Acerit, Mamauag, Sibal, Soriano PDF

PRODUCTION OF ETHANOL FROM CORN
A Plant Design Report
In Partial Fulfillment of the
Requirements for the Degree
Bachelor of Science in Chemical Engineering
Second Semester
S.Y. 2017-2018
By:
Harvey O. Acerit
Aileen T. Mamauag
Arjanelle A. Sibal
Jonalbeth B. Soriano
May 2018
LETTER OF TRANSMITTAL
May 27, 2018
Engr. CAESAR POBRE LLAPITAN
Instructor
Chemical Engineering Department
Cagayan State University
Dear Engr. Llapitan:
We are submitting herewith our plant design report entitled “Production of Eethanol from
Corn” as a chemical engineering plant design course requirement. The objective of the design
report is to perform a study on the proposed process design for the production of ethanol using
corn as the raw material.
The report shows a concise overall process flow diagram, detailed Material and Energy
balance, Piping and Instrumentation Diagram (P&ID), Qualitative and Quantitative Block
Diagrams, the process description, summary of material and energy balance calculations and
equipment design and specifications, market study, costing and product safety, health and
environmental impacts. We hope that this will merit your approval.
Very truly yours,
Harvey O. Acerit
Aileen T. Mamauag
Arjanelle A. Sibal
Jonalbeth B. Soriano
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ACKNOWLEDGEMENT
We would like to express our gratitude to the people who have given us strength and
support throughout the completion of this Chemical Engineering Plant Design report:
To Engr. Caesar Pobre Llapitan, for his constant guidance, profound insights,
constructive suggestions and motivation in the completion of this report.
To our friends and classmates for their support and encouragement when we are
apprehended by the urgency of the situation to finish thoroughly this requirement.
To our families for their invaluable support morally and financially, unconditional love,
prayers and encouragement.
Above all, to the Almighty God, our creator and provider of knowledge and strength
and to whom this design report is endowed strength and to whom this design report is endowed.
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CERTIFICATION
This Project Design hereto entitled “Production of Ethanol from Corn”, prepared and submitted
by Harvey O. Acerit, Aileen T. Mamauag, Arjanelle A. Sibal and Jonalbeth B. Soriano in
partial fulfillment of the requirements for the course Plant Design, has been examined and is
recommended for acceptance and approval.
___________________________
ENGR. CAESAR P. LLAPITAN
Instructor
APPROVAL
This Project Design is hereby approved and accepted as partial fulfillment of the requirements
for the course Plant Design.
___________________________
ENGR. MONICO U. TENEDOR
Department Chairperson
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EXECUTIVE SUMMARY
The Philippines is a major and user of renewable energy and has for years required
biodiesel and ethanol in local petroleum diesel fuel and gasoline. Bioethanol production is one
of the most potential and realistic method for producing renewable energy source. Bioethanol
is produced mainly from sugar cane and corn. The design of a sustainable process for producing
bioethanol requires a methodological approach whereby economical, environmental and social
criteria are systematically integrated from the early stages of the process design.
Chapter 1 includes the product information and product properties. Process selection
is also shown in this chapter where it includes the comparison of the alternatives that are
commonly used in the manufacturing process and the anatomy of the new process design based
from these alternatives.
In Chapter 2, the product demand and supply of ethanol are shown. The chapter shows
that demand of ethanol is increasing while the supply is not enough to cover the demand. It
also discusses the type of consumers and the major firm-users that purchase ethanol. Marketing
program, promotions and the package that will be used are also indicated.
In Chapter 3 the technical study of the ethanol plant is presented. Block flow diagrams
are indicated to show the general flow of processes. Process topology is also included in this
chapter which shows the different streams and equipment used. It also discusses the material
and energy balances accounted in the process of ethanol production. Different utility
requirements such as energy consumption and water consumption were also elaborated. This
chapter shows the process flow diagram and the Piping & Instrumentation diagram of the
processes and equipment used for the said product.
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In Chapter 4, the economic study of the ethanol plant is discussed. The plant total
capital investment s are shown in constant annual profit and changing annual profit based on
the yearly demand from market study. It also elaborates the estimated cost for each equipment,
the payback period, the return of investment and other economic aspect for putting up the plant.
Cash flow diagrams for are shown for easy understanding of its feasibility. The graphical
representations also denote that the plant will be profitable if constructed.
Chapter 5 discusses the safety and health of workers and the environment. Risk
management and government regulations involved in the process were provided.
Environmental constraints like hazard and operability studies, pollution prevention, and life
cycle analysis were also discussed in this chapter.
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TABLE OF CONTENTS
Title Page
Letter of Transmittal....................................................................................................................i
Acknowledgement......................................................................................................................ii
Certification and Approval........................................................................................................iii
Executive Summary..................................................................................................................iv
Table of Contents......................................................................................................................vi
List of Tables..........................................................................................................................viii
List of Figures...........................................................................................................................ix
CHAPTER I ............................................................................................................................. 1
INTRODUCTION.................................................................................................................... 1
A. Product Information ............................................................................................................... 1
B. Product Properties .................................................................................................................. 5
C. Process Selection ..................................................................................................................... 6
D. Proposed process of Ethanol Production ............................................................................. 10
E. Site Selection .......................................................................................................................... 12
1. Comparative Factors ........................................................................................................ 13
2. Site Considerations ........................................................................................................... 14
3. Site Layout ......................................................................................................................... 15
4. Plant Layout ...................................................................................................................... 16
CHAPTER II .......................................................................................................................... 17
MARKET STUDY ................................................................................................................. 17
A. GLOBAL ETHANOL MARKET ........................................................................................... 17
1. Global Past and Future Ethanol Production for Years ...................................................... 21
B. LOCAL MARKET (PHILIPPINES) ...................................................................................... 22
1. Production ............................................................................................................................. 23
2. Consumption ......................................................................................................................... 24
3. Local Past and Future Ethanol Production for Years ........................................................ 25
C. DIFFERENT CONSUMERS .................................................................................................. 25
D. PACKAGING ........................................................................................................................... 26
E.TRADE AND PRICES .............................................................................................................. 26
CHAPTER III ........................................................................................................................ 28
TECHNICAL STUDY ........................................................................................................... 28
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A. Process Description ............................................................................................................... 28
B. Material Balance Summary.................................................................................................. 35
C. Energy Balance Summary .................................................................................................... 43
D. Utility Requirement .............................................................................................................. 48
E. Equipment Summary ............................................................................................................ 49
F. Piping and Instrumentation Diagram ................................................................................. 67
CHAPTER IV......................................................................................................................... 77
COSTING AND PROJECT EVALUATION ...................................................................... 77
A. Estimation of Equipment Cost ............................................................................................. 77
B. Estimation of Fixed Capital Investment (FCI) .................................................................... 79
C. Estimation of Total Capital Investment .............................................................................. 84
D. Estimation of Production Cost ............................................................................................. 84
E. Profitability Analysis ............................................................................................................ 87
CHAPTER V .......................................................................................................................... 93
HEALTH, SAFETY AND THE ENVIRONMENT............................................................ 93
A. Risk Assessment .................................................................................................................... 93
B. Government Regulations ...................................................................................................... 98
C. HAZOP Studies ................................................................................................................... 104
D. Pollution Prevention ........................................................................................................... 106
E. Life Cycle Analysis .............................................................................................................. 106
CHAPTER VI....................................................................................................................... 110
SUMMARY, CONCLUSIONS AND RECOMMENDATIONS ..................................... 110
REFERENCES ..................................................................................................................... 112
APPENDIX ........................................................................................................................... 115
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LIST OF TABLES
Table 1.1 Property of Ethanol 5
Table 1.2 Comparison of the Three Alternatives Method 10
Table 2.1 Philippine Ethanol Mandate 23
Table 3.1 Grain Composition 36
Table 3.2 Dry Mill Process Solid/Liquid Percentages 36
Table 3.3 Conversion Rates as a Percentage of Theoretical Yield 37
Table 3.4 Ethanol Content of the Down Streams 37
Table 3.5 Theoretical Weight of Enzymes Needed 38
Table 3.6 Summary of Material Balance Calculations 41
Table 3.7 Legend of Streams in Figure 3.3 44
Table 3.8 Specific Heat Capacity of Streams 45
Table 3.9 Summary of Energy Balance Calculations 46
Table 3.10 Average Energy and Water Usage per Gallon Ethanol Produced 49
Table 3.11 Control Element Symbols 67
Table 3.12 Instrumentation Line Symbols 68
Table 3.13 Location of Instruments 68
Table 3.14 ISA Identification Letters 68
Table 3.15 Control Valve 69
Table 4.1 Cost Indices 77
Table 4.2 Purchased Equipment Cost 78
Table 4.3 Breakdown of Direct and Indirect Costs 80
Table 4.4 Calculated Percentage of Components and Items 81
Table 4.5 Fixed Charges 85
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Table 4.6 Summary of Total Production Cost 86
Table 4.7 Depreciation using MACRS 89
LIST OF FIGURES
Figure 1.1 Wet Milling Process for the Production of Ethanol 7
Figure 1.2 Dry Milling Process for the Production of Ethanol 8
Figure 1.3 Ethanol Production from Cellulosic Material 9
Figure 1.4 Anatomy of the Proposed Process 10
Figure 2.1 Global Bioethanol Market by Type 17
Figure 2.2 Global Bioethanol Market by Blend 18
Figure 2.3 Global Bioethanol Market by Application 19
Figure 2.4 Global Bioethanol Market by Region 20
Figure 2.5 World Ethanol Production/Trade 22
Figure 2.6 Fuel Ethanol Production of Philippines 24
Figure 2.7 Fuel Ethanol Consumption of Philippines 24
Figure 2.8 Fuel Use Projection 25
Figure 2.9 Global Ethanol Production, Trade and Prices (2017) 27
Figure 3.1 Block Flow Diagram 33
Figure 3.2 Process Topology 34
Figure 3.3 Qualitative Block Diagram 39
Figure 3.4 Quantitative Block Diagram 40
Figure 3.5 Temperature Profile for Ethanol and DDGS Production 44
Figure 3.6 Piping and Instrumentation Diagram 71
Figure 3.7 Control and Instrumentation of Hammer Mill 72
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Figure 3.8 Control and Instrumentation of Weigh Tank 72
Figure 3.9 Control and Instrumentation of Slurry Tank 73
Figure 3.10 Control and Instrumentation of Steam Cooker 73
Figure 3.11 Control and Instrumentation of Cook Retention Tank 74
Figure 3.12 Control and Instrumentation of Saccharification Tank 75
Figure 3.13 Control and Instrumentation of Fermentor 75
Figure 3.14 Control and Instrumentation of Beer Column 76
Figure 3.15 Control and Instrumentation of Ethanol Column 76
Figure 4.1 Cumulative Cash Flow Position Diagram 91
Figure 5.1 Inputs and Outputs of the System 106
Figure 5.2 System Boundaries 106
Figure 5.3 Raw Material Acquisition 107
Figure 5.4 Consumer Use and Final Disposal 107
Figure 5.5 Recycling Subsystem 108
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CHAPTER I
INTRODUCTION
A. Product Information
Ethanol (CH3CH2OH) is a clear, flammable, colorless and slightly toxic chemical
compound with acceptable odor. It can be produced either from petrochemical
feedstock by acid-catalyzed hydration of ethane, or from biomass feedstock through
fermentation. It is also known as ethyl alcohol, grain alcohol, and EtOH. On a global
scale, synthetic ethanol accounts for about 3-4% of total production while the rest is
produced from fermentation of biomass-mainly sugar crops. Ethanol has the same
chemical formula regardless of whether it is produced from starch-and sugar-based
feedstock, such as corn grain, sugarcane, or from cellulosic feedstock.
1. Technology
Ethanol or ethyl alcohol has existed since the beginning of recorded history. The
ancient Egyptians produced alcohol by naturally fermenting vegetative materials.
Also in ancient times, the Chinese discovered the art of distillation, which increases
the concentration of alcohol in fermented solutions. Ethanol was first prepared
synthetically in 1826, through the independent effort of Henry Hennel in Britain
and S.G in France. Michael Faraday prepared ethanol by the acid-catalyzed
hydration of ethylene in 1828, in a process similar to that used for industrial
synthesis of ethanol today. The face of ethanol production technology is old and
ever changing. It is widely noted that centuries ago man discovered and began
employing fermentation technology to produce alcohol/ethanol.
Feedstock for the ethanol production can be broadly classified into : (i)
Monomeric Sugars, these are substrates in which carbohydrate is present in the form
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of simple, directly fermentable six-and twelve carbo sugar molecules such as
glucose, fructose, and maltose. Such feedstock include sugarcane, sugar beets, fruit
(fresh or dried), citrus molasses, and cane sorghum. (ii) Starch, contain slightly
complex carbohydrates and need to be enzymatically processed to yield simple
sugars. Examples of these are corn, grain sorghum, barley, and wheat and
root/tubular crops such as cassava, potatoes, cacti and arrowroot. (iii) Cellulosic
Biomass, lignocellulosic biomass such as that obtained from forest and agricultural
residues, also serves as feedstock for ethanol production.
2. Worldwide production of ethanol
Bioethanol and biodiesel are the most promising clean and alternative
renewable fuels. These can be used in the form of a gasoline/ diesel blend.
Bioethanol is currently produced mainly from corn (United States) and sugarcane
in Brazil. The United States and Brazil are the two major country in producing
ethanol. There is also growing interest in developing commercially viable cellulose
to ethanol technology. The use of ethanol as an alternative fuel source is presently
a worldwide topic of discussion and research. Through decades of research and
development, the production of fuel ethanol has been developing throughout the
world. Conventional processes have been maximized while advances continue to
be made in lignocellulosic biomass conversion. (Onuki; 2008)
3. Local production
The Philippines, Biofuels Act of 2006 (R.A. 9367) provides the legal basis for
the production in the country. Specifically for the Philippine sugar industry, ethanol
production for fuel will expand the market for sugar. The Republic Law No. 9367
enforces the blending of Bio-ethanol to Automobile Fuels. There are four feedstock
used in the production of ethanol in the country namely sugarcane, molasses,
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cassava and sweet potato but sugarcane and molasses are the most currently used
as ethanol feedstock in the country. (Survey; 2014)
4. Uses and Application of Ethanol
a. Medical
i. As an Antiseptic
Ethanol is used in medical wipes and in most common antibacterial hand
sanitizer gels.
ii. As an Antitussive agent
Ethanol is also widely used, clinically and over the counter, as an
antitussive agent.
iii. As an Antidote
Ethanol may be administered as an antidote to methanol poisoning.
b. Recreational
Ethanol is commonly consumed as a recreational drug, especially while
socializing, due to its psychoactive effects.
c. Fuel
i. Engine Fuel
The largest single use of ethanol is as an engine fuel and fuel additive.
A percentage of ethanol is combined with gasoline. This is beneficial
because the ethanol:
 decreases the fuel's cost
 increases the fuel's octane rating
 decreases gasoline's harmful emissions
Any amount of ethanol can be combined with gasoline, but the most
common blends are E10 and E85 in US and E25 in Brazil. More than 20%
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of Brazilian cars are able to use 100% ethanol as fuel, which includes
ethanol-only engines and flex-fuel engines. Flex-fuel engines in Brazil are
able to work with all ethanol, all gasoline or any mixture of both. In the US
flex-fuel vehicles can run on 0% to 85% ethanol (15% gasoline) since higher
ethanol blends are not yet allowed or efficient.
ii. Rocket Fuel
Ethanol was commonly used as fuel in early bipropellant rocket (liquid
propelled) vehicles, in conjunction with an oxidizer such as liquid oxygen.
The German V-2 rocket of World War II, credited with beginning the space
age, used ethanol, mixed with 25% of water to reduce the combustion
chamber temperature. The V-2's design team helped develop U.S. rockets
following World War II, including the ethanol-fueled Redstone rocket
which launched the first U.S. satellite.
iii. Fuel Cells
Commercial fuel cells operate on reformed natural gas, hydrogen or
methanol. Ethanol is an attractive alternative due to its wide availability,
low cost, high purity and low toxicity.
iv. Household Heating
Ethanol fuels flue-less, real flame fireplaces. It provides almost the same
visual benefits of a real flame log or coal fire without the need to vent the
fumes via a flue as ethanol produces very little hazardous carbon monoxide,
and little or no noticeable scent. An additional benefit is that, unlike a flue
based fireplace, 100% of the heat energy produced enters the room. This
serves to offset some of the heat loss from an external air vent, as well as
offset the relatively high cost of the fuel compared to other forms of heating.
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d. Feedstock
Ethanol is an important industrial ingredient. It has widespread use as a
precursor for other organic compounds such as ethyl halides, ethyl esters,
diethyl ether, acetic acid, and ethyl amines.
e. Solvent
Ethanol is miscible with water and is a good general purpose solvent. It is
found in paints, tinctures, markers, and personal care products such as
mouthwashes, perfumes and deodorants.
B. Product Properties
Ethanol, also called ethyl alcohol; can be used as fuel alcohol, drinking alcohol,
and grain alcohol. The common type of ethanol is the one found in alcoholic beverages.
It is also used as fuel for cars and often called alcohol or spirit. A fuel’s octane rating
is the measure of its ability to resist “knocking” or “pinging”. Ethanol has an octane
rating of 113 which offers more engine knock resistance at a lower cost than any other
gasoline additive on the planet. Ethanol is the lowest-cost octane source. Table 1 shows
the different property of ethanol.
Table 1.1 Property of ethanol
Ethanol
Chemical Formula C2H6O

Molar Mass 46.07 g/mol
Appearance Colorless liquid
Density 0.789 g/cc
Melting Point −114 °C
Boiling Point 78.37 °C
5
Flash point 14 ˚C
Other names Absolute alcohol/ Alcohol
Cologne spirit, Drinking alcohol
Ethane monoxide
Ethylic alcohol, EtOH
Ethyl alcohol
Ethyl hydrate
Ethyl hydroxide
Hydroxyethane
Methylcarbinol
C. Process Selection
The ethanol production process varies with the feedstock types. Depending on the
substrate complexity, various pretreatment methods are needed. For the production
from sugarcane, sugar beets and sorghum stalks, all of which contain simple sugars
such as glucose and sucrose, no pretreatment is needed except size reduction and
pressing. For starchy such as corn, sorghum and cassava, grinding or milling followed
by enzyme hydrolysis is needed to be obtain fermentable sugar. Lignocellulosic
biomass requires more comprehensive physical and chemical pretreatment to
enzymatic hydrolysis to release simple sugars.
1. Different processes use for the production of Ethanol
a. Wet milling process
The first step in the wet milling process is steeping, where the corn kernel is
placed in an aqueous solution of 0.1–0.2% SO2 and allowed to cook at 48–52◦C
for 30–50 hours. This facilitates downstream fractionation by hydrolyzing
disulfide bonds in proteins so that they are more soluble. The corn is then ground
in its wet state and oil, fiber, and gluten are separated from the starch for further
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processing into value-added co-products. During saccharification, enzymes
break down the starch into glucose. In the fermentation step, yeast grown in
seed tanks is added to the corn mash to ferment the simple sugars (glucose) to
ethanol. Finally, ethanol is separated from the water by means of distillation and
dehydration. (Chaudhary; 2012).
Gluten
Corn Fiber
(Gluten Meal)
(Gluten Feed)
Steeping
Starch/Gluten
Centrifugation
Separation
Starch
Grinding
Alpha-amylase/ Saccharification
Gluco-amylase
Germ (oil)
Yeast Fermentation
Germ Separation
Distillation
200 proof
Dehydration
Ethanol
Figure 1.1 Wet milling process for the production of ethanol
b. Dry Milling process
In a dry mill, cleaned corn is first ground in hammer mills, which breaks the
tough outer coating of the seed and grinds the corn into a fine powder. During
the liquefaction process, water and enzymes are added to the ground corn in
order to create a slurry. The gelatinized starch feedstock is easier to hydrolyze
into monomeric sugars than uncooked corn, although processes that avoid the
cooking step are being considered for ethanol plants. Saccharification and
fermentation are similar to the processes performed in a wet mill. Ethanol is
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obtained from the water slurry via a number of complex steps including
distillation and dehydration. A co-product of the dry milling process, heavy
stillage, leaves the bottom of the first distillation column. The heavy stillage is
centrifuged to remove the majority of the solids. The thin stillage is partly
recycled to the liquefaction step. The centrifuged solids are referred to as wet
cake or wet distiller’ grain (35-40% solids). These are further dried to give
DDGS. (Chaudhary; 2012)
Ethanol
Gluco-amylase Dehydration
Alpha-amylase,
Corn Yeast
water
Milling Liquefaction Saccharification Fermentation Distillation
Heavy
Stillage
Separation Centrifugation
Backset Thin Stillage
Wet cake
Dryer
Syrup
Dried Distiller's
Grain with
Solubles(DDGS)
Figure 1.2 Dry milling process for the production of ethanol
c. Ethanol from Cellulosic Biomass
The difficulties of using cellulosic materials are there poor porosity, high
crystallinity, and lignin contents. Various kinds of pretreatment techniques have
been investigated, such as steam, acid and alkali treatments. In the ethanol
production from cellulosic material, the feedstock is delivered to the feed
handling area for storage and size reduction. From there, the biomass is
8
conveyed to pretreatment and conditioning. Pretreatment is used to reduce the
crystallinity of cellulose and disrupt the heterogeneous structure of cellulosic
material and in this process detoxification is applied. Enzymatic hydrolysis (or
saccharification) coupled with co-fermentation of the detoxified hydrolyzate
slurry is carried out in a continuous hydrolysis trank and anaerobic fermentation
tanks in series. After several days of saccharification and fermentation, most
cellulose will have been converted to ethanol. Product recovery is present after
fermentation which involves distilling the beer to separate the ethanol from the
water and residual solids. (Farid;2008)
Ammonia
Steam Glucose Enzyme
Acid Production
Nutrients
Cellulase Enzymatic
Feedstock Feed chips Pretreatment/
Hydrolyzate Hydrolysis and
Handling Conditioning
Nutrients Fermentation
Recycle
Evaporation Water
Vent Beer Vent
Flash
Condensate
Distillation
Wastewater
Nutrients Steam Dehydration
Treatment
Solids Separation
Stillage
Lignin Ethanol
Product
Fuel Burner/Boiler Steam

Anaerobic Turbogenerator
Electricity Storage
iogas
Figure 1.3 Ethanol production from Cellulosic material
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Table 1.2 Comparison of the tree alternatives method
Process Advantage Disadvantage
Wet milling process  More versatile  Higher cost of
construction and
operation
Dry milling process  More efficient  A need of

 A variety of high- sophisticated
valued coproducts marketing to dispose
are produced. of coproduct
Process using cellulosic  Greater ethanol  Conversion of
material production cellulosic biomass to
ethanol is more
difficult
D. Proposed process of Ethanol Production
1. Anatomy of the process
The basic component of a typical chemical process of the ethanol production is
shown in the figure below. Each block represents a stage in the overall process a
product from the raw materials wherein the raw material used in the process is corn
kernel. The figure represents a generalized process; not all the stages will be needed
for any particular process and the complexity of each stage will depend on the nature
of the process.
Product Purification Product Sales
Raw Material Raw Material Product Separation Storage
Reaction
Storage Preparation
Dehydration
Feedstock Product
Milling Liquefication Saccharification Fermentation Distillation Distribution
Storage Storage
Centrifugation
Drying
Stage 1 Stage 2 Stage 3 Stage 4 Stage 6
Stage 5
Figure 1.4 Anatomy of the proposed process
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a. Stage 1. Raw Material Storage
Corn kernels are stored in a storage room ready for the feed preparation
b. Stage 2. Feed Preparation
The first process for the feed preparation involves milling wherein the size
reduction of corn kernels will happen. The feed preparation also involves
liquefaction and saccharification, conversion of starch to dextrin to glucose
happens respectively.
c. Stage 3. Reaction
Fermenter is the reactor present in the process which is the heart of the
process. Fermentation is the most important part in the process.
d. Stage 4. Product Separation
The product and by-product are separated using distillation. Ethanol is
delivered to a molecular sieve for the next stage which is dehydration and a
stillage is also delivered to a centrifuge ready for the next stage to produce a by-
product of distillers’ dried grain
e. Stage 5. Product Purification
The main product ethanol will undergo dehydration to produce a 99-100 %
ethanol. Centrifuge is used to purify the whole stillage removing the liquid
phase of the stillage which will be ready for drying to produce a dried distillers’
grain.
f. Stage 6. Product Storage
The ethanol is the main product in the process which will be stored in tanks.
The distillers’ dried grain is the by-product in the process. Both products will
be stored in their respective storage ready for the distribution.
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Below shows the general conversion of starch and its conversion rates to ethanol.
A detailed process of ethanol production from corn will be discuss in the chapter 2 of
this paper.
alpha- gluco- Yeast

amylase amylase
Starch
(C6 H10 O5 )n Dextrin Glucose Ethanol
+ 98% (C6 H12 O6 )10 99% (C6 H12 O6 ) 94% 2(C2H5OH)
Water (H2 O)
E. Site Selection
Determining the possible site location is very vital in starting an ethanol plant.
For this purpose, different considerations need to be reviewed to optimize the location
of the plant. The accessibility of the feedstock for ethanol plant is the most important
factor to be considered because it is beneficial to the operational phase of the plant.
Ilagan City also known as the “Corn Capital of the Philippines” is the most
promising place in building the ethanol plant. The city contributes for the 21% annual
national yellow corn production in Isabela which is cited as the top grain producer of
the Philippines, achieving high production rates for corn (almost 16% of the national
Production. The Philippine Statistics Authority (PSA) shows that 21.68% share of the
total agricultural output of the Cagayan Valley is corn.
Based on the information, the availability of the feedstock is not a problem in
Isabela, hence, a site within or near the region is considered as a practical choice
considering the availability of the feedstocks.
Ilagan City is selected as a probable area for building up ethanol production
plant because of the capacity of the city in producing corn.
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1. Comparative Factors
 Raw Material Supply
Despite natural calamities such as floods and drought, Isabela continues its lead in corn
production and remains as the Philippine’s top corn producing province. In addition, part of
the development plans of the province is to concentrate on high value commercial crops,
including fruits and vegetables, and identify the niche markets. Value-added production
commands higher prices for raw agricultural products. By applying this development strategy,
it opens more agribusiness possibilities and other investment areas as well.
As stated in the Official page of Isabela, it contributes 21% of the annual national yellow corn
production in the Philippines. So, the demand for the feedstocks is not a major problem in
putting the ethanol plant in Ilagan City, Isabela.
 Transportation
For travel between cities and towns, there are buses and van shuttles that ply the major
highways. For short trips around towns, the tricycle is the main mode of transport. But if you’re
traveling in a group, it’s really more convenient to have your own private vehicle for getting
around. Getting to some of the eco-tourism sites requires long land travel on rough roads where
jeeps and trucks are the main mode of transport.
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Going to Calamagui 2nd will take 41 minutes with reference to the center of Ilagan City, Isabela.
Therefore, the proximity of road and estimated cost for transportation is less.
 Availability of Labor
In the 2015 census, Ilagan City has a population of 1,593,566. The labor force participation
rate based on 2018 was found to be 65.3 with an employment rate of 95.8% in whole Region
2.
Therefore, putting up ethanol plant in Ilagan City, Isabela will result in more available works
in the city which is advantageous to residence since the employment rate is very high.
 Utilities
The power service in the city is mainly supplied by Isabela II Electric Cooperative (ISELCO
II). Water and power supply for the municipality has yet to be improved. The level III
waterworks within the urban area has served only 30 % of the existing households. Power
outages should be minimized to support the socio-economic activities with the locality that
would redound to better service delivery from these vital economic boosters.
 Telecommunication
The site has a better signal quality needed for communication purposes. The telephone and
internet services are provided by Philippines Long Distance Telephone Company (PLDT). For
the cellular phone services, Globe Telecom and Smart Communications are in charge.
2. Site Considerations
Calamagui 2nd is a barangay in the city of Ilagan, in the province of Isabela. Its population as
determined by the 2015 Census was 3,109. This represented 2.14% of the total population of
Ilagan. It is situated at approximately 17.1214, 121.8659, in the island of Luzon. Elevation at
these coordinates is estimated at 54.6 meters or 179.1 feet above mean sea level. The land is
14
mainly composed of residential areas and high plateaus. The Cagayan River runs through the
western portion of the city.
3. Site Layout
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4. Plant Layout
Maintenance
Canteen
Office Storage Facility
Administration Parking
Building Area
House
Guard
Parking Area
Clinic
Main Gate
Cagayan River
Control
Room
Laboratory
Parking
Production Area Area for
Trucks
Co-generation
Area
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CHAPTER II
MARKET STUDY
A market study (also known as market analysis, market assessment, market sounding,
market research, etc.) allows us to determine how suitable a particular market is for your
industry. It can be used to evaluate your current, or look at new markets. Market study helps
us to identify the attractiveness of a market and also detects current and future risks of operating
in that location. Market study provides a holistic, or well-rounded picture of the markets you
are interested in operating in.
A. GLOBAL ETHANOL MARKET
The global bioethanol market was valued at US$57,650 million in 2017 and is expected
to register a Compound Annual Growth Rate (CAGR ) of over 5%.
i. BY TYPE
Figure 2.1 Global Bioethanol Market by Type
On the basis of type segmentation, corn-based bioethanol segment is expected to
contribute major revenue share and expected to maintain its dominance over the forecast
17
period. Corn-based bioethanol witness highest CAGR over 5.0%, owing North America and
Latin America provides subsidies for corn production to promote corn production.
ii. By Blend
Figure 2.2 Global Bioethanol Market by Blend
On the basis of blend segmentation, E15 to E70 segment is estimated to contribute
major revenue share and expected to maintain its dominance over the forecast period. US
government passed a regulation under Energy Independence and Security Act, which mandates
consumption of renewable fuels in transportation sector. E70 blend is used as winter blend in
US and Sweden as transportation fuel during cold weather to avoid starting problems of
vehicles. While, the Brazilian government made mandated of blending ethanol with gasoline
between 10% to 22%.
18
iii. By Application
Figure 2.3 Global Bioethanol Market by Application
Among all the application segments, transportation segment is expected to register
highest CAGR over 5.5%. Bioethanol is used to blend the petrol that is used fuel in
transportation. Ethanol burns clean and protects the engines, and often extends engine
maintenance, boosting octane, and release low greenhouse gas emissions compared to pure
gasoline.
Government initiatives to promote the use of bioethanol as fuel in transportation is
expected to fuel the market growth over the forecast period. Bioethanol for Sustainable
Transport (BEST) was a four-year plan started by European Union for promoting bioethanol
as vehicle fuel in Europe.
19
iv. By Region
Figure 2.4 Global Bioethanol Market by Region
North America market is expected to dominate the global bioethanol market, and it
accounts for largest market revenue over US$ 24,500 million in 2017 as compared to that of
markets in other regions. Dominance by North America market is expected to continue over
the forecast period with comparatively higher CAGR than that of other regions, owing to higher
demand among consumers in countries in the region. Presence of leading bioethanol
manufacturers in this region and increasing consumers of bioethanol in this region is expected
to fuel the market growth over the forecast period. North America is the largest producer and
consumer of bioethanol.
In 2017, Latin America accounted for the second largest revenue share contribution to
the global bioethanol market. Revenue from the bioethanol market in Brazil is expected to
expand significantly over the forecast period, owing to increasing number of industries engaged
in ethanol manufacturing, and abundant availability of sugarcane in the country.
Brazil is a major exporter of bioethanol, which is further expected to drive market
growth. According to the Economic Commission for Latin America and the Caribbean
20
(ECLAC), Brazil is the second largest producer of bioethanol. Most of the vehicles in Brazil
are ran on ethanol fuel. Bioethanol accounts about 40% of the fuel consumed in the country.
The Asia Pacific is expected to be the fastest growing region in the global bioethanol
market. China has been one of the largest importers of bioethanol in the Asia Pacific region
and is expected to continue this trend over the forecast period. This can be attributed to rapidly
growing transportation industry and rising demand for bioethanol for alcoholic beverages in
the country.
1. Global Past and Future Ethanol Production for Years
Coarse grains and sugarcane will remain the dominant ethanol feedstock. Molasses use
in ethanol production will increase in India. Vegetable oil continues as the feedstock of choice
in biodiesel production. Biodiesel production based on non-agricultural feedstock and in
particular waste oil and tallow will develop in the European Union and the United States.
Lignocellulosic biomass based ethanol is projected to account for less than 1% of world ethanol
production by 2025.
Biofuel production is expected to consume 10.4% and 12% of global coarse grains and
vegetable oil production respectively in 2025. By 2025, 22% of global sugarcane production
should be used to produce ethanol.
21
Figure 2.5 World Ethanol Production/Trade (2008-2025)
Source: OECD/FAO (2016), “OECD-FAO Agricultural Outlook”, OECD Agriculture
statistics (database)
B. LOCAL MARKET (PHILIPPINES)
The Philippines was the first country in Southeast Asia to enact biofuels legislation.
The blend mandate was gradually increased in accordance with the Biofuels Act 2007, ending
with a 10 percent ethanol requirement in August 2011, which remains the current mandate. In
table 2.1, the aspirational goals to raise ethanol mandate are based on the National Renewable
Energy Program of the Philippine Energy Plan 2012-2030 to meet the government’s Energy
Reform Agenda.
22
Table 2.1 Philippine Ethanol Mandate
PHILIPPINE ETHANOL MANDATE
Date Signed Published Effective Remarks
R.A. 9367 1/12/2007 1/22/2007 2/06/2007
Ethanol
- 5% blend 2/06/2009 - By volume
- 10% 8/06/2011 - Implementation of 10%
blend blend
Target
Blend 2012 - - All oil companies
- 10% (full) onwards - Projected
- 20% 2020 - Projected
- 85% 2025
1. Production
In 2016, fuel ethanol production for the Philippines was 4 thousand barrels per day. Fuel
ethanol production of the Philippines increased from 0 thousand barrels per day in 1996 to 4
thousand barrels per day in 2016 growing at an average rate of 16.60%.
23
Figure 2.6 Fuel Ethanol Production of Philippines
2. Consumption
In 2016, fuel ethanol consumption for the Philippines was 8.4 thousand barrels per day.
Fuel ethanol consumption of Philippines increased from 0 thousand barrels per day in 1997 to
8.4 thousand barrels per day in 2016 growing at an average annual rate of 201.07%.
Figure 2.7 Fuel Ethanol Consumption of Philippines
24
3. Local Past and Future Ethanol Production for Years
In a report by USDA Foreign Agricultural Services, the continued growth of Philippine
economy and its expanding population are expected to drive fuel demand through 2026.
Starting from 2016, fuel demand projections are based on Post’s estimates with the assumption
of five percent demand growth annually.
Figure 2.8 Fuel Use Projection
(Source: USDA Foreign Agricultural Service GAIN Report: Philippine Biofuels Situation
and Outlook 2016)
C. DIFFERENT CONSUMERS
Bioethanol can be used as a transportation fuel, fuel for power generation, feedstock in
chemical industry, fuel for fuel cells and in cogeneration systems, in cosmetics industry and in
manufacturing processes owing to its clean burning and easy availability. Rapid growth in the
transport and automotive sector all over the globe is likely to propel the consumption for these
fuels over the next seven years. Fluctuating oil prices and rising dependence on conventional
sources will drive the bioethanol market growth over the forecast period. Moreover, increasing
25
consumption of power is likely to spur the use of ethanol in power plants and chemical industry.
In addition, government and environmental regulations from European Union and the U.S. will
surge the market growth over the projected period. Rapidly growing cosmetic industry is
further predicted to propel the growth in the near future. Furthermore, it can be blended with
petrol or diesel which makes it environment friendly and improves the efficiency of the fuel
owing to high octane value, thus leading to energy security. Blending ethanol with conventional
fuel does not require change of vehicle engines which will spur the demand for bioethanol as
a fuel over the projected period. Encouraging the use of this renewable resource is likely to
impact the agricultural sector and rural economy on account of higher demand for fuel crops.
D. PACKAGING
Ethanol can be packaged in small or large amount. Since ethanol is volatile, the
container should be closed tight. The containers should be properly labelled. Labels shall
contain the following information like symbol of flammable, statement of necessary
precautions, etc. The container is recyclable and can be refilled by sales outlet nearby.
E.TRADE AND PRICES
Global trade in biofuels relative to production remains modest; only about one-tenth of
total biofuel production by volume is traded internationally. Over the past years, ethanol price
per liter has been unstable but is remarkably increasing through the years. The price of ethanol
is usually set at 25% to 30% less than gasoline because of its lower thermal capacity. However,
the price gap is narrowing down given the expected continuing increase in the price of gasoline
and as well as ethanol economy. Government incentives in the form of tax subsidies also play
an important role in reducing the price of bioethanol.
26
Figure 2.9 Global Ethanol Production, Trade and Prices, with projections to 2017
27
CHAPTER III
TECHNICAL STUDY
A. Process Description
1. Reactor Feed Preparation
a. Cleaning
The corn kernels must be cleaned prior to processing. The incoming stream of
corn kernels, as received, is typically passed through a screener or scalper or
multiple screeners or scalpers arranged to remove oversized materials (e.g., corn
cobs, husks, sticks) and smaller materials. The unwanted materials tend to account
for a very small portion of the incoming corn stream. The corn may also pass
through a destoner, which separates objects based on weight and can be used to
remove heavier objects (e.g., stones, glass) from the process stream. During the
cleaning process, pressurized air may be used to remove chaff and dust. In addition,
the process stream will usually pass through a magnetic separator to remove any
tramp metal that may be remaining.
b. Milling
Once the corn has been cleaned, the whole kernels are conveyed to a milling
operation typically a hammer mill or impact mill. A kernel of corn consists of a
fiber shell which contains starch, protein, gluten and germ. The shell needs to be
broken and the starch disrupted to enhance enzymatic hydrolysis during cooking.
This can be accomplished using a hammer or roller mill (with screens between 3.2
to 4.0 mm) to grind the corn into a fine meal.
28
c. Liquefaction
Corn Starch is composed of glucose units joined through a linkage in chains by
a 1-4 and in branches by a 1-6 glycosidic bonds. The linear starch molecules are
called amulose, whereas the branched on is called amylopectin. The whole milled
grain is slurried with water, and a thermo-stable enzyme a-amylase is added which
breakdown the starch polymer (hydrolyze a 1-4 bond) and produce soluble dextrin.
The most effective use of alpha-amylase occurs when the pH of the slurry is
between 6.0 and 6.5, and the pH is kept in this range from the time the alpha-
amylase is added until liquefaction is complete. Anhydrous ammonia and various
other bases (e.g. lime) may be added if the pH falls below the optimal range,
whereas sulfuric acid might be added if the pH starts to exceed the optimal range.
Liquefaction is accomplished using jet-cookers that inject steam into the corn flour
slurry to cook it at temperatures above 100°C (212°F). The heat help reduce the
levels of bacteria in the mash by 90%.
Reaction:
 amylase
(C6 H10O5 ) n  H 2 O a (C6 H12O6 )10
d. Saccharification
After liquefaction, the slurry, now called “corn mash,” is cooled to
approximately 30°C (86°F), and a second enzyme (glucoamylase) is added.
Glucoamylase breaks down the dextrins into glucose, which completes the
breakdown of the starch into simple sugars. The most effective use of glucoamylase
occurs when the solution pH is between 4.0 and 5.5, which is considerably lower
than the pH in the liquefaction process. Therefore, the solution pH must be lowered
to achieve optimal enzymatic activity. The pH reduction at this stage is typically
29
accomplished by blending in a lower pH stillage solution generated later in the
process or by adding sulfuric acid.
Reaction:
C6 H12O6 10 gamylase

10C6 H12O6
2. Reactor
a. Fermentation
Yeast is added to the mash to ferment the sugars. During this process, the yeast
eat the sugars, and in the process produces heat, ethanol and carbon dioxide. The
whole process requires 48-72 hours and the liquid phase of the beer is typically 8 to
12 percent ethanol by weight. CO2 released can be captured and sold for the use in
carbonating soft drinks, dry ice and some beverages industries. Unlike the upstream
processes (milling, liquefaction, saccharification) that operate continuously,
fermentation typically operates as a batch process. Most facilities have numerous
tanks dedicated to fermentation and they typically operate in groups of three: while
one tank is being filled, another is fermenting, and the third is emptying and made
ready for filling. With this arrangement, upstream production never needs to halt
between batches. Larger facilities can have multiple groupings of three tanks.
Reaction:
C6 H12O6  2C2 H 5OH  CO2

yeast
3. Separator
a. Distillation
The beer mixture is pumped into a beer column where the purified ethanol is
collected from the vapor portion of columns and spent solids (stillage) from the
30
bottom. The ethanol stream is further purified in an ethanol column. The columns
utilize the differences in the boiling points of ethanol (78oC) and water (100oC) as
a milestone to boil off and separate the ethanol. By the time the product stream is
ready to leave the distillation columns, it contains about 95% ethanol by volume
(190-proof).
b. Dehydration
The ethanol still contains about 5% water. Alcohol and water form an azeotrope
at this point and cannot be separated further. To carry out this operation, it is passed
through a molecular sieve to physically separate the remaining water from the
ethanol. The molecular sieve is a bed of specialized beads that selectively adsorb
water based on molecule size. The beads are commonly made from zeolite, a type
of aluminosilicate. Similar to fermentation tanks, facilities typically operate
multiple molecular sieves so that when one sieve needs to be regenerated another is
always available to handle the ethanol stream. This step produces 99-100% ethanol.
c. Centrifugation
The stillage collected from the beer column contains 66% liquid. Centrifuge is
used to separate the liquid and solid phase of the whole stillage. The Wet Distillers’
Grain with Solubles or WDGS (40% moisture) is transported into a dryer using a
conveyor while the thin stillage (93% moisture) is first sent to an evaporator. Some
of the thin stillage is routed back to the slurry tank as a makeup water.
d. Evaporation
The evaporator concentrates the thin stillage from 93% to 40% moisture
content. The feed is heated up to 105oC and the water evaporated can be utilize in
the cooker reducing the amount of heat and fresh water required in the upstream.
31
e. Dryer
WDGS is often dried to 10-12 percent moisture. This can be done in a rotary
drum dryer or in a ring dryer to form dried distillers’ grain with solubles (DDGS).
Dryer temperatures can vary considerably (from 220 oF to 380oF) depending on
many factors, such as the type of dryer used, the dryer residence time and feed rate,
and the target moisture content.
32
Steam
Thin Stillage
Fresh water Acid Gluco-amylase Yeast Water
CO2
Corn Hammer Milled Slurry Mash Saccharification Mash CO2

Cooker Fermentors CO2
Kernels Mill Grains Tank Slurry (Dextrin) Tank (Glucose) Scrubber
Alpha-amylase
Waste Water
Ammonia
Beer
Lime
EthanolWater
Wet Ethanol
Azeotropic Ethanol
Dehydrated Molecular Ethanol Beer

Ethanol Sieve Column Column
Process Water
Stillage
Steam
Evaporator Centrifuge
Thin Stillage
Conc.Thin Stillage Wet Distillers Grain

with Soluble (WDGS)
Water
Distillers' Grain
with Soluble
Dryer
Dried Distillers Grain
with Soluble (DDGS)
Figure 3.1 Block Flow Diagram
33
M-101 T-101 T-102 R-101 H-101 T-103 E-101 R-102 E-102 R-103 G-101 N-101
Hammer Weigh Slurry Steam Steam Cook Mash Saccharification Mash Fermentors Degasser Beer Degas
Mill Tank Tank Cooker Heater Retention Tank Pre-Cooler Tank Post-Cooler Vent Condenser
S-101 T-104 T-105 T-106 T-107 E-103 E-104 E-105 C-101 T-108 V-101 D-101
CO2 Beer Ethanol Adsorption Adsorption Anhydrous Ethanol Water Stillage Centrifuge Thin Stillage Stillage DGS
Scrubber Column Column Column 1 Column 2 Ethanol Cooler Cooler Cooler Tank Evaporator Dryer
G-AMYLASE
8
A-AMYLASE
4
WATER
3
CORN
1
H-101
2 M-101
R-102
E-101
6
5 7
R-101
T-101 T-103
T-102 E-102
9
WATER CO2
14 15
YEAST WASTE WATER
10 16
S-101
E-103
ETHANOL
21
13
18 19
R-103
N-101 T-104 T-105 T-106 T-107
11
12 17
G-101
E-105
22
Figure 3.2 Process Topology E-104

23 PROCESS WATER
20
26
24
MOISTURE
V-101
28
34 T-108 27
D-101 DDGS
C-101 29
25
B. Material Balance Summary
For each of the block shown in the block flow diagram, the material balance is
written as:
Material in  Material out
or
Mi  Mo
m n
or M
j 1
i, j   M o ,k
k 1
Where j represents the type of material inputs with a total of m inputs, and k
represents the type of material outputs with a total of n outputs.
The plant is assumed to produce a 100 000 kg/day of 99.5% ethanol and DDGS
as a co-product in a dry mill process.
In the dry mill ethanol process, the whole grain is processed, and the residual
components are separated at the end of the process. The ethanol production facility
run continuously with scheduled shut down periods for maintenance.
The basic steps include milling, cooking, liquefaction, saccharification,
fermentation, distillation/dehydration, centrifugation, evaporation, and drying. If
the ethanol plant is taken as a single system, the inputs are corn and water plus
energy, while the outputs are ethanol, solids (by‐products), wastewater, and CO2.
Degrees of freedom analysis are used when the number of unknowns and
independent equations have been determined. It is an analysis whether a problem is
solvable or not.
The following tables of properties are used for the material balance calculations:
the grain composition, the solid/liquid percentage of every streams, the assume
ethanol content in the downstream, the theoretical conversion rates of the three main
reactions as well as the needed weight of enzymes.
35
Table 3.1 Grain Composition
Grain Percent Average (Dry matter)
Carbohydrates (Total) 84.1
Starch 72.0
Fiber (NDF) 9.5
Simple Sugars 2.6
Protein 9.5
Oil 4.3
Minerals 1.4
Others 0.7
TOTAL 100
The production starts with corn as input. Table 3.1 lists the composition of corn.
It is used mainly in the upstream material balance calculations especially
component balances.
Table 3.2 Dry Mill Process Solid/Liquid Percentages

Product Liquid (w/w%) Solids (w/w%)
Slurry 67.0 33.0
Mash 77.8 22.2
Beer 89.0 11.0
Whole Stillage 66.0 34.0
Thin Stillage 93.0 7.0
WDGS 40.0 60.0
DDGS 89.0 11.0
Table 3.2 is used along with the conversion rates in Table 3.3 to determine the
theoretical yield of co-products from grain and the water needed in the production.
36
Table 3.3 Conversion Rates as a Percentage of Theoretical Yield
Starch to Dextrin Conversion : 98.0%
 amylase
(C6 H10O5 ) n  H 2 O a (C6 H12O6 )10
Dextrin to Glucose Conversion: 99.0%

10C6 H12O6
Starch 
 Glu cos e 97.0%
Glucose to Ethanol Conversion: 94.0%
C6 H12O6  2C2 H 5OH  CO2

yeast
Starch 
 Ethanol 91.2%
Ethanol and CO2 yields were calculated as function of the corn composition and
conversion rates. The DDGS came from starch, dextrin and glucose that was not
converted to alcohol in the fermentation process.
Table 3.4 Ethanol Content of the Down streams

Streams Weight Percent Ethanol
Beer 8.9
Wet Ethanol 60.0
Process Water 0.05
Azeotropic Ethanol 95.0
Ethanol Water (Recycle) 73.0
Dehydrated Ethanol 99.5
Aside from the main raw materials needed in the plant, the addition of enzymes
greatly contributes to the production process. Table 3.4 shows the corresponding
amount of enzymes needed for the three main reactions of the process.
37
Table 3.5 Theoretical Weight of Enzymes Needed in the Dry Mill Process
Estimated Weight
weight needed
Enzymes Unit Process needed
(kg)
(kg/kg corn)
A-Amylase Liquefaction 0.000811 per kg starch 0.000582
G-Amylase Saccahrification 0.000854 per kg dextrin 0.000680
Yeast Fermentation 0.000244 per kg glucose 0.000194
38
Steam
Fresh water Thin Stillage
605991.93 Gluco-amylase Yeast Water
kg/day
CO2
Milled Mash Mash
Corn Kernels Slurry Cooker Saccharification
Hammer Mill Grains Slurry Tank (Dextrin) (Glucose) Fermentors CO2 Scrubber
210 o C, 1atm Tank CO2
40 o C, 1atm 80 o C, 1atm 35 o C, 1atm 30 o C, 1atm
68 o C, 1atm
Waste Water
Beer
Alpha-amylase
Ethanol Water
Wet Ethanol
Azeotropic Ethanol
Dehydrated
Ethanol Molecular Ethanol Column Beer Column
Sieves 80 o C, 1atm 80 o C, 1atm
80 o C, 1atm
Process Water
Stillage
Steam
105 o C, 1atm Thin Stillage 70 o C, 1atm
Conc.Thin Stillage Wet Distillers' Grain

with Soluble (WDGS)
Water
Distillers' Grain with
Soluble Dryer
150 o C, 1atm
Dried Distillers' Grain
with Soluble (DDGS)
Figure 3.3 Qualitative Block Diagram
39
Steam
Fresh water Thin Stillage
605991.93 Gluco-amylase Yeast Water
208. 41 kg/day 58.95 kg/day 111073.00
kg/day
CO2 kg/day
Milled Mash Mash
Corn Kernels Slurry
Hammer Grains Slurry (Dextrin)Saccharification (Glucose) CO2
Cooker Fermentors CO2
312244.33 Mill 312244.33 Tank 953153.86 1415811.96 Tank 1415811.96 Scrubber
kg/day kg/day kg/day kg/day kg/day
Waste Water
Beer
Alpha-amylase
1304738.97
182.28 kg/day Ethanol Water
Wet Ethanol kg/day
20454.55 Azeotropic Ethanol
kg/day 165888.24
Dehydrated 120454.55
kg/day
Ethanol Molecular kg/day Ethanol Beer
Sieves Column Column
100000.00
kg/day Process Water
Stillage
65888.24 1138850.73
Steam kg/day 34917.59 kg/day
462658.11 kg/day
kg/day 523763.90
kg/day
Thin Stillage
580169.24
Conc.Thin Stillage Wet Distillers' Grain kg/day
61105.79 with Soluble (WDGS)
kg/day Water
208954.78
Distillers' Grain
kg/day
with Soluble
Dryer
Dried Distillers' Grain
432320.24 with Soluble (DDGS)
kg/day
Figure 3.4 Quantitative Block Diagram
40
A summary of flow rates table is established to show and to check whether the
sum of all input flow rates equals the sum of the output stream.
Table 3.6 Summary of Material Balance Calculations

Inflow Outflow
Equipment Streams
(kg/day) (kg/day)
Corn Kernels 312244.33
Hammer Mill Milled Grains 312244.33
Milled Grains 312244.33
Fresh Water 605991.93
Slurry Tank Recycle from
34917.59
Centrifuge
Slurry 953153.86
Slurry 953153.86
Steam from
Cooker 462658.11
Evaporator
Mash (Dextrin) 1415811.96
Mash (Dextrin) 1415811.96
Saccharification Tank
Mash (Glucose) 1415811.96
Mash (Glucose) 1415811.96
Fermentors Beer 1304738.97
Carbon Dioxide 111073.00
Beer 1304738.97
Beer Column Wet Ethanol 165888.24
Stillage 1138850.73
Wet Ethanol 165888.24
Ethanol Water
20454.55
Ethanol Column from Mol.Sieves
Process Water 65888.24
Molecular Sieves Ethanol Water 20454.55
41
Stillage 1138850.73
Thin Stillage
34917.59
(to Slurry Tank)
Centrifuge Thin Stillage
523763.90
(to Evaporator)
Wet Distillers' Grain
580169.24
with Solubles
Thin Stillage 523763.90
Steam to Evaporator 462658.11
Evaporator
Concentrated Thin
61105.79
Stillage
Wet Distillers' Grain
580169.24
with Solubles
Concentrated Thin
61105.79
DGS Dryer Stillage
Water 208954.78
Dried Distillers'
432320.24
Grain with Solubles
TOTAL 9428260.03 9428260.03
42
C. Energy Balance Summary
Two heat balance equations were used in the calculations.
Q  mCpT
Q  mH
Where
m is the mass flowrate in kg/s,
Cp is the specific heat capacity in kJ/kgoC,
ΔT is the temperature difference in oC and
ΔH is the enthalpy in kJ/kg.
From Chemical Reaction Engineering by Octave Levenspiel, the energy balance
equation on reactor is:
Q  Cp2 Tx A  Cp1 T (1  x A )  H r x A
Where
Cp2 is the mean specific heat capacity of the converted product,
Cp1 is the mean specific heat of unreacted feed stream,
xA is the fractional conversion and
ΔHr heat of reaction
Energy can be in the form of mechanical energy done on the system, a heat gain
or loss due to a change in temperature or work done. Data and assumptions
regarding the streams leaving and entering the equipment such as sensible heat, heat
of vaporization, heat capacity and mass flow rates and temperature of streams were
needed.
43
250
200
150
T(deg.C)
100
50
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13
Streams
Figure 3.5 Temperature Profile for Ethanol and DDGS Production
Table 3.7 Legend of Streams in Figure 3.3
Streams Black Blue Red

1 Corn Kernels
2 Milled Grains
3 Slurry
4 Mash (Dextrin)
5 Mash (Dextrin)
6 Mash (Dextrin)
7 Mash (Glucose)
8 Mash (Glucose)
9 Beer
10 Wet Ethanol Stillage
Azeotropic Thin Stillage(up)/
11
Ethanol WDGS(down)
Conc. Thin
Dehydrated
12 Stillage(up)/
Ethanol
WGDS(down)
Dehydrated
13 DDGS
Ethanol
44
Table 3.8 Specific Heat capacity of Streams
Streams Cp (kJ/kgoC)
Corn/Milled Grains 1.800
Slurry 1.218
Mash(Dextrin) 1.218
Mash(Glucose) 1.2552
Beer 0.805
CO2 0.9185
Wet Ethanol 3.055
Stillage/WDGS 4.184
DDGS 2.536
Ethanol Water 3.055
Process Water 4.188
Table 3.8 shows the different specific heat capacities used for the computation of the
sensible heat of streams or the heat gain/loss of a stream.
45
Table 3.9 Summary of Energy Balance Calculations
Input, Output, Heat
Temp.
Equipment Streams Qin Qout Loss/Gain
(oC)
(kW) (kW) (kW)
Corn Kernels 25 162.63
Hammer Mill Milled 97.58
40 260.21
Grains
Milled
40 260.21
Grains
Fresh Water 25 790.83
Slurry Tank -10.59
Thin Stillage
70 118.65
(Recycle)
Slurry 80 1074.96
Slurry 80 1074.96
Steam 210 15516.84
Cooker -12400.33
Mash
210 4191.47
(Dextrin)
Mash
210 4191.47
Cook Retention (Dextrin)
-2594.72
Tank Mash
80 1596.75
(Dextrin)
Mash
Pre-cooler to 80 1596.75
(Dextrin)
Saccharification -997.97
Mash
Tank 30 598.78
(Dextrin)
Mash
30 598.78
Saccharification (Dextrin)
799.91
Tank Mash
68 1398.69
(Glucose)
Post-cooler Mash
68 1398.69
from (Glucose)
-781.62
Saccharification Mash
30 617.07
Tank (Glucose)
46
Mash
30 617.07
(Glucose)
Fermentors Carbon -150.26
35 41.34
Dioxide
Beer 35 425.47
Beer 35 425.47
Beer Column Wet Ethanol 38 222.89 4209.36
Stillage 80 4411.94
Wet Ethanol 38 222.89
Ethanol
35 25.34
Water
Ethanol
Azeotropic 194.60
Column 40 187.19
Ethanol
Process
80 255.64
Water
Azeotropic
40 187.19
Ethanol
Moecular Ethanol
80 57.92 22.25
Sieves Water
Dehydrated
80 151.52
Ethanol
Ethanol
80 57.92
Ethanol Water Water
-32.58
Cooler Ethanol
35 25.34
Water
Dehydrated
80 151.52
Dehydrated Ethanol
-85.23
Ethanol Cooler Dehydrated
35 66.29
Ethanol
Stillage 80 4411.94
Stillage Cooler -551.49
Stillage 70 3860.45
Evaporator Thin Stillage 70 1780.35 12866.78
47
Steam to
105 14336.53
Cooker
Conc. Thin
105 310.60
Stillage
WDGS 70 1966.69
Conc. Thin
105 310.60
DGS Dryer Stillage 6344.98
Water 150 6718.75
DDGS 150 1903.52
D. Utility Requirement
1. Water Consumption
The water used in the bioethanol pant can be city water, groundwater or surface
water. The type of water used depends on its application. Water is recycled and re-
used, after prior appropriate purification treatment, for specific process applications
such as liquefaction, cooking, steam generation, scrubbing and cooling. Water
treatment is used to provide the requisite quality of water to a variety of different
processes, many of which with have their own individual technical requirements.
2. Energy Consumption
Ethanol production requires electrical and thermal energy at every step of the
process. Electricity is needed for lighting, for plant process control, for heating and
as driving power for machinery. It is usually generated and supplied by utility
companies. When steam and electricity are generated on-site the efficiency factor
can be considerably higher.
48
Table 3.10 Average Energy and Water Usage per gallon of Ethanol produced
Utility Unit Value
Energy (Ave Use per gal EtOH)
a. Thermal Mbtu’s 31 879
b. Electrical kWh’s 1.14
TOTAL Mbtu’s 31.879
Water (Ave Use per gal EtOH)
a. Fresh Gal 4.9
b. Recycled Gal 1.2
TOTAL Gal 6.1
E. Equipment Summary
Equipment Unit Operation/Process
Hammer Mill Milling
Slurry Tank Mixing
Steam Cooker Cooking
Mash Pre-cooler Cooling
Saccharification Tank Saccharification
Fermentor Fermentation
Beer Column Distillation
Ethanol Column Distillation
Adsorption Column Adsorption
Anhydrous Ethanol Cooler Cooling
Ethanol Water Cooler Cooling
49
Stillage Cooler Cooling
Centrifuge Centrifugation
Stillage Evaporator Evaporation
DGS Dryer Drying
50
EQUIPMENT SPECIFICATION SHEET
GENERAL DETAIL
Equipment Name: Hammer Mill
Equipment Code: M-101
Type/Description: Swing-sledge Hammer Mill
Function: To reduce the size of corn kernels.
Mode of Operation: Continuous
TECHNICAL DETAIL
No. of Units: 1
Dimensions:
Length: 1.5494 m
Width: 1.7272 m
Inside Diameter: 0.7620 m
Inside Width: 0.5080 m
Feed Opening: 0.4318 by 0.5080 m
Pulley Speed: 1000 – 3000 rpm
Approximate hp: 40
Feed Particle Size: 5 to 30 mm
Product Particle Size: 0.01 to 0.1 mm
Reduction Ratio: 400
Operating Conditions: 40°C, 1 atm
Material of Construction: Steel

Method of Procurement: Purchase
51
GENERAL DETAIL
Equipment Name: Slurry Tank
Equipment Code: T-102
Type/Description: CSTR
Function: To prepare the milled grains before
cooking (liquefaction).
TECHNICAL DETAIL
No. of Units: 1
Dimensions:
Diameter: 1.8885 m
Height: 3.7770 m
Impeller Diameter: 0.5666 m
Width of Baffles: 0.1889 m
Material of Construction: Carbon Steel

Method of Procurement: Fabrication
52
GENERAL DETAIL
Equipment Name: Steam Cooker
Equipment Code: R-101
Function: To breakdown the starch polymer
(hydrolyze a 1-4 bond) and produce
soluble dextrin.
TECHNICAL DETAIL
No. of Units: 1
Dimensions:
Head Thickness: 4.5484 mm
Shell Thickness: 4.7927 mm
Diameter: 1.3360 m
Length: 4.0081 m
Volume: 6.6162 m3
Inside Depth of Dish: 0.5926 m

53
GENERAL DETAIL
Equipment Name: Mash Pre-cooler
Equipment Code: E-101
Type/Description: Heat Exchanger
Function: To prepare the mash before
Saccharification.
TECHNICAL DETAIL
No. of Units: 1
Area: 84.17 m2
Type: Shell-and-Tube
Operating Conditions: 30-80°C, 1 atm

54
GENERAL DETAIL
Equipment Name: Saccharification Tank
Equipment Code: R-102
Function: To breakdown the dextrins into
fermentable sugars.
TECHNICAL DETAIL
No. of Units: 1
Dimensions of Reactor Vessel:
Height: 12.7250 m
Diameter: 6.3625 m
Impeller Diameter: 1.9088 m
Width of Baffles: 0.6363 m
Material of Construction:
Shell: Stainless Steel
Outer Jacket: Carbon Steel
55
GENERAL DETAIL
Equipment Name: Mash Post-cooler
Function: To prepare the mash before
Fermentation.
TECHNICAL DETAIL
No. of Units: 1
Area: 90.60 m2

56
GENERAL DETAIL
Equipment Name: Fermentors
Equipment Code: R-103a, R-103b, R-103c
Function: To convert the fermentable sugars
into ethanol.
TECHNICAL DETAIL
No. of Units: 3
Dimensions of Reactor Vessel:
Thickness: 0.0306 m
Height: 15.11 m
Diameter: 10.07 m
Volume: 1419.3630 m3
Dimensions of Impeller:
Diameter: 3.36 m
Distance from Tank Bottom: 3.36 m
Disc Diameter: 2.52 m
Blade Length: 0.84 m
Blade Width: 0.67 m
Blade Tip Distance from Tank Bottom: 2.01 m

57
GENERAL DETAIL
Equipment Name: Beer Column
Type/Description: Closed, vertical
Function: To separates the liquid content of the
beer from its solid part
TECHNICAL DETAIL
No. of Units: 1
No. of Stages: 12
Reflux Ratio: 2.00
Feed Location: 4
Type of Column Internal: Sieve Tray
Dimensions of Column:
Diameter: 2.57 m
Height: 51.40 m

58
GENERAL DETAIL
Equipment Name: Ethanol Column
Type/Description: Closed, vertical
Function: To concentrate ethanol-water mixture
TECHNICAL DETAIL
No. of Units: 1
No. of Stages: 45
Reflux Ratio: 4.3
Feed Location: 4
Type of Column Internal: Sieve Tray
Diameter: 3.05 m
Height: 61 m

59
GENERAL DETAIL
Equipment Name: Adsorption Columns
Equipment Code: T-106, T-107
Type/Description: Closed, vertical, pressure swing with
regeneration
Function: To adsorb water from azeotropic
ethanol using an adsorbent.
Mode of Operation: Continuous, Bulk Separation
TECHNICAL DETAIL
No. of Units: 2
Properties of Adsorbent:
Adsorbent: 3A Molecular Zeolite
Pore Diameter: 0.3 mm
Particle Density: 670 – 740 kg/m3
Particle Porosity: 0.2
Surface Area: 7×10-5 m2/kg
Water Capacity: 20%
Diameter: 1.83 m
Height: 4.88 m
Height of Adsorbent inside the Column: 2.89 m

60
GENERAL DETAIL
Equipment Name: Anhydrous Ethanol Cooler
Function: To cool the ethanol from adsorber
columns.
TECHNICAL DETAIL
No. of Units: 1
Area: 5.51 m2

61
GENERAL DETAIL
Equipment Name: Ethanol-Water Cooler
Function: To cool the ethanol-water mixture
from adsorber columns back to
ethanol column.
TECHNICAL DETAIL
No. of Units: 1
Area: 2.11 m2

62
GENERAL DETAIL
Equipment Name: Stillage Cooler
Function: To cool the stillage from ethanol
column before centrifugation.
TECHNICAL DETAIL
No. of Units: 1
Area: 18.09 m2

63
GENERAL DETAIL
Equipment Name: Centrifuge
Equipment Code: C-101
Type/Description: Centrifugal Sedimentation
Function: To separate the solids from liquid
part of the stillage.
TECHNICAL DETAIL
No. of Units: 1
Diameter: 11.0110 m
Height: 12.2112 m
Rotational Speed: 1000 rpm

64
GENERAL DETAIL
Equipment Name: Stillage Evaporator
Equipment Code: V-101
Type/Description: Calendria
Function: To concentrate the thin stillage before
drying.
TECHNICAL DETAIL
No. of Units: 1
Area: 115 m2
Tube Thickness: 4.85 mm
Calendria Sheet Thickness: 10 mm
Material of Construction:
Shell: Carbon Steel
Tube: Brass
65
GENERAL DETAIL
Equipment Name: DGS Dryer
Equipment Code: D-101
Type/Description: Rotary Drum
Function: To dry the DGS for animal feed.
TECHNICAL DETAIL
No. of Units: 1
Length: 22.43 m
Inner Diameter: 2.46 m
Shell Thickness: 10 mm
Insulation Thickness: 40 mm
Feed Pipe Diameter: 21”
Inlet Pipe Diameter: 28”
Outlet Pipe Diameter: 32”
Rotation: 3 rpm

66
F. Piping and Instrumentation Diagram
Piping and Instrumentation Diagram (P&ID) is a detailed diagram that shows
the piping and vessels with its proper instrumentation and control devices. P and ID is
foundational to the maintenance of the process that it graphically represents. Also, it
provides the basis for the development of control schemes, like Hazard and Operability
Study (HAZOP).
P and ID diagram is established thoroughly for the production of ethanol
from corn kernel. This diagram will show the complete details of instruments, piping
requirement, different control loops, control systems, signal lines, and different
equipment/vessel comprising the facility. Equipment use in the production of ethanol
are carefully analyze in order to produce the expected quality of ethanol. This will
consider the preliminary treatment of the corn kernels, effectiveness in conversion of
starch to dextrin to glucose and into ethanol, temperature and concentration during
fermentation and distillation and nutrient amount necessary for cultivating microbes.
These factors need to be considered because it will greatly affects the flow of operation.
Piping and Instrumentation Diagrams entails with logical, concise and easy-to-
understand sequence of unit process equipment.
1. Symbols and Codes
Table 3.11 Control Element Symbols
Symbol Description
Gate valve
 Control valve
 Pneumatic valve
67
Table 3.12 Instrumentation Line Symbols
Symbol Applications
Process connection to instruments
Electrical signal
Table 3.13 Location of Instruments
Discrete Location and Accessibility
 Located in Field.
 Not panel, cabinet, or console mounted.
 Visible at field location.
 Normally operator accessible.
2. Instrumentation, Systems, and Automation (ISA) Identification Letters
Table 3.14 ISA Identification Letters

Letter Position - (XYY)
First Letter (X) Succeeding Letters(YY)
A Alarm
C Controller
F Flow
H High
I Indicator
L Level Low
T Temperature Transmitter
68
3. Selection of Control Valve
The control valve manipulates a flowing fluid, such as gas, steam, water or chemical
compounds, to compensate for the load disturbance and keep the regulated process
variable as close as possible to the desired set point.
Table 3.15 Control Valve

Control Equipment
Operating Principle
Valve Name
Rate of flow control valve prevents
excessive flow by limiting flow to
a preselected minimum rate,
regardless of changing line
pressure. The pilot control
responds to the differential
Rate of Flow pressure produced across an orifice

Flow Control Valve
Control Valve plate installed downstream of the
valve. Accurate control is achieved
as very small changes in the
controlling differential pressure
produce immediate corrective
action of the main valve. (CLA-
VAL)
Modulating float valve will be
Modulating used in the production process.

Level Control Valve
Control Valve Modulating float valves maintain a
constant liquid level in a storage
69
tank by compensating for
variations in supply or demand and
are used to control the flow into or
out of a tank by either opening or
closing on a rising level. (CLA-
VAL)
70
G-AMYLASE
A-AMYLASE
WATER TI
FT
FT
CORN FT
TA FC
FC
FC H-101 TI TIH TIL
FT
2 TC
M-101 FC
FC
LA R-102
`
FC FC E-101 TI
LC
`
FC
Figure 3.6 Piping and Instrumentation Diagram for the
`
R-101 ` ` FC
FC
FC T-103
T-101 TC TI E-102
T-102
Production of Ethanol from Corn Kernel
FC FC `
WATER CO2
FC
YEAST WASTE WATER
S-101
FC FC
FC
FT FC ETHANOL
FC TT
E-103
TI
TT FC FC TT
TC
TI TI TI
R-103 FT
TI T-104 T-105 T-106 T-107
FC N-101
FC
FT FC FT
FC TT
FC
FC TI
FC
FC
FC
G-101
TI FC
FC FC
TI
E-104
PROCESS WATER
E-105
FC
FC LI FC FT
FC
MOISTURE
V-101
TC
71 T-108
FT FC
DDGS
TI
C-101
D-101
4. Individual Control and Instrumentation of Equipment
a. Hammer Mill
CORN
FC
Figure 3.7 Control and Instrumentation of Hammer Mill
After the preliminary treatment of corn, flow controller is installed after this
equipment to control the flow of treated corn. This will help to prevent choking in
the next equipment which is the major cause of stopping the whole operation.
b. Weigh Tank
LA
LC
Figure 3.8 Control and Instrumentation of Weigh Tank
Since the flow is controlled in hammer mill, it is necessary also to control the
level of weighing tank. Inside the tank, there is a level alarm which is triggered
when it meets the capacity of the tank. This alarm is connected to level controller
automatically.
72
c. Slurry Tank
A-AMYLASE
WATER
FT
FC
FT
FC
FC
FC
Figure 3.9 Control and Instrumentation of Slurry Tank
Water, A-amylase and the treated corn must in proper ratio. Therefore, flow
controller in each of them is installed. After mixing, another flow controller is
installed at the product stream in order to observe the amount that needs to be
processed further.
d. Steam Cooker
TI
TA
TC
Figure 3.10 Control and Instrumentation of Steam Cooker
73
Heat is very significant in this equipment. Cooking requires a specific amount
of heat to prevent over cooked. Hence, temperature control is necessary. Manual
controlling of heat is difficult and take a high risk in safety. So, temperature control
is installed to avoid accident and to easily control cooking the slurry.
e. Cook Retention Tank
TI TIH TIL
FC
FC TI
`
` `
Figure 3.11 Control and Instrumentation of Cook Retention Tank
Before entering in this equipment, flow and temperature of the mash must be
controlled. Cook retention tank is use as storage and use in lowering the temperature
of the mash. When the desired temperature of the mash is reach, the mass out is also
controlled by flow controller. After the heat exchanger, temperature indicator is
installed to verify the temperature of the mash.
74
f. Saccharification Tank
G-AMYLASE
FT
FC
FC
`
FC
TC TI
Figure 3.12 Control and Instrumentation of Saccharification Tank
Mash is charged into saccharification tank and mixed with G-amylase. Starch
content of the mash will be converted into dextrin in this equipment. Flow is
controlled in both mash stream and G-amylase so that proper ratio is secured.
g. Fermentor
YEAST
FC
FC TT FT FC
TI
TI
FC
Figure 3.13 Control and Instrumentation of Fermentor
The amount of inputs in fermentors must be controlled. The mash temperature
must also know in order to cultivate the yeast. The flow of yeast is also controlled
so that the volume requirement of fermentors must be maximized.
75
h. Beer Column
FT
FC
FT FC
FC
TI
Figure 3.14 Control and Instrumentation of Beer Column
Flow controllers are very necessary in this equipment. The formation of beer
takes place in this equipment.
i. Ethanol Column
FT
FC TT
FC
TI
PROCESS WATER
Figure 3.15 Control and Instrumentation of Ethanol Column
The beer formed will proceed to ethanol column. The flow and temperature of
the beer will tell the efficiency of the separation process. Ethanol is the product of
this scheme, therefore, it is very important to account the volume of ethanol
produced.
76
CHAPTER IV
COSTING AND PROJECT EVALUATION
A. Estimation of Equipment Cost
The cost of purchase equipment is the primary basis in estimating the capital investment
of any processing industry. Cost of purchased equipment are estimated and obtained
from reliable sources such as fabricators, manufacturers or suppliers. The capacity of
equipment calculated in the equipment design and other specifications presented in the
study are used as the basis for cost estimation of each equipment. Cost estimates in this
study were obtained from www.matche.com and some, particularly distillation column,
are obtained from the book entitled “Plant Design and Economics for Chemical
Engineers” 5th Edition by Peters et.al using www.mhhe.com. Cost indices are utilized
to give the cost estimate for the present time.
Table 4.1 Cost Indices
Year Chemical Engineering Plant Source/Used as Cost Index
Cost Index, CEPCI
2002 390.4 Plant Design and Economics for
Chemical Engineers, 5th Edition;
www.mhhe.com
2014 567.3 September, 2013 final cost index
2018 587.96 March 2018 (Prelim) cost index
 Cost index at 2018 

Present Cost(2018)  (Original Cost at 2014) 
 Cost index at 2014 
77
 Cost index at 2018 
Present Cost(2018)  (Original Cost at 2002) 
 Cost index at 2002 
Table 4.2 Purchase Equipment Cost
Name of No. of Cost($) in Cost ($) in Total Cost Cost(Ᵽ) in
Equipment Units 2014 2018 ($) in 2018 2018
Major
Equipment
Hammer Mill 1 145200 150487.9112 150487.9112 7917199.106
Fermentor 3 654800 678646.5856 2035939.757 107111197.8
Beer Column 1 656509 988732.1507 988732.1507 52017396.19
Ethanol Colum 1 986645 1485931.85 1485931.85 78175171.81
Adsorption 2 80708 121549.8865 243099.773 12789527.68
Column
DGS Dryer 1 94100 97526.94518 97526.94518 5130912.091
Stillage 1 327500 339426.9346 339426.9346 17857318.91
Evaporator
Auxiliary
Equipment
Steam Cooker 1 50500 52339.11511 52339.11511 2753571.314
Slurry Tank 1 116200 120431.7857 120431.7857 6335940.332
Saccharification 1 113000 117115.2477 117115.2477 6161456.605
Tank
Anhydrous 1 10700 11089.67389 11089.67389 583429.9613
Ethanol cooler
78
Ethanol Water 1 7700 7980.419531 7980.419531 419851.4676
cooler
Stillage cooler 1 10100 10467.82302 10467.82302 550714.2626
Centrifuge 1 257900 267292.2334 267292.2334 14062297.86
Mash Pre- 1 43900 45498.75551 45498.75551 2393698.627
cooler
Mash Post- 1 45200 46846.09907 46846.09907 2464582.641
cooler
TOTAL 5914806.475 311179151.6
Note: $1.00 = Ᵽ52.6102 (Updated as of May 25, 2018)
B. Estimation of Fixed Capital Investment (FCI)
The fixed capital investment is defined as the capital needed to supply the required
manufacturing and plant facilities. It is categorized into manufacturing fixed capital
investment (direct costs) and nonmanufacturing fixed capital investment (indirect
costs).
The estimation of FCI is based from the book, “Plant Design and Economics for
Chemical Engineers” by Peters, Timmerhaus & West (2003). This is calculated by
choosing the appropriate percent fixed capital investment (%FCI) shown in Table 4.2.
The obtained value of FCI is Ᵽ1,580,790,090.
79
Table 4.3 Breakdown of Direct and Indirect Costs
Component Range Selected Normalized FCI, Estimated Cost (Ᵽ)
of FCI, FCI, % %
Direct Cost
Purchased 15-40 25 19.68503937 311179151.6
Equipment
Purchased 6-14 10 7.874015748 124471660.6
Equipment
Installation
Instrumentation 2-12 8 6.299212598 99577328.51
and Controls
Piping 4-17 10 7.874015748 124471660.6
Electrical 2-10 7 5.511811024 87130162.45
Systems
Buildings 2-18 12 9.448818898 149365992.8
(including
services)
Yard 2-5 3 2.362204724 37341498.19
Improvements
Service 8-30 20 15.7480315 248943321.3
Facilities
Land 1-2 1 0.7874015748 31117915.16
Indirect Costs
80
Engineering & 4-20 10 7.874015748 124471660.6
Supervision
Construction 4-17 9 7.086614173 112024494.6
Expenses
Legal Expenses 1-3 2 1.57480315 24894332.13
Contractor’s 2-6 2 1.57480315 24894332.13
Fee
Contingency 5-15 8 6.299212598 99577328.51
TOTAL FCI 127 100 1,580,790,090
Checking if the estimated costs are within the range known in the book “Plant Design
and Economics for Chemical Engineers” by Peters, Timmerhaus, & West (2003):
Table 4.4 Calculated Percentage of Components and Items
COMPONENT Estimated Cost Range Calculated
(Ᵽ) Percentage (%)
Direct Cost 1039298542 65-85% of FCI
Purchased 311179151.6 15-40% of FCI 19.68503937
Equipment
Purchased 124471660.6 25-55% of purchased- 40
Equipment equipment cost
Installation
Instrumentation 99577328.51 8-50% of purchased- 32
& Controls equipment cost
81
Piping 124471660.6 10-80% of purchased- 40
equipment cost
Electrical 87130162.45 10-40% of purchased- 28
Systems equipment cost
Building 49365992.8 10-70% of purchased- 15.86417102
(including equipment cost
services)
Yard 286284819.5 40-100% of purchased- 92
Improvements equipment cost
and Service
Facilities
Land 31117915.16 1-2% of FCI 1.968503937
Indirect Costs 385862148 15-35% of FCI
Engineering & 124471660.6 5-30% of direct cost 11.9765068
Supervision
Construction 136918826.7 10-20% of FCI 8.661417323
Expenses &
Contractor’s
Fee
Legal Expenses 24894332.13 1-3% FCI 1.57480315
Contingency 99577328.51 5-15% of FCI 6.299212599
82
Checking if the Direct and Indirect Costs are within the allowable range:
Direct Costs = material and labor involved in actual installation of complete facility
(65-85% of FCI)
Direct Costs = Equipment + Installation + Instrument + Piping + Electrical + Buildings
+ Service Facilities + Yard Improvements + Land
Total Direct Costs = 1039298542 PHP
Total Direct Costs

% Direct Costs  x 100%
FCI
1039298542
%Direct Costs  x 100%
1580790090
%Direct Costs  65.74551223 PHP
This is within the allowable range which is 65-85% of FCI.
Indirect Costs are expenses which are not directly involved with material and labor of
actual installation of complete facility (15-35% of FCI).
Indirect Costs = Engineering and Supervision + Legal Expenses + Construction
Expenses + Contractor’s Fee + Contingency
Total Indirect Costs = 385862148 PHP
Total Indirect Costs

% Indirect Costs  x 100%
FCI
385862148
%Indirect Costs  x 100%
1580790090
%Indirect Costs  24.40944882 PHP
This is within the allowable range which is 15-35% of FCI.
83
C. Estimation of Total Capital Investment
The total capital investment includes all the capitals necessary to get the project in
progress. This includes the manufacturing fixed-capital investment and the working-
capital investment along with the investment required for all necessary auxiliaries and
nonmanufacturing facilities. In most chemical process industries, working capital
initially amounts to 10-20% of total capital investment. In this report, the Working
Capital is calculated as 15% of the Total Capital Investment.
Total Capital Investment = Fixed Capital investment + Working Capital Investment
TCI  FCI  WCI

TCI  1580790090  0.15(TCI)
(1 - 0.15)TCI  1580790090
TCI  1859753047 PHP
Thus the value of the working capital investment can be computed as follows:
WCI  0.15TCI
WCI  0.15 ( 1859753047 )
WCI  278962957.1 PHP
D. Estimation of Production Cost
Production costs refer to the costs incurred in manufacturing a good or providing a
service. This includes a variety of expenses including, but not limited to, labor, raw
materials, consumable manufacturing supplies and general overhead. Production cost
is generally divided into two categories: manufacturing costs and general expenses.
Manufacturing costs are also referred to as operating or production costs. This is further
subdivided into interpretation of variable, fixed, and overhead costs.
84
Fixed Charges
This classification covers the expenses that are practically constant from year to year and not
greatly influenced by the rate of production such as depreciation, property taxes, insurance, and
rent. The tax and insurance rates were estimated at 1% and 0.4% of the fixed capital investment
(FCI), respectively. No cost for rent was considered.
Table 4.5 Fixed Charges
Cost Items Percentage Range Basis Cost Estimate
Local taxes 1-4% of FCI 1 % of FCI 15807900.9
Insurance 0.4-1% of FCI 0.8% of FCI 12643207.2
TOTAL 142271108.1
Total Production Cost
Using the estimated value of fixed charges, initial estimation of the total production
cost can be calculated. Considering that fixed charges is 10-20% of total production
cost, a value of 15% is arbitrarily selected. Thus, the initial value of the total production
cost is estimated as follows:
Fixed charges  0.15 (Total Production Cost)

Fixed charges
Total Production Cost 
0.15
142271108.1
Total Production Cost (TPC) 
0.15
Total Production Cost (TPC)  984874054 PHP
From the estimated total production cost, the different cost items are determined. The
estimates presented are determined by arbitrarily selecting percentage among the ranges
provided by Peters & Timmerhaus.
85
Table 4.6 Summary of Total Production Costs
Cost Items Allowable range Basis of Cost Estimate/yr
Computations
I. Manufacturing Cost
A.Direct Production About 66% of
Cost TPC
Raw Materials 10-80% of TPC Selling price (15% 147731108.1
of TPC)
Operating Labor 10-20% of TPC 10% of TPC 98487405.4
Direct supervisory and 10-20% of 10% of TPC 98487405.4
clerical labor operating labor
Utilities 10-20% of TPC 20% of TPC 196974810.8
Mainetenance and 2-10% of FCI 3% FCI 29546221.62
repairs
Operating supplies 0.5-1% of FCI 1% FCI 9848740.54
Laboratory charges 10-20% of 15% of operating 14773110.81
operating labor labor
Patents and royalties 0-6% of TPC 1% of TPC 9848740.54
B. Fixed charges 10-20% of TPC
Local Taxes 1-4% of FCI 1% of FCI 15807900.9
Insurance 0.4-1% of FCI 0.8% of FCI 12643207.2
C. Plant Overhead 5-15% of TPC 10% of TPC 98487405.4
Cost
II. General Expenses 15-25% of TPC
86
Administrative costs 2-5% of TPC 2% of TPC 19697481.08
Distribution and 2-20% of TPC 10% of TPC 98487405.4
marketing costs
Research and 5% of TPC 5% of TPC 49243702.7
development costs
Total Production Cost 875442794.5
E. Profitability Analysis
A profitability is made in order to present and provide a measure of the attractiveness
and feasibility of the project.
Currently, according to ICIS, a market information provider, the fuel-grade ethanol
price in Southeast Asian market is $527 per cubic meter or approximately Ᵽ26350 per
cubic meter in Philippine currency. With this information, this report must have a lower
bioethanol price or equivalent to the current market price to compete in the market.
Total Product Cost

Ethanol Price 
Annual Plant Capacity
875442794.5
Ethanol Price 
100000 * 365 kg/yr
785.1 kg/m 3
Ethanol Price  18830.41474 PHP
The calculated ethanol price is lower than the market price which means that the ethanol
produced could compete in the market together with experienced producers. Hence, in
order to maximize the profit of the plant, the selling price of the ethanol produced would
be Ᵽ23000/m3.
87
Total Income  Annual Plant Capacity Selling Price 
 100000 * 365kg/yr 
Total Income   3

 23000 / m 3 
 785.1 kg/m 
Total Income  1069290536 PHP / yr
This accounts for the total money received annually by the company from selling all
the ethanol produced during operation.
Gross Income  Total Income - Total Product Cost

Gross Income  1069290536  875442794.5
Gross Income  1944733331 PHP
Therefore, the gross income accounts for a total money received annually by the
company from selling all the ethanol produced during operation and deducting total
cost of production. Hereafter, considering a 35% tax rate and having to subtract it from
the gross income.
Nevertheless, to compute for the time when the capital invested is returned or more
commonly known as payback period, the depreciation which accounts for the allocated
cost of tangible assets over its useful life must be known. The cost of tangible assets is
the direct cost from less the non-depreciable assets, land and equipment installation
cost.
Tangible Assets Cost  Direct Cost  Land Cost  Equipment Installati on Cost
Tangible Assets Cost  385862148 - 31117915.16 - 124471660.6
Tangible Assets Cost  230272572.2 PHP
88
Using Straight-Line Depreciation Method,
Recovery Period of Chemical Plant = 10 years
Tangible Assets Cost

Depreciati on 
Recovery Period
230272572.2
Depreciati on 
10
Depreciati on  23027257.22 PHP
1580790090
Payback Period 
1264076665  23027257.2
Payback Period  1.23 years
Using Modified Accelerated Cost Recovery System (MACRS),
Recovery Period of Chemical Plant = 5 years
Table 4.7 Depreciation using MACRS
Year Unadjusted Depreciation Depreciation Adjusted Basis
Basis rate
0 230272572.2 20 46054514.44 178691516
1 230272572.2 32 73687223.1 206324224.7
2 230272572.2 19.2 44212333.86 176849335.5
3 230272572.2 11.52 26527400.32 159164401.9
4 230272572.2 11.52 26527400.32 132637001.6
5 230272572.2 5.76 132637001.6 0
89
Total 349645873.6
Depreciation
Average 58274312.27
Annual
Depreciation
1580790090
Payback Period 
1264076665  58274312.27
Payback Period  1.20 years
Since, the payback periods for the depreciation methods are close, with MACRS faster
by just a factor of 0.03 to Straight-line method, the design engineer can choose either
of the two. However, given the economical setup of Philippines, it is more preferable
to use straight line method. Therefore, for this design paper, a payback period of 1.23
years is chosen.
Return of Investment
Return of investment (ROI) is an economical tool used for financial decision. This
measures the benefits obtained from inventing of some resource. Moreover, this is a
profitability ratio to determine the profit of an investment as a percentage of its original
cost.
90
Annual Net Profit
%ROI  100
Total Capital Investment
1264076665
%ROI  100
1859753047
%ROI  67.97 %
It can be concluded from the calculated ROI that this report is considered attractive for
operations.
91
Figure 4.1 Cumulative Cash Flow Position Diagram
92
CHAPTER V
HEALTH, SAFETY AND THE ENVIRONMENT
A. Risk Assessment
An industry with its complex nature of activities involving various plant
machineries, raw materials, products, operations, and environmental discharge has a
number of associated hazards. A minor failure can lead to major failures resulting into
a disaster causing heavy losses to life, property, and environmental. A number of
hazards associated with the biofuel industry in each stage of the plant cycle from the
concept selection through to the discharging. There are many other challenges like
engineering unknowns, lack of reliable failure rate data, inconsistency in applicable
regulations, low skills, and entry of new manufacturers (Nair, 2011). Risk assessment
is being conducted to guarantee safety and reliability of any new plant. It is necessary
to have a risk assessment studies as they form an integral part of an occupational health
and safety management plan. Risk assessment in process design can be considered
under the following broad headings:
 Identification of hazards and risk factors.
 Analysis and evaluation of risk associated with the hazard.
 Elimination of hazard or control of risk.
1. Hazard Identification
In process safety and loss prevention, it is said, ‘once the hazards have been
identified, half the battle is won’ (Mannan). A number of hazard identification
methods and techniques are available and have been practiced. Different methods
are required at different stages of a project and also the depth of the study depends
on the complications and extent of risk from the facility/operation.
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Hazards associated with the biofuel industry are categorized as follows:
a. Hazards from Materials
The principal hazards from materials in the form of raw materials, catalysts,
intermediates and finished products include:
 Fire Hazards.
 Explosion hazards and overpressure releases.
 Runaway/uncontrolled reaction.
 Toxic hazards.
 Steam flashes.
b. Hazards from Operations and Handling
Operational accidents in the biofuel industry range from slips, trips, and falls
to major incidents like fire and explosion. Hazards, causes, hazardous events
and related consequences during operation and handling (storage, processing,
handling etc.) are given below:
i. Storage of Flammable and Toxic Materials
This includes raw materials, additives, intermediates, finished products
and by-products in different forms/phases, sizes, shapes, temperature, and
pressure as required by the process.
ii. Processing of Hazardous Materials
One of the major hazards is the accidents that could result from biofuel
manufacture is release of flammables, toxics and corrosives. Some
examples of hazards related to processing is given below:
 High operating or storage temperature/pressure (e.g. leading to process
runaway)
 Overflow of tank, vessel, reactor or tanker.
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 Lower temperature (solidification of biodiesel often resulting in
plugging).
 Improper selection of appropriate equipment/machinery/rated
vessels/pipe work suitable for the process.
 Inadequate installation, inspection and maintenance.
 Use of unclassified equipment and machinery in explosive atmosphere.
iii. Material Handling
A range of materials in solid form, liquid form and gaseous form are
transferred between equipment, process vessels, storage etc. This involves
a number of tools and transfer system from shovel to conveyor system to
pipelines and pumps. Manual handling of hazardous materials results in
occupational injuries and sometimes fatalities. Some related hazards are:
 Material loss, damage due to inadequate or improper conveyor system.
 Poor housekeeping leading to dust hazards and dust explosion hazards.
 Release from pipelines, vessels and valves.
a. Hazards from Design, Construction, and Commissioning
Typically, biofuel plants mainly small/medium scale and occasionally large
scale plants are built in an existing facility/building or near to an existing
facility/building/plant. Some of the hazards are very significant when the
existing facility (old barn, garage or storage deport) is modified and converted
to a biofuel processing facility. One of the common failures is failing to
recognize the additional requirements to adhere to (e.g. building regulation
codes, electrical installation requirements etc). If the associated hazards in
conversion are not identified and addressed, the facility as such could pose high
risk due to operation.
95
The following are some of the causes associated to biofuel plant projects
that may result hazards and hazardous events:
i. Improper selection of:
 The technology or methodology for the manufacture.
 The chemical and raw materials used for the production.
 The location of the facility.
ii. Inadequate facility for the selected process:
 Land area.
 Nearby facility and effects from and on them.
 Proximity to utilities (water, steam, power etc.).
iii. Unsafe design and layout.
 Inadequate separation distances (to restrict the spread of fire etc.).
 Inadequate design specification (not for maximum design pressure etc.).
 No access for inspection, maintenance etc.
 No provision of emergency escape.
 Thermal radiation from open flames/flares or equipment/vessel
operating at high temperature (no or improper insulation etc.).
iv. Faulty construction and commissioning.
 Use of inappropriate material of construction of the facility
(incompatible for the material handled/processed).
 No/improper foundation.
 Inadequate strength of load bearing members.
v. No/inadequate provision for:
 Ventilation.
 Lighting.
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 Rest and cleaning.
 Weather protection.
 Protection from external factors (vehicle collision, attacks from
animals/pests etc.).
2. Risk management
Risk management is the term used to cover the whole process of identifying and
assessing risk, setting goals and creating and operating systems for their control.
Though the biofuel manufacturing facility often does not come under major
accident hazard regulations, it is prudent that the risk from the biofuel industry is
assessed and managed considering the nature of hazards and the stakeholders
involved. The depth of risk assessment should be proportional to the extent of risk
involved in the process and facility.
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B. Government Regulations
The policy and legislative actions of any government, at national, state, and local
levels, have significant impacts on the management and control of risk in the biofuel
industry.
Occupational Safety and Health Administration (OSHA) Compliance
Occupational safety and health administration ensures safety and healthy working
environment by enforcing workplace laws and standards. At the request of the
Renewable Fuels Association (RFA), the ERI Solutions, Inc. of Colwich, KS developed
an outline of the general plant and employee safety regulatory compliance requirements
for the bioethanol production industry.
a. Recordkeeping (OSHA 1904).
The Occupational Safety and Health Act of 1970 (OSHA) requires covered
employers to prepare and maintain records of occupational injuries and illnesses.
OSHA also establishes requirements and criteria for reporting work-related injuries,
illnesses, and fatalities.
b. Walking/Working surfaces (OSHA Subpart D).
Establishes requirements concerning guarding floor & wall openings, stairs and
ladders. OSHA requires the use of a guardrail system to protect workers from falls
of 4’ or more to lower levels.
c. Exit routes (OSHA 1910.37).
Establishes requirements for the proper design and construction of exit routes.
Requirements cover construction materials, opening dimensions, accessibility
conditions and capacity.
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d. Emergency Action Plan (OSHA 1910.38).
An Emergency Action Plan (EAP) must be developed and include procedures
for reporting emergencies, emergency evacuation, and for employees performing
medical or rescue duties. OSHA also establishes requirements for alarm systems
and training personnel on the EAP.
e. Fire Prevention Plan (OSHA 1910.39).
Establishes requirements for employers to identify flammable and combustible
materials stored in the workplace and develop ways to control workplace fire
hazards. Completing a fire prevention plan and training employees will reduce the
probability that a workplace fire will occur or spread.
f. Occupational Noise Exposure (OSHA 1910.95).
Requires employers to identify if any employees are exposed to noise levels at
85 decibels or more over eight (8) working hours. A hearing conservation program
must be implemented if it is determined that employees may be exposed to levels
above this threshold.
g. Flammable and Combustible Liquids (OSHA 1910.106).
Establishes requirements for the handling, storage and use of flammable and
combustible liquids with a flash point below 200°F. Ethanol is considered a Class
1B flammable liquid (Flash point 73°F).
h. Storage and Handling of Anhydrous Ammonia (NH3) (OSHA 1910.111).
Facilities that have anhydrous ammonia systems must comply with this
standard. If the process contains over 10,000 pounds of anhydrous ammonia, OSHA
1910.119 also applies (see Process Safety Management (PSM) below).
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i. Process Safety Management (PSM) (OSHA 1910.119).
The purpose of this standard is to prevent or minimize the consequences of a
catastrophic release of toxic, reactive, flammable, or explosive chemicals. Since
ethanol is considered a flammable liquid, ethanol production facilities are required
to comply with this standard if they process or store over 10,000 pounds of ethanol.
OSHA also lists threshold quantities for other highly hazardous chemicals that are
covered under the PSM regulation. Other common chemicals in use at ethanol
production facilities that may fall under PSM regulations are anhydrous (or
aqueous) ammonia, hydrochloric acid, denaturant, and chlorine dioxide. This is not
an all-inclusive list, but if you have these chemicals at your site, you should
determine for sure whether or not you meet the threshold quantity for that specific
chemical.
j. Emergency Response (OSHA 1910.120).
Employers must address what action employees are to take when there is an
unwanted release of hazardous chemicals. Employers may decide to train and
mobilize employees to control or mitigate the release according to the requirements
of 1910.120 the Hazardous Waste Operations and Emergency Response
(HAZWOPER) standard. Employers may also decide to have employees evacuate
the danger area and have local community emergency response organizations
respond to the release.
k. Personal Protective Equipment (PPE) (OSHA Subpart I).
Contains regulations for Personal Protective Equipment (PPE) selection and use
concerning eyes, face, head and extremities. All ethanol production facilities must
perform and document a workplace hazard assessment so the proper PPE can be
designated and communicated for all areas of your facility.
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l. Permit Required Confined Spaces (OSHA 1910.146).
Requires employers to develop practices and procedures to protect employees
working in permit-required confined spaces (PRCS). The standard requires an
evaluation to determine the existence of PRCSs, the implementation of a written
confined space program, and the establishment of rescue/emergency procedures.
The employer must decide either to train employees on entry rescues or rely on
available external sources to provide entry rescues. Either method must be
documented as to its availability and reliability to respond in the event of an
emergency. All PRCSs must be labelled or communicated according to the
requirements of the standard.
m. Lockout/Tagout (OSHA 1910.147).
Requires implementing practices and procedures to shut down equipment,
isolate it from energy sources and prevent the release of potential hazardous energy
while maintenance and service activities are being performed. Employers must
develop and document specific procedures for all equipment and machinery that
may be serviced within their facility.
n. Medical Services and First Aid (OSHA 1910.151).
Employers must ensure that medical personnel and adequate first aid supplies
are available to workers to handle potential workplace injuries if a medical facility
is not in near proximity to the workplace.
o. Fire Protection (OSHA Subpart L).
Standards for portable fire extinguishers, fire brigades, and employee alarm
systems, automatic sprinkler systems and fixed extinguishing systems.
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p. Powered Industrial Trucks (OSHA 1910.178).
Establishes requirements for powered industrial trucks and training
requirements for operators of powered industrial trucks.
q. Machinery and Machine Guarding (OSHA 1910.212).
General requirements for machine guarding.
r. Welding, Cutting and Brazing (OSHA Subpart Q).
Contains regulations for oxygen fuel cutting and welding, arc welding and
cutting, and resistance welding. The standards also contain training requirements
for personnel who will be performing welding, cutting or brazing.
s. Grain Handling (OSHA 1910.272).
Contains requirements for control of grain dust fires or explosions and other
hazardous associated with grain handling facilities.
t. Electrical (OSHA Subpart S).
Contains regulations regarding electrical hazards in the workplace. Subpart S is
based on older versions of the national consensus standard NFPA 70E. OSHA has
proposed an update to Subpart S to reflect the more current editions of NFPA 70E.
u. Access to Employee Exposure and Medical Records (OSHA 1910.1020).
This standard is triggered if an employee is exposed to toxic substances or
harmful physical agents in the workplace. These exposure and medical records must
be retained in accordance with this regulation. The records must also be made
available to employees or their designated representative.
v. Blood borne Pathogens (OSHA 1910.1030).
This standard applies to all possible occupational exposure to blood or other
potentially infectious materials (OPIM). Occupational exposure means reasonably
anticipated contact with blood or other potentially infectious materials that may
102
result from performance of an employee’s duties. Employees who are responsible
for rendering first aid or medical assistance as part of their job duties are covered
by the protections of the standard.
w. Hazard Communication (OSHA 1910.1200).
Also, referred to as the “Right-to-Know” standard, Hazard Communication
establishes requirements for ensuring that chemical hazards and their associated
protective measures are disseminated to employees who could be potentially be
affected by these hazards.
x. Occupational Exposure to Hazardous Chemicals in Labs (OSHA 1910.1450).
This standard requires a laboratory to develop a Chemical Hygiene Plan which
addresses specific hazards found in the laboratory. This standard does not apply to
typical facility laboratory, as they generally only perform quality assurance/quality
control type laboratory operations.
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C. HAZOP Studies
Safety and reliability in the design of plant initially relies upon the application of
various codes of practice, or design codes and standards. These represent the
accumulation of knowledge and experience of both individual experts and the industry
as a whole. Such application is usually backed up by the experience of the engineers
involved, who might well have been previously concerned with the design,
commissioning or operation of similar plant. However, it is considered that although
codes of practice are extremely valuable, it is important to supplement them with an
imaginative anticipation of deviations which might occur because of errors in operation
(e.g. equipment malfunction, operator error etc.). The HAZOP Study is an opportunity
to correct these faults before such changes become too expensive, or impossible to
accomplish.
A HAZOP study is a structured and systematic examination of a planned of existing
process or operation in order to identify and evaluate problems that may represent risks
to personnel or equipment, or prevent efficient operation. The basic concept of HAZOP
study is to take full description of the process and to question every part of it to discover
what deviations from the intention of the design can occur and what the causes and
consequences of these deviations may be. (Hazard Identification and Control, Sam
Mannan, 2005)
Potential Hazards in Biofuels Production and Handling
 Fire and explosion Hazards of Biofuels
Employers producing biofuels may expose workers to potential fire and
explosion hazards, and protect them from these hazards by preventing releases,
avoiding ignition of spills, and having appropriate fire protection systems and
emergency response procedures.
104
Sufficient controls include:
 Good facility layout
 Proper design of vessels and piping systems
 Proper selection of electrical equipment for use in hazardous areas
 Adequate instrumentation with alarms, interlocks, and shutdowns
 Operating procedures
 Good maintenance practices
 Safe work procedures
 Chemical Reactivity Hazards in Biofuel Manufacturing
Biofuels manufacturing processes can present reactive hazards. The gases
produced during ethanol fermentation need to be properly vented to avoid over
pressuring equipment and piping.
Controls to keep the process within safe limits include:
 Controlling the rate and order of chemical addition
 Providing robust cooling
 Segregating incompatible materials to prevent inadvertent mixing
 Use of detailed operating procedures
 Toxicity Hazards in Biofuel Manufacturing
Biofuels and the chemicals used in the manufacturing process present toxic
exposure hazards that need to be carefully controlled to protect workers.
Controls needed include:
 Good engineering, design and fabrication
 Maintenance practices to prevent releases, ventilation, and drainage to
reduce exposures
 Appropriate use of personal protective equipment
105
These hazards are in addition to normal workplace hazards, such as walking/working
surface hazards, electrical hazards and other similar hazards.
D. Pollution Prevention
The increasing production of ethanol has been established as an important
contributor to future energy independence. But the waste streams from many varying
processes that are being developed contain a variety of components which could be
potentially harmful to the environment if adequate care is not taken to manage those
risks (Menetrez, 2010). Pollution prevention is needed to reduce risks and
environmental concerns. At production facilities, there are several points in the process
that create the possibility of release:
 Storage in tanks
 Movement in piping systems
 During transfer to trucks
E. Life Cycle Analysis
Life cycle analysis is used to quantify and evaluate the environmental performance
of a product, process or activity from cradle to grave, that is, considering the whole life
cycle of the process. It starts at the first step of the process being investigated. For this
proposed design, the first step is the transportation of corn kernels to the mill.
Additionally, this accounts all the wastes released to the environment and the
corresponding waste treatment the plant will put up to minimize the risk of the waste in
the environment and nearby community.
The LCA at the different stage of ethanol production methods and product
development is presented in the following illustration.
106
1. Inputs and Outputs of a System
INPUTS OUTPUTS
RAW EMISSIONS TO AIR

CO2 (111, 072.9956 kg/day)
Corn Kernels (312, 244.3329 kg/day ),
Yeast (58.95 kg/day)
ENERGY USABLE PRODUCTS

SYSTEM
Ethanol (100, 000 kg/day),
stillage (1, 138, 850.728 kg/day)
WATER OTHER RELEASES

(Heat)
Figure 5.1 Inputs and Outputs of the System
The figure shows the input materials necessary for the production of ethanol
and the corresponding emissions. CO2 emissions are subjected to treatment which
is the CO2 scrubber for recycle and industrial use. From the heat balance, there are
less amount of heat losses so there is no need for the tanks to be jacketed.
a. System Boundaries
INPUTS OUTPUTS
Raw Materials Atmospheric emissions

(Corn kernels, Enymes) Raw Material Acquisition (CO2)
(Milling)
Material Manufacture
(Fermentation, Distillation)
Solid & Liquid wastes

Energy (dirt,water)
Final Product Collection
(Storing in Cylindrical Vessels)
Transportation/Distribution
(Trucks/ Alcoholic beverage
manufacturers, refueling stations)
Other Environmental Release
Water (Heat)
Consumer use and Final Disposal
(Fuel, Alcoholic beverages)
Figure 5.2 System Boundaries
107
The corn kernels will be acquired from milling and fresh water will be used.
The product which is the ethanol will be stored in a tank for distribution. For the
whole process, the atmospheric emissions will be a negligible amount of steam
coming out of the cooker. CO2 will be scrubbed in the process. The dried stillage
will be used as feed for animals.
2. Raw Material Acquisition
Inputs
(Corn Kernels)
Transportation
(Carrier trucks)
Outputs
Energy
(Milled Grains)
Equipment
(Hammer Mill)
Figure 5.3 Raw Material Acquisition
The main raw material (corn kernels) will be harvested at different places and
is delivered to the milling stage through carrier trucks. The milling stage uses
hammer mill to produce the milled grains used for the processing of the ethanol.
3. Consumer Use and Final Disposal
USE
(Denaturing plants)
Point of Use MAINTENANCE

Transportation/Distribution Waste
(beverages, fuel) (Stored before Disposal
(Trucks) Management
distribution)
Recycle
RE-USE
(by-products: DDGS,
CO2 )
Figure 5.4 Consumer Use and Final Disposal
108
The final product which is 99.5 % ethanol has a variety of uses. In its denatured
state, it is used as the main element of biofuels. It can also be used as solvent in
chemical solutions. For distribution, the product will be contained in a rigid and
sealed containers to avoid losses due to leakage or evaporation since the product is
volatile. As long as there is no contamination of the final product, no amount is
wasted and disposed.
4. Recycling
CORN CORN
KERNELS KERNELS
ETHANOL CO2
Stillage, DDGs CO2
Drying Scrubbing with water
Feed stocks and CO2 scrubbed

fertilizer
Figure 5.5 Recycling Subsystem
Recycling is made in order to minimize the harmful effects of ethanol plant
emissions into the environment and it is also of great effect on the profitability of
the plant. Thus, the stillage removed from the beer column is recovered and is dried
for use as feed stocks. As for the carbon dioxide, it will be scrubbed with water
using the CO2 scrubber to produce carbonic acid.
109
CHAPTER VI
SUMMARY, CONCLUSIONS AND RECOMMENDATIONS
Summary and Conclusions
The ultimate purpose for developing detailed process design and cost estimate is to
determine the economics of ethanol production from corn. The purpose of this analysis is to
demonstrate whether or not corn-based ethanol can be cost-competitive on its own merits and
if it cannot, to give policy makers a sense of magnitude of incentive required to make it so.
Based on our economic analysis with annual net profit of 1,264,076,665, the payback
period calculated is 1.23 years which makes production of ethanol from corn feasible.
Economic analysis based on annual demand of ethanol in the Philippines is also shown in our
economic study. The return of investment (ROI) calculated is 67.97% which signifies that this
report is deemed attractive for operation.
In addition to the reasons of ethanol plant’s feasibility is that the Philippines produces
more corn than its demand wherein Region 2 and Isabela is the top corn producer region and
province in the country, respectively. This would be the first plant that will produce a corn
based ethanol in the Philippines. Supply of raw materials will not be a problem during
operations.
110
Recommendations
To improve the feasibility of the design project, the designers recommends
1. Exploring other raw materials for ethanol production that is cheaper and at the
same time will produce a product of good quality. Corn biomass can also be
used as a feed for the production of ethanol.
2. It is also recommended that further study of the process design and choice of
equipment must be conducted to validate or improve its feasibility. Choice of
materials and improvement of equipment may greatly affect the feasibility of
the project.
3. It is advised to consider co-generation operations of the plant in order to
augment profit and project self-sufficiency in the use of energy.
4. Economic viability of by-products must be explored for added income to the
company.
111
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Directorate of Maize Research, Pusa Campus, New Delhi -110 012 Technical Bulletin
2012/7 pp.28
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Biological Engineering, Purdue University.
Singh, V. (2009). Dry Grind Corn Processing – New Technologies. Associate Professor,
Department of Agricultural & Biological Engineering University of Illinois at Urbana-
Champaign, Urbana, IL
Wrenn, B.A. (2008). Summary Report for Pursuit Dynamics. National Corn-to-Ethanol
Research Center
Onuki, S., et. al. (2008). Ethanol production, purification, and analysis techniques: a review.
Agricultural and Biosystems Engineering, Iowa State University.
Szymanowska, D., Grajek, D. (2009). Fed-batch Simultaneous Saccharificationa nd Ethanol
Fermentation of Native Corn Starch. Poznań University of Life Sciences, Poznań,
Poland
Levenspiel, O. Chemical Reaction Engineering Third Edition. Department of Chemical
Engineering, Oregon State University. Copyright © 1999 John Wiley & Sons, Inc.
Green, D.W. & Perry, R.H. Perry’s Chemical Engineers’ Handbook Eight Edition. Copyright
© 2008 by The McGraw-Hill Companies, Inc.
Dale, R.T., Tyner, W.E. (2006) Economics and Technical Analysis of Ethanol Dry Milling:
Model User’s Manual. Purdue University.
Sapna, et.al. Corn to Ethanol: Retrospect’s and Prospects, Maize: Leading to a new Paradigm.
Directorate of Maize Research, Pusa Campus, New Delhi -110 012 Technical Bulletin
2012/7 pp.28
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from lignocellulosic materials. Electronic Journal of Biotechnology ISSN: 0717-3458
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114
APPENDIX
A. Material Balance Calculations
1. Adsorption
Basis: 100 000 kg dehydrated ethanol /day
Ethanol Water
m2 (recycle to Ethanol Column)
73 wt% EtOH
Azeotropic Ethanol Molecular

m1
95 wt% EtOH Sieves
m3 Dehydrated Ethanol
99.5 wt% EtOH
Overall Mass Balance:
m1 = m 2 + m 3
m1 = m2 + 100 000 (1)
Ethanol Balance:
0.95m1 = 0.73m2 + 0.995m3
0.95m1 = 0.73m2 + 0.995(100 000) (2)
Degree of Freedom analysis: 2 unknown variables – 2 equations = 0
The problem is solvable.
Solving Eq. 1 and 2:
m1 = 120 454. 5455 kg azeotropic ethanol/day
m2 = 20 454. 5455 kg ethanol water/day
115
2. Ethanol Distillation
Ethanol Water
(from Molecular Sieves)
m4 = 20 454. 5455 kg/day
Azeotropic Ethanol
73 wt% EtOH
m2 m2 = 120 454. 5455 kg/day
95 wt% EtOH
m4
Wet Ethanol Ethanol
m1
60 wt% EtOH Column
m3 Process Water
0.05 wt% EtOH
m1 + m4= m2 + m3
m1 + 20 454. 5455 = 120 454. 5455 + m3 (1)
Ethanol Balance:
0.50m1 + 0.73m4 = 0.95m2 + 0.0005m3
0.60m1 + 0.73(20 454. 5455) = 0.95(120 454. 5455) + 0.0005m3 (2)
m1 = 165 888. 2402 kg wet ethanol/day
m3 = 65 888. 24022 kg process water/day
116
3. Beer Distillation
Wet Ethanol
m2 m2 = 165 888. 2402 kg/day
70 wt% EtOH
Beer
11 wt% Solid
m1 Beer Column
89 wt%Liquid with
10 wt% Ethanol
Stillage
m3 34 wt% Solids
66 wt% Liquid with
negligible EtOH content
m1 = m 2 + m 3
m1 = 165 888.2402 + m3 (1)
Ethanol Balance:
(0.10)(0.89)(m1) = 0.70m2
0.089m1 = 0.70(165 888.2402) (2)
m1 = 1 304 738. 968 kg beer/day
m3 = 1 138 850. 728 kg stillage/day
117
4. Centrifugation
25% of m2
(routed back to Slurry Tank)
m4
Thin Stillage
7 wt% solids m2 m5
Stillage
m1 = 1 138 850. 728 kg/day m1 Centrifuge
34 wt% solid
WDGS
m3
60 wt% solid
m1 = m 2 + m 3
1 138 850. 728 = m2 + m3 (1)
Solid Balance:
0.34m1 = 0.07m2 + 0.60m3
0.34(1 138 850. 728) = 0.07m2 + 0.60m3 (2)
Splitter:
m2 = m 4 + m 5 (3)
0.25m2 = m4 (4)
Solving Eq. 1, 2, 3 and 4:
m2 = 558 681. 4892 kg thin stillage/day
m3 = 580 169. 2388 kg WDGS/day
m4 = 34 917. 59308 kg/day
m5 = 523 763. 8961 kg/day
118
5. Evaporation
Steam
m2
(to Cooker)
Thin Stillage
m1 = 523 763. 8961 kg/day m1 Evaporator
7 wt% solids
Conc. Thin Stillage

m3
60 wt% solids
m1 = m 2 + m 3
523 763. 8961 = m2 + m3 (1)
Solid Balance:
0.07m1 = 0.60m3
0.07(523 763. 8961) = 0.60m3 (2)
m2 = 462 658. 1082 kg H2O/day
m3 = 61 105. 78788kg conc. thin stillage/day
119
6. Distillers’ Grains with Solubles (DGS) Drying
Conc. Thin Stillage

m2 = 61 105. 78788 kg/day
60 wt% solids
m3 H2O
m2
WDGS
m1 = 580 169. 2388 kg /day m1 DGS Dryer
60 wt% solids
m4 DDGS
11 wt% moisture
m1 + m2= m3 + m4
580 169. 2388 + 61 105. 78788 = m3 + m4 (1)
Solid Balance:
0.60m1 + 0.60m2 = 0.89m4
0.60(580 169. 2388) + 0.60(61 105. 78788) = 0.89m4 (2)
m3 = 208 954. 784 kg H2O/day
m4 = 432 320. 2427 kg DDGS/day
120
7. Fermentation
Yeast
my mCO2
Beer
m2 = 1 304 738. 968 kg/day
Mash (Glucose) m1 Fermentors m2 11 wt% Solid
89 wt%Liquid with
10 wt% Ethanol
Glucose to Ethanol Conversion: 94.0%
C6 H12O6  2C2 H 5OH  CO2

yeast
180 kg 92 kg 88 kg
0.0002 kg of yeast is needed for every 0.82 kg of glucose feed.
m1 = m2 + mCO2 (1)
CO2 produced:
88
mCO2 = (0.10) (0.89) m2 × (2)
92
Glucose in the feed:
m1glucose = (0.10) (0.89) m2 × 180 (3)

92(0.94)
Yeast needed:
0.0002
my = m1glucose × (4)
0.82
121
Solving Eq. 1, 2, 3 and 4:
m1 = 1 415 811.964 kg mash(glucose)/day
mCO2 = 111 072. 9956 kg CO2/day
m1glucose = 241 696. 5572 kg glucose/day
my = 58.95 kg yeast/day
8. Saccharification
g-amylase
mg
Mash(Glucose)
Saccharification
Mash (Dextrins) m1 m2 m2 = 1 415 811. 964 kg/day
Tank
mglucose = 241 696. 5572 kg/day
Dextrin to Glucose Conversion: 99.0%

10C6 H12O6
0.0007 kg of g-amylase is needed for every 0.82 kg of dextrin feed.
m1 = m 2 (1)
Dextrin in the feed:
1
m1dextrin = 241 696. 5572 × (2)
0.99
G-amylase needed:
0.0007
mg = m1dextrin × (3)
0.82
122
Solving Eq. 1, 2 and 3:
m1 = 1 415 811.964 kg mash(dextrin)/day
m1dextrin = 244 137. 9366 kg dextrin/day
mg = 208. 41 kg g-amylase/day
9. Liquefaction
Makeup water from Centrifuge Steam from Evaporator

Fresh Water m3 = 34 917. 59308 kg/day m4 = 462 658. 1082 kg/day
m2 m3 m4
Milled Grains
72 wt% Starch Mash(Dextrin)
m1 Slurry Tank Slurry Cooker m5 m5 = 1 415 811. 964 kg/day
mdextrin = 244 137. 9366 kg/day
ma
a-amylase
Starch to Dextrin Conversion: 98.0%
 amylase
(C6 H10O5 ) n  H 2 O a (C6 H12O6 )10
0.74 kg 0.82 kg
0.0006 kg of g-amylase is needed for every 0.74 kg of dextrin feed.
m1 + m 2 + m 3 + m4 = m 5 (1)
Starch in the feed (milled grains):
0.74
m1starch = 244 137. 9366 × (2)
0.82(0.98)
m1starch = 0.72m1 (3)
123
A-amylase needed:
0.0006
ma = m1starch × (4)
0.74
Solving Eq. 1, 2 and 3:
m1 = 312 244. 3329 kg milled grains/day
m1starch = 224 815.9197 kg starch/day
m2 = 605 991. 9298 kg H2O/day
ma = 182.28 kg a-amylase/day
10. Milling
Corn Kernels m1 Hammer Mill m2 Milled Grains

m2 = 312 244. 3329kg/day
m1 = m 2 (1)
Degree of Freedom analysis: 1 unknown variable – 1 equation = 0
Solving Eq. 1:
m1 = 312 244. 3329 kg corn kernels/day
124
B. Energy Balance Calculations
1. Heat Gained During Milling
Corn Kernels, 25oC Hammer Mill Milled Grains, 40oC

m = 312 244. 3329kg/day m = 312 244. 3329kg/day
Given:
m = 3.614kg/s ; Tin = 25oC ; Tout = 40oC ; Cp = 1.800kJ/kgoC
Where:
m = mass flowrate
Cp = specific heat
The energy required
Q  mCpT  3.614(1.800)(40  25)
Q = 97.58 kW
2. Slurry Tank
Fresh Water, 25oC Thin Stilage from Centrifuge, 70oC

m2 = 605 991. 9298 kg/day m3 = 34 917. 59308 kg/day
Milled Grains, 40oC Slurry, 80oC

Slurry Tank
m1 = 312 244. 3329kg/day m4 = 953 153. 8558kg/day
Stream Mass Flowrate Temperature Cp H

(kg/s) (oC) (kJ/kgoC) (kJ/kg)
Milled Grains 3.614 40 1.800 -
Fresh Water 7.014 25 - 112.75
Thin Stillage 0.404 70 - 293.69
Slurry 11.032 80 1.218 -
125
Input:
Sensible Heat of Milled Grains
Q  mCpT  3.614(1.800)(40)
Q  260.21kW
Sensible Heat of Fresh Water
Q  mH  7.014(112.75)
Q  790.83kW
Sensible Heat of Thin Stillage
Q  mH  0.404(293.69)
Q  118.65kW
Output:
Sensible Heat of Slurry
Q  mCpT  11.032(1.218)(80)
Q  1074.96kW
Q  output  input
Q  1074.96  (176.07  790.83  118.65)
Q = -10.59 kW
3. Steam Cooking
126
Steam, 210oC
m2 = 462 658. 1082 kg/day
Slurry, 80oC Mash(Dextrin), 210oC

Cooker
m1 = 953 153. 8558kg/day m3 = 1 415 811. 964 kg/day

o
(kg/s) ( C) (kJ/kgoC) (kJ/kg)
Slurry 11.032 80 1.218 -
Steam 5.355 210 - 2897.64
Mash(Dextrin) 16.387 210 1.218 -
Input:
Sensible Heat of Slurry
Q  mCpT  11.032(1.218)(80)
Q  1074.96kW
Sensible Heat of Steam
Q  mH  5.355(2897.64)
Q  15516.84kW
Output:
Sensible Heat of Mash
Q  mCpT  16.387(1.218)(210)
Q  4191.47kW
Q  4191.47  (1074.96  15516.84)
Q = -12400.33 kW
4. Cook Retention Tank
127
Mash(Dextrin), 210oC Cook Retention Mash(Dextrin), 80oC
m = 1 415 811. 964 kg/day Tank m = 1 415 811. 964 kg/day
Heat Lost on the Retention Tank
Q  mCpT  16.387(1.218)(80  210)
Q = -2594.72 kW
5. Pre-Cooling to Saccharification Tank
Cooling Water, 25oC
Mash(Dextrin), 80oC Mash(Dextrin), 30oC

Cooler
m = 1 415 811. 964 kg/day m = 1 415 811. 964 kg/day
Cooling Water, 50oC
Given:
Where:
m = mass flowrate
Cp = specific heat
The energy required
Q  mCpT  16.387(1.218)(30  80)
Q = -997.97 kW
Enthalpy of Water at 1atm (Perry 8th)
128
T = 25oC ; H = 112.75 kJ/kg
T = 50oC ; H = 209.83 kJ/kg
ΔH = 97.08 kJ/kg
Required Cooling water Flowrate
Q 997.97
m 
H 97.08
m = 10.28 kg/s
6. Saccharification Tank
Mash(Dextrin), 30oC Saccharification Mash(Glucose), 68oC

99.0% Conversion of Dextrin to Glucose
68oC conversion Temperature
From Chemical Reaction Engineering by Octave Levenspiel, the energy
balance equation on reactor is:
Q  Cp2 Tx A  Cp1 T (1  x A )  H r x A
Where:
Cp2 = mean specific heat capacity of completely converted product
Cp1 = mean specific heat of unreacted feed stream
ΔHr = heat of reaction
Data:
129
Cp2 = 1.2552 kJ/kgoC
Cp1 = 1.200 kJ/kgoC
ΔHr = 0.722 kJ/kg
Substituting the data,
Q  1.2552(68  30)(0.99)  1.200(68  30)(1  0.99)  0.722(0.99)
Q = 48.391 kJ/kg
At feed mass flowrate of 16.387kg/s, the heat required is
Q  16.378(48.391)
Q = 792.55 kW
For Heat Loss Calculation
Input:
Q  mCpT  16.387(1.218)(30)
Q = 598.78 kW
Output:
Q  mCpT  16.387(1.2552)(68)
Q = 1398.67 kW
Q  1398.67  598.78
Q = 799.91 kW
7. Post-Cooling after Saccharification Tank
130
Cooling Water, 25oC
Mash(Glucose), 68oC Mash(Glucose), 30oC

Cooler
m = 1 415 811. 964 kg/day m = 1 415 811. 964 kg/day
Cooling Water, 50oC
Given:
The energy required
Q  mCpT  16.387(1.2552)(30  68)
Q = -781.62 kW
Q 781.62
m 
H 97.08
m = 8.05 kg/s
8. Fermentors
131
CO2
Beer, 35oC
m2 = 1 304 738. 968 kg/day
Mash(Glucose), 30oC 11 wt% Solid
Fermentors
m1 = 1 415 811. 964 kg/day 89 wt%Liquid with
10 wt% Ethanol
Stream Mass Temperature Cp

Flowrate(kg/s) (oC) (kJ/kgoC)
Mash 16.387 30 1.2552
CO2 1.286 35 0.9185
Beer 15.101 35 0.805
Input:
Sensible Heat of Mash
Q  mCpT  16.387(1.2552)(30)
Q  617.07kW
Output:
Sensible Heat of CO2
Q  mCpT  1.286(0.9185)(35)
Q  41.34kW
Sensible Heat of Beer
Q  mCpT  15.101(0.805)(35)
Q  425.47kW
Q  (41.34  425.47)  617.07
Q = -150.26 kW
9. Beer Column
132
Wet Ethanol, 38oC
m2 = 165 888. 2402 kg/day
70 wt% EtOH
Beer, 35oC
m2 = 1 304 738. 968 kg/day
11 wt% Solid Beer Column
89 wt%Liquid with
10 wt% Ethanol
Stillage, 80oC
m3 = 1 138 850. 728 kg/day
34 wt% solid
Stream Mass Flowrate Temperature Cp

(kg/s) (oC) (kJ/kgoC)
Beer 15.101 35 0.805
Wet Ethanol 1.920 38 3.055
Stillage 13.181 80 4.184
Input:
Sensible Heat of Beer
Q  mCpT  15.101(0.805)(35)
Q  425.47kW
Output:
Sensible Heat of Wet Ethanol
Q  mCpT  1.920(3.055)(38)
Q  222.89kW
Sensible Heat of Stillage
Q  mCpT  13.181(4.184)(80)
Q  4411.94kW
Q  (222.89  4411.94)  425.47
Q = 4209.36 kW
10. Ethanol Column
133
Ethanol Water, 35oC
m2 = 20 454. 5455 kg/day
Azeotropic Ethanol, 40oC
73 wt% EtOH
m3 = 120 454. 5455 kg/day
95 wt% EtOH
Ethanol
Wet Ethanol, 38oC
Column
m1 = 165 888. 2402 kg/day
70 wt% EtOH
Process Water, 80oC
m4 = 65 888. 2402 kg/day
0.05 wt% EtOH

Ethanol Water 0.237 35 3.055
Wet Ethanol 1.920 38 3.055
Azeotropic Ethanol 1.394 40 3.357
Process Water 0.763 80 4.188
Input:
Sensible Heat of Wet Ethanol
Q  mCpT  1.920(3.055)(38)
Q  222.89kW
Sensible Heat of Ethanol Water
Q  mCpT  0.237(3.055)(35)
Q  25.34kW
Output:
Sensible Heat of Azeotropic Ethanol
Q  mCpT  1.394(3.357)(40)
Q  187.19kW
Sensible Heat of Process Water
Q  mCpT  0.763(4.188)(80)
Q  255.64kW
134
Q  (187.19  255.64)  (222.89  25.34)
Q = 194.60 kW
11. Molecular Sieves
Ethanol Water, 80oC

(recycle to Ethanol Column)
m2 = 20 454. 5455 kg/day
73 wt% EtOH
Molecular
m1 = 120 454. 5455 kg/day
Sieves
95 wt% EtOH
Dehydrated Ethanol, 80oC

m3 = 100 000 kg/day
99.5 wt% EtOH

Azeotropic Ethanol 1.394 40 3.357
Dehydrated Ethanol 1.157 80 1.637
Ethanol Water 0.237 80 3.055
Input:
Sensible Heat of Azeotropic Ethanol
Q  mCpT  1.394(3.357)(40)
Q  187.19kW
Output:
Sensible Heat of Ethanol Water
Q  mCpT  0.237(3.055)(80)
Q  57.92kW
Sensible Heat of Dehydrated Ethanol
Q  mCpT  1.157(1.637)(80)
Q  151.52kW
Q  (57.92  151.52)  187.19
135
Q = 22.25 kW
12. Cooling of Ethanol Water (Recycle to Ethanol Column)
Cooling Water, 25oC
Ethanol Water, 80oC Ethanol Water, 35oC

(recycle to Ethanol Column) Cooler (recycle to Ethanol Column)
m = 20 454. 5455 kg/day m = 20 454. 5455 kg/day
73 wt% EtOH 73 wt% EtOH
Cooling Water, 50oC
Given:
The energy required
Q  mCpT  0.237(3.055)(35  80)
Q = -32.58W
Q 32.58
m 
H 97.08
m = 0.34 kg/s
136
13. Cooling of Dehydrated Ethanol
Cooling Water, 25oC

Cooler m = 100 000 kg/day
m = 100 000 kg/day
99.5 wt% EtOH
99.5 wt% EtOH
Cooling Water, 50oC
Given:
The energy required
Q  mCpT  1.157(1.637)(35  80)
Q = -85.23W
Q 85.23
m 
H 97.08
m = 0.88 kg/s
137
14. Cooling of Stillage
Cooling Water, 25oC
Stillage, 80oC Cooler Stillage, 70oC

m = 1 138 850. 728 kg/day m = 1 138 850. 728 kg/day
34 wt% solid 34 wt% solid
Cooling Water, 50oC
Given:
The energy required
Q  mCpT  13.181(4.184)(70  80)
Q = -551.49W
Q 551.49
m 
H 97.08
m = 5.68 kg/s
15. Evaporator
138
Steam (to Cooker), 105oC
m2 = 462 658. 1082 kg/day
Thin Stillage, 70oC

m1 = 523 763. 8961 kg/day Evaporator
7 wt% solids
Conc. Thin Stillage, 105oC

m3 = 61 105. 78788 kg/day
60 wt% solids

Thin Stillage 6.062 70 - 293.69
Steam 5.355 105 - 2677.22
Conc. Thin Stillage 0.707 105 4.184 -
Input:
Sensible Heat of Thin Stillage
Q  mH  6.062(293.69)
Q  1780.35kW
Output:
Sensible Heat of Steam
Q  mH  5.355(2677.22)
Q  14336.525kW
Sensible Heat of Conc. Thin Stillage
Q  mCpT  0.707(4.184)(105)
Q  310.60kW
Q  (14336.525  310.60)  1780.35
Q = 12866.775 kW
16. DGS Dryer
139
Conc. Thin Stillage, 105oC
m2 = 61 105. 78788 kg/day
60 wt% solids
H2O, 150oC
m3 = 208 954. 784 kg/day
WDGS, 70oC
m1 = 580 169. 2388 kg /day DGS Dryer
60 wt% solids
DDGS, 150oC
m4 = 432 320. 2427 kg /day
11 wt% moisture

Conc. Thin Stillage 0.707 105 4.184 -
WDGS 6.715 70 4.184 -
Steam 2.418 150 - 2778.64
DDGS 5.004 150 2.536 -
Input:
Sensible Heat of Conc. Thin Stillage
Q  mCpT  0.707(4.184)(105)
Q  310.60kW
Sensible Heat of WDGS
Q  mCpT  6.715(4.184)(70)
Q  1966.69kW
Output:
Sensible Heat of Steam Sensible Heat of DDGS
Q  mH  2.418(2778.64) Q  mCpT  5.004(2.536)(150)
Q  6718.75kW Q  1903.52kW
Q  (6718.75  1903.52)  (310.60  1966.69)
Q = 6344.98 kW
C. Equipment Design Calculations
140
1. Hammer Mill
Corn Kernels m1 Hammer Mill m2 Milled Grains

m2 = 312 244. 3329kg/day
The grinder that will be used in this project is hammer mill. Hammer mills
accomplish size reduction by impacting a slow moving target with a rapidly
moving hammer. It employs rotating elements that beat the material until it is
small enough to pass through a screen located at the bottom of the mill casing.
312244.3329
m  14.34tons / hr
24  907.185
From Table 12.9 (a) of Chemical Process Equipment- Selection and Design
by Walas, at this capacity, 1 swing- Sledge Hammer mill is used. The grate spacing
is ¼ inch. The following data were also obtained:
Length = 5’1” or 1.5494 m
Width = 5’8” or 1.7272 m
Inside Diameter = 30” or 0.762 m
Inside width = 20” or 0.508 m
Feed opening = 17” × 20” or 0.4318 m × 0.508 m
Pulley speed = 1000 – 1300 rpm
Approximate hp = 40
2. Slurry Tank
141
Fresh Water, 25oC Thin Stilage from Centrifuge, 70oC
m2 = 605 991. 9298 kg/day m3 = 34 917. 59308 kg/day
Milled Grains, 40oC Slurry, 80oC

Slurry Tank
m1 = 312 244. 3329kg/day m4 = 953 153. 8558kg/day
The viscous mixture with enzymes is mixed for up to 0.25 hours.
For calculations the following data were used,
Mass of slurry = 953153.8558kg/day
Density of mash = 1220 kg/m3
Feed Volume
953153.8558 0.25
V    8.1383m 3
1220 24
For bioreactors the actual volume is 1.2-1.3 times the capacity.
V f  1.38.1383  10.5797m 3
From the book entitled Fundamentals of Biochemical Engineering by Rajiv Duta,
the ratio of height to its diameter is 2. Therefore, the diameter of the reactor is:
D 2 H D 2 (2 D)
Vf  ; 10.5797 
4 4
D  1.8885m
For the Height
H  2 D  3.7770 m
Reactor impeller: According to Rajiv Duta, the ratio of the impeller diameter to
the tank diameter is equal to 0.3.
impeller diameter  0.3(1.8885)  0.5666m
1
Baffles: width  D  0.1889m
10
3. Steam Cooker
142
The slurry is then pumped through a jet cooker and held for 5 minutes.
Mass of mash = 1 415 811.964 kg/day
Mass of Slurry = 953153.8558 kg/day
Mass of Water = 462658.1082 kg/day
Density of Slurry = 1220 kg/m3
Density of Water = 998 kg/m3
Feed Volume
 953153.8558 462658.1082  5
V     4.3224m 3
 1220 998  24  60
Vessel:
V f  1.3(4.3224)  5.6192m 3
L  3D
D 2 3D 3
Vf  L
4 4
D  1.3360m
L  4.0081m
Reactor Thickness:
Pstatic  gh  1137.33(9.81)( 4.0081)  44719.0938Pa

P  1.33(44719.0938  101325)  194238.6448Pa
For spot-examined carbon steel, E = 0.85 and S = 94500 kPa
Maximum Corrosion Allowance C = 0.003175 m (ASME Section I)
143
P( D / 2)
t reactor   C  4.7927mm
SE  0.6 P
0.885PLa
t head  C
SE  0.1P
where La = D/2
t head  4.5484mm
Inside Depth of Dish (IDD)

IDD  La  La  r   La  t head  r 
2 2

1
2
Where knuckle radius r = 0.06(D/2)
IDD  0.5926 m
Volume in Head
 2
Vhead  0.9 La 2 IDD 
 3 
Vhead  0.4985m 3
Total Reactor Volume
V  6.6162m 3
4. Mash Pre-Cooler
144
Cooling Water, 25oC
Mash(Dextrin), 80oC Mash(Dextrin), 30oC

Cooler
m = 1 415 811. 964 kg/day m = 1 415 811. 964 kg/day
Cooling Water, 50oC
Log mean temperature difference:
(80  50)  (30  25)

Tlm  =13.95°C
 80  50 
ln  
 30  25 
Correction Factor, F:
Th ,in  Th ,out 80  30
R  = 2.00
Tc ,out  Tc ,in 50  25
Tc ,out  Tc ,in 50  25
P  = 0.45
Th ,in  Tc ,in 80  25
From Figure 14.5a&b (Peters, Timmerhaus & West, 2004):
F < 0.85 (Appendix E: F should not less than 0.85)
Two shell passes, two rows of tubes (for more than two passes, use F = 1)
Tlm  1.00(13.95) = 13.95°C
Q 997970W
A  = 84.17 m2
UTlm W
(850 2 )(13.95K )
m K
5. Saccharification Tank
145
Mash(Dextrin), 30oC Saccharification Mash(Glucose), 68oC
Residence time in the saccharification tank is 6 hours.
Mass of mash = 1 415 811.964 kg/day
Mass of Slurry = 953153.8558 kg/day
Mass of Water = 462658.1082 kg/day
Density of Slurry = 1220 kg/m3
Density of Water = 998 kg/m3
Feed Volume
 953153.8558 462658.1082  6
V     311.2147m 3
 1220 998  24
For bioreactors the actual volume is 1.2-1.3 times the capacity.
V f  1.3(311.2147)  404.5792m 3
From the book entitled Fundamentals of Biochemical Engineering by Rajiv Duta,
the ratio of height to its diameter is 2. Therefore, the diameter of the reactor is:
D 2 H D 2 (2 D)
Vf  ; 404.5791 
4 4
D  6.3625m
H  2 D  12 .7250 m
Reactor impeller: According to Rajiv Duta, the ratio of the impeller diameter to
the tank diameter is equal to 0.3.
impeller diameter  0.3(6.3625)  1.9088m
1
Baffles: width  D  0.6363m
10
6. Mash Post-Cooler
146
Cooling Water, 25oC
Mash(Glucose), 68oC Mash(Glucose), 30oC

Cooler
m = 1 415 811. 964 kg/day m = 1 415 811. 964 kg/day
Cooling Water, 50oC
(68  50)  (30  25)

Tlm  =10.15°C
 68  50 
ln  
 30  25 
Th ,in  Th ,out 68  30
R  = 1.52
Tc ,out  Tc ,in 50  25
Tc ,out  Tc ,in 50  25
P  = 0.58
Th ,in  Tc ,in 68  25
Tlm  1.00(10.15) = 10.15°C
Q 781620W
A  = 90.60 m2
UTlm W
(850 2 )(10.15K )
m K
7. Fermentors
147
The whole fermentation process usually requires 48-72 hours.
myeast = 58.95 kg/day
58.95kg
V yeast  3
 0.0651m 3
905.105kg / m
mfeed = 1 415 811. 964 kg mash/day
1415811.964kg
Vmash  3
 925.37m 3
1530kg / m
Vtotal  925.43m 3
Reactor Volume:
Vreactor = 1.3Vcalc = 1.3(925.43) = 1203.06 m3
Reactor Diameter and Height:
H/D = 1.5
8Vreactor
Dreactor  3  10.07m
3
H reactor  15.11m
Reactor Thickness:
Pstatic  gh  1530(9.81)(15.11)  226790.523Pa

P  1.33(226790.523  101325)  436393.65Pa
For spot-examined carbon steel, E = 0.85 and S = 94500 kPa
Maximum Corrosion Allowance C = 0.003175 m (ASME Section I)
P( D / 2)
t reactor   C  0.030620m
SE  0.6 P
0.885PLa
t head  C
SE  0.1P
where La = D/2
t head  0.027397m
Inside Depth of Dish (IDD)

IDD  La  La  r   La  t head  r 
2 2

1
2
148
Where knuckle radius r = 0.06(D/2)
IDD  4.5265 m
Volume in Head
 2
Vhead  0.9 La 2 IDD 
 3 
Vhead  216.30m 3
Total Reactor Volume
V  1419.3630m 3
Dimensions of Impeller and Baffle
Dimpeller = Dreactor/3 = 3.36 m
Imp. Distance from Tank Bottom = 3.36 m
Baffle width = Dreactor/10 = 1.007 m
Imp. Disc Diameter = 3Dimp/4 = 2.52 m
Imp. Blade Length = Dimp/4 = 0.84 m
Imp. Blade Width = Dimp/5 = 0.672 m
Baffle Tip Distance from Tank Bottom = Dreactor/5 = 2.014 m
8. Beer Column
149
Wet Ethanol, 38oC
m2 = 165 888. 2402 kg/day
70 wt% EtOH
Beer, 35oC
m2 = 1 304 738. 968 kg/day
11 wt% Solid Beer Column
89 wt%Liquid with
10 wt% Ethanol
Stillage, 80oC
m3 = 1 138 850. 728 kg/day
34 wt% solid
9. Ethanol Column
Ethanol Water, 35oC

m2 = 20 454. 5455 kg/day
73 wt% EtOH
m3 = 120 454. 5455 kg/day
95 wt% EtOH
Ethanol
Wet Ethanol, 38oC
Column
m1 = 165 888. 2402 kg/day
70 wt% EtOH
Process Water, 80oC
m4 = 65 888. 2402 kg/day
0.05 wt% EtOH
10. Adsorption Columns
The pressure required for this adsorption system ranges from 1 to 2.5 atm.
According to Green & Perry (2008), adsorption columns with pressures above
atmospheric must be designed like process pressure vessels. A process
pressurevessel has the following dimensions:
Column height = 4.88 m; Column diameter = 1.83 m
Height of adsorbent inside the column = 2.89 m
Operating conditions:
Temperature: 35-116°C; Pressure: 1-2.5atm
To determine the amount of 3A Molecular Zeolites needed, the following
ratio will be used:
20 kg H2O : 100 kg 3A zeolite
11. Anhydrous Ethanol Cooler

150
Cooling Water, 25oC

Cooler m = 100 000 kg/day
m = 100 000 kg/day
99.5 wt% EtOH
99.5 wt% EtOH
Cooling Water, 50oC
(80  50)  (35  25)

Tlm  =18.20°C
 80  50 
ln  
 35  25 
Th ,in  Th ,out 80  35
R  = 1.80
Tc ,out  Tc ,in 50  25
Tc ,out  Tc ,in 50  25
P  = 0.45
Th ,in  Tc ,in 80  25
Tlm  1.00(18.20) = 18.20°C
Q 85230W
A  = 5.51 m2
UTlm W
(850 2 )(18.20K )
m K
12. Ethanol Water Cooler
151
Cooling Water, 25oC
Ethanol Water, 80oC Ethanol Water, 35oC

(recycle to Ethanol Column) Cooler (recycle to Ethanol Column)
m = 20 454. 5455 kg/day m = 20 454. 5455 kg/day
73 wt% EtOH 73 wt% EtOH
Cooling Water, 50oC
(80  50)  (35  25)

Tlm  =18.20°C
 80  50 
ln  
 35  25 
Th ,in  Th ,out 80  35
R  = 1.80
Tc ,out  Tc ,in 50  25
Tc ,out  Tc ,in 50  25
P  = 0.45
Th ,in  Tc ,in 80  25
Tlm  1.00(18.20) = 18.20°C
Q 32580W
A  = 2.11 m2
UTlm W
(850 2 )(18.20K )
m K
13. Stillage Cooler
152
Cooling Water, 25oC
Stillage, 80oC Cooler Stillage, 70oC

m = 1 138 850. 728 kg/day m = 1 138 850. 728 kg/day
34 wt% solid 34 wt% solid
Cooling Water, 50oC
(80  50)  (70  25)

Tlm  =36.99°C
 80  50 
ln  
 70  25 
Th ,in  Th ,out 80  70
R  = 0.40
Tc ,out  Tc ,in 50  25
Tc ,out  Tc ,in 50  25
P  = 0.45
Th ,in  Tc ,in 80  25
From Figure 14-4&14-5 (Peters, Timmerhaus & West, 2004):
F = 0.97 (One shell pass, two tube passes)
Tlm  0.97(36.99) = 35.88°C
Q 551490W
A  = 18.09 m2
UTlm W
(850 2 )(35.88K )
m K
153
CHEMICAL ENGINEERING PLANT DESIGN ASSESSMENT RUBRIC
Project Name: PRODUCTION OF ETHANOL FROM CORN Date:
Team Members: 1. Acerit, Harvey O.

2. Mamauag, Aileen T.
3. Sibal, Arjanelle A.
4. Soriano, Jonalbeth B.
Category/ Exceptional Acceptable Marginal Unacceptable Points

Dimensions (4) (3) (2) (1)
Organization Information is presented in a Information is presented in a Work is hard to follow as Sequence of information is
& Style logical, interesting way, which is logical manner, which is easily there is very little continuity.
difficult to follow.
easy to follow. followed. No apparent structure or
(2) Purpose of work is stated, continuity.
Purpose is clearly stated and Purpose of work is clearly stated but does not assist in Purpose of work is not
explains the structure of work. assists the structure of work. following work. clearly stated.
Content Demonstration of full At ease with content and able Uncomfortable with No grasp of information.
& knowledge of the subject with to elaborate and content. Clearly no knowledge of
Knowledge explanations and explain to some degree. Only basic concepts are subject matter. No
elaboration. demonstrated and questions are answered. No
(2) interpreted. interpretation made.
Design Clear and complete Overall sound understanding of Some understanding of Little or no grasp of
Problem and understanding of design goal the problem and constraints. problem. Major deficiencies problem.
Boundaries and constraints. Does not significantly impair that will impact the quality Incapable of producing a
solution. of Successful solution.
(2) solution.
Alternative Final design achieved after Alternative approaches Serious deficiencies in Only one design presented
Designs review of reasonable identified to some degree. exploring and identifying or clearly infeasible
alternatives. alternative designs. alternative given.
(1)
154
Use of Computer–aided tools are Computer–aided tools used Minimal application and Serious deficiencies in
Computer– used effectively to develop with moderate effectiveness use of appropriate tools. Understanding the correct
Aided Tools and analyze designs. to develop designs. selection and/or use of
(1) tools.
Application of Critical selection and Effective application of Serious deficiencies in No or erroneous

Engineering application of engineering Engineering principles proper selection and use of application of
Principles Principles ensuring reasonable resulting in reasonable engineering principles. engineering principles
results. solution. yielding unreasonable
(3) solution.
Final Design Design meets or exceeds Design meets desired Barely capable of achieving Not capable of achieving
desired objectives. objectives. desired objectives. desired objectives.
(5) Effective implementation of Moderately effective Minimal utilization of resource No implementation of

resource conservation and utilization of resource conservation and recycle resource conservation
recycle strategies. conservation and recycle potentials. and
potentials. Recycle strategies.
Format Format is consistent Format is generally Mostly consistent format. Work is illegible, format
& Aesthetics throughout including heading consistent including changes throughout, e.g.
styles and captions. heading styles and captions. font type, size etc.
(1)
Figures, Figures and tables are Figures and tables are neatly Figures and tables are legible, Figures and tables are
Graphs & presented logically and done and provide intended but not convincing. sloppy and fail to provide
Tables reinforce the text. information. intended information.
Many tables are not interpreted. Tables are not used
All tables are effectively Most tables are properly Important features are not effectively. Little
(2) interpreted and discussed in interpreted and important communicated or understood. understanding of
the report. features noted. important features or
issues.
Safety & Complete understanding of Sound understanding of Serious deficiencies in No understanding or
Health Issues health and safety issues health and safety issues. addressing health and safety appreciation of safety
leading to sound and Mostly effective in achieving issues leading to an unsupported and health related issues.
(2) supported results. supported results. and/or infeasible result.
155
Environmental Complete understanding of Sound understanding of Environmental aspects are No understanding or
Aspects Environmental aspects. Environmental aspects. Addressed ineffectively with appreciation of the
Effective in addressing of Mostly effective in little or no effect on end results. importance of
(2) Environmental issues leading addressing environmental environmental concerns.
to a better result. issues.
Spelling Negligible misspellings and/or Minor misspellings and/or Several spelling and Numerous spelling and
& Grammar grammatical errors. grammatical errors. grammatical errors. grammatical errors.
(1)
References Reference section complete Minor inadequacies in Inadequate list of references or No referencing system
and comprehensive. references. references in text. used.
Consistent and logical Consistent referencing Inconsistent or illogical
(1) referencing system. system. referencing system.
TOTAL
156

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PRODUCTION OF ETHANOL FROM CORN

A Plant Design Report

In Partial Fulfillment of the

Requirements for the Degree

Bachelor of Science in Chemical Engineering

May 27, 2018

Engr. CAESAR POBRE LLAPITAN

Chemical Engineering Department

Cagayan State University

Dear Engr. Llapitan:

corn as the raw material.

environmental impacts. We hope that this will merit your approval.

Very truly yours,

by Harvey O. Acerit, Aileen T. Mamauag, Arjanelle A. Sibal and Jonalbeth B. Soriano in

recommended for acceptance and approval.

ENGR. CAESAR P. LLAPITAN

ENGR. MONICO U. TENEDOR

bioethanol requires a methodological approach whereby economical, environmental and social

from these alternatives.

processes and equipment used for the said product.

representations also denote that the plant will be profitable if constructed.

management and government regulations involved in the process were provided.

cycle analysis were also discussed in this chapter.

Table 1.1 Property of Ethanol 5

Table 1.2 Comparison of the Three Alternatives Method 10

Table 2.1 Philippine Ethanol Mandate 23

Table 3.1 Grain Composition 36

Table 3.2 Dry Mill Process Solid/Liquid Percentages 36

Table 3.3 Conversion Rates as a Percentage of Theoretical Yield 37

Table 3.4 Ethanol Content of the Down Streams 37

Table 3.5 Theoretical Weight of Enzymes Needed 38

Table 3.6 Summary of Material Balance Calculations 41

Table 3.7 Legend of Streams in Figure 3.3 44

Table 3.8 Specific Heat Capacity of Streams 45

Table 3.9 Summary of Energy Balance Calculations 46

Table 3.11 Control Element Symbols 67

Table 3.12 Instrumentation Line Symbols 68

Table 3.13 Location of Instruments 68

Table 3.14 ISA Identification Letters 68

Table 3.15 Control Valve 69

Table 4.1 Cost Indices 77

Table 4.2 Purchased Equipment Cost 78

Table 4.3 Breakdown of Direct and Indirect Costs 80

Table 4.4 Calculated Percentage of Components and Items 81

Table 4.5 Fixed Charges 85

Table 4.7 Depreciation using MACRS 89

Figure 1.1 Wet Milling Process for the Production of Ethanol 7

Figure 1.2 Dry Milling Process for the Production of Ethanol 8

Figure 1.3 Ethanol Production from Cellulosic Material 9

Figure 1.4 Anatomy of the Proposed Process 10

Figure 2.1 Global Bioethanol Market by Type 17

Figure 2.2 Global Bioethanol Market by Blend 18

Figure 2.3 Global Bioethanol Market by Application 19

Figure 2.4 Global Bioethanol Market by Region 20

Figure 2.5 World Ethanol Production/Trade 22

Figure 2.6 Fuel Ethanol Production of Philippines 24

Figure 2.7 Fuel Ethanol Consumption of Philippines 24

Figure 2.8 Fuel Use Projection 25

Figure 2.9 Global Ethanol Production, Trade and Prices (2017) 27

Figure 3.1 Block Flow Diagram 33

Figure 3.2 Process Topology 34

Figure 3.3 Qualitative Block Diagram 39

Figure 3.4 Quantitative Block Diagram 40