ,i} CTM =1.18 ($2072648.713) = $2445725.481 CTM = $2446000

Pump/Valve (kW) 394 PM-101 0.01 7892.2348₄₈ 1 2.3 4.995 * 39421.713₀₇ * 39421.7130 PM-102 0.01 7892.2348₄₈ 1 2.3 4.995 * 39421.713₀₇ * 39421.7130 PM-103 0.01 7892.2348₄₈ 1 2.3 4.995 * 39421.713₀₇ * 39421.7130 Reactor/Ves sel (m3) SFR-101 1.7 13733.216₇ 1 3.1 7.892 * 108382.54₆₂ * 108382.546 FR-101 1.4 12385.953₃ 1 3.1 7.892 * 97749.943₄₆ * 97749.9434 R-101 1.4 12385.953₃ 1 3.1 7.892 * 97749.943₄₆ * 97749.9434 R-102 1.4 12385.953₃ 1 3.1 7.892 * 97749.943₄₆ * 97749.9434 R-103 1.2 11410.936₄₉ 1 3.1 7.892 * 90055.110₇₅ * 90055.1107 ST-101 1.5 40864.187₃ 1.2 3.1 9.0204 * 368611.31₅₂ * 368611.315 V-101 0.6 7891.3600₁₂ 1 1 4.07 4.07 32117.835₂₅ 32117.835₂₅ 32117.8352 Tower (m3) INX-101 100 66680.676₉₂ 1 1 4.07 4.07 271390.35₅₁ 271390.35₅₁ 271390.355 Filter (m2) MF-101 14 59269.161₇₅ * * 1.65 * 97794.116₈₉ * 97794.1168 PFF-101 1.5 21867.448₀₇ * * 1.8 * 39361.406₅₂ * 39361.4065 TOTAL 75.055₄ 8.14 1419227.6₅₅ 303508.19₀₄ 1419227.65

4.3 ESTIMATION OF MANUFACTURING COSTS

In order to estimate the manufacturing cost, the information that provided on the PFD, an estimate of the fixed capital investment and an estimate the number of operator required to operate the plant. There are many factors that will influence the cost manufacturing chemicals. 4.3.1 Factors Affecting the Manufacturing Cost

1. Direct manufacturing costs

- It is represent the operating expenses that vary the production rate. The manufacturing cost related to the demand of the product.

2. Fixed manufacturing costs

- Do not effect by the level of the production. It depends of the changes in production rate such as property taxes, insurance and depreciation.

3. General Expenses

- The cost related the management level and administrative activities. It not directly related to the manufacturing process

Direct Cost Fixed Cost General Expenses

-raw material - waste treatment -utilities -operating labor -operating supplies -property taxes -insurance -depreciation

-Plant overhead cost

-administration cost -financing

-research

Table 2: Factors Affecting the Manufacturing Cost Cost of Manufacturing

1. Fixed capital investment(FCI) 2. Cost of operating labor(COL) 3. Cost of utilities( CUT)

4. Cost of waste treatment(CWT) 5. Cost of materials(CRM)

With depreciation:

Without depreciation:

Fixed Cost Investment

Based on the calculation of the fixed cost investment, Fixed investment cost, FCI @ CTM = 2446000

CTM =1.18

∑

i=1 n CBM , i CTM = 1.18(2073000) CTM= $ 2446000 Stream Factor

In order to calculate the yearly cost of raw materials or utilities, the fraction time that the plant is operating in a year must be known. This fraction known as the stream factor where,

Stream factor, f =

number of day operate

₃₆₅

*The value of factor in range of 0.96 to 0.90. Based on the number of day operate = 330 days

Stream Factors, f =

330

₃₆₅

COM = 0.280FCI + 2.73C

OL

+ 1.23(C

UT

+ C

WT

+ C

RM

)

= 0.9041

4.3.2 Cost Operating Labor, COL

In order to estimate the cost operating labor, the average hourly wage of an operator is required. The cost of labor is broken into direct and indirect costs. Direct costs include wages for the employees physically making a product, like workers on an assembly line. Indirect costs are associated with support labor, such as employees that maintain factory equipment but don't operate the machines themselves. When manufacturers set the price of a good they take the cost of labor into account. This is because they need to charge more than that good's total cost of production. If demand for a good drops or the price consumers are willing to pay for the good falls, companies must adjust their cost of labor to remain profitable. They can reduce the number of employees, cut back on production, require higher levels of productivity, reduce indirect labor costs or reduce other factors in the cost of production. The technique used to estimate operating labor requirements is based on data obtained from five chemical companies and correlated by Alkayat andGerrard.

Based on the Alkahayat and Gerrard method:

*When refer to the equation: NOL = Number of operator shifts

P = Number of processing steps involving particulate solids Nnp = Number of non-particulate processing steps

Based on the Alkahayat and Gerrard method:

C

OL

= f × N

OL

× annual salary

Equipment Type Number of Equipment Nnp Vessels Reactors Pumps Filter Valve Mixing Heater 1 5 4 3 2 1 1 -5 -3 -1 1 *Pumps, valves and vessels are not counted in evaluating Nnp

Table 3: Estimation of Operating Labor Requirement for Succinic Acid Process Therefore, the total Nnp= 5 + 3 + 1 + 1

= 10

Number of operator needed for one equipment

Table 4: Total Salary/Month

Assumptions to estimate the cost operating:

Working day for 1 operator = 4 shift per operator per days Plant operates = 3 Shift per day

Plant running = 24 hours per day Operation hour = 330 days per year × 24 hour = 7920 hours per year 1 year = 47 weeks per year 1 year = 330 days per year Maintenance = 5 weeks per year Table 5: Assumptions to Estimate The Cost Operating

Salary Per Month

Operator = $1500 Manager = $4500 Assistant Manager = $3000 Engineer = $4000

Therefore, the number of operators per shift, NOL NOL = (6.29 + 31.7P2 + 0.23Nnp) 0.5 NOL = (6.29 + 31.7(1)2 + 0.23 (10))0.5 NOL= 6.34 operator per shift

For number of plant operating

330 days/year×3 shift/days = 990 shift/year For single worker

330 days/ year ×1 weeks/day=47 week/year Thus,

47 weeks/year× 4 shift operator per week =188 shift per operator per year Thus,

FOL=

990 shift

year

×

operater

_{188 shift}

=5.27 per operator Hence operating labor

= FOL× Number of operator per shift = 5.81× 6.34

=36.8~ 37

Cost of operating labor, COL = FOL×Labor salary = 37 × 13000

4.3.3 Cost of utilities, CUT

Basically, the costs of utilities are directly influenced by cost of a fuel. The cost also related to the direct impact of fuel gas, oil, coal, electric power, steam, cooling water, process water, boiler feed water, instrument air, inert gas and refrigeration costs. To determine the utility cost can be quite complicated and the true cost of such streams is often difficult to estimate in a large facility. For the approach, assume the capital investment is required to build a facility to supply the utility. Therefore,the method used to estimate operating labor requirements is based on data obtained from five chemical companies and correlated by Alkayat andGerrard.

By using Alkahayat and Gerrard method: Pump utility cost

Electric power=(Output Power)/Efficiency

Once the electrical power is being calculated the yearly cost is being calculated. Incremental Economic analysis

The calculated overall utilities cost is then must be adjusted to corresponding total operating cost for the assumed of the life of the plant which in our case is 10 years. This is done through the incremental economic analysis. This is due to the fact that the utility cost of each year remains constant even though inflation continues to rise over time. Assume that the discount rate is 7%. The analysis can be evaluated from:

Where: I = discount rate n = no. of years

The calculated value is then multiplied by the yearly cost to obtain the accumulated cost over the 10 years period of time.

Pump

Shaft work = 0.01 kW

Utility Description Cost $/GJ Cost $/ Common Unit Electrical substation Electric distribution

110 V 220 V

440 V 16.8 $0.06 kWh Table 6: Data of Pump Utility Assume that the efficiency of 90%,

Electrical power = 0.01/ 0.9 = 0.011

Therefore, yearly cost for electrical substation = 0.011×0.06×24×365×0.9041 = $ 5.227

Electrical power =

output power

efficiency

Slurry Tank

Utility DescriptionCost $/GJ Cost $/ Common Unit

Other Water High purity water

a. Process use $0.067/1000kg b. Boiler feed water(available at 115◦_{C) $2.45/1000kg} c. Potable (drinking) $0.26/1000kg d. Deionized water $1.00/1000kg Table 7: Data of Slurry Tank Utility

Based on the equation,

Thus,

Cb =

649

100

× 0.067

Cb = $0.043/1000kg

Hence, the yearly cost for other water =0.043 × 24 × 365 × 0.9041 = $340.56

Ca

Cb

=

Aa

Ab

Mixing

Utility Description Cost $/GJ Cost $/ Common Unit

Waste water a. primary(filtration) $41/1000m3

treament b. Secondary (filtration + activated $43/1000m3 sludge

c. Tertiary ( Filtration, activated sludge $56/1000m3 and chemical processing)

Table 8: Data of Mixing Utility Thus,

Cb =

293.010

1000

× 56

Cb = $16.41/1000kg Hence, the yearly cost for other water =16.41 × 24 × 365 × 0.9041

= $ 129965.82

Therefore, total utility cost, CUT = $ 5.227 + $340.56 + $ 129965.82 = $130311.61

Discount rate for the 10 years period with assumption of 7% discount rate

P/A =

(1+i)

n

−

1

i(1+i)

n =

(1+0.07)

10

₋₁

0.07(1+0.07)

10

Thus, yearly cost accumulated cost over 10 year period, CUT = $130311.61 × 7.0235 CUT = $915243.6

4.3.4 Waste treatment cost, CWT

When dealing with chemical it related to treat the waste and by-product being produced from the process. As environmental regulations continue to tighten, the problems and costs associated with the treatment of waste chemical streams will increase. In recent years there has been a trend to try to reduce or eliminate the volume of these streams through waste minimization strategies. Nowadays, it has be create a strategies involve utilizing alternative process technology or using additional recovery steps in order to reduce or eliminate waste streams. Although waste minimization will become increasingly important in the future, the need to treat waste streams will continue. The calculation of this cost should be done with extreme caution

Production of waste = 1,602,583 kg/year

Utility Description Cost $/GJ Cost $/ Common Unit

Waste Solid Waste Gaseous - $200-2000/tonne Table 9: Cost of Waste Treatment Utility

Waste treatment cost, CWT = 1,602,583 kg/year× 200 /1000 = $ 320,516.6