DESIGN OF A PLANT FOR THE ISHAYA GARBA HARUNA (2001/11548EH)

Transcription

1 DESIGN OF A PLANT FOR THE PRODUCTION OF 10,MILLION LITRES PER ANNUM OF BIO~'ETHANOL FROM CASSAVA (CASSAVA (~RA TER AND HYDROLYSIS) f.j BY ISHAYA GARBA HARUNA (2001/11548EH) DEP ARTMENT OF CHEMICAL ENGINEERING, SCHOOL OF. ENGINEERING AND ENGINEERING TECHNOLOGY, FEDERAL UNIVERSITY OF TECNOLOGY MINNA, NIGER STATE, NIGERIA. NOVEMBER, i

2 DESIGN OF A PLANT FOR THE PRODUCTION OF 10 MILLION LITRES PER ANNUM OF BIO-ETHANOL FROM CASSAVA (CASSAVA GRATER AND HYDROLYSIS) BY ISHA YA GARBA HARUNA (2001/11548EH) A FINAL YEAR PROJECT SUBMITTED TO THE DEPARTMENT OF CHEMICAL ENGINEERING IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR AN A WARD OF, BACHELOR OF ENGINEERING (B.ENG) DEGREE IN CHEMICAL ENGINEERING OF THE FEDERAL UNIVERSITY OF TECNOLOGY MINNA, NIGER STATE, NIGERIA. NOVEMBER,

3 DEDICATION This project is dedicated to the wisdom of God who at every stage of my study gave me inspiration, strength and courage to continue despite all the odds. It is also dedicated to my parents Mr. and Mrs. Ishaya D. Haruna, and my brother I-Iaruna Ishaya who has been a major source of encouragement in every aspect of my studies. It is also dedicated to all staff of The Department of chemical Engineering FUT Milma. God bless you all. 111

4 DECLARATION I, ISHAYA GARBA HARUNA, declare that this Plant Design on the production of 10 Million litres per annum of bio-ethanol from cassava (Cassava grater and hydrolysis) lmder the surpervision of Prof. F.Aberuagba is solely the result of my work and has never been submitted anywhere for any degree. All the literature cited have been duly acknowledged in the reference ii/iv! err ~ II II..... STUDENT DATE IV

5 CEI~TIFICATION This work titjcd "Plant design for the fj!u,-~~:ctinn or 10 ~lillioi1\iln.:s per annum or bioethanol from' cassava" by ISHA Y A GARBA IIAIUJNA meets thi,.: regulations governing theawi,lrd of the degree of Bal:helor or Fngim:ering (Che\11i<.:a\ Fngim:ering) or the Federal University of Technology. Minna and is approved ror its l:(ll1tributioi1 to knowledge and literary presentation... ~~ Prof. r. ABERUAGBA Project Supervisor.... II/t /&? L t.~... DATE ' *...,,. DR.M.O.EDOGA Head of Department Cb.emicaI Engineering... ~ DATE OATE v

6 ACKNOWLEDGEMENT When I did not have the formulation; and my first attempt at production did not work out properly; at the peak moment when things are tough, hopeless and frustrating; He shared my pains, comfort me, provide for me, favour me and participate in the production. I reverence the Almighty God, my Father and closest Friend for all these that He had done for me.to you, that was chosen from the folmdation of the earth, you are a cloud with rain, an autumn trees that brings out fruits and a sparkling star that change darkness into brightness. I must not forget the support of my supervisor Prof. F Aberuagba who has been very instrumental during the plant design project. I am very grateful for your advice and suggestion. My special thanks goes to my parent, Mr. and Mrs. Ishaya Haruna who have been my Alpha and Omega. They will continue to remain the secret of my success. Lastly my appreciation would be incomplete ifmy cousins, room mates, Aunties, classmates are not fully acknowledged; they include,malik M,Alex Z"Akasi A,Akai A,Obina N, Danlami Y.I,Mechack Cisse,Mrs Yakowa A,Habat H,Jenom K,Esther K,Nomtai,Zainab,Adamu H,David, Kyndon L,Bulus B, Damola, Mr. Tare, etc who as coueaque encouraged and supported me, I said thank you all and continue to be good ally. Though you are from different ethic group but God and ESM brought us together, Baliat, Ibrahim Yahaya, Abba Yakubu, Julius Makama, Idris Tanko, Shehu, Malik, Doris Tumaka, Sir Philemon, Fughar, Ayelo, A wulo Apollos. You are priceless jewel! VI

7 ABSTRACT The design of a plant for the production of 10 million liters per aiidum of Bio-ehtanol using Cassava as a basic feed stock by an enzymic hydrolysis process has been sucessfully carried out using Auto Card and Mathcad (CAD) software.this design project covers materials and energy balances for the entire process. The process flow sheet shows the mojor and the minor equipments, their operating conditions and material flows.the design of the major equipments was restricted to cassava Grater (Crusher) and the starch hydrolysis vessel.in addition, potential hazards were identified and safety measures recommended. It is recommended that the plant be sited in Eleme, Rivers State.Bassed on the economic analysis of the plant, it can be deduced that the plant is profitable, as it has a positive cash flow and return on investment of 23%. vii

8 Title page Dedication Declaration Certification Acknowledgement Absract Table of contents CHAPTER ONE 1.0 Introduction CHAPTER TWOs 2.0 Literature Review 2.1 Ethanol TABLE OF CONTENTS IV V VI V11 Vlll Background of Ethanol Types of Resources Suitable for Ethanol Production Properties of Ethanol Chemical Properties of Ethanol Important Properties of bio-ethanol Important Properties of Ethanol Sources of Ethanol Benefits of ethanol Disadvantage of fuel ethanol 2.2 Historical Background of Cassava Types of Cassava Starch PropeIiies of Cassava Starch viii

9 Physical Properties Functional Properties of Cassava Starch Cassava Starch Hydrolysis Enzyme Hydrolysis Chemical Hydrolysis 2.3 Ethanol Blends Ethanol- Gasoline Blend Ethanol- Diesel Blends 2.4 Principle of Ethanol Production CHAPTER THREE 3.0 Material BALANCES 24 CHAPTER FOUR 4.0 Energy Balances 4.1 Thermodynamics Properties Heat of Capacity coefficient of the components Heat of Fonnation of the Components 4.2 Formulation ofthe Energy Balance Equation Energy Balances Calculations Enthapy of the Feedstock Storage Tan1( Enthalpy ofthe Washer Enthapy ofthe Miller Enthalpy of the Cooking Vessel Enthalpy ofthe Fermenter 4.3 Gasoline Blending Tank Gasohol Blending Tank IX

10 CHAPTER FIVE 5.0 Flow Sheet/Diagram 5.1 Introduction 5.2 Computer Aided-Design (CAD) for Flow Sheet CHAPTER SIX 6.0 Equipment Design 6.1 Design of a Cassava Grater Hydrolytic Vessel Design Feed Rate to the Hydrolytic Vessel Hydrolytic Vessel Design Calculation Hydrolytic Vessel Volume Hydrolytic Vessel Diameter Hydrolytic Vessel Stirrer Power Requirement Hydrolytic Vessel Efficiency Hydrolytic Vessel Impeller Diameter CHAPTER SEVEN 7.0 Equipment Optimization 7.1 Equipment for the Optimization Optimization of the converter using the Principle of Minimizing the Length and Diameter 121 CHAPTER EIGHT 8.0 Safety and Quality Control 8.1 Safety Harzards in Bio-ethanol Plant Inventory x

11 Material Inventory Equipment Inventory Identification of Harzards Explosion Fire Poisoning Chemical Splash Safety Meaasures Strategies for Safer Process Design Safety Decision via Risk Mapping 8.2 Quality COlU1trol Quality Assurance Principle of Quality Assurance Quality Management CHAPTER NINE 9.0 Process Control and Instrumentation 9.1 Process Control of Equipments Process Control of Air Scruber Process Control of a Heater Absorber Control Compressor Comol Process Control of a Heat Exchanger Fermenter (Reactor) Control Column Control Xl

12 Control of Feed, High Purity Disdillate Composition, Bottom Temperature Control of Distillate Rate, Distillate Composition, Bottom Composition Control of Distillate Rate, Bottom Rate, Bottom Composition A Control of Bottom Rate Distillate Composition,Bottoms Composition 9.2 Specification of Controller/Instrument Type CHAPTER TEN 10.0 Enviromental Acceptabilty 10.1 Definition of Problem Identificaion of Possible Pollutants Indentification of Sources of Pollutants Indentification Mechanism 10.2 Effects of Pollutants Effects of Carbon Dioxide Effects of Carbon Monoxide Effects of Nitrogen Oxides 10.2A Effects of Hydrocarbons Effects of Particulate Matters 10.3 Pollution treatment and Prevention Strategies loa Heath Effects of Bio-ethanol 147 CHAPTER ELEVEN 11.0 Start Up and Shut Down Procedure 11.1 Start up Procedures 11.2 Shut down procedures xii

13 Emergency Shut Down of Plant Start up after Emergency shut Down CHAPTER TWELVE 12.0 Site for Plant Location 12.l Factors Considered for Site and Plant Location Location with respect to the Marketing Area Raw Materials Transport Availability of Labour Utilities (Services) Eviromental Impact, and Effluent Disposal Local Community Considerations Availability of Suitable Land(Site Consideratios) Climate Political and Strategies Consideration 12.2 Selection of Site 12.3 Justification of the Selected Site Availability of Raw Materials Nearness to Marketing Area Transport Availability of Labour Climate Political and Strategic Considerations Utilities xiii

14 12.4 Plant Layout Costs Process Requirement Operatrion Mintanance Safety Plant Expansion Modular Construction CHAPTER THIRTEEN 13.0 Economic Analysis 13.1 Introduction 13.2 Accuracy and Purpose of Capital Cost Estimates 13.3 Fixed and Working Capital 13.3.l Fixed Capital Working Capital 13.4 Operation Cost Fixed Operation Cost Variable Operating Cost 13.5 Computer-Aided Algorithm CHAPTER FOURTEEN 14.0 Conclusion 14.1 Recommendation to the Industrialist REFERENCES XIV

15 LIST OF TABLES 2.1 Common Biomass Feedstock to Consider for a Biomass to Ethanol plan A table showing the different types of alcohol,their sources,chemical Formola, names and bioling point 2.3 The physical properties of Ethanol 2.4 Fuel properties of ethanol compaired to petrol LIST OF FIGURES 9.1 Air 5mbber Control Absorber Control Flow and Pressure Control of a Centrifugal Compressor Heat Exchanger Control (temperature and pressure control) a Fermenter (Reactor) Controller b Cascade Control of the Fennenter a Control feed, high purity distillate composition, bottoms temperature b Control of distillate rate, distillate composition,bottoms compositions c Control of distillate rate, bottoms rate, bottoms composition d Control of bottoms rate, distilllate composition, bottoms composition Bioethanol site layout 161 xv