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Abhishek Singh
Abhishek Singh

The document describes the production of biobutanol through fermentation and downstream processing. Key points: - Biobutanol is produced through a fermentation process in a large reactor vessel. The document sizes the reactor to hold 50,000L based on standard length to diameter ratios. - The fermented biobutanol is then stored in a holding tank before further processing. The document designs a holding tank 55,555L in volume and 34m in diameter and 68m in length to store the biobutanol. - The document also includes mechanical design details for the fermenter, holding tank, heat exchanger and distillation column used in downstream processing of the biobutanol

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PRODUCTION OF BIOBUTANOL Guided by: Presented by: Dr. N.N Dutta Abhishek Singh(091401) Dhyananand Yadaw(091409)
Distillation Column Design A=0.753, B=5.4*10^-4, E=0.246, 32C, 1atm A=0.299, B=0.602, E=0.098, 76.1C, 8atm B=0.99, A=1.5*10^-4, E=6.1*10^-4, 105C, 1atm
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Dew point calculation: -
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Mav = 66.49 kg/kmol F = 273.18 kg/hr or 4.108 kmol/hr D = 108.40 kg/hr or 1.985 kmol/hr B = 164.56 kg/hr or 2.220 kmol/hr Now, molar flow rate of vapor and liquid in top section: - L = R*D = 4.36 1.985 = 8.654 kmol/hr V = (R+1)*D = 5.36 1.98 = 10.639 kmol/hr Now, molar flow rate of vapor and liquid in bottom section: - L = L + F*q = 8.654 + 4.108 1 = 12.762 kmol/hr V = F*(q-1)+V = 4.108(1-1)+V = 10.639 kmol/hr
Calculation of tower diameter: -
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Heat Exchanger Design Design: - Shell and Tube type heat exchanger Design pressure: - By additional of 5% to the maximum working pressure. Design temperature: - 10C higher than the maximum temperature. ABE, 10atm 5C, 402 kg/hr Water, 1atm Water, 1atm 102C, 10.3 kg/hr 90C, 10.3 kg/hr ABE, 10atm 39C, 402 kg/hr
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No. of tube passage Np = 4 For triangular arrangement: - Db (tube bundle diameter) Db= do(Nt/k1)1/h1 K1 and h1 are constant Pt/do = 1.25, for this arrangement K1=0.175, h1=2.285 Db =373.31mm Di = Db+C = 390mm C= 10-20mm for U-tube heat exchanger
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Calculation for shell side pressure drop: -
Mechanical Design: - Shell Material: Carbon Steel Corrosion allowance: 3mm Number of shell: 1 Number of passage: 4 Fluid: ABE mixture Working pressure: 0.33 N/mm2 Design pressure: 0.5 N/mm2 Temperature inlet: 5 C Temperature outlet: 39 C Segmental baffles (25% cut) with tie rods and spacers.
Head Crown Radius: 400mm Knuckle Radius: 40mm Shell flange: female facing Gasket: Flat metal jacketed asbestos filled Bolts: 5% Cr Mo steel Nozzles Inlet and Outlet: 75mm Vent: 25mm Drain: 25mm Opening for relief valve: 50mm Permissible stress for CS: 95 N/mm2 Permissible stress for bolt material: 140.6 N/mm2
Tube Side: - Tube and tube sheet material: Stainless Steel Working pressure: 19 N/mm2 Design pressure: 21.5 N/mm2 Inlet temperature: 102 C Outlet temperature: 90 C Permissible stress: 100.6 N/mm2 Pitch of tube: 25mm Channel and Channel cover: - Material: Carbon Steel Permissible stress: 95 N/mm2
Shell side: - (Triangular pitch of tubes)
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Tube Side: -
Fermenter Reactor:- Assume:- L/D=6 Volume of the reactor = Volume of one Reactor= 50000 L So, Dia. Of Reactor(d)= 22m.
Holding Tank:- Process Design Usually we must design the storage tank which has volume more than the reactor. Volume of vessel = 55,555L Assume, Ratio of So, Dia. (d)=34m. Length(L)=68m.
Mechanical Design Operating condition :- Pressure = 1atm, Temp.=33C, L = 68m., d = 34m. Sp. gravity of liquid = 1 Fixed conical roof Slope permissible = 1 in 5 Superimposed load = 1250 Material = CS (structural) IS-2062 Permissible stress = 142 Density = 1000 Modulus of elasticity =
Continued This design is based on the Indian std. design IS-803. Corrosion allowance (c) = 0.7mm Shell design Internal pressure p = 0.677 Thickness of the shell at bottom: t = 96mm.
Continued Butt joints are provided for welding the vertical joints between plates to form the lowest layer of the shell. An allowance of 2mm. is made between two adjacent plate to facilitate welding and total circumference is welded with 16 plates.so Length of the each plate = 6.67m. Size of the plate selected from IS-1730 is 6700mm. (length)*2000mm(width). To determine the number of the layers to be used with 16mm thick plate it is necessary to determine the height of up to which a plate of lesser thickness on be used. Assuming thickness of 75 mm. so
Continued Bottom diameter ( Db )= Db= 34.192m Circumference of bottom = 3.14*Db = 107.36m
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  • 1. PRODUCTION OF BIOBUTANOL Guided by: Presented by: Dr. N.N Dutta Abhishek Singh(091401) Dhyananand Yadaw(091409)
  • 2. Distillation Column Design A=0.753, B=5.4*10^-4, E=0.246, 32C, 1atm A=0.299, B=0.602, E=0.098, 76.1C, 8atm B=0.99, A=1.5*10^-4, E=6.1*10^-4, 105C, 1atm
  • 7. Mav = 66.49 kg/kmol F = 273.18 kg/hr or 4.108 kmol/hr D = 108.40 kg/hr or 1.985 kmol/hr B = 164.56 kg/hr or 2.220 kmol/hr Now, molar flow rate of vapor and liquid in top section: - L = R*D = 4.36 1.985 = 8.654 kmol/hr V = (R+1)*D = 5.36 1.98 = 10.639 kmol/hr Now, molar flow rate of vapor and liquid in bottom section: - L = L + F*q = 8.654 + 4.108 1 = 12.762 kmol/hr V = F*(q-1)+V = 4.108(1-1)+V = 10.639 kmol/hr
  • 8. Calculation of tower diameter: -
  • 13. Heat Exchanger Design Design: - Shell and Tube type heat exchanger Design pressure: - By additional of 5% to the maximum working pressure. Design temperature: - 10C higher than the maximum temperature. ABE, 10atm 5C, 402 kg/hr Water, 1atm Water, 1atm 102C, 10.3 kg/hr 90C, 10.3 kg/hr ABE, 10atm 39C, 402 kg/hr
  • 16. No. of tube passage Np = 4 For triangular arrangement: - Db (tube bundle diameter) Db= do(Nt/k1)1/h1 K1 and h1 are constant Pt/do = 1.25, for this arrangement K1=0.175, h1=2.285 Db =373.31mm Di = Db+C = 390mm C= 10-20mm for U-tube heat exchanger
  • 18. Calculation for shell side pressure drop: -
  • 19. Mechanical Design: - Shell Material: Carbon Steel Corrosion allowance: 3mm Number of shell: 1 Number of passage: 4 Fluid: ABE mixture Working pressure: 0.33 N/mm2 Design pressure: 0.5 N/mm2 Temperature inlet: 5 C Temperature outlet: 39 C Segmental baffles (25% cut) with tie rods and spacers.
  • 20. Head Crown Radius: 400mm Knuckle Radius: 40mm Shell flange: female facing Gasket: Flat metal jacketed asbestos filled Bolts: 5% Cr Mo steel Nozzles Inlet and Outlet: 75mm Vent: 25mm Drain: 25mm Opening for relief valve: 50mm Permissible stress for CS: 95 N/mm2 Permissible stress for bolt material: 140.6 N/mm2
  • 21. Tube Side: - Tube and tube sheet material: Stainless Steel Working pressure: 19 N/mm2 Design pressure: 21.5 N/mm2 Inlet temperature: 102 C Outlet temperature: 90 C Permissible stress: 100.6 N/mm2 Pitch of tube: 25mm Channel and Channel cover: - Material: Carbon Steel Permissible stress: 95 N/mm2
  • 22. Shell side: - (Triangular pitch of tubes)
  • 26. Fermenter Reactor:- Assume:- L/D=6 Volume of the reactor = Volume of one Reactor= 50000 L So, Dia. Of Reactor(d)= 22m.
  • 27. Holding Tank:- Process Design Usually we must design the storage tank which has volume more than the reactor. Volume of vessel = 55,555L Assume, Ratio of So, Dia. (d)=34m. Length(L)=68m.
  • 28. Mechanical Design Operating condition :- Pressure = 1atm, Temp.=33C, L = 68m., d = 34m. Sp. gravity of liquid = 1 Fixed conical roof Slope permissible = 1 in 5 Superimposed load = 1250 Material = CS (structural) IS-2062 Permissible stress = 142 Density = 1000 Modulus of elasticity =
  • 29. Continued This design is based on the Indian std. design IS-803. Corrosion allowance (c) = 0.7mm Shell design Internal pressure p = 0.677 Thickness of the shell at bottom: t = 96mm.
  • 30. Continued Butt joints are provided for welding the vertical joints between plates to form the lowest layer of the shell. An allowance of 2mm. is made between two adjacent plate to facilitate welding and total circumference is welded with 16 plates.so Length of the each plate = 6.67m. Size of the plate selected from IS-1730 is 6700mm. (length)*2000mm(width). To determine the number of the layers to be used with 16mm thick plate it is necessary to determine the height of up to which a plate of lesser thickness on be used. Assuming thickness of 75 mm. so
  • 31. Continued Bottom diameter ( Db )= Db= 34.192m Circumference of bottom = 3.14*Db = 107.36m