Skincare Foundation
Sunblock
Hair gel
Lotion body
Lipstick
Scar removal gel
Health and hygiene Shower cream
Perfume
Talcum powder
Deodorant
Sanitizer
Feminine wash
Concept Screening
Criterion Alternative
1 2 3 4 5 6 7 8 9 10 11 12
Odor + + + + - - + + + + + +
Quality - - 0 0 - 0 + - 0 - 0 0
Price - - 0 0 - - 0 - 0 0 + +
Environmental - - 0 0 - - 0 - 0 - 0 0
friendly
Hygiene - - - - - - + - 0 + + +
Healthy - - - + - - + - - 0 0 0
Skin care 0 0 - 0 - 0 + - 0 0 - -
Cosmetic - - - - 0 - - 0 - - - -
Total score -5 -5 -3 0 -7 -6 4 -5 -1 -1 1 1
Rank 8 8 7 4 12 11 1 8 5 5 2 2
Concept Scoring
Criterion Weight Alternatives
4 7 11 12
Odor 2% 3 5 4 3
Quality 2% 3 3 3 3
Price 2% 3 4 3 3
Environmental 2% 2 3 3 3
friendly
Hygiene 30% 2 5 5 4
Healthy 30% 2 4 4 3
Skin care 30% 4 5 2 2
Cosmetic 2% 1 1 1 1
Total score 2.64 4.52 3.58 2.96
Rank 4 1 2 3
Based on the screening and scoring method, alternative 7 is chosen (shower cream).
=
824.8684
=
3546.8830 2722.046
= 1.000038
vi. Issue on competing reaction and selectivity
Selectivity is generally defined as the number of moles of desired product divided by the
number of moles of the undesired product (Fogler, 1992). The selectivity that was achieved
with the stoichiometry and conversion set was
=
824.8684
=
2722.046
= 0.3030
Saponification is the reaction between a fat or oil and a base, producing glycerol and a salt.
Thus, it can be said that the base, potassium and salt are alkali or having a pH greater than
having an alkali shower cream or soap is essential to balance out the pH of the skin.
Variable skin pH values are being reported in literature, all in the acidic range but with a
broad range from pH 4.0 to 7.0 (Lambers, et.al, 2006). With this, people having acidic skin
should be encouraged to use alkali soap to achieve a balanced skin pH of 5.5 for an optimal
healthy skin (Health24, 2005).
Factor Reasoning
Size Smaller processes to help ease the difficulty of
moving large amounts of chemicals from
equipment to equipment.
Product Quality The product quality of each batch must be
verified and certified especially with the fact that
soap has to be approved by the Ministry of Health
Malaysia.
Operational Flexibility The stirrer tank, in which the grinded up leaves of
Hibiscus Rosa Sinensis and methanol are mixed,
can be used as a mixer and also a sedimentation
tank for the heavy grinded up leaves.
Standardized Equipment Multiple The process flow structure of the designed plan is
Products able to produce either bar soap or liquid soap.
Process Efficiency More efficient compared to continuous process as
the process requires recycling and filtering of
either the methanol or the waste of grind up
leaves.
Maintenance and Operation Labour Higher cost due to equipment cleaning and
preparation time before a new batch is made.
Feedstock Availability The feed of Hibiscus Rosa Sinensis is available
all year round, thus there should be no shortage of
supply to the plant.
Product Demand Product demand is available all year round.
However, since the plant is flexible, it can
produce other hygiene products.
Rate of Reaction to Produce The process to produce soap is not as fast as other
Products chemical reactions, thus batch process is
reasonable.
Equipment Fouling Batch process is chosen as the equipment can
experience fouling, and cleaning of equipment is
always a standard operating procedure.
Safety Operator training is needed in chemical exposure
and equipment is critical.
Controllability The efficiency of scheduling of equipment would
not be a problem as the main product produced is
soap and the equipment does not have to perform
more than one task at one particular time.
= +
0.3
119 kg of caustic potash
total weight of caustic potash and water =
0.3
total weight of caustic potash and water = 663.33kg
Amount of water:
= ( ) ( )
= 663.33 199
= 464.33
1000
1000
1
=
(12.0107 57) + (1.00794 110) + (15.9994 6)
1000000
=
891.4797
= 1121.7305 mol
Let
A= (C18H35O2)3C3H5
B= KOH
C= C3H5(OH)3
D= C18H35O2K
6 3 6
Oxygen: (1121.7305 mol) (1 ) + (3546.8830) (1 ) = (33.8192mol) (1 ) +
3 3 6
(2 ) ( ) + (3 ) (1 ) + (4 ) (1 )
1
110 3 110
Hydrogen: (1121.7305 mol) ( ) + (3546.8830) (1 ) = (33.8192mol) ( )+
1 1
3 3 105
(2 ) ( ) + (3 ) (1 ) + (4 ) ( )
1 1
3 3 3
Potassium: (3546.8830 mol) (1 ) = (2 ) (1 ) + (4 ) (1 )
10640.649 = 32 + 34
Thus, the equations are:
1. 33 + 544 = 62010.9441
2. 32 + 33 + 64 = 17168.1168
3. 32 + 33 + 1054 = 130310.892
4. 32 + 34 = 10640.649
From the material balance as shown above, it can be said that the amount of Potassium
Hydroxide, KOH, is a lot. Thus, it can be recycled back into the system to save cost on fresh
supply of KOH. Also, the desired product, Potassium Stearate, with 70% conversion rate is
1142.8563 moles in the output. From here, the total mass of shower cream that can be made
is:
= 1142.8563 322.5676
= 368648.4138 368.4841
(1142.8563 moles) x (322.5676 g/mol) = 368648.4138 g or 368.4841 kg of shower cream.
iv. Chemical Engineering Design (sizing) and Heuristics
Sizing of the Equipment based on Heuristics
1. Pump
From Table 11.5
Rule 1: electric motor (85-95%)
-Selected 90% - dr
-Shaft power 70 kW
Rule 6:
Drive Power =
70
Drive Power = 0.9 = 77.78 kW
2. Heat Exchanger
Rule 1: Set F = 0.9
Rule 6: minimum temperature = 10C
Rule 8: 280 W
A =
Q = noutHout - ninHin
Reference state: (KOH, C57H110O6, C3H8O3, C18H35KO2, 1 atm, 80C)
Component nin Hin nout Hout
KOH 0.7507 - 0.77310 H1
C57H110O6 0.2403 - 0.06194 H2
C3H8O3 - - 0.01314 H3
C18H35KO2 - - 0.15180 H4
15 15
H1 = 80 : 80 65.87 = 4281.55
15
H2 = 80 1969.4 = 128011
15
H3 = 80 150 = 9750
15
H4 = 80 2496 = 162240
Q = (0.77310 4281.55) + (0.06194 128011) + (0.01314 9750) +
(0.15180 162240)
Q = 35995.215 Watt
3. Separator
Flowrate liquid: 377.3 kg/h Flowrate vapour: 10622.7 kg/h
l = 1690 kg/m3 v = 1650 kg/m3
Rule 9:
u = kl/v 1m/s
u = 0.03051690/1650 1m/s
u= 0.00475 m/s
75% UACT = 3.562510-3 m/s
Mass of vapour flowrate = u vD2/4
10622.7
= = 2.95075 kg/s
3600
4. Filters
Rule 1: Pressure vessels inside which are fitted a number of filter cartridges. Almost
without exception the flow is from the outside inwards. Cartridges are available in
cleanable or (much more common) disposable form. A very wide variety of materials,
textures, pore size and physical sizes are available.
Rule 2: Cartridge filter is used to filter the solid leaf to obtain liquid product in mesh form.
Rule 6: Cake buildup is negligible clarification is accomplish with cartridges, pre-coat
drums, or sand filters.
Rule 8: For finely ground ores and minerals, rotary drum filtration rates may be 1500
lb/(day)(sqft) at 20 rev/min and 18-25 in Hg vacuum.
5. Storage tank
Volume of glycerol, retinol and stearin is 54 L (range 55-60L):
0.264172
54 = 14.27
1
The type of storage tank for glycerol, retinol and stearin is vertical tanks on legs
time ln(1/1-x)
0 0
6.67 0.1054
13.34 0.2231
20 0.3567
26.68 0.5108
33.35 0.6931
40.02 0.9163
46.69 1.204
53.36 1.6094
60 2.3026
Volume of reactor:
=
=
1119.94
0.7
=
336.5192 60
0.0281
3
= 13.773
Diameter:
d2 h
=
4
(4)13.773
=
(7)
= 1.5826
= 4.4231
d) Recycle Structure
Inlet
Assumptions:
1) Recycle ratio = 0.7
2) Recycle composition, A3 = 0.1, B3 = 0.9
3) Assume that KOH is negligible because it was fed in access and continuously in access
in the process. KOH outlet flow are also being recycled back.
=
= 0.7
4668.611
= 3268.0277
Mol flowrate entering the reactor per hour:
= 4668.611 mol/hr + 3268.0277 mol/hr
= 7936.6387 mol/hr
A = 0.1825(7936.6387) = 1448.4365
= 0.8175(7936.6387) = 6488.2017
34 + 544 = 57792.6135
6 3
Oxygen: (1448.4365 mol) (1 ) + (6488.2017 mol) (1 ) =
6 3 3 6
(434.531 mol) ( ) + (4) (1 ) + (4) (1 ) + (4) (1 )
1
110 3
Hydrogen: (1448.4365 mol) ( ) + (6488.2017 mol) (1 ) =
1
110 3 3 105
(434.531 mol) ( ) + (4) (1 ) + (4) (1 ) + (4) ( )
1 1
e) Downstream Processing
Balance at separator
Overall balance at separator,
Product = Recycle + Final product
Final product = Product - Recycle
Final product = 7014.9068 mol/hr - 3268.0277 mol/hr = 3746.8791 mol/hr
Balance of A
7014.9068(0.06194) = 3268.0277(0.1) + 3746.8791(A)
A = 0.02874
Balance of B
7014.9068(0.7731) = 3268.0277(0.9) + 3746.8791(B)
B = 0.6624
Balance of C
7014.9068(0.01314) = 3746.8791(C)
C = 0.0246
Balance of D
7014.9068(0.1518) = 3746.8791(D)
D = 0.2842
Thus, it is proven that with recycle stream added, the amount of desired product increases
significantly compared to the system without recycle stream. The amount of increase is by
1064.8630 [0.2086(3954.7857)]
(%) = 100%
1064.8630
= 22.53%
The purchased cost and an attribute of the equipment are the most common simple
relationship related to units of capacity and it is given by
= ( )
Where: A = Equipment cost attribute
C = Purchased cost
N = Cost exponent
Subscripts: a refers to equipment with the required attribute
b refers to equipment with the base attribute
FBM= B1 + B2FMFP
B1 and B2 can be obtained from Table A.4
FM can be obtained by referring the Table A.3 for the identification number for the material
and then refer the material factor at Figure A.8
CBM = CPoFBM
Sample of Calculations
Calculations for heat exchanger :
Step 1 (Characteristics)
E1 A = 14.28 Double Pipe CS-shell / CS-tube
E2 A = 14.28 Double Pipe CS-shell / CS-tube
E10 A = 14.28 Double Pipe CS-shell / CS-tube
E11 A = 14.28 Double Pipe CS-shell / CS-tube
i) FP for E1 = 1
ii) FP for E2 = 1
iii) FP for E10 = 1
i) FP for E11 = 1
i) FP for P1 and P2 = 1
i) CPo for V1, V2, V3, V4, V5, V6, V7, V8,V9, V10 and V11
CPo = $ 1 781.76
i) CBM for V1, V2, V3, V4, V5, V6, V7, V8, V9,V10 and V11
CBM = $ 6 016.26
i) CBM for V1, V2, V3, V4, V5, V6, V7, V8, V9,V10 and V11
CBM = $ 6 565.17
n
o
CGR = CTM + 0.50 CBM
i=1
= RM 6702299.12
Equipment
No. Actual bare module cost, CBM ($)
identification
E1 13 049.56
E2 13 049.56
Heat Exchanger
E10 13 049.56
E11 13 049.56
P1 41 604.68
Pump
P2 41 604.68
F1 21 155.29
F2 21 155.29
Filter
F3 21 155.29
F4 21 155.29
V1 6 016.26
V2 6 016.26
V3 6 016.26
V4 6 016.26
V5 6 016.26
Vessel
V6 6 016.26
V7 6 016.26
V8 6 016.26
V9 6 016.26
V10 6 016.26
V11 6 016.26
Reactor R1 667 206.08
Total bare module cost, CBM2011
953 413.70
($)
Total bare module cost, CBM2014
1 122 417.05
($)
Table: Estimation of fixed and total capital investment cost
H. Laboratory charges Costs of routine and special laboratory tests required for
product quality control and troubleshooting.
The cost of manufacturing, COM, can be determined when the following costs are known
or can be estimated:
1. Fixed capital investment (FCI) : (CTM or CGR)
2. Cost of operating labor (COL)
3. Cost of utilities (CUT)
4. Cost of waste treatment (CWT)
5. Cost of raw materials (CRM)
The table above gives data that are needed to calculate to estimate the individual cost items
that are identified above. With the exception of the cost of raw materials, waste treatment,
utilities, and operating labor all the data need to be calculate by using certain equations. If
no other information is available, the midpoint values for each of these ranges is used to
estimate the costs involved. Hence, all the summation of the datas for the calculation of
manufacturing cost can be simplified into these equations:
We can obtain the total manufacturing cost by adding these three categories together and
solving for the COM and the result is:
COM = 0.280FCI + 2.73COL + 1.23(CRM+ CWT + CUT)
The technique used to calculate operating labor requirements is based on data obtained
from five chemical companies and correlated by Alkayat and Gerrard. According to this
method, the equation for the operating labor requirement for a chemical processing plant is
given by:
NOL= (6.29 + 3.17P2 + 0.23Nnp)0.5
Where NOL is the number of operators per shift, P is the number of processing step
involving the handling of particulate solids, and Nnp is the number of nonparticulate
processing steps handling steps includes compression, heating and cooling, mixing, and
reaction.
Nnp =
The value of NOL is the number of operators required to run the process unit per shift. A
single operator works on the average 49 weeks (3 weeks time off for vacation and sick
leave) a year, five 8-hour shift a week.
= 49 week/yr 5 shift/week
= 245 shifts per operator/year
A chemical plant operates 8 hours per day. This requires (365 days/year 1 shift/day) 365
operating shifts per year. The number of operators needed to provide this number of shifts
is
The cost of operating labor, COL is equal to the salary given to each of operator yearly which
in this case the yearly salary given is RM14 400
ii.Cost Of Utilities
Yearly cost for raw materials = (Mass of raw materials per kg) x (cost, RM/kg)
Yearly cost for stearin = (2.92 x 106 kg/year) x (RM 2.20) = RM 6.42 x 106
Yearly cost for KOH = (581080 kg/year) x (RM 4.62) = RM 2.68 x 106
Yearly cost for Hibiscus = (7.05 x 106 kg/year) x (RM 2.50) = RM 17.62 x 106
Total cost for raw materials, CRM = RM 6.42 x 106 + RM 2.68 x 106 + RM 17.62 x 106
= RM 26.72 x 106
General Expenses
=0.177COL + 0.009FCI + 0.16COM
=RM [0.177(57 600.00) + 0.009(11.39 x 106) + 0.16(33 613 265.83)]
=RM 5 400 237.80
Total Cost
=CRM + CWT + CUT + 2.215COL + 0.0190COM + 0.146FCI + depreciation
=RM [26.72 x 106.00 + 0.00 + 178 513.20 + 2.215(57 600.00) + 0.0190(33 613 265.00) +
0.146(11.39 x 106)]
=RM 35 611 044.86
Profitability analysis
1100
Cumulative Discounted Cash Flow
900
700
500
300
100
-100 0 2 4 6 8 10 12 14
-300
-500
Time (years)