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    Plant Design

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    etayhailu
    The document describes a project to design an ethanol production plant from molasses. It includes: 1) An outline of the project with problem statement, objectives, process flow diagram, equipment sizing, and economic analysis. 2) Details of the general and specific objectives, which are to design the plant and processes to maximize profit. 3) The process flow, which involves mixing molasses and water, fermentation with yeast, and distillation to produce ethanol.

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    Plant Design

    Uploaded by

    etayhailu
    640 views20 pages
    The document describes a project to design an ethanol production plant from molasses. It includes: 1) An outline of the project with problem statement, objectives, process flow diagram, equipment sizing, and economic analysis. 2) Details of the general and specific objectives, which are to design the plant and processes to maximize profit. 3) The process flow, which involves mixing molasses and water, fermentation with yeast, and distillation to produce ethanol.

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    The document describes a project to design an ethanol production plant from molasses. It includes: 1) An outline of the project with problem statement, objectives, process flow diagram, equipment sizing, and economic analysis. 2) Details of the general and specific objectives, which are to design the plant and processes to maximize profit. 3) The process flow, which involves mixing molasses and water, fermentation with yeast, and distillation to produce ethanol.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    640 views20 pages

    Plant Design

    Uploaded by

    etayhailu
    The document describes a project to design an ethanol production plant from molasses. It includes: 1) An outline of the project with problem statement, objectives, process flow diagram, equipment sizing, and economic analysis. 2) Details of the general and specific objectives, which are to design the plant and processes to maximize profit. 3) The process flow, which involves mixing molasses and water, fermentation with yeast, and distillation to produce ethanol.

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    of 20

    ADIGRAT UNIVERSITY

    COLLEGE OF ENGINEERING &TECHNOLOGY


    DEPARTMNT OF CHEMICAL ENGINEERING

    PROJECT ON: ETHANOL PRODUCTION FROM


    MOLASSES
    GROUP MEMBERS ID NO
    1. ALEMTSHAY H/KIROS 0111/06
    2. ETAY HAILU 0457/06
    3. KIROS G/MEDHIN 0937/06
    4. LETU DESALEGN 0969/06
    5. LICHIYA ALEM 0971/06
    6. MERESA HILUF 1083/06
    7. NGUS DEGU 1215/06
    8. ZERAY G/SLASSIE 1703/06
    Out line for our project
    Problem statement of the project
    Objective of the project
    General objective
    Specific objective

    Flow diagram of ethanol production


     Equipment sizing
    Economic analysis
    Statement of problem
    Ethanol is an alcoholic beverage that is usually needed by the people.
    But in many reasons it cannot be found abundantly or in excess form. As
    a result, the demand descends that is supply of the production is
    decreased. Most of the time ethanol is produced from sugars, and other
    vegetables. However, this method is somewhat costly and tired some.
    Comparing that, ethanol production from molasses (byproduct of sugar)
    by yeast is cheap and profitable. And it is a more environmental friend
    than of petrol and other fuels .For this reason, we want to solve the
    problem using the intermediate sugar molasses by yeast to grow the
    supply of the product for the community. To maximize the profit of sugar
    factories design of ethanol production from molasses plant is mandatory.
    Objectives
     General objective
    To design plant for production of ethanol from molasses

     Specific Objectives
    To design equipment’s used to produce ethanol from molasses.
    To make material and energy balance for the whole process of ethanol
    production
    Showing process flow diagram, process flow description of ethanol
    production from molasses
    To perform economic analysis for the plant and to recommend
    preferable plant location
    Process flow of molasses ethanol production

    yeast
    SIZING OF MAJOR EQUIPMENTS
     Sizing of molasses storage tank
     Sizing of water storage tank
     Sizing of mixer
     Sizing of Fermenter
     Sizing of ethanol Storage tank
     Sizing of distillation column
     column
     Pump for delivering of water
    COST ESTIMATION
    Total Capital Investment (TCI)
     Total purchased equipment cost
    Equipment name Quantity Capacity Unit price ($) Total price ($)

    Sugar molasses storage tank 1 284m3/day 17,121 17,121

    Water Storage Tank 2 5.6m3/day 6,070 12,140


    Fermenter 2 755m3/batch 11,500 23,000

    Distillation 1 21m3/hr 7,000 7,000


    Molecular sieve 1 45.27kg/hr 5,584 5,584

    Ethanol St. Tank 1 0.6m3/week 6,059 6,059


    Centrifugal pump 2 0.004m3/s 2,450 4,900

    Total purchased equipment cost 75804


     Estimation cost of direct, indirect and fixed capital
    investment
    Direct cost (DC) Factor Cost (ETB)
    Purchased equipment 1 2046697.13
    Purchased equipment installation 0.47 961947.65
    Instrumentation and control 0.18 368405.48
    Piping (installed) 0.66 1350820.12
    Electrical( installed) 0.11 225136.68
    Building 0.18 368405.48
    yard improvement 0.1 204669.71
    Service facilities 0.3 614009.14
    Land 0.06 122801.83
    Total plant direct cost (TPDC) =Σ DC 6262893.22
    Indirect cost (IDC) Factors Cost (ETB)
    Engineering and supervision 0.33 675410.05
    Construction and expense 0.41 839145.82
    Contractors fee (CF) 0.21 429806.4
    Contingency (C) 0.40 818678.85
    Indirect cost (IDC) = ΣID 2763041.12
    From the above table we can calculate the total capital
    investment
    TCI=FCI+WC
    but WC= (10-20) % TCI
    TCI =FCI+0.15TCI
    TCI = FCI/0.85
    TCI =9025934.34 /0.85,
    TCI= 10,786,093.87 Birr
    Manufacturing cost
     Variable Operating Costs
    Item Cost (ETH
    Birr)
    Raw materials 0.5Birr/kg*10968 5484060
    120kg
    1 Operating labor(L) 84*1200*12 1209600
    2 Direct supervisors and 0.1L 120960
    clerical labor
    3 Utilities(electric & water 217573 + 18901 236474
    cost)
    4 Maintenance and repair 0.06FCI 541556.06
    5 Operating supplies 0.01FCI 90259.34
    Total direct production cost = 7682906.4
     Fixed Operating Costs

    S. No Items Cost (ETH


    Birr)
    1 Depreciation 0.1FCI 902593.43
    2 Local taxes 0.02FCI 180518.69
    3 Insurance 0.005FCI 45129.67
    4 Rent 0.08(land + 39296.58
    building)
    Total fixed charges 1167538.37
     Plant overhead cost

    S. No Item Cost
    (ETH
    Birr)
    1 Plant overhead 2*8000*12 192000
    cost

    Manufacturing cost = variable + fixed operating cost + plant


    overhead cost
    = 7682906.4 + 1167538.37+ 192000
    = 9,042,444.77 Birr
    Total production cost
     General expense

    S. No Item Cost(ETH Birr)

    1 Administrative cost 0.5L = 0.5*1209600 604800

    2 Distribution and sell cost 0.2L = 0.2*1209600 241920

    Total general 846720


    expense

    Total production cost = manufacturing cost + general expense


    = 9042444.77 + 846720
    = 9889164.77
    TPC = 9,889,164.77 Birr
    Profit analysis
     Net income
    Annual revenue = 6*3000000
    = 18000000Birr
    Total production cost = 9889164.77Birr
    Gross annual profit = 18000000 - 9889164.77Birr
    = 8110835.23Birr
    Income tax on gross profit (35%) = 0.35*8110835.23
    = 2433250.57Birr
    Net income = 8110835.23- 2433250.57
    = 5,677,584.66Birr
    Percent profit
    % profit = 57.41%
     Percent rate of return
    % ROR = 52.64%
     Payback period
    Payback period =1.37years
    So, the payback period of the project is estimated to be 2years
    CONCLUSION
    The molasses that contains much enough sugar content biomass are
    mixed with water to their component sugars for subsequent
    conversion to ethanol by a fermentation process. Molasses are
    usually treated with a chemical process (acid) or biological
    (enzyme) to remove the impurity. Ethanol was produced molasses
    through the process of fermentation, distillation and dehydration
    using molecular sieve respectively. In ethanol plant distillation
    column is the major equipment from the design part. Since the cost
    estimation and cost analysis are acceptable the design is feasible.
    RECOMMENDATION
    Based on the project that we have done the following
    recommendations are given:
     Further researches have to be carried out to increase the yield of
    ethanol from molasses by use other microorganisms which are
    capable of converting 5- and 6- carbon sugar into ethanol.
     Optimization of fermentation and distillation processes are
    recommended to maximize the yield of ethanol from molasses.
    Molasses is rich in sugar content, due to this reason further
    research is required to utilize this largely available by-product
    molasses
    Detailed economic feasibility studies in the production process
    are recommended, since it is critical for the rationale of
    commercialization.

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