Bioethanol Production From Corn Stover PDF

Bioethanol Production from Corn Stover
A Plant Design Report

Submitted to the Faculty of the College of Engineering
Cagayan State University – Carig Campus
In Partial Fulfillment of the

Requirements for the Degree of
Bachelor of Science in Chemical Engineering
Martin Baccay Jr.

Princess Janine Catral
Karl Ian Martinez
Viejay Ordillo
May 2017
LETTER OF TRANSMITTAL
May 2017
ENGR. CAESAR P. LLAPITAN

Associate Professor III
Chemical Engineering Department
Cagayan State University
Dear Engr. Llapitan:
We are submitting herewith our process and equipment design report entitled “Bioethanol
Production from Corn Stover” as a chemical engineering process and equipment design course
requirement.
The objective of this design report is to show a detailed presentation of the equipment, feed,
operating conditions and feasibility of the processes involved in the manufacture of corn stover as
a potential feedstock for bioethanol.
The design report includes an introduction on the product and process overviews, process
descriptions and flow diagrams, material and energy balances, process control system design,
equipment design specifications, costing and project evaluation and safety, health and environment
analysis.
We hope that this report will merit your favorable approval.
Sincerely yours,
Martin G. Baccay Jr.

Princess Janine B. Catral
Karl Ian O. Martinez
Viejay Z. Ordillo
i
CERTIFICATION
This Project Design hereto entitled “Bioethanol Production from Corn Stover”, prepared and
submitted by Martin G. Baccay Jr., Princess Janine B. Catral, Karl Ian O. Martinez, and Viejay Z.
Ordillo in partial fulfillment of the requirements for the course Plant Design, has been examined
and is recommended for acceptance and approval.
____________________________
ENGR. CAESAR P. LLAPITAN
Instructor
APPROVAL
This Project Design is hereby approved and accepted as partial fulfillment of the requirements for
the course Plant Design.
_____________________________
ENGR. MONICO U. TENEDOR
Department Chairman
ii
ACKNOWLEDGEMENT
We would like to express our deepest gratitude to the people who helped and guided us
for the completion of this Process and Equipment Design report:
To Engr. Caesar P. Llapitan for his continuous guidance and understanding, instructive
suggestions and constructive motivations for the accomplishment of this design report.
To our friends and classmates for their support and encouragement in softening the
difficulties involved in this design report.
To our families for their constant support emotionally and financially, love, prayers and
inspiration in our endeavors.
And above all, to the Almighty God, our supreme maker and provider of knowledge and
strength and to whom this design report is endowed.
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EXECUTIVE SUMMARY
Bioethanol production is one of the most potential and realistic methods for lessening our
reliance on the currently depleting fossil fuels for energy source. The use of agricultural and
industrial waste as raw material guarantees that such method has no intention for environmental
degradation. Also, it is an economic responsibility for the country to impose the use and
production of renewable fuels for future security and investment. Thus, this plant design report
focuses on the fulfillment of such objectives.
In Chapter 1, the product information, process selection, site considerations and plant
layout are discussed. Based on the site considerations, the plant will be located at Brgy. San Jose,
Echague, Isabela.
For Chapter 2, the current demand and supply for bioethanol production in the Philippines
is discussed together with the existing laws and regulations regarding its manufacture.
Chapter 3 details the chemical processes and unit operations involved in the production.
Included here are the process control and equipment design for each equipment used.
Furthermore, Chapter 4 elaborates the estimated cost for each equipment, the payback
period, the return of investment and other economic aspect for putting up the plant
Finally, Chapter 5 lays out the environmental hazards and safety rules and regulations
particular to the plant production especially the material and safety data sheet for each chemical
substance used and produced and a waste disposal measure.
The material and energy balance, equipment design calculations, equations, tables and rules
of thumb used for equipment design are also included.
iv
Table of Contents
Title Page
Letter of Transmittal i
Acknowledgment ii
Certification and Approval iii
Executive Summary iv
Table of Contents v
List of Figures x
List of Tables xi
Chapter 1 – Introduction 1
I. Product Information 1
II. Properties of the Product 1
III. Process Selection 1
A. General Production of Ethanol from Lignocellulosic Biomass 4
B. Industrial Production of Ethanol from Corn 5
C. Ethanol Production from Corn Straw Using Alkaline Pretreatment 6
D. Modified Production Method 6
IV. Site Selection 7
A. Development of Potential Location Cases 7
B. Comparative Factors 8
C. Site Layout 10
D. Plant Layout 11
Chapter 2 – Market Study 12
I. Bioethanol Demand and Supply 12
II. Bioethanol Pricing 17
A. Cost of Imports 17
v
B. Cost of Locally-Produced Ethanol 18
C. Cost of Transportation 18
D. Tariff Assumed/Expected 19
III. Marketing Program 20
A. Terms of Use 21
B. Distribution 21
C. Promotion 22
D. Packaging 23
Chapter 3 – Technical Study 24
I. Process Description 24
A. Reactor Feed Preparation 24
1. Milling 24
2. Steam Explosion 24
3. Enzyme and Yeast 24
B. Reactor 24
C. Separator Feed Preparation 25
D. Separator 25
1. Beer Distillation 25
2. Gas Absorption 25
3. Ethanol Distillation 25
4. Adsorption 26
E. Recycle 26
II. Process Flowsheets 27
A. Process Flow Diagram 27
B. Process Topology 28
III. Material and Energy Balance Tables 29
vi
A. Summary of Material Balance 29
B. Summary of Energy Balance 31
IV. Equipment Summary 32
A. List of Equipment 32
B. Equipment Design Specification 33
1. Roller Mill 33
2. Steam Explosion Reactor 35
3. Pre-Cooler (SE Reactor to Hydrolyzer) 37
4. Hydrolyzer 39
5. Fermenter 41
6. Beer Column 43
7. Pre-Cooler (Beer to Absorber Column) 45
8. Absorber Column 47
9. Ethanol Column 49
10. Adsorber Column 51
11. Pre-Cooler (around Adsorber Column) 53
C. Piping and Instrumentation 55
1. Piping and Instrumentation Diagram 55
2. Valve Selection 56
3. Piper Sizing and Selection 58
4. Control and Instrumentation 60
a. Steam Explosion Reactor 60
b.Hydrolyzer 62
c. Fermenter 64
d. Beer Column 65
e. Absorber 66
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f. Ethanol Column 67
g. Adsorber Column 68
Chapter 4 – Costing and Project Evaluation 69
I. Estimation of Equipment Cost 69
II. Estimation of Working Capital 73
A. Fixed Capital Investment 73
B. Total Capital Investment 77
C. Working Capital 77
III. Estimation of Production Cost 78
A. Manufacturing Cost 78
1. Direct Cost 78
2. Fixed Charges 80
3. Overhead Cost 80
B. General Expenses 81
1. Administrative Cost 81
2. Distribution and Marketing Cost 81
3. Research and Development Cost 81
III. Feasibility Analysis 83
A. Profitability 83
B. Payback Period 84
C. Return of Investment 86
Chapter 5 – Safety, Health, and Environment 88
I. Safety and Loss Prevention 88
A. Hazard Identification 88
1. Hazards from Materials 89
2. Hazards from Operation and Handling 89
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3. Hazards from Design, Construction and Commissioning 90
B. Risk Management 92
II. Environmental Constraints and Analysis 97
III. Materials Safety Data Sheets 98
IV. Waste Disposal 106
A. Description and Quantity of Waste to be Disposed 106
B. Description of Waste Disposal Method 106
Chapter 6 – Conclusion and Recommendation 108
Bibliography 109
Appendix I – List of Equations Used 111
Appendix II – Cited Charts and Tables 114
Appendix III – Material Balance Calculations 115
Appendix IV – Energy Balance Calculations 125
Appendix V – Rules of Thumb Used for Equipment Design 142
Appendix VI – Equipment Design Calculations 146
ix
List of Figures
Figure 1.1 General Production of Ethanol 4
Figure 1.2 Industrial Production of Ethanol 5
Figure 1.3 Modified Production Method 6
Figure 1.4 Site Layout 10
Figure 1.5 Plant Layout 11
Figure 2.1 Final Energy Consumption by Sector 12
Figure 2.2 Final Energy Consumption by Fuel 13
Figure 2.3 Bioethanol Demand and Production 2009 – 2015 15
Figure 2.4 Fuel Use Projection from 2016 – 2026 16
Figure 2.5 Philippine price assessment for imported ethanol 2013-2014 17
Figure 2.6 Bioethanol Reference Price (Sept 2016-present) 18
Figure 2.7 Marketing Strategy for Bioethanol 20
Figure 2.8 Primary Packaging for Ethanol 23
Figure 3.1 Process Flow Diagram 27
Figure 3.2 Process Topology 28
Figure 3.3 Piping and Instrumentation Diagram 55
Figure 3.4 Instrumentation Diagram of Steam Explosion Reactor 60
Figure 3.5 Instrumentation Diagram of Hydrolyzer 62
Figure 3.6 Instrumentation Diagram of Fermenter 64
Figure 3.7 Instrumentation Diagram of Beer Column 65
Figure 3.8 Instrumentation Diagram of Absorber 66
Figure 3.9 Instrumentation Diagram of Ethanol Column 67
Figure 3.10 Instrumentation Diagram of Adsorber columns 68
Figure 4.1 Cumulative Cash Flow Position Diagram 87
x
List of Tables
Table 1.1 Top corn producers in Isabela 8
Table 1.2 Municipal Profile of Echague 9
Table 3.1 Table for Material Balance Summary 29
Table 3.2 Table for Energy Balance Summary 31
Table 3.3 Equipment Used and Their Corresponding Unit Operations 32
Table 3.4 Valves for Steam Explosion 56
Table 3.5 Valves for Hydrolysis 56
Table 3.6 Valves for Fermentation 56
Table 3.7 Valves for Beer Distillation 56
Table 3.8 Valves for Gas Absorption 56
Table 3.9 Valves for Ethanol Distillation 57
Table 3.10 Valves for Dehydration (Adsorption) 57
Table 3.11 Variables Involved for Steam Explosion Reactor 61
Table 3.12 Variables Involved for Hydrolyzer 63
Table 3.13 Variables Involved for Fermenter 64
Table 3.14 Variables Involved for Beer Column 65
Table 3.15 Variables Involved for Absorber 66

Table 3.16 Variables Involved for Ethanol Column 67
Table 3.17 Variables Involved for Adsorber Columns 68
Table 4.1 Table of Equipment Cost Using CAPCOST 2008 (CEPCI = 553.1) 70
Table 4.2 Detailed Summary of Estimation of Equipment Cost 72
Table 4.3 Breakdown of Direct Costs and Indirect Costs 74
Table 4.4 Calculated Percentages of Components and Items 75
Table 4.5 Summary of Product Cost Estimation 82
Table 4.6 Depreciation Using MACRS 85
xi
Chapter 1
INTRODUCTION
I. Product Information
Bioethanol (C2H5OH) is an alcohol produced by fermentation, mostly from carbohydrates
obtained in sugar or starch crops such as corn, sugarcane, or sweet sorghum. This can be classified
into first generation bioethanol derived from food crops such as corn and sugar cane and second
generation bioethanol derived from lignocellulosic biomass. This type of biomass can be in the
form of forest residues, agricultural wastes such as rice, corn and wheat straw and industrial wastes
such as paper sludge, sugar press mud, bagasse and molasses.
II. Properties of the Product
Ethanol is a very widely used compound in beverages and many food applications. Aside
from this, it has also good liquid fuel properties. It can be utilized as a fuel for vehicles in its pure
form, but it is usually used as a gasoline additive to increase octane and improve vehicle emissions.
Ethanol can be used in petrol engines as a replacement for gasoline; it can be mixed with gasoline
to any percentage. Most existing car petrol engines can run on blends of up to 15% bioethanol
with petroleum/gasoline. Ethanol has a smaller energy density than that of gasoline; this means it
takes more fuel (volume and mass) to produce the same amount of work. An advantage of ethanol
is that it has a higher octane rating than ethanol-free gasoline available at roadside gas stations,
which allows an increase of an engine’s compression ratio for increased thermal efficiency.
Ethanol is also used to fuel bioethanol fireplaces. As they do not require a chimney and
are “flueless", bioethanol fires are extremely useful for newly built homes and apartments without
a flux. The downsides to these fireplaces is that their heat output is slightly less than electric heat
or gas fires, and precautions must be taken to avoid carbon monoxide poisoning.
III. Process Selection
In general, bioethanol production undergoes (1) pretreatment, (2) hydrolysis, (3) fermentation
using Saccharomyces cerevisiae, and (4) purification by distillation. The goal of any bioethanol
1
process is (1) to break down the feedstocks’ hemicellulose, cellulose and lignin, (2) maximize the
yield of sugars to be converted into ethanol and (3) reduce inhibition of yeast cells during the
fermentation process. Other aims are to shorten fermentation time, decrease the energy input
during the purification processes and to minimize carbon dioxide emission during fermentation.
Researchers have modified this mode of production and numerous trends have been achieved.
Corn straw, consisting of the stalks and leaves, is composed of about 70 percent cellulose
and hemicellulose, and 15 to 20 percent lignin. Cellulose and hemicellulose can be converted to
ethanol, and lignin burned as a boiler fuel for steam/electricity generation. Developing ways to
quickly collect, handle and store biomass economically is required for biomass-to-ethanol
commercialization, along with improved process technology. Theoretically speaking, according to
scientists, around 130 gallons of ethanol could be produced per ton of corn stover (Koundinya,
2016).
The two important routes to converting corn straw into biofuels are: biological conversion
and thermochemical conversion. Biological conversion involves four steps: pretreatment,
enzymatic saccharification, fermentation and recovery. The thermochemical conversion involves
gasification and pyrolysis. Pyrolysis oil (bio-oil) is produced when corn straw is rapidly heated in
the absence of air to temperatures ranging from 400 to 600oC. In gasification, the straw is gasified
and carbon monoxide, hydrogen and carbon dioxide in the synthesis gas are fermented into
ethanol (Koundinya, 2016).
For the fermentation process, two methods can be employed. These are simultaneous
saccharification and fermentation (SSF) and separate hydrolysis and fermentation (SHF). SSF has
higher ethanol yields due to removal of end product inhibition of saccharification step. It also
poses low production costs and a decrease in the number of reactors required. On the other hand,
the difference in optimum temperature conditions of enzyme for hydrolysis and fermentation may
pose some problems. For SHF, each step can be processed at its optimal operating conditions.
2
However, inhibition may take place which minimizes the yield of ethanol. Contamination can also
be expected due to the long period process (Sarkar et al. 2012).
The last major step in bioethanol production is product purification to maximize ethanol
yield. Typical ethanol concentrations are in the range of 3–6 v/v % only, very low in comparison
with 12 to 15 v/v % obtained from 1st generation feedstock. Due to the higher water content of
the fermentation broth, additional distillation efforts are required. Different process improvements
are also used such as energy pinch, very high gravity fermentation, and other hybrid processes
(Kang et al. 2014).
3
A. General Production of Ethanol from Lignocellulosic Biomass
Figure 1.1 shows an industrial process of converting biomass into ethanol using steam
addition and hydrolysis as pretreatment method. The fermentation process used is SHF (Kang
et al. 2014).
Lignocellulosic
Biomass
Harvesting
Pretreatment ST
Hydrolysis ST
1st stage
Hydrolysis
2nd stage
CO2
CHP Wastes Fermentation
Wastewater
Treatment
ST Distillation
ST
Drying to
ST anhydrous
ethanol
Figure 1.1 General production of ethanol
4
B. Industrial Production of Ethanol from Corn
Figure 1.2 shows an industrial process of converting corn into bioethanol. The
pretreatment method that is used is liquefaction while the fermentation process applied is SSF.
Note a more extensive purification process than the lignocellulosic approach
Enzyme Enzyme
Urea Sulfuric Yeas
Lime acid t
Corn Milling Liquefaction Saccharification Fermentation
Condensate
Broth
Vent
Backs Steam Vent
et
Recycle
water Distillation/
Evaporation Centrifugation Dehydration/
Absorber
COC
Wet
EtOH
Product
COC
Drying Storage
Figure 1.2 Industrial production of ethanol
5
C. Ethanol Production from Corn Straw Using Alkaline Pretreatment
Other processes for bioethanol production from corn straw used steam explosion and
alkaline pretreatment which was followed by enzymatic hydrolysis using cellulose as the
enzyme. This yielded fermentable sugars xylose (23.6 g/L), glucose (56.7 g/L) and arabinose
(5.7 g/L). Alkaline pretreatment and steam explosion was used to separate the hemicellulose,
cellulose and lignin fibers and to make it easier for the enzyme, cellulose, to degrade them
(Sarkar et. al 2012).
D. Modified Production Method
Process Steam
Enzyme Yeast
Corn Milling Steam Hydrolysis Fermentation

Stover explosion
Broth
Process Water
Beer
Ethanol Gas
Adsorption Distillation
Distillation Absorption
Stillage
Ethanol Carbon dioxide Wastewater

(product) (to be condensed) Treatment
0
Figure 1.3 Modified production method
6
Corn stover will be used as the primary raw material since it has a huge potential as
biomass because it is an agricultural waste. First, raw corn stover will undergo mechanical
pretreatment through milling to increase its particle size. Increasing the particle size means a
larger surface area for reaction. Milled corn stover will then go through physicochemical
through steam explosion a. Steam explosion is used to free the hemicellulose and cellulose
sugars for enzymatic hydrolysis. Fermentation will be used to convert pretreated corn stover
into ethanol. The use of the SHF method ensures higher ethanol yields due to removal of end
product inhibition of saccharification step and reduction in the number of reactors required.
After fermentation, the fermented broth will undergo a series of purification steps starting with
beer distillation. This separates the stillage (liquid and solid waste) from the broth. Next is the
gas absorption step where carbon dioxide will be removed. Concentration of ethanol will be
accomplished in the ethanol distillation until the ethanol-water mixture reaches its equilibrium
state. Wet ethanol from the distillation column will then be further purified to produce fuel-
grade ethanol. The ethanol will be the overhead product and be cooled using the water
adsorbed from the adsorption.
IV. Site Selection
A. Development of Potential Location Cases
According to Agriculture Regional Director Lucrecio Alviar, the province of
Isabela contributed the most to the 1.6 million MT aggregate corn production of Cagayan
Valley producing 1,049,954 MT, Nueva Vizcaya with 218,446 MT, and Quirino with 73,
423 MT.
Contributing as well to the province’s high productivity in agriculture is the
presence of the Magat Dam which irrigates most of the agricultural lands in Isabela
(PIAnews).
7
B. Comparative factors
In terms of raw material supply, Isabela produced 1,175,322 MT of corn
(Philippine Statistics Authority, 2014). Among the cities and municipalities of Isabela, the
following are the top 3 corn producers:
Table 1.1 Top Corn Producers in Isabela
City/Municipality Metric Tons Rank Hectarage
Ilagan City 57,872 1 16,474
Cauayan City 51, 117 2 11,874
Echague 42, 165 3 9, 884
Of the three, the most viable location in putting up a plant is Echague, Isabela.
The first two cities, Ilagan and Cauayan, have a higher residential population due to its
status as a city.
Echague is a 1st class municipality located in southern Isabela province. It is
bounded on the north by the towns of San Isidro, Alicia, Angadanan, and San Guillermo,
on the east by Dinapigue, on the south by Quirino Province, San Agustin, and Jones, and
on the west by Santiago City. It has a total land area of 680 square kilometers and is
politically subdivided into 64 barangays. Echague is one of the main corn producers of
Isabela.
8
The following table provides information on the other comparative factors (e.g.
transport, availability of labor, utilities, telecommunications, land and political and strategic
considerations):
Table 1.2 Municipal Profile of Echague
Basic Profile
LGU Type Municipality
Income class 1st
Population 73,709
Total Land area in hectares 68,080.0
No. of Barangays 64
No. of Households 13,869
Financial Profile
IRA share P 129,198,640.00
Local-Sourced Revenues P 10,697,480.46
Other Revenues P 19,191,118.24
Total LGU Income P 159,087,238.70
Ecosystems Agricultural Ecosystem
Forest Ecosystem
Freshwater Ecosystem
Economic Activity Agricultural
Industrial
Commercial and Service Center
Mining
Government Officials
Mayor Hon. Melinda G. Kiat
Vice Mayor Hon. Liza Katrina G. Kiat
Source: PENRO-Isabela
9
C. Site Layout
Figure 1.4 Site Layout
10
D. Plant Layout
Figure 1.5 Plant Layout
11
Chapter 2
MARKET STUDY
I. Bioethanol Demand and Supply
In Philippine Energy Plan (2007), one of the country’s Five-Point Reform Package is the
pursuance of energy independence agenda to achieve energy self-sufficiency and globally
competitive energy sector. In 2011, the transport sector had the highest energy consumption
representing 34.7% of the country’s final energy consumption, followed by residential (26.1%),
industry (25.9%), commercial (11.9%), and AFF (1.3%).
AFF
1%
Commercial
12%
Transport
35%
Industry
26%
Residential
26%
Figure 2.1 Final Energy Consumption by Sector
Within the transportation sector in 2010, road transport accounted for 79% of the overall
sectors’ energy consumption followed by international civil aviation (11%), water transport (8%),
domestic air and rail transport (3%). Petroleum products supplied 97.9% of the sector’s total
energy demand in 2010, with diesel taking the biggest share (48%), followed by gasoline (32%).
12
In addition, final energy consumption by fuel included 48.6% oil products, 21.1% biomass,
21% electricity, 8% coal, 1% biofuels, and 0.3% natural gas.
Biofuel Natural Gas

1% 0%
Coal
8%
Electricity
21% Oil Products
49%
Biomass
21%
Figure 2.2 Final Energy Consumption by Fuel
The lead agency responsible for the country’s Biofuels Program is the Philippine
Department of Energy (DOE). The country’s biofuels strategy is expressed in the National
Biofuels Plan (NBP) which is based on the Philippine Energy Plan (PEP). The PEP reflects the
mission to ensure the delivery of secure, sustainable, sufficient, affordable and environmentally-
friendly energy to all economic sectors, while the NBP is a preliminary assessment of the previous
year’s NBP, and outlines the short-, medium- and long-term plans of the National Biofuels Board
(NBB).
According to DOE, among biofuels, ethanol is an ideal motor fuel for spark ignition
engines, mainly as additive for gasoline. This is because ethanol has a high natural octane rating
that prevents premature detonation under load; burns more clearly and slightly cooler, extending
engine life; and has a higher volumetric efficiency contributing to increased power.
13
In recent years, however, Philippines is among the largest importers of ethanol in the world
due to lack of local ethanol supply and insufficient investments in ethanol infrastructures.
Additionally, ethanol producers in the country lack the scale and efficiencies necessary to be
competitive in the global ethanol market.
To mitigate the country’s dependence on ethanol imports, Philippines pioneered a biofuels
legislation, R.A. 9367 a.k.a. Biofuels Act of 2006, in southeast Asia, and enacted R.A. 9513 or
Renewable Energy Act of 2008. The former mandates the blending of biodiesel and bioethanol in all
locally distributed diesel and gasoline, while the latter aims to accelerate the exploration and
development of renewable energy resources, thereby increasing the utilization renewable energy.
According to R.A. 9367, within two years from its effectivity, at least five percent (5%)
bioethanol shall comprise all the annual total volume of gasoline fuel actually sold and distributed
by each and every oil company in the country. And in succeeding years, ethanol blend shall be
gradually increased upon the recommendation of National Biofuel Board created under this law.
Table 2.1 Philippine Ethanol Mandate
PHILIPPINE ETHANOL MANDATE
Date Published Effective Remarks

Signed
R.A. 9367 1/12/2007 1/22/2007 2/06/2007
Ethanol
- 5% blend 2/06/2009 - By volume
- 10% 8/06/2011 - Implementation of 10%
blend blend
Target
Blend 2012 - - All oil companies
- 10% (full) onwards - Projected
- 20% 2020 - Projected
- 85% 2025
Source: Department of Energy
14
In table 2.1, the aspirational goals to raise ethanol mandate are based on the National
Renewable Energy Program of the Philippine Energy Plan 2012-2030 to meet the government’s
Energy Reform Agenda.
Currently, there are 10 operating distilleries in the Philippines, five are located in Luzon
and the remaining five in Visayas. The local ethanol producers have an estimate combined capacity
of 282 million liters per year. According to DOE, the demand and production of ethanol in the
Philippines has increased from 208 – 522 and 23.28 – 168 million liters per year, respectively, from
2009 – 2015.
600
500
400
300
200
100
0
2009 2010 2011 2012 2013 2014 2015
Demand Production
Figure 2.3 Bioethanol Demand and Production 2009 – 2015
(Source: USDA Foreign Agricultural Service GAIN Report: Philippine Biofuels Situation and
Outlook from 2010-2016)
However, as observed from figure 2.1, there is a huge gap between the ethanol demand
and production despite the Philippine mandate of ethanol blend. In order to meet the annual
ethanol consumption of the Philippines, the NBB allowed ethanol importation for oil companies.
15
In a report by USDA Foreign Agricultural Services, the continued growth of Philippine
economy and its expanding population are expected to drive fuel demand through 2026. Starting
from 2016, fuel demand projections are based on Post’s estimates with the assumption of five
percent demand growth annually.
Fuel Use Projection (million liter)

16000
14000
12000
10000
8000
6000
4000
2000
0
2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026
Gasoline Diesel Jet Fuel
Figure 2.4 Fuel Use Projection from 2016 – 2026
(Source: USDA Foreign Agricultural Service GAIN Report: Philippine Biofuels Situation and
Outlook 2016)
16
II. Bioethanol Pricing
A. Cost of Imports
In the Philippines, the United States Department of Agriculture (USDA)
estimates ethanol production in the country will start to ramp up and in turn demand for
imports from the US will fall to 281 million liters in 2016 and 278 million liters in 2017
from the 311 million liters imported in 2015 at a value of $170 million (8.5 billion Php).
The Philippines was the US’s third-largest ethanol export destination in 2015 (Biofuels
Digest, 2016).
Figure 2.5 shows the Philippine price assessment for imported ethanol conducted
by Platts Biofuelscan. Platts Biofuelscan is a daily report, covering the latest worldwide
biofuel news and prices. It provides a daily summary of market events and developments,
along with closing market price assessments from the Americas, Europe, and Asia. In the
figure, imported fuel-grade ethanol prices in the Philippines were assessed $13.67/cubic
meter (683.5 php/cu m) higher from March 14 at $699.67/cu m (34,983.5 php/cu m) CIF
on March 17.
Figure 2.5 Philippine price assessment for imported ethanol 2013-2014
17
B. Cost of ethanol produced locally
The Sugar Regulatory Administration (SRA) of the Department of Agriculture is tasked
in keeping a bi-monthly ethanol reference price (Php/liter) as a guide for production firms
using sugarcane molasses as the reference feedstock. The bioethanol price index as of
February 2017 is 54.70 Php/liter.
Figure 2.6 Bioethanol Reference Price (Sept 2016-present)

C. Cost of Transportation
The location of ethanol production plants affects transportation costs. In 2016, of
the 10 distilleries operating, five are located in Luzon island and the remaining five found
in the Visayas region. Four of the five distilleries in the Visayas are found in the island of
Negros, which accounts for roughly 60 percent of domestic Philippine sugar production.
According to contacts, the distillers from Negros supply the ethanol requirements of the
entire Visayas and the southern island of Mindanao which represent around 30 percent of
overall ethanol demand. The SRA estimates the cost of transporting ethanol out from
Bacolod at P450 ($10) per ton. According to the same source, this is why new ethanol
18
plants are being set up in Luzon, where an estimated 70 percent of demand is located.
However, since Luzon has less than 40 percent of national sugar production, feedstock
supply is an issue (Biofuels Annual, 2016).
D. Tariff assumed or expected for the project
In general terms, ethanol tariffs under various free trade agreements of the
Association of Southeast Asia Nations, including the Philippines, fell to zero in 2016, down
from five percent in 2015. Most Favored Nation tariffs for WTO-member countries,
including the United States, are also at zero percent in 2016, down from 10 percent the
previous year. An additional one percent duty is imposed if the ethanol is to be used for
fuel-blending purposes under the Philippine Fuel Ethanol Program (Biofuels Annual,
2016). According to RA 1937 or the Tariff and Customs Code of the Philippines, a 0.75
Php/liter import duty for ethanol is mandated.
19
III. Marketing Program
Marketing activities is one of the cost intensive component of projects. While
developing promotion and marketing tools there is a need to have thorough assessment that
could lead to having effective tools both in terms of output as well as cost. We have to look
at the most cost effective promotional tools that consider the target market. In this aspect
one need to optimize a certain tool for both urban and rural coverage as well as effectiveness
in influencing purchase decisions.
The marketing strategy of bioethanol is defined based on the pillars that enhance the
product demands, strengthen the supply and encourage the enabling environment. Each
pillar is found out as basic elements to create sustainable bioethanol market.
Promote the awareness of ethanol  Encourage local production

technologies and the adoption of  Capacity building
ethanol measures  Finance production
Intensive promotional activities Enhance Strengthen
Synergizing with other Demand Supply
stakeholders like health,
agriculture, gender,
environment, etc.
Reduce the costs
Encourage Enabling
Target early adopters to build
Environment
the markets
Promote strong participation of the private sector in the

development and provision of bioethanol to end users
Enforce quality standards
Tax exemption
Policy advisory
Synergizing with stakeholders
Figure 2.7 Marketing Strategy for Bioethanol
20
A. Terms of Sale
The terms of sale for the bioethanol products are the following:
1. The prices payable by Buyer for goods and services to be supplied by Supplier under
this Agreement will be specified in the applicable Order. Unless otherwise expressly
stated in an Order, all prices exclude shipping and taxes.
2. Payment terms are net thirty (30) calendar days from the date of the invoice. If Buyer
does not pay an invoiced amount within terms, Buyer will in addition pay finance charges
of one and one-half percent (1.5%) per month on the late
3. Upon reasonable request by the Supplier, Buyer shall provide copies of its most recent
audited financial statements or other reasonable evidence of its financial capacity and
such other information as Supplier reasonable requests to determine credit status or
credits limits.
4. Buyer shall provide notice within five (5) business days of the occurrence of any event
which materially affects Buyer’s ability to perform its obligations under this Agreement
including but not limited to: (i) the material default of any supplier or sub-contractor; (ii)
labor strike or dispute; or (iii) material uncured default with respect to any debt
obligations of Buyer.
5. Pricing schedules (whether attached to this Agreement or an Order) are subject to
change upon a change in the price of applicable raw materials (as reflected on a
recognized trade or commodity pricing tracker) in excess of five percent (5%) from the
date of such schedule.
6. Unless otherwise specified in the Order, work will be delivered to Supplier’s
manufacturing facility and will be shipped to Buyer via carriers selected by Supplier.
B. Distribution
Ethanol will be distributed in bulk basis from the plant to the sales outlets
21
directly to the consumers that demand the product. In this sense, the consumers
would be the Petroleum distributors, Supermarkets / Minimarkets and National
Alcohol and Liquor Factories. Sales outlet shall be located near the manufacturing
plants that utilize ethanol as industrial raw material.
Trucks will be used to transport bulk of containers of ethanol from the main plant
to the sales outlets. A typical transport truck can carry about 8,000 gal/load. Trucking
of ethanol is the most efficient and cost-effective transportation mode for distances up
to about 300 miles.
C. Promotions
Promotion is one of the key intervention areas that contributes to efficient
dissemination of the products.
Different types of promotion are devised to market bioethanol to the
respective target groups.
1. Production and distribution of posters and user leaflets.
2. Participation on trade fairs and exhibitions. This tool can address not only
buyers/users but also people who are engaged in different developmental activities
as well as higher officials, which is very important for further integration with
interested stakeholders.
3. Medias (TV/ Radio) are used to broadcast different educational films,
advertisement clips and also to address the coherent effect of modern energy
development and energy efficiency on other related sectors like environment, gender
and health by integrating in different programs.
4. Billboards and signboards are also used as information board to transmit basic
issues by putting eye catching colorful pictures of the product and some important
tag lines and information.
5. Newspaper is used for posting addresses of all producers in all regions where the
22
project is intervening as well as to post some important issues that are related with
energy in general.
D. Packaging
Since ethanol is a volatile and flammable liquid, the packaging for transportation must
have the three basic components. (1) Primary packaging, such as a vial, tube, jar and
drums. Closures of primary packaging must be held securely in place with tape, wire,
metal crimps or other positive means. (2) Secondary packaging, such as a zip lock or other
plastic bag. Intermediate packaging must contain enough absorbent material to absorb
all contents. (3) Outer packaging, such as a cardboard (fiberboard) box. The
dimensions of the outer box must be at least 100 mm on two of three sides. The
containers should be properly labelled also. Labels shall contain the information from the
Material Safety Data Sheets.
Figure 2.8 Primary Packaging for Ethanol
23
Chapter 3
TECHNICAL STUDY
I. Process Description
A. Reactor Feed Preparation
1. Milling
The raw material, corn stover, composed of the leaves, stalks, husks and cobs, is
milled using a roller mill. The parameters to be used for the milling process are ball
speed of 350 r/min, a solid/liquid ratio of 1:10, raw material particle size with 0.5 mm,
and number of balls of 20 (steel ball, Φ=10 mm) and grinding for 30 min. The milled
corn stover must attain a particle size of 0.16-0.23 in, a density of 9-11 lb/ft3 and
moisture content of 20% (Lin, et al, 2010).
2. Steam Explosion
The milled corn stover undergoes steam explosion for a few minutes in a reactor
equipped with a heating jacket and an automatic control for steam pressure,
temperature and retention time. Saturated steam of 20-50 bar and 160-290oC is
incorporated into the reactor to release the hemicellulose and cellulose sugars.
3. Enzyme and Yeast
The enzyme cocktail and yeast inoculum will be stored in tanks. The enzyme and
yeast to be used will be cellulase and Saccharomyces cerevisiae.
B. Reactor
To convert the biomass into fermentable hexose and pentose sugars and then into
ethanol, separate hydrolysis and fermentation (SHF) will be used. Conversion will take
place in a reactor with the following reactions:
C6H12O6 → 2C2H5OH + 2CO2
3C6H10O5 → 5C2H5OH + 5CO2
24
The theoretical maximum yield of both hexoses and pentoses is 0.511 kg ethanol
and 0.489 kg CO2/ kg sugar. The overall theoretical ethanol yield (at 20oC) hence becomes
0.719 and 0.736 liters per kg of glucan (and/or other 6C structures) and xylan (and/or
other 5C structures), respectively (Kang et.al, 2014). The optimum time for saccharification
will be 36 hours while 156 hours will be the fermentation time (Liu et.al, 2014).
C. Separator Feed Preparation
Before beer distillation, the fermented broth from the SSF reactor will first be
stored in beer holding tanks before introducing it into the beer columns.
D. Separator
1. Beer Distillation
Fermented broth from the reactor (5.4 wt % ethanol) is fed to the beer column.
The beer column removes the CO2 to the overhead while removing 90 wt % of the
water to the bottoms. The stillage consisting of 90 wt % water and 10 wt % solids will
be fed to the boiler for power generation of steam and electricity.
2. Gas Absorption
The overhead from the beer column is fed to the Absorber with an approximate
composition of 85 wt % CO2, 11 wt % ethanol and 4wt% water. The desired overhead
composition is 99.7 wt % CO2 and 0.3 wt % ethanol while the bottoms overhead
composition is 76 wt% ethanol and 24 wt % water.
3. Ethanol Distillation
The bottoms product from the Absorber will be fed to the ethanol distillation
column. An overhead product of 95.6 wt % ethanol and 4.4 wt % water will be
produced. The bottoms product will be composed of 99.95 wt % water and 0.05 wt
% ethanol. Further purification of the overhead ethanol-mixture using a distillation
column is not advisable since the mixture is already an azeotrope mixture (it has
reached equilibrium).
25
4. Adsorption
Wet ethanol (95.6 wt% ethanol) from the ethanol distillation column will be
further purified using two adsorption columns to produce dehydrated ethanol with a
percent composition of 99.5 wt% ethanol and 0.5 wt% water. The adsorbent to be
used will be 3A molecular zeolite. Regeneration of the adsorbent will be done by a
vapor slipstream from the dehydrated ethanol stream.
E. Recycle
Process water coming from the bottoms of the ethanol distillation column will be
recycled back to the wet oxidation reactor. Stillage from the beer column will be fed to
the boiler as fuel for power generation of steam and electricity.
26
II. Process Flow Sheets
A. Process Flow Diagram
Process Steam
Enzyme Yeast
Corn
Stove Roller Reactor Reactor Reactor
r Miller (Steam (Hydrolysis) (Fermentation
Explosion) )
Broth
Process Water
Ethanol
Adsorber Absorber Beer Column
Column
Stillage
Carbon dioxide Wastewater

Ethanol
(to be condensed) Treatment
(product)
0
Figure 3.1 Process Flow Diagram
27
B. Process Topology
Figure 3.2 Process Topology
28
III. Material and Energy Balance Tables
A. Summary of Material Balance
In a unit process or operation, it is important to note the mass flow rates of all
entering and leaving process streams. To do this, one must have a basic knowledge of an
equipment’s input and output materials, the components in each material and the necessary
assumptions needed.
A systematic way of determining the mass flow rates of each stream must be
utilized given the components and assumptions taken up from literature and design
handbooks. This usually starts with an overall material balance followed by a series of
component balances. In a reactor system, however, it is necessary to know the reactions
taking place and the number of moles of the reactants and products so that a stoichiometric
ratio can be determined. A degree of freedom analysis must also be computed at the end
of each material balance calculation so that the data used to form equations is sufficient to
supply the mass flow rates of all streams in each equipment.
Furthermore, a summary of flow rates table must be established to show the overall
process streams and to check whether the sum of all input flow rates equals the sum of the
output streams.
Table 3.1 Table for Material Balance Summary
Equipment Input (kg/day) Output (kg/day)
Adsorber 116688.0616 Azeotropic Ethanol 100000 Dehydrated Ethanol
16688. 0616 Ethanol Water
Ethanol Column 148759.7637 Wet Ethanol 116688.0616 Azeotropic Ethanol
32071.7021 Process Water
Absorber 127849.5284 Beer 148759.7637 Wet Ethanol
32071.7021 Process Water 11161.4668 CO2
29
Beer Column 168335.2124 Fermented Broth 127849.5284 Beer
40485.684 Stillage
Fermenter 329358.6625 Fermentable Sugar 168335.2124 Fermented Broth
161023.45 CO2
Hydrolyzer 609676. 7631 PCS 356805.2175 Lignin
76487.1169 Water 329358.6625 Fermentable Sugar
SE Reactor 304838.3816 Process Steam 609676.7631 PCS
304838.3816 MCS
Roller Mill 304838.3816 RCS 304838.3816 MCS
Total 2524101.955 2524101.955
30
B. Summary of Energy Balance
A process stream undergoes a change in energy if its composition or phase
changes. This can be either a gain wherein the stream increases in temperature and
becomes a vapor or a loss wherein the stream decreases in temperature and becomes a
liquid. Thus, it is necessary to calculate the energy balance in each equipment so that
one can trace the energy needed.
Energy can be in the form of mechanical energy done on the system, a heat gain
or loss due to a change in temperature or work done. Data and assumptions regarding
the streams leaving and entering the equipment such as heat of vaporization, heat
capacity and mass flow rates must be accurate.
The energy balances of each equipment and the data used for calculations will
serve as a basis for the equipment design specifications.
Table 3.2 Table for Energy Balance Summary
Equipment Heat Input Heat Output Heat
(kJ/s) (kJ/s) Loss/Gain
Adsorber system 529.9882 443.3516 -86.6366
Ethanol Column 178.8434 223.5919 44.7485
Absorber 260.9451 196.4541 -64.491
Pre-cooler 403.5644 403.5644 0

(Beer/Absorber Column)
Beer Column 62.7449 705.338 642.5931
Fermenter 143.5446 131.2038 -12.3408
Hydrolyzer 549.9476 549.9476 0
Pre-cooler 1238.3982 1238.3982 0

(SE Reactor/Hydrolyzer)
SE Reactor 3108.9087 1714.7052 -1394.2035
31
IV. Equipment Summary
The full realization of a manufacturing process entails a basic understanding of the unit
operations involved and the piece of equipment needed to do it. For instance, a reactor needed to
convert reactant A into product B may well be utilized in different industries. Its function, remains
the same, that is conversion but the type of reactor needed according to the production’s purposes
can be changed. Alterations depend on several variables such as temperature, pressure,
concentration and volume. The materials needed to build a reactor may also depend upon the type
of chemicals being handled. Thus, appropriate guidelines and rules of thumb have been established
for the design of an equipment and must be strictly followed.
A. List of Equipment
Table 3.3 Equipment Used and Their Corresponding Unit Operation
Equipment Unit Operation
Roller Mill Milling
Steam Explosion Reactor Steam Explosion
Pre-cooler Cooling
(SE Reactor/Hydrolyzer)
Hydrolyzer Hydrolysis
Fermenter Fermentation
Beer Column Beer Distillation
Pre-cooler Cooling
(Beer/Absorber Column)
Absorber Gas Absorption
Ethanol Column Ethanol Distillation
Adsorber Adsorption
Condenser Condensation
32
B. Individual Equipment Design Specification
1. Roller Mill
Design of the equipment:
1. An understanding of the raw material to be milled should be established.
2. Capacity, speed and circumference of the roller mill is calculated based on
assumptions on dimensions.
Assumptions:
1. The roller mill has a speed of 300 rpm
2. The roller mill has 2 rollers
3. The feed entering the roller mill has a particle size of 12 mm with a product
particle size of 4 mm
4. The roller has a diameter of 910 mm
5. The length of the face of the rolls is 410 mm
6. The distance between the rolls is 4 mm
33
EQUIPMENT SPECIFICATION SHEET
GENERAL DETAIL
Equipment Name: Roller mill
Equipment Code: M-101
Type/Description: Smooth roller mill
Function: For size reduction of the corn stover
Operation: Continuous
TECHNICAL DETAIL
No. of Unit: 1
Speed: 300 rev/min
Roller diameter: 910 mm
Length of rolls: 410 mm
Distance between rolls: 4 mm
Circumference of the roller mill: 285.88 cm
Feed particle size: 12 mm
Product particle size: 4 mm
Capacity of the roller mill: 522,183.6459 cm3/min
OPERATING CONDITION
Temperature: 25 °C
Pressure: 1 atm
Flowrate in: 304,838.3816 kg/day raw corn stover

Materials of Construction: Steel
Method of Procurement: Purchase
34
2. Steam Explosion Reactor
1. Mass flow rates and characteristics of the reactant should be clearly defined.
2. Operating conditions must be established.
Assumptions:
1. Bulk density of milled corn stover: 130 to 160 kg/m3
35
GENERAL DETAIL
Equipment name: SE Reactor
Equipment code: R-101
Type/description: Pressure Vessel/Autoclave
Function: Prepares the raw corn stover for hydrolysis by releasing the cellulose and
hemicellulose from lignin
Mode of operation: Continuous
TECHNICAL DETAIL
No of units: 1
Dimensions:
Head Thickness: 0.0544 m
Shell Thickness: 0.062 m
Diameter: 3.5250 m
Length: 10.5749 m
Volume: 118.9092 m3
Inside Depth of Dish: 1.3414 m
Operating Conditions: 2100C
19.74 atm
Material of Construction: Carbon Steel
Method of procurement: Shop fabrication
36
3. Pre-cooler (SE Reactor to Hydrolyzer)
1. Mass flow rate of entering fluid should be clearly defined.
Assumptions:
1. The specific heat of pre-treated corn stover is 2.7 kJ/kg-°C.
2. Fluid 1 is pre-treated corn stover and fluid 2 is water.
3. The overall heat transfer coefficient for water-medium organics is 250-600 W/m2-
K (Peters, Timmerhaus, & West, 2004).
4. The heat exchanger is shell-and-tube (one-shell and two-tube pass) floating head
type.
5. The fluid flow is countercurrent.
37
GENERAL DETAIL
Equipment name: Pre-cooler (SE Reactor to Hydrolyzer)
Equipment code: E-101
Type/description: Heat exchanger
Function: Prepares the pretreated corn stover for hydrolyzer
TECHNICAL DETAIL
No of units: 1
Area: 122.6387 m2
Type: Floating head
One-shell and two-tube pass
Operating Conditions: 20-900C
1-2.5 atm
38
4. Hydrolyzer
1. Characterization of pretreated corn stover must be established.
2. Feed conditions must be clearly defined.
Assumptions:
1. Density of glucan  1110 kg3

m
2. Density of xylan  1130 kg3

m
3. Density of water at 25 o C  997.08 kg3

m
39
GENERAL DETAIL
Equipment name: Hydrolyzer
Type/description: CSTR
Function: Converts glucan and xylan into fermentable sugars
TECHNICAL DETAIL
No of units: 1
Dimensions of reactor vessel:
Reactor height: 5.5679 m
Reactor diameter: 2.7840 m
Dimensions of impeller:
Impeller Diameter: 0.8352 m
Impeller Distance from Tank Bottom: 0.8352 m
1atm
Material of Construction: Shell: Stainless steel
Outer jacket: Carbon steel
40
5. Fermenter
1. Feed and operating conditions must be established.
Assumptions:
1. Density of yeast (ρyeast) = 905.105 kg/m3
2. Density of sugar (ρsugar) = (ρglucose + ρxylose)/2 = (1, 540 + 1, 520)/2 = 1, 530 kg/m3
41
GENERAL DETAIL
Equipment name: Fermenter
Type/description: CSTR
Function: Converts the fermentable sugars, glucose and xylose, into ethanol
TECHNICAL DETAIL
No of units: 1
Dimensions of reactor vessel:
Thickness: 0.00566 m
Height: 3.2210 m
Diameter: 2.1474 m
Volume: 11.899 m3
Dimensions of impeller:
Impeller Diameter: 0.7158 m
Impeller distance from tank bottom: 0.7158 m
Impeller Disc Diameter: 0.5368 m
Impeller Blade Length: 0.1790 m
Impeller Blade Width: 0.1432 m
Blade tip distance from tank bottom: 0.4294 m
1 atm
42
6. Beer Column
1. Feed conditions should be established.
2. Calculations on the number of stages must be fully supported by appropriate
equations.
3. The height/diameter ratio of a tower should be based upon established design
guidelines.
Assumptions:
1. Feed is in the vapor phase (Peters, Timmerhaus, & West, 2004).
2. R = 1.2Rmin (Peters, Timmerhaus, & West, 2004)
3. There is an 60% flooding (Peters, Timmerhaus, & West, 2004).
4. The downcomer is assumed to be 15% (Peters, Timmerhaus, & West, 2004).
5. Height over diameter ratio is 20 (Green & Perry, 2008).
43
GENERAL DETAIL
Equipment name: Beer Column
Equipment code: T-101
Type/description: Closed, vertical
Function: Separates the liquid content of the fermented broth from its solid parts
TECHNICAL DETAIL
No of units: 1
No of stages: 12
Reflux ratio: 1.989
Location of feed: Stage 4
Type of column internal: Sieve tray
Tray spacing: 0.61 m
Dimensions of column:
Column height: 14.15 m
Column diameter: 0.707 m
1-2.5 atm
44
7. Pre-cooler (Beer Column to Absorber Column)
Assumptions:
1. The specific heat of beer is 3.542 kJ/kg-°C.
2. Fluid 1 is beer and fluid 2 is water.
3. The overall heat transfer coefficient for water-light organics is 375-750 W/m2-K
(Peters, Timmerhaus, & West, 2004).
type.
45
GENERAL DETAIL
Equipment name: Pre-cooler (Beer Column to Absorber Column)
Function: Cools the beer before entering the absorber column
TECHNICAL DETAIL
No of units: 1
Area: 13.84 m2
Type: Floating head
1-2.5 atm
46
8. Absorber Column
1. Feed and product conditions must be established.
2. An equilibrium must be established between solute and absorbent.
Assumptions:
1. Assume sieve tray as column internal
47
GENERAL DETAIL
Equipment name: Absorber
Function: Absorbs carbon dioxide gas from ethanol-water mixture using water as absorbent
TECHNICAL DETAIL
No of units: 1
No of stages: 20
Column height: 10 m
1992 atm
48
9. Ethanol Column
1. Feed conditions should be established.
2. Calculations on the number of stages must be fully supported by appropriate
equations.
3. The height/diameter ratio of a tower should be based upon established design
guidelines.
Assumptions:
1. Feed is in the vapor phase (Peters, Timmerhaus, & West, 2004).
2. R = 1.2Rmin (Peters, Timmerhaus, & West, 2004)
3. There is an 80% flooding (Peters, Timmerhaus, & West, 2004).
4. The downcomer is assumed to be 15% (Peters, Timmerhaus, & West, 2004).
5. Height over diameter ratio is 20 (Green & Perry, 2008).
49
GENERAL DETAIL
Equipment name: Ethanol Column
Function: Concentrates ethanol-water mixture until it reaches 95.6 wt%
TECHNICAL DETAIL
No of units: 1
No of stages: 45
Reflux ratio: 4.296
Location of feed: Stage 4
Tray spacing: 0.46 m
1-2.5 atm
50
10. Adsorber Column
1. Identification of the adsorbent to be used which depends upon the feed containing
the adsorbate must be established.
2. Properties of the adsorbent such as pore diameter, particle density, particle porosity,
surface area, water capacity and regeneration temperature must be specified.
3. Finally, selection of an appropriate adsorption cycle is done based upon the process
condition of the feed. Adsorption cycles vary depending on the phase of the feed and
the regeneration used.
Assumptions:
1. Properties of the adsorbent, 3A molecular zeolite (Peters, Timmerhaus, & West,
2004):
Pore Diameter: 0.3 mm
Particle Density: 670-740 kg/m3
Particle Porosity: 0.2
Surface Area: 7 x 10-5 m2/kg
H2O Capacity: 20 wt%
2. Water adsorbed is 0.2 kg of water per kg of adsorbent.
( (Peters, Timmerhaus, & West, 2004) is used.
51
GENERAL DETAIL
Equipment name: Adsorber column
Equipment Code: T-104, T-105
Type/description: Closed, vertical, pressure swing with regeneration
Function: Adsorbs water from azeotropic ethanol using an adsorbent
Mode of operation: Continuous, bulk separation
TECHNICAL DETAIL
No of units: 2
Properties of Adsorbent
Adsorbent: 3A molecular zeolite
Pore Diameter: 0.3mm
Particle Density: 670-740 kg/m3
Particle Porosity: 0.2
Surface Area: 7 x 10-5 m2/kg
Amount: 23171.3735 kg
Water Capacity: 20%
Height of adsorbent inside the column: 2.89 m
1-2.5 atm
52
11. Pre-cooler (Around Adsorber Column)
Assumptions:
1. The specific heats of adsorbed fluid and cooling fluid are 2.046 and 2.484 kJ/kg-°C,
respectively.
2. Fluid 1 is adsorbed fluid and fluid 2 is cooling fluid.
3. The overall heat transfer coefficient is the same for water-light organics is 375-750
W/m2-K (Peters, Timmerhaus, & West, 2004).
type.
53
GENERAL DETAIL
Equipment name: Pre-cooler (around Adsorber Column)
Function: Cools the ethanol from adsorber column
TECHNICAL DETAIL
No of units: 1
Area: 17.8038 m2
Type: Floating head
1-2.5 atm
54
C. Piping and Instrumentation
1. Piping and Instrumentation Diagram
Figure 3.3 Piping and Instrumentation Diagram
55
2. VALVE SELECTION
Table 3.4 Valves for Steam Explosion
Stream Valve Type Mode and Function
High Pressure Steam (hps) Globe valve Control valve, modulating
______ Pressure relief valve (pilot- Emergency valve, self-
operated) actuating
Table 3.5 Valves for Hydrolysis

Enzyme Pinch valve Control valve, modulating
Pretreated Milled Corn Diaphragm valve Control valve, modulating
Stover and Enzyme Mixture (straightway)
Coolant Globe valve Control valve, modulating
operated) actuating
Table 3.6 Valves for Fermentation

Yeast Pinch valve Control valve, modulating
Fermentable Sugar and Yeast Diaphragm valve Control valve, modulating
Mixture (straightway)
Coolant Globe valve Control valve, modulating
Table 3.7 Valves for Beer Distillation

Broth Diaphragm valve Control valve, modulating
(straightway)
Beer Globe valve Control valve, modulating
Reflux Globe valve Control valve, modulating
Stillage Gate valve On/Off
Cooling and heating fluids Globe valve Control valve, modulating
Table 3.8 Valves for Gas Absorption

Beer Globe valve Control valve, modulating
Process Water Globe Valve Control valve, modulating
Wet Ethanol Gate Valve On/Off
Recycle Stream Gate valve On/Off
56
Table 3.9 Valves for Ethanol Distillation
Wet Ethanol Gate Valve On/Off
Ethanol (concentrated) Globe valve Control valve, modulating
Reflux Globe valve Control valve, modulating
Process Water Globe valve Control valve, modulating
Steam (reboiler) Gate Valve On/Off
Cooling Water Globe valve Control valve, modulating
Table 3.10 Valves for Dehydration (Adsorption)

Ethanol (concentrated) Globe valve Control valve, modulating
Adsorber columns inflow Globe valve Control valve, modulating
Adsorber columns outflow Gate valve On/Off
(top)
Adsorber columns outflow Globe valve Control valve, modulating
(bottom)
Anhydrous Ethanol (pre- Globe valve Control valve, modulating
cooling)
Anhydrous Ethanol (pre- Globe valve Control valve, modulating
compression)
Cooling and heating fluids Globe valve Control valve, modulating
operated) actuating
57
3. PIPE SIZING AND SELECTION
a. Miller to Steam Explosion Reactor (Screw Conveyor)
Bulk Density of Milled Corn Stover: 160 kg/m3 or 9.9884 lb/ft3
Mass Flowrate of Milled Corn Stover: 304,838.3816 kg/day or 28,000.912 lb/h
Conveyor Condition (Type = Horizontal Short-pitch, Single-flight; 45% trough
loading)
Calculations:
Based on (Screw Conveyor Engineering Guide, 2016)
SC  CFH  CF
where, SC  selection capacity
CFH  required capacity in cubic feet per hr
CF  capacity factor
m 28,000.912
CFH  
ρ 9.9884
CFH  2,803.3430 ft 3 /hr
For short-pitch, single-flight screw conveyor, CF = 1.5 (Appendix A.2)
SC  2,803.343( 1.5)
SC  4,205.014 ft 3 /hr
For selection of proper screw conveyor diameter (D) and speed (N),
Use D of CRPMmax at 45% loading where SC < CRPMmax
D  14 inches or 0.3556 m (Appendix A.3)
SC
N where, C1RPM  31.2
C1RPM
4,205.0145
N
31.2
N  134.776 rpm
N  135 rpm
58
b. Steam Explosion Reactor to Hydrolyzer (Screw Conveyor)
Average Density of Pre-Treated Corn Stover: 1,120 kg/m3 or 69.9193 lb/ft3
Mass Flowrate of Pre-Treated Corn Stover: 609,676.7631 kg/day or 56,004.466
lb/h
Conveyor Condition (Type = Horizontal Short-pitch, Single-flight; 45% trough
loading)
Calculations:
Based on Screw Conveyor Engineering Guide (2016)
SC  CFH  CF
where, SC  selection capacity
CFH  required capacity in cubic feet per hr
CF  capacity factor
m 56,004.466
CFH  
ρ 69.9193
CFH  800.9872 ft 3 /hr
For short-pitch, single-flight screw conveyor, CF = 1.5 (Appendix A.2)
SC  800.9872 (1.5)
SC  1,201.4808 ft 3 /hr
For selection of proper screw conveyor diameter (D) and speed (N),
Use D of CRPMmax at 45% loading where SC < CRPMmax
D  9 inches or 0.2286 m (Appendix A.3)
SC
N where, C1RPM  8.2
C1RPM
1,201.4808
N
8.2
N  146.522 rpm
N  147 rpm
59
4. CONTROL AND INSTRUMENTATION
a. Steam Explosion Reactor
Figure 3.4 Instrumentation Diagram of Steam Explosion Reactor
In the pre-treatment process, the milled corn stover (MCS) is contacted with high
pressure steam in a reactor to release the cellulose and hemi-cellulose. The temperature
in the reactor is regulated by manipulating the flow of the high pressure steam (HPS)
to the reactor. A cascaded control strategy is used in this section of the process. The
temperature controller (TC), the master controller, generates a control effort that
serves as the setpoint to the flow controller (FC) which is the slave or secondary
controller. This ensures that the change in the flow rate of the steam entering the
reactor is not due to uncontrollable problems such as steam pressure changes or valve
problem, rather, due to the temperature inside the reactor.
To maintain the level in the reactor, the inflow of the MCS to the reactor is also
manipulated. A feedback strategy is used in this part. The level reading in the reactor
serves as the setpoint to which the control valve changes its position, thus adjusting
the flow of the MCS to the reactor to maintain a desired reactor level. Safety alarms
LAH and LAL are located in the central control panel (CCP) to signal for high and
low levels, respectively, in the reactor.
60
Monitoring of the pressure in the tank is also necessary in cases of failure in the
temperature reading in the reactor. PAH and PAL are also found in the CCP to alarm
operators during extreme pressure levels in the tank. Should critical conditions such as
overshooting of the pressure in the reactor occur, a pressure relief valve is available to
relieve the reactor off of excess pressure.
Table 3.11 Variables Involved for Steam Explosion Reactor
Input Output
Disturbance Manipulated (Controlled)
 Flow of MCS, FMCS  Tank Level, H
 Flow of HPS, FHPS  Tank Temperature, T
61
b. Hydrolyzer
Figure 3.5 Instrumentation Diagram of Hydrolyzer
In the hydrolyzer, the pre-treated corn stover (PCS) is reacted enzymatically to
produce sugars. For certain amount of PCS, a certain amount of enzyme is required.
Therefore, a ratio control strategy is used. The AIT analyses the composition of the
mixed flow entering the reactor and transmits it to the ratio computer. Since the
composition analysis is a ratio between the amount of PCS and the enzyme, it is
multiplied by the PCS flowrate (wild flow) to give the needed flow of enzyme
(controlled flow) into the reactor to achieve the desired composition.
The reactor level is maintained within a set range by manipulating the rate of the
mixed flow to the reactor. The control valve adjusts its position based on the reading
fed to it by the LIT. Feedback strategy is used. LAL and LAH are alarms in the CCP
for cases of reactor level readings beyond the set range.
The temperature in the reactor is regulated by manipulating the flow of the cooling
water into the sides of the reactor. A feedback scheme is used. To account for the
pressure disturbances in the reactor, two alarms PAH and PAL are located in the CCP
to signal for extreme pressure levels in the reactor. A pressure relief valve is available
to release excess pressure in the reactor.
62
Table 3.12 Variables Involved for Hydrolyzer
Input Output
 Flow of PCS, FPCS  Mixed Flow Composition
 Flow of enzyme, FE  Reactor Level, H
 Flow of Coolant, FC  Reactor Temperature, T
63
c. Fermenter
Figure 3.6 Instrumentation Diagram of Fermenter
Similar to the hydrolyser, a ratio exists between the two inflows to the fermenter,
therefore a ratio control strategy is possible for this process. The flow of fermentable
sugars (wild flow) is multiplied by the composition analysis from the AIT to control
the flow of yeast (controlled flow) to the reactor.
The rate of the mixed flow to the reactor is manipulated to maintain the level in
the reactor. The control valve receives level readings from the LIT and adjusts its
position based on it. Meanwhile, the reactor temperature is controlled by manipulating
the flow of the coolant to the fermenter. Control strategy for both reactor level and
temperature is feedback.
Table 3.13 Variables Involved for Fermenter
Input Output
 Flow of FS, FFS  Mixed Flow Composition
 Flow of yeast, FE  Reactor Level, H
 Flow of Coolant, FC  Reactor Temperature, T
64
d. Beer Column
Figure 3.7 Instrumentation Diagram of Beer Column
The configuration above is the best control suited for the beer distillation column
since the top product is the main concern in the process. The overhead composition
is regulated by adjusting the steam rate at the base of the column (reboiler). Since the
response of the column to heat input changes is quite rapid, this strategy is acceptable.
Pressure in the column is maintained by monitoring the flow of the cooling water into
the condenser. Controls for the overhead composition and column pressure are both
feedback.
The rate of fermented broth entering the column as well as the rate of beer leaving
the reflux drum are also controlled. Both uses feedforward strategy.
Table 3.14 Variables Involved for Beer Column

Input Output
 Flow of Fermented  Flow of cooling water to  Overhead Stream
Broth, FFB condenser, FCW Pressure, P
 Flow of steam to reboiler,  Distillate
FS Composition
 Distillate Rate, FD
65
e. Absorber
Figure 3.8 Instrumentation Diagram of Absorber
The flow rate of beer entering the Absorber is manipulated to maintain the level
in the scrubbing column. The level readings are used as set points in the LCV. Level
alarms LAL and LAH are located in the CCP to signal for low and high levels in the
column.
The flow of scrubbing fluid (water) to the tank is being manipulated to allow for
greater contact time between the two streams entering the column. The composition
of the wet ethanol leaving the column is dependent on contact time in the Absorber.
Feedback control strategy is used.
Table 3.15 Variables Involved for Absorber
Input Output
 Flow of Beer, FB  Column Level, H
 Flow of Process Water,  Wet Ethanol
FPW Composition
66
f. Ethanol Column
Figure 3.9 Instrumentation Diagram of Ethanol Column
For high purity tops, the distillate flow rate is used to control the distillate
composition. It can be shown that for a high purity column i.e. one with a large reflux,
the composition of the distillate is sensitive to the distillate flow but insensitive to the
reflux rate. Therefore, the control scheme outlined above is used. It should be noted
that tight control on the level in the reflux drum is required using the reflux rate.
Table 3.16 Variables Involved for Ethanol Column
Input Output
 Wet Ethanol Rate,  Flow of cooling water to  Overhead Stream
FWE condenser, FCW Pressure, P
 Reflux Rate, FR  Reflux Drum Level, H
 Distillate Rate, FD  Distillate Composition
 Process Water Flow,
FPW
67
g. Adsorber columns
Figure 3.10 Instrumentation Diagram of Adsorber columns
Ethanol enters the two adsorption columns where it is further concentrated. The
water adsorbed by the zeolite adsorbents is used to cool the anhydrous ethanol
product. A part of this product is used to regenerate the adsorption columns by
adsorbing the water removed from the feed. This is done through a difference in the
pressures of the adsorption and regeneration schemes. Feedback control strategy is
used in this system.
Table 3.17 Variables Involved for Adsorber Columns
Input Output
 Pressure, temperature  Amount of water
and flow of ethanol adsorbed inside the
 Concentration of column
anhydrous ethanol  Concentration of
 Concentration of anhydrous ethanol
ethanol-water  Concentration of
ethanol-water
68
Chapter 4
COSTING AND PROJECT EVALUATION
I. Estimation of Equipment Cost
In the past, the estimation of equipment cost is quite laborious and tedious job which
requires working with general equations or chart, or obtain cost relations on equipment size,
operating conditions, material of construction, equipment type, and auxiliary equipment
considerations (Peters, Timmerhaus, & West, 2003). For a more accurate equipment cost
estimation, equipment price quotation from a suitable vendor must be provided (Turton et. al
2012).
Fortunately, because of the rapid technological advancement, the routinely process of cost
estimation has become easier. Equipment cost estimation can now be done automatically, with
increased accuracy than previous practices, using a computer software.
Here, the estimation of purchased equipment costs is based on the capacity of the
equipment calculated in the equipment design and is estimated using CAPCOST 2008 from the
book “Analysis, Synthesis and Design of Chemical Processes” by Turton et al. The necessary data
like the current cost index based on the Chemical Engineering Plant Cost Index (CEPCI) is used.
Currently, for the first quarter of 2017, Chemical Engineering Plant Cost Index is equivalent to
553.1.
69
Table 4.1 Table of Equipment Cost Using CAPCOST 2008 (CEPCI = 553.1)
Compressors Compressor Type Purchased Equipment Bare Module
Cost Cost
C-101 Rotary $33,200 $80,000
Conveyors Type Purchased Equipment Bare Module
Cost Cost
Cv-101 Screw $9,920 $19,800
Cv-102 Screw $8,030 $16,100
Exchangers Exchanger Type Purchased Equipment Bare Module
Cost Cost
E-101 Floating Head $38,700 $127,000
E-102 Floating Head $26,200 $86,300
E-103 Floating Head $25,600 $84,400
Pumps (with Pump Type Purchased Equipment Bare Module
drives) Cost Cost
P-101 Centrifugal $7,480 $29,800
P-102 Centrifugal $6,930 $27,600
P-103 Centrifugal $6,830 $27,200
P-104 Centrifugal $6,830 $27,200
P-105 Centrifugal $6,830 $27,200
P-106 Centrifugal $6,830 $27,200
Reactors Type Purchased Equipment Bare Module
Cost Cost
R-101 Autoclave $909,000 $1,360,000
R-102 Jacketed Agitated $115,000 $172,000
R-103 Fermenter $66,200 $99,300
Towers Tower Description Purchased Equipment Bare Module
Cost Cost
T-101 12 Carbon Steel Sieve $27,200 $71,800
Trays
Trays
Trays
T-104 Empty Vertical Vessel $18,600 $79,400
T-105 Empty Vertical Vessel $18,600 $79,400
Miller Miller Description Purchased Equipment Bare Module
Cost Cost
M-101* Roller Mill $88,423.0342 -
(Note: M-101 is manually inputted because there is no miller equipment in CAPCOST)
70
For M-101,
Using a Ball Mill with capacity of 1 to 30 ton/h as cost model based on CHEMCAD 6,
Model Cost = $ 92,100 for 2014
2014 CEPCI = 576.1
2017 CEPCI = 553.1
Equipment Cost = Model Cost (current cost index/previous cost index)
Equipment Cost = 92,100 (553.1/576.1)
Equipment Cost = $ 88,423.0342
71
Table 4.2DetailedSummaryofEstimationofEquipmentCost
Equipment Code Type Pressure Power Area (m2) No.of Volume Height (m) Diameter (m) Material of EquipmentCost
(barg) (kW) Spares (m3) Construction ($)
Compressor C-101 Rotary - 18 - - - - - CarbonSteel 33200
Conveyor CV- Screw - - 4.27 - - - - CarbonSteel 9920
101
Conveyor CV- Screw - - 2.74 - - - - CarbonSteel 8030
102
Exchanger E-101 Floating 2.533 - 122.64 - - - - CarbonSteel 38700
Head
Exchanger E-102 FlHead
oating 2.533 - 13.84 - - - - CarbonSteel 26200
Exchanger E-103 FlHead
oating 2.533 - 17.8 - - - - CarbonSteel 25600
Pump P-101 Centrifugal 1.01 2.31 - 1 - - - CarbonSteel 7480
Pump P-104 Centrifugal 20 0.53 - 1 - - - CarbonSteel 6830
Reactor R-101 Autoclave 20 - - - 119 10.5749 3.535 CarbonSteel 909,000
Reactor R-102 Jacketed 1.01 - - - 33.6 5.5679 2.784 CarbonSteel 115000
Agitated
Reactor R-103 Fermenter 1.01 - - - 11.899 3.221 2.1474 CarbonSteel 66200
Tower T-101 (12)Tray
Sieve 2.533 - - - - 14.2 0.707 CarbonSteel 27200
Sieve 2.533 - - - - 10 0.65 CarbonSteel 28800
Sieve 2.533 - - - - 18.06 0.903 CarbonSteel 69900
Tower T-104 Vertical 2.533 - - - - 4.88 1.83 CarbonSteel 18600
Vessel
Tower T-105 Vertical 2.533 - - - - 4.88 1.83 CarbonSteel 18600
Vessel
*Miller M-101 RollerMill - - - - - CarbonSteel 88423.0342
SUB-TOTAL 1525103.034
FreightCharge 152510.3034
(10%)
TOTAL($) 1677613.338
TOTAL 83,880,666.88
(PHP)
72
II. Estimation of Working Capital
A large sum of money must be supplied to purchase and install the necessary machinery
and equipment, before an industrial plant can be put into operation. Land and service facilities
must be obtained and the plant must be established with complete piping, controls and services.
Furthermore, it is necessary to have money available for the payment of expenses involved in the
operation of the plant.
A. Fixed Capital Investment
Fixed Capital Investment is defined as the total cost of processing installations, buildings,
auxiliary services and engineering involved in the establishment of a new plant. About 85 to
90 percent of the total capital is comprised of fixed capital. It is categorized into manufacturing
fixed capital investment also known as direct costs and nonmanufacturing fixed capital
investment also known as indirect costs.
The cost estimation of the Fixed Capital Investment is based from the book “Plant Design
and Economics for Chemical Engineer” by Peters, Timmerhaus, and West (2003). This is
calculated by selecting the appropriate percent Fixed Capital Investment (%FCI) shown in
Table 4.2. The estimated costs were verified using the % purchase equipment cost listed in
Table 6-18 of the same book. The obtained value of FCI is 451,277,987.8 PHP.
73
Table 4.3 Breakdown of Direct Costs and Indirect Costs
COMPONENT Range of FCI, % Selected FCI, % Normalized FCI, % Estimated Cost (PHP) Calculated FCI, %
Direct Costs
Purchased Equipment 15-40 25 18.79699248 83880666.88 18.58736059
Purchased Equipment Installation 6-14 10 7.518796992 33552266.75 7.434944238
Instrumentation & Controls 2-12 8 6.015037594 26841813.4 5.94795539
Piping 4-17 10 7.518796992 33552266.75 7.434944238
Electrical Systems 2-10 8 6.015037594 26841813.4 5.94795539
Buildings (including services) 2-18 15 11.27819549 50328400.13 11.15241636
Yard Improvements 2-5 3 2.255639098 10065680.03 2.230483271
Service Facilities 8-30 20 15.03759398 67104533.5 14.86988848
Land 1-2 1 0.751879699 8388066.688 1.858736059
Indirect Costs
Engineering & Supervision 4-20 10 7.518796992 33552266.75 7.434944238
Construction Expenses 4-17 8 6.015037594 26841813.4 5.94795539
Legal Expenses 1-3 2 1.503759398 6710453.35 1.486988848
Contractor's Fee 2-6 26 4.511278195 20131360.05 4.460966543
Contingency 5-15 7 5.263157895 23486586.73 5.204460967
TOTAL 133 100 451277987.8 100
74
Checking if the estimated costs are within the percentage range given in the book “Plant Design and Economics for Chemical Engineers” by Peters,
Timmerhaus, & West (2003):
Table 4.4 Calculated Percentages of Components and Items
COMPONENT Estimated Cost (PHP) Range Calculated Percentage, %

Direct Costs 340555507.5 65-85% of fixed capital investment
Purchased Equipment 83880666.88 15-40% of fixed capital investment 18.58736059
Purchased Equipment
33552266.75 25-55% of the purchased equipment cost 40
Installation
Instrumentation & Controls 26841813.4 8-50% of purchased equipment cost 32
Piping 33552266.75 10-40% of purchased equipment cost 40
Electrical Systems 26841813.4 10-80% of purchased equipment cost 32
Buildings (including services) 50328400.13 10-70% of purchased equipment cost 60
Yard Improvements and Service 77170213.53
40-100% of purchased equipment cost 92
Facilities
Land 8388066.688 1-2% of fixed capital investment 1.858736059
Indirect Costs 110722480.3 15-35% of fixed capital investment
Engineering & Supervision 33552266.75 5-30% of direct costs 9.852216749
Construction Expenses &
46973173.45 10 -20% of fixed capital investment 10.40892193
Contractor’s Fee
Legal Expenses 6710453.35 1-3% of fixed capital investment 1.486988848
Contingency 23486586.73 5-15% of fixed capital investment 5.204460967
75
Checking if the Direct Costs and Indirect Costs are within the allowable range:
Direct Costs = material and labor involved in actual installation of complete facility (65-85% of
fixed capital investment).
Direct Costs = Equipment + Installation + Instrument + Piping + Electrical + Buildings +
Service Facilities + Yard Improvements + Land
Total Direct Cost = 340555507.5
340555507  5
% Direct Cost   100%
451277987.8
% Direct Cost  75.464%
This is within the allowable range which is 65-85% of FCI.
Indirect Costs = expenses which are not directly involved with material and labor of actual
installation of complete facility (15-35% of fixed capital investment).
Indirect Costs = Engineering and Supervision + Legal Expenses + Construction Expenses +
Contractor's Fee + Contingency
Total Indirect Cost = 110722480.3
110722480.3
% Indirect Cost   100 %
451277987.8
% Indirect Cost  24.535
This is within the allowable range which is 15-35% of FCI.
76
B. Total Capital Investment
The total capital investment is the sum of the fixed capital investment and of the working
capital. In this report, the Working Capital is calculated as 15% of the Total Capital
Investment.
Total Capital Investment = Fixed Capital Investment + Working Capital
Total Capital Investment = 451277987.8 PHP  0.15 Total Capital Investment
(1 - 0.15) Total Capital Investment = 451277987.8 PHP
Total Capital Investment  530915279.8 PHP
C. Working Capital
The Working Capital required to start up the plant and finance ordinarily amounts to
the production cost before revenues from the process start. This consists of the total amount
of money invested in raw materials and supplies carried in stock, finished products in stock
and semi-finished products in the process of being manufactured, accounts receivable, cash
kept on hand for monthly payment of operating expenses such as salaries, wages and raw
material purchases, accounts payable and taxes payable as well.
Total Capital Investment  Fixed Capital Investment  Working Capital
Working Capital  Total Capital Investment - Fixed Capital Investment
Working Capital  530915279.8 - 451277987.8
Working Capital  79637291.97
77
III. Estimation of Production Cost
The cost effectiveness of a process depends on the production costs of a product.
Production costs are the costs incurred in manufacturing a good or providing a service. It includes
a variety of expenses including, but not limited to, labor, raw materials, consumable manufacturing
supplies and general overhead. Additionally, any taxes levied by the government or royalties owed
by natural resource extracting companies are also considered production costs.
The cost of production is directly related to the manufacturing cost or the costs of both
the materials and the labor required in the creation of a product. Indirect costs include overhead
such as rent, administrative salaries or utility expenses. Generally, the total production cost is the
sum of the manufacturing costs and the general expenses.
In the estimation of the production costs presented in this chapter, an annual cost basis
was used as this method offers the convenience in considering equipment operating factor and
infrequently occurring large expenses. It also permits a more rapid calculation of the operating
costs and smoothens out seasonal variations within the operation of the plant.
A. Manufacturing Costs
Manufacturing costs may be classified under three sub-categories: direct cost, fixed charges
and overhead-plant costs.
1. Direct Costs
In manufacturing industries, the cost of raw materials and labor cost are primarily
classified as direct costs. These are directly associated to the manufacturing process and
may include other expenses such as the costs of utilities and repair and maintenance costs.
The amount of the raw materials which must be supplied per unit of time or per unit
of product can be determined from process material balances. Direct price quotations from
prospective suppliers are preferable to published market prices. For preliminary cost
analyses, market prices are often used for estimating raw-material costs. In chemical plants,
raw-material costs are usually in the range of 10 to 50 percent of the total product cost.
78
The cost of raw materials was estimated on an annual basis with the adapted price of
corn stover (University of Missouri) as $45/ton or approximately Php2250.00/ton, yeast
as 50,000 php/ton (Alibaba), and cellulase as 100,000php/ton (Alibaba).
One method of estimating labor requirements as a function of plant capacity is based
on adding up the various principal processing steps on the flow sheet (as proposed by HE
Wessel). In this method, a process step and the number of employee-hours per production
per step are specified. The number of hours per step is multiplied by the total number of
processing steps to give the total employee hours per production
Three principal processing steps were considered and the labor cost was estimated on
the basis of 50 - employee hour in a day for each processing step and the plant runs
throughout the 365 days of a year. An hourly wage rate of $33.67 (Php1683.50) for skilled
workers was used.
A certain amount of direct supervisory is always required for a manufacturing
operation. The extent of necessity for this type of labor depends on the total amount of
operating labor, complexity of the operation, and product quality standards. The cost for
direct supervisory was estimated at 10 percent of the operating labor cost.
Utility costs for ordinary chemical processes amount to 10 to 20 percent of the total
product cost. The cost of utilities such as process water, steam, and electricity was
estimated as 10 percent of the total production cost.
To keep the plant in efficient operating condition, repair and maintenance are
necessary and the expenses for this include the cost for labor, materials, and supervision.
For complicated processes where severe corrosion operating conditions or extensive
instrumentation are primary concern, annual maintenance cost is estimated at 7-11 percent
of the FCI, about 4-6 percent of which is for the materials needed and 3-5 percent for the
labor.
79
Annual costs for equipment maintenance were estimated at 7 percent of the estimated
cost of the purchased set of equipment. This estimation is reasonable enough as repair and
maintenance expenses are usually estimated ranging from 2 - 10 percent of the costs of
equipment in processing industries. Costs of supplies during operations were taken as 10
percent of the costs of repair and maintenance.
2. Fixed Charges
This classification covers the expenses that are practically constant from year to year
and not greatly influenced by the rate of production such as depreciation, property taxes,
insurance, and rent.
The tax and insurance rates were estimated at 1% and 0.4% of the fixed capital
investment (FCI), respectively. No cost for rent was considered.
3. Overhead Costs
The expenditures required for the routine services of a complete plant functioning as
one unit are included in plant & overhead costs. The direct costs and fixed charges of non-
manufacturing machinery, equipment, and buildings necessary for many of the general
plant services are part of the plant-overhead costs.
Similar to the fixed charges, these costs do not vary widely with changes in the
production rate. It may include costs for hospital and medical services; general plant
maintenance and overhead; safety services; payroll overhead including pensions, vacation
allowances, social security, and life insurance; packaging, restaurant and recreation
facilities, salvage services, control laboratories, property protection, plant superintendence,
warehouse and storage facilities, and special employee benefits.
80
The plant-overhead cost for chemical plants is about 50 to 70 percent of the total
expense for operating labor, supervision, and maintenance. A rough estimate of 50 percent
was considered.
B. General Expenses
Besides the manufacturing costs, other general expenses are involved in any company’s
operations. These general expenses may be classified as (1) administrative expenses, (2)
distribution and marketing expenses, and (3) research and development expenses.
1. Administrative Costs
The expenses connected with top-management or administrative activities cannot be
charged directly to manufacturing costs; however, it is necessary to include the
administrative costs if the economic analysis is to be complete. These costs may vary
markedly from plant to plant and depend somewhat on whether the plant under
consideration is a new one or an addition to an old plant. As a quick estimate, the
administrative costs may be approximated as 20 to 30 percent of the operating labor. As
such, 20% estimate was used.
2. Distribution and Marketing Costs
This classification of costs varies widely for different types of plants depending on the
particular material being produced, other products sold by the company, plant location,
and company policies. Typically, for most chemical plants these costs range from 2 to 20
percent of the total product cost. The higher figure usually applies to a new product or to
one sold in small quantities to a large number of customers while lower figures apply to
large-volume products, such as bulk chemicals.
3. Research and Development Costs
Emphasis on research and development paves the creation of new methods and
products in chemical industries. In the chemical industry, costs for research and
development amount to about 2 to 5 percent of the total product cost.
81
Table 4.5 Summary of Product Cost Estimation
Cost Items Basis of Computation Annual Cost Estimate

(Php)
I. Manufacturing Cost 523908793.3
A. Direct Production Costs 463960684.4
Raw Materials 2250 php/ton corn stover
50,000 php/ton yeast 285266023.2
100,000 php/ton cellulase
Operating Labor Php1683.5/hr (skilled) 92171625
Supervisory 10% of Operating Labor 9217162.5
Utilities 10% of TPC 61629899.81
Maintenance and Repairs 7% of Purchased Equipment
5871646.682
Cost
Operating Supplies 10% of Maintenance and
587164.6682
Repairs Cost
Laboratory Charges 10% of Operating Labor 9217162.5
B. Fixed Charges 6317891.829
Local taxes 1% of FCI 4512779.878
Insurance 0.4% of FCI 1805111.951
C. Plant Overhead Costs 50% of Total Labor Cost 53630217.09
II. General expenses 61575254.87
Administrative Costs 20% of Operating Labor 18434325
Distribution and Marketing
2% of TPC 12325979.96
Costs
Research and Development
5% of TPC 30814949.9
Costs
TOTAL PRODUCT COST 616298998.1
82
III. Feasibility Analysis
This feasibility analysis assesses the practicality of the proposed plant design. This can be
done by comparing the current market price of bioethanol to the proposed price of bioethanol
from this report, calculating the return of investment, profitability, and payback period. Through
the following factors enumerated, this plant design report may be plausible and suitable for
operation.
A. Profitability
Currently, according to ICIS, a market information provider, the fuel-grade ethanol price
in Southeast Asian market is $518 - $522 per cubic meter or approximately P25,900 - P26,100
per cubic meter in Philippine currency. With this information, this design report must have a
lower bioethanol price or equivalent to the current market price to compete in the market.
Total Product Cost

Ethanol Price =
Annual Plant Capacity
P 616298998.1/yr
Ethanol Price 
100000 * 365 kg/yr
( )
785.1kg./m3
Ethanol Price  P13,256.33818/m 3
The calculated ethanol price is almost half the market price which means the ethanol
produced could compete in the market along with experienced ethanol producers. Thus, to
maximize the plant profit, the selling price of ethanol produced corn stover would be
P23,000/m3.
83
Total Income  (Annual Plant Capacity)(Selling Price)
23,000/m 3
Total Income  (365)(100,000 kg/day)( )
785.1kg/m3
Total Income  P1,069,290,536/yr
The total income accounts for the total money received annually by the company from
selling all the ethanol produced during operation.
Gross Income  Total Income - Total Product Cost
Gross Income  1,069,290,536 - 616,298,998.1
Gross Income  P452,991,538.1
Consequently, the gross income accounts for the total money received annually by the
company from selling all the ethanol produced during operation and deducting total cost of
production. Hence, considering a 35% tax rate and subtracting it from the gross income,
Annual Net Profit  (1 - Tax Rate)(Gross Income)
Annual Net Profit  (1 - 0.35)(452,991,538.1)
Annual Net Profit  P294,444,499.8
Therefore, the annual plant profit is calculated as P294,444,499.8. It can be inferred from
this that a fast payback period can be expected when compared to the capital investment for
the plant.
B. Payback Period
Fixed Capital Investment

Payback Period 
Annual Net Profit  Depreciation
However, to compute for the time that the capital invested is returned or more commonly
known as payback period, the depreciation which accounts for the allocated cost of tangible
84
assets over its useful life must be known. The cost of tangible assets is the direct cost from
Table 4.4 less the non-depreciable assets, land and equipment installation cost.
Tangible Assets Cost  Direct Cost - Land Cost - Equipment Installation Cost
Tangible Assets Cost  340555507.5 - 33552266.75 - 8388066.688
Tangible Assets Cost  P298,615,174.1
Using Straight-Line Depreciation Method,
Recovery Period of Chemical Plant = 9.5 yrs
Tangible Assets
Depreciation 
Recovery Period
298,615,174.1
Depreciation 
9.5
Depreciation  P31,433,176.22
451277987.8
Payback Period 
294444499.8  31433176.22
PaybackPeriod  1.38 yrs
Using Modified Accelerated Cost Recovery System (MACRS),
Recovery Period of Chemical Plant = 5 yrs
Table 4.6 Depreciation Using MACRS
Year Unadjusted Depreciation Depreciation Adjusted

Basis Rate Basis
0 298615174.1 20 59723034.82 238892139.3
1 298615174.1 32 95556855.71 143335283.6
2 298615174.1 19.2 57334113.43 86001170.14
3 298615174.1 11.52 34400468.06 51600702.08
4 298615174.1 11.52 34400468.06 17200234.03
5 298615174.1 5.76 17200234.03 0
Total Depreciation 298615174.1
Average Annual 49769195.68
Depreciation
85
451277987.8
Payback Period 
294444499.8  49769195.68
PaybackPeriod  1.31 yrs
Since, the payback periods for both the depreciation methods are close, with MACRS
faster by just a factor 0.07 years to Straight-Line method, the design engineer can choose
either of the two. However, given the economical setup of Philippines, it is more preferable
to use straight-line method. Therefore, for this design report, a payback period of 1.38
years is chosen.
C. Return of Investment
Return of investment is an economical tool used for financial decisions. It measures the
benefits obtained from investing of some resource. Additionally, this is a profitability ratio to
determine the profit of an investment as a percentage of its original cost.
Annual Net Profit

%ROI  (100)
Total Capital Investment
294444499.8
%ROI  (100)
530915279.8
%ROI  55.46
From the calculated ROI, it can be concluded that this report is deemed attractive for
operation.
86
Life of project earnings
2750
Land, salvage, and working
capital recovery
2250
1750 Cumulative cash position = net profit

after taxes + depreciation - total capital
investment
Cumulative cash
1250 position over total
life of project
Construction 750
period
Total capital
investment
(including land) Annual net profit
Start of
construction 250 after taxes
(constant)
-3 capital
Fixed -2 -1 0 1 2 3 4 5 6 7 8 9 10 11
investment -250
(depreciable)
Land, salvage, and working
Annual depreciation Book value of investment capital recovery
Zero-time line charge (straight line) (with 9.5 straight-line depreciation)
Working capital
-750
Figure 4.1 Cumulative Cash Flow Position Diagram
87
Chapter 5
SAFETY, HEALTH AND ENVIRONMENT
I. Safety and Loss Prevention
A number of hazards are associated with the biofuel industry in each stage of the project
and plant life cycle from the concept selection through to the decommissioning. There are many
other challenges like engineering unknowns, lack of reliable failure rate data, inconsistency in
applicable regulations, low skills and competence and entry of new manufacturers. In addition to
these, legislative requirements, corporate policy and commitments, economic benefits, reputation,
public perception to the projects etc. make it obligatory to establish a system for hazard
identification and risk management. It is commonly believed amongst biofuel manufacturers, that
process safety can be achieved by common sense; however, the fact is expertise is needed to
comprehensively identify and manage biofuel manufacturing risks (Nair, 2011).
The term “loss prevention” on the other hand is an insurance term, the loss being the
financial loss caused by an accident. This loss will not only be the cost of replacing damaged plant
and third party claims, but also the loss of earnings from lost production and lost sales opportunity.
Safety and loss prevention in process design can be considered under the following broad headings:
(1) Identification and assessment of the hazards.
(2) Control of the hazards: for example, by containment of flammable and toxic materials.
(3) Control of the process. Prevention of hazardous deviations in process variables
(pressure, temperature, flow), by provision of automatic control systems, interlocks,
alarms, trips; together with good operating practices and management.
(4) Limitation of the loss. The damage and injury caused if an incident occurs: pressure
relief, plant layout, provision of fire-fighting equipment.
A. Hazard Identification
In process safety and loss prevention, it is said, ‘once the hazards have been identified, half
the battle is won. A number of hazard identification methods and techniques are available and
88
practiced. Different methods are required at different stages of a project and also the depth of
the study depends on the complications and extent of risk from the facility/operation.
Hazards associated with the biofuel industry are categorized as follows:
1. Hazards from Materials
The principal hazards from materials in the form of raw materials, catalysts,
intermediates and finished products include the following:
 Fire hazards.
 Explosion hazards and overpressure releases.
 Runaway/uncontrolled reaction.
 Toxic hazards.
 Steam flashes.
2. Hazards from Operations and Handling
Operational accidents in the biofuel industry range from slips, trips and falls to major
incidents like fire and explosion. Hazards, causes, hazardous events and related
consequences during operation and handling (storage, processing, handling etc.) are given
below:
a. Storage of Flammable and Toxic Materials
This includes raw materials, additives, intermediates, finished products and by-
products in different forms/phases, sizes and shapes, temperature and pressure as
required by the process.
b. Processing of Hazardous Materials
One of the major hazards is the accidents that could result from biofuel
manufacture is release of flammables, toxics and corrosives.
 High operating or storage temperature/pressure (e.g. leading to process
runaway).
89
 Overflow of tank, vessel, reactor or tanker.
 Lower temperature (solidification of biodiesel often resulting in plugging).
 Improper selection of appropriate equipment/machinery/rated vessels/pipe
work suitable for the process.
 Inadequate installation, inspection and maintenance.
 Use of unclassified equipment and machinery in explosive atmosphere.
c. Material Handling
A range of materials in solid form, liquid form and gaseous form are transferred
between equipment, process vessels, storage etc. This involves a number of tools and
transfer system from shovel to conveyor system to pipelines and pumps. Manual
handling of hazardous materials results in occupational injuries and sometimes
fatalities.
 Material loss, damage due to inadequate or improper conveyor system.
 Poor housekeeping leading to dust hazards and dust explosion hazards.
 Release from pipelines, vessels and valves.
3. Hazards from Design, Construction and Commissioning
Typically, biofuel plants mainly small/medium scale and occasionally large scale plants
are built in an existing facility/building or near to an existing facility/building/plant.
Some of the hazards are very significant when the existing facility (old barn, garage or
storage deport) is modified and converted to a biofuel processing facility. One of the
common failures is failing to recognize the additional requirements to adhere to, e.g.
building regulation codes, electrical installation requirements etc. If the associated hazards
in conversion are not identified and addressed, the facility as such could pose high risk due
to operation.
90
The following are some of the causes associated to biofuel plant projects that may
result hazards and hazardous events:
a. Improper selection of:
 The technology or methodology for the manufacture.
 The chemical and raw materials used for the production.
 The location of the facility.
b. Inadequate facility for the selected process:
 Land area.
 Nearby facility and effects from and on them.
 Proximity to utilities like water, steam, power etc.
c. Unsafe design and layout:
 Inadequate separation distances (to restrict the spread of fire etc.).
 Inadequate design specification (not for maximum design pressure etc.).
 No access for inspection, maintenance etc.
 No provision of emergency escape.
 Thermal radiation from open flames/flares or equipment/vessel operating at
high temperature (no or improper insulation etc.).
d. Faulty construction and commissioning:
 Use of inappropriate material of construction of the facility (incompatible for
the material handled/ processed).
 No/improper foundation.
 Inadequate strength of load bearing members.
e. No/inadequate provision for:
 Ventilation.
 Lighting.
91
 Rest and cleaning.
 Weather protection.
 Protection from external factors like vehicle collision, attacks from
animals/pests etc.
B. Risk Management
Risk management is the term used to cover the whole process of identifying and assessing
risk, setting goals and creating and operating systems for their control. Though the biofuel
manufacturing facility often does not come under major accident hazard regulations, it is prudent
that the risk from the biofuel industry is assessed and managed considering the nature of hazards
and the stakeholders involved. The depth of risk assessment should be proportional to the extent
of risk involved in the process and facility.
Occupational Safety and Health Administration (OSHA) Compliance
At the request of the Renewable Fuels Association (RFA), the ERI Solutions, Inc. of
Colwich, KS developed an outline of the general plant and employee safety regulatory compliance
requirements for the bioethanol production industry.
1. Recordkeeping (OSHA 1904). The Occupational Safety and Health Act of 1970 (OSHA)
requires covered employers to prepare and maintain records of occupational injuries and
illnesses. OSHA also establishes requirements and criteria for reporting work-related injuries,
illnesses, and fatalities.
2. Walking/Working surfaces (OSHA Subpart D). Establishes requirements concerning
guarding floor & wall openings, stairs and ladders. OSHA requires the use of a guardrail system
to protect workers from falls of 4’ or more to lower levels.
3. Exit routes (OSHA 1910.37). Establishes requirements for the proper design and
construction of exit routes. Requirements cover construction materials, opening dimensions,
accessibility conditions and capacity.
92
4. Emergency Action Plan (OSHA 1910.38). An Emergency Action Plan (EAP) must be
developed and include procedures for reporting emergencies, emergency evacuation, and for
employees performing medical or rescue duties. OSHA also establishes requirements for alarm
systems and training personnel on the EAP.
5. Fire Prevention Plan (OSHA 1910.39). Establishes requirements for employers to identify
flammable and combustible materials stored in the workplace and develop ways to control
workplace fire hazards. Completing a fire prevention plan and training employees will reduce
the probability that a workplace fire will occur or spread.
6. Occupational Noise Exposure (OSHA 1910.95). Requires employers to identify if any
employees are exposed to noise levels at 85 decibels or more over eight (8) working hours. A
hearing conservation program must be implemented if it is determined that employees may be
exposed to levels above this threshold.
7. Flammable and Combustible Liquids (OSHA 1910.106). Establishes requirements for the
handling, storage and use of flammable and combustible liquids with a flash point below
200°F. Ethanol is considered a Class 1B flammable liquid (Flash point 73°F).
8. Storage and Handling of Anhydrous Ammonia (NH3) (OSHA 1910.111). Facilities that
have anhydrous ammonia systems must comply with this standard. If the process contains
over 10,000 pounds of anhydrous ammonia, OSHA 1910.119 also applies (see Process Safety
Management (PSM) below).
9. Process Safety Management (PSM) (OSHA 1910.119). The purpose of this standard is to
prevent or minimize the consequences of a catastrophic release of toxic, reactive, flammable,
or explosive chemicals. Since ethanol is considered a flammable liquid, ethanol production
facilities are required to comply with this standard if they process or store over 10,000 pounds
of ethanol. OSHA also lists threshold quantities for other highly hazardous chemicals that are
covered under the PSM regulation. Other common chemicals in use at ethanol production
facilities that may fall under PSM regulations are anhydrous (or aqueous) ammonia,
93
hydrochloric acid, denaturant, and chlorine dioxide. This is not an all-inclusive list, but if you
have these chemicals at your site, you should determine for sure whether or not you meet the
threshold quantity for that specific chemical.
10. Emergency Response (OSHA 1910.120). Employers must address what action employees
are to take when there is an unwanted release of hazardous chemicals. Employers may decide
to train and mobilize employees to control or mitigate the release according to the
requirements of 1910.120 the Hazardous Waste Operations and Emergency Response
(HAZWOPER) standard. Employers may also decide to have employees evacuate the danger
area and have local community emergency response organizations respond to the release.
11. Personal Protective Equipment (PPE) (OSHA Subpart I). Contains regulations for
Personal Protective Equipment (PPE) selection and use concerning eyes, face, head and
extremities. All ethanol production facilities must perform and document a workplace hazard
assessment so the proper PPE can be designated and communicated for all areas of your
facility.
12. Permit Required Confined Spaces (OSHA 1910.146). Requires employers to develop
practices and procedures to protect employees working in permit-required confined spaces
(PRCS). The standard requires an evaluation to determine the existence of PRCSs, the
implementation of a written confined space program, and the establishment of
rescue/emergency procedures. The employer must decide either to train employees on entry
rescues or rely on available external sources to provide entry rescues. Either method must be
documented as to its availability and reliability to respond in the event of an emergency. All
PRCSs must be labeled or communicated according to the requirements of the standard.
13. Lockout/Tagout (OSHA 1910.147). Requires implementing practices and procedures to
shut down equipment, isolate it from energy sources and prevent the release of potential
hazardous energy while maintenance and service activities are being performed. Employers
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must develop and document specific procedures for all equipment and machinery that may be
serviced within their facility.
14. Medical Services and First Aid (OSHA 1910.151). Employers must ensure that medical
personnel and adequate first aid supplies are available to workers to handle potential workplace
injuries if a medical facility is not in near proximity to the workplace.
15. Fire Protection (OSHA Subpart L). Standards for portable fire extinguishers, fire brigades,
and employee alarm systems, automatic sprinkler systems and fixed extinguishing systems.
16. Powered Industrial Trucks (OSHA 1910.178). Establishes requirements for powered
industrial trucks and training requirements for operators of powered industrial trucks.
17. Machinery and Machine Guarding (OSHA 1910.212). General requirements for machine
guarding.
18. Welding, Cutting and Brazing (OSHA Subpart Q). Contains regulations for oxygen fuel
cutting and welding, arc welding and cutting, and resistance welding. The standards also
contain training requirements for personnel who will be performing welding, cutting or
brazing.
19. Grain Handling (OSHA 1910.272). Contains requirements for control of grain dust fires or
explosions and other hazardous associated with grain handling facilities.
20. Electrical (OSHA Subpart S). Contains regulations regarding electrical hazards in the
workplace. Subpart S is based on older versions of the national consensus standard NFPA
70E. OSHA has proposed an update to Subpart S to reflect the more current editions of NFPA
70E.
21. Access to Employee Exposure and Medical Records (OSHA 1910.1020). This standard
is triggered if an employee is exposed to toxic substances or harmful physical agents in the
workplace. These exposure and medical records must be retained in accordance with this
regulation. The records must also be made available to employees or their designated
representative.
95
22. Blood borne Pathogens (OSHA 1910.1030). This standard applies to all possible
occupational exposure to blood or other potentially infectious materials (OPIM). Occupational
exposure means reasonably anticipated contact with blood or other potentially infectious
materials that may result from performance of an employee’s duties. Employees who are
responsible for rendering first aid or medical assistance as part of their job duties are covered
by the protections of the standard.
23. Hazard Communication (OSHA 1910.1200). Also, referred to as the “Right-to-Know”
standard, Hazard Communication establishes requirements for ensuring that chemical hazards
and their associated protective measures are disseminated to employees who could be
potentially be affected by these hazards.
24. Occupational Exposure to Hazardous Chemicals in Labs (OSHA 1910.1450). This
standard requires a laboratory to develop a Chemical Hygiene Plan which addresses specific
hazards found in the laboratory. This standard does not apply to typical facility laboratory, as
they generally only perform quality assurance/quality control type laboratory operations.
96
II. Environmental Constraints and Analysis
Corn is widely cultivated throughout the globe. As one of the most important crops used
in the food, cosmetics and textile industry, its production is growing every year. With its increasing
manufacture yearly, the amount of its by-products such as Corn Stover also increases. Due to lack
of utilization, processing and post-harvest technology, these are eventually converted to organic
wastes. Through the action of microbe methanogens, these wastes emit methane which is found
to be 25 times more destructive greenhouse gas compared to carbon dioxide. Methane emission
can be reduced if organic wastes will be minimized. One good way of helping in the reduction of
emission is to utilize surplus by-products such as Corn Stover into beneficial goods like ethanol.
Bioethanol is an environment friendly renewable energy source of fuels. As compared to
gasoline, the best ethanol has lower lifecycle global warming pollution. Ethanol represents closed
carbon dioxide cycle. After burning of ethanol, the release carbon dioxide is recycled back into
plant material because plants use carbon dioxide to synthesize cellulose during photosynthesis.
Furthermore, it only uses energy from renewable energy sources and no net carbon dioxide is
added to the atmosphere making it environmentally beneficial energy source. Ethanol derived from
biomass is the only liquid transportation fuel that does not contribute to the greenhouse gas effect.
97
III. Material Safety Data Sheets
I. Ethanol
SECTION 1. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION
Product Name Ethyl Alcohol

Chemical Name Ethyl Alcohol
Chemical Formula CH3CH2OH
Synonyms Ethanol; Ethyl Alcohol Anhydrous; Ethyl
Hydrate; Ethyl Hydroxide; Fermentation
Alcohol; Grain Alcohol
Company Identification
For information, call +639 552 876 908
SECTION 2. COMPOSITION AND INFORMATION ON INGREDIENTS
Name Ethyl Alcohol

CAS # 64-17-5
% by Weight 100
EINECS/ELINCS 200-578-6
Hazard Symbols F
Risk Phrases 11
SECTION 3. HAZARDS IDENTIFICATION
Appearance Colorless clear liquid. Flash point: 16.6 deg C.

Flammable liquid and vapor. Causes
respiratory tract irritation. May cause central
nervous system depression. Cause severe eye
irritation. This substance has caused adverse
reproductive and fetal effects in humans.
Causes moderate skin irritation. May cause
liver, kidney and heart damage.
Target Organs Kidneys, heart, central nervous system, liver.

Potential Health Effects
Eye Contact Causes severe eye irritation. May cause painful
sensitization to light. May cause conjunctivitis
and corneal damage.
Skin Contact Causes moderate skin irritation. May cause

cyanosis of the extremities.
Ingestion May cause gastrointestinal irritation with

nausea, vomiting and diarrhea. May cause
systemic toxicity with acidosis. May cause
central nervous system depression,
characterized by excitement, followed by
98
headache, dizziness, drowsiness, and nausea.
Advanced stages may cause collapse,
unconsciousness, coma and possible death due
to respiratory failure.
Inhalation Inhalation of high concentrations may cause

central nervous system effects characterized
by nausea, headache, dizziness, unconscious-
ness and coma. Causes respiratory tract
irritation. May cause narcotic effects in high
concentration. Vapors may cause dizziness
or suffocation.
Chronic Exposure May cause reproductive and fetal effects.

Laboratory experiments have resulted in
mutagenic effects. Animal studies have
reported the development of tumors.
Prolonged exposure may cause liver, kidney,
and heart damage.
SECTION 4. FIRST AID MEASURES
Eye Contact Immediately flush eyes with running water for

at least 15 minutes, keeping eyelids open. Cold
water may be used. Get medical aid.
Skin Contact Immediately flush skin with plenty of water.

Cover the irritated skin with an emollient.
Remove contaminated clothing and shoes.
Cold water may be used. Get medical attention.
Serious Skin Contact Wash with disinfectant soap and cover the
contaminated skin with an anti-bacterial cream.
Seek medical attention.
Inhalation Remove from exposure and move to fresh air
immediately. If not breathing, give artificial
respiration. If breathing is difficult, give
oxygen. Get medical aid. Do NOT use mouth-
to-mouth resuscitation.
Serious Inhalation Evacuate the the victim to a safe area as soon

as possible. Loosen tight clothing such as a
collar, tie, belt or waistband. If breathing is
difficult, administer oxygen. If the victim is not
breathing perform mouth-to-mouth
resuscitation. Get medical attention.
Ingestion Do not induce vomiting unless directed to do

so by medical personnel. Never give anything
by mouth to an unconscious person. Loosen
99
tight clothing such as a collar, tie, belt or
waistband. Get medical attention if symptoms
appear.
Notes to Physician Treat symptomatically and supportively.

Persons with skin or eye disorders or liver,
kidney, chronic respiratory diseases, or central
and peripheral nervous system diseases may be
at increased risk from exposure to this
substance.
Antidote None reported.
SECTION 5. FIRE FIGHTING MEASURES
General Information Containers can build up pressure if exposed

to heat and/or fire. As in any fire, wear a
self-contained breathing apparatus in
pressure-demand, MSHA/NIOSH
(approved or equivalent), and full protective
gear. Vapors may form an explosive mixture
with air. Vapors can travel to a source of
ignition and flash back. Will burn if involved
in a fire. Flammable Liquid. Can release
vapors that form explosive mixtures at
temperatures above the flashpoint. Use
water spray to keep fire-exposed containers
cool. Containers may explode in the heat of
a fire.
Fire Extinguishing Media For small fires, use dry chemical, carbon
dioxide, water spray or alcohol-resistant
foam. For large fires, use water spray, fog,
or alcohol-resistant foam. Use water spray
to cool fire-exposed containers. Water may
be ineffective. Do NOT use straight
streams of water.
Autoignition Temperature 363°C ( 685.40°F)

Flash Point 16.6°C ( 61.88°F)
Explosion Limits, lower 3.3 vol%
Explosion Limits, upper 19.0 vol%
NFPA Rating Health: 2; Flammability: 3; Instability: 0
100
SECTION 6. ACCIDENTAL RELEASE MEASURES
General Information Use proper personal protective equipment as

indicated in Section 8.
Spills/Leaks Absorb spill with inert material (e.g.

vermiculite, sand or earth), then place in
suitable container. Remove all sources of
ignition. Use a spark-proof tool. Provide
ventilation. A vapor suppressing foam may be
used to reduce vapors.
SECTION 7. HANDLING AND STORAGE
Precautions Keep away from heat. Keep away from sources

of ignition. Ground all equipment containing
material. Do not ingest. Do not breathe
gas/fumes/vapor/spray. Wear suitable
protective clothing. In case of insufficient
ventilation, wear suitable respiratory
equipment, if ingested, seek medical advice
immediately and show the container or the
label. Avoid contact with skin and eyes. Keep
away from incompatibles such as oxidizing
agents, acids, alkalis, moisture.
Handling Wash thoroughly after handling. Use only in

a well-ventilated area. Ground and bond
containers when transferring material. Use
spark-proof tools and explosion proof
equipment. Avoid contact with eyes, skin,
and clothing. Empty containers retain
product residue (liquid and/or vapor) and
can be dangerous. Keep container tightly
closed. Avoid contact with heat, sparks and
flame. Avoid ingestion and inhalation. Do
not pressurize, cut, weld, braze, solder, drill,
grind, or expose empty containers to heat,
sparks or open flames.
Storage Keep away from heat, sparks, and flame. Keep

away from sources of ignition. Store in a tightly
closed container. Keep from contact with
oxidizing materials. Store in a cool, dry, well-
ventilated area away from incompatible
substances. Flammables-area. Do not store
near perchlorates, peroxides, chromic acid or
nitric acid.
101
SECTION 8. EXPOSURE CONTROLS, PERSONAL PROTECTION
Engineering Controls Use explosion-proof ventilation equipment.

Facilities storing or utilizing this material
should be equipped with an eyewash facility
and a safety shower. Use adequate general or
local exhaust ventilation to keep airborne
concentrations below the permissible exposure
limits.
Personal Protection Splash goggles. Lab coat. Vapor respirator. Be

sure to use an approved/certified respirator or
equivalent. Gloves. Use a respirator if the
exposure limit is exceeded.
Personal Protection in Case of a Large Splash goggles. Full suit. Vapor respirator.
Spill Boots. Gloves. A self-contained breathing
apparatus should be used to avoid inhalation
of the product. Suggested protective clothing
might not be sufficient; consult a specialist
BEFORE handling this product.
Personal Protective Equipment

Eyes Wear appropriate protective eyeglasses or
chemical safety goggles as described by
OSHA's eye and face protection
regulations in 29 CFR 1910.133 or
European Standard EN166.
Skin Wear appropriate protective gloves to prevent

skin exposure.
Clothing Wear appropriate protective clothing to

prevent skin exposure.
Respirators A respiratory protection program that meets

OSHA's 29 CFR 1910.134 and ANSI Z88.2
requirements or European Standard EN 149
must be followed whenever workplace
conditions warrant a respirator's use.
SECTION 9. PHYSICAL AND CHEMICAL PROPERTIES
Physical State Clear liquid

Appearance Colorless
Odor Mild, pleasant, like wine or wiskey. Alcohol-
like; Ethereal, vinous.
Taste Pungent. Burning
pH Not available
Boiling Point 78.5 °C (173.3 °F)
102
Melting Point -114.1 °C (-173.4 °F)
Critical Temperature 243 °C (469.4 °F)
Specific Gravity 0.789 (Water = 1)
Vapor Pressure 5.7 kPa (@20 °C)

Vapor Density 1.59 (Air = 1)
Odor Threshold 100 ppm
Viscosity 1.200 cP @ 20 °C
SECTION 10. STABILITY AND REACTIVITY
Chemical Stability Stable under normal temperatures and

pressures.
Conditions to Avoid Incompatible materials, ignition sources,

excess heat, oxidizers.
Incompatibilities with Other Materials Strong oxidizing agents, acids, alkali metals,
ammonia, hydrazine, peroxides, sodium, acid
anhydrides, calcium hypochlorite, chromyl
chloride, nitrosyl perchlorate, bromine
pentafluoride, perchloric acid, silver nitrate,
mercuric nitrate, potassium-tert- butoxide,
magnesium perchlorate, acid chlorides,
platinum, uranium hexafluoride, silver oxide,
iodine heptafluoride, acetyl bromide,
disulfuryl difluoride, tetrachlorosilane plus
water, acetyl chloride, permanganic acid,
ruthenium (VIII) oxide, uranyl perchlorate,
potassium dioxide.
Hazardous Decomposition Products Carbon monoxide, irritating and toxic

fumes and gases, carbon dioxide.
Hazardous Polymerization Will not occur
SECTION 11. TOXILOGICAL INFORMATION
Carcinogenicity ACGIH: A4 - Not Classifiable as a Human

Carcinogen
Epidemiology Ethanol has been shown to produce
fetotoxicity in the embryo or fetus of
laboratory animals. Prenatal exposure to
ethanol is associated with a distinct pattern of
congenital malformations that have
collecetively been termed the "fetal alcohol
syndrome".
Teratogenicity Oral, Human - woman: TDLo = 41
103
gm/kg (female 41 week(s) after
conception) Effects on Newborn - Apgar
score (human only) and Effects on
Newborn - other neonatal measures or
effects and Effects on Newborn - drug
dependence.
Reproductive Effects Intrauterine, Human - woman: TDLo = 200

mg/kg (female 5 day(s) pre-mating) Fertility -
female fertility index (e.g. # females pregnant
per # sperm positive females; # females
pregnant per # females mated).
Neurotoxicity No information available.
Mutagenicity DNA Inhibition: Human, Lymphocyte = 220

mmol/L.; Cytogenetic Analysis: Human,
Lymphocyte = 1160 gm/L.; Cytogenetic
Analysis: Human, Fibroblast = 12000 ppm.;
Cytogenetic Analysis: Human, Leukocyte = 1
pph/72H (Continuous).; Sister Chromatid
Exchange: Human, Lympho- cyte = 500
ppm/72H (Continuous).
Other Studies
Standard Draize Test(Skin, rabbit) =
20 mg/24H (Moderate) Standard
Draize Test: Administration into the
eye (rabbit) = 500 mg (Severe).
SECTION 12. ECOLOGICAL INFORMATION
Environmental Toxicity Fish: Rainbow trout: LC50 = 12900-15300

mg/L; 96 Hr; Flow-through @ 24-24.3°C
Rainbow trout: LC50 = 11200 mg/L; 24 Hr;
Fingerling (Unspecified) ria: Phytobacterium
phosphoreum: EC50 = 34900 mg/L; 5-30
min; Microtox test 250
ppm/6hr/goldfish/lethal/fresh water.
Environmental Ethanol: In water, will volatilize and

probably degrade.
Physical No information available.
Other Not expected to bioconcentrate in fish.
104
SECTION 13. DISPOSAL CONSIDERATIONS
Chemical waste generators must determine whether a discarded chemical is classified

as a hazardous waste. US EPA guidelines for the classification determination are
listed in 40 CFR Parts 261.3. Additionally, waste generators must consult state and
local hazardous waste regulations to ensure complete and accurate classification.
RCRA P-Series None listed.

RCRA U-Series None listed.
SECTION 14. TRANSPORT INFORMATION
Shipping Name Ethanol

Hazard Class 3
UN Number UN 1170
Packing Group II
Other FP180
SECTION 15. REGULATORY INFORMATION
US Federal
TSCA CAS# 64-17-5 is listed on the TSCA
inventory.
Health & Safety Reporting List None of the chemicals are on the Health
& Safety Reporting List.
Chemical Test Rules None of the chemicals in this product are

under a Chemical Test Rule.
Section 12b None of the chemicals are listed under
TSCA Section 12b.
TSCA Significant New Use Rule None of the chemicals in this material have a
SNUR under TSCA.
Clean Air Act This material does not contain any hazardous
air pollutants. This material does not contain
any Class 1 Ozone depletors. This material
does not contain any Class 2 Ozone depletors.
Clean Water Act None of the chemicals in this product are listed
as Hazardous Substances under the CWA.
None of the chemicals in this product are listed
as Priority Pollutants under the CWA. None of
the chemicals in this product are listed as Toxic
Pollutants under the CWA.
105
IV. Waste Disposal
A. Description and quantity of the waste to be disposed
Typical residuals generated in the dry mill production of ethanol that can be used for other
purposes include:
1. Distillers grains (DGs) or sometimes called mash. A typical 100 MMgy plant
produces 320,000 tons of distiller grains annually.
2. Syrup which may also be called evaporated thin stillage. It is the liquid that was
separated from the mash during the distilling process which has been partially dehydrated.
When it is added back to DGs, it creates distillers dried grain with soluble (DDGs).
Other wastes may be generated from the following:
• Routine tank and pipe cleaning wastes
• Routine facility operations and cleaning wastes
• Process upsets
• Water treatment wastes e.g. reverse osmosis or softener reject water
• Off test material that cannot be used as product
• Cooling waters
• Sanitary wastewater (from bathrooms/break rooms)
B. Description of the waste disposal method
DGs, DDGs, and syrup can be used as animal feed if economic to transport and used
appropriately. However, the Food and Drug Administration (FDA) has voiced three primary
concerns about antibiotic residues in distiller grains (DGs):
1. Potential to transfer antibiotic residues from distiller grains into animal tissues.
2. Potential for harm to humans that eat tissues containing antibiotic residues
3. Potential for harm to the animal’s health from antibiotic residues in distillers grains
On the other hand, there are many other possible options in disposing the wastes generated
in bioethanol plants and the following are listed below:
106
• The syrup may be burned for energy recovery. The syrup would not be considered to be
a solid waste as long as it is burned in a boiler, industrial furnace, or power plant that
has a permit from the Air Quality Division.
• The syrup could be solidified and disposed at a licensed landfill.
• The syrup could be disposed at a publicly owned treatment works (POTW) with that
facility’s approval. The POTW may limit the amount of syrup that they will accept due
to the high BOD associated with the syrup.
• The syrup would be an ideal material to use in a research, development, and
demonstration project at a licensed landfill to increase the generation rate of methane.
In this plant design, the waste generated shall be burned for energy recovery. This method
of waste disposal could provide adequate energy that can be utilized during plant operations.
107
Chapter 6
CONCLUSION AND RECOMMENDATION
6.1 Conclusion
The main objective in developing a plant design is to determine the economic efficiency
of the production of bioethanol from corn stover in a real life setting. This analysis serves as a
basis for measuring the effectiveness of a plant in terms of production, management, costing and
environmental safety.
In terms of profitability, a maximum selling price of P23,000/m3 of ethanol is calculated
which is lesser than the fuel-grade ethanol price for Southeast Asian Markets with a price of
P25,900 –P26,100/m3. Thus, ethanol produced based from this design report can be market-
competitive. The payback period calculated is 1.38 years which means that bioethanol production
from corn stover is feasible. The return of investment (ROI) calculated is 55.46% which signifies
that this report is deemed attractive for operation.
Furthermore, using corn stover, a biomass, for bioethanol production contributes largely
to the awareness of various sectors to consider biofuels as a new source of energy. Utilizing waste
materials for energy production is environmentally sound which makes it more profitable.
6.2 Recommendations
For this design project, the following are recommended:
1. Investigate the potential of other biomass which can be used as raw materials for bioethanol
production
2. Modification of the process design to reduce end-of-pipe waste
3. Conduct an analysis on the possible uses of other by-products in ethanol production to
maximize plant profit
108
Bibliography
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https://www.doe.gov.ph/sites/default/files/pdf/issuances/dc_2007-05-0006.pdf
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Energy Website: https://www.doe.gov.ph/pep/philippine-energy-plan-2012-2030
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Hill.
Harmsen, P., Hujigen, W., Bermudez-Lopez, L., & Bakker, R. (2010). Literature Review of
Physical and Chemical Pretreatment Processes for Lignocellulosic Biomass. Food &
Biobased Research.
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http://www.agmrc.org/renewable-energy/corn-stover/
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from http://provinceofisabela.ph/index.php/municipalities/fourth-district/2013-07-10-
15-14-05
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https://www.platts.com/products/biofuelscan
Sarkar, N., Gosh, S., Bannerjee, S., & Aikat, k. (2012). Bioethanol production from agricultural
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Sinnott, R. (2003). Coulson & Richardson's Chemical Engineering. Burlington: Elesevier, Inc.
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and Design of Chemical Processes. Pearson Education, Inc.
110
APPENDIX I
List of Equations Used
In this section, the equations used for the computation of important data needed for the
material and energy balances are presented in Table A.1 with their corresponding nomenclature
of the variables and the source of each.
Table A1.1 Equations used for computation of data
Equation Nomenclature Source

Q = sensible heat (Green & Perry,
m = mass flow rate 2008)
Q  mCpT Cp = specific heat of
substance
∆T=change in
temperature of
substance
dLs Q  Capacity (Green & Perry,
Q 2008)
2.96 d  Distance between
rolls
L  Length of rolls
s  Peripheral speed
treactor = thickness of (Green & Perry,

reactor 2008)
Pr i P = pressure
t reactor   Cc ri = inner radius
SE j  0.6P
S = allowable stress
Ej = Elongation
0.885PL a Cc = corrosion
t head   Cc
SE j  0.1P allowance
La = ri
thead = thorispherical
head of shell
2π IDD = inside depth (Green & Perry,
Vhead  0.9[ (L a ) 2 (IDD)] of dish 2008)
3
Vhead = volume of
ehad
La = inner radius
IDD = inside depth (Green & Perry,
of dish 2008)
IDD  La  [(La  r) 2  (La  t head  r) 2 ]1/2 La = inner radius
thead = thorispherical
head of shell
r = radius
111
Ki= Equilibrium (Peters,
constant Timmerhaus, &
Hi Hi= Henry’s law West, 2004)
Ki  constant
p
p = pressure of gas
Ai = solute absorption (Peters,
factor Timmerhaus, &
L L = entering liquid West, 2004)
Ai  flow rate
KiV
V = entering vapor
flow rate
K
A iN 1  A i Ai = solute absorption (Peters,
 solute fraction absorbed factor Timmerhaus, &
A iN 1  1
N = theoretical West, 2004)
number of stages
Fenske equation Nmin = minimum (Peters,
number of stages Timmerhaus, &
ln[(x LK / x HK ) D ( x LK / x HK ) B ] xLK = mole fraction of West, 2004)
N min  light key component
ln  LK
HK xHK = mole fraction of
heavy key component
Underwood equation Rmin = minimum (Peters,
reflux ratio Timmerhaus, &
n
 i x D ,i xD,i = mole fraction of West, 2004)
R min  1   component in
i 1 i  
distillate
xF, i = mole fraction of
n
 i x F ,i

i 1 
 1 q component in feed
αi = relative volatility
i
Eduljee relation N = actual number of (Peters,

stages Timmerhaus, &
N  N min Nmin = minimum West, 2004)
 R  R min 
0.566
 0.751   number of stages

N 1  R 1  R = reflux ration
Rmin = minimum
reflux ratio
Kirkbride method ND = equilibrium (Peters,
stages above feed tray Timmerhaus, &
 NB = equilibrium West, 2004)
 B  x HK   ( x LK ) B  
2
ND 
log  0.206 log       stages below feed tray
NB  D  x LK  F  ( x HK ) D  
  B = molar flow rate of
bottoms
D = molar flow rate
of distillate
Vnf = net vapor (Peters,
velocity Timmerhaus, &
Csb = Souders and West, 2004)
brown factor
112
 L  V 
0.3 α = surface tension of

0.2
Vnf  Csb     HK component

 20   V  ρL = density of HK
component in liquid
phase
ρv = density of HK
component in vapor
phase
Vn  0.8Vnf Vn = actual vapor (Peters,
velocity Timmerhaus, &
Vnf = net vapor West, 2004)
velocity
m 'V An = net column area (Peters,
An  m’v = volumetric flow Timmerhaus, &
Vn
rate of vapor West, 2004)
Vn = actual vapor
velocity
An Ac = cross-sectional (Peters,
Ac 
0.85 area of column Timmerhaus, &
An = net column area West, 2004)
1/ 2 D = column diameter (Peters,
 4A 
D c  Ac = cross-sectional Timmerhaus, &
   area of column West, 2004)
113
APPENDIX II
Charts and Tables
The charts and tables used in the computation of data for this design report is presented
in Table A2.1. The purpose of using the chart or table, source and page number is indicated.
Table A2.1 Charts and tables used
TABLE NO. & NAME PURPOSE SOURCE & PAGE
NO.
Table 2-112 Ethyl Alcohol (C2H5OH)*, Density of ethanol- (Green & Perry, 2008),
water mixture p 2-117
Table 2-199 Thermodynamic Properties of Specific heat of carbon (Green & Perry, 2008),
Carbon Dioxide dioxide pp 2-240, 2-241
Table 2-214 Thermodynamic Properties of Density of saturated (Green & Perry, 2008),
Ethanol ethanol and specific p 2-265
heat
Table 2-305 Thermodynamic Properties of Specific heat of water (Green & Perry, 2008),
Water pp 2-413, 2-414
Fig. 15. 5, Chart for estimating values of Csb Souders and Brown (Peters, Timmerhaus,
factor estimation, Csb & West, 2004) p. 778
Table 2-123 Solubility as a Function of Henry’s law constant (Green & Perry, 2008),
Temperature and Henry’s constant at 250C of CO2 at 306K p 2-130
for gases in water
114
Appendix III
Material Balance Calculations
A. Adsorption
Basis: 100, 000 kg/day dehydrated ethanol
Flowchart:
m3
m4 m5
Azeotropic Adsorber Cooler Dehydrated
Ethanol m1 Ethanol, m6
m2
Ethanol Water, m7
Solution:
Overall Material Balance: m1= m6 + m7
m1 = 100000 + m7 (1)
Ethanol Balance: 0.956m1 = 0.995 (100000) + 0.7223 m7 (2)
Solving for equations 1 and 2: m1= 116,688.0616 m7= 16688.0616
Material Balance around cooler: m3 + m5 = m6 + m7 (3)
m3 = m7 = 16688.0616 (4)
m5 = m6 = 100000 (5)
Material Balance around splitter: m4 = m2 + m5 (6)
m4 = 12053.7869 + 100000
m4 = 112053. 7869
Regeneration of adsorbent:
Water adsorbed = 0.2777(16688. 0616) = 4634. 2747
Ethanol needed to adsorb water = (1 - 0.2777)16688.0616 = 12053.7869 = m2
Degree of freedom analysis: 6 unknown variables - 6 equations = 0, the problem is solvable
115
B. Ethanol Distillation
Basis: 116, 688 kg/day of ethanol vapor
Flowchart:
Azeotropic Ethanol
m2=100, 000 kg/day
EtOH
95.6% EtOH
Wet Ethanol 4.4% H2O
m1 Ethanol
75% EtOh Column
25% H2O
Process Water
m3
99.95% H2O
0.05% EtOH
Solution:
Overall Material Balance: m1  m 3  116,688 .0616 (1)
Ethanol Balance: 0.75m1  0.0005 m 3  0.956(116,688.0616 ) (2)
Solving for m1 and m3: m1= 148759.7637 kg/day Wet Ethanol
m3= 32071.70205 kg/day Process Water
Degree of freedom analysis:
2 unknown variables- 2 equations = 0 The problem is solvable
116
C. Gas Absorption
Basis: 148759.7637 kg/day Wet Ethanol, 32071.70205 kg/day Process water
Flowchart:
Process Water,
Beer, m1
m2
85% EtOH
99.95% H2O
11% H2O
0.05% EtOH
4% CO2
Absorber
Wet Ethanol, Carbon dioxide
m3 effluent, m4
75% EtOH 80% H2O
25% H2O 20% CO2
Solution:
m1  m 2  m 3  m 4
Overall Material Balance: m1  32071 .70205  148759 .7637  m 4 (1)
m1  m 4  116688 .0617
0.11m1  0.8m 4  0.25(148759 .7637 )  0.9995 (32071 .70205 )

H2O Balance: (2)
0.11m1  0.8m 4  5134 .27473
Solving for m1 and m4: m1= 127849.5284 kg/day Beer
m4= 11161.46675 kg/day CO2 effluent
Degree of Freedom Analysis:
2 unknown variables – 2 equations = 0 The problem is solvable
117
D. Beer Distillation
Basis: 108695.6522 kg/day Beer
Flowchart:
Beer, m2
85% EtOH
11% H2O
4% CO2
Fermented broth,
m1 Beer
50% EtOH
Column
30% H2O
15% solids
5% CO2 Stillage, m3
90% H2O
10% EtOH/solids
Solution:
m1  m 2  m 3
Overall Material Balance: m 1  127849 .5284  m 3 (1)
m 1  m 3  127849 .5284
H2O Balance: 0.3m1  0.9m 3  0.11(127849 .5284 )  14063 .4481 (2)
Solving for m1 and m3: m1=168335.2124 kg/day Fermented broth
m3= 40485.684 kg/day stillage
2 unknown variables – 2 equations = 0 The problem is solvable.
118
E. Reactor (Fermentation)
Basis: 168335.2124 kg/day Fermented broth
Flowchart:
Yeast
Fermentable Fermented broth

Sugars Fermenter 50% Ethanol
Carbon dioxide
Solution:
Mass of ethanol in fermented broth: (1)
Mass of ethanol in fermented broth= 0.5(168335.2124) = 84167.6062 kg
Mass of fermentable sugars: (2)
Fermentable sugars needed to produce ethanol are mainly glucose and xylose.
C6H12O6 → 2C2H5OH + 2CO2
3C6H10O5 → 5C2H5OH + 5CO2
0.5111 kg ethanol 84167.6062 kg ethanol

Using the ratio: 
1 kg glucose mass of fermentabl e glucose
Mass of fermentable glucose = 164679.3312 kg
0.5111 kg ethanol 84167.6062 kg ethanol

Using the ratio: 
1 kg xylose mass of fermentabl e xylose
Mass of fermentable xylose = 164679.3312 kg
Total mass of fermentable sugars = 164679.3312 kg + 164679.3312 kg
Total mass of fermentable sugars = 329358.6625 kg/day
119
Mass of Carbon dioxide: (3)
1 kg glucose 164679.331 2 kg glucose


0.4889 kg CO 2 mass of CO 2
Mass of CO2= 80511.7251
Total mass of carbon dioxide = 2(80511.7251) = 161023.4502 kg/day
Check:
Mass of fermentable sugar = mass of fermented broth + total mass of carbon dioxide
329358.6625 = 168335.2124 + 161023.45
329358.6625=329358.6625
120
F. Reactor (Enzymatic hydrolysis)
Basis: 329358.6625 kg/day fermentable sugar
Flowchart:
Enzyme Water
Fermentable sugar
50% glucose
Pretreated corn 50% xylose
stover, PCS Hydrolyzer
Lignin
Solution:
Assuming that the pretreated corn stover contains 60% glucan and 40% xylan
Conversion of glucan to glucose:
1 kg glucan 0.6 (mass of glucan)


1. 11 kg glucose 164679.331 2 kg glucose
Mass of glucan = 247266.2631 kg/day
Water needed in this conversion:
1 kg glucan 247266.263 1 kg glucan


0.11 kg water Mass of water
Mass of water= 27199.2889 kg/day
Conversion of xylan to xylose:
1 kg xylan 0.4 (mass of xylan)


1.136 kg xylose 164679 .3312 kg xylose
Mass of xylan = 362410.5 kg/day
Water needed in this conversion:
1 kg xylan 362410.5 kg xylan


0.136 kg water Mass of water
Mass of water = 49287.828 kg/day
Total mass of PCS = Mass of glucan + Mass of xylan (1)
121
= 247266.2631 + 362410.5
Total mass of PCS = 609676. 7631 kg/day
Total mass of water = 27199.2889 kg/day + 49287.828 kg/day (2)
Total mass of water= 76487.1169 kg/day
Lignin = PCS + Water – Fermentable Sugars (3)
= 609676.7631 + 76847.1169 – 329358.6625
Lignin = 356805.2175 kg/day
122
G. Steam Explosion
Basis: 609676.7631 kg/day pretreated corn stover
Assumption: at 210oC, 2 MPa, Specific volume= 0.099587 m3/kg; Assume ratio of process
steam to corn stover is 0.5:1
Flowchart:
Process Steam, m1
SE Reactor Pretreated corn stover (PCS),
Milled Corn Stover, m2 m3
Solutions:
Overall Material Balance: m1 + m2 = 609676.7631 kg (1)
0.5 kg Process Steam Process Steam

From Ratio:  (2)
1 kg PCS 609676.763 1 kg PCS
Process Steam, m2 = 304838.3816 kg/day
m1 = 609676.7631 kg/day – 304838.3816 kg/day
m1 = 304838.3816 kg/ day Milled Corn Stover
123
H. Milling
Basis: 304838.3816 kg/ day Milled Corn Stover (MCS)
Assumption: Complete milling of corn stover feedstock
Flowchart:
Raw Corn Stover, m1 Roller Mill Milled Corn Stover, m2
Solution:
m1=m2=304838.3816 kg/day raw corn stover (RCS) needed (1)
1 unknown variable – 1 equation = 0 The problem is solvable.
Amount of Yeast and Enzyme

Basis: 304838.3816 kg/day raw corn stover (RCS)
Assumptions:
1. The yeast needed is determined by the ratio of 2.765 x 10-4 kg yeast: kg corn stover.
2. According to Cellulase enzyme based method for the production of alcohol and glucose from
pretreated lignocellulosic feedstock, 3 mg cellulase per gram of lignocellulosic feedstock.
2.765 x 10 -4 kg yeast Yeast

Amount of Yeast: 
1 kg raw corn stover 304838 .3816 kg
Yeast = 84.2878 kg
0.003 kg enzyme Enzyme
Amount of Cellulase: 
1 kg raw corn stover 304838.381 6 kg
Enzyme = 914.5 kg
124
APPENDIX IV
Energy Balance Calculations
A. Steam Explosion
Flowchart:
Process Steam, 2100C

SE Reactor Pretreated corn stover
Milled Corn Stover, 25 C0 (PCS), 900C
Given:
Stream Mass Flowrate Temperature Cp

(kg/s) (0C) (kJ/kg0C)
Process Steam 3.5282 210 1.996
Milled Corn Stover 3.5282 25 2.2
Pretreated Corn Stover 7.0564 90 2.7
Solution:
Input:
Sensible heat of process steam:
kg  kJ 
Q  mCpΔC  3.5282 1.996 0 210 0 C
s  kg C 
kJ
Q  1,478.8803
s
Sensible heat of milled corn stover:
kg  kJ 
Q  mCpΔC  3.5282  2.2 0 250 C
s  kg C 
kJ
Q  1,630.0284
s
kJ kJ
Total heat input  1,478.8803  1,630.0284
s s
Total heat input = 3,108.9087
125
Output:
Sensible heat of pretreated corn stover:
 kJ 
Q  mCpΔC  7.0564  2.7 0 900 C
 kg C 
kJ
Q  1,714.7052
s
Total heat output = 1,714.7052 kJ/s
Heat Gain/Loss = Total heat output – Total heat input

= 1,714.7052 – 3,108.9087
Heat Loss = -1,394.2035 kJ/s
126
B. Pre-cooler (SE Reactor to Hydrolyzer)
Flowchart:
Water, 200C
Pre-treated Corn
Cooler PCS (Glucan & Xylan)
Stover, 900C
250C
Water, 500C
Given:
mPCS = 7.0564 kg/s
Th,in = 90oC
Th,out = 25oC
Solution:
The energy (Q) required to cool the PCS from 90 to 25oC can be calculated by,
Q = mCpΔT
Where,
m = mass flowrate of fluid (kg/s)
Cp = specific heat of fluid (kJ/kg-oC)
ΔT = inlet and outlet temperature (oC)
kg kJ
Q  7.0564 (2.7 )(25 - 90C)
s kg  C
Q = -1,238.3982 kJ/s
The negative sign indicates cooling of entering fluid, therefore, the energy requirement is
Q = 1,238.392 kJ/s
127
C. Reactor (Enzymatic Hydrolysis)
Flowchart:
Fermentable sugar
Glucan, Xylan Hydrolyzer
300C
250C 500C
50% glucose
50% xylose
Assumptions: Conversion of glucan and xylan to glucose and xylose is 95.9%
Given:
Using the equation to determine Q, the total heat added to a reactor per mole of entering
reactant (Levenspiel):
Q = Cp’’(T2-T1)XA + Cp’(T2-T1)(1-XA) + ∆HrXA
Where:
Cp’ = Mean specific heat of unreacted feed stream
Cp’’ = Mean specific heat of completely converted product
∆Hr = heat of reaction per mole of entering reactant
kJ
Cp of unreacted feed  2
kg 0 C
kJ
Mean Cp of glucose and xylose  0.281
kg 0 C
128
Solution:
H r  2(heat of formation of glucose) - 2(heat formation of corn stover 

heat of formation of water)
 kJ   kJ kJ 
H r  2  1250   2 2347 .87  241 .8 
 mol   mol mol 
kJ
H r  6712 .14
mol
kJ
H r  37.29
kg
Q = 0.281(50-30)0.959 + 2(50-30)(1-0.959) + 37.29(0.959)
Q = 42.79 kJ/s
Coolant:
Flowrate of water as coolant in reactor = 7.0564 kg/s
Cp at 250C = 4.2 kJ/kg0C
Q = 35.26(4.2)(50-30)
Q = 592.7376 kJ/s
Heat gained by coolant = 592.7376 – 42.79
Heat gained by coolant = 549.9476 kJ/s
Heat loss in the reactor = Heat gained by coolant
Heat loss in the reactor = -549.9476 kJ/s
Heat Gain/Loss = 0 kJ/s
129
D. Reactor (Fermentation)
Flowchart:
Glucose, Fermenter Fermented broth

300C 400C 50% Ethanol
400C
CO2, 400C
Given:
Process Stream Mass Flow Rate Temperature Cp

Glucose 3.8120 30 1.2552
CO2 1.8636 40 0.9185
Fermented Broth 1.9483 40 0.805
Solution:
Input:
Sensible heat of glucose:
kg  kJ 
Q  mCpT  3.8120 1.2552 0 30 0 C
s  kg C 
Q = 143.5446 kJ/s
Output:
Sensible heat of CO2:
kg  kJ 
Q  mCpT  1.8636  0.9185 0 40 0 C
s  kg C 
Q = 68.4686 kJ/s
Sensible heat of fermented broth:
kg  kJ 
Q  mCpT  1.9483  0.805 0 40 0 C
s  kg C 
Q = 62.7352 kJ/s
130
Total heat output = 62.7352 + 68.4686
Total heat output = 131.2038 kJ/s
Heat Gain/Loss = 131.2038 – 143.5446
Heat loss = -12.3408 kJ/s
131
E. Beer Distillation
Flowchart:
Beer, 1170C
85% EtOH
11% H2O
Fermented broth, 4% CO2
Beer
400C Column
50% EtOH
Stillage, 470C
90% H2O
10% solids
Given:

Fermented Broth 1.9483 40 0.805
Beer 1.4797 117 3.542
Stillage 0.4685 47 4.184
Solution:
Input:
Sensible heat of fermented broth:
kg  kJ 
Q  mCpΔC  1.9483  0.805 0 40 0 C
s  kg C 
Q = 62.7449 kJ/s
Total heat input = 62.7449 kJ/s
Output:
Sensible heat of beer:
kg  kJ 
Q  mCpΔC  1.4797  3.542 0 117 0 C
s  kg C 
Q = 613.2084 kJ/s
132
Sensible heat of stillage:
kg  kJ 
Q  mCpT  0.4685  4.184 0 47 0 C
s  kg C 
Q = 92.1296 kJ/s
Total heat output = 92.1296 + 613.2084
Total heat output = 705.338
Heat gain/loss = Total heat output – Total heat input = 705.338 – 62.7449
Heat gain = 642.5931 kJ/s
133
F. Pre-cooler (Beer Column to Absorber Column)
Flowchart:
Water, 200C
Beer, 1170C Cooler Beer, 400C
Water, 500C
Given:
mbeer = 1.4797 kg/s
Th,in = 117oC
Th,out = 40oC
Solution:
The energy (Q) required to cool the beer from 117 to 40oC can be calculated by,
Q = mCpΔT
Where,
m = mass flowrate of fluid (kg/s)
Cp = specific heat of fluid (kJ/kg-oC)
ΔT = inlet and outlet temperature (oC)
kg kJ
Q  1.4797 (3.542 )(40 - 117 C)
s kg  C
Q = -403.5644 kJ/s
The negative sign indicates cooling of entering fluid, therefore, the energy requirement is
Q = 403.5644 kJ/s
134
G. Gas Absorption
Flowchart:
Beer, 400C
Process Water,
85% EtOH
330C
11% H2O
99.95% H2O
4% CO2
0.05% EtOH
Absorber
Wet Ethanol, Carbon dioxide
340C effluent, 380C
75% EtOH 80% H2O
25% H2O 20% CO2
Given:
Beer 1.4797 40 3.542
Process Water 0.3712 33 4.188
Wet Ethanol 1.7218 34 3.055
Carbon dioxide 0.1292 38 3.581
Solution:
Input:
Sensible heat of beer:
kg  kJ 
Q  mCpΔC  1.4797  3.542 0 400 C
s  kg C 
Q = 209.6438 kJ/s
Sensible heat of process water:
kg  kJ 
Q  mCpT  0.3712  4.188 0 330 C
s  kg C 
Q = 51.3013 kJ/s
135
Output:
Sensible heat of wet ethanol:
kg  kJ 
Q  mCpΔC  1.7218  3.055 0 340 C
s  kg C 
Q = 178.8434 kJ/s
Sensible heat of CO2:
kg  kJ 
Q  mCpΔC  0.1292  3.581 0 380 C
s  kg C 
Q = 17.6107 kJ/s
Heat loss = Total heat output – Total heat input
= 196.4541 – 260.9451
136
H. Ethanol Distillation
Flowchart:
Azeotropic Ethanol
95.6% EtOH
4.4% H2O
Wet Ethanol
Ethanol
75% EtOh
Column
25% H2O
Process Water
99.95% H2O
0.05% EtOH
Given:

Wet Ethanol 1.7218 34 3.055
Azeotropic Ethanol 1.3506 38 3.357
Process Water 0.3712 33 4.188
Solution:
Input:
Sensible heat of wet ethanol:
kg  kJ 
Q  mCpΔC  1.7218  3.055 0 340 C
s  kg C 
Q = 178.8434 kJ/s
Output:
Sensible heat of azeotropic ethanol:
kg  kJ 
Q  mCpΔC  1.3506  3.357 0 380 C
s  kg C 
Q = 172.2906 kJ/s
137
Sensible heat of process water:
kg  kJ 
Q  mCpT  0.3712  4.188 0 330 C
s  kg C 
Q = 51.3013 kJ/s
Heat gain = Total heat output – Total heat input
= 223.5919 – 178.8434
138
I. Adsorption
Flowchart:
Cooling fluid
Adsorbed fluid
Azeotropic Dehydrated
Adsorber Cooler
Ethanol Ethanol, m6
Regenerating fluid
Ethanol Water
Given:

Azeotropic ethanol 1.3506 38 3.357
Regenerating fluid 0.1395 116 2.046
Cooling fluid 0.1931 35 2.484
Adsorbed fluid 1.2969 116 2.046
Ethanol water 0.1931 71 3.411
Dehydrated Ethanol 1.1574 38 1.637
Solution:
Input (adsorber):
Sensible heat of azeotropic ethanol:
kg  kJ 
Q  mCpΔC  1.3506  3.357 0 380 C
s  kg C 
Q = 172.2906 kJ/s
Sensible heat of regenerating fluid:
kg  kJ 
Q  mCpΔC  0.1395  2.046 0 116 0 C
s  kg C 
Q = 33.1084 kJ/s
139
Output (adsorber)
Sensible heat of cooling fluid:
kg  kJ 
Q  mCpΔC  0.1931  2.484 0 350 C
s  kg C 
Q = 16.7881 kJ/s
Sensible heat of adsorbed fluid:
kg  kJ 
Q  mCpΔC  1.2969  2.046 0 116 0 C
s  kg C 
Q = 307.8011 kJ/s
Heat loss/gain = Total heat output –Total heat input
= 324.5892 -205.399
Input (cooler):
Sensible heat of cooling fluid:
Q = 16.7881 kJ/s
Sensible heat of adsorbed fluid:
Q = 307.8011 kJ/s
Output (cooler):
Sensible heat of ethanol water
kg  kJ 
Q  mCpΔC  0.1931  3.411 0 710 C
s  kg C 
Q = 46.7652 kJ/s
140
Sensible heat of dehydrated ethanol:
kg  kJ 
Q  mCpT  1.1574 1.637 0 380C
s  kg C 
Q = 71.9972 kJ/s
Heat loss/gain = Total heat output – Total heat input = 118.7624 – 324.5892
141
APPENDIX V
Rules of Thumb Used for Equipment Design
A. Roller mill
1. The gap between the rolls is approximately equal to the maximum size of the product.
2. The speed of roller mills ranges from 50-300 rpm (McCabe).
3. The particle size of the product ranges from 1 to 12 mm (0.04 to 0.5 in) with a feed particle
size ranges from 12 to 75 mm (0.5 to 3 in). (McCabe).
4. Rolls are usually 12 to 16 inches across the face and 22 to 36 inches in diameters (911
Metallurgy Corporations).
B. Steam explosion reactor
1. Vactual = 1.3Vcalculated (Green & Perry, 2008)
2. Consider maximum corrosion allowance Cc = 0.003175 m (ASME Section I) (Green &
Perry, 2008).
3. Lvessel =3Dvessel (Green & Perry, 2008)
4. For spot-examined carbon steel, Ej = 0.85 and S = 94, 500 kPa (Peters, Timmerhaus, &
West, 2004).
C. Pre-cooler (SE Reactor to Hydrolyzer)
1. The energy requirement for heating or cooling is Q = mCpΔT.
2. The energy requirement for fluid 1 is equal to the energy requirement for fluid 2.
D. Hydrolyzer
2. H reactor  2D reactor (Green & Perry, 2008)
3. Dimpeller  0.3D reactor (Green & Perry, 2008)
1
4. W  (D impeller ) (Green & Perry, 2008)
10
142
E. Fermenter
2. Consider maximum corrosion allowance Cc = 0.003175 m (ASME Section I) (Green &
Perry, 2008).
3. Lvessel =3Dvessel (Green & Perry, 2008)
4. For spot-examined carbon steel, Ej = 0.85 and S = 94, 500 kPa (Peters, Timmerhaus, &
West, 2004).
F. Beer Column
1. Fenske equation is used to determine the minimum number of stages (Peters, Timmerhaus,
& West, 2004).
2. The Underwood equation is used to developed the Rmin (Peters, Timmerhaus, & West, 2004).
3. The equation proposed by Eduljee is used to determine the number of theoretical stages
4. The Kirkbride method is used to determine the number of stages below and above the feed
point (Peters, Timmerhaus, & West, 2004).
5. Sieve tray is used as the most common tray internal because its tray fundamentals are well-
established and low risk (Peters, Timmerhaus, & West, 2004).
G. Pre-cooler (Beer Column to Absorber Column)
H. Absorber
1. Use a packed column when column diameter is less than 0.65m and the packed height is
less than 6 m. If not, use a trayed column (Peters, Timmerhaus, & West, 2004).
2. Pressure should be greater than the ambient pressure and the temperature near ambient
143
Hi
3. For an ideal solution at subcritical temperature, K i  where Hi is the Henry’s law
p
constant and p is the pressure of the gas (Peters, Timmerhaus, & West, 2004).
4. Kremser method is used to calculate the number of equilibrium stages (Peters, Timmerhaus,
& West, 2004)
I. Ethanol Column
1. Fenske equation is used to determine the minimum number of stages (Peters, Timmerhaus,
& West, 2004).
2. The Underwood equation is used to developed the Rmin (Peters, Timmerhaus, & West, 2004).
3. The equation proposed by Eduljee is used to determine the number of theoretical stages
4. The Kirkbride method is used to determine the number of stages below and above the feed
point (Peters, Timmerhaus, & West, 2004).
5. Sieve tray is used as the most common tray internal because its tray fundamentals are well-
established and low risk (Peters, Timmerhaus, & West, 2004).
J. Adsorber column
1. Continuous bulk separation is applied for adsorbate with a weight concentration greater
than 1% (Peters, Timmerhaus, & West, 2004).
2. The adsorbent recommended for ethanol-water systems is 3A molecular zeolites with the
following properties (Peters, Timmerhaus & West, 2004).
3. Feed conditions in which this mixture is nearly saturated but it has not yet reached its critical
temperature use the type II adsorption isotherm ( (Peters, Timmerhaus, & West, 2004).
4. Adsorption columns with pressures above atmospheric must be designed like process
pressure vessels (Green & Perry, 2008).
144
K. Pre-cooler (Around Adsorber Column)
145
APPENDIX VI
Equipment Design Calculations
A. Roller Mill
Speed of the roller mill:
300rev π  100cm
s 
min 1rev
s  94,247.78 cm/min
Capacity of the roller mill:
Using the Ribbon theory from Perry’s Chemical Engineers Handbook 8th edition, the
capacity of the miller can be calculated according to the formula:
dLs
Q
2.96
0.4cm  41cm  94,247.78c m/min

Q
2.96
Q  522,183.64 59 cm3/min
Circumference of the roller mill:
C  πD
C  π  91 cm
C  285.88 cm
146
B. Steam Explosion Reactor
From material and energy balance:
Mass of milled corn stover: 12,701.5992 kg/h
Operating Conditions:
Temperature = 210°C
Pressure = 2 MPa or 290.075 psi
Volume of Milled Corn Stover (Vmcs)
m 12,701.599 2 kg
Vmcs  
ρ 160 kg/m 3
Vmcs  79.3850 m3
Diameter of Vessel (Dvessel)
Vshell  1.3Vmcs
Vshell  1.3 (79.3850m 3 )
Vshell  103.2004m 3
For pressure vessels operating at 250  P  500 psi,
L
 3~ 4
D
L  3D
π 2 3π 3
V D L D
4 4
4 (103.2004)
D vessel  3
3π
D vessel  3.5250 m
Length of Vessel (Lvessel)
Lvessel =3Dvessel
Lvessel = 3 (3.5250)
Lvessel = 10.5749 m
147
Thickness of Torispherical Head Vessel (tshell)
Pstatic  ρgH  (160)(9.81 )(10.5749)
Pstatic  16,598.429 3 Pa or 16.598kPa
P  1.33(Pstatic  Po )  1.33(16.59 8  2,000)
P  2, 682.075 kPa
For spot-examined carbon steel, Ej = 0.85 and S = 94, 500 kPa
Consider maximum corrosion allowance Cc = 0.003175 m (ASME Section I)
Pri
t shell   Cc
SE j  0.6P
(2628.075) (3.5250/2)
t shell   0.003175
94,500(.85 )  0.6(2628.0 75)
t shell  0.062 m
0.885PL a
t head   Cc where La  ri
SE j  0.1P
0.885(2,62 8.075)(3.5 250/2)

t head   0.003175
94,500(.85 )  0.1(2,628. 075)
t head  0.0544 m
Inside Depth of Dish (IDD)
IDD  La  [(L a  r) 2  (L a  t head  r) 2 ]1/2
where, r  knuckle radius  0.06ri  0.106 m
IDD  1.7625  (1.7625 - 0.106) 2  (1.7625  0.0544  0.106) 2
IDD  1.3414 m
Volume in Head (Vhead))
2π
Vhead  0.9[ (L a ) 2 (IDD)]
3
2π
Vhead  0.9[ (1.7625) 2 (1.3414)]
3
Vhead  7.8544 m 3
148
Total Volume of Pressure Vessel
Vtotal  Vshell  2 Vhead
Vtotal  103.2004  2 (7.8544)
Vtotal  118.9092 m3
149
C. Pre-cooler (SE Reactor to Hydrolyzer)
mPCS = 25,403.1984 kg/h
Energy requirement for fluid 1, Q1:
kg kJ
Q1  25,403.198 4 (2.7 )(90  25C)
h kg  C
Q1  4,458,261. 319kJ/h
Mass flowrate of water, m2:
Q1  Q 2
kJ
4,458,261. 319  m 2 (4.2 )(50  20C)
kg  C
m 2  35,383.026 3kg/h
Log mean temperature difference, ΔTlm:
(90  50)  (25  20)

ΔTlm 
40
ln( )
5
ΔTlm  16.83 C
Correction factor, F:
Th,in  Th,out 90  25
P   2.167
Tc,out  Tc,in 50  20
R   0.75
Th,in  Tc,in 90  50
From figure 14 - 4 (Peters, Timmerhaus , & West, 2004),
F  1.0 (since P  1.0)
150
Area for the shell-and-tube exchanger, A:
ΔTm  F Δ Tlm  1.0(16.83)  16.83 C
Q
A
U Δ Tm
4,458,261. 319kJ/h
A
W 1K kJ/h
600 2 ( )(16.83 C)(3.6 )
m K 1C W
A = 122.6387 m2
151
D. Hydrolyzer
Mass of Pretreated Corn Stover: 25,403.1984 kg/h
Mass of glucan 10,302.761 kg/h
Mass of xylan: 15,100.4375 kg/h
Mass of water needed: 3186.9632 kg/h
Volume of Pretreated Corn Stover, Vpcs:
kg
Density of glucan  1110
m3
mglucan 10,302.761 kg
Vglucan  
ρglucan 1110 3
kg
m
Vglucan  9.2817m 3
kg
Density of xylan  1130
m3
m xylan 15,100.437 5 kg
Vxylan  
ρ xylan 1130 3
kg
m
Vxylan  13.3632m 3
Vpcs  Vglucan  Vxylan
Vpcs  9.2817m 3  13.3632m 3
Vpcs  22.6448m 3
Volume of water, Vwater:
kg
Density of water at 25 o C  997.08
m3
m water 3186.9632k g
Vwater  
ρ water kg
997.08 3
m
152
Vwater  3.1962m 3
Total Volume of Entering Material, Vtotal:
Vtotal  Vpcs  Vwater
Vtotal  22.6448m 3  3.1962m 3
Vtotal  25.841m 3
Reactor Volume, Vreactor:
Vactual = 1.3Vcalculated
Vreactor  1.3(25.841 m3 )
Vreactor  33.5933m 3
Reactor Height and Diameter:
H
2
D
πD 2
Vreactor  H
4
π(Dreactor) 2
33.5933m  3
2D reactor
4
D reactor  2.7840m
H reactor  2D reactor
H reactor  2(2.7840m)
H reactor  5.5679m
Impeller Diameter:
Dimpeller  0.3D reactor
Dimpeller  0.3(2.7840 m)
153
Dimpeller  0.8352m
Impeller Distance from Tank Bottom:
Z  Dimpeller  0.8352m
Baffle Width:
1
W (D impeller )
10
0.8352 m
W
10
W  0.08352 m
154
E. Fermenter
Mass of yeast (myeast) = 3.512 kg/h
Mass of sugar (msugar) = 13,723.2276 kg/h
Operating Conditions (Temperature = 40°C and Pressure = 1 atm or 101.325 kPa)
Volume of Yeast (Vyeast)
m yeast 3.512 kg
Vyeast  
ρ yeast 905.105 kg/m 3
Vyeast  0.0039m 3
Volume of Sugar (Vsugar)
msugar 13,723.227 6 kg
Vsugar  
ρsugar 1,530 kg/m 3
Vsugar  8.9694 m3
Total Material Volume (Vm)
Vm  Vyeast  Vsugar
Vm  0.0039  8.9694
Vm  8.9733 m3
Volume of Reactor (Vreactor)
Rule of Thumb for Reactor Design : Vactual  1.3Vcalculated
Vreactor  1.3 (8.9694)
Vreactor  11.6652 m3
Diameter and Height of Reactor (Dreactor)
H
 1.5
D
155
π 2 3π
V D H  D3
4 8
D reactor  3 8Vreactor/3π
8 (11.6652)
D reactor 3
3π
D reactor  2.1474m
H reactor  3.2210 m
Thickness of Reactor (treactor)
(1,530  905.105)
Pstatic  ρgH  (9.81)(3.2 21)
2
Pstatic  38472.236 Pa or 38.472 kPa
P  1.33(Pstatic  Po )  1.33 (38.472  101.325)
P  185.93 kPa
For spot-examined carbon steel, Ej = 0.85 and S = 94, 500 kPa
Consider maximum corrosion allowance Cc = 0.003175 m (ASME Section I)
Pri
t reactor   Cc
SE j  0.6P
(185.93)(2 .1474/2)
t reactor   0.003175
94,500(.85 )  0.6(185.93 )
t reactor  0.00566 m
0.885PL a
t head   Cc where La  ri
SE j  0.1P
0.885(185. 93)(2.1474 /2)

t head   0.003175
94,500(.85 )  0.1(185.93 )
t head  0.00575 m
156
Inside Depth of Dish (IDD)
IDD  L a  [(L a  r) 2  (L a  t head  r) 2 ]1/2
where, r  knuckle radius  0.06ri  0.0644 m
IDD  1.0737  (1.0737 - 0.0644) 2  (1.0737  0.00575  0.0644) 2
IDD  0.1076 m
Volume in Head (Vhead))
2π
Vhead  0.9[ (L a ) 2 (IDD)]
3
2π
Vhead  0.9[ (1.0737) 2 (0.1076)]
3
Vhead  0.2338 m 3
Total Volume of Reactor
Vtotal  Vreactor  Vhead
Vtotal  11.6652  0.2338
Vtotal  11.899 m 3
Dimensions of impeller and baffle:
Impeller Diameter (Di )  D reactor/3  0.7158 m
Impeller Distance from Tank Bottom (Z)  Di  0.7158 m
Baffle Width (W)  D reactor/10  0.21474 m
Impeller Disc Diamerer (D d )  3D i /4  0.5368 m
Impeller Blade Length (I)  Di /4  0.1790 m
Impeller Blade Width (b)  Di /5  0.1432 m
Baffle Tip Distance from Tank Bottom (m)  D reactor/5  0.4294 m
157
F. Beer Column
Feed: F = 1807 mol/s ; x(EtOH)F = 0.508 ; x(H2O)F = 1.299
Distillate: D = 0.952mol/s ; x(EtOH)D = 0.656; x(H2O)D = 0.296
Bottoms: B = 0.4951 mol/s ; x(EtOH)B = 0.024 ; x(H2O)B = 0.563
Minimum number of stages, Nmin using the Fenske eqn:
ln[(x LK /x HK ) D (x HK /x LK ) B ]
N min 
lnα LK
HK
ln[0.656/0 .296)(0.56 3/0.024)]

N min 
ln 5.4322
N min  2.3 stages
Minimum reflux ratio, Rmin using the Underwood eqn :
n
αi x F,i
α
i 1 Θ
 1 q
i
5.4322(0.5 08) 1(1.299)

  1 0 Assume feed is in the vapor phase : q  0
5.4322  Θ 1 Θ
Θ  3.5935
n
αi x D,i
R min  1  
i 1 αi  Θ
5.4322(0.6 56) 1(0.296)

R min  1  
5.4322  3.5935 1  3.5935
R min  0.824
Reflux ratio, R:
Assume R = 1.2Rmin
R = 1.2 (0.824)
R = 0.989
158
Actual number of theoretical stages, N using the Eduljee eqn:
N  N min  R  R min 
0.566
 0.751  
N 1  R 1 
N  2.3  0.989  0.824 

0.566
 0.751  
N 1  0.989  1 
N  12 theoretic al stages
Location of feed using the Kirkbride method:
ND  B  x   (x )  2 
log  0.206log   HK   LK B  
NB  D  x LK  F  (x HK ) D  
 0.587  1.299   (0.024)  2 

 0.206log     
 0.952  0.508   (0.656)  
ND
log  0.55118155 24
NB
N  ND  NB
12  N D  N B
ND
log  0.55118155 24
12  N D
N D  3 theoretic al stages
N B  9 theoretic al stages
Location of feed is at stage 4.
Souders and Brown factor for flood conditions at flood conditions, Csb:
0.5
 L  ρ V 
0.3
 0.989  692.07 
       0.073
 V  ρ L   1.989  423920 
Assuming a tray space of 0.61m for a sieve tray column internal, the Csb from Fig.15.5
(see Appendix 2) is 0.097 m/s.
159
Net vapor gas velocity, Vnf :
0.3
 ρL  ρV 
0.2
 α   
Vnf  Csb  
 20   ρ V 
 22.1   423920  722.0522 

0.2 0.3
 0.097    
 20   722.0522 
Vnf  0.670m/s
Actual vapor velocity, Vn:
Vn  0.6Vnf  0.6(0.670)  0.402m/s
Net column area An:
m'V 1.989(46.7 6)/692.07

An    0.334m 2
Vn 0.536
Assume the downcomer occupies 15% of Ac:
An 0.334
Ac    0.393m 2
0.85 0.85
Column diameter, D:
1/2 1/2
 4A   4(0.393) 
D c    0.707m
 π   π 
Column height, H:
Assume H=20D
H  20D  20(0.707)
H  14.15m
160
G. Pre-cooler (Beer Column to Absorber Column)
mbeer = 5327.0636 kg/h
kg kJ
Q1  5327.0636 (3.542 )(117  40C)
h kg  C
Q1  1,452,871. 364 kJ/h
Q1  Q 2
kJ
1,452,871. 364  m 2 (4.2 )(50  20C)
kg  C
m 2  11,530.725 1 kg/h
(117  50)  (40  20)

ΔTlm 
67
ln( )
20
ΔTlm  38.88 C
Th,in  Th,out 117  40

P   2.567
R   0.44
Th,in  Tc,in 117  50
F  1.0 (since P  1.0)
161
ΔTm  F Δ Tlm  1.0(38.88)  38.88 C
Q
A
U Δ Tm
1,452,871. 364 kJ/h

A
W 1K kJ/h
750 2 ( )(38.88 C)(3.6 )
m K 1C W
A = 13.84 m2
162
H. Absorber
From material balance calculations:
Tabsorbent = 330C
Tabsorbed fluid = 380C
Process water (absorbent) = 0.495 kmol/s
Carbon dioxide + water (absorbed fluid) = 0.152 kmol/s
Carbon dioxide (solute) mole fraction = 0.093
Hi = 1992 atm
Pressure of gas = 612 atm
Equilibrium constant, Ki:
1992
Ki   3.254
612
Absorption factor, Ai:
L 0.495
Ai  
K i V 3.254(0.15 2)
A i  1.000792
Number of equilibrium of equilibrium stages, N using the Kremser method:
A iN 1  A i
 solute fraction absorbed
A iN 1  1
1.000792 N 1  1.000792
 0.093
1.000792 N 1  1
Assume N = 2Ntheo
N = 2(10)
N = 20 actual stages
Assume column diameter is 0.65 m and height is 10 m.
163
I. Ethanol Column
Feed: F = 1.248 mol/s ; x(EtOH)F = 0.54 ; x(H2O)F = 0.46
Distillate: D = 0.753 mol/s ; x(EtOH)D = 0.895 ; x(H2O)D = 0.105
Bottoms: B = 0.4951 mol/s ; x(EtOH)B = 0.0002 ; x(H2O)B = 0.9998
Minimum number of stages, Nmin using the Fenske eqn:
ln[(x LK /x HK ) D (x LK /x HK ) B ]
N min 
lnα LK
HK
ln[0.895/0 .105)(0.99 98/0.0002) ]

N min 
ln 2.3033
N min  13.2 stages
Minimum reflux ratio, Rmin using the Underwood eqn :
n
αi x F,i
α
i 1 Θ
 1 q
i
2.3033(0.5 4) 1(0.46)
  1 0 Assume feed is in the vapor phase : q  0
2.3033  Θ 1 Θ
Θ  1.5995
n
αi x D,i
R min  1  
i 1 αi  Θ
2.3033(0.8 95) 1(0.105)

R min  1  
2.3033  1.5995 1  1.5995
R min  3.58
Reflux ratio, R:
Assume R = 1.2Rmin
R = 1.2 (3.58)
R = 4.296
164
Actual number of theoretical stages, N using the Eduljee eqn:
N  N min  R  R min 
0.566
 0.751  
N 1  R 1 
N  13.2  4.296  3.58 

0.566
 0.751  
N 1  4.296  1 
Location of feed using the Kirkbride method:
ND  B  x   (x )  2 
log  0.206log   HK   LK B  
NB  D  x LK F  (x HK )D  
 0.4951  0.46   (0.0002)  2 

 0.206log     
 0.753  0.54   (0.105)  
ND
log  1.17256365 6
NB
N  ND  NB
45  N D  N B
ND
log  1.17256365 6
45  N D
N D  3 theoretic al stages
N B  42 theoretic al stages
Location of feed is at stage 4.
Souders and Brown factor for flood conditions at flood conditions, Csb:
0.5 0.3
 L  ρ V   4.296  722.0252 
  
     0.12
 V  ρ L   5.296  423920 
Assuming a tray space of 0.46m for a sieve tray column internal, the Csb from Fig.15.5
(see Appendix 2) is 0.079 m/s.
165
Net vapor gas velocity, Vnf :
0.3
 ρL  ρV 
0.2
 α   
Vnf  Csb  
 20   ρ V 
 22.1   423920  722.0522 

0.2 0.3
 0.079   
 20   722.0522 
Vnf  0.545m/s
Actual vapor velocity, Vn:
Vn  0.8Vnf  0.8(0.545)  0.436 m / s
Net column area An:
m 'V 5.296 (32.41) / 722 .0522

An    0.545 m 2
Vn 0.436
Assume the downcomer occupies 15% of Ac:
An 0.545
Ac    0.641m 2
0.85 0.85
Column diameter, D:
1/2 1/2
 4A   4(0.641) 
D c    0.903m
 π   π 
Column height, H:
Assume H=20D
H  20D  20(0.903)
H  18.06m
166
J. Adsorber Column
From Material and Energy Balance:
Mass of azeotropic ethanol = 1.35 kg/s
Mass of regenerating fluid = 0.14 kg/s
Mass of cooling fluid = 0.19 kg/s
Mass of adsorbed fluid = 1.30 kg/s
Mass of ethanol water = 0.19 kg/s
Dehydrated ethanol = 1.16 kg/s
Operating conditions:
Temperature: 35-1160C
Pressure: 1-2.5 atm
To determine the amount of 3A molecular zeolites needed, the following ratio is used:
20 kg H 2 O 4634.2747 kg H 2 O

100 kg 3A zeolite Mass of 3A zeolite
Amount of adsorbent needed = 23171.3735 kg 3A molecular zeolite
Adsorber column dimensions
The pressure required for this adsorption system ranges from 1 to 2.5 atm. According to
Green & Perry (2008), adsorption columns with pressures above atmospheric must be designed
like process pressure vessels. A process pressure vessel has the following dimensions:
 Column height = 4.88 m
 Column diameter = 1.83 m
 Height of adsorbent inside the column = 2.89 m
167
Selection of adsorption cycle
To determine the appropriate adsorption cycle, the process conditions of the feed and
product streams must be observed (Peters, Timmerhaus, & West, 2004). From the data used in
the material and energy balances, there is a pressure difference for each stream. Since ethanol has
a boiling point temperature of 780C (Green & Perry, 2008), the temperature of the feed (azeotropic
ethanol) has already exceeded this but note that it will not still evaporate since it has not reached
yet 1000C, the boiling point of water. Thus, this mixture is nearly saturated but it has not yet
reached its critical temperature and pressure. For this feed condition, the type II adsorption
isotherm ( (Peters, Timmerhaus, & West, 2004) is used.
168
K. Pre-cooler (around Adsorber Column)
m1 = 4668.84 kg/h
kg kJ
Q1  4668.84 (2.046 )(116 - 38C)
h kg  C
Q1  745,090.83 79kJ/h
Q1  Q 2
kJ
745,090.83 79  m 2 (2.484 )(71 - 35C)
kg  C
m 2  8332.1126k J/h
(116  71)  (38  35)

ΔTlm 
45
ln( )
3
ΔTlm  15.50C
Th,in  Th,out 116  38

P   2.167
Tc,out  Tc,in 71 - 35
R   0.44
Th,in  Tc,in 116  35
F  1.0 (since P  1.0)
169
ΔTm  F Δ Tlm  1.0(15.50)  15.50 C
Q
A
U Δ Tm
745,090.83 79kJ/h
A
W 1K kJ/h
750 2 ( )(15.50 C)(3.6 )
m K 1C W
A = 17.8038 m2
170
CHEMICAL ENGINEERING PLANT DESIGN ASSESSMENT RUBRIC
Project Name: ___________________________________________ Date: May 15, 2017
Team Members: 1.
2.
3.
4.
Category/ Exceptional Acceptable Marginal Unacceptable Points

Dimensions (4) (3) (2) (1)
Organization Information is presented in Information is presented in Work is hard to follow as Sequence of information is
& Style a logical, interesting way, a logical manner, which is there is very little continuity. difficult to follow.
which is easy to follow. easily followed. No apparent structure or
Purpose of work is stated, continuity.
(2) Purpose is clearly stated Purpose of work is clearly but does not assist in Purpose of work is not
and explains the structure stated assists the structure following work. clearly stated.
of work. of work.
Content Demonstration of full At ease with content and Uncomfortable with No grasp of information.
& Knowledge knowledge of the subject able to elaborate and content. Clearly no knowledge of
with explanations and explain to some degree. Only basic concepts are subject matter. No
elaboration. demonstrated and questions are answered.
(2) interpreted. No interpretation made.
Design Clear and complete Overall sound Some understanding of Little or no grasp of
Problem and understanding of design understanding of the problem. Major problem.
Boundaries goal and constraints. problem and constraints. deficiencies that will Incapable of producing a
Does not significantly impact the quality of Successful solution.
(2) impair solution. solution.
Alternative Final design achieved after Alternative approaches Serious deficiencies in Only one design presented
Designs review of reasonable identified to some degree. exploring and identifying or clearly infeasible
alternatives. alternative designs. alternative given.
(1)
171
Use of Computer–aided tools are Computer–aided tools Minimal application and Serious deficiencies in
Computer– used effectively to develop used with moderate use of appropriate tools. Understanding the correct
Aided Tools and analyze designs. effectiveness to develop selection and/or use of
designs. tools.
(1)
Application of Critical selection and Effective application of Serious deficiencies in No or erroneous
Engineering application of engineering Engineering principles proper selection and use application of engineering
Principles Principles ensuring resulting in reasonable of engineering principles. principles yielding
reasonable results. solution. unreasonable solution.
(3)
Final Design Design meets or exceeds Design meets desired Barely capable of Not capable of achieving
desired objectives. objectives. achieving desired desired objectives.
objectives.
(3) Effective implementation Moderately effective No implementation of
of resource conservation utilization of resource Minimal utilization of resource conservation and
and recycle strategies. conservation and recycle resource conservation and Recycle strategies.
potentials. recycle potentials.
Process Effective use of profitability Reasonable profitability Reasonable cost estimates No or totally erroneous cost
Economics analysis leading to Analysis presented, but no presented, but no Estimates presented.
improvement interpretation of the results. profitability analysis
(2) recommendations included.
Format Format is consistent Format is generally Mostly consistent format. Work is illegible, format
& Aesthetics throughout including consistent including changes throughout, e.g.
heading styles and heading styles and font type, size etc.
(1) captions. captions.
Figures, Graphs Figures and tables are Figures and tables are Figures and tables are Figures and tables are
& Tables presented logically and neatly done and provide legible, but not convincing. sloppy and fail to provide
reinforce the text. intended information. intended information.
172
(2) All tables are effectively Most tables are properly Many tables are not Tables are not used
interpreted and discussed interpreted and important interpreted. Important effectively. Little
in the report. features noted. features are not understanding of important
communicated or features or issues.
understood.
Safety & Health Complete understanding Sound understanding of Serious deficiencies in No understanding or
Issues of health and safety issues health and safety issues. addressing health and appreciation of safety and
leading to sound and Mostly effective in safety issues leading to an health related issues.
(2) supported results. achieving supported unsupported and/or
results. infeasible result.
Environmental Complete understanding Sound understanding of Environmental aspects are No understanding or

Aspects of Environmental aspects. Environmental aspects. Addressed ineffectively appreciation of the
Effective in addressing of Mostly effective in with little or no effect on importance of
(2) Environmental issues addressing environmental end results. environmental concerns.
leading to a better result. issues.
Spelling Negligible misspellings Minor misspellings and/or Several spelling and Numerous spelling and
& Grammar and/or grammatical errors. grammatical errors. grammatical errors. grammatical errors.
(1)
References Reference section Minor inadequacies in Inadequate list of No referencing system
complete and references. references or references in used.
comprehensive. Consistent referencing text.
(1) Consistent and logical system. Inconsistent or illogical
referencing system. referencing system.
TOTAL
173

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Bioethanol Production from Corn Stover

A Plant Design Report

In Partial Fulfillment of the

Martin Baccay Jr.

ENGR. CAESAR P. LLAPITAN

Dear Engr. Llapitan:

We hope that this report will merit your favorable approval.

Martin G. Baccay Jr.

and is recommended for acceptance and approval.

ENGR. CAESAR P. LLAPITAN

the course Plant Design.

ENGR. MONICO U. TENEDOR

for the completion of this Process and Equipment Design report:

difficulties involved in this design report.

inspiration in our endeavors.

strength and to whom this design report is endowed.

focuses on the fulfillment of such objectives.

substance used and produced and a waste disposal measure.

of thumb used for equipment design are also included.

Certification and Approval iii

II. Properties of the Product 1

III. Process Selection 1

A. General Production of Ethanol from Lignocellulosic Biomass 4

B. Industrial Production of Ethanol from Corn 5

C. Ethanol Production from Corn Straw Using Alkaline Pretreatment 6

D. Modified Production Method 6

IV. Site Selection 7

A. Development of Potential Location Cases 7

Chapter 2 – Market Study 12

I. Bioethanol Demand and Supply 12

II. Bioethanol Pricing 17

III. Marketing Program 20

Chapter 3 – Technical Study 24

A. Reactor Feed Preparation 24

3. Enzyme and Yeast 24

C. Separator Feed Preparation 25

II. Process Flowsheets 27

A. Process Flow Diagram 27

III. Material and Energy Balance Tables 29

B. Summary of Energy Balance 31

IV. Equipment Summary 32

B. Equipment Design Specification 33

2. Steam Explosion Reactor 35

3. Pre-Cooler (SE Reactor to Hydrolyzer) 37

7. Pre-Cooler (Beer to Absorber Column) 45

10. Adsorber Column 51

11. Pre-Cooler (around Adsorber Column) 53

C. Piping and Instrumentation 55

1. Piping and Instrumentation Diagram 55

3. Piper Sizing and Selection 58

4. Control and Instrumentation 60

a. Steam Explosion Reactor 60

Chapter 4 – Costing and Project Evaluation 69

I. Estimation of Equipment Cost 69

II. Estimation of Working Capital 73

A. Fixed Capital Investment 73

B. Total Capital Investment 77

III. Estimation of Production Cost 78

2. Distribution and Marketing Cost 81

3. Research and Development Cost 81

III. Feasibility Analysis 83

Chapter 5 – Safety, Health, and Environment 88

I. Safety and Loss Prevention 88