'OTU ASSIAN GE'ORGE EH DEPARTMENT 'OF CHEMICAL ENGINEERING SCH'O'OL 'OF ENGINEERING AND ENGINEERING I TECHN'OL'OGY

Transcription

1 i A;PLMT DESIGN:rFORR'ODUCE IOOOOOGALLON :OF-CORN 'OIL PER BY 'OTU ASSIAN GE'ORGE EH DEPARTMENT 'OF CHEMICAL ENGINEERING SCH'O'OL 'OF ENGINEERING AND ENGINEERING I TECHN'OL'OGY FEDERAL UNIVERSITY 'OF TECHN'OL'OGY, MINNA I, -\,. NIGER STATE, NIGERIA. N'OVEMBER, 007

2 I A PLANT DESIGN TO PRODUCE GALLON OF CORN OIL PER YEAR FROM CORN SEED OTU ASSIAN GEORGE 001lJ1633EH A PROJECT SUBMITTED IN PARTIAL FULFILLMENT UF THE REQUIREMENT FOR THE AWARD OF BACHELGe OF ; ENGINEERING (B. ENG) DEGREE IN " CHEMICAL ENGINEERING DEPARTMENT OF FEDERAL UNIVERSITY OF TECHNOLOGY, MINNA NIGER STATE, NIGERIA NOVEMBER,

3 DECLARATION I, OTU ASSIAN GEORGE, with matriculation number EH do solemnly dedare that this project work, "A plant design to prodnce gallon of corn oil per year from corn,seed," was undertaken by me under a close supervision ofengr Afolabi. The authors of any books.. ) I and publications tharbecame helpful for the completion of this project work were gracefully and gratefully acknowledged. And as much as I know, this is going to be the first presentation of this particular work, ever ~-~~ OTU ASSIAN GEORGE Signature & Date 111

4 CERTIFICATION/APPROVAL PAGE This is to certify that this project titled, "A plant design to produce gallon of corn oil per year from corn seed" was fully carried out by Otu Assian. G. under the able supervision of MR.E.A Afolabi and submitted to the Department of Chemical Engineering, Federal University of Technology Minna, in partial fulfillment of the requirements for the award of a Bachelor of Engineering Degree (B. Eng.) In Chemical Engineering. _~~=_n~~ ~~!!. MR. E.A. Afolabi {'4-..-(?- ~">-~, Date Head of Department Date External Examiner --: Date iv

5 DEDICATION Thisproject is dedicated to my lovely parents Mr. and Mrs. Otu Ayi whom have been financially, morally and spiritually there for me, my cousin, Sylvester Ayi for his wonderful support and most especially my elder sister Mrs. Vincent Precious for her love and total \, 0 commitment towards my success, my siblings, my kith and kin too numerous to mention. I thank you all. / i v

6 ACKNOWLEDGEMENT I express my gratitude to Almighty God for guiding and protecting me through from the beginning.. to the end, surely, every thing that has a beginning has an end. First my gratitude goes to my most unique supervisor Mr. A,. Afolabi, for his wonderful personality and total commitment towards success. Taking time out of his busy schedule to explain and correct my short comings. I appreciate the assistance of my lectures; Prof Odigure, Prof K.R Onifade, Dr Doncan and other members of staff of the department, who at one time or the other has been of tremendous help to me. I pray that God mercy will be on each and every one of you. Amen. I could not have reached this level if not for the unquantifiable assistance given to me by my loving and caring parents, Mr. and Mrs. Otu Ayi for their prayers and support throughout my education career. I cannot but also thank my loving sister Mrs. Vincent Precious for her multidimensional support. I appreciate every step of your efforts and may God almighty grant your prayer in Jesus name. Amen. Also, my heart felt thanks goes to my sisters and brothers; Joy, Joseph and Godwin who have been all to me throughout the course of my study. I also recognize the support of certain people that God has elevated to be good friends indeed: Anthony Imogu, Emmanuel Waziri, Titi, Olalekan Adebayo, Ikechukwu, Justin and au that which I didn't remember I appreciate you all for your wonderfull support. May the good Lord bless you all Amen.

7 Title page TABLE OF CONTENTS Page Declaration Certification Dedication, Acknoledgement 'Abstract Table of contents CHAPTER ONE 1.0 INTRODUCTION Aims and Objective 1, Problem Statement 1..1 The project 1,. TIie process 1..3, Product specification 1..4 Utilities 1.3 Scope of Work Process design 1.3. Chemical engineering design Cost analysis 1.4 Methodology CHAPTER TWO.0 LITERATURE SURVEY.1 BackgrouJId. Component of the Com Kernel,.3 The Com Wet Milling Process.4 Products '..5 Com Oil Manufacturing,Process.5.1 Refining,.6 Packaging, Transportation and Storage.7 Physical and Chemical Properties.8 Nutritional Properties ".8.1 Role of com oil in the diet.8.3 Cholestrol and conary heath dise~ses.8.4 Blood pressure.8.5 Trans Fatty Acids.9 Com.Oil Production.10 Foo~ Use of Vegetable Oils.10.1 Food use of com oil.11 Industrial Use of Com Oil <;HAPTER THREE IV V VI vii, l MATERIAL BALANCE vii

8 3.1 Introduction 3. Conservation of Mass 3.3 Computer Aided Algorithm of Material Balance Split fraction concept CAHPTER FOUn. 4.0 ENERGY BALNCE 4.1 Energy Balance of Dryer 4. Energy Balance of Extractor 4.3 Energy Balance of Recovery Unit CHAPTER FIVE 5.0 FLOW SHEETING CHAPTER SIX 6.0 SELECTION OF EQUIPMENTS 6.1 Selection of Decorticator 6. Selection of Kernel Cleaning Unit 6.3 Selection of Dryer 6.4 Selection of Crusher 6.5 Selection of Extractor 6.6 Selection of Solvent Recovery Unit CHAPTER SEVEN 7.0 EQUIPMENT OPTIMIZATION 1.1 Equipment Optimization Optimization of the converter IIsing the principle of minimzing the lenght and diameter ~ '/ ' '60 60 CHAPTER EIGHT 8.0 SAFETY AND QUALIYTY CONTROL 8.1 Safety Hazards in com oil plant Inventory Material inventory Equipment inventory 8.1. Identification of hazards Explosion Fire Poisoning Chemical splash Safety measures Strategies for safer process design Safer decision via risk mapping 8. Quality Control 8..1 Quality assurance Principles of quality assurance Viii

9 8..1. Quality management 71 CHAPTER NINE 9.0 PROCESS CONTROL AND INSTRUMENTA non Process Control of Equipments Process control of air scrubber Process control of a vapourizer Absorber control Compressor control Process control of heat exchanger Converter control Column control Control of feed,high purity distillate composition,bottom temperature Control of distillate rate,distillate composition,bottom composition Control of distillate rat, bottom rate,bot1om composition Control of bottom rate,distillate composition,bottom composition Specification of Controller and Instrument Type 81 CHAPTER TEN 10.0 ENVIROMENTAL ACCEPTABJtlTY 10.1 Definition of the Problem Identification of possible pollutants Identification of sources of pollutants Identification of the mechanism 10. Effects of the I~olllJtant 10..] Effects of carbon dioxide 10.. Effects of carbon monoxid e Effects of nitrogen oxides ] 0..4 Effects of hydrocarpon 10.3 Pollution Treatment and Prevention Strategies CHAPTER ELEVEN 11.0 START UP AND SHUT DOWN PROCEDURE, 11.1 Start,Up Procedures 11. Shutdown Procedures Emergency shllt(,~own of plant CHAPTER TWELVE 1.0 SITE FOR PLANT LOCATION 1.1 Factors Considered for Site and Plant Location Location, with 'respect to market area 1.1. Raw material Transport A vaijability of labour.' Utilities (services) EnvirornentaIi,mpact and eftluent disposal lx ,

10 1.1.7 Local community consideration Availability of suitable land Climate Political and strategic consideration 1, Selection of Site 1.3 Justification of Selected Site Availability of raw material 1.3. Nearness to market Transport Availability oflabour Climate Political and strategic consideration Utilities 1.4 Plant Layout Cost 1.4. Process requirement Operation, Maintainance Safety Plant expansion Modular construction CHAPTER THIRTEEN 13.0 ECONOMIC ANAL YSIS 13.1 Introduction 13. Accuracy and Purpose of Capital Cost Estimates ] 3.3 Fixed and Working Capital Fixed capital 13,3, Working capital ] Operating costs Fixed operating costs Variable Operating costs 13.4 Computer Aided Algorithm for Costing } 13.4.] Estimation of capital investment cost CHAllTER FOURTEEN 14.0 RECOMMENDATION TO THE INDUSTRIALIST REFERENCES , , , 116

11 ABSl'RACT The project is aimed at designing a small scale plant to produce gallons of corn oil from corn seed per year. A basis of lookg per day of corn seed was used with the i~puts calculated at the start of th~ material balance based on the targeted production. The ) detailed design work comprises of introduction, literature review, and explanations of the manufacturing process route. This was followe~ by a detailed material and energy balance, equipment design,. including chemical and mechanical design of the major equipments and cost estimation were carried out. (Math CAD) was used in the design j calculations. Safety, control, environmental impact assessment and plant location and layout were carried out as well in this design project. Standard cost estimation was carried out and the fixed capital investment (FCl) was 40.1 million naira, purchasing equipment cost (PEe) was found to be 9.6 million naira, the rate of return (ROR) was I., 1.5%, with profit aftertax of approximately million naira per annum and a pay back period of 8years. Finally, it is recommended that the expansion of the plant to a large scale production should not be delayed since the project is economically viable. Vll