MINI PROJECT SEPTEMBER 2015CPE604GROUP MEMBERS:

MUHAMMAD NASRUL BIN BOJY (2014662104)MOHAMMAD AMIR HAKIM BIN RUSLI (2014294432)

HANEARYTHA LITAD CHARLES (2014679702)CHE MUHAMMAD FAIZ BIN CHE LAH (2014807942)NURADILLA BT IRWAN SHAH JOSEPH (2014442236)

PRODUCTION OF LIQUID FUEL FROM PE WASTE

GROUP MEMBERS:MUHAMMAD NASRUL BIN BOJY (2014662104)

MOHAMMAD AMIR HAKIM BIN RUSLI (2014294432)HANEARYTHA LITAD CHARLES (2014679702)

CHE MUHAMMAD FAIZ BIN CHE LAH (2014807942)NURADILLA BT IRWAN SHAH JOSEPH (2014442236)

CHEMICAL PRODUCT DESIGN

IDENTIFICATION OF NEEDS

• heat homes• run the vehicles• power industry and manufacturing• produce electricity.

IDENTIFICATION OF IDEAS

• Producing fuel from animals fat• Producing biofuel from waste cooking oil• Producing fuel from mix carbon dioxide• Producing fuel from lignocellulosic biomass• Producing fuel from algae• Producing of fuel using rubber• Use water steam as a fuel• Coconut oil as a fuel• Producing fuel from animal waste (biomass)• Producing of fuel from plastic waste

• SELECTION OF IDEAS

Screening ScoringCriteri

on

IDEAS

1 2 3 4 5 6 7 8 9 10

1 + 0 + + 0 - + + 0 0

2 + 0 + + 0 - 0 + + 0

3 + - 0 - - 0 + - 0 0

4 0 0 0 + - + - 0 - 0

5 + 0 + 0 + - + 0 + 0

Score +4 -1 +3 +2 +1 0 +3 +1 +1 0

Rank 1 6 2 3 4 5 2 4 4 5

 

Criterion

 

Weight

IDEAS

1 3 4 7

1 30% 4 3 3 3

2 30% 3 2 3 3

3 20% 2 2 1 2

4 10% 2 2 3 1

5 10% 3 2 2 2

Total Score 3.0 2.3 2.5 2.5

Rank 1 3 2 2

Criteria 1: The availability of the feed stock

Criteria 2: The cost of the feed stock

Criteria 3: The ratio of the product to the feed stock

Criteria 4: Environmental friendly of the process.

Criteria 5: The quality of the feed stock

MARKETING STRATEGY

• Produce 4000L per day x 382 Batch• 1056.688 gallon per day• Supply to Oil and Gas Company to refining the pyrolysis oil

• “On average, U.S. refineries produce about 19 gallons of motor gasoline12 gallons of diesel fuel, and 4 gallons of jet fuel from a 42 gallon barrel of crude oil.” (U.S Energy Information Administration, November 2015)

• HIGH OPERATING COSTREQUIRE LARGE NUMBER OF EMPLOYEEMUCH SPACE OF LAND REQUIRED

SELECTION OF PROCESS ROUTES

CHEMICAL REACTION INVOLVE

PYROLYSIS

P

Chemical Reactions in Pyrolysis Process

1) Initiation

Sketch of random scission reaction in plastic pyrolysis.

2) Propagation

Illustration of mid chain β-scission reaction.

Illustration of end chain β-scission reaction

3) Termination

Sketch of the termination reaction or radical combination reaction

STOICHIOMETRIC EQUATION

KINETIC-CONTROLLED

• The Pyrolysis of hydrocarbon polymers is a very complex process, which undergo hundreds of reaction and products.

• Thus, the Pyrolysis reaction is a kinetic-controlled as there are a number of factors that will affect the process and the reactions such as catalyst and reactor type.

CATALYST

• The type of catalyst that is used in the process is zeolite.

EXCESS REACTANT

• No excess reactant that is fed into the reaction system in order to yield a higher yield.

• The choice of using PE waste compare to other type of plastic is the decision that is made in order to yield greater yield of the desired product which is the liquid fuel.

COMPETING REACTIONS AND SELECTIVITY

• the difference of various functional group bond energies in the lignin induces the different functional group that is broken under different temperature and therefore, the entire pyrolysis process displays many pyrolysis competing reactions

• the selectivity in pyrolysis process to obtain the liquid product which is the liquid fuel can be controlled by tuning of the acidity and pore size of catalyst into a high acidity in pH and also with big pore size of catalyst

SPECIAL CONDITION OF TEMPERATURE AND pH

• pyrolysis is by subjected to a special condition of temperature which is a high temperature of about 400 oC in the absence of oxygen

• high acidity in order to yield more production of liquid fuel production.

99% conversion

SINGLE PASS CONVERSION

CHEMICAL REACTOR DESIGN

Heuristics for Reactor

1. Rule 3: The optimum proportions of stirred tank reactor are with liquid level equal to the tank diameter, but at high pressures slimmer proportions are economical.

2. Rule 6: Batch reactions are conducted in stirred tanks for small daily production rates or when the reaction times are long or when some condition such as feed rate or temperature must be programmed in some way.

3. Rule 11: The effect of temperature on chemical reaction rate is to double the rate every 10 oC.

4. Rule 12: The rate of reaction in a heterogeneous system is more often controlled by the rate of heat or mass transfer than by the chemical reaction kinetics.

The total volume of the Volume of batch reactor is 12 m3.

The volume of reactor is based on the real size reactor that used in the pyrolysis process by companies that produce the pyrolysis oil.

Every 1 tonne of feed, 3 m3 of reactor size will be used. Thus, for 4 tonne of feed, 12 m3 of the batch reactor is used.

The reactor is cylindrical shape and made of carbon steel. The reactor has a single inlet and outlet stream.

The reaction is helped with the presence of catalyst which is zeolite.

RECYCLE STRUCTURE

FEEDSTOCK TO BE RECYCLE

• In the pyrolysis, the reaction converts the 99% of the PE waste into products consists of pyrolysis oil and gas. Thus, the 1% of the unreacted PE left in the batch reactor will be recycled into the next batch. The 40 kg unreacted PE will be mixed with the feed of the next batch. Thus, the next batch will only requires only requires 3960 kg of the PE waste.

RECYCLING OF PE WASTE

RECYCLE SYSTEM

DOWNSTREAM PROCESSING

SEPARATION PROCESS• The separation system process to be used in pyrolysis started from the

reactor. • This is because there is separation process occurs in the reactor itself.• The separation system in the reactor resembles the simple batch distillation.• In pyrolysis, the resulting oil which is the mixture of liquid hydrocarbon is

continuously distilled once the waste plastic inside the reactor are decomposed enough to evaporate upon reaching the reaction temperature.

• The separation process produces a pure stream of product to undergone further process which is purification process while leaving the pure unreacted in the reactor to be recycled.

• The unreacted PE waste is easily recovered and put into the storage tank. The unreacted PE waste will then mixed into the feed of the next batch of the pyrolysis of the PE waste.

MATERIAL BALANCE SEPARATION SYSTEM

PURIFICATION PROCESS• The purification process in this is by using a condenser and a

separator vessel. • The pyrolysis process produces products in gas phase. • After the pyrolysis oil in gas phase exits the reactor, some of the

hydrocarbons with high boiling point will undergo condensation process in a water-cooled condenser.

• The liquid hydrocarbons which are the liquid-fuel product are then collected in a storage tank through a receiver tank.

• The separation system produces pure stream of the products and by-products due to huge difference in their boiling point.

• The liquid-fuel has a high boiling point which is above 100 oC while the gas-fuel has the boiling point below 0oC. Thus, the liquid-fuel is assumed to be 100% separated from the uncondensed gaseous.

MATERIAL BALANCE PURIFICATION SYSTEM

DESIGN OF SEPARATION & PURIFICATION SYSTEM

DESIGN OF SEPARATION & PURIFICATION SYSTEM

• The size of the batch reactor which is design as part of the separation system is 12 m3.

• The size of the process vessel or separator is determined through the heuristics in Table 11.6.

• The separator provides surge capacity or separation of entrained phases and the size is relatively small.

• In the separation process, the product which is the pyrolysis oil is separated in gas and liquid phase. Thus, the separator is in vertical.

• The optimum ratio of length to diameter = 3, but the range is 2.5 to 5 is common.

• Assume that 60% of liquid fuel volume is going to fill up the tank. Thus, the volume of the process vessel is going to be 6.7 m3.

• From the ratio given, the length of the process vessel will be 4.35 m and the diameter is 1.4 m to give the ratio of length to diameter ≈ 3.

CAPITAL COST ESTIMATION

TYPE OF EQUIPMENTNUMBER OF

EQUIPMENT BARE MODULE COST ( RM)

SHREDDER

1 40320.00REACTOR

1 1302600.6HEAT EXCHANGER

2 469957.12STORANGE TANK

2 1571691.61PROCESS VESSEL

1 179877.76BARE MODULE

- 5606095.82TOTAL BARE MODULE COST, CBM2015 (RM)

-  RM6615193.07

BARE MODULE COST

MANUFACTURING COST

Cost Of Raw Materials

Polyethylene waste=4000 kg x x x x 0.92 =RM 307,017.14 per year

Zeolite catalyst1 ton of zeolite catalyst = RM 950 per year

Total annual cost of raw material

= Polyethylene waste + Zeolite catalyst= RM 307,017.14 + RM 950 = RM 307967.14

Cost Of Operating Labor

NOL =(6.29 + 31.7P2 + 0.23Nmp)0.5

=[6.29 + 31.7(0)2 + 0.23(5)]0.5

=2.73 335 operating days x = 48 weeks 48 x 7 = 336 shifts per operator per year 335 x = 1005 shifts/year 1005 x = 3 operators Operating Labor = (2.99) (2.73)

= 8.16= 8 persons

Annual cost of operating labor = 8 persons x RM 21,600 = RM 172,800/year

Cost Of Utilities

Utility Description Cost RM/year

Chilled water

Electricity

Process cooling water at 30oC

1500.00

80000.00

Total per year RM 81500.00

Cost item Value used

Direct Manufacturing costa. Raw materialsb. Utilitiesc. Operating Labord. Direct supervisor and clerical labore. Maintenance and repairsf. Operating suppliesg. Laboratory chargesh. Patents and royalties

Cwt

Cut

Col

0.2Col

0.05FCI

0.005FCI

0.2Col

0.01COM

Total Direct Manufacturing Cost = CRM +CUT + 1.40COL + 0.01COM + 0.055FCI

Fixed costsa. Depreciationb. Local taxesc. Insuranced. Plant overhead costs)

0.1FCI

0.02FCI

0.01FCI

0.5(COL+0.2COL + 0.05FCI)

Total Fixed Manufacturing Cost = 0.6COL + 0.055FCI + depreciation

General expenses

a. Administration costsb. Distribution and selling costsc. Research and development

0.15(COL+0.2COL + 0.05FCI)

0.10COM

0.05COM

Total General Expenses = 0.18COL + 0.0075FCI + 0.15COM

Table of Multiplication Factors for Estimating Manufacturing Cost

Total Direct Manufacturing Cost

DMC =CRM +CUT + 1.40COL + 0.01COM + 0.055FCI

=RM [307967.14 + 81500 + 1.40(172,800) +0.01(1929949) + 0.055(6,402,937.31)]

=RM 1,002,848.18

Total Fixed Manufacturing Cost

FMC =0.6COL + 0.055FCI + depreciation

=RM [0.6(172,800) + 0.155(6,402,937.31)]=RM 1,096,135.28

Total General Expenses

GE =0.18COL + 0.0075FCI + 0.15COM

=RM [0.18(172,800) + 0.0075(6,402,937.31) + 0.15(1929949)]=RM 368618.38

COM = DMC + FMC + GE

COM =1.19(CRM +CUT) + 2.595COL + 0.259FCI=RM 2,570,243

COM,d =1.19(CRM +CUT) + 2.595COL + 0.159FCI

=RM 1,929,949

Cost Of Manufacturing

Cost Of Manufacturing (without depreciation)

PROFITABILITY ANALYSIS

Estimation Annual Revenue

Product = 4000 L / batch Liquid-fuel

4000 L x RM 2.70/L = RM 10,800 per batch

RM 10,800 x 382 batch/ year = RM 4,125,600 per year

Discounted After – Tax Cash Flow

End of

Year Investment Depreciation

Allowance FCI - ∑dk Revenue COMd

(R-COM-dk)x(1-t) + dk

Cash Flow

After Tax cash flow

(10%) Cumulative Cash Flow

0 -560,000 6,402,937 -560,000 -560,000 -560,000

1 -4,482,056 6,402,937 -

4,482,056 -4,074,596 -4,634,596

2 -2503153.1 6,402,937 -

2,503,153 -2,068,722 -6,703,318

3 1,280,587.4 5,122,350 4,125,600 1,929,949 1,514,142 1,514,142 1,137,597 -5,565,721

4 1,280,587.4 3,841,762 4,125,600 1,929,949 1,514,142 1,514,142 1,034,179 -4,531,541

5 1,280,587.4 2,561,175 4,125,600 1,929,949 1,514,142 1,514,142 940,163 -3,591,378

6 1,280,587.4 1,280,587 4,125,600 1,929,949 1,514,142 1,514,142 854,694 -2,736,685

7 1,280,587.4 0 4,125,600 1,929,949 1,514,142 1,514,142 776,994 -1,959,690

8 0 4,125,600 1,929,949 1,322,053 1,322,053 616,747 -1,342,943

9 0 4,125,600 1,929,949 1,322,053 1,322,053 560,680 -782,263

10 0 4,125,600 1,929,949 1,322,053 1,322,053 509,709 -272,555

11 0 4,125,600 1,929,949 1,322,053 1,322,053 463,372 190,817

12 0 4,125,600 1,929,949 1,322,053 1,322,053 421,247 612,064