Bioethanol production . slides comprises of mechanical drawings, control, waste treatment, safety..

1. Lim Kah Huay A132816
Low Bee Chan A132764
Sonia Dilip Patel A/P Dilip Kumar A133115
Fatin Atikah Binti Kassim A132739
Jamilah Binti Ahmad A133159
Muhammad Khairil Azim bin Abdullah A133275
PRODUCTION OF BIOETHANOL FROM GLYCEROL
USING Enterobacter aerogenes TISTR1468
Group KB4

2. 2
CONTENT
1. Introduction
2. Summary of Production
3. List of improvement work
4. Heat integration
5. PFD after heat integration
6. Piping and Instrumentation
7. P&ID after HAZOP
8. Detailed Unit & Mechanical Design
9. Waste Management
10. Process Hazard Analysis
11. Plant Layout
12. Conclusion

3. SUMMARY OF PRODUCTION
Specifications Description
Product Bioethanol
Microorganism used Enterobacter aerogenes TSITR
1468
Processes involved • Micro-aerobic fermentation
• Stripping
• Binary Distillation
• Extraction
• Flash Vaporization
Production basis (per hour) 3676.47 kg
Bioethanol sale price (RM / kg) 3.04
Return on investment, ROI 0.25
Payback period, PBP 3.46 years
Net present value, NPV RM 10.37 million
Discounted cash flow rate of return, DCFRR 0.19
Site location Pengerang, Johor
3

4. List of Improvement Work
4
CHAPTERS PROBLEM CORRECTION DONE
Chapter 3 - PFD • Size of bioreactors in series
doesn’t shows its
effectiveness in improving
productivity of fermentation
process
• Mass flow rate of medium
from distillation column to
condensers and reboilers are
too big
• Stream tables lacks of data
• Bioreactors
arrangement in parallel
• Re-calculation of mass
balance
• Edited stream table data
Chapter 5 - Heat
integration
Mistakes in inlet and outlet
temperature
Corrected pinch analysis
with heat recovery
integrated in PFD
To be continued…

5. 5
CHAPTERS PROBLEM CORRECTION DONE
Chapter 6 – Piping and
Instrumentation
• Control loops with
electrical signal were
not drawn correctly and
some loops were not
complete
• Relief valve for after
HAZOP study was not
done
• Mistakes in P&ID
drawing
• Complete drawing of
controllers for the entire
plant
• Sizing calculated and
type of valve
determined
• Improved drawing with
second layer of safety
incorporated
Chapter 7 – Detailed
Process Design
Design calculation had
some mistake since inlet
and outlet of stream
changed
All the design calculation
had been calculated and
redesign for all unit
Chapter 8 - Mechanical
Design
The calculation for the
design and mechanical
drawing are not complete
All the calculation design
and drawing AUTOCAD
is done
…continue
List of Improvement Work
To be continued…

6. 6
CHAPTERS PROBLEM CORRECTION DONE
Chapter 10 – Production
Hazard Analysis
HAZOP was incomplete
and did not consider P&ID
HAZOP done after
complete P&ID drawing
Chapter 11 – Site Location
and Plant Layout
Plant layout need to
reconstruct, details were
not drawn out clearly and
wrong arrangement of unit
operations in plant layout
Completed plant layout
drawing
List of Improvement Work
…continue

7. 7
Temperature
interval start with 0KW
start with 5.915445
kW
107.5 0
105.5 0.004115 -0.004115 0.004115 5.91133
92.9 0.33933 -0.343445 0.33933 5.572
92.5 2.262 -2.605445 2.262 3.31
77.5 2.01 -4.615445 2.01 1.3
67.5 1.3 -5.915445 1.3 0
52.5 -0.4455 -5.469945 -0.4455 0.4455
29.5 0.0824 -5.552345 0.0824 0.3631E-103

8. PROCESS FLOW DIAGRAM after Heat integration
8

9. Relief System
 Spring-loaded relief valve
 Gas leaks when pressure
reaches 92-95%
 Bursting disc (rupture disc)
 ‘engineered weak spot’
 Low cost, leak tight, instantaneous
response , reliable operation
9

10. DESIGN OF RELIEF VALVE
Location Type Function A (mm2)
F-101 Spring-loaded To prevent the rupture of vessel due to
overpressure during process and
sterilization
20 921.57
F-102 Spring-loaded To prevent rupture of vessel due to
overpressure during process and
sterilization
18 673.24
F-103 Spring-loaded To prevent rupture of vessel due to
overpressure during process and
sterilization
21 879.60
C-101 Spring-loaded To avoid damage to C-101 due to
overpressure
17 614.22
C-102 Spring-loaded To avoid damage to C-101 due to
overpressure
16 392.17
C-103 Spring-loaded To avoid damage to C-101 due to
overpressure
15 670.20
C-104 Spring-loaded To avoid damage to C-101 due to
overpressure
17 986.11
10

11. 11P&ID after HAZOP

12. DETAIL UNIT &
MECHANICAL DESIGN
i. Seed Fermenter, F-101
ii. Stripping Column, C-01
iii. Binary Distillation Column, C-102
iv. Extractive Column, C-103
v. Flash Drum, C-104
vi. Cooling Tower
vii. Heat Exchanger, E-103
12

13. Dimension layout of impeller design
Axial hydrofoil with 3 blades Pitched-blade impeller
Source: Lightnin 2013
Source: Hayward Gordon Ltd. 2013
Source: Geankoplis 2013
DETAILED
DESIGN
Lim Kah Huay
(A132816)
13
Fermenter layout
Source: iGEM 2010

14. Detailed Design Fermenters
Design Parameters F-101 F-102 & F-103
Tank diameter, Dt 1.91 m 3.50 m
Tank height, Ht 5.72 m 10.49 m
Working volume, V 16.35 m3 100.86 m3
Design of Cooling Jacket
Height of jacket 2 m 3.5 m
Spacing between jacket
and vessel wall
50 mm 50 mm
Overall heat transfer
coefficient, U
500.63 W/m.°C 201 W/m.°C
Pressure drop, ∆P 0.42 kPa 0.16 kPa
Design of Impeller
Type of impeller Axial flow 3 blades
hydrofoil
Axial flow pitched-blade
45°impeller
Impeller diameter, Da 0.98 m 1.05 m
Depth of impeller in
vessel, H
1.96 m 3.50 m
To be continued… 14

15. 15
Design Parameters F-101 F-102 & F-103
Height of impeller above vessel floor, C 0.65 m 1.17 m
Impeller width, W 0.20 m 0.13 m
Length of impeller width, L 0.25 m 0.26 m
Diameter of impeller base, Dd 0.65 m 0.70 m
Baffle width, J 0.16 m 0.29 m
Power number, Np 0.3 1.6
Flow number, Nq 0.55 0.85
Impeller speed 0.10 rps 0.01 rps
Power, P 0.3057 W 0.0008 W
Sparger ring diameter, Ds 1.08 m 1.15 m
Sparger location above vessel floor, S 0.49 m 0.53 m
Mixing time, tT 6.67 s 2041.06 s
Circulation rate, Q 0.05 m3/s 0.29 m3/s
…Continue
Detailed Design Fermenters

16. 16
MECHANICAL DESIGN
SEED FERMENTER, F-101
Process Description
 Microaerobic continuous fermentation with an aeration rate of 0.5
vvm, medium consistently mixed by agitator.
 Glycerol and ammonium phosphate serve as raw material of carbon
and nitrogen source respectively
 Fermentation output consists of bioethanol and carbon dioxide
Material of Construction
 Carbon Steel SA 537

17. 17
Design Specifications Details
Operating Pressure 1 atm (15 psia)
Operating Temperature 37 C (310 K)
Corrosion Allowance 2 mm
Vessel Layout Vertical
H/D ratio 3:1
Volume
Torispherical Head (Top and Bottom Design)
Crown radius, R (m) 1.81
Knuckle radius, a (m) 0.19
Distance from the center of the torus to the center of the torus
tube, c (m)
0.76
Height from the base of the dome to the top, h (m) 0.38
Cylindrical Shell (Shell Design)
4.96
Effective Length, L (m) 5.21

18. 18
Vessel Parts Dimensions (mm)
Torispherical Top 5.72
Cylindrical Shell 8.89
Torispherical Bottom 5.72
Overall 11
Minimum Wall Thickness
Design of Cooling Jacket
Design Parameters Details
Type Type 1 (confined entirely
to the cylindrical shell)
Closure Type (b-2)
Material of Construction Carbon Steel SA537
Jacket Space 50 mm
0.91 mm
2.91 mm
Corner radius of torus closures 5.84 mm

19. 19
Stresses Details
4.83
9.66
0.6324
Primary stresses
6.53
4.40
5.26
157
1361.54
Combined Loading

20. 20
Design Parameters Details
Type of support Bracket support
Type of bracket Double gusset Type 1
Type of beam Wide-flange
Number of legs 4
47 kN
Standard wide flange
beam leg type base plate
W6

21. 21
Flanged Joint Design
Design Parameters Details
Type of flanged joint Welding neck flange
Flange faces Gasket between bolt
circle
Outside diameter of
flange (mm)
Stream 2&4 – 107.95
Stream 3&5 – 152.4
Stream 1&6 – 228.6

22. DISTILLATION COLUMN (C-101)
SONIA DILIP PATEL (A133115)
C-101
D-101
H-101
BIOETHANOL
BIOMASS
WATER
55% Bioethanol
45%Water
WASTEWATER
TREATMENT/ STILLAGE
S14
S16
S18 S17
S20
S19
S21
Parameter Dimension
Column design Tray
Diameter, DT (m) 1.913
Height, H (m) 9.772
Tray spacing(m) 0.457
Number of actual stages 17
Design of plate Sieve plate
Plate spacing (m) 0.457
Downcomer area 0.2725m2
Active area 1.726m2
Holes area, 0.173m2
Number of holes 8805
22

23. MECHANICAL DESIGN OF C-101
SONIA DILIP PATEL (A133115)
• Material used
SS-308
• Properties
Source : MIT Department of Civil and Environment 1999
Element Content (%)
Iron, Fe 66
Chromium, Cr 20
Nickel, Ni 11
Manganese, Mn 2.0
Silicon, Si 1.0
Carbon, C 0.080
Phosphorus, P 0.045
Sulfur, S 0.030
Properties Metric
Density 8 g/cm3
Tensile strength 585 MPa
Yield strength 240 MPa
Poisson’s ratio 0.27-0.30
23

24. • Design parameter for C-101
Parameter Value (SI unit) Value (English unit)
Temperature, T 100 OC 212 OF
Operating pressure (gage), P0 101.325 kPa 15 psig
Height of vessel , H 9.3262 m 367.1732’’, 30.5978’
Inside diameter of vessel, Di 1.91 m 75.1969’’,6.6224’
Height of cylinder shell, Hcylinder 7.772 m 305.9843”, 25.4987’
Height of torispherical heads, Htoris 0.3688 m 14.5197”, 1.2100’
Torispherical head
24

25. • Combine loading
Primary Stress Value (N/mm2)
3.6226
7.2453
-0.7885
Criterion met. Design is satisfied.
25

26. Vessel Support
 Straight Cylindrical skirt.
Criterion satisfied, 2 mm CA added. Final skirt thickness = 12 mm
26

27. • Base ring and Anchor Belt Design
Nb = 4 bolts
Bolt size = nominal diameter (BS 4190: 1967)
Bolt used = M24 with root area = 353 mm2.
• Flanged Joint
Welding Neck Flange
27

28. 28

29. DISTILLATION COLUMN (C-102)
LOW BEE CHAN (A132764)
Parameter Dimension
Column design Tray
Diameter, DT (m) 1.524
Height, H (m) 26.50
Tray spacing(m) 0.46
Number of actual stages 53
Design of plate Sieve
Plate spacing (m) 0.457
Downcomer area (m2) 0.146
Active area (m2) 0.925
Holes area (m2) 0.0925
Number of holes 4720
29

30. Mechanical Design Of Stripping Column C-102
LOW BEE CHAN A132764
Process Description:
Purify ethanol-water mixture to form azeotrope with 95.63% ethanol and
4.37% water (by weight)
Material Selection:
Austenitic Stainless Steel 304L
Design Specification:
• External pressure vessel
• Cylindrical shell
• Torispherical heads
31

31. Minimum wall thickness (mm)
Top and bottom heads 5.08
Cylindrical shell 15.24
Overall(standard) 18
Primary Stresses (N/mm2)
Longitudinal Stress, σL 2.1447
Circumferential Stress, σh 4.2894
Direct Stress, σw 6.65
Bending Stress, σb 46.66
Elasticity Stability (N/mm2)
CYLINDRICAL COLUMN
DESIGN
31

32. VESSEL SUPPORT DESIGN
Resultant Stresses (N/mm2)
<
STRAIGHT SKIRT SUPPORT
Skirt thickness (mm) 20
Skirt height (mm) 2000
Base Ring and Anchor Bolt Design
Number of bolts 12
Actual width 220mm
Minimum thickness 50mm
M56 bolts (BS 4190: 1967)
32

33. FLANGE DESIGN
Parameter
S26
feed
S27
top
S29
refluxed
S31
bottom
S32
reboiled
Flow rate (kg/s) 0.4233 4.314 3.356 1.054 4.314
Density (kg/m3) 846.389 1.507 770.216 796.255 1.429
Optimum diameter 34.103 614.71 97.20 54.47 625.19
Nominal pipe size 50.8 660.4 101.6 101.6 660.4
Flange class 150 150 150 150 150
Outside flange diameter,
O
152.4 831.85 228.6 228.6 831.85
Thickness of flange, Tf 17.526 63.5 22.352 22.352 63.5
Diameter of hub, X 77.724 708.152 134.874 134.874 708.152
Chamfer beginning
diameter, A
60.452 609.6 114.3 114.3 609.6
Length through Hub, Y 61.976 127 74.676 74.676 127
Bore 52.578 355.6 102.362 102.362 355.6
Number of bolts 8 8 8 8 8
• Welding Neck Flange
33

34. DESIGN SUMMARY
Parameter Value
Operating temperature 100
Operating pressure (atm) 1
Material of construction Austenitic stainless steel Type 304L
Vessel internal diameter (m) 1.524
Vessel height (m) 2.65
Type of head and bottom Torispherical
Type of vessel Cylindrical
Vessel wall thickness (mm) 18
Stress analysis (N/mm2) (Δσ)max S < , (7.7128 < 137.89) [Safe]
Elastic stability (N/mm2)
Type of vessel support Straight conical skirt
Type of flanged joint Welding neck flange
Flange faces Gasket between bolt circle
Flange diameter (mm) 50.8, 101.6, 660.4
34

35. Specifications H-101 H-103
Pitch pattern Square pitch Square pitch
Brass, kw (W/m C) 110 110
Floating head Split-ring Split-ring
Shell pass 1 1
Tube pass 4 4
Number of tubes, Nt 998 1596
Outer diameter, do(m) 0.0381 0.0381
Inner diameter, di(m) 0.0168 0.0168
Length of tubes, l (m) 5 7
Tube pitch, Pt (m) 0.0125 0.0125
Heat transfer area, A (m2) 596.96 1336.46
Shell inside diameter, Ds (m) 1.915 2.335
Baffle spacing, lB(m) 0.036 0.036
Baffle cut, (%) 45 45
Tube side coefficient, hi(W/m2∆ C) 12473.48 11138.26
Shell side coefficient, hs(W/m2∆ C) 3310.721 1053.628
Overall coefficient, Uo(W/m2 C) 991.88 603.28
Tube side pressure drop, ∆Pt(kPa) 78.83 44.67
Shell side pressure drop, ∆Ps (kPa) 1.47 14.36
CONDENSER DESIGN
35

36. KETTLE REBOILER DESIGN
Specifications H-102 H-104
Pitch pattern Square pitch Square pitch
Carbon steel, kw (W/m. C) 55 55
Number of U tubes 404 374
Outer diameter, do(m) 0.022 0.0381
Inner diameter, di(m) 0.01688 0.0168
Length of tubes, l (m) 5 4
Heat transfer area, A (m2) 158.78 94.09
Baffle spacing, lB (m) 0.036 0.036
Baffle cut (%) 45 45
Tube side coefficient, hi(W/m2∆ C) 736000 734000
Shell side coefficient, hnb (W/m2∆ C) 28137.52 28565.69
Overall coefficient, Uo (W/m2 C) 1444 1239.23
Tube side pressure drop, ∆Pt (kPa) 174.89 168.6
Shell side pressure drop, ∆Ps (kPa) 14.59 14.36
36

37. EXTRACTIVE DISTILLATION COLUMN (C-103)
JAMILAH AHMAD (A133159)
Material Carbon steel 516
Actual no of stages 27
Diameter of the column (m) 4.68
Height of the column (m) 21.19
CONDENSER H-105
Cooling water flow rate 11409.8
Area required 3.531 m2
Outside diameter 19.05 mm
Inside diameter 14.83 mm
Length 5 m
Number of tube 12
Diameter of the bundle, Db 0.11 m
Shell-side coefficient 1030.137 W/m2oC
Tube-side coefficient 8982.51 W/m2oC
Overall heat transfer cofficient, Uo 649.99 W/m2oC
Total heat load (kW) 771
6.3
Shell side coefficient
Overall heat
transfercoefficient
(W/m2oC)
496
Pressure drop (kPa) 12.1
KETTLE REBOILER H-106
37

38. MECHANICAL DESIGN
EXTRACTIVE COLUMN
JAMILAH AHMAD (A133159)
INTRODUCTION
• Wall thickness required for the vessel
• Pressure exerted by the outside force weather the vessel can
withstand or not.
• Type of top & bottom and shell used for the
vessel
• Type of vessel support to withstand the vessel.
38

39. EXTRACTIVE COLUMN
Parts Value/Description
Main Part:
•Vessel height
•Diameter
•Shell height
•Top & bottom height
•Thickness
•Type of shell
•Type of head & bottom
•Material
• 21.49 m
• 4.68 m
• 19.15 m
• 1.17 m
• 30 mm
• Cylindrical
• Torispherical
• Carbon steel 516
Support
•Type
•Material
•Height
•Thickness
• Straight skirt
• Carbon Steel
• 1.219 m
• 30 mm
Flanges
• Type of flange • Welding neck
39

40. Detailed Design of Flash Drum C-104
KHAIRILAZIM (A133275)
Inlet
(S41)
Vapour Outlet
(S42)
Liquid Outlet
(S43)
h=1.219m
Dv=0.366
Flash drum C-104 is used to separate
the vapour and liquid. For design
calculations it is normally assumed that
the vapour and liquid are in equilibrium
and the vessel is adiabatic
Condition Value
Temperature 100 oC
Pressure 1 atm
Density of Water 958.4 kg/m3
Vapour Density 1.422 kg/m3
From the calculation,
•The diameter must be large enough
•The high of vessel outlet above the
gas inlet should be sufficient for
liquid drops.
•Liquid level will depend on hold up
time necessary for smooth
operations and control
hv=0.283 m3
The conclusion from the calculation,
Minimum vessel diameter,
Dv = 0.366 m
Liquid depth required,
hv = 0.238 m3
Height of the tank,
H = 1.219 m

41. Mechanical Design of Flash Drum C-104
KHAIRILAZIM (A133275)
Parts Value/Description
Main Part:
•Height
•Diameter
•Thickness
•MAWPvessel
1.219 m
0.366 m
3.5 mm
1.714 kPa
Support
•Type
•Material
•Height
•Thickness
Conical skirt
Plain Carbon Steel
0.25 m
3.5 mm
Flanges
•Feed
•Liquid
•Vapour
Welding neck
Welding neck
Welding neck
Design Summary of C-104
41

42. Properties Value
Cooling water flow rate (kg/h) 105458
Water inlet temperature (°C) 37
Water outlet temperature (°C) 28
Ambient wet bulb temperature
(°C)
23.9
Tower characteristic, KaL/V 1.5
Minimum tower area (m2) 17
Height of cooling tower (m) 10.4Source : HarrisonCooling
Tower 2002
FATIN ATIKAH (A132739)
42

43. Number of tube 43
Length tube 4 m
Shell-Side Pressure Drop 78.94 kPa
Tube-Side Pressure Drop 1.84 kPa
Shell-side coefficient 63.94 W/m2oC
Tube-side coefficient 661 W/m2oC
Overall heat transfer
cofficient, Uo
549.47 W/m2oC
Shell and Tube Exchanger
FATIN ATIKAH (A132739)
43

44. Parts Value/Description
Main Part:
•Vessel length
•Height vessel
•Inner diameter
•Outer diameter
4.0 m
0.267 m
0.016 m
0.02 m
Support
•Type
•Material
•Height
•Thickness
Saddle support
Carbon Steel
0.8 m
0.15 m
Flanges Welding neck
Shell and Tube Exchanger
Saddle support Welding neck flanges
FATIN ATIKAH (A132739)
44

45. T-102 Primary Clarifier A-101 Air Blower T-105 Sludge Storage Tank
Check Pond
Wastewater
from production
plant
Air
Flocculants and
Coagulant
T-101
T-102
T-103
A-101
T-104
T-105
1
2
3
4
5
7
8
9
10
6
WASTEWATER MANAGEMENT
ACTIVATED SLUDGE WASTEWATER TREATMENT PLANT
PROCESS FLOW DIAGRAM
Stream 1
Flowrate(m3/day) 892.99
S,BOD (mg/L) 362422.7
X, SS (mg/L) 16792.5
Stream 8
Flowrate (m3/day) 0.47
S,BOD (mg/L) -
X, SS (mg/L) 5850.5
Stream 7
Flowrate (m3/day) 4.25
S,BOD (mg/L) -
X, SS (mg/L) 5850.5
Stream 6
Flowrate(m3/day) 4.72
S,BOD (mg/L) -
X, SS (mg/L) 5850.5
Stream 5
Flowrate (m3/day) 884.29
S,BOD (mg/L) 362422.7
X, SS (mg/L) 5940.5
Stream 4
Flowrate(m3/day) 9.45
S,BOD (mg/L) -
X, SS (mg/L) 11775.7
Stream 3
Flowrate(m3/day) 883.54
S,BOD (mg/L) 362422.7
X, SS (mg/L) 5016.8
Stream 2
Flowrate (m3/day) 892.99
S,BOD (mg/L) 362422.7
X, SS (mg/L) 16792.5
Stream 10
Flowrate (m3/day) 879.57
S,BOD (mg/L) 45
X, SS (mg/L) 90
Stream 9
Flowrate(m3/day) 9.92
S,BOD (mg/L) -
X, SS (mg/L) 12290.9
Flocculation
tank
Sludge
storage tank
Aeration
tank
Secondary
clarifier
Primary
clarifier
46.51 m3
60 min
93.02 m3
SL: 40m3/m2.day
188. 06 m3
Length: 8.17 m
Width: 3.8 m
Height: 3m
93.02 m3
Length: 9.3 m
Width: 5 m
Height: 2 m
45

46. 46
PLANT LAYOUT

47. Process Hazard Analysis
Components Hazardous
Properties
Glycerol • Flammable
• Explosion
• Toxic
Ammonium phosphate • Toxic
Oxygen • Flammable
• Toxic
Ethanol • Fire
• Explosion
• Toxic
Carbon dioxide • Explosion
• Toxic
Nitrogen • Toxic
Hazard Identification
Legal Acts Requirement
1. Environmental Quality Act
(EQA) 1974
2. Occupational Safety and Health
Act (OSHA) 1994
3. Factory and Machinery Act
(FMA) 1967
Methods for PHA:
1. HAZOP analysis
2. FMEA
Set of organized and systematic assessments of the potential hazards associated with an
industrial process. A PHA provides information intended to assist managers and employees
in making decisions for improving safety and reducing the consequences of unwanted or
unplanned releases of hazardous chemicals.
47

48. FMEA method
- Systematic process to identify potential failures to fulfill the intended function,
to identify possible failure and locate the failure impacts
- Example of the method is shown in Seed Fermenter F-101
Component Failure mode Failure effects Symptom Safeguard Action
Level control
valve
Valve fails open
Valve fails
closed
Fluid will
exceed the level
of storage tank
causing
overflow and
rupture the tank
Liquid overflow None Schedule
inspection and
maintenance
required
Pure glycerol
valve
Valve fails open No glycerol in
the tank. Product
produce does
not meet the
specification.
The reaction is
not complete
None Daily check
Temperature
control valve
Valve fails open High
temperature in
the tank. It will
effect product
reaction
No cooling
water is supply
to the tank
Low level alarm Daily check
Process Hazard Analysis
48

49. Component Failure mode Failure effects Symptom Safeguard Action
Heat exchanger Tube failure High pressure and
could cause a cause
a major fire
Odors at the
cooling tower
None Daily check and
schedule
maintenance
Centrifugal pump Pump stop Loss of power
which cause
mechanical failure
Risk of upstream
process pump
damage due to
overpressure
None Preventive
maintenance
Temperature
control valve
Heater failure Electric device
failure. Loss of
electric power
May cause over
temperature which
will rupture the
wall
None Schedule
inspection and
maintenance
Condenser(Cooler) Power failure Unable to cool the
outlet stream
Very high
temperature is
flowing out
None Back-up power
supply generator
Level control valve Valve fails open
Valve fails closed
Fluid will exceed
the level of storage
tank causing
overflow and
Liquid overflow None Schedule
inspection and
maintenance
required
- FMEA analysis for Distillation Column C-101
49

50. PROCESS HAZARD ANALYSIS
HAZOP Analysis
• HAZOP Analysis is to identify how a process deviation can be prevented
or mitigate to minimize the potential hazard. Example of the analysis is
in the distillation column.
Project name : Process Plant Design
Process : Bio ethanol production
Part : Distillation Column
Study node Process parameter
Deviations
(guide words)
Possible causes Possible consequence Action required
Stream 28 Flow NO Pipe broken or plugging Loss of feed into column/not achieve into
desired output.
Level decrease in distillation column.
Off specification product.
1. Schedule inspection
and maintene.an
LOW 1. Pipe partial plugged or leakage. 1. Level decrease in distillation
column.
2. Off specification product.
3. Back flow of material.
Install check valve.
HIGH 1. High pressure from source 1. Flooding in distillation column. 1. Install bypass line with
manual valve.
Distillation column Level HIGH 1. Output pipe blockage. Overpressure of reflux drum.
Condensed liquid flow back to
distillation.
1. Install high level alarm
2. Scheduling inspection
LOW Pipe partial clogged & leakage. Level decrease in the vessel
The valve closed.
Back flow of material.
1. Scheduling inspection
2. Install valve.
Temperature HIGH 1. Low incoming flow from H-101
cause overheating.
Off specification product. Install temperature sensor.
LOW 1. H-101 malfunction.
2. High incoming flow through H-
101.
Low level inside reboiler.
Off specification product.
1. Scheduling inspection
2. Install temperature sensor.
50

51. 51
 A high yield and potential for ethanol as fuel from Enterobacter
aerogenes. Pengerang has been the best location judging from the
coming development as Asia’s largest storage terminal.
 Production rate of 3276 kg/hr and high demand in 2018 (projection) will
leave a very stable economic growth for ethanol.
 65% saving of energy through pinch and heat exchanger installation will
further bloom the net profit.
 Mechanical calculations and drawings for main utilities provide a clearer
insight of the sizing and supports.
 Safety has been of top consideration through FMEA and HAZOP
performed. Layers of control aspect will further enhance the safety and
continuous operation of ethanol plant.
 Waste management has been of top priority and calculations from waste
treatment plant designed is able to lower down pollutants to allowable
limits.