via Extractive distillation using Ethylene Glycol as entrainer in Aspen Plus software. Process ... to column & pure solvent is recovered (99.9 % mole purity).
Department of Chemical Engineering, Thapar Institute of Engineering & Technology, Patiala Production of 100 TPD Ethanol using molasses as feedstock and its dehydration using ASPEN PLUS via extractive distillation Submitted ByTarun Jain (101401083); Keshav Dua (101451001); Osheen Garg (101451011); Shubham Verma (101451006); Vaibhav Singh (101401086)
CAPSTONE PROJECT JAN – MAY 2018
SUPERVISOR: Dr. Neetu Singh
Brief Introduction • Ethanol is commercially produced by catalytic hydration or fermentation of sugars [1]. • In this capstone project Ethanol is manufactured using molasses as feedstock • Currently there is an active research in area of biofuels which can replace conventional sources of energy which are limited in supply.
• Anhydrous Ethanol is considered as potential biofuel and renewable source of energy [2]. • The objective of this work is to produce 100 TPD of Ethanol. • The purity obtained of Ethanol is 80% (by mole) which is further concentrated to 99.9 mole % via Extractive distillation using Ethylene Glycol as entrainer in Aspen Plus software.
Methodology 1.
Energy Balance Unit
Reboiler Duty (kW)
Condenser Load (kW)
Beer Still
1967.072041
2296.045299
Aldehyde Still
512.2168468
1900.366456
Rectification Still
8.651303995
1232.38251
Unit
Heat Evolved
Conversion
Fermenter
5539.97
97%
• Material Balance • Energy Balance
2.
• Equipment Design • Process Economics
3.
• Environmental and Safety Considerations • Simulation of Ethanol Dehydration
Column Design
Process Description 1. Diluter: Molasses are fed in diluter to obtain 15% (wt.) sugar solution. 2. Fermenter: Sugars are converted into alcohols at 32oC by action of yeast which releases CO2 as well. 3. Scrubber: Ethanol vaporized from fermenter is scrubber with water and sent back to fermenter. 4. Beer Still: Ethanol is concentrated to 60% (wt.) in the distillation column and aldehydes are formed. 5. Aldehyde Still: All Aldehydes are removed and Ethanol is concentrated to 75% (wt.). 6. Rectification Still: Ethanol is concentrated to 91% (wt.) by simple distillation. 7. Extractive Distillation Column (EDC): High Purity Ethanol is obtained by using Ethylene Glycol (EG) as entrainer. 8. Solvent Recovery Column: Bottom stream of EDC is fed to column & pure solvent is recovered (99.9 % mole purity)
Process Flow / Results
Ethanol Dehydration Flowsheet
1 Shell Pass 1 Tube Pass HE Design
Parameter
Value
Parameter
Value
Turndown ratio
70%
Inner diameter of tube
31.29 mm
No. of trays
22
Outer diameter of tube
38.1 mm
Column pressure drop
21.582 kPa
Length of tube
4.88 m
Area of 1 tube
0.577 m2
Total tubes required
115
Total flow area
0.0883 m2
Water linear velocity
0.314 m/s
Bundle Diameter
743.93mm
Shell inside diameter
807.93 mm
Pressure at bottom
122.907 kPa
Flooding velocity
13.89 m/s
Tray spacing
0.6
Column diameter
Temperature profile in EDC
1.2 m
Column height
12.6 m
Weir height
50 mm
Hole size
5 mm
Plate thickness
5 mm
No. of holes
1314 holes
Actual velocity
17.84 m/s
Indirect Costs = Rs. 366113308.6 Contngency, 25627931.6 Engineering& Supervision Costs, 73222661.71
CE & CC, 73222661.71
Liquid phase conc. profile of ethanol in EDC Direct Production Costs = Rs. 322504768.2
Direct Costs = Rs. 366113308.6 SF&YIC, 82404925
Land Cost, 7063279.36
Purchased Equipment Cost, 117721322.7
Electrical Cost, 29430330.68 Instrumentatio n and control cost, 23544264.54
Piping cost, 58860661.1
Installation costs, 41202462.95
Operating P & RC, LCC, Supllies, 13856604.71 3498212.663 3325585.131
Conclusions
M & RC, 64664155.32
Utilities Cost, 3325585.13 DS & CLC, 22170567.54
Raw Material cost, 184751729.5
•
Fixed Costs = Rs. 69283023.55
Local Taxes, 10763731.27
•
Insurance Cost, 3229119.38
General Expenses = Rs. 151216830
•
Financing intersest, 40363992.27 R & DC, 2309434.19
D & SC, 69283023.56 Administrative Costs, 184751729.5
100.04 TPD of Ethanol is produced using 1220 TPD molasses as feedstock. Ethylene Glycol is proven to be a good entrainer for Ethanol Dehydration via extractive distillation. Total energy requirements according to simulated flowsheet for ethanol dehydration is 2.66 MW using EG.
References
Depriciation Cost, 55290172.89
• Rate of Return - 90.39% • Total Income – Rs 154.9 Crores • Net Profit - Rs 60.81 Crores • Total Production Cost - Rs. 58.91 Crores
[1]. Rao , M Gopala, Dryden's Outlines Of Chemical Technology., Paperback [2]. Kumar Santosh, Singh Neetu, Prasad Ram, Anhydrous ethanol: A renewable source of energy, Renewable and Sustainable Energy Reviews
