Integrated Design

APPROVAL SHEET
This project study entitled PRODUCTION OF HIGH-VALUE ANIMAL FEEDS

FROM PROTEIN-ENRICHED AGRO-INDUSTRIAL WASTES prepared and
submitted by Vera Luwesa M. Allera, Mary Rose M. Estrada, Johdem I. Torayno, and
Mary Jane V. Yap, in partial fulfillment of the requirements for the degree of Bachelor of
Science in Chemical Engineering has been examined, accepted and passed for oral
examination.
____________________________
HERCULES R. CASCON, Ph. D.
Mentor
Faculty, ChE Department
PLANT DESIGN REPORT ON PRODUCTION OF HIGH VALUE ANIMAL
FEEDS FROM PROTEIN-ENRICHED AGRO-INDUSTRIAL WASTES
An Undergraduate Research Study

Presented to
the Faculty of the Department of Chemical Engineering
Xavier University Ateneo de Cagayan
In Partial Fulfillment
for the Requirements for the Degree
Bachelor of Science in Chemical Engineering
by
Allera, Vera Luwesa M.
Estrada, Mary Rose M.
Torayno, Johdem I.
Yap, Mary Jane V.
February 2015
Chemical Engineering Department
College of Engineering
Corrales Avenue, Cagayan de Oro City
28 February 2015
HERCULES R. CASCON, Ph.D.
Supervisor
Chemical Engineering Department
Re: Submission of Process Design Report
Dear Sir:
With due respect and honor, we submit herewith the process design report of our study
entitled Plant Design Report on the Production of High-Value Animal Feeds from
Protein-enriched Agro-industrial Wastes. During the preparation of the report, we have
tried our best to create our finest process design report and tried to show all sort of salient
points of the study: the process flow diagram, material and energy balances, equipment
list and unit description, profitability and environmental impact assessment.
2
We have collected all the updated information necessary for the improvement of our
study. We hope this report will provide a clear scenario of introducing our proposed
process design.
We shall be available to answer any question for clarification. Thank you for your sincere
support to make our research endeavors successful.
Table of Contents
Table of Figures .................... iii
List of Tables .................... v
1. Introduction ..........1
2. Process Flow Diagram and Description......2
2.1. Process Flow Diagram Development....................................3
2.2
2.1.1.
Input/output Diagram............ 3
2.1.2.
Block Flow Diagram .......... 3
2.1.3
Specifying the process ... 4
2.1.4
Detailed Process Flow Diagram .7
Process Description 9
3. Material, Energy Balances, and Utility Requirement . 13

3. 1 Material Balances ... 13
3.1.1
Summary Quantitative Flow Diagram ... 13
3.1.2
Details of Material Balance Calculation ... 15

2
Material Balance for Washer . 16

Material Balance for Air Dryer . 18
Material Balance for Grinding .. 22
Material Balance for Substrate Preparation... 23
Material Balance for Preparation of Starter Culture . 27
Material Balance for Fermentation Vessel 28
Material Balance for Filtration .. 33
Material Balance for Second Drying . 35
Material Balance for Pelletizing 37
Accounting for unused raw material . 38
3.2
Process Operation Scheduling 35

Calculations Involved 38
3.3
Energy Balances . 43
3.3.1
Summary Quantitative Flow Diagram .... 45
3.3.2
Details of Energy Balance . 37
Equipment .. 46
Washer ... 46
Dryer .. 47
Grinder ... 59
Mixer 1 .. 62
Mixer 2 .. 63
Fermentor ... 63
Filter Press 70
Vacuum Dryer 70
Pelletizer 71
Utilities ............... 72
Pumps . 72
Screw Conveyor . 84
Belt Conveyor 85
3
Air Heater ...

85
Compressor 86
4. Equipment Design and Specifications ...... 91
Dryer... 92
Air Duct Heater... 103
Mixer... 107
Fermenter 116
5. Process Control 122
Dryer... 122
Air Duct Heater... 126
Mixer... 127
Fermenter 130
6. Bibliography ............... 136
List of Figures
Fig. 2.1
Input/output Diagram structure......... 3
Fig. 2.2
Block flow Diagram.. 4
Fig. 2.3
Expanded block flow process diagram .... 4
Fig. 2.4
More detailed block flow process diagram ... 6
Fig. 2.5
Detailed process flow diagram .. 8
Fig. 3.1
A quantitative flow diagram for the production of single cell protein from
agro-industrial wastes through semi-solid state fermentation using C. utilis
and S. cerevisiae
14
Fig. 3.1.2.1
Material balance around Washer ....... 17
Fig. 3.1.2.2
Material balance around Dryer for Cassava Peels .... 18
Fig. 3.1.2.3
Material balance around Dryer for Pineapple Pomace . 20
Fig. 3.1.2.4
Material balance around Dryer for Ipil-ipil leaves 21
Fig. 3.1.2.5
Material balance around Grinder for Cassava Peels . 22
Fig. 3.1.2.6
Material balance around Grinder for Pineapple Pomace .. 22
Fig. 3.1.2.7
Material balance around Grinder for Ipil-ipil Leaves ... 23
Fig. 3.1.2.8
Material balance around Mixer for Substrate Preparation .... 24
Fig. 3.1.2.9
Material balance around Starter Vessel for the Preparation of the Starter
27
Culture ...
29
Fig. 3.1.2.10
Material balance around Fermentor ...
Fig. 3.1.2.11
Material balance around Filter Press . 34
Fig. 3.1.2.12
Material balance around Pelletizer .... 36
Fig. 3.1.2.13
Material balance around Dryer ... 37
Fig. 3.2.1
Shortened overall Ghantt chart for plant operations 40
Fig. 3.3.1
Energy balance around Washer ............ 48
Fig. 3.3.2
Energy balance around Dryer .. 49
Fig. 3.3.3
Humidity chart for the determination of wet bulb temperature ... 50
Fig. 3.3.4
Energy balance around Grinder ... 62

5
Fig. 3.3.5
Energy balance around Fermentor ........... 66
List of Tables
Table 2.1.
33
Amount of Material Entering/Generated .....
Table 2.2. Amount of Material Exiting (product).. 33

6
Abstract
Agro-industrial wastes can be further processed to produce products with economic value
and at the same time reduce the environmental threat posed by their uncontrolled
accumulation. For this plant design, the locally available agro-industrial wastes
specifically cassava peels and pineapple pomace are utilized as raw materials for the
production of high-value animal feeds through semi-solid state fermentation. Biological
treatment was done in order to enrich the protein content of these wastes. These waste
materials are known to have low-protein content and thus, through semi-solid state
fermentation using Saccharomyces cerevisiae, their protein content is enriched. In this
study, particularly, high-value animal feeds are produced from the protein enriched agroindustrial wastes.
The process flow of the system is established and presented in a diagram. The established
process flow diagram is incorporated with a process description in order to further
understand the process. Subsequently, material and energy balances calculations were
employed in order to determine the amount of material to be used and the amount of
product to be produced in the process. Moreover, the energy balance is employed in order
to account for the energy requirement of each process involved in the system. Both
balances can also aid the assessment of the economic feasibility of the system. Based on
literature, it is expected have a protein increase of 262% after fermentation. It was
determined that with a desired product of 10,000 kg HVAF, 23,606.09 kg of total
substrate is needed, thus, giving a yield of 42.36%.
Keywords: high-value animal feeds, agro-industrial wastes, single cell protein, semisolid state fermentation, livestock
CHAPTER ONE
Introduction
1.1 Production of High-Value Animal Feeds from Agro-Industrial Wastes
Agro industry is an integral part of the world economic activity (Rodrigues et al.
2014) and this industry has progressed over time. Different industrial plants produce
agro-industrial products through fruit processing for various applications. The by-product
of these wastes are the so-called agro-industrial wastes which have low chemical risks,
potentially available on a large scale and can generate a biomass, rich in natural
pigments, and are potentially cost competitive (Jacob-Lopes & Franco, 2013). According
to Dhanasekaran, et al. (2011), these wastes are a renewable source of a great variety of
biotechnological potential. Currently though, due to the lack of proper handling and
utilization methods, these wastes are released directly into the environment giving a
serious impact since they emit greenhouse gases. However, such wastes are usually rich
in sugars, proteins and minerals and should be considered as raw materials for other
industrial processes. The presence of these macronutrients makes it suitable for growth of
microorganisms. One way of utilizing agro-industrial wastes is through semi-solid state
fermentation (SSSF) for the enrichment of its protein content which can be later used as
animal feed (Musatto S. I., Ballisteros, Martins, & Teixeira, 2014).
For this study, cassava peels and pineapple pomace are used as solid substrates for
the fermentation, while using ipil-ipil leaves as co-substrate for nitrogen source. The
fermentation process will be aided by the yeasts, Saccharomyces cerevisiae and Candida
utilis. Agro-industrial wastes such as cassava peels and pineapple pomace possess great
potential as raw materials for the production of different products nowadays. Animal
feeds are one of the products from further processing of these wastes. The production of
animal feed can be done through microbial fermentation. In this study, high-value animal
feeds are produced from the protein enriched agro-industrial wastes.
The product of this fermentation process is called Single Cell Protein (SCP)
which can be utilized as animal feeds. SCP refers to microbial cells grown and harvested
1
for animals or human food due to its high protein content. It may refer to the source of
mixed protein extracted from pure and mixed culture of algae, yeast, fungi and bacteria
(Adedayo, Ajiboye, Akintunde, & Odaibo, 2011). It can be considered as one of the
novel foods, those that are new to the population in question or have not been eaten in
significant amounts. Due to this, studies must be undertaken to ensure their acceptability
for human use. Studies using animals should be performed initially then followed by
closely supervised human studies. The Protein Advisory Group (PAG) of the United
Nations System has formulated guidelines to assist nutritionists and food scientists in
evaluating novel foods for human consumption. Preliminary testing includes a complete
chemical analysis of the SCP, including quantitative and qualitative information
regarding the protein, lipid, carbohydrate, vitamin, and mineral composition. Thereafter,
animal tests should be performed to determine the available energy content of the food,
quality of protein, digestibility, and availability of minerals. Experiments on animal
feeding must be performed to ensure that no adverse side effects or toxicity associated
with the use of SCP. This toxicity study include evaluation of the animals blood and
major organs after feeding SCP for extended periods as outlined by the PAG
recommendations (Badan Pengkajian dan Penerapan Teknologi, 1983).
Nutrients are essential components of a fermentation broth which would ensure
the growth of the microorganisms. In a fermentation process, an addition of nitrogen
source would aid the growth of the microorganisms. Leucaena leucocephala is a plant
which is commonly known as Ipil-ipil. According to the study by Escalada, R.G, it can be
considered as an efficient and cheap source of nitrogen. The leaves of ipil-ipil contain
4.3% nitrogen by weight and considerable amounts of potassium and phosphorus.
(Escalada & Ratilla, 1998) Ipil-ipil is a plant that is locally available.
1.2 Plant Location and Layout
The location of the plant is an important factor to be considered in the design of
the plant. For the production of the animal feeds, the target location of the plant is in
Manolo Fortich, Bukidnon along Sayre Highway. The site location has a coordinates of
82214.79 North (latitude) and 1245211.998 East (longitude). The figure below
gives an illustration of the target site for the establishment of the plant.
Figure 1.2.1: Plant site in Manolo Fortich, Bukidnon (Google Maps, 2015).
The primary consideration considered in the selection of the location is
accessibility of the raw materials specifically cassava peels and pineapple peels and
pomace. A cassava production is located near the area enabling the easy access for
cassava peels. Bukidnon is also known due to the two major pineapple-based industries
located in the area. This allows the easy access to pineapple pomace which is a major raw
material for the animal-feed production plant. The accessibility of the raw materials will
positively contribute to the progress of the animal feed production plant. Less transport
cost can be attained due to the close distance between the processing plant and the raw
material source.
Moreover, the proposed plant site is near the Mangima River. This is illustrated in
the Figure given below. The close distance of the plant site to a body of water would
imply that there is a possible source of water for the production process.
Figure 1.2.2: Plant site located near Mangima River (Google Maps, 2015).
Another important consideration in the selection of the plant location is the
accessibility of forms of transport. The location is close to Sayre Highway which will
allow easy access to land transportation.
Figure 1.2.3: Plant Location close to Sayre Highway (Google Maps, 2015).
In terms of accessibility of the probable market, the availability of different

piggery in the area would be favorable for the animal feed production plant. The different
piggery includes backyard and commercial piggery farms.
Plant Layouts
Process units and ancillary buildings are laid out to give the most economical
flow of materials and personnel around the site. Consideration is also given to the future
expansion of the site (Seider, Seader, & Lewin, 2010). The following figure shows the
proposed site plan of thee proposed plant design.
Figure 1.2.4: Site plan.

Plant layout determines how well the plant and equipment used in the process is
laid out and is a determining factor for the economic construction and efficient operation
of a process unit (Seider, Seader, & Lewin, 2010). A proposed plant layout is shown in
the figure below.
5
Figure 1.2.5: Plant layout.
CHAPTER TWO
Process Flow Diagram and Description
The process flow sheet is the definitive document of the process. Thus, the
presentation needs to be clear, comprehensive, accurate and complete. This section
presents the development of the detailed process flow diagram and its process
description.
2.1 Process Flow Diagram Development
The process concept diagram or input/output diagram identifies the feed, chemical
reactions taking place, and product. For this study, cassava peels, pineapple pomace, ipilipil leaves, yeast, and water are the main raw materials of the processing. These raw
materials basically undergo semi-solid state fermentation (SSSF). With this, an output of
animal feeds, carbon dioxide, water, and ethanol are generated. Fig. 2.1 below presents
the structure of the process concept diagram of the agroindustrial wastes fermentation.
Fig. 2.1: Input/output Diagram structure.

The block diagram is the simplest form of presentation. A block can represent a
single piece of equipment or a complete stage in the process. They are useful for
representing a process in a simplified form than the complicated one. (Sinnott, 2005)
From the simple input/output diagram, the block flow diagram can then be
developed. It includes the basic operations needed in the development of the desired
plant. Basically, these include feed preparation, semi-solid state fermentation,
7
purification, and pelletizing as shown in Fig. 2.2 below. Based on literature, the three
main sections of the fermentation plant to be designed are feed preparation, fermentation,
and product recovery (Simpson, Astudillo, & Acevedo, 2005) which basically is just
similar with the proposed design. The proposed detailed block flow diagram is shown in
Fig. 1. The processes involved in the main sections are basically provided in details.
Fig. 2.2: Block flow Diagram.

From the simplified block flow diagram, the processes involved are now
presented as shown in Fig. 2.3 below. Under feed preparation (labeled 1), washing,
drying, grinding, and storage of the raw materials are undertaken. Cassava peels are to be
washed due to the presence of unwanted materials such as soil and other microorganisms.
Ipil-ipil leaves and pineapple pomace are to be subjected directly to drying due to the
abundant presence of water in the latter. These raw materials are then stored separately
after the grinding process. After the feed preparation, the fermentation process is
implemented; it includes mixing of the minerals and fermentation media, preparation of
starter media, and the semi-solid state fermentation proper. Separation follows which is
just solid-liquid separation mainly, then, followed by the pelletizing process.
Fig. 2.3: Expanded block flow process diagram.

A more specified block glow process diagram is shown in Fig. 2.4 below. The
mixing process in square 2 is specified clearly of which another mixer is available for the
mixing of the minerals. The dissolved minerals are then added to mixer 1 where it is
mixed with the fermentation media which are just the agroindustrial wastes. A starter
vessel for the preparation of the fermentation media and the culturing of the yeast is
added. Two fermentors are basically used in this process, where one will serve as the
backup as shown in square 2 of the Fig. below. For the soli-liquid separation process in
square 3, filtration is employed, where the filter cake is of more value than the filtrate.
The pelletizing process includes pelletizing and drying of which the desired product,
animal feeds, can then be obtained.
Fig. 2.4: More detailed block flow process diagram.
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From the development of the process concept diagram into a specified block flow
process diagram, a detailed process flow diagram can then be obtained. For this part, the
names of the equipment are used instead of the process itself. The labels for each
equipment are shown in Fig. 2.5 below and the description of each are presented just
above the figure. A detailed process description then follows after the detailed PFD.
Basically, as shown in the figure, all of the input materials are placed in the left side,
while the output are placed on the right side.
BC-101
Belt
Conveyor 1
BC-102
Belt
Conveyor 2
P-102
Slurry Pump for
Starter Culture to
Starter Vessel
C-101
Air
Compressor to
Dryer 1
CR-101
Hammer Mill for
Raw Material
Size Reduction
P-103
Slurry Pump for Starter Culture to
Fermentor 1 and 2
CT-101
Cooling Tower for
cooling water to
Fermentor 1 and 2
P-104
Centrifugal Pump
for Cooling Water
to Fermentor 1 and
2
D-101
Dryer for
Raw
Materials
P-105
Centrifugal Pump
for Wastewater
from Washer
D-102
Dryer for
Biomass
SC-101
Screw Conveyor for
Ground Raw Materials
F-101
Fermenter
1
F-102
Fermenter 2
SC-102
Screw Conveyor for
Pelletized Biomass
11
FI-103
Filter Press
for Raw
Materials
H-101
Electric
Heater for Air
Supply
MI-101
Pelletizer
ST-101
Storage Tank
for Cassava
Peels
ST-102
Storage Tank
for Pineapple
Pomace
ST-103
Storage Tank
for Ipil-ipil
Leaves
MX-101
Mixer for
fermentation media
and mineral
solution
V-101
Starter Vessel
MX-102
Mixer for liquid
concentration/mineral
solution
V-102
Storage vessel for HCl
P
Slurry Pum
Solutio
V-103
Storage
vessel for
NaOH
Fig. 2.5: Detailed process flow diagram.

2.2. Process Description
The preliminary block flow diagram for the production of high-value animal feeds is
divided into four units: Feed Preparation, Semi-solid State Fermentation, Separation, and
Pelletizing. The operations under these units are already discussed in the previous
sections. Here, the detailed process description of Fig. 2.5 is presented.
Fresh cassava peels, Stream 1, enter a polywash washer, WA-101, to remove sand and
unwanted matters. Water at room temperature and pressure of 1 atm enters WA-101.
Excess water exits WA-101 and proceeds to the wastewater treatment facility.
12
After washing, the cassava peels pass through a discharge conveyor belt, Stream 3, and
then enters an air dryer, D-101, where it will be heated at 55C for 48 hours (2 days). The
drying process is also applied to other raw materials: pineapple pomace and ipil-ipil
leaves, however, it is done by batch. The cassava peels go first followed by the pineapple
pomace then ipil-ipil leaves since they have different initial moisture content and thus,
drying time. Basically, drying is done to avoid deterioration and growth of unwanted
microbes.
The dried cassava peels from the dryer then enter a grinder, CR-101, through Stream 5
with sieve (1 mm) for size reduction. Pineapple pomace and ipil-ipil leaves are also
subjected to this process. This is also done by batch. After each raw material has been
grounded, it then enters a storage tank, ST-101, by passing through a screw conveyor,
SC-101, where it will be temporarily stored prior to usage.
Mixer 1, MX-101, is where the fermentation media is prepared comprising of substrates
(cassava peels and pineapple pomace) and co-substrate (ipil-ipil leaves) coming from
Stream 7 and mineral solution coming from Stream 8. The moisture content (liquid
concentration) is prepared in Mixer 2, MX-102, and enters through Stream 8 into MX101. It is where distilled water and other minerals (Stream 15) are mixed to produce a
mineral solution. The minerals are composed of (NH 4)2SO4, MgSO4H2O, KH2PO4, and
MnSO4 which are fed manually due to their negligible amounts.
A simultaneous process occurring in one area of the plant is the microorganism and
inoculum preparation. The microorganism S. cerevisiae, Stream 11 are fed to the starter
vessel, V-101, where a portion of the fermentation media will be fed through Stream 10.
After which, the prepared starter culture is then fed to Fermentor 1 and 2 through Stream
13.
Prior to use, Fermenter 1 and 2, are injected with steam for sterilization at 121 C for 20
minutes. The fermentation media then enters the fermentor. The inoculum prepared from
starter vessel, V-101, enters F-101/2, where it is then inoculated to the fermentation
13
media where it will be fermented for 3 days at 30 C to carry on the semi-solid state
fermentation.
After the 3-day fermentation, the slurry then enters a filter press, FI-101, to force separate
the water from the slurry at room temperature, 25 C. The water exits the unit and the
single cell protein enters a pellet mill, MI-101. The pellet mill presses the SCP and gives
the pellet (cylindrical) shape of the product under temperature, pressure, and moisture. It
leaves the mill through Stream 17 and passes a screw conveyor for storage.
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CHAPTER THREE
Material, Energy Balances, and Utility Requirement
This chapter presents the material balance, energy balance, and utility requirement
calculations for the proposed plant design. It is important to have detailed quantitative
calculations of the materials required since it would eventually determine the feasibility
of the design.
3.1. Material Balances
One important matter to be considered in producing products is the material
balance. It involves the accounting of the input (raw materials) and the output (products,
byproducts, wastes, etc.) of the processes. This section provides a material balance of the
processes involved which will be provided in the succeeding sections of this paper. It will
provide an overview of the accounting of the amount of raw materials (agro-industrial
waste, water, minerals and yeast) that will be used and the corresponding amount of highvalue feeds that will be produced in each process. Moreover, the amount of by-products
that will be produced in the process will also be calculated. The plant design starts from
the preparation of raw materials which includes washing, drying, grinding, and storage.
Then, fermentation procedure is employed in order to increase the protein content of the
substrate. Separation is then employed in order to separate the products and by-products.
The process then continues to the product separation and by-product purification.
In solving for the material balance of the system and checking if the objectives are
met, the protein content increase of the substrate is to be calculated. Available values of
moisture content are used to determine the value as to which the raw materials are dried.
Ethanol and CO2 yield of the substrates are based on literature. To determine certain
values which have no existing literature to validate, calculations were carried out. The
amount of protein produced with respect to the substrate is basically the main aim of this
fermentation process.
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3.1.1 Summary Quantitative Flow Diagram

A quantitative summary of the materials that enter and leave the processes are
shown in Fig. 3.1 below. A sum of 61,968.14 kg input and output is obtained. The
breakdown of the amount of these materials is shown in the Fig. below. This is then
followed by a detailed calculation of the values.
Basis: 1 operating batch
Unit designed to produce 10,000 kg HVAF per day
Fig. 3.1.: A quantitative flow diagram for the production of high-value animal feeds from
protein-enriched agro-industrial wastes.
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3.1.2 Details of Material Balance Calculation

Material balance is employed in order account for all material that enters and
leaves each process. For this process, high value animal feeds are the product to be
produced. It is produced from fermented agro-industrial wastes namely cassava peels and
pineapple pomace. Initially, an overall material balance for the entire system is done.
Figure 3.1 gives an illustration of the general input and output streams of the system. The
basis for the entire calculation is 10,000 kg high-value animal feeds (HVAF). Production
of the animal feeds is not limited by the availability of the raw materials. The two main
raw materials, namely, cassava peels and pineapple pomace, are readily available due to
the use of cassava and pineapple as raw materials in different industries. In the
succeeding discussion below, a material balance is employed for each major process
involved.
BASIS:
10,000 kg HVAF/day
a. Pelletizer
A product preparation step which is pelletizing is employed. It is to form the final
product into pellets to be dried which will then be ready for consumption. For the
material balance calculation of the pelletizing process, the following assumptions are
considered:
1. Negligible mass loss.
2. Steam does not affect the mass of the product.
Figure 3.2.1: Material balance around Pelletizer.

Calculation:
17
m=mout
mmeal=?
mmeal=10,000 kg meal /day
b. Dryer 2
Drying is employed to further reduce the moisture content of the filtered material
and to eliminate the remaining ethanol content of the same material. For the process, air
is the heat medium. It is desired to have a moisture content of 18% after drying. The
following assumptions are taken into consideration:
1. The output material has 18% moisture content.
2. No ethanol remains in the liquid component of the fermented after drying.
3. 5% ethanol is removed.
4. 25% water is removed from the meal.
Figure 3.1.2.2: Material balance around Dryer 2.

Calculating for amount of filtered meal (mfm) fed to dryer,
mfm=mmeal +m lr +methanol
(Eqn. 1)
where
mlr =0.25 mfm
(Eqn. 2)
18
methanol=0.05 mfm
(Eqn. 3)
Substitute Eqns. 2 and 3 to 1,

mfm=mmeal +m fm ( 0.25 ) +mfm ( 0.05 )
mfm=10,000+mfm ( 0.25 ) +mfm ( 0.05 )
mfm ( 10.250.05 )=10,000 kg
mfm=14,285.71 kg
Liquid removed (Eqn. 2),
m lr =0.25(14,285.71 kg)
mlr =3,571.43 kg
Ethanol removed (Eqn. 3),
methanol=0.05 (14,285.71kg)
methanol=714.29 kg
c. Filtration
Filtration is a process to employ solid liquid separation. There are different
equipments that can be used to employ filtration. For the given system, the filtration
process is employed through a filter press. The main objective of this process is to
reduce the liquid component of the fermented material. The following assumptions
are considered in the calculation:
1. 70% of the liquid component is removed.
2. 10% of fermented material is lost. The material could either be in the filter press
or in the filtrate.
3. The equipment used for filtration is filter press.
4. The material after filtration contains around 25 to 70% solid content (National
Metal Finishing Resource Center).
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5. Approximately 47% of the fermented substrate is liquid (based on previous

calculations).
6. 65% of the liquid from the fermented substrate is removed or recovered (filtrate).
35% goes with the filtered meal.
Figure 3.1.2.3: Material balance around Filter Press.

Calculations:
OMB:
m=mout
mfs =mlr +mlm
mfs =mlr +14,285.71
(Eqn. 4)
(where fs=fermented substrate, lr=liquid recovered, fm=filtered meal)

Liquid balance:
mfs (0.47)=mlr +14,285.72 kg ( 0.35 ) (0.47)
Solving equations 1 and 2 simultaneously gives,
mfs =22,520.21 kg
mlr =8,234.50 kg
Liquid unrecovered
mlm=( 0.35 ) (.47)(14,285.71 kg)
20
(Eqn. 5)
mliquidthe meal=2,350.00 kg
Solids
msolids =14,285.71 kg2,350.00 kg
msolids =11,935.71 kg
Percent solid composition after filtration
solids=
solids=
msolid component out

100
mfiltration output
11,935.71 kg
100
11,935.71 kg +8,234.50 kg
solids=60
which falls within the range set by (National Metal Finishing Resource Center).
d. Fermenter
The most important process in the production of high-value animal feeds is the
fermentation. The fermentation is employed in order to increase the protein content of the
substrate through the use of yeast. The enrichment is done through semi-solid state
fermentation. In this process, the substrate contains 55% water. Two fermentation setups
are to be employed for the process. Both setups will have the same amount of substrate
and starter culture. Different factors are considered for the process and the following
assumptions are taken into consideration:
1. Initial protein content of raw materials: cassava peels is 4.21%, pineapple pomace
is 6.4% and ipil-ipil leaves is 23%.
2. There is a 262% increase in the protein content of the material (Gelinas &
Barrette, 2007).
3. 424 mmol CO2 is produced per 100 g of cell biomass produced (Jeppson, Yu, &
Hahn-Hagerdal, 1996).
21
4. Ratio of ethanol to carbon dioxide is 1 mol:1mol (Jeppson, Yu, & Hahn-Hagerdal,

1996).
5. The substrate will be equally distributed in each fermentor.
6. 50% of the yeast is protein.
7. The amount of biomass produced is equal to the amount substrate consumed.
8. Substrate consumed = biomass added.
9. 2.3% of ethanol and CO2 is generated from the total substrate.
Figure 3.1.2.4: Material balance around Fermenter.

OMB:
msubstrate =mC O + methanol+ 22,520.21kg
(Eqn. 6)
mC O =0.023 msubstrate
(Eqn. 7)
methanol=0.023 msubstrate
(Eqn. 8)
where
Substitute Eqns. 7 & 8 to 6,

msubstrate =0.023 msubstrate +0.023 msubstrate +22,520.21 kg
msubstrate =23,606.09 kg
For Protein
Before fermentation:
(Eqn. 9)
moriginal protein =( mCPdried ) ( 0.0421 ) + ( mPP dried ) ( 0.0640 ) + ( m ILdried ) (0.2300)
22
After fermentation:
maccumulated protein =0.5 m yeast +3.62 moriginal protein
(Eqn. 10)
mfermented meal=mtotal substrate msubstrate consumed mtotal water added +mbiomass added
(Eqn. 11)
For fermented meal
mC O =22,520.21 kg ( 0.023 ) msubstrate =542.94 kg=methanol

2
Biomass added
mbiomassadded =
maccumulated protein
0.50
For starter culture

mstarter culture =0.01m substrate
m starter culture =0.02(23,606.09 kg)
mstarter culture =471.12 kg
where half of the culture is yeast.
Original mass of substrate before culture is added
msubstr ate=23606.09 kg
472.12 kg
2
msubstrate =23,370.03 kg
Moreover, the mass of the total biomass is calculated:

23
(Eqn. 12)
mtotal biomassadded =mtotal protein out
1 biomass
0.5 protein
Eq. 13
Then, the percent ethanol in the liquid component can then be calculated:
ethanol liquid component =
methanol produced
100
mliquid component
Eq. 14
e. Starter Culture Tank

A starter culture is prepared in order to allow the yeast to adjust to the
fermentation conditions that to be adopted. The same substrate that will be used in the
fermentation procedure is introduced in the starter vessel.
Assumptions:
1. 1% of the substrate from the mixer will be used for the inoculation.
2. Mass of yeast added is 1% of the total substrate. Therefore, there is 1:1 mass
proportion.
3. Yeast culture is added not pure yeast.
Figure 3.1.2.5: Material balance around Starter Culture Tank.

Mass of substrate to culture,
substrate
m culture =m substrate ( 0.10 )
(Eqn. 15)
Mass of yeast for substrate,

m yeast =msubstrate ( 0.10 )
(Eqn. 16)
24
Calculating mass of starter culture,

substrate
msc =m culture +m yeast =msubstrate ( 0.10 ) +msubstrate ( 0.10 )
(Eqn. 17)
(where sc=starter culture)

Thus,
m yeast =0.01 ( 23,606.09 kg )
substrate
m yeast =236.06 kg=m culture
msc =236.06 kg+236.06 kg
msc =472.12 kg
f. Mixing 1
Then, mixing of the components of the substrate is done. Minerals, solid agroindustrial wastes and water is added in the mixers. The mixer for minerals allows the
mixing of minerals prior to introduction to the total mixer. Four minerals are to be added
and diluted with water. The total mixer on the other hand, allows the mixing of all
components of the substrate namely, ground raw materials, water and mineral solution.
The following assumptions are considered in the calculation:
1. The total substrate is composed of 17.5 % cassava peels, 17.5% pineapple
pomace, 5% ipil-ipil leaves, 5% minerals and 55% water.
2. 94.4% of mineral solution is water.
3. Mineral solution: 1.5 g (NH4)2SO4/kg substrate, 0.05 g MnSO4/ kg substrate, 0.8 g
KH2PO4/kg substrate and 0.45 g MgSO4/kg substrate.
25
Figure 3.1.2.6: Material balance around Mixer 1.

Assumptions:
msubstrate =mCP +m PP+ mIL+ mH O + mMS
2
23,370.03 kg=mCP +m PP +m IL+m H O + mMS
(Eqn. 18)
where
mCP=0.175 ( msubstrate )
(Eqn. 19)
mPP=0.175 ( msubstrate )
(Eqn. 20)
mIL=0.05 ( msubstrate )
(Eqn. 21)
mH O=0.55 ( m substrate )
(Eqn. 22)
mMS =0.05 ( m substrate )
(Eqn. 23)
where mMS,
mMS =m( N H
m( N H ) S O =
4 2
mMnS O =
4
+ m MnS O4 +m K H 2 P O4 +mMgS O 4
) S O4
4 2
(Eqn. 24)
1.5 g ( N H 4 ) 2 S O 4
kg substrate
0.05 g MnS O 4
kg substrate
(Eqn. 25)
26
mK H
PO4
0.8 g K H 2 P O4
kg substrate
mMgS O =
0.45 g MgS O 4
kg substrate
mH
O added
(Eqn. 26)
(Eqn. 27)
0.944 kg H 2 O
kg MS
(Eqn. 28)
Total water added

H 2 O added
H2 O
mtotal water=m MS +m substrate
mtotal water=
0.994 kg H 2 O
+ 0.55 ( msubstrate )
kg MS
(Eqn. 29)
Thus, substitute calculated values to Eqns. 19-29,

mCP=0.175 (23,370.03 kg )=4,089.76 kg
mPP=0.175 ( 23,370.03 kg )=4,089.76 kg
mIL=0.05 ( 23,370.03 kg )=1,168.50 kg
mH O=0.55 ( 23,370.03 kg )=12,853.52 kg
2
mMS =0.05 ( 23,370.03 kg )=1,168.50 kg
m( N H ) S O =
4 2
1.5 g ( N H 4 ) 2 S O4
1 kg
( 23,370.03 kg )
=35.06 kg ( N H 4 ) 2 S O4
kg substrate
1000 g
mMnS O =
4
mK H
2PO4
0.05 g MnS O 4
1 kg
( 23,370.03 kg )
=1.17 kg MnS O 4
kg substrate
1000 g
0.8 g K H 2 P O4
1 kg
( 23,370.03 kg )
=18.70 kg K H 2 P O4
kg substrate
1000 g
27
mMgS O =
4
mH
0.45 g MgS O 4
1 kg
( 41,928.73 kg )
=18.87 kg MgS O4
kg substrate
1000 g
O added
0.944 kg H 2 O
( 1.168 .50 kg )=1,103.07 kg H 2 O
total MS
Now, the mass of original protein from the substrate can be determined since the
amounts of raw materials to be used are obtained.
Before fermentation (Eqn. 9):
moriginal protein =( 4,089.76 kg )( 0.0421 ) + ( 4,089.76 kg ) ( 0.0640 ) + ( 1,168.50 kg ) (0.2300)
moriginal protein =702.68 kg
After fermentation (Eqn. 10):
maccumulated protein =0.5 m yeast + moriginal protein
maccumulated protein =moriginal protein ( 2.62 )m yeast ( 0.50 )
maccumulated protein =702.68 kg ( 2.62 )236.06 kg(0.50)
maccumulated protein =1,722.99 kg
g. Grinding
Grinding is employed in order to reduce the particle size of the raw materials. Smaller
size for raw materials would allow the microorganisms during fermentation to easily
access the nutrients available in the raw materials. The following assumptions are
considered in the calculation:
1. No material is lost during the process. Thus, input is equal to the output.
2. Each material is ground separately.
Cassava Peels
28
Figure 3.1.2.7: Material balance around Grinder for Cassava Peels.

mdriedCP =mgroundCP
(Eqn. 30)
mdriedCP =4,089.76 kg
Pineapple pomace
Figure 3.1.2.8: Material balance around Grinder for Pineapple Pomace.

mdried PP=mground PP
(Eqn. 30)
mdried PP=4,089.76 kg
Ipil-ipil Leaves
Figure 3.1.2.9: Material balance around Grinder for Ipil-ipil Leaves.

mdried IL =mground IL
mdried IL =1,168.50 kg
29
(Eqn. 31)
h. Drying
Drying is employed after washing in order to achieve desired moisture content of

the raw material for the succeeding processes. For this system, the heating medium is
dry air. The air is heated by a fired heater. The drying process is employed at 55 C. It is
important to consider the temperature of the system to avoid degradation of important
components of the raw material that is significant to the succeeding processed. Moreover,
the drying process is employed in batch condition. Each raw material is dried separately.
The following assumptions are considered for the calculation:
1. Each raw material is dried separately
2. After drying, 14% moisture content remains
3. Original moisture content (wet basis) of raw materials is 27% for cassava peels,
35.4% for pineapple pomace and 16% for ipil-ipil leaves.
Cassava Peels
Figure 3.1.2.10: Material balance around Dryer 1 for CP.

Initially, based on literature, 27% moisture content is available in the cassava
peels. Calculate moisture content dry-basis,
moisture content dry basis=
moisture content dry basis=37
30
0.27
100
10.27
Accounting the moisture absorbed by the peels during washing,

initial moisture content =43.75
Solids balance:
mwashed CP ( 10.4375 )=m dried CP (10.14)
mwashed CP ( 10.4375 )=4,089.76 kg(10.14)
mwashed CP =6,252.78 kg CP
Water removed
mwater =6,252.78 kg4,089.76 kg=2,163.03 kg H 2 O
Pineapple pomace
Figure 3.1.2.11: Material balance around Dryer 1 for PP.

Initially, moisture content is 34.5% dry basis, calculating for the percent moisture
content in dry basis of the pineapple pomace,
moisture content dry basis=52.67
31
0.345
100
10.345
Calculate mass of pineapple pomace to be dried,

mPP ( 10.5267 )=mdried PP (10.14)
mPP ( 10.5267 )=4,089.76 kg (10.14)
mPP=7,431.21 kg PP
Water removed
mwater =7,431.21kg4,089.76 kg=3,341.45 kg H 2 O
Ipil-ipil Leaves
Figure 3.1.2.12: Material balance around Dryer 1 for IL.

Calculating for the percent moisture content in dry basis of the ipil-ipil leaves,
0.16
100
10.16
moisture content dry basis=19
Solids balance:
mIL ( 10.19 )=mdried IL (10.14)
mIL ( 10.19 )=1,168.50 kg (10.14)
32
mIL=1,240.63 kg IL
Water removed:
mwater =1,240.63 kg1,168.50 kg=72.13 kg H 2 O
i. Washing
Washing is employed in order to remove unnecessary solid particles (i.e. soil)
from the raw materials. For this process, only cassava peels is washed. Moreover, the
following assumptions are considered in the calculation:
1. Meyers PolywashTM Multi-Produce Washers is to be used for washing.
2. 10% of the water used remains in the material.
3. Only cassava peels will be washed.
4. Ratio of water and cassava peels is 1:1. This is to ensure that there is
enough water added to remove the impurities.
5. The amount of waste removed is negligible.
6. 10% of the moisture (water) is absorbed by the cassava peels.
Figure 3.1.2.13: Material balance around Washer.

Calculating mass of cassava peels fed to washer,
mCP=mH
33
(Eqn. 32)
m washe d CP =mCP (1.10)
mCP=
6252.78 kg CP
1.10
mCP=5,684.35 kg=m H O
2
Water out
mH
O out
=0.90(5,684.35 kg)
34
mH
O out
=5,115.91 kg
3.3 Energy Balances
Energy balance is one of the important requirements for the design of an industrial
plant. For this study, it is important to calculate the heat and power requirements of the
equipment and utilities involved in the processing of the agro industrial wastes into highvalue animal feeds. This is done to validate if the plant is feasible and has economical
value for materialization in the future. An energy balance of the heat and power
requirements for the processing of the agro-industrial wastes into high-value animal feeds
is done in this report. Also, calculations for the power requirement for washing, belt and
screw conveyors, milling, and pelletizing are presented. These will be shown in the
succeeding sections of this paper.
In this energy balance, the determination of the energy requirements of the
processes is to be specified and accounted using available data from journal articles,
Perrys Chemical Engineering Handbook, from calculations described in books by
Timmerhaus, Seider, and other available online sources.
The assumptions made were the following:
1. The water used for washing is not absorbed by the raw materials. Thus, m water
in
=mwater out.
2. There are no mass losses in the grinding of the raw materials.

3. Only CO2 leaves the fermenter during fermentation.
3.3.1 Summary Quantitative Flow Diagram of Power/Heat Requirement
A summary of the quantitative flow of the energy and power requirements is
shown in the figure below.
35
Table 3.3.1: Summary of power requirements for the various equipments and utilities and
the amount of utilities to be used per batch of high value animal feeds produced.
Equipments and Utilities
A. Electric Power
Air Heater
Belt conveyor
Belt conveyor (Washer)
Blower
Compressor
Filter Press
Grinder
Mixer 1
Mixer 2
Pelletizer
Pump (Cooling Water)
Pump (Washer Feed)
Pump (Drain Water in Washer)
Pumps (Slurry)
Screw Conveyor
Tunnel Dryer
B. Cooling Water (Tin =
Number of
Power/ Heat
Units
Requirement
1
2
1
1
1
1
1
1
1
1
1
1
1
8
1
1
-
275.98 kW
1.94 kW
0.916 kW
10.39 kW
202.51 kW
90 kW
36 kW
76.43 kW
0.023 kW
325 kW
0.35 kW
0.122 kW
0.54 kW
128 kW
2.23 kW
11.4 kW
-
Amount (kg)
240,813.87
20C, T = 10C)
3.3.2 Details of Energy Balance Calculation
The energy balance of the processes is presented in the succeeding sections.
i. Equipment
A. Washer
Fresh cassava peels are first washed to remove unwanted particles such as soil.
Assumptions:
1. It is assumed that a PolywashTM Washer is employed for washing.
Cassava Peels
36
Figure 3.3.2.1: Energy balance around Washer.

The Polywash uses advanced technology for washing and cleaning of fruit,
vegetables, leafy products, tubers, roots, seafood, fish, and more, hence, it is applicable
for cassava peels.
Figure 3.3.2.2. Mechanism of a Polywash Washer.

The Polywash uses an innovative combination of turbulent and calm zones to
produce a highly effective wash while removing fine debris that would otherwise be
37
carried out with the product. Sediment is flushed from the system periodically through
the main waste valve.
The Polywash has a capacity of up to 50 tons/hr or 13.89 kg/s.
In this equipment, it does not give a specific power requirement; however, the
power required will be used for the pump, blower and discharge belt conveyor. The
discussion on the power requirement will be shown the utilities section.
B. Dryer
Drying of the feed is basically done to increase the percent dry matter content
which has little effect on the crude protein.
Figure 3.3.2.3: Energy balance around Dryer.

In the calculation for the heat balance in the dryer, it is initially assumed that the
air and the raw material have a counter current flow. The conditions of the raw material
are known. The air is the heating medium for the system. Since the conditions for the dry
air are not known then the following assumptions for the dry air are considered:
T A 1=120 C
H 1=0.05
kgH 2 O
kgDA
NTU = 1.75
Then, the temperature of the outlet of the air stream, TA2, can then be calculated.
The equation used in determining the outlet temperature of the air is given as:
NTU =ln
T A 2t w
T A 1t w
38
Eq. 64
wheretw is the wet bulb temperature of the air. The value for the wet bulb temperature of
air can be taken from the humidity chart for air and gas given in the Principles of
Transport Processes and Separation Processes by Geankoplis, 2003.
Figure 3.3.2.4: Humidity chart for the determination of wet bulb temperature.
Given that the inlet temperature of air is 120 C and the humidity is 0.05 kg water vapor/
kg dry air, it can determined using the humidity chart that the wet bulb temperature of the
system is 48C.
Calculating for the outlet temperature of the air:
NTU =ln
2.0=ln
T A 2t w
T A 1t w
12048
T A 248
Eq. *
T A 2=57.7441O C
39
Three different materials will be dried in the process: cassava peels, pineapple
pomace and ipil-ipil leaves. Each material requires different amount of heat for drying.
First, the calculation of the heat balance for drying the cassava peels was employed.
Cassava peels
Considering the equation for the material balance on the moisture of the air and
the cassava peels:
m A 1 H 1 +ms 2 x 2=m A 2 H 2 +ms 1 x1
Eq. 65
From the overall material balance within the dryer, the equation is given by:
m A 1 +ms 2=m A 2 +ms 1
Eq. 66
The following variables are known:

ms 2=4,089.76 kg cassava peels
x 2=0.14 kg total moisture /kg dry solid
H 1=0.05
kg watervapor
kg dry air
ms 1=6,252.78 kg cassava peels

x 1=0.4375 kg total moisture/kg dry solid
Substituting known values to the equations gives,
m A 1 H 1 + 4,089.76 ( 0.14 )=mA 2 (0.05)+ 6,252.78(0.4375)
Eq. 67
m A 1 +4,089.76=m A 2 +6,252.78
Eq. 68
And
The, the enthalpy of the gas in the outlet stream in kJ/ kg dry air was then
calculated using the equation
H 'G 2=c s ( T A 2T o ) + H 2 o
Eq. 69
40
where cs is the humid heat given by the expression
c s=1.005+ 1.88 H
, o is the latent
heat of water at temperature To. The To of the system is 0C which corresponds to a value
of o equal to 2501 kJ/kg. Substituting known values:
H 'G 2=[ 1.005+1.88 ( .050 ) ] (1200 )+ ( 25010.050 )
'
H G 2=256.93
kJ
kgDA
Then, the enthalpy of the gas in the inlet stream was calculated.
H 'G 1=c s ( T A 1T o ) + H 1 o
where TA1 is 57.7441C, the same expression for cs and the same value for To and o.
'
H G 1=[ 1.005+1.88 ( .050 ) ] (57.74410 ) + ( 2501 H 1 )

'
H G 1=63.4607659+2501 H 1
In calculating for the enthalpy of the wet solid raw material in the inlet, the
equation used was:
H 's 1=c ps ( T S 1T o ) + x 1 c PA (T s 1T o )
Eq. 70
where cps is the specific heat of cassava peel , 2.455 kJ/kg C, TS1 is equal to 25C, To is
equal to 0C, x1 is equal to 0.4375 and cPA is the specific heat of the water in the raw
material, 4.187 kJ/kg. Substituting known values:
H 's 1=2.455 ( 250 ) +( 0.4375)(4.187)(250)
'
H s 1=107.1703
kJ
kg
For the enthalpy of the wet solid in the outlet stream, same calculations were
applied, only that the value for TS2 is 60C and the fraction of water in the material, x 2 is
0.14.
H 's 2=c ps ( T S 2T o ) + x 2 c PA (T s 2T o)
H 's 2=2.455 ( 600 ) +(0.14)(4.187)(600)
41
H 's 2=182.4708
kJ
kg
Then, the calculation for the amount of dry air to be used in the system can be
employed. Given the equation:
'
'
'
'
Eq. 71
m A 2 H G 2+ ms 1 H s 1=mA 1 H G 1 +ms 2 H s 2
Substituting known values:
Eq. 72)
m A 2 (256.93 )+ ( 6,252.78 )( 107.1703 )=mA 1 ( 63.4607659+2501 H 1 ) + ( 4,089.76 )( 182.4708
Thus, using equation 7:

m A 1 +4,089.76=m A 2 +6,252.78
m A 1=m A 2 +2163.02
Eq. 73
Substituting this to equations 6 and 11 gives:

m A 1 H 1 + 4,089.76 ( 0.14 )=mA 2 ( 0.05 ) +6,252.78 ( 0.4375 )
m
( A 2+2163.02) H 1+ 4,089.76 ( 0.14 )=m A 2 (0.05)+6,252.78(0.4375)
H 1=
0.05 mA 2+ 2163.02
m A 2+ 2163.02
Eq. 74
Substituting the equations 12 and 13 to equation 11 gives:

m A 2 (256.93 )+ ( 6,252.78 )( 107.1703 )=mA 1 ( 63.4607659+2501 H 1 ) + ( 4,089.76 )( 182.4708 )
m A 2 (256.93 )=m A 1 ( 63.4607659+2501 H 1 ) +76149.47
m A 2 (256.93 )=(mA 2+2163.02) 63.4607659+2501

m A 2=82,186.38 kg dry air
42
))
0.05 m A 2 +2163.02
+ 76149.47
m A 2 +2163.02
Substituting the value to equations 12 and 13 gives:

m A 1=m A 2 +2163.02
m A 1=82,186.38+2163.02
m A 1=84,349.40 kg DA
and
H 1=
0.05 mA 2+ 2163.02
m A 2+ 2163.02
H 1=
0.05(82,186.38)+2163.02
(82,186.38)+2163.02
H 1=0.074
kgwatervapor
kgdryair
Pineapple Pomace
the pineapple pomace:
m A 1 H 1 +ms 2 x 2=m A 2 H 2 +ms 1 x1
Eq. 75
m A 1 +ms 2=m A 2 +ms 1
Eq. 76

ms 2=4,089.76 kg pineapple pomace
H 1=0.05
kgwat ervapor
kgdryair
ms 1=7,431.21 kg pineapple pomace

43
m A 1 H 1 + 4,089.76 ( 0.14 )=m A 2 (0.05)+7,431.21( 0.5267)
Eq. 77
m A 1 +4,089.76=m A 2 +7,431.21
Eq. 78
And
H 'G 2=c s ( T A 2T o ) + H 2 o
Eq. 79
c s=1.005+ 1.88 H
, o is the latent
H 'G 2=[ 1.005+1.88 ( .050 ) ] (1200 )+ ( 25010.050 )
'
H G 2=256.93
kJ
kgDA
H 'G 1=c s ( T A 1T o ) + H 1 o
H 'G 1=[ 1.005+1.88 ( .050 ) ] (57.74410 ) + ( 2501 H 1 )
'
H G 1=63.4607659+2501 H 1
equation used was:
Eq. 80
where cps is the specific heat of pineapple pomace and assumed that it is the same with
cassava peels since they are both biomass, 2.455 kJ/kg C, TS1 is equal to 25C, To is equal
to 0C, x1 is equal to 0.5267and cPA is the specific heat of the water in the raw material,
4.187 kJ/kg. Substituting known values:
'
H s 1=2.455 ( 250 ) +(0.5267)(4.187)(250)
44
H 's 1=116.5073
kJ
kg
0.14.
'
H s 2=2.455 ( 600 ) +(0.14)(4.187)(600)

H 's 2=182.4708
kJ
kg
m A 2 H 'G 2+ ms 1 H 's 1=mA 1 H 'G 1 +ms 2 H 's 2
Eq. 81

m A 2 (256.93 )+ (7,431.21 ) ( 116.5073 ) =m A 1 ( 63.4607659+ 2501 H 1 ) + ( 4,089.76 )( 182.4708
Eq. 82)

m A 1 +4,089.76=m A 2 +7,431.21
m A 1=m A 2 +3341.45
Eq. 83

m A 1 H 1 + 4,089.76 ( 0.14 )=mA 2 ( 0.05 ) +7,431.21 ( 0.5267 )
(m A 2 +3341.45) H 1 +4,089.76 ( 0.14 )=m A 2 ( 0.05 ) +7,431.21 ( 0.5267 )
H 1=
0.05 m A 2+ 3341.45
mA 2+3341.45
Eq. 84
45
m A 2 (256.93 )+ (7,431.21 ) ( 116.5073 ) =m A 1 ( 63.4607659+ 2501 H 1 ) + ( 4,089.76 )( 182.4708 )

m A 2 (256.93 )=m A 1 ( 63.4607659+2501 H 1 ) 119,528.43
m A 2 (256.93 )=(mA 2+3341.45) 63.4607659+2501
))
0.05 m A 2 +3341.45
119,528.43
m A 2 +3341.45
m A 2=123,495.81 kg dry air

m A 1=m A 2 +3341.45
m A 1=123,495.81+3341.45
m A 1=126,837.26 kg DA
and
H 1=
0.05 m A 2+ 3341.45
mA 2+3341.45
H 1=
0.05(123,495.81)+3341.45
123,495.81+3341.45
H 1=0.075
kgwatervapor
kgdryair
Ipil ipil Leaves

the ipil ipil leaves:
m A 1 H 1 +ms 2 x 2=m A 2 H 2 +ms 1 x1
Eq. 85
m A 1 +ms 2=m A 2 +ms 1
Eq. 86

ms 2=1,168.50 kg ipilipil leaves
46

H 1=0.05
kgwatervapor
kgdryair
ms 1=1,240.63 kg ipilipil leaves

x 1=0.19 kg total moisture/kg dry solid
m A 1 H 1 +1,168.50 ( 0.14 )=m A 2 (0.05)+1,240.63(0.19)
Eq. 87
m A 1 +1,168.50=m A 2 +1,240.63
Eq. 88
And
H 'G 2=c s ( T A 2T o ) + H 2 o
Eq. 89
c s=1.005+ 1.88 H
, O is the latent
'
H G 2=[ 1.005+1.88 ( .050 ) ] (1200 )+ ( 25010.050 )

H 'G 2=256.93
kJ
kgDA
H 'G 1=c s ( T A 1T o ) + H 1 o
H 'G 1=[ 1.005+1.88 ( .050 ) ] (57.74410 ) + ( 2501 H 1 )
H 'G 1=63.4607659+2501 H 1
equation used was:
47
Eq. 90
where cps is the specific heat of ipil ipil leaves and has the same value with the cassava
peels, 2.455 kJ/kg C, TS1 is equal to 25C, To is equal to 0C, x1 is equal to 0.5267and cPA
is the specific heat of the water in the raw material, 4.187 kJ/kg. Substituting known
values:
H 's 1=2.455 ( 250 ) +(0.19)( 4.187)(250)
'
H s 1=81.26325
kJ
kg
0.14.
H 's 2=2.455 ( 600 ) +(0.14)(4.187)(600)
H 's 2=182.4708
kJ
kg
m A 2 H 'G 2+ ms 1 H 's 1=mA 1 H 'G 1 +ms 2 H 's 2
Eq. 91

m A 2 (256.93 )+ (1240.63 )( 81.26325 ) =m A 1 ( 63.4607659+ 2501 H 1 ) + ( 1168.50 )( 182.4708
Eq. 92
)

m A 1 +1168.50=m A 2+ 1240.63
m A 1=m A 2 +72.13
Eq. 93
48

m A 1 H 1 +1168.50 ( 0.14 )=m A 2 (0.05)+1240.63( 0.19)
(m A 2 +72.13) H 1 +1168.50 ( 0.14 )=m A 2 (0.05)+1240.63(0.19)
H 1=
0.05 mA 2+72.13
m A 2+ 72.13
Eq. 94

m A 2 (256.93 )+ (1240.63 )( 81.26325 ) =m A 1 ( 63.4607659+ 2501 H 1 ) + ( 1168.50 )( 182.4708 )
m A 2 (256.93 )=m A 1 ( 63.4607659+2501 H 1 ) +112,399.50
m A 2 (256.93 )=( m A 2 +72.13 ) 63.4607659+ 2501
m A 2=4,346.35 kg dry air

m A 1=m A 2 +72.13
m A 1=4,346.35+72.13
m A 1=4,418.48 kg DA
and
H 1=
0.05 mA 2+72.13
m A 2+ 72.13
H 1=
0.05(4,346.35)+72.13
4,346.35+ 72.13
H 1=0.0655
kgwatervapor
kgdryair
49
))
0.05 mA 2+72.13
+112,399.50
mA 2+72.13
Table 3.3.2: Summary of the Humidity, H1, leaving and mass of dry air, mA1, required in
each drying process.
Raw Material
Humidity of air exiting, H1

(kg water vapor/kg dry air)
0.074
0.075
0.0655
Total
Cassava Peels
Pineapple Pomace
Ipil-ipil Leaves
Mass of Dry Air

(kg)
82,186.38
123,495.81
4,346.35
210,028.54
In calculating for the heat required for the drier, the equation below is used given
that the heat capacity of air at 120C is 1.013 kJ/kgK ( (Air Properties, 2014):
H=m A c p , A T
In drying the cassava peels for 18.783 hrs, the amount of heat required is:
kJ
( 12057.7441) K
kgK
3600 s
18.783 hrs
1hr
( 82,186.38 kg ) 1.013
H=
H=76.65 kW
In drying the pineapple pomace for 28.224 hrs, the amount of heat required is:
kJ
( 12057.7441 ) K
kgK
3600 s
28.224 hrs
1hr
( 123,495.81kg ) 1.013
H=
H=76.65 kW
In drying the ipil ipil leaves for 0.933 hrs, the amount of heat required is:
kJ
( 12057.7441 ) K
kgK
3600 s
0.993 hrs
1 hr
( 4,346.35 kg ) 1.013
H=
H=76.68 kW
50
Thus, the total heat required for drying the raw materials is:
H Total =76.65 kW +76.65 kW + 76.68 kW
H Total =229.98 kW
C. Grinder (Size reduction)

Assumptions:
1. There is no mass loss in the milling process.
2. Grinding process produces uniform particle size.
3. The work index used is from the smallest possible value for work index since
there is no available literature relating the work index to the cassava peels,
pineapple pomace and ipil- ipil leaves and that is from the clay material, which
has a work index of 6.30 (McCabe, Smith, & Harriott, 2005).
4. The reduction ratio for cassava peels and pineapple pomace, DP/DF, is 40 (Kayode
Coke, 2007) since there is no known size for the two raw materials.
5. The mass flow rate for all the three is at the maximum capacity, 2 kg/s.
The raw materials will be reduced to particle size 1 mm which will be aided by
the hammer mill. These mills are applicable for materials with solid hardness, 1-3 moh.
Size reduction is basically employed to improve the mixing efficiency of ingredients in
the biomass. It would also allow an easier access of the nutrients for consumption of the
yeasts.
Figure 3.3.2.5: Energy balance around Grinder for CP and PP.

The equation applicable for this type of mill is shown in equation 1 (McCabe,
Smith, & Harriott, 2005).
51
P
=0.3162 W i
m
1
1
DP DF
Eq. 95
P= power kW
where
m
s =maximum capacity ,
max
tons
hr
D P = product mm
D F =feed mm
W i=work index of the material
For cassava peels and pineapple pomace:
From the assumed reduction ratio of 40 and a product size of 1 mm, the feed size is
calculated.
D P =Reductionratio ( D F )
DP =40 ( 1 mm )
D P =40 mm
Substituting the values,
P
=0.3162 W i
m
1
1
DP DF
P
=0.3162(6.30)
kg 3600 s
1 ton
2
s
hr
1000 kg
)(
( 11mm 401mm )
P=12.075 kW
P=12 kW
Thus, the power used for each of the grinding process of cassava peels and
pineapple pomace is 12 kW.
For the ipil ipil leaves:
52
Figure 3.3.2.6: Energy balance around grinder for IL.

The size of ipil ipil leaves ranges from 2 5 cm (Stuart, 2014). Taking the mean
of the highest and lowest value, the assumed size of ipil ipil leaves is 3.5 cm or 35 mm.
The same work index was used. The power needed for the grinding process is then
calculated.
P
=0.3162 W i
m
1
1
DP DF
P
=0.3162(6.30)
kg 3600 s
1 ton
2
s
hr
1000 kg
)(
( 11mm 351mm )
P=11.918 kW
P=12 kW
D. Mixer 1
The mixer 1 is used to mix the substrates and the mineral solution with water
before it goes to the fermenter. It has 40% solids, 55% water, and 5% mineral solution as
its feeds. The schematic presentation of the system is shown below.
53
Figure 3.3.2.7: Energy balance around Mixer 1.

From the composition of the feeds, which is 40% solids and 60% liquid, in the
mixer the mixture at hand can be considered to be a light paste. It can be noted then that
mixing is difficult to define and evaluate with solids and pastes than it is with liquids as
in the previous activities. (McCabe, Smith, & Harriott)
Based on literature and other references, the density of the solids, composed of
cassava peels, pineapple pomace, and ipil-ipil leaves is
solids =256.6991 kg /m
. Given
this information, the density of the slurry can then be determined by adopting the
calculation from EngineeringToolbox.com,
m=
cw
+
s
100
[ 100 c w ]
l
Eq. 123
where
3
m=density of slurry (lb /ft , kg / m )

c w =concentrationof solids by weightthe slurry ( )
s =density of the solids(lb / ft 3 , kg /m3) and is equal to 256.6991 kg/m3
l=density of liquid without solids(lb/ft 3 , kg /m3 ) (Slurry - Density)
Assumption:
54
1. The density of the liquid to be used is that of water since the mineral solution has
a negligible amount.
m=
100
[(
40
256.6991
m=463.34
kg
m3
[ 100 40 ]
999.98
kg
m3
kg
m3
The density of the mixture is 463.34 kg/m3. Thus, volume of slurry in the mixture
can be determined since the mass is given to be 23,606.09 kg,
=
m
V
Eq. 124
V slurry =
23,606.09 kg
kg
463.34 3
m
V slurry =50.95 m3
Typically, the working volume will be 70-80% of the total mixer volume. For the
study, a working volume of 70% is assumed.
V tank =
50.95 m 3
=72.78 m 3
0.70
It is predicted that the design of the mixer will be similar to that of a gate or
anchor paddle shown in Figure 2 below since it is applicable also for mixing of solids and
liquids. The paddle fills the tank completely and thus can scrape the solids stuck in the
walls of the tank.
55
Figure 3.3.2.8: Gate or anchor paddle(Geankoplis, 1993).

Since viscosity is needed to determine the Reynolds Number, Re, of the slurry, an
assumption or estimation is made. It is assumed that the slurry produced will have a
viscosity similar to that of ketchup or mustard. According to Viscosity Scales (Viscosity
Sales), the viscosity of peanut butter ranges from 150,000-150,000 cP as shown by the
Figure below.
Figure 3.3.2.9: Viscosity range of different products (Viscosity Sales).
56
The average of the range was taken to be used for the calculations.
150,000 cP+250,000 cP
2
=200,000 cP
Thus, the mixture has an estimated viscosity of 200,000 cP or 200 Pas.

In order to calculate for the tank height and diameter, the following assumptions
are made.
Assumption:
1. The height and diameter of the tank is similar,
2
H t =Dt
Dt H D t ( D t )
V=
=
4
4
V=
D3t
4
Dt = 3
Eq. 125
4 V 3 4 (72.78 m )
=
D t =4.52 m=H
For the agitator impeller diameter, it is said that Da
2/3
of tank diameter.
Thus,
2
D a= D t
3
Eq.126
2
D a= (4.52 m)
3
D a=3.01 m
57
Since no reference can be used for this type of system, it is assumed that the
agitator rpm is 30 rev/min.
N=30
rev
rev
=0.5
min
sec
Calculating for Reynolds Number, NRe, in order to determine the power number
NP using Figure 4 (Geankoplis, 1993).
'
N =
D2a N
Eq. 127
rev
kg
463.34 3
sec
m
200 Pa s
( 3.01 m)2 0.5

N '=
)(
N '=10.49 10
A red line is made to locate the curve and power number as shown in Figure 4
below.
Figure 3.3.2.10: Power correlations of various impellers and baffles (Geankoplis, 1993).
58
Since the impeller used is that of the gate paddle, the curve to be used here is only
assumed. It is assumed that Curve 4 is similar to the one used.
Thus, from the figure, the system has a power number of approximately 4.
Substituting to the equation to solve power requirement,
N P=
P
3 5
P=N P N Da
3
5
N Da
P=( 5 ) 463.34
Eq. 128
kg
rev 3 (
5
0.5
3.01 m )
3
s
m
)(
J
P=76,432.67 W =76.43 kW
s
P=76.43 kW
1 hp
=102.25hp
( 0.7475
kW )
The power requirement needed for operating this mixer is 102.25hp .

E. Mixer 2
The mixer 2 is used to mix water with the minerals in order to produce mineral
solution that is needed for the microorganisms to grow. From the material balance, the
solid component is just 5.6% of the total mixture while the liquid component, or water,
constitute to the 94.4%.
Since, the mixture in mixer 2 is mainly composed of water, the following
assumptions are made in order to compute for the power.
Assumption:
1. The density and viscosity of the mixture is that of water since the mineral solution
has a negligible amount. Thus, mixture = 999.98 kg/m3 and = 0.001 Pas
From the material balance, the total amount of mixture in the mixer is 1168.50 kg,
hence, the volume of the mixture can be determined.
59
m
V
Eq. 124
V mineral soln =
1168.50 kg
kg
999.98 3
m
V mineral soln =1.17 m 3
Typically, the working volume will be 70-80% of the total mixer volume. For the
study, a working volume of 70% is assumed.
V tank =
1.17 m3
=1.67 m3
0.70
It is predicted that the design of the mixer will be similar to that of a flat six
blade turbine with disk having four baffles each.
In order to calculate for the tank height and diameter, the following assumptions
are made.
Assumption:
1. The height and diameter of the tank is similar,
H t =Dt
2. The ratio of the agitator diameter to the tank diameter is 0.4. This is the average
geometric proportion from the range given in Table 3.4-1 in Geankoplis, 1993.
2
V=
D2t H D t ( D t )
=
4
4
D3t
V=
4
Dt =
Eq. 125
4 V 3 4 (1.67 m )
=
60
D t =1.29m=H
For the agitator impeller diameter, it is said that D a
0.4
of tank diameter.
Thus,
D a=0.4 D t
Eq.126
Da=0.4(1.29 m)
D a=0.516 m
Since no reference can be used for this type of system, it is assumed that the
agitator rpm is 30 rev/min.
N=30
rev
rev
=0.5
min
sec
Calculating for Reynolds Number, NRe, in order to determine the power number
NP using Figure 4 (Geankoplis, 1993).
D2a N
N =
Eq. 127
'
rev
kg
999.98 3
sec
m
0.001 Pa s
( 0.516 m )2 0.5
'
N =
)(
'
N =133,125.34
A red line is made to determine the curve and power number in Figure 3.3.2.10.
Since the impeller used is that of flat six blade turbine with disk having four baffles
each. It is said to be that Curve 1 is the one to be used. From the figure, the system has a
power number of approximately 4. Substituting to the equation to solve power
requirement,
N P=
P
P=N P N 3 D5a
3
5
N Da
Eq. 128
61
P=( 5 ) 999.98
kg
rev (
5
0.5
0.516 m )
3
s
m
)(
J
P=22.86 W =0.023 kW
s
P=0.023 kW
1 hp
=0.03 hp
( 0.7475
kW )
The power requirement needed for operating this mixer is 0.03 hp .
F. Fermentor
The fermentation process is shown below:
Figure 3.3.2.11: Energy balance around Fermentor.

Assumptions:
1. Heat for combustion for yeast is -21.2 kJ/kg (Doran, 1995). This is because at the
present time, the thermodynamic properties of cells cannot be found in literature
because cells are not pure substances. Cells also dont have finite enthalpy,
entropy and free energy of formation. In order to obtain the cellular enthalpy of
formation, it is necessary to measure the heat of combustion and to construct an
equation representing the combustion of a unit mass of cells (Kemp, 1999).
2. Agitation is minimal. Thus Ws = 0.
62
3. Evaporation is negligible. Thus, Mv = 0.

4. All the N-content of ipil ipil leaves and in the mineral solution are consumed in
the process as a source of NH3.
5. There is glycerol and water formed during the reaction, however, for glycerol,
ther was no literature available relating the production of biomass from the
substrates to the glycerol formed. Thus, it is assumed that the amount of glycerol
formed is minimal and negligible. For the water formed, it is assumed that the
change in the water content in the fermentation tank is negligible since during
fermentation, a large amount of water is added.
6. In the energy balance, only the glucose in the substrate is reacted and is accounted
and the biomass stated is the accumulated protein.
The chemical reaction for the fermentation process is given below:
Substrate + N H 3 Biomass +Glycerol+ Ethanol+C O2+ H 2 O
Since negligible glycerol and water produced, the chemical reaction becomes:
Glucose Substrate + N H 3 Biomass+C O2 + Ethanol
Eqn. *
In order to determine the amount of glucose present in the substrate, the glucose
in the cassava peels and pineapple pomace are calculated. From the material balance, it is
known that the feed that is introduced in each fermenter is 394 kg and contains 137.55 kg
cassava peels and 137.55 kg pineapple pomace. Hence, the amount of glucose in each
fermenter is calculated.
For the glucose in the cassava peels (CP), according to literature, cassava peels
contain 51.93% starch. Thus, the amount of starch is given by:
mstarch=mCPsubstrate ( starch )
mstarch=4,089.76 kg CP
( 0.5193kgkgCPstarch )
mstarch=2123.81 kg starch
In order to calculate the amount of glucose from starch, the equation is given by:
63
mglucose =
mstarch
0.9
Thus, the amount of glucose can be calculated below:

mglucose =
2123.81kg starch
0.9
mglucose =2359.79 kg glucose

For the glucose in the pineapple pomace (PP), according to Correia, Magalhes,
& Macdo, 2007, pineapple pomace contain approximately 27.2% glucose. Thus, the
amount of glucose from the pineapple pomace can be calculated and is given by the
equation below:
mglucose =mPP substrate ( glu cose )
mglucose =4,089.76 kg PP
( 0.272kgkgPPglucose )

Adding the two values to calculate the total amount of glucose present in the
substrate:
glucose
glucose
mtotal glucose =m CP + m PP
mtotal glucose =2359.79 kg glucose+1112.41kg glucose
mtotal glucose =3472.20 kg glucose

For the amount of NH3 in the fermentation process, it is assumed that the NH 3 is
obtained from three different sources: ipil ipil leaves, cassava peels and mineral
solution. According to Abdullah & Hossain, 2006, ipil ipil leaves contain 4.3% nitrogen
(N) and from Ismadji, Ju, Chun, Kurniawan, & Ong, 2012, cassava peels contain 1.2% N.
Also, in the mixer 1, a mass of 1.179 kg of (NH4)2SO4 is added.
Hence, in order to calculate the number of moles of NH3, it is given by:
For the NH3 in CP:
64
n N H =mCP ( N )
3
NH
() 1 mol
1 mol N )
1
MW of N
n N H =4,089.76 kg CP
3
kg N 1000 g 1mol N
( 0.012
kg CP )( 1 kg )( 14.01 gN )(
1 mol N H 3
1mol N
n N H =3503.01mol N H 3
3
For the NH3 in IL:

n N H =mIL ( N )
3
( MW1of N )(
n N H =1,168.50 kg IL
3
1 mol N H 3
1 mol N
0.043 kg N
kg IL
)(
1000 g
1 kg
)(
1mol N
14.01 gN
)(
1 mol N H 3
1mol N
n N H =3586.40 mol N H 3
3
For the NH3 in the mineral solution:

n N H =m(NH 4 )2 SO 4
3
n N H =35.06 kg
3
1000 g
1 kg
)(
1
(
MW of NH 4 ) 2 SO 4
)(
1 mo l ( NH 4 ) 2 SO 4
1000 g
1 kg
32.065 g ( NH 4 ) 2 SO 4
n N H =2186.81mol N H 3
3
Adding the three values:

n N H =3503.01mol +3586.40 mol+2186.81 mol
3
n N H =9276.22 mol N H 3
3
The mass of the NH3 produced is equal to:

mN H =9276.22 mol N H 3
3
g
1kg
( 17.034
)(
1 mol
1000 g )
mN H =158.01 kg N H 3
3
65
NH
() 1mol
1 mol N )
)(
2 mol N
1 mol ( NH 4 ) 2 SO 4
)(
1 mol N H 3
2 mol N
1 mol N
1 mol ( NH 4 ) 2 SO 4
)(
In the fermentation process, it is assumed that not all glucose in the substrate is
consumed. From the material balance, it is determined that the amount of accumulated
biomass, ethanol and carbon dioxide are 118.03 kg, 542.94 kg and 542.94 kg
respectively. Hence, the amount of glucose consumed is calculated using the material
balance around the fermenter and is given by:
m=mout
mglucose + m N H =mbiomass + methanol+ mCO
3
mglucose + 158.01kg=118.03 kg+542.94 kg +542.94 kg

In order to calculate the percent of glucose reacted or consumed, it is given by:
glucose reacted=
mglucose consumed
100
mtotal glucose
glucose reacted=
1045.90 kg glucose
100
3472.20 kg glucose
glucose reacted=30.12
For the energy balance for the fermentation process, it is adapted in the book of Doran
and is given below:
H rxnM v hv Q+W s=0
Eq. 98
Since Mv = 0 and Ws = 0, the equation becomes:

H rxnQ=0
H rxn=Q
The Hrxnis the heat of combustion reaction for the chemical reaction below:
Glucose+ N H 3 Biomass+ Ethanol+C O2
Thus, the heat of combustion is given below:
66
Eq. 99
H rxn=m( hc )products m( hc )reactants
The heats of combustion in the fermentation process are given below:

kJ
( h c ) glucose = 2,805.0 gmol

kJ
( h c ) N H = 382.6 gmol
3
g
kJ
=22,505.88
)( 117gmolg )( 1,000
)
kg
kg
kJ
g
kJ
=15,583.33
)( 1180gmolg )( 1,000
)
kg
kg
( h c ) ethanol= 1,655.4 gmol
g
kJ
=17,993.48
)( 192gmolg )( 1,000
)
kg
kg
kJ
( h c ) protein/ yeast =21.2 kg

( h c ) carbondioxide =0
Thus, the heat of reaction can be calculated below:
H rxn=m( hc )products m( hc )reactants
mglucose + 158.01kg=118.03 kg+542.94 kg +542.94 kg
H rxn= 118.03 kg 21.2
][
kJ
kJ
+ 542.94 kg ethanol 17,993.48
+542.94 kg C O 2 ( 0 ) 1045.90 kg glu
kg
kg
H rxn=10,082,876.68 kJ
Thus, Q =
10,082,876.68 kJ for each fermenter. This means that the heat
should be removed in the fermentation. Thus, cooling water must be supplied during
fermentation to maintain the condition at 30C. The equation is given by:
Q=m cooling water c p T
Eq. 100
From heuristics, it is found out that the maximum T for cooling water is 30F. It
is assumed that the temperature of the entering cooling water is 20C 68F and the
67
temperature of the exiting cooling water is the same as the fermenters temperature,
which is 30C 86F. Hence, it gives a T of 10C / K or 18F. Also, from the table of
the properties of water, it is obtained that the cp,water = 4.187 kJ/kgK using interpolation at
the temperature of 20C. Thus, the mass of the cooling water can now be computed.
Q=m cooling water c p T
10,082,876.68 kJ =m cooling water 4.187
kJ
( 10 K )
kgK
mcooling water =240,813.87 kg cooling water
Therefore, for each fermenter in one batch, the amount of cooling water needed is
240,813.87
kg. On an hourly basis, it can be computed since one batch of
fermentation would consume approximately 3 days.

mcooling water =
240,813.87 kg cooling water 1batch

batch
3 days
mcooling water =3344.64
kg
cooling water
hr
mcooling water =3344.64
kg
1 hr
cooling water
hr
60 min
)(
)( 241day
hours )
1m3
999.97 kg
L
1 gal
)( 1000
(
)
3.785412
L)
1m
3
mcooling water =14.73 gpm cooling water

K. Filter Press
For the solid liquid separation of the product produced after fermentation, a filter
press is used. There is no definite equation to solve the power requirement for the filter
press. Thus, the power requirement is achieved through a design specification. The filter
press to be used is Outotec Larox FFP 2 512. From the design specification, it is desired
to separate a filter volume of 14.29 m 3 and the equipment has a filter volume range of 5.4
68
15.4 m3, that is why, the equipment is appropriate for the desired solid liquid
separation. Hence, for this type of equipment, the installed power (hydraulics) is 90 kW,
which is given from the design specification (Outotec Larox, 2013).
L. Pelletizer
In pelletization, biomass is compressed against a heated metal plate (known as die)
using a roller. The die consists of holes of fixed diameter through which the biomass
passes under high pressure. Due to the high pressure, frictional forces increase, leading to
a considerable rise in temperature. High temperature causes the lignin and resins present
in biomass to soften which acts as a binding agent between the biomass fibers. This way
the biomass particles fuse to form pellets.
The rate of production and electrical energy used in the pelletization of biomass are
strongly correlated to the raw material type and processing conditions such as moisture
content and feed size. The average energy required to pelletize biomass is roughly
between 16 kWh/t and 49kWh/t. During pelletization, a large fraction of the process
energy is used to make the biomass flow into the inlets of the press channels. (Zafar,
2014)
Assumptions:
1. The pelletizer applicable to this process operates between 16 kWh/t to 49kWh/t.
Solution:
Take average energy of pelletizer,
E=
( 16+ 49 ) kWh /t
2
E=32.5 kWh/t
Multiplying the amount of feed (from material balance) injected to the pelletizer,
69
Energy requirement=32.5
kWh 1 ton
( 10,000 kg )
t 1000 kg
Energy requirement=325 kWh

In the pelletizer, it is specified to have a total time of 1 hour in its operation. Thus,
calculating the energy requirement in kW:
Energy requirement =325 kWh(1 hr )
Energy requirement =325 kW

M. Tunnel Dryer
In drying the final output after filter press, the pellets are discharged into a screen
belt of a horizontal tunnel drier. In this dryer, the materials to be dried are sent to the air
heated tunnel for drying purpose. The material will enter at one end and the dried
material is collected at the other end of the tunnel. The outgoing material meets the
incoming air to ensure maximum drying and the outgoing air contacts the wettest
material so that the air was as nearly saturated as possible (Islam, 2012).
The tunnel dryer used has a 1.2 m width, 8 m drying section length and a 10 80
mm thickness of material covered. It operates at a temperature of 60 100C having a
steam pressure of 0.2 0.8 MPa. The steam consumption is 120 300 kg/h. The power
required for the blower is 9.9 kW and the power required for the equipment is 11.4 kW
(Zhengzhou Bangke Machinery Manufacturing Co., Ltd., 2014).
ii. Utilities
a. Pumps
Cooling Water Pump
Assumptions:
1. A 2 in. Schedule 40 nominal size for the pipe was used.
2. An elevation of 50 ft was used.
3. The efficiency of the pump is 40%.
70
From the energy balance around the fermenter, the volume flow rate of the
cooling water is obtained. It has a value equal to 31.52 gpm. Converting the value into a
unit of ft3/s:
gal 1min
1 ft 3
VFR=14.73
min 60 sec 7.481 gal

VFR=0.0328
ft 3
s
From the assumed size of the pipe, the cross sectional area of the pipe is
0.02330 ft2. Having the cross sectional area, the velocity of the cooling water is given
by:
v=
VFR
A
3
ft
s
v=
0.02330 ft 2
0.0328
v =1.41
ft
s
Using the overall mechanical energy balance:

2
Eq. 101
v
g p
+ z +
+ F=W s
2 gc
gc
For the kinetic energy:
ft 2
s
v2
=
2 gc
lbm ft
2 32.174
lbf s 2
1.41
v2
lbf ft
=0.031
2 gc
lbm
For the potential energy:
71
ft
g
s2
z =50 ft
gc
lbm ft
32.174
2
lbf s
32.174
g
lbf ft
=50
gc
lbm
For the friction losses inside the pipe:
For the friction loss in pipe fittings:

Assumptions:
1. Use 1 90 elbow
2. Use 1 gate valve
The Kf for a 90 elbow is equal to 0.75. Hence, the friction loss for the 90 elbow
is calculated.
Eq. 102
( )
v
h f =K f
2 gc
ft 2
s
h f =0.75
lbm ft
2 32.174
lbf s2
h f =0.023
1.41
lbf ft
lbm
The Kf for the gate valve is 0.17. Thus, the friction loss due to the use of gate
valve is obtained.
2
v
h f =K f
2 gc
( )
ft 2
s
h f =0.17
lbm ft
2 32.174
lbf s2
3.014
]
72
h f =0.005
lbf ft
lbm
For the friction loss in the 2 in. pipe:

Assumption:
1. Commercial steel pipe is used.
2. The length of pipe is 150 ft.
Calculating the Reynolds number for the cooling water:
N =
Dv
Eq.103
At a temperature of 25C, the density of water is 62.2477 lb m /ft3, its viscosity is

6.00539589x10-4lbm / fts and the inner diameter of the pipe is 2.067 in
(Geankoplis, 1993). Thus, the Reynolds number is obtained.
Dv
N =
2.067
ft
lbm
ft )(1.41 ) 62.2477
(
(
12
s
ft )
N =
3
6.00539589 104
lb m
fts
N =25,174.45
For a commercial steel pipe, the equivalent roughness is equal to 4.6x10-5m or
1.509186352x10-4-ft (Geankoplis, 1993). Computing the relative roughness:
1.509186352 104 ft
=
D
2.067
ft
12
=8.7616 104 =0.00087616

D
For an NRe of 25,174.45 and a relative roughness of 0.00087616, the friction
factor from Fig. 2.10-3 is f = 0.006. The friction loss is calculated and is given by:
F f =4 f
L v2
D 2 gc
Eq. 104
73
ft
s
150 ft
F f =4(0.006)
2.067
lbm ft
ft 2 32.174
12
lbf s 2
F f =0.646
1.41
)(
lbf ft
lbm
Thus, the total friction loss can be calculated.
F=0.023
lbf ft
lbf ft
lbf ft
+ 0.005
+0.646
lbm
lbm
lbm
F=0.674
lb f ft
lbm
For the pressure difference:

In order to calculate for the pressure difference, the pressure head was used. A
table is found in Static Pressure and Pressure Head in Fluids, 2014 where velocity, in ft/s,
corresponds to the certain pressure head of water, in ft. The table is shown below:
Since the calculated velocity is 1.41 ft/s, the value of the pressure head is
interpolated from the table given. The value for the pressure head of water is 0.03158 ft.
The pressure difference is calculated using the equation below:
p2 p1=
gh
gc
Eq. 105
74
lb m
ft
62.2477
32.174
(0.03158 ft )
(
)(
ft
s )
p=
3
32.174
p=1.966
lbm ft
lbf s2
lb f
f t2
The shaft work for the pump can be calculated.

v2
g p
+ z +
+ F=W s
2 gc
gc
0.031
lbf ft
lbf ft
+50
+
lbm
lbm
W s=50.74
1.966
lb f
f t2
lbf ft
+ 0.674
=W s
lb m
lbm
62.2477 3
ft
lbf ft
lbm
Calculating the mass flow rate of the cooling water:

m=VFR
lb m
ft 3
m=0.0328
62.2477 3
s
ft
m=2.04
lb m
s
Calculating the shaft work in lbf /fts:

W s=50.74
lb
lbf ft
2.04 m
lbm
s
W s=103.51
lbf ft
s
Calculating the work needed for the pump:
75
W p=
W s
lbf ft
s
0.40
103.51
W p=
W p=258.77
lbf ft
s
Thus, the work can be calculated in hp.

W p=258.77
lbf ft
1hp
lbf ft
550
s
W p=0.47 hp=0.35 kW
Slurry Pumps (for slurry materials)

Pumping slurry materials is more difficult than pumping liquid materials. One
type of pump that aids the pumping of slurry is slurry pump. These are which are capable
of handling tough and abrasive materials. The determination of the power requirement of
the slurry pump is constrained by the limited data available for the pump. However, it
was determined that the standard power requirement for slurry pumps having a RPM of
1455 is 16 kW. A total of eight (8) slurry pumps will be used in the system. (Filter
Sterilization Guide: Steam Sterilization & Alternative Methods)
b. Screw Conveyor
Eq.
hp=106 ( ALN +CWLF )

where
A=sizefactor=54
L=conveyorlength
N=conveyor (rev /min)=( 154 mm ) 100 rev / min

C=quantityofmaterialhandled=10,000 kg410.056 f t 3
76
W =densityofmaterial=53.764 lb/ f t
F=materialfactor=0.5
=90 efficiency
Assumption:
6
hp=10
( 54 )
L=50 m62500 /381 f t

rev
ft 100
+ ( 410.056 f t ) 53.764
ft ( 0.5 )
( 62500
( flbt )( 62500
]
381 )(
min )
381 )
3
hp=2.694 hp
hp 2.694 hpor 2.01 kW
With respect to efficiency,

W required =
W required =
2.694 hp
0.9
W required =2.99 hp2.23 kW
c. Belt Conveyor
Discharge Belt Conveyor in the Washer
Assumption:
Length: 5-20 feet, assumed to be 15 ft
hp=(C /100)( 0.4+0.00345 L)
where
L=distance conveyor centers ( ft )=15 ft

C=quantity of material=6,252.78 kg6.253 ton
77
W =width of belt conveyor =30.

Empty: 1.2 hp
To move the load: 0.10 hp
Thus,
Total hp=1.2 hp+0.028 hp
Total hp=1.228 hp=0.916 kW
d. Air Heater
For the air heater, the following equation is used to calculate for the required
heating capacity (Chromalox Precision Heat and Control).
H=H Total SF
Eq. 106
where: HTotal = total heat required for drying

SF = safety factor
For this, it is assumed that the heater has a safety factor of 20%. The total heat required
for drying is 412.61 kW. Thus, the heating capacity can be obtained.
H=H Total SF
H=229.98 kW 1.2
H=275.98 kW
e. Compressor
For the Air for Drying:

Assumption:
1. p2 = 151.99 kPa and p1 = 95.36 kPa
2. An adiabatic compression is assumed.
3. Efficiency, = 0.70
The mass of total air is expressed in kg/s using a drying time of 1 day or 24 hrs
and is shown below:
78
m=
210,028.54 kg
1hr
48 hrs
3600 s
m=1.215
kg
s
Calculating for the heat capacity of air having a humidity of 0.05 kg water
vapor/kg dry air:
c p=1.005+1.88 ( H )
c p=1.005+1.88 ( 0.05 )
c p=1.099
kJ
kg dry air K
The heat capacity is expressed in J/molK using a molecular weight of air to be 29

kg/kgmol.
c p=1.099
kJ
kg
29
kg dry air K
kgmol
c p=31.871
kJ
kgmol K
The ratio of heat capacities, , is then calculated.

=
cp
c
= p
c v c p R
Eq. 107
31.871
=
31.871
kJ
kgmol K
kJ
J
1 kJ
8314.34
kgmol K
kgmol K 1000 J
=1.353
Thus, the shaft work can be calculated.
79
R T1
W s=
1 M
W s=
[( ) ]
p2
p1
Eq. 108
(8314.34 kgmolJ K ) (120+ 273.15 ) K
1.353
1.3531
kg
29
kgmol
W s=55,872.25
[(
151.99 kPa
95.36 kPa
J
kg
Calculating the brake power:

brake kW=
W s m
1000
J
kg
1.215
kg
s
J
0.70 1000
kJ
55,872.25
brake kW=
brake kW=96.98 kW
It can also be expressed as brake hp and is given by:

brake hp=96.98 kW
1 hp
0.74570 kW
brake hp=130.05 hp
f. Blower (for Washer)

Assumptions:
Air flow rate is 1/2 of mass flowrate of water (10 m3/hr).
Standard air density: 1.2007 kg/m3
Adiabatic compression occurs.
Mechanical efficiency of blower is 70%.
5. =1.40 for air (Geankoplis, 1993).
1.
2.
3.
4.
80
1.3531
1.353
M =28.97
6.
kg
kmol
for air.
Calculation:
1
1
kg
kg
kg
mair = m = 10,000
=5,000 =1.39
2 HO 2
hr
hr
s
Equation to use,
RT 1
W s=
1 M
[( ) ]
p2
p1
(Eqn. *)
Determine p1 (absolute initial pressure).

Manolo Fortich is located 509 m above sea level (www.maps-streetview.com,
2011), calculating for initial pressure (atmospheric),
5.25588
p1=101,325 ( 12.25577 x 105 h )

509 m
5
5.25588
12.25577 x 10 ( )
p 1=101,325
p1=95,357.86 Pa
Determine p2 (absolute final pressure).
Assume p2 to be 101.325 kPa.
Substitute known values to equation above,
W s=
1.40
1.401
( 8,314.3 kmolJ K )(298.15 K )

kg
28.97
kmol
W s=5,237.02
Calculate power requirement (brake kW).
81
J
kg
[(
101.325 kPa
95.36 kPa
1.401
1.40
brake kW=
W s m
1000
(Eqn. *)
J
kg
5,237.02 )( 1.39 )
(
kg
s
brake kW=
0.70(1000)
brake kW=10.39 kW (13.93 hp)
3.4. Equipment Sizing and Specification

The section aims to present the equipment design and specification for the various
equipments involved in the production of high-value animal feeds from agro-industrial
wastes.
a. Dryer
For the study, two sets of drying procedure are to be conducted. The first drying is
done prior to fermentation. The second drying is then done in order to reduce the
moisture content of the final product to the desired value. The equipment specification of
the report will focus on the drying procedure of the raw materials prior to processing.
Moreover, the drying process is employed in batch condition. The figures below illustrate
the schematic diagrams of the drying procedure for each raw material used.
Figure 3.4.1: Schematic Diagram of the drying procedure for cassava peels.
82
Figure 3.4.2: Schematic Diagram of the drying procedure for pineapple pomace
Figure 3.4.3: Schematic Diagram of the drying procedure for ipil-ipil leaves
The drying procedure employed in the production of animal feeds would involve
the use of tray dryer as the drying equipment. In a tray dryer, the material is uniformly
spread on a metal tray. Heated air is then used as the heat-source for the system.
The material and energy balance are considered in the calculations of the design
parameters of the dryer. The data for this is given in Section 2 and 3 of this paper.
Moreover, for the equipment specification, the drying of the pineapple pomace is system
of interest. For the calculations, the following conditions are adopted:
Table 3.4.1: Drying Parameters
83
Drying Parameters
Inlet Temperature of air (C)
Outlet Temperature of air (C)
Inlet Temperature of solid (C)
Outlet Temperature of solid (C)
Inlet Humidity of air (kg moisture/kg DA)
Outlet Humidity of air (kg moisture/kg DA)
Values
120
57.7441
25
60
0.05
0.075
i. Calculating for humid volume, vH:

Using equation (Geankoplis 2003) given below, the humid volume can be
calculated.
3
Eq. 109
v H =(2.83 10 +4.56 10 H )T
v H =( 2.83 103+ 4.56 103 ( 0.05 ) ) ( 120+273 )
3
v H =1.2018
m
kg DA
ii. Calculating for the density of the air entering the system:
=
( 1+0.05 )
1.2018
=0.8737
kg
3
m
iii. Calculating for the mass velocity of air:

Assuming that the velocity of the air entering between trays is 2 m/s. the mass
velocity can then be calculated.
G=V i
Eq. 110
84
( ms )( 0.8737 mkg )
G= 2
G=1.7474
kg
m2 s
iv. Calculating for the heat transfer coefficient:

The heat transfer coefficient can be calculated using the equation (Geankoplis
2003) given below:
h=0.0204 G0.8
Eq. 111

kg
3600 s
h=0.0204 1.7474 2
1 hr
m s
h=22.31
0.8
W
2
Km
v. Calculating for the area between trays:

For the calculations, it is assumed that there are 24 trays available. Based on
energy balance, the amount of dry air is 210,028.54 kg. The area between the trays can
then be calculated using the equation (Geankoplis 2003):
A between trays=
amount of air enterin g per second per tray

air density velocity of air entering betweentrays
85
Eq. 112
210,028.54 kg dry air

48
kg
1h
24
h tray 3600 s
A between trays=
kg
m
0.8737 3 2
s
m
A between trays=0.02898
m2
m2
0.03
tray
tray
vi. Calculating for the width of the trays:

It is assumed that the distance between the trays is 3 cm. The width of the trays
can then be calculated.
W trays =
A betweentrays
distance between trays
Eq. 113
m2
tray
W trays =
0.03 m
0.03
W trays =1.00 m
vii. Calculating for the length of the trays
The calculation for the length of the trays was employed using the equation
(Geankoplis 2003):
T
( 2T w )
( T 1T w )
H Lt
=ln
G C s ( b W trays )
Eq. 114
86
It is known that the wet bulb temperature of the system is 48 C. Substituting known
values:
T
( 2T w )
( T 1T w )
G C s ( b W trays )
Lt =
ln
h
Eq. 114
where
C s=( ( 1.005+ 1.88 ( 0.05 ) ) 1000 )=1,099
Substitute to Eq. *,
0.03 m
1.00 m
()
kg
1.7474 2 (1,099)
m s
Lt =
Lt=5.1647 m 5.16 m
ix. Calculating for the depth of the tray:
In the calculation for the depth of the tray, the density of the material to be dried is
to be considered. For the system, the density of the pineapple pomace, cassava peels and
ipil-ipil leaves are 150, 862.5 and 265 kg/m3, respectively. 7,431.21 kg of pineapple
pomace, 5,684.35 kg cassava peels and 1,240.63 kg ipil-ipil leaves are introduced to the
drier. Moreover, it is assumed that two batches for drying will be employed. The volume
of the pineapple pomace per tray can be calculated.
Pineapple pomace:
87
7,431.21 kg
2
V pineapple pomace per tray =
24 trays per batch
V pineapple pomace per tray =1.0321 m
1
150
kg
m3
Cassava peels:
5,684.35 kg
2
V cassava peels per tray =
24 trays per batch
1
862.5
kg
m3
V cassava peels per tray =0.1373 m3

Ipil-ipil leaves:
1,240.63 kg
2
V ipilipil leaves per tray =
24 trays per batch
1
265
kg
m3
V ipilipil leaves per tray =0.0975 m3

The volume of the tray can then be calculated (adopting the conditions for pineapple
pomace). The tray is assumed to be 80% full, then, the tray volume is:
V tray =
1.0321m3
0.80
V tray =1.2901 m3
Therefore, the depth of the tray is:
88
D tray=
V tray
Ltray W tray
Eq. 115
Dtray =
1.2901 m
5.16 m1 m
D tray=0.2500 m 0.25 m=25 cm

Then, the depth of each material:
D material =
V material
Ltray W tray
Eq. 116
Pineapple Pomace:
3
D pineapple pomac e =
1.0321 m
5.16 m 1 m
D pineapple pomace=0.2000 m 0.20 m

Cassava peels:
3
D cassava peels =
0.1373 m
5.16 m 1 m
D cassava peels =0.0266 m 0.03 m

Ipil-ipil leaves:
3
D ipilipil leaves=
0.0975 m
5.16 m 1m
D ipilipil leaves=0.0190m 0.02 m
89
x. Calculating for the height of the dryer:

It is assumed that 0.15 m is the distance of the bottom of the drier to the nearest
tray and 0.15 is also the distance of the top of the drier to the nearest tray. It is assumed
that the distance between the trays is 0.03 m. The height of the drier can be calculated
using the equation:
Eq. 117
H dryer =( no . of trays depthof the trays ) + ( 11 distance between the trays ) +0.15(2)
H dryer =( 24 0.25 m ) + ( 11 0.03 m ) +0.30 m
H dryer =6.63 m
xi. Calculating for the length of the drier:
It is assumed that 0.15 m is the distance of the left side of the drier to the tray and 0.15
is also the distance of the right side of the drier to the tray. There is also an existing
distance between the two columns equal to 0.15. The length of the drier can be calculated
using the equation:
Ldryer= ( Number of columns width of trays ) +0.15+0.15+ 0.15
Eq. 118
Ldryer= ( 21 m ) +0.15+0.15+ 0.15

Ldryer=2.45 m
xii. Calculating for the width of the drier:
It is assumed that there are existing spaces around the dryer equal to 0.05 m. The width
can be calculated:
W dryer =length of trays+0.05+0.05
Eq. 119
W dryer =2.45 m+0.05+0.05
90
W dryer =2.55 m
xiii. Calculating for the area and diameter of the air inlet pipe:
The area of the bulk air in the inlet considering a bulk velocity of inlet air equal to 5
m/s:
210,028.54 kg air
1
1
1 hr
48 hr
m
kg
3600 s
5
1.7474 2
s
m s
A bulk air inlet =
A bulk air inlet =0.1391 m2 0.14 m2

Then, the diameter of the pipe can be calculated:
4
D bulk air inlet = A
1
2
4
0.14 m2
D bulk air inlet =
Eq. 120
1
2
D bulk air inlet =0.4222 m 0.42 m

Table 3.4.2: Equipment Specification Sheet for Tray Dryer
EQUIPMENT SPECIFICATION SHEET
Item Name
Tray Drier
Quantity
1
Project Description (i.e. pilot scale)
Industrial Scale
Function (i.e. reaction vessel)
Drier
Mode of Operation (i.e. batch)
Batch
TANK PARAMETERS
Orientation (i.e. horizontal)
Vertical
Dimensions: height, length, tangent-toLength = 2.45 m, Height = 2.45 m, Width
tangent, m
= 2.55 m
Design Temperature, C
>300C
Design Pressure, atm
>10 atm
MATERIALS OF CONSTRUCTION
91
Tank (i.e. Stainless Steel 316)

Stainless steel
Trays (i.e. Stainless Steel 316)
Stainless steel
Jacket Type (i.e. simple, no baffles)
FEED CONDITIONS
Inlet Temperature of air (C)
120
Inlet Temperature of solid ( C)

25
Inlet Humidity of air (kg moisture/kg
0.05
DA)
OUTPUT CONDITIONS
Outlet Temperature of air ( C)

57.7441
Outlet Temperature of solid (C)
60
Outlet Humidity of air (kg moisture/kg
0.075
DA)
TANK CAPACITY
3
Volume of drier, m
41.42
b. Electric Heater
For the design specification of the electric heater, the following conditions are
adopted:
Table 3.4.3: Electric Heater Conditions

Inlet
30
5
Temperature ( C)
Gauge Pressure (atm)
Energy Required (kW)
Air Velocity (m/min)
Outlet
120
18.4
90
Using the given conditions, the calculation was carried out.

i.
Calculation of the air flow inside the duct.

Using the equation taken from Tempco Guidebook to Duct forced air heater
design, expressed as:

CMM Density
kW =
Eq. 121
( mkg ) T
3
57.5
92
Rearranging,
CMM =
ii.
57.5kW
57.518.4
m3
=
=13.45
Density T 0.8737(12030)
min
Calculation of Standard cubic meter per minute

13.45P
274.15+30
1atm
SCMM =
T +274.15
where P = operating pressure, T = operating temperature (set at 121C)
13.455+1
30+ 273.15
1
m3
SCMM =
=62.09
121+273.15
min
iii.
Calculation of duct area.

The air velocity was calculated using the equation given below:
Air velocity=
SCMM
Duct cross sectional area
Eq. 122
Values for the air velocity inside the duct air heater system are obtained from Tempcos
guidebook to designing air heaters.
Rearranging this equation will give the following result:
m3
62.09
min
Are a duct=
=0.69 m2
m
90
min
Fixing one side of the duct to be equal to 0.5m, the width, the other side will simply be
the quotient of the area and the set dimension. Thus,
L=
iv.
0.69 m2
=1.38 m
0.5 m
Estimating the pressure drop of the air inside the duct.

To estimate the pressure drop of the fluid traveling inside the duct the following
diagram, taken from the guidebook, is used below.

93
Figure 3.4.4: Air Velocity versus Approximate Pressure Drop Graph

The pressure drop is estimated by intersecting the air velocity value with that of
the energy requirement operating line of the given system. A line going down the X-axis,
the pressure drop axis, is then made starting from the intersection formed and the value of
the pressure drop is obtained. It is found that the pressure drop is at 0.00135 kPa.
Table 3.4.5: Equipment Specification Sheet for Air Duct Heaters
Operating Conditions
5. ELEMENT DIAMETER:
1. APPLICATION (Describe in Detail):
11 mm
6. TERMINAL SEALS:Silicone Fluid (260 C)

7.TERMINAL BOX CONSTRUCTION:
This air duct heater is use to heat air that will be use as the
drying fluid for the drying operations of the cassava peel,
pineapple pomace, ipil-ipil leaves and the final animal feed
product in the animal feed production.
General Purpose
Moisture Resistant
Explosion Resistant
2.AIR FLOW:
62.09 cu.m/min
8. TERMINAL BOX MATERIAL: 316 SS
3.INLET AIR TEMPERATURE:
30 C
9.FLANGE MATERIAL:
4.OUTLET AIR TEMPERATURE: 120 C

5.OPERATING TEMPERATURE:
6.OPERATING PRESSURE:
7.
Indoor
304 SS
10. INSULATION HOUSING (Below Flange):

Yes
121 C
5 atm (gauge)
No
11. INSULATION HOUSING:
Outdoor
304 SS
94
316 SS
8.DUCT DIMENSIONS:
m
L : 1.38 m
9.AIR FLOW DIRECTION:
W:0.5
Upward
10. air velocity:
12. INSULATION THICKNESS: 89mm
90 m/min
Heater Specifications
1. RATING: Volts
240V
Phase
Kilowatts 18.4
2. HEATING ELEMENTS:
13. HEATER DIMENSION (mm):

A: 267
B: 508
C: 708
E: 88.9
F: 222.25
G: 304.8
H: 76
I: 152.4
Tubular(std)
14. OTHER SPECIAL FEATURES:
Tubular:
Corrosion Resistant
INCOLOY (STD)
304 Stainless Steel
15. PRESSURE DROP:
316 Stainless Steel
0.00135 kPa
Nichrome wire (80%Ni, 20%Cr)
4. HEATING ELEMENT WATT DENSITY:

20W/sq.cm.
D: 267
3.HEATING ELEMENT SHEATH MATERIAL:
Other (specify)
Other(Specify)
22W/sq.cm.
16.MODEL NO.:
*DE 101
30W/sq.cm.
Other(Specify)
5.NUMBER OF ELEMENTS:
18
* fictional
Mechanical Layout
Figure 3.4.6: Diagram for the duct (left) and schematic diagram of electric heater (right).
c. Mixer
95
The equipment specifications for the mixer were also solved in the energy balance
section. A summary of the specs are given in the table below and a mechanical layout of
the mixer follows.
Table 3.4.4: Equipment Specification Sheet for Mixer
EQUIPMENT SPECIFICATION SHEET
Item Name
Mixing tank
Quantity
1
Project Description
Industrial scale
Function
Mixing vessel
Mode of Operation
Batch
TANK PARAMETERS
Orientation
vertical
Shell
_______cylindrical______
Shell length, tangent-to-tangent, m
___________2____________
Diameter, m
4.40
Heads
Top (i.e. Dished, 2:1 Elliptical)
________Dished__________
Bottom
________Dished__________
48 [2]
1
pH range
13.7 [3]
MATERIALS OF CONSTRUCTION
Tank
Stainless Steel 316
Impeller
Stainless Steel 316
INSTALLATIONS
Agitation
Impeller Type (i.e. rushton)
Gate paddle
Number of impellers
1
Impeller Diameter, m
3.01
Motor Power, hP
102.25
Impeller speed, rpm
30
Jacket Type
simple, unbaffled
FEED/CONTENTS
Flowrate, kg/batch (Solids)
9,348.01
Initial Temperature, C
30
Flow, inlet
Top
Flowrate, kg/batch (Water)
12,583.52
Initial Temperature,C
30
Flow, inlet
Top
Flowrate, kg/batch (Mineral solution )
1,168.50
Initial Temperature, C
30
96
Flow, inlet
Top
OUTPUT
Flowrate, kg/batch
Final Temperature, C
Flow, outlet
23,606.09
30
Bottom
TANK CAPACITY
Volume of tank, completely full, m3
100
Mechanical Layout of the Mixer
Figure 3.4.7: Specifications of the mixer.
Figure 3.4.8: Specifications of the impeller.

d. Fermenter
The most important process in the production of high-value animal feeds is the
fermentation. The fermentation is employed in order to increase the protein content of the
substrate through the use of yeast. The enrichment is done through semi-solid state
fermentation. In this process, the substrate contains 55% water. Two fermentation setups
97
are to be employed for the process. Both setups will have the same amount of substrate
and starter culture.
For the design of the fermenter that is implemented in the study, it is shown in the
figure below:
Figure 3.4.9: Design of a Fermenter

The total volume occupied by the materials is shown below:
Thus, the total volume occupied by the materials needed or the working volume
can be calculated using the density of the mixture equal to 463.34 kg/m 3. Considering
two fermenters will be used:
V working =
mass os substrate
density of substrate
23,606.09 kg
2
V working =
kg
463.34 3
m
V working =25.47 m 3
98
Typically, the working volume will be 70-80% of the total fermenter volume. For
the study, a working volume of 70% is assumed. Thus, the total fermenter volume is
calculated below:
V Total =
V Working
0.70
Eq. 129
25.47 m3
V Total =
0.70
V Total =36.38 m
The headspace volume is thus equal to 10.91 m3.

From the geometric proportions of a standard agitation system (Geankoplis, 1995)
as shown in the table 4.4, the measurements are calculated.
The figure below shows the schematic of the agitation system:
Figure 3.4.10: Schematic Diagram of the Agitation System
In calculating the tank diameter:
V Working=
2
D H
4 t
Eq. 130
99
Since H = Dt, thus, the equation becomes:

V Working=
3
D
4 t
36.38 m3 = D t3
4
D t =3.59 m
Thus, H = 3.59 m.
For the impeller diameter, Da, a Da/Dt = 1/3 is assumed.
Da 1
=
Dt 3
1
D a= D t
3
1
D a= ( 3.59 m )
3
Da=1.2 m
To calculate for W:
W 1
=
Da 5
1
W= Da
5
1
W = (1.2 m )
5
W =0.24 m
To calculate for Dd:
Dd 2
=
Da 3
100
2
Dd = Da
3
2
D d = ( 1.2m )
3
D d =0.8 m
To calculate for L:
L 1
=
Da 4
1
L= Da
4
1
L= ( 1. 2m )
4
L=0.3 m
To calculate for C:
C 1
=
Dt 3
1
C= Dt
3
1
C= ( 3.59 m)
3
C=1.2 m
To calculate for J:
J
1
=
Dt 12
J=
1
D
12 t
101
J=
1
(3.59m)
12
J =0.3 m
In calculating the total height of tank:
V Total =
Ht=
Ht=
2
D H
4 t t
Eq. 131
V Total
2
D
4 t
36.38 m 3
(3.59 m)2
4
H t =3.59m
For the power requirement of the agitated vessels, the viscosity of the slurry
assumed is 200 Pas. The turbine is assumed to be operated at 60 rpm or equal to 1 rev/s
since minimal agitation is needed.
'
N =
D2a N
( revs )( 463.34 mkg )
( 1.2 m)2 1
'
N =
200 Pa s
N '=3.34 3
Using curve 1 (for flat six blade turbine with disk) in figure 3.4-4, the N p = 17 for
'
N =3 . Solving for P using equation (3.4-2) and substituting known values, the power
requirement is obtained.
102
N P=
P
N 3 D 5a
P=N P N 3 D 5a
kg
rev 3 (
5
P=(17) 463.34 3 0.5
1.51 m )
s
m
)(
J
P=7,729.36 =7.73 kW=10.36 hp
s
For the material used, the inner cylinder will be stainless steel and the outer
cylinder will be made of glass.
e. Filter Press
Initially, the volume of the filtrate is to be determined. Using the data specifically
the density and the mass of the filtrate, the volume of the filtrate can then be calculated.
The density of the filtrate is taken to be 999.98kg/m 3 and the mass of the filtrate cake is
14,285.71 kg.
Figure 3.4.11: Schematic Diagram of Filter Press

V filtrate =
mas s filtrate
filtrate
103
V filtrate =14,285.71 kg
1
999.98 kg
m3
V filtrate =14.29 m3
Then the ratio of the mass of the dry cake and the volume of the filtrate is
determined.
C s=
14,285.71 ( 0.65 )
14.29
C s=649.80
kg solid
m3 filtrate
The specific cake resistance is then calculated:

=4.37 109 ( p )0.3
=4.37 109 (101.325 )0.3
=1.387 1011
It is required to determine the total effective filtration area for the further
calculations of the design specification of the filter press. Considering that the material to
be used is cast iron, the effective filtration area per chamber can be determined.
Assuming the size of the filter plate to be 1 000 mm, the effective filtration area is 1.74
m2.
104
Figure 3.4.12: Area and Cake Capacity of Various Sizes of Plate and Frame Filters
\
It is also assumed that there will be 30 plates, then the total effective area of the
filter press is:
A=effective filtrationarea number of plates
A=1.74 m2 30
A=52.2 m 2
Calculating for the constant, KP
K P=
C s
2
A ( P)
Assuming that the viscosity of the filtrate is 805.75 x 10-6 Pa.s,

52.2 m
6
( 805.75 10 ) ( 1.387 1011 ) (649.80)
K P=
105
K P =263.03
s
6
m
For constant pressure filtration, the filtration time required is calculated using the
equation:
tf=
KP 2
( V ) + BV
2
It is assumed that the filtration time is approximately 8 hours. Thus the value for B can be
calculated:
B=
tf
KP 2
(V )
2
V
3600 s 263.03
8 hrs
( 14.29 m )
(
1 hr )
2
B=
3 2
14.29 m
B=136.05
Calculating for the filtration rate:
K
( P+V )+ B
1
dV 1
=
dt 4
dV 1
1
=
dt 4 ( 263.03+14.29 ) +136.05
dV
m
=6.05 104
dt
s
f. Storage Tank
106
Storage tanks are necessary in order to store the raw materials prior to mixing in
the mixing tank. Three storage tanks are requires, one for each agro-industrial waste. For
the volume of the agro-industrial wastes:
Cassava Peels
V cassava peels =4,089.76 kg CP
m3
862.5 kg
V cassava peels =4.74 m3 CP

Pineapple Pomace
3
V pineapple pomace=4,089.76 kg PP
m
150 kg
V ineapple pomace=27.26 m3 PP
Ipil-ipil leaves
m3
V ipilipil leaves=1,168.50 k g IL
265 kg
3
V ipilipil leaves=4.41 m IL
For the working volume of each tank, it is assumed that the raw materials occupy 70% of
the tank, thus,
Cassava Peels
3
V working volume CP ST =
4.74 m
0.7
V working volume CP ST =6.77 m3

Pineapple Pomace
27.26 m
V working volume PP ST =
0.70
107
V working volume PP ST =38.94 m
Ipil-ipil Leaves
V working volume IL ST =
4.41 m3
0.70
3
V working volume IL ST =6.30 m
It is assumed that the height of the tank is 3 m, thus the surface area of each tank will be:
Cassava Peels
A working CP ST =
6.8 m3
3m
A working CP ST =2.27 m
Pineapple Pomace
39 m3
A working PP ST =
3m
A working PP ST =13 m
Ipil-ipil Leaves
A working IL ST =
6.8 m 3
3m
A working IL ST =2.27 m
108
CHAPTER FOUR
Economic Analysis
Profitability measures play a crucial role throughout the design process since it
helps the design team select the best design alternatives. This chapter presents the
economic analyses of the feasibility of the plant. In this study, the cost estimation of the
equipment involved in the plant were based from method of Guthrie preliminary design
cost estimations, Lang factors and from credible equipment suppliers in the market.
4.1 Equipment Costing
Expenses of a plant significantly include installation and purchase of equipment.
These values are usually accounted in the total capital investment of the plant and part of
the profitability analysis. Presented in Table 4.1 is the total purchase cost of the major
equipment by the plant. A detailed calculation follows for each equipment follows.
Table 4.1. Total purchase cost of major equipment units.
Equipment
Washer
Dryer
Eleactric Duct Heater
Belt Conveyor
Hammer Mill
Storage Tank
Mixing Tank 1
Fermenter
Filter Press
Pelletizer
Screw Conveyor
Pumps
Cooling Tower
TOTAL
Amount (Php)
244,772.00
409,507.00
182,118.72
1,732,275.00
8,336,895.28
8,954,732.74
34,227,354.58
53,244,076.37
5,426,712.44
5,695,880.61
307,075
793,410
1,189,945
120,744,754.73
Based on literature, the CEPCI index for the base year to be used in this study is
394. On the other hand, the CEPCI used is 580.2 based on 2014 (Chemical Engineering
Plant Cost Index (Cepci), 2015). It is also assumed in the calculations presented in this
109
paper that $ 1=44.20 Php
based on January 31, 2015 (XE Currency Converter, 2015).
From this, the total permanent investment (fixed capital investment, without the
working capital) and total capital investment of the proposed design can be obtained
using the equation below from (Seider, Seader, & Lewin, 2010).
CTpI =1.05 f L
TPI
CTCI =1.05 f L
TCI
Ii
C
Ib P
( )
Ii
C
Ib P
( )
Thus, to obtain the total capital investment, the present cost of each equipment
must be obtained and then summed and multiplied to the appropriate Lang factor and to
1.05. For this study,
f L =4.9
TCI
as given in the table below.
Therefore, the total capital investment of the project can be calculated if

the total purchase cost of equipment is considered,
CTCI =1.05 ( 4.9 ) (total purchase cost of major equipment)
110
Php
CTCI =1.05(4.9)
CTCI =Php
120,744,754.73
621,231,763.09
4.1.1 Washer
A good equipment in the cleansing of the cassava peels would use a rolling drum
brush washing equipment. The high-pressure sprinkles and the rotating brushes of the
equipment are the ones responsible for the cleaning of the peelings from mud and debris.
However, the required throughput required for the equipment is higher compared to the
raw material input (Equipment Input > 350kg/day) of the plant and the cleaning of the
peels is not completely guaranteed to totally remove the mud on it, thus it is advisable
that manual cleaning of the cassava peels be implored instead. Based from the
Department of Labor and Employments (DOLE) current minimum wage matrix for an
agricultural labor classified as category 3 (Bukidnon area: Valenica, Manolo Fortich) the
minimum wage of a worker is set at 284 Php/day for region 10 as shown in the figure
below. This is effective as of January 21, 2015.
Table *. Minimum wage rates for Region 10 with respect to sector and category (Bureau
of Labor and Employment Statistics, 2015).
For this particular processing step the total number of workers that the plant
would be employing is 10 individuals. This would total to a labor cost of
111
Php2,840 /day . This means that for a year the plant will have an annual labor cost, for
the washing process, of Php 1,931,200/yr.
For washing the cassava peelings a total number of 20 workers, each having a
quota of 12.5 kg of cassava peels per day would give a total wage of 5,680 Php/day.
4.1.2 Air Dryer
Drying is employed in order to remove excess moisture content from the raw
materials before fermentation. For the production of high-value animal feeds, air is used
as drying medium in a tray dryer. Based on the design specification, the following
specifications were determined:
Table 4.1.2 Specifications for Air Dryer.
Item Name
Quantity
Mode of Operation (i.e. batch)
Orientation (i.e. horizontal)
Shell (i.e. cylindrical)
Dimensions: height, length, tangent-totangent, m
Diameter, m
Tank (i.e. Stainless Steel 316)
Jacket (i.e. Stainless Steel 316)
Support (i.e. Saddles, Carbon Steel)
Trays (i.e. Stainless Steel 316)
Volume of drier, m3
Tray Drier
1
Batch
Vertical
Length = 3.91 m, Height = 4.23 m, Width
= 9.03
>300C
>10 atm
Stainless steel
Stainless steel
149.35
The present purchase cost can be calculated.

$ 5189 . 72
( 580.2
325 )
C2 =
C2 =$ 9,264.85=Php 409,507
4.1.3 Electric Duct Heater
112
This section will discuss the cost estimation for an electric heater.
Operating Conditions
5. ELEMENT DIAMETER:
6. TERMINAL SEALS:
Fluid (260 C)
1. APPLICATION (Describe in Detail):
11 mm
Silicone
7.TERMINAL BOX CONSTRUCTION:

This air duct heater is used to heat air that will be
utilized as the drying fluid for the drying operations
of the cassava peel, pineapple pomace, ipil-ipil
leaves and the final animal feed product in the animal
feed production.
General Purpose
Moisture Resistant
Explosion Resistant
2.AIR FLOW:
36.33 cu.m/min
8. TERMINAL BOX MATERIAL: 316 SS
3.INLET AIR TEMPERATURE:
30 C
9.FLANGE MATERIAL:
4.OUTLET AIR TEMPERATURE:
55 C
10. INSULATION HOUSING (Below Flange):
5.OPERATING TEMPERATURE:
58 C
6.OPERATING PRESSURE:
7.
Yes
5 atm (gauge)
Indoor
12. INSULATION THICKNESS: 89mm
90 m/min
Heater Specifications
1. RATING: Volts
240V
Phase
Kilowatts 18.4
2. HEATING ELEMENTS:
13. HEATER DIMENSION (mm):

A: 267
B: 508
C: 708
E: 88.9
F: 222.25
G: 304.8
H: 76
Tubular(std)
14. OTHER SPECIAL FEATURES:
Tubular:
Corrosion Resistant
INCOLOY (STD)
304 Stainless Steel 15. PRESSURE DROP:
316 Stainless Steel
0.00135 kPa
Nichrome wire (80%Ni, 20%Cr)
16.MODEL NO.:
4. HEATING ELEMENT WATT DENSITY:

22W/sq.cm.
5.NUMBER OF ELEMENTS:
D: 267
3.HEATING ELEMENT SHEATH MATERIAL:
20W/sq.cm.
316 SS
Other(Specify)
Upward
10. air velocity:
Other (specify)
304 SS
L : 1.81 m
9.AIR FLOW DIRECTION:
No
11. INSULATION HOUSING:
Outdoor
8.DUCT DIMENSIONS:
W: 1.33 m
304 SS
*DE 101
30W/sq.cm.
18
* fictional
113
I: 152.4
In order to calculate for the total capital investment of the electric duct heater
using the Lang Method the following factors were used: an MS equipment cost index was
used as the reference since the CE indices is limited to heat exchangers. Second, the
purchase cost of the electric duct heater is calculated using the six-tenths rule given
below:
C P=C P 1
Capacit y 2
Capacit y 1
0.6
Thus,
1283
C P=$ 1092
90
0.6
=$ 5378
For the calculation of the purchase cost of the duct, Figure B.2 of Timmerhaus
was used to estimate the fabrication of an aluminum clad duct. This is done by plotting
the cross sectional area of the duct and intersecting it to the line of the material it is made.
The resulting purchase cost, $300/m, is multiplied to the length of the duct given in the
table below as H.
114
Figure 4: Cost of ductwork as a function of the cross-sectional area, including hangers

and supports.
Note: There is a slight difference with the result for this figure and the one used based on
the book. (Figure presented is from the 4th edition while the one used is from the fifth
edition)
In order to calculate for the CTCI , the equation below was used:
CTPI =1.05 f TPI
I
C
I base P
For this particular equipment a Lang factor,
f TCI
, of 5.93 was used since the
equipment utilizes air, a fluid. The base index used is that of 2011, as stated in the table
below, and an MS cost index for 2014 = 1559.55.
115
Table *. Summary of the equipment design and its corresponding purchase cost.
Equipmen
t
Name
Electric
Duct
Heater
Duct
Capacity
Material
1283 f t 3 /min Incoloy
2.42 m2
Design
Temperature
(C)
58
Design
Pressure
(atm)
5
Purchase Cost, $
(MS Index =
1519.6)
2,533
1500
Total
4,033
Aluminu
m
(LW )
H=5 m
Calculating the present cost,
( $ 4, 033 )
( 1559.55
1519.6 )
C2 =
C2 =$ 7,058.82=Php
182, 119
4.1.4 Grinder
From energy balance, the power required for each of the three crushers is
approximately 12 kW. According to Seider, for a hammer mill, the following equation is
used for the purchase cost,
C P=3,000 W 0.78
where
W =feed rate , ton /hr .
Also, from material balance, feed rate of 2 kg/s maximum was set equivalent to
7.2 tons/hr. Thus,
116
C P=3,000 ( 305.73 )
0.78
C P=$ 260,426.36
Present cost of the equipment,
($ 260,426.36)
( 580.2
394 )
C2 =
C2 =$ 20 , 602 .61=Php11,463,968.31
4.1.5 Storage tank
The total purchase cost for the calculation the storage tanks is given by the
equation below:
C p =C S0.6
where C is the cost of a single storage tank and S, the surface area of the tank. Since there
are three storage tanks needed the equation above becomes a summation of the three
values of the storage tanks needed.
Thus,
C p =Php105, 648 ( 12.530.6 +69.890.6 + 11.300.6 ) =Php2,275,935.78
4.1.6 Mixing Tank 1

For this part, the cost of the mixer which uses a gate or anchor paddle will be
evaluated. The specifications of the mixer are given below.
Table 4.1.6 Specifications for Mixing Tank 1.

Item Name
117
Mixing tank
Quantity
Function
Orientation
Shell
Shell length, tangent-to-tangent, m
Diameter, m
Tank
Impeller
Impeller Type (i.e. rushton)
Number of impellers
Impeller Diameter, m
Motor Power, hP
Impeller speed, rpm
Jacket Type
Volume of tank, completely full, m3
In addition,
A=5.86 m2=63.06 f t 2 and
1
Mixing vessel
vertical
Cylindrical
2
1.3656
Stainless Steel 316
Stainless Steel 316
Gate paddle
1
0.9104
6.54
90
simple, unbaffled
2
P=6.54 hp=5 kW .
The purchase cost of the equipment can be determined by adopting Equation 6.7
of Chemical Engineering Design by Sinott.
Ce=C S
where
Ce= purhcased equipment cost ,

S=characteristic
C=cost constant
n=index for the type of equipment
From Table 6.2 (Sinott, 2005), using the parameters for an agitator since those for
a mixer is not available.
118
For the propeller,

Ce=( $ 1900 ) ( 5 )0.5
Ce=$ 4,248.53
For the turbine,
Ce=( $ 3000 ) ( 5 )
0.5
Ce=$ 6,708.20
For the vessel, the calculation of the purchase cost is done by obtaining the bare
module cost from figure 2, and the material and pressure factor from figure 3. This can be
summarized by the equation below:
bare cost
Purchase cos t=( figure ) ( Material fatcor )( pressure factor)
119
Figure 2. Equipment costing for vessels.

For vessels with diameter approximately 2m, curve 2 is used. Thus,
euipment cost=$ 8,000 , since vessel height is 1.565 m approximately 2 m.
Figure 3. Material and Pressure factors.

where MF=2.0 and PF=1.0 Substituting the obtained values,
Ce=$ 8,000 ( 2.0 ) (1.0)
Ce=$ 16,000
Summing up the calculated purchase cost,
Ce=$ 4,824.53+ $ 6,708.2+ $ 16,000
Ce=$ 27,532.73
120
Calculating the present cost of the equipment with base cost index 2004 =444.2.
Thus,
( $ 27,532.30)
( 580.2
444.2 )
C2 =
C2 =$ 35,961.82=Php 1,589,513
This mixing tank is adjusted to accommodate a bigger production output from its initial
capacity of 600L the mixer has been upgraded to a capacity of 100, 000L. Using the sixtenths rule to calculate the new purchase cost of the mixer yields the following new
purchase cost.
0.6
100000
Cp=
Php 1,589, 513=Php 34, 227,936
600
4.1.7 Fermenter
For the design of the fermenter that is implemented in the study, it is shown in the
figure below:
In the fermenter design, a jacketed, agitated stainless steel vessel is to be used and
the reactor volume is said to be around 2.426921 m3 or 641.125 gallons. From the
description of the fermenter design, it can be noted that they have the same description
with an autoclave. An autoclave is predominantly a vertical, cylindrical stirred tank
121
reactor, which can be jacketed as a means of transferring heat to or from the vessel.
Hence, the purchased cost of an autoclave is obtained. For a stainless steel autoclave
having turbine agitator and heat transfer jacket, the purchase cost equation is shown
below (Seider):
C P=1,980 S0.58
where:
CP = purchased equipment cost on a CE Index = 500
S = size parameter in gallons
Thus, the purchased cost, Cp, based on CE Index = 500 is calculated.
C P=1,980 S0.58
0.58
C P=1,980(641.12)
C p =$ 84,080
Calculating present cost of equipment, the CEPCI for 2014, which is 580.2, is
used against the CEPCI = 500, in which the data is based.
C2 =C P
Ii
Ib
( )
i
( $ 84,080)
( 580.2
500 )
C2 =
C2 =$ 97,566.43=Php 4,312,436
122
Using the same process as the mixer the up scaled cost of the fermenter from its initial
capacity of 2 cubic meters to a 131.91 cubic meter fermenter is equal to 52, 244, 076Php
4.1.8 Filter Press
Based from the calculations conducted for the design specification of a filter
press, it was calculated that the total effective filtration area is 26.1 m 2 or 280.938 ft2. The
purchase cost for the filter press can be calculated using the equation taken from Product
and Process Design Principles by Seider:
Ce=C S
The cost constant, C and the index, n is obtained from Chemical Engineering
Design by R.K. Sinnott and are given below:
Substituting values:
Ce=8800(26.1)0.6
Ce=$ 62,296.98
Calculating for the present cost:
123
( $ 62,296.98 )
( 580.2
444.2 )
C2 =
C2 =$ 81,370.35=Php3,580,295
Up scaled version of the filter press was made from a filtration area capacity of 26.1
square meters to a 52.2 square meters capacity, and the calculated cost for this is
equivalent to 5,426,712.44Php.
4.1.9 Pelletizer (Extruder)
A specification for the pelletizer or extruder is given by Table4.1.10. Detailed
calculation follows.
Table 4.1.9 Technical specifications for pelletizer.
Parameter
Production capacity, kg/h for pelleted feed
Power consumption for pelleted feed, kW/h
Consumption of steam, kg/h
Length, mm
Width, mm
Height, mm
124
Value
10,000
62
100
2400
2400
2850
Using Lang method to solve for the Total Capital Investment for the extruder equipment:
The f.o.b. purchase cost for this type of equipment is at $16 800 from 2011 price.
To calculate the present cost of this equipment, Marshall and Swift index of
1519.6 and 1559.55 for 2011 and 2014 is used. Thus,
( $ 126,078.44)
( 1559.55
1519.6 )
C2 =
C2 =$ 129,393.02=Php 5,695,880.61
4.1.10 Pumps
In calculating for the cost of the pumps used in the production process, the
following operating conditions are to be considered:
Table 4.1.10.1: Operating Conditions for Pumps
Pump for cooling water
Pump for drain water
Flow rate (gpm)

3.726
5.837
Head (ft)
50
50
The cost estimation is initiated by estimating the size factor. Calculating for the
size factor of the pump:
S=Q H 0.5
The flow rate and the pressure head of the fluid are 3.726 gpm and 50 ft for the pumps for
the cooling water. Substituting values:
S=(3.726)(50)0.5
S=26.35
125
Calculating for the base cost of the centrifugal pump using the equation given in Product
and Process Design Principles by Seider:
9.29510.6019 ln ( S ) +0.0519 ( ln ( S ))
C B =exp
Substituting equations:
2
9.29510.6019 ln ( 26.35 ) +0.0519 ( ln ( 26.35 ) )

C B=exp
C PC =$ 2647.74
Calculating for the purchase cost:
C PC =F T F M C B
FT is the pump type factor while FM is the material factor. These values are given the in
the tables provided in the Product and Process Design Principles by Seider.
126
Calculating for the purchase cost:

C PC =( 1.0 ) ( 1.0 ) ( 2432.83 )
C PC =$ 2432.83
For the pumps for drain water, the volumetric flow rate of the water is 5.837 gpm.
The head is taken to be 50 ft. Calculating for the size factor:
S=Q H 0.5
S=(5.837)(50)0.5
S=41.274
Calculating for the base cost:
127
9.29510.6019 ln ( 41.274 ) +0.0519 ( ln ( 41.274 ) )

C B =exp
C B=$ 2378.43
Then, calculating for the purchase cost:
C PC =F T F M C B
C PC =( 1.0 ) ( 1.0 ) ( 2378.43 )
C PC =$ 2378.43
It is noted that 4 pumps are used in the entire production process. The thirds pump
is considered to have same parameters as the pump for the drain water. The last pump to
be used is a slurry pump. For the slurry pump, the following information will be used:
Table 4.1.10.2: Cost for Slurry Pumps
Model
Supplier
Supplier Address
Price
SRL-C Slurry Pump

Allis-Chalmers
Ontario, Canada
$5,000
Calculating for the total purchase cost for the pump:

T PC =2432.83+2378.43+2378.43+5000
T PC =$ 12,189.72
Thus, present purchase cost of the pumps is,
( $ 12,189.72 )
( 580.2
394 )
C2 =
128
C2 =$ 17,950.45=Php793,410
4.1.11 Belt Conveyor
The purchase cost for belt conveyors is calculated based on the equation given by
Seider on Table 16.32 (Seider, Seader, & Lewin, 2010),
C P=16.9 WL
W =width ,.
where
L=length , ft
Specifications are listed in Table 4.1.11 below.

Table 4.1.11 Specifications for belt conveyor.
Specification
Length, L, ft
32.81
Width, W, in.
24
Speed, m/s
Capacity, m3/batch
Data
0.508
0.822
Substitute known values to equation above,

C P=16.9 ( 24. ) ( 32.81 ft )
C P=$ 13,307.09
For its present purchase cost,
( $ 13,307.09 )
( 580.2
394 )
C2 =
129
C2 =$ 19,595.87=Php 866,137.55
There are two belt conveyors proposed in the design, however, it is assumed that
the two have similar cost. Thus, for the belt conveyors,
C2 =Php 866,137.55(2)
C2 =Php 1,732,275
4.1.12 Screw Conveyor
Screw conveyors are suitable for transport of sticky and abrasive solids. Thus, for
the transport of the milled raw materials it is used. Based on heuristics, the equipment is
limited to 3.81 m or so because of shaft torque strength (Rules of Thumb: Summary),
therefore its length would be
L=3.81 m=12.5 ft .
From Product and Process Design Principles by Seider (Table 16.32), the
purchase cost of a screw conveyor can be calculated by the following equation,
C P=55.6 D L0.50
where
D=diameter ,.
L=length , ft
Based on heuristics, a 304.8 mm (12 in.) diameter conveyor can handle 2838495
m3/h 10003000 ft3/h, at speeds ranging from 40 to 60 rpm (Rules of Thumb: Summary).
For this process,
D=12. and
N=50 rpm . Substituting known values to equation
above gives,
C P=55.6 ( 12. )( 12.5 ft )
0.50
130
C P=$ 2,358.91
Thus, the present purchase cost is,
( $ 2,358.91 )
( 580.2
394 )
C2 =
C2 =$ 3,473.70=Php153,537.74
In the proposed deisgn, two screw conveyors are used. Thus,
C2 =Php 153,537.74(2)
C2 =Php 307,075
4.1.13 Cooling Tower
In the process, a cooling tower is to be used as a storage of cooling water to be
used during fermentation. For one batch of production, the cooling water needed is
30.463 m3 or 8,047.47 gal. The design of the cooling tower is based on heuristics. For
storage tanks having a capacity of 1000-10000m3 , a horizontal tank on concete support is
used. From Seider's Product and Process Design Principles, for a carbon steel cone roof
storage tanks operating up to 3psig and having a range, S, of 10,000 to 1,000,000 gallons,
the solution for the purchased cost is given by:
Cp = (210)(V).51
Cp = (210)(8047.47).51
Cp = $20,611.30
Calculating present purchase cost of equipment,
($ 20,611.30)
( 580.2
444.2 )
C2 =
131
C2 =$ 26,921.83=Php1,189,945
4.2 Total Capital Investment Estimation

The total capital investment of a chemical plant is analogous to the purchase price
of a new house where the price includes purchase of land, building, permit fees,
excavation of the land, improvements to the land to provide utilities and access, etc. It is
a one-time expense for the design, construction, and start-up of a new plant or a
renovation of an existing plant (Seider, Seader, & Lewin, 2010).
Using Lang factors to account the cost of installation, construction, etc, the total
capital investment can be obtained. Lang factor values are obtained from Sinnott (2005).
The total purchase cost of the major equipment is summarized in Table 4.2. The fixed
capital is the sum of direct and indirect costs. The Lang factors for a fluid- solid type
plant is shown and is used to calculate for the direct costs (total physical plant cost) used.
Table 4.2. Lang factors used for estimation of project fixed capital cost (Sinott, 2005).
Item
Fluids-Solids Cost (Php)
1. Major Equipment, Total Purchase Cost
PCE
16,314,848
f1 Equipment erection
0.45
7,341,682
f2 Piping
0.45
7,341,682
f3 Instrumentation
0.15
2,447,227
f4 Electrical
0.10
1,631,485
f5 Buildings, process
0.10
1,631,485
f6 Utilities
0.45
7,341,682
f7 Storages
0.20
3,262,970
f8 Site development
0.05
815,742
f9 Ancillary Buildings
0.20
3,262,970
2. Total physical plant cost (PPC) = PCE(1+f1++f9)
3.14
51,391,771
f10 Design and Engineering
0.25
12,847,943
f11 Contractors Fee
0.05
2,569,589
f12 Contingencies
0.10
5,139,177
3. Fixed Capital = PPC(1+f10+f11+f12 )
1.40
71,948,480
4. Working Capital = FC(0.1)
7,194,848
5. Total Capital Investment = FC+WC
79,143,328
4.3 Profitability
132
The feasibility of the project can be determined by subjecting it to profitabitly

analysis. Here, a discounted profitability analysis will be done and the discounted
payback period and the discounted cumulative cash position will be obtained. After
obtaining the required total capital investment for the project, the total product cost will
now then be obtained. Total product cost will be divided into the following: direct
production cost, fixed charges, plant overhead costs, administrative expenses, distribution
and marketing expenses, research and development, financing and gross earnings
expense.
Direct Production Costs
a. Cost for raw materials
Table **. Annual cost for raw materials
Raw Material
Unit
Amoun
t per
batch
Amount per
year, (110
batches/year
)
5,684.35
625,278.50
0.76
817,433.10
136,469.30
3.33
0.50
Cost in
Php/unit
Actual cost
in Php
Cassava peels
Pineapple pomace
kg
kg
Ipil-ipil leaves
kg
7,431.21
1,240.63
S.cerevisiaea
Ammonium
sulphateb
Magnesium
sulphateb
kg
236.06
25,966.60
95.00
477,087.50
2,720,090.3
8
68,234.65
2,466,827.0
0
kg
35.06
3,856.60
6.80
26,224.88
kg
10.52
1,157.20
17.56
20,320.43
Manganese sulphatec
Potassium
phosphatec
TOTAL
kg
1.17
128.70
28.32
3,644.78
kg
18.70
2,057.00
44.68
91,906.76
5,874,336.3
9
Prices are obtained from sigmaaldrich.com.

Prices are obtained from icis.com.
c
Prices are obtained from ychsenfa.en.alibaba.com.
b
b. Operating Labor
133
8 process are considered in the calculation for the total operating labor cost. Given
in the table below, 66 operators are required for the operations of these processes. In the
calculation for the cost, a daily salary of Php 284.00 is considered based from the
minimum rate of Region X effective last January 1, 2015. It is assumed that the plant will
operate for 24 hours meaning it will have 2 shifts (day and night) and for 300 days in a
year. The given table below shows the summary of the operating labor cost of each
process.
Table **. Information on operating labor of the plant.
Unit
Equipmen
No. of
No. of
Process
t
operators/shift/d operators/d
ay
ay
Washing
Drying
Grinding
Mixing
Fermentatio
n
Filtration
Pelleting
Drying of
Animal
Feed Pellets
None
Air Dryer
+ Electric
Duct
Heater
Hammer
Mill
Mixer
Fermentor
+ starter
culture
tanks +
Plate and
Frame
Filter
Press
Extruder
Air Dryer
1
2
20
8
Total
daily
salary of
operators
, Php
5680
2272
1136
374,880
2
3
6
6
1704
1704
562,320
562,320
12
1704
562,320
2
2
4
6
1136
1704
374,880
562,320
Total Cost of Operating Labor
c. Direct supervisory and clerical labor
134
Total
annual
salary of
operators
, Php
1,874,400
749,760
5,623,200
Supervisory labor includes the managers and supervisors assigned on different

processes. Clerical labor includes workers in the administration. Operating cost on
supervisory and on clerical labor is taken to be 25% of the total cost of operating labor
(Timmerhaus, 2003).
Supervisionclericallabor cost=0.25(Operating labor cost )
Supervisionclericallabor cost=0.25( Php 5,623,200)
Supervisionclericallabor cost=Php1,405,800
d. Laboratory Charges
Laboratory charges is taken to be 10% of the total operating labor cost
(Timmerhaus, 2003).
Laboratory charges=0.10 ( Php5,623,200 )
Laboratory charges=Php562,320
e. Maintenance and repair
Cost of maintenance and repair of machineries in the plant are taken to be 2% of
the fixed capital investment (Timmerhaus, 2003).
Cost of maintenancerepair =0.02 FCI
0.02(Php71,948,480)
Php1,438,970
f. Power and utilities

135
The main utilities used in this plant are electricity, steam and water. The amount
of electricity, steam and water for the yearly operation are obtained from the equipment
specification and material balance calculations. For 2015 the current rate for power
consumption of a high load industrial plant is at 0.1153Php/kWh + 2623.43 Php/mo
(ERC, 2015). Total power consumption of plant is seen at 236.93 kW not including
lighting and other devices.
Calculating for the annual cost of electric consumption
cos t electric=236.93 kW 16
hours
day
Php
days 2,633.43 Php
mo
330
+
12
=175,720 Php/ yr
)( 0.1153
)(
)
(
kWh
yr
mo
yr )
Therefore, costs for the power consumption for a year would reach to 175,720
Php/yr and direct production can then be calculated.
Direct production cost=Cost of raw materials+operating labor +Supervisory labor+ Laboratory charge
Substituting values, the direct production cost is equal to:

Direct production cost=Php 12,084,955
Fixed Charges
a. Depreciation
Using straight-line method, it is assumed that the salvage value of the plant will
be zero since there will be no anticipated value by the end of its useful life and its life is
estimated to be 10 years. Thus, annual depreciation cost can be calculated using the
following equation,
Depreciation, D=
where:
FC S
n
FC= capital
136
S=salvage value
n=lifeof the project
Substitute known values,
Depreciation, D=
Php71, 948, 4800

10
Php7, 194,848
b. Local taxes
This may be estimated as 3% of the fixed capital investment (Timmerhaus, 2003).
Local taxes=0.03 FCI
Local taxes=0.03(Php 71,948, 480)
Local taxes=Php Php 2,158,454
c. Insurance
This may be estimated as 1% of the fixed capital investment (Timmerhaus, 2003).
Insurance=0.01 FCI
Insurance=0.01(Php 66,700,819.58)
Insurance=Php 719,485
Therefore, total fixed charges can be calculated
cha rges=Depreciation+ Local taxes+ Insurance
7,194,848+2,158,454+719,485
137
charges=Php 10,072,787
Plant Overhead Costs (POC)

This cost is estimated to be 50-70% of the sum of operating labor, supervision and
maintenance (Timmerhaus, 2003). Taking the value as 60% of the operating labor,
supervision and maintenance,
Plant Overhead Cost =0.50(Operating labor+ Supervisory cost+ Maintenance )
0.50(5,623,200+1,405,800+1,438,970)
POC=Php 4,233,985
Administrative Expenses
This cost is estimated to be 15% of the sum of operating labor, supervision and
maintenance (Timmerhaus, 2003).
Administrative Expenses=0.15(Operatingl abor + Supervisory cost+ Maintenance )
Administrative Expenses=0.15(5,623,200+1,405,800+1,438,970)
Administrative Expenses=Php 1,270,196
Distribution and Marketing Expenses

This cost is estimated to be 2-20% of the total product cost (Timmerhaus, 2003).
Total Distribution Cost =0.02TPC
Total Distribution Cost =0.02 ( 31,111,305.69 )

Total Distribution Cost =Php 622,226.11
138
Research and Development

This cost is estimated to be 5% of the total product cost (Timmerhaus, 2003).
Total ResearchDevelopment Cost =0.05 TPC
Total ResearchDevelopment Cost =0.05 ( 31,111,305.69 )

Total ResearchDevelopment Cost =Php1,555,565.29
Financing
This cost is estimated to be 0-10% of the total capital investment (Timmerhaus,
2003). As of December 11, 2014 in the Philippines, the interest rate on borrowed money
is 4% for the year 2015 as set by the Bangko Sentral ng Pilipinas (BSP) (Taborda, 2014).
FinancingCost =0.04 (TCI )
FinancingCost =0.04 ( Php 79,143,328 )
FinancingCost =Php3,165,733
Gross-earnings Expense
In the Philippines, the gross earning expense is 30% of the taxable income.
Moreover, the taxable income is calculated by obtaining the difference between the total
income and the total product cost.
Calculation of the total income
This section shows the total income or revenue generated from the production of
biodiesel.
Table . Calculation of the total income/total revenue.
139
Product
HVAF
Annual production (kg)

228900
Price (Php/kg)
Income (Php)
30
5,722,500
TOTAL INCOME Php 5,722,500.00
Calculation of total product cost

This section shows the calculation of the total product cost. All components are
equated and arranged so that the total product cost can be determined. Moreover, the total
product cost per kg of HVAF is calculated. This serves as basis for the market price of
HVAF from agro-industrial wastes.
Component
Direct Production Costs
Fixed Charges
Plant Overhead Cost
Administrative Expenses
Distribution and Marketing Expenses
Research and Development
Financing
Total Product Cost
Total Revenue
Gross-earnings expense
Cost
12,084,955
10,072,787
4,233,985
1,270,196
0.02(TPC)
0.05(TPC)
3,165,733
TPC
5,722,500
0.30(2,100,000 - TPC)
TPC=12,084,955+10,071,787+ 4,233,985+1,270,196+0.02 TPC +0.05 TPC +3,165,733+5,722

TPC=Php 31,111,306
Total product cost for HVAF=
TPC
Total Amount of HVAF production
Total product cost for HVAF=
31,111,306
228900
140
Total product cost for HVAF=Php135.92

Calculation of the net present worth and discounted payback period
The criteria for profitability will be the net present worth and the discounted
payback period. The following assumptions are considered in the calculations:
a. the plant will operate at 80% capacity during the first year
b. the plant will operate at 90% capacity during the second year
c. the plant will operate at 100% capacity in the succeeding years
d. the time-value of money is 4% per year (Banko Sentral ng Pilipinas, 2015)
I. Net Present Value
Calculating for the net cash flow in first and second year and the succeeding
years:
net cash flow first year=0.8 ( 5,722,500 )31,111,306=Php 26,247,181
net cash flow second year =0.9 ( 5,722,500 )31,111,306=Php 25,961,056
net cash flow for the succeeding years=( 5,722,500 )31,111,306=Php 25,388,806
Present value of all positive cash flows=
Since the values for the net cash flow are lesser than zero, then the project is not
profitable.
II. Discounted Payback Period
The following are previously calculated:
fixed capital investment = Php 71, 948, 480
141
net cash flow in the first year = Php 26,247,181

net cash flow in the second year = Php 25,961,056
net cash flow in the succeeding years = Php 25, 388, 806
These values are not given interest yet and these values gain interest through
time at a nominal interest rate of 4% per year. Assuming that these values are periodic
and that the plant will deposit money in the bank every month, then an effective interest
rate, i may be calculated as follows:
( 1+i' )12=1.04
i ' =0.0033
This means that the nominal interest of 4% per year is equal to 0.33%
compounded monthly. During the first year of operation, the plant will be able to deposit
a monthly value of: 26,247,181
monthly deposit for 1 st year =
Php 26, 247,181

=Php 2,187, 265
12
Therefore, the remaining time in order to recover the remaining balance of the
investment is
71, 948, 480=2, 187,265
1.0033n1
0.0033
n=31months
Thus, the discounted payback period is 31 months or 2 years and 7 months. This
is the time required to attain breakeven. The desired payback period for engineering is
less than 2 years. Thus, the calculated value implies that it is not desired because the
calculated value exceeds the desire payback period.
142
143
CHAPTER FIVE
Environmental Consideration
This section will contain a 3-4 page summary of the LCA or any waste treatment
design outputs that your group had accomplished as requirement in ChE 52 (Ind. Waste
Management and Control).
5.1. Definition of Goal and Scope
The processes designed in the feasibility study on production of high value animal
feeds aim to address the local communitys alternative source of animal feed that is
cheaper yet packed with the right amount of nutrients for their pigs. The industry uses
biological resources, S. cereviseae, and agro-industrial wastes, cassava peels and
pineapple pomace, as raw materials for the production of high value animal feeds. This
study is intended to assess whether the process designed for the production of high value
animal feeds from agro-industrial wastes is economical and safe both to the surrounding
areas and humans.
5.2. Life Cycle Inventory Analysis
5.3. Life Cycle Impact Assessment

5.3.1. Characterization of Global Warming Impact per Sub-process
5.3.2 Grouping of Indicators
5.4. Life Cycle Interpretation

5.4.1 Evaluation of the Completeness, Sensitivity and Consistency of Data
5.4.2 Findings
144
Wastewater Treatment Design

Total wastewater plant =43.04
m3
m3
=4.986 x 104
day
s
Process Flow Diagram
Adapted from: watercorporation.com.au 2013 (Typical Wastewater Treatment Plant Flow

Diagram)
Layout
145
Figure*: Wastewater treatment layout.
146
CHAPTER SIX
Conclusions and Recommendations
The principal conclusions of the design study should be presented, together with a
clear statement of recommendations, accompanied by justifications, for management.
Again, you can use your imagination here to connect it with the letter of transmittal.
147
148
Acknowledgments
The proponents of this study would like to extend their gratitude to the following
persons and institutions for the valuable support and completion of this study:
Dr. Hercules R. Cascon, the groups research adviser and FYPS instructor, for his
guidance and advices in the development and success of this study;
Dr. Maria Rosario Mosqueda and the Agriculture lab Pool Technicians for
allowing use their automatic distillation and titration apparatus.
Mr. and Mrs. Joel Allera, Mr. and Mrs. Estrada, Mr. and Mrs. Jose B.Torayno, and
Mr. and Mrs. Yap, the parents of the proponents, for their undying support and
understanding during the conduct of this research;
Classmates and friends of the proponents, for their physical and moral support;
And above all, to our Almighty God, for the strength and wisdom, and for making
the proponents final year project study successful.
149
150
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Curriculum Vitae
VERA LUWESA M. ALLERA
Zone 2, Ampenican, Salay,
Misamis Oriental
veraluwesa@yahoo.com
0915-270-0005
PERSONAL INFORMATION
Birth date:
September 20 1993
Birth place:
Cagayan de Oro City
Age:
21
Civil status:
Single
Religion:
Roman Catholic
Gender:
Female
Nationality:
Filipino
Father:
Joel B. Allera
Occupation:
Mother:
Mary Ann M. Allera
Occupation:
Policeman
Misamis Oriental Police
Provincial Office, San Martin,
Villanueva, Misamis Oriental
Teacher
DepEd Region X, Mastersons
Ave., Cagayan de Oro City
EDUCATIONAL BACKGROUND
Tertiary
Corrales St., Cagayan de Oro City
S.Y. 2010-2015
Secondary
Salay National High School
Salay, Misamis Oriental
2007-2010
St. John the Baptist High School
Lagonglong, Misamis Oriental
High School
161
Elementary (Intermediate)
Elementary (Primary)
2006-2007
Salay Central School
2005-2006, 2003-2004
East City Central School
Lapasan, Cagayan de Oro City
Elementary
2004-2005
Salay Central School
2001-2003
East City Central School,
Lapasan, Cagayan de Oro City
2000-2001
RELATED EXPERIENCES
POSITION
COMPANY NAME
First Industrial
On-theJob-Trainee Plastics Venture,
Incorporated (FIPVI)
DENROn-theJob-Trainee Environmental
Management Bureau
Region 10
AWARDS
NAME/TYPE OF
AWARD
KSSR Award
Fr. Araneta Scholar
Academic Scholar
ORGANIZATIONS
POSITION
Member
Member
COMPANY
ADDRESS
Alwana Business Park,
Cugman, Cagayan de
Oro City
DENR 10 Compound,
Macabalan, Cagayan
de Oro City
AWARD-GIVING BODY
Kinaadman Research Center
Office of Scholarship and Finance
Aid
Office of Scholarship and Finance
Aid
INCLUSIVE
DATES
April 1127, 2013
April 7-June 2,
2014
DATE
AWARDED
January 2015
S.Y. 2014-2015
S.Y. 2010-2013
NAME OF ORGANIZATION
INCLUSIVE
DATES
Junior Philippine Institute of Chemical

Engineers
Christian Life Community
S.Y. 2010-2015
162
S.Y. 2013-2015
SEMINARS/TRAININGS ATTENDED
Capillary Electrophoresis for the Analysis of Bioactive Compounds
AVR 3, SBM Building, Xavier University Ateneo de Cagayan,
Cagayan de Oro City
Lecture on Entrepreneurship
Little Theater, Xavier University Ateneo de Cagayan, Cagayan de
Oro City
Earth Day Environmental Symposium
DENR-10, Macabalan, Cagayan de Oro City
November 21, 2014
April 22, 2014
SIGMA: The Engineering Youths Response to the Nations Call for

a Greener Nation
Activity Center, Ayala Centrio Mall, Cagayan de Oro City
PANAGDUYOG Chemical Engineering Summit
Malasag Gardens, Ecovillage, Cugman, Cagayan de Oro City
SKILLS
Knowledgeable in basic computer
software (MS Office)
Knowledgeable in Visual C++
programming
Knowledgeable in DraftSight and has a
background on AutoCAD for
designing purposes
Knowledgeable in MS Visio for
process and plant designs
Knowledgeable in ChemSep and
VenSim for distillation and reaction
simulations
Able to solve chemical engineering
problems (unit operations, unit
processes)
Knowledgeable on process equipment
design and plant design
DATE
January 21, 2015
January 31-February 2,
2014
Has a background on industrial waste

and management control
Has a background on safety
management/engineering,
environmental engineering, food safety
engineering, solid waste management,
and wastewater treatment
Willing to be trained
Good communication and interpersonal
skills
Can work under pressure and can
handle time effectively
Able to work effectively alone or in a
team
Can do research and development tasks
CHARACTER REFERENCE
Available upon request.
163
February 22, 2014
MARY ROSE M. ESTRADA

Zone 4 Bayabas Boundary, Cagayan de Oro City
meeray99@gmail.com
+639268084682
EDUCATIONAL ATTAINMENT
S.Y. 2014-2015
SKILLS
Good communication skills in oral and in Good background in environmental
written
engineering
Good interpersonal skills
Knowledgeable in solid waste management
Ability to facilitate and lead a group
Ability of conducting laboratory works for
Knowledgeable in making risks, environmental
quality control
Skills in identifying, formulating and
and cleaner production assessment reports
Knowledgeable in basic chemical engineering
solving chemical engineering problems
Skills in Basic Computer Drafting

plant design, process equipment design and
control system
(AutoCAD, Vensim, ChemSep)
Knowledgeable in wastewater engineering
Knowledgeable in basic computer software
Good public speaking skills
(MS Word, MS Excel, MS Powerpoint)
Ability to analyzed experimental data
Skills in managing events
Ability to work under less supervision
Skills in organizing events
Ability to work under pressure
Able to adapt to various work conditions
RELATED EXPERIENCES
POSITION
OJT
OJT
COMPANY NAME
SHEMBERG Marketing
Corporation
First Industrial Plastic
Ventures Inc.
COMPANY
ADDRESS
Mandaue City,
Cebu
Cugman, Cagayan
de Oro City
164
INCLUSIVE DATES
April 21 May 29,
2014
April 11 27, 2013
AWARDS
NAME/TYPE OF AWARD
KSSR Award
Scholar
ORGANIZATIONS
POSITION
Internal Vice President
President
Board of Director
Board Member
Student Representative
AWARD-GIVING BODY
XU - Kinaadman Research Center
XU Office of the Scholarships and
Financial Aid
Engineers
Engineers
Association of the College of
Engineering Students
Philippine Institute of Chemical
Engineers Junior Chapter Mindanao
Philippine Institute of Chemical
Engineers
165
DATE AWARDED
December 17, 2014
A.Y. 2010 2011 to
A.Y. 2012 - 2013
INCLUSIVE DATES
A.Y. 2014-2015
A.Y. 2013-2014
A.Y. 2013-2014
A.Y. 2013-2014
A.Y. 2013-2014
JOHDEM I. TORAYNO
Zone 7, Patag, Cagayan de Oro
jhdmtorayno@yahoo.com
+639059343099
EDUCATIONAL ATTAINMENT
S.Y. 2014 - 2015
SKILLS
Knowledgeable in Process and Plant
Design
Knowledgeable in Vensim, ChemSep and
CAD software
Good background in MS applications
Good communication skills

Capable in laboratory works and analysis
for Quality Control
Capable in working in teams or alone
Able to read basic Kanji characters
Resourceful
Dedicated to assigned task
Creative
Capable in facilitating people
RELATED EXPERIENCE/S
POSITIO
COMPANY NAME
N
Trainee
Nestle Philippines Inc.
CDO Factory
Trainee
First Industrial Plastic

Ventures Incorporated
(FIPVI)
Knowledgeable in material balancing
Fluent in English and basic Nihong-go
Knowledgeable in different plant processes

and unit operations
Organized
Knowledgeable in herbal medicine and
basic pharmaceutical terms
Highly adaptable to social environment
Optimistic
Capable in video editing
Capable in reading maps
Critical thinker
COMPANY ADDRESS
INCLUSIVE DATES
Tablon, Cagayan de Oro

City
April 7 June 5, 2014
Gusa, Cagayan de Oro City
April 2013
AWARDS
NAME/TYPE OF AWARD
Kinaadman Research Grant
AWARD GIVING BODY

Kinaadman Research Center
DATE AWARDED
January 2015
Pryce Grant (Scholarship)
Xavier University Alumni Office
November 2014
166
Top Book Borrower
Xavier University Libraries
November 19, 2014
DOST R-10 Office
April 2009
DOST RA7687 S&T

Scholarship
ORGANIZATIONS
POSITION
Representative (Youth with
Special Needs Sector)
Oro Youth Development Council
(OYDC)
INCLUSIVE DATES
March 2014 - present
Treasurer
Circulo de Arte
AY 2014 - 2015
Student Program Officer

(SPO)
Kristohanong Katilingban sa
Pagpakabana Social Involvement
Office(KKP-SIO)
AY 2014 - 2015
DACA Head
DMSA Head
Junior Philippine Institute of Chemical AY 2013 2014

Engineers (JPIChE)
AY 2012 - 2013
SEMINARS/ TRAININGS ATTENDED

Lecture on Entreprenuership
Little Theater, Xavier University, Cagayan de Oro City
DATES
November 21,
2014
Youth Advocacy Series: Solid Waste Management

City Tourism Hall, Cagayan de Oro City
June 5, 2014
Basic Microbiology Seminar and Hazard Analysis Critical Control Point

Seminar
Nestle Philippines Training Center, Cagayan de Oro City
April 23, 2014
Hazard Identification Risk Assessment and Determining Controls

Orientation Seminar
Nestle Philippines Training Center, Cagayan de Oro City
April 22, 2014
Food Handlers Seminar

City Health Office, Cagayan de Oro City
April 3, 2014
Sigma: The Engineering Youth Response

Centrio Activity Center, Cagayan de Oro City
February 22, 2014
Panagduyog (Mindanao-wide Chemical Engineering Summit)

Xavier University Ateneo de Cagayan, Cagayan de Oro
January 30
February 1, 2014
3rd Greeneration Summit: A Gathering for Youth Empowerment on Climate
August 2, 2013
167
Change for Mindanao

Capitol University, Corrales Avenue Osmea Street, Cagayan de Oro
The Best of Me: Personal Development Seminar and Workshop
AVR 4, Xavier University, Cagayan de Oro City
References available upon request
168
February 13, 2013

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APPROVAL SHEET

This project study entitled PRODUCTION OF HIGH-VALUE ANIMAL FEEDS

An Undergraduate Research Study

Block Flow Diagram .......... 3

Specifying the process ... 4

Detailed Process Flow Diagram .7

3. Material, Energy Balances, and Utility Requirement . 13

Summary Quantitative Flow Diagram ... 13

Details of Material Balance Calculation ... 15

Material Balance for Washer . 16

Process Operation Scheduling 35

Summary Quantitative Flow Diagram .... 45

Details of Energy Balance . 37

Air Heater ...

Input/output Diagram structure......... 3

Block flow Diagram.. 4

Expanded block flow process diagram .... 4

More detailed block flow process diagram ... 6

Detailed process flow diagram .. 8

Material balance around Washer ....... 17

Material balance around Dryer for Cassava Peels .... 18

Material balance around Dryer for Pineapple Pomace . 20

Material balance around Dryer for Ipil-ipil leaves 21

Material balance around Grinder for Cassava Peels . 22

Material balance around Grinder for Pineapple Pomace .. 22

Material balance around Grinder for Ipil-ipil Leaves ... 23

Material balance around Mixer for Substrate Preparation .... 24

Material balance around Fermentor ...

Material balance around Filter Press . 34

Material balance around Pelletizer .... 36

Material balance around Dryer ... 37

Shortened overall Ghantt chart for plant operations 40

Energy balance around Washer ............ 48

Energy balance around Dryer .. 49

Humidity chart for the determination of wet bulb temperature ... 50

Energy balance around Grinder ... 62

Energy balance around Fermentor ........... 66

Table 2.2. Amount of Material Exiting (product).. 33

In terms of accessibility of the probable market, the availability of different

Figure 1.2.4: Site plan.

Figure 1.2.5: Plant layout.

Fig. 2.1: Input/output Diagram structure.

Fig. 2.2: Block flow Diagram.

Fig. 2.3: Expanded block flow process diagram.

Fig. 2.4: More detailed block flow process diagram.

Fig. 2.5: Detailed process flow diagram.

3.1.1 Summary Quantitative Flow Diagram

3.1.2 Details of Material Balance Calculation

Figure 3.2.1: Material balance around Pelletizer.

Figure 3.1.2.2: Material balance around Dryer 2.

Substitute Eqns. 2 and 3 to 1,

5. Approximately 47% of the fermented substrate is liquid (based on previous

Figure 3.1.2.3: Material balance around Filter Press.

(where fs=fermented substrate, lr=liquid recovered, fm=filtered meal)

msolid component out

4. Ratio of ethanol to carbon dioxide is 1 mol:1mol (Jeppson, Yu, & Hahn-Hagerdal,

Figure 3.1.2.4: Material balance around Fermenter.

Substitute Eqns. 7 & 8 to 6,

For fermented meal

mC O =22,520.21 kg ( 0.023 ) msubstrate =542.94 kg=methanol

For starter culture

Moreover, the mass of the total biomass is calculated:

mtotal biomassadded =mtotal protein out