EXECUTIVE SUMMARY

A conceptual plant design is presented for furfural from bagasse. Bagasse, locally

known as sugar cane fibers and has a scientific name of Gramineae Saccharum

officinarum, is a waste product from the sugar industry. Most of the world’s sugar cane is

grown in subtropical and tropical areas. Furfural is an important industrial chemical as it

is a chemical that is widely used in the petroleum processing industry, the manufacture of

lubricants, the manufacture of nylon, and also in the food and agricultural industry. Due

to furfural’s properties and versatility, this compound is vastly used in the manufacturing

of furfural alcohol resins which has been in demand globally and expected to have a great

positive influence on the market growth.

The major equipment involved in the process are LPG-Fired Steam Boiler,

conveyor mesh belt dryer, hammer mill, vibrator screener, quaker batch process, counter

flow heat exchanger, LW Series Decanter Centrifuge, non-backwashing acid neutralizer

and steam distillation. The furfural plant is designed to be energy-efficient, sustainably

effective, economically attainable, and environment-friendly.

This plant aims to produce 400 tons of furfural annually in a continuous operation.

The total gross annual income of the plant is PHP 133,102,000.00 and an annual net profit

of PHP 8,354,503.57 with a rate of return (ROR) of 81.17% and the payback period is

1.23 years. Recommendations for further studies and detailed designed are necessary to

grow new systems and advancements to improve the yield of pure furfural and the over-

all effectiveness of the plant.

i
 ACKNOWLDGEMENT

With immeasurable love and appreciation, we would like to extend our utmost and

sincerest gratitude to the following individuals that helped us, one way or another, in

making this book possible.

To the Lord Almighty for the perpetual guidance and the wisdom imparted to us in

the creation of this book.

To our parents, for your prayers, sacrifices, love, support, and understanding, you

were, are, and always will be our inspiration and source of strength. A special mention

should be given to Joshua L. Climaco for allowing us to use her residence for our group

meetings.

To Engr. Vera Marie Lanaria, our course adviser, for her admirable guidance, for her

expertise on the methodology on how to properly conceptualize the chapters of this book

as clearly as possible, and for granting us the feedback we need to pursue our study of

chemical engineering.

To our friends, classmates, and schoolmates who gave meaning to our lives and

something to look forward to by the end of a day’s hard work

Lastly, to our university, Cebu Institute of Technology – University, as well as the

Chemical Engineering Department, for providing to us the knowledge of the essential

skills, and fundamentals of plant design, as well as the opportunity to create this

equipment design, the venue for the majority of our fabrication, as well as the resources

we needed to create this design.

ii
 TABLE OF CONTENTS

EXECUTIVE SUMMARY i
ACKNOWLEDGMENT ii
TABLE OF CONTENTS iii

LIST OF TABLES vii

CHAPTER 1 INTRODUCTION 1
CHAPTER 2 PROCESS OPTION AND SELECTION 4
2.1 EQUIPMENT SELECTION AND DESIGN 4
2.2 MODES OF OPERATION 5
2.3 GENERAL PROCESS 5
2.3.1 DRYING 6
2.3.2 GRINDING 7
2.3.3 SIEVING 8
2.3.4 ACID CATALYSIS 9
2.3.5 CONDENSATION 11
2.3.6 DECANTATION 11
2.3.7 NEUTRALIZATION 13
2.3.8 DISTILLATION 14
CHAPTER 3 BASIS OF DESIGN 16
3.1 PURPOSE 16
3.2 CONTEPTUAL PLANT DESIGN 16
3.2.1 PROCESS CONCEPT 16
3.2.2 PROCESS DEFINITION 17
3.2.3 BLOCK SCHEMATIC DIAGRAM 18
3.3 BASIC ASSUMPTION 19
3.3.1 PLANT CAPACITY 19
3.3.2 PLANT SITE LOCATION AND PLANT 19
LAYOUT
3.4 BATTERY LIMITS 22
CHAPTER 4 THERMODYNAMIC PROPERTIES 23
CHAPTER 5 PROCESS STRUCTURE AND DEFINITION 27
5.1 PROCESS STRUCTURE 27
5.1.1 COLLECTION OF BAGASSE 27
5.1.2 DRYING 27
5.1.3 MILLING 27
5.1.4 SIEVING 28
5.1.5 EXTRACTION 28
5.1.6 DECANTER 29
5.1.7 NEUTRALIZER 29
5.1.8 DISTILLATION 29
CHAPTER 6 HEAT AND MASS BALANCES 30
CHAPTER 7 PROCESS AND EQUIPMENT DESIGN 33
7.1 EQUIPMENT SELECTION AND DESIGN 32
iii
7.1.1 BOILER 32
7.1.2 CONVEYOR DRYER 35
7.1.3 HAMMER MILL GRINDER 36
7.1.4 VIBRATOR SCREENER 38
7.1.5 QUAKER BATCH PROCESS 40
7.1.6 HEAT EXCHANGER 42
7.1.7 DECANTER 44
7.1.8 NEUTRALIZER 46
7.1.9 DISTILLATION 48

iv
 7.2 Auxiliaries 50
7.2.1 PUMPING SYSTEMS 50
7.2.2 VALVES 51
7.2.3 FITTINGS 51
7.2.4 GASKETS 51
7.2.5 BOLTS 52
7.2.6 SUPPORT 52
CHAPTER 8 PROCESS CONTROL 53
8.1 PROCESS CONTROL FOR BOILER 53
8.2 PROCESS CONTROL FOR CONVEYOR DRYER 54
8.3 PROCESS CONTROL FOR MILLING 55
8.4 PROCESS CONTROL FOR SCREENER 56
8.5 PROCESS CONTROL FOR QUAKER BATCH 57
REACTOR
8.6 PROCESS CONTROL FOR HEAT EXCHANGER 58
8.7 PROCESS CONTROL FOR DECANTER 59
8.8 PROCESS CONTROL FOR NEUTRALIZER 60
8.9 PROCESS CONTROL FOR STEAM DISTILLATION 61
CHAPTER 9 WASTES MANAGEMENT 62
9.1 SOLID WASTES 62
9.2 RESIDUE AND BY PRODUCTS 64
9.3 LIQUID WASTES 64
9.4 GASEOUS WASTES 66
CHAPTER 10 PROCESS SAFETY 67
10.1 PROCESS SAFETY INFORMATION 68
10.2 PROCESS HAZARD ANALYSIS 68
10.3 STANDARD OPERATION PROCEDURES 69
10.4 PREMISE OF ESTABLISHMENT 69
AND OCCUPATIONAL HEALTH & CONTROL
10.5 TRAINING OF PERSONNEL IN OSH 70
10.6 ELECTRICAL SAFETY 71
10.7 SAFETY ASPECTS OF EQUIPMENT 71
10.7.1 HAZARD AND OPERABILITY ANALYSES OF THE
PROCESS EQUIPMENT AND PROCEDURE 71
10.8 MATERIAL SAFETY DATA SHEET 72
10.9 GOOD MANUFACTURING PRACTICES 73
10.9.1 PERSONNEL PRACTICES 74
10.9.2 EQUIPMENT 75
10.9.3 ENVIRONMENTAL CONTROL 75
10.9.4 MAINTENANCE AND CLEANING 75
10.9.5 SANITATION SYSTEM 76
10.9.6 WATER SAFETY 76
CHAPTER 11 ECONOMY 77
11.1 ESTIMATION OF CAPITAL INVESTMENT COST 78
11.2 ESTIMATION OF ANNUAL PRODUCTION COST 79
11.2.1 MANUFACTURING COST 79
11.2.2 GENERAL EXPENSES 79
11.2.3 TOTAL PRODUCTION COST 80
11.3 ECONOMIC FEASIBILITY 80
11.3.1 GROSS INCOME 80
11.3.2 NET INCOME 80
11.3.3 RATE OF RETURN 80
11.3.4 BREAKEVEN ANALYSIS 80
11.3.5 PAYBACK PERIOD 81
CHAPTER 12 CONCLUSION AND RECOMMENDATION 82
APPENDICES
 APPENDIX A HEAT AND MASS BALANCE CALCULATION 83
APPENDIX B MATERIAL SAFETY DATA SHEETS 90
APPENDIX C ECONOMY 99
APPENDIX D CURRICULUM VITAE 104
REFERENCES 109
 LIST OF TABLES

Table 2.1 General Criteria for Selection Processes

Table 2.2 Mode of Operation

Table 2.3.1 Comparison of Drying Method

Table 2.3.2 Comparison of Grinders

Table 2.3.3 Comparison of Sieving Methods

Table 2.3.4 Comparison of Reactors

Table 2.3.5 Heat Exchanger Types Comparison

Table 2.3.6 Decanter Comparison

Table 2.3.7 Comparison of Neutralizing Methods

Table 2.3.8 Distillation Methods Comparison

Table 3.4.1 Battery Limits of the Design Project

Table 4.1 Thermodynamic Properties of Saturated Liquid Water

Table 4.2 Thermodynamic Properties of Superheated Steam at 153ᵒC and 5bar

Table 4.3 Thermo Physical Properties of Bagasse

Table 4.4 Thermodynamic Properties of Furfural (Gas Phase)

Table 4.5 Thermodynamic Properties of Furfural (Condensed Phase)

Table 4.6 Thermodynamic Properties of Furfural (Phase Change Data)

Table 4.7 Thermodynamic Properties of Pentosan

Table 4.8 Standard Enthalpy and Gibs Free Energy of Formation

Table 6.1 Dryer Heat Balance (Reference Temperature @ 0ᵒC)

Table 6.2 Heat Exchanger Heat Balance (Reference Temperature @ 0ᵒC)

Table 6.3 Batch Distillation Heat Balance (Reference Temperature @ 0ᵒC)

Table 7.1.2 Conveyor Dryer Specifications Sheet

Table 7.1.3 Hammer Mill Specifications Sheet

Table 7.1.4 Vibrator Screener Specifications Sheet

Table 7.1.5 Quaker Batch Process Specifications Sheet

Table 7.1.6 Counter Flow Heat Exchanger Specifications Sheet

Table 7.1.7 Solid Bowl Decanter Centrifuge Specification Sheet

Table 7.1.8 Acid Neutralizer Specification Sheet

Table 7.1.9 Stainless Steel Distiller Specification Sheet

Table 11.1 Summary of Total Capital Investment

Table 11.2.1 Summary of Manufacturing Cost

Table 11.2.2 Summary of General Expenses

Table 11.2.3 Summary of Total Production Cost

Table 11.3.1 Annual Gross Income Computation

Table 11.3.2 Annual Net Income Computation

Table 11.3.3 Rate of Return Computation

Table 11.3.4 Break Even Analysis

Table 11.3.5 Payback Period Computation

Figure 1.1 Chemical Structure of Furfural

Figure 1.2 Stoichiometry of Pentosane by Aqueous Acid Catalysis

Figure 3.2-1 Process Scheme for Furfural from Bagasse

Figure 3.2.3 Block Schematic Diagram for the Production of Furfural from Bagasse

Figure 3.3-1 Satellite View of the Plant Site

Figure 3.3-2 Plant Layout (Ground

Level)

Figure 3.3-3 Second Level Plant Layout

Figure 6.1 Plant Lay out with Material Balance

Figure 7.1.1 LPG-Fired Steam Boiler

Figure 7.1.2 Conveyor Mesh Belt Dryer

Figure 7.1.3 Hammer Mill

Figure 7.1.4 Linear Vibrating Screener Machine

Figure 7.1.5 Quaker Batch Process

Figure 7.1.6 Counter Flow Heat Exchanger

Figure 7.1.7 LW Series Decanter Centrifuge

Figure 7.1.8 Acid Neutralizer

Figure 7.1.9 Stainless Steel Distiller

Figure 8.2 Dryer Unit Process Control

Figure 8.3 Miller Unit Process Control

Figure 8.4 Screener Unit Process Control

Figure 8.5 Reactor Unit Process Control

Figure 8.7 Decanter Unit Process Control

Figure 8.8 Neutralizer Unit Process Control

Figure 8.9 Distillation Unit Process Control

Figure 9.1 - a Primary Solid Waste Recycling

Figure 9.1 - b Secondary Solid Waste Disposal

Figure 9.3 Wastewater Treatment Process