FACULTY INCHARGE Mr. Rahul Shrivatava (Dept. of CHE Engg.

SUBMITTED BY: Aniket Chaki(101410) Vivek sharma(101451)

Selected process
Bioethanol can be produced by three processes:

sugarcane processing, Cereal processing and lignocellulose processing. Among the most used Bioethanol production is by sugarcane.

Flowsheet

Process description
1.Preparation of the medium: Water is added to the molasses to bring down the sugar concentration to the desired level (usually 30 to 40 percent). A measured quantity of acid is then added so as to adjust the pH on the acidic side. 2.Addition of yeast: After adjusting the desired temperature, a yeast starter is allowed to be mixed thoroughly with the molasses mesh in the fermentation tank.

contd
3. Fermentation: Fermentation by the yeast process starts and soon becomes vigorous. A large quantity of carbon dioxide is evolved during the process. 4. Separation of ethyl alcohol: The fermented medium contains alcohol as well as other volatile constituents and unused constituents of the molasses. Therefore, separation of ethyl alcohol from other impurities is necessary.
5. Distillation (Purification): Finally, alcohol is purified with the help of rectifying columns and stored in bonded warehouses.

Plant capacity
30 tons per day of bio ethanol from the rectification column

(95% by weight) 1 ton = 1000 kg Therefore, 30 tons per day= 1000*30 kg per day 1 day = 24 hrs Therefore, 30 tons per day = 1000*30/24 kg per hr = 1250 kg/hr

Mass balance
FERMENTER Assumptions : Molasses = 52% sucrose + 48% water 95% sucrose Bioethanol 10% less alcohol is produced due to pipe losses 1 kg=2.694*10^-3 kg Ammonium sulphate 1 kg=2.1544*10^-3 kg H2SO4 1kg H2SO4 = 0.2 kg H2O Density of ethanol: 0.789 kg/l Ratio of water to molasses is 4:1

 Streams Input Mesh ( water + molasses Yeast culture + yeast cells Output CO2 Mixture of ethanol, water and biomass C12H22O11+H2O2C6H12O64C2H5OH+4CO2

CALCULATIONS

342 kg of sucrose gives 184 kg of bio ethanol 342 kg of sucrose will give 184*0.95=174.8 kg bio ethanol Molasses for 342 kg sucrose = 342/0.52=657.69 kg molasses 174.8 kg bio ethanol requires 657.69 kg molasses Or 1 kg bio ethanol requires 3.76 kg of molasses Due to 10% pipe losses, 1kg bio ethanol requires =3.76+(0.1*3.76)= 4.136 kg of molasses According to our capacity (i.e. 1250 kg/hr), molasses required= 12,50*4.136 = 5170 kg/hr molasses Water added to molasses is 4 times of molasses = (4*5170)=20,680 kg/hr Therefore, total feed (i.e. Mesh) produced= (5170+20680) =25850 kg/hr

 Since molasses contain 52% fermentable sugar in the form of

sucrose, sucrose in the molasses (feed)=(0.52*5170)=2688.4 kg sucrose/hr From our reaction, we know that, 342 kg sucrose gives 174.8 kg pure ethanol; therefore 2688.4 kg sucrose/hr gives 1374.071 kg ethanol/hr. Yeast culture needed =5% by weight of mesh Therefore, yeast culture= (0.05*25850) =1292.5 kg/hr Cell concentration=12.5 gm*kg of mesh So, cells present in the culture=12.5*10^-3 *25850 =323.125 kg cells/h Ammonium sulphate in 25850 kg/hr mesh= 69.6 kg/hr 1 kg =2.154*10^-3 kg H2SO4 H2SO4 in 25850 kg/hr mesh= 2.1544*10^-3*25850=55.6912 kg/hr Water formed by 55.692 kg H2SO4=11.138 kg/hr

Water balance
1 kg H2SO4=0.2 kg H2O
Total water in=20680+11.138=20691.138 kg/hr 342 kg sucrose requires 18 kg water therefore 2688.4 kg

sucrose gives 141.494 kg/hr water. Water out =20691.138- 141.494=20549.64 kg/hr

CO2 produced
Moles of CO2 produced is equal to the moles of ethanol

produced. Moles of CO2 produced = moles of ethanol produced/46= 1374.071/46 = 29.871 kmol/hr

Biomass

dx/ds=0.5g/g=(x-xo)/(s-so) Where, X is dry cell mass finally Xo is dry cell mass initially S is substrate mass finally So is substrate mass initially Xo=323.125 kg/hr cells So=2688.4 kg of sugar/hr S is the final weight of substrate or the left moles of ethanol=1374.071/46=29.871 kmol/hr According to the stoichiometry, 1 mole of sucrose equal to 4 moles of ethanol then the moles of sucrose reacted 29.871/4=7.468 kmol /hr

Contd..
Initial mole of sucrose = 2688.4/342= 7.861 kmol/hr
Moles of unconverted sucrose =7.861-7.468=0.393 kmol/hr Kg of sucrose unconverted (s) final=0.393*342=134.406 kg /hr Now, X=1600.122 kg of cells/hr Along with cells, about 50% water also goes

out=0.5*1600.122=800.061kg water/hrs Therefore, wt. of biomass = 800.061+1600.122=2400.183 kg/hr.

Material Balance across Fermenter

Kg/hr(inlet) 5170 Components Diluted Molasses Molasses Kg/hr(outlet)

20680
1292.5 323.125 55.69124

Water
Yeast Culture Yeast Cells H2SO4 CO2 Bioethanol Biomass Sucrose Residual Molasses

20549.64

55.692 1314.324 1374.071 2400.183 134.406 1693.320 27521.636

27521.317

Yeast treatment
Assumptions

Yeast culture needed is 5% by weight of mesh Cell concentration is 12.5g /kg of feed Nutrients by ammonium sulphate pH control by H2SO4
Streams:

Input H2SO4 Yeast culture + yeast cells Output Mixture of streams 5&6

Material balance across yeast treatment reactor

Kg/hr (inlet) 55.69124 323.125 1292.5 2400.183 4071.49 Components H2SO4 Yeast Cells Yeast feed Biomass Kg/hr(outlet) 55.69124 323.125 1292.183 2400.183 4071.49

Centrifuge
Streams:

Input Mixture of ethanol, water, biomass and sucrose Output Mixture of ethanol, water and sucrose Biomass recycled

Material balance across centrifuge

Kg/hr(inlet) 2400.183 1374.071 134.406 Components Biomass Bioethanol Sucrose Kg/hr(outlet) 2400.183 1374.071 134.406

20549.643
24458.303

Water

20549.643
24458.303

Distillation column
80% by weight of ethanol in distillate 2 % by weight of ethanol in bottom product

Streams: Input Mixture of ethanol, water and sucrose Output Distillate: 80% ethanol Bottom: Vinasse
% of alcohol in spent wash= 1374.071/ (24458.3-2400.183)*100 = 6.229 %

Calculations
Overall material balance: F=D+R F=24458.3-2400.183 kg/hr 22058.117=D+R
Component balance for ethanol: F*f=D*d + R*r 22058.117*(6.229/100) =D*0.8+ (22058.117-D)*0.02 D=1195.94 kg /hr R=20862.177 kg/hr

Material Balance across Distillation Column

kg/hr (inlet) 1374.071 20684.046 components Ethanol Water Ethanol (80%) Vinasse 22058.117 1195.94 20862.177 22058.117 kg/hr (outlet)

Rectification column
95% by weight of ethanol in the distillate 1% by weight of ethanol
Streams: Input Distillate from distillation column Recycle from molecular sieve dehydrator Output Distillate: 95% ethanol Bottom: residue

Calculations
Overall material balance: F=D+R x+1195.94=R+1250 x=R+54.06
Component balance: 0.01*R+0.95*1250=0.97*(R+54.06)+0.8*1195.94 R=185.739 kg/hr x= 239.8 kg/hr.

Material balance across Rectification Column

Kg/hr(inlet) 1195.94 239.8 Components 80% Ethanol Recycled Ethanol (97%) Residue Ethanol (95%) 1435.74 185.739 1250 1435.739 Kg/hr(outlet)

Dehydration column
Streams:

Input Feed: Hydrous Ethanol (95% by weight of ethanol) Output Top Product: Recycle stream to the rectification column Bottom Product: Anhydrous ethanol (99.5% by weight of ethanol)

Calculations
Overall material balance

D=x +E+W 1250=239.8+E+W

Component balance

0.95*1250=0.995*E+0.97*239.8 E=896.878 kg/hr W=113.22 kg/hr

Material balance across Dehydration Column

Kg/hr(inlet) 1250 Components Ethanol (95%) Water 113.22 Kg/hr(outlet)

Anhydrous Ethanol (99.5%)

Recycled Ethanol (97%) 1250

896.878
239.8 1250

Overall Material Balance of the process

kg/hr (inlet) 5170 20680 1292.5 323.125 Components molasses water Yeast culture yeast vinasse Residue(rectification column) Anhydrous ethanol (99.5%) 55.692 27521.317 H2SO4 CO2 Total 27521.317 20862.177 185.739 896.878 5603.523 kg/hr (outlet)

Energy balance
H=miHi (outlet)-miHi (inlet)
Q-Ws=H+Ek+Ep

C12H22O11+H2O2C6H12O64C2H5OH+4CO2 T=298K (assuming isothermal conditions) P=1atm

 Energy Balance in fermenter:

H=4(Hformation Ethanol) +4(Hformation CO2)2(Hformation glucose)

Enthalpies of formation

Hformation (Ethanol) =-276.5kJ/mol Hformation (CO2) =-393.5kJ/mol Hformation H2O (l) = -285.8 kJ/mol Hformation H2O (g) = -241.8 kJ/mol Hformation (glucose) (g) =-1250 kJ/mol Hformation (sucrose) (g) =-2220kJ/mol Therefore, H= [4(-276.5) +4(-393.5)-2(-1250)] = -180kJ/mol

Calculations
Sucrose balance:

Min of molasses=5170 kg/hr But, sucrose content in molasses=52% Sucrose=0.52*5170 =2688.4 kg/hr Moles of sucrose=2688.4/342=7.860 kmol Nout of sucrose= 1344.16/342=0.393 kmol

Water balance: Nin=20691.130 /18=1149.50 kmoles Nout=20549.64/18=1141.64 kmoles

CO2 balance: Nout =13143.288/44=29.871 kmoles

C2H5OH balance: Nout= 13,740.71/46=29.871 kmoles

Energy Balance across the fermenter

nin (kmol) 7.860 1149.50 0 0 Hin(kJ/mol) -2220 -285.8 -276.5 -393.5 species C12H22O11 H2O C2H5OH CO2 nout(kmol) 0.393 1141.64 29.871 29.871 Hout(kJ/mol) -2220 -285.8 -276.5 -393.5

 Assumption: Power input=1.6 watt/kg of input

Total input=275213.135kg/hr
Power Input=Ws=440.341 Ho =793.126 KW

Q=H+Ws=793.126+440.341= 1233.47kw/hr

Distillation column
Assumptions:

Temperature of distillate=82oC Boiling point of ethanol=78.5oC Boiling point of water=100oC Feed enters at 25oC Hv = enthalpy of vaporization

H=49519.6089 kJ Q=mCpT=H Cp=43.99kJ/kgoC T=75oC , Therefore, Steam required, m=15kg/hr

 For ethanol in distillate:

78.5

H H v

c dt
p

25

= 38.58+5.516 = 44.034 kJ/mol

For water in distillate:

H H v c p dt
25 100 78.5

c dt
p

Ethanol in residue:

100

= 40.656+5.655-1.6211=44.69 kJ/mol = 38.58+103.1*10^-3(100-25) =46.3125kJ/mol

H H v c p dt
25

100

Water in residue:
H H v c p dt = 40.656+75.4*10^-3(100-25) =46.311 kJ/mol
25 100

Energy balance across the Distillation Column

Species Feed nin(mol) Hin(kJ/mol) Distillate nout(mol) Hout(kJ/mol) Residue nout(moles) Hout(kJ/mol)

Ethanol Water

29.871

20.798 245.09

44.034 44.69

3.07 904.02

46.3125 46.311

1149.113 4.0339

Rectification column
Assumptions:
Feed Temperature- 78.5oC Distillate Temperature-78.5oC Residue-100OC H=10957.41292.71kJ/mol Q=mCpT=H

therefore, m= 3.32kg of steam/hr

Energy Balance across the Rectification column

Species Feed nin(mol) Distillate Hin(kJ/mol) nout(mol) Hout(kJ/mol) Residue nout(moles) Hout(kJ/mol)

Ethanol

25.85

25.81

38.58

0.034

40.797

Water

245.489

0.113

3.472

40.656

242.20

40.656

Control strategies of distillation column

 FC-Flow Controller
LC-Level Controller PC-Pressure Controller

TC-Temperature Controller

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