Final Report Group 6

Preli Preli minary Design Design of Vani ll in Production Production Plant Fr om Black Black L iquor

Table of Content

Table of Content .......................................... ................................................................. ............................................. ..................................... ............... i CHAPTER 1 ............................................. ................................................................... ............................................ ........................................ .................. 1 INTRODUCTION ........................................... ................................................................. ............................................ ................................. ........... 1 1.1

Plant Development Development Background............................................ .............................................................. .................. 1

1.2

Plant Development Development Goal ............................................ ................................................................... ............................. ...... 7

1.3

Plant Development Development Analysis .......................................... ................................................................. ........................... 8

1.3.1

Raw Material Analysis............................................. .................................................................... ........................... 8

1.3.2

Location Analysis ............................................ ................................................................... ............................... ........ 12

1.3.3

Market & Capacity Analysis.......................................... .......................................................... ................ 16

CHAPTER 2 ............................................. ................................................................... ............................................ ...................................... ................ 23 PROCESS DESIGN ....................... ............................................. ............................................ ............................................ ........................... ..... 23 2.1

Process Technology Selection ............................................ ................................................................ .................... 23

2.2

Process Description .......................................... ................................................................ ...................................... ................ 26

2.2.1

Type Of Process ............................................ ................................................................... .................................. ........... 26

2.2.2

BFD and Description ........................................... .................................................................. ........................... .... 30

2.2.3

PFD and Description ............................................ ................................................................... ........................... .... 32

CHAPTER 3 ............................................. ................................................................... ............................................ ...................................... ................ 36 MASS AND ENERGY BALANCE .......................................... ................................................................. ........................... .... 36 3.1

Mass Balance............................................ ................................................................... ............................................. ........................ 36

3.1.1

Overall Mass Balance .......................................... ................................................................. ........................... .... 36

3.1.2

Mass Balance Process Units ........................................... ........................................................... ................ 37

3.2

Energy Balance ............................................ .................................................................. .......................................... .................... 40

CHAPTER 4 ............................................. ................................................................... ............................................ ...................................... ................ 45 UTILITIES.............................................................. ..................................................................................... .............................................. ....................... 45 4.1

Water Utility .......................................... ................................................................ ............................................ ........................... ..... 45

4.1.1

Water Utility Classification ............................................ ............................................................ ................ 45

4.2

Electric Utility ........................................... ................................................................. ............................................ ........................ 46

4.3

Steam Utility ............................................ ................................................................... ............................................. ........................ 48

BAB 5 ............................................ .................................................................. ............................................ ............................................ ........................... ..... 49

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SIZING ............................................. .................................................................... ............................................. ............................................ ........................ 49 5.1 Vessel .......................................... ................................................................ ............................................ .......................................... .................... 49 5.1.1

Black Liquor Storage Tank (S-101) ........................................... ................................................ ..... 49

5.1.2

Acidification Tank (V-101) ............................................ ............................................................ ................ 50

5.1.3


5.1.4

Blending Tank (V-103) ............................................ ................................................................... ....................... 53

5.1.5

Lignin Slurry Storage (S-102)......................................... (S-102)......................................................... ................ 54

5.1.6

Waste Storage (S-103) ............................................. .................................................................... ....................... 55

5.1.7

H2SO4 Storage (S-104) ............................................ ................................................................... ....................... 56

5.1.8

NaOH Storage (S-105) ............................................. .................................................................... ....................... 57

5.2

Filtration ............................................ .................................................................. ............................................ ............................... ......... 58

5.2.1

Plate and Frame Filter (PF-101)...................................... (PF-101)...................................................... ................ 58

5.2.2


5.3

Pump........................................... ................................................................. ............................................ ...................................... ................ 60

5.3.1

Black Liquor Pump (P-101) ............................................ ............................................................ ................ 60

5.3.2

Black Liquor Acidification pump (P-102) ...................................... ...................................... 60

5.3.3

Lignin Acidification Pump (P-103) ........................................... ................................................ ..... 61

5.3.4

Lignin Solution Pump (P-104) ............................................ ........................................................ ............ 62

5.3.5


5.3.6

Vanillin Slurry Pump (P-106) ......................................... ......................................................... ................ 63

5.3.7

Vanillin Solution Pump (P-107) ............................................ ..................................................... ......... 64

5.3.8

Water Pump (P-109) ............................................ ................................................................... ........................... .... 65

5.4

Conveyor ........................................... ................................................................. ............................................ ............................... ......... 66

5.5 Bubble Column Reactor ......................... ............................................... ............................................. ............................... ........ 67 5.6 Ultrafiltration ................................... ......................................................... ............................................ ...................................... ................ 68 5.7 Spray Dryer ....................................................... ............................................................................. .......................................... .................... 69 5.8 Heat Exchanger .............................. .................................................... ............................................ ...................................... ................ 70 5.8.1 Heat Exchanger HE-101 ........................................ .............................................................. ............................... ......... 70 5.8.2 Heat Exchanger HE-102 ........................................ .............................................................. ............................... ......... 70 CHAPTER 6 ............................................. ................................................................... ............................................ ...................................... ................ 71 PROCESS CONTROL ............................................ .................................................................. ............................................ ........................ 71 6.1

Process Control Instrumentation ............................................ ............................................................ ................ 71

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SIZING ............................................. .................................................................... ............................................. ............................................ ........................ 49 5.1 Vessel .......................................... ................................................................ ............................................ .......................................... .................... 49 5.1.1

Black Liquor Storage Tank (S-101) ........................................... ................................................ ..... 49

5.1.2


5.1.3


5.1.4

Blending Tank (V-103) ............................................ ................................................................... ....................... 53

5.1.5

Lignin Slurry Storage (S-102)......................................... (S-102)......................................................... ................ 54

5.1.6

Waste Storage (S-103) ............................................. .................................................................... ....................... 55

5.1.7

H2SO4 Storage (S-104) ............................................ ................................................................... ....................... 56

5.1.8

NaOH Storage (S-105) ............................................. .................................................................... ....................... 57

5.2

Filtration ............................................ .................................................................. ............................................ ............................... ......... 58

5.2.1


5.2.2


5.3

Pump........................................... ................................................................. ............................................ ...................................... ................ 60

5.3.1

Black Liquor Pump (P-101) ............................................ ............................................................ ................ 60

5.3.2

Black Liquor Acidification pump (P-102) ...................................... ...................................... 60

5.3.3

Lignin Acidification Pump (P-103) ........................................... ................................................ ..... 61

5.3.4


5.3.5


5.3.6

Vanillin Slurry Pump (P-106) ......................................... ......................................................... ................ 63

5.3.7

Vanillin Solution Pump (P-107) ............................................ ..................................................... ......... 64

5.3.8

Water Pump (P-109) ............................................ ................................................................... ........................... .... 65

5.4

Conveyor ........................................... ................................................................. ............................................ ............................... ......... 66

5.5 Bubble Column Reactor ......................... ............................................... ............................................. ............................... ........ 67 5.6 Ultrafiltration ................................... ......................................................... ............................................ ...................................... ................ 68 5.7 Spray Dryer ....................................................... ............................................................................. .......................................... .................... 69 5.8 Heat Exchanger .............................. .................................................... ............................................ ...................................... ................ 70 5.8.1 Heat Exchanger HE-101 ........................................ .............................................................. ............................... ......... 70 5.8.2 Heat Exchanger HE-102 ........................................ .............................................................. ............................... ......... 70 CHAPTER 6 ............................................. ................................................................... ............................................ ...................................... ................ 71 PROCESS CONTROL ............................................ .................................................................. ............................................ ........................ 71 6.1

Process Control Instrumentation ............................................ ............................................................ ................ 71

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6.2

Process Control on Raw Material Storage Tank .................................... .................................... 71

6.3

Process Control on Heat Exchanger ........................................... ....................................................... ............ 72

6.4

Process Control on Reboiler ............................................ ................................................................... ....................... 72

6.5

Process Control on Black Liquor Treatment Vessel .............................. .............................. 72

6.6

Process Control on Acidification Vessel and Lignin Solution Vessel ... 73

6.7

Process Control on Oxidation Reactor .......................................... ................................................... ......... 74

6.8

Process Control on Spray Dryer ......................................... ............................................................. .................... 76

CHAPTER 7 ............................................. ................................................................... ............................................ ...................................... ................ 82 PLANT LAYOUT AND PIPING P IPING DESIGN .................................. ........................................................ ........................ 82 CHAPTER 8 ............................................. ................................................................... ............................................ ...................................... ................ 86 HEALTH, SAFETY, AND ENVIRONMENT MANAGEMENT....................... ....................... 86 8. 1

Health Aspects........................................... ................................................................. ............................................ ........................ 87

8. 2

Safety Aspects ........................................... ................................................................. ............................................ ........................ 87

8.2.1

Hazard Identification and Risk Assessment (HIRA) ...................... ...................... 87

8.2.3 Hazard Operability Study (HAZOP) (HAZOP) of Vanillin Plant....................... Plant....................... 94 8. 3. Environmental Aspects ........................................... .................................................................. ............................... ........ 99 8. 3. 1. Liquid Waste............................................ .................................................................. .......................................... .................... 99 8. 3. 2. Solid Waste ........................................... ................................................................. ............................................ ........................ 99 8. 3. 3. Waste Gas .......................... ................................................ ............................................ .......................................... .................... 99 8. 4. Risk Management Management......................................... ............................................................... .......................................... .................... 99 8.4.1. Personal Protection Equipment................................. Equipment....................................................... ......................... ... 100 8.4.2. Fire extinguisher ................................. ....................................................... ............................................ ......................... ... 105 8.4.3. MSDS (Material Safety Data Sheet)........................................ Sheet).................................................. .......... 107 8.5. Quality Control in Vanillin Plant ................................................... ............................................................. .......... 107 CHAPTER 9 ............................................. ................................................................... ............................................ .................................... .............. 108 ECONOMIC ANALYSIS .......................................... ................................................................ ........................................ .................. 108 9.1 Plant Cost Estimation ......................... ................................................ ............................................. ................................ .......... 108 9.2

Annual Operating Costs .......................................... ................................................................. ............................. ...... 113

9.2.1

Raw Material Costs .......................................... ................................................................. ............................. ...... 113

9.2.2

Operating Labor Costs ........................................... ................................................................ ..................... 115

9.2.3

Utilities Costs ............................................ .................................................................. .................................... .............. 116

9.2.4

Total Direct Costs ............................................ ................................................................... ............................. ...... 117

iii

Preli minary Design of Vani ll in Production Plant Fr om Black L iquor

9.2.5

Total Fixed Costs .......................................................................... 117

9.2.6

Plant Overhead .............................................................................. 117

9.2.7

Total Manufacturing Cost ............................................................. 117

9.2.8

Expenses Cost ............................................................................... 118

9.2.9

Total Operating Cost ..................................................................... 118

9.3

Equity ................................................................................................... 119

9.4

Investment feasibility Analysis ............................................................ 120

9.5.1

Cash Flow ..................................................................................... 120

9.5.2

IRR ................................................................................................ 122

9.5.3 Net Present Value (NPV).................................................................... 124 9.5.4 Pay Back Period.................................................................................. 125 9.5.5Break Event Point (BEP) ..................................................................... 125 9.5.6 Sensitivity Analysis ............................................................................ 126 APPENDIX ......................................................................................................... 129 1.

2.

3

Vessel ....................................................................................................... 129 1.1

Black Liquor Storage Tank (S-101) ................................................. 129

1.2

Acidification Tank (V-101) ............................................................. 130

1.3

Acidification Tank (V-102) .............................................................. 132

1.4

Blending Tank ( V-103).................................................................... 133

1.5

Lignin Slurry Storage (S-102) .......................................................... 135

1.6

Waste Storage (S-103) ...................................................................... 137

1.7

H2SO4 Storage (S-104)..................................................................... 138

1.8

NaOH Storage (S-105) ..................................................................... 140

Plate and Frame Filter .............................................................................. 141 2.1

Plate and Frame Filter (PF-101) ....................................................... 141

2.2

Plate and Frame Filter (PF-102) ....................................................... 143

Pump ........................................................................................................ 144 3.1

Black Liquor Pump (P-101)&(P-102) .............................................. 144

3.2

Black Liquor Acidification Pump (P-102) ....................................... 146

3.3

Lignin Acidification Pump (P-103) .................................................. 148

3.4

Lignin Solution Pump (P-104) ......................................................... 150

3.5

Lignin Solution Pump (P-105) ......................................................... 152

iv


3.6

Vanillin Slurry Pump (P-106)........................................................... 154

3.7

Vanillin Solution Pump (P-107) ....................................................... 156

3.8

Water Pump (P-108) ......................................................................... 158

4

Bubble Column Reactor........................................................................... 161

5

Ultrafiltrasi ............................................................................................... 163

6

Spray Dryer .............................................................................................. 165

7.

Material Safety Data Sheet (MSDS) ........................................................ 171

REFERENCE...................................................................................................... 174

v


CHAPTER 1 INTRODUCTION 1.1

Plant Development Background

Vanillin (4-hydroxy-3-methoxybenzaldehyde) is the major flavor constituent of vanilla. This organic compound possesses the aldehydic, etheric and phenolic functional groups, and its molecular formula is C 8H8O3 corresponding to a molecular weight of 152.15 (Washburn, 2003). The chemical structure and geometry of vanillin are presented in Figure 1.1. Some relevant physical properties of vanillin are shown in Table 1.1.

Figure 1.1. Chemical structure (a) and geometry (b) of vanillin molecule.

Vanillin occurs widely in nature, especially in the cured beans of the tropical Vanilla orchids. It is the major component among about 200 other flavor compounds

found in these beans (Walton et al., 2003). Isolated vanillin occurs in the form of white needle-like crystalline powder with a pleasant aromatic vanilla odor and an intensively sweet taste, which are the main reasons for its widespread demand. Table 1.1. Physical properties of vanillin.

1


Vanillin has a wide range of applications in food industry as a flavor agent and in perfumery as an additive. Other applications are as chemical precursor in the pharmaceutical industry, ripening agent, antifoaming agent in lubrication oils, brightener in zinc coating baths, vulcanization inhibitor, and starting material for insecticides and herbicides (Mathias, 1993; Villar et al., 1997). There are around 150 varieties of vanilla, but only two of them are grown commercially – Bourbon and Tahitian vanilla (McGregor, 2005). Vanilla has it origins on Mesoamerican Mexico, with this country dominating the world production until the late 19th century. Since then, the focus of development was shifted to the former French colonies, in particular Madagascar, Comoros, Reunion and Tahiti. Nowadays, vanilla is grown on numerous countries, with data from 2005 indicating that Madagascar was the largest producer, accounted for around 60% of the world production, followed by Indonesia and China, with 23% and 10%, respectively. Looking at the last 20 years, the vanilla production has oscillated between 1200 and 4000 tonnes, with a world consumption varying from 1800 to 3000 tonnes (McGregor, 2005). The natural vanilla market is characterized by very volatile prices. Normally the price pattern of vanilla is made up of high peaks and prolonged periods of relatively low prices. These prices have been particularly sensitive to events affecting a single country – Madagascar. From 1989 to 1995, the vanilla market was regulated by the Univanille cartel, an alliance of vanilla exporters. The major buyers and producers, principally Madagascar, met annually to determine demand and export pricing. In Figure 1.2 is schematically shown the evolution on the market prices of natural vanilla, since the early 1990’s to the first half of 2005.

2


Figure 1.2. Evolution of natural vanilla prices since th e early 1990’s to 2005 (Jaeger (2005 )

Vanilla does not consist of vanillin alone, but contain several tens of aromatic compounds. For example, the vanilla world trade in 2001 (2300 tonnes) represents less than 50 tonnes of natural vanillin (Loeillet, 2003), which only constitutes a yield around 2%. Historically, the production of vanillin was its direct extraction from vanilla beans. However, according to the constantly increasing markets, new chemicals routes were developed. Synthetic vanillin became widely used and competition of markets is longstanding and turns more fierce when prices of natural vanilla rockets. Vanillin was first pro duced by Haarmann and Reimer in the late 1800’s, using guaiacol from phenol. This was the main route for more than 40 years, until it was discovered that vanillin could be produced from lignin present in the waste liquor of pulp and paper industry. The commercial production of vanillin from lignin started in 1937. This process become the dominant one for many years, with 80% supply ratio of the synthetic vanillin market (Triumph Venture Capital, 2004). However, in the 1980’s some changes in the processes of pulp and paper

3


industry led to a decrease in the available raw material required by the vanillin plants. The traditional calcium sulphite pulping process produced huge amounts of disposable effluents, that combined with the growing public awareness on environmental issues were leading to unsustainable waste treatment costs. These mills started to close, or were converted to new technology that allowed the recycling of the waste liquors for chemical recovery and thus making these by products streams not available for vanillin production. Since 1993, only Borregaard was producing vanillin from lignin. Nowadays the synthesis of vanillin from guaiacol accounts for 85% of the world supply, with the remaining 15% being produced from lignin (Triumph Venture Capital, 2004b). Commercial users can choose between natural vanilla (very expensive and used only in niche markets), synthetic vanillin and artificial vanilla flavor (ethyl vanillin). Synthetic vanillin is a cost effective alternative to vanilla and is increasingly substituting the natural product. It not only substitutes vanilla, but also supplements adulterated vanillin extracts. Global demand for synthetic vanillin currently is around 16000 tonnes per year. But guaiacol is petroleum derivatives and it has been limited. Natural "vanilla extract" is a mixture of several hundred different compounds in addition to vanillin. Artificialvanilla flavoring is a solution of pure vanillin, usually of synthetic origin. Because of the scarcity and expense ofnatural vanilla extract, there has long been interest in the synthetic preparation of its predominant component. The first commercial synthesis of vanillin start with the more readily available natural compound eugenol today, artificial vanillin is made from either guaiacol or from lignin, a constituent of wood which is a byproduct of the pulp industry, Lignin based artificial vanilla flavoring is alleged to have a richer flavor profile than oil based flavoring; the difference is due to the presence of acetovanillone in the ligninderived product. Rhodia SA dominates the world vanillin market using the catecholguaiacol process. Rhodia entered the USA vanillin market in 1986 with the purchase of the Monsanto plant. This plant was subsequently closed down in 1991. In November 1993, Rhodia purchased the ITT Rayonier vanillin business and immediately closed the plant. After that, their main target has been China.

4


Borregaard (Norway), the second largest vanillin producer, is the only remaining producer of lignin. The company also has guaiacol vanillin and ethyl vanillin production capacity as it acquired Eurovanillin in 1995 (Triumph Venture Capital, 2004). Borregaard mainly supplies the European market and its lignin vanillin production is almost exclusively for large costumers under long-term contracts. Lignin based vanillin is in high demand in certain market sectors, particularly the perfume industry, European chocolate manufacturers, and the Japanese market, and as such tends to command a price premium. The price of lignin vanillin is consistently maintained at about $1.00 to $2.00 per kg above that of guaiacol based vanillin (Triumph Venture Capital, 2004b). The ethyl vanillin price follows the same basic trend as the vanillin price. It is maintained at about twice that of vanillin, but as it has about three times the flavour intensity of vanillin there is a cost saving associated with substituting vanillin with ethyl vanillin. The main source of pure lignin is the pulp and paper industry, where nowadays the Kraft process prevails with approximately 80% of the world chemical pulp production (Ullmann’s Encyclopedia, 2003). A by-product stream

of this process, known as black liquor , contains typically 30 to 34% of lignin in dry solid weight basis. This stream is burned to provide energy for mill operations, and to facilitate the recovery of pulping chemicals. Due to the complex energetic integration of the Kraft process, an expansion in the production of pulp implies a revamp in the burners. An alternative plant design to the burners revamp will be a utilization of the increased amount of black liquor in the production of high-added value products and the elimination of a production bottleneck at the recovery boiler (Axelsson et al., 2006). In this work, the focus is on the production of synthetic vanillin from lignin obtained from black liquor. A flow sheet of a process to produce synthetic vanillin from lignin in a pulp and paper industrial unit is proposed in Figure 1.2. A portion of the by product stream, black liquor, is processed to extract lignin. This extraction can be done by the traditional acidification/precipitation followed by separation, or using an improved method similar to one developed by a Swedish group and known as LignoBoost (Öhman et al., 2006). After obtaining purified lignin, the subsequent

5


process is based on three main steps studied in LSRE. The first step consists on the alkaline lignin oxidation in a bubble column reactor, which is the main subject of this thesis. Then, the mixture obtained in the reaction passes through a membrane ultrafiltration process where the bigger molecules of degraded lignin are retained. Sodium vanillate (salt of vanillin) and other low molecular weight species goes to the permeate stream (Zabkova, 2006). Finally, the permeate containing smaller molecules and excess NaOH flows through a packed bed on acid resin in H+ form, in order to convert the sodium vanillate into vanillin (Zabkova et al., 2007). This ion exchange step is accompanied by neutralization reaction resulting in a lower pH for the product exit stream. In order to have a reference point for the results to achieve, it is important to refer a study developed in South Africa that revealed a benchmark final vanillin concentration was 4.2 g/l, for a production process based on Kraft black liquors (Triumph Venture Capital, 2004a). A process which final product has a concentration below this value should not be very competitive in the present scenario of the synthetic vanillin market.

Figure 1.3. Flow sheet of a process for vanillin production integrated in a pulp and paper mill

(Zabkova, 2006).

6


In the wide scope of the forestry activities the black liquor is obtained as a by-product of the pulp and paper industry. For this reason, this work deals with this industry. Pulp and paper industries are unquestionably of great relevance to the Indonesia economy. In fact Badan Pusat Statistik (BPS) noted that pulp export from January until September 2011 had increased by 72,37% from 1,05 juta tonne to 1,81 million tonne. Indonesia take 9 th place in the world in pulp production. The total of pulp industry is 13 units, where 6 units is in Sumatera. The production capacity is for about 6,5 million tonne pulp per year. Black liquor is the main raw material for vanillin making from lignin. Black liquor is obtained from one of the biggest pulp and paper industry in Indonesia that loctaing in Riau, PT Riau Andalan Pulp & Paper. The available side product capacity of pulp is 4.920.000 m 3/year. Because of the large side production of black liquor, PT Riau Andalan concern to process the black liquor beside to use it as fuel. Therefore, PT Riau Andalan Pulp & Paper decide to make Vanillin Plant based on lignin that use black liquor as the raw material. By see the ability of black liquor production and the excellence compared to China in product shipping cost, the vanillin product from this plant can compete with competitive price with good margin profit. Beside to fulfill the needs of vanillin demand in Indonesia, the development of this plant will also create new job opportunity, expand the vanillin export, and give contribution for local communities. This is the first vanillin plant from lignin in Indonesia, it is expected to increase confidence and independence of this nation to apply knowledge and technology in real life. 1.2

Plant Development Goal

Market increase, raise in energy prices and high volatility in natural vanilla prices are a strong driving force to have a deeper understanding of alternative methods to produce vanillin. Vanillin obtained from lignin can employ a lowvalue fuel to produce a high- added value and also represents a “green process”, since it is biomass-based. The guaiacol process to produce vanillin employs benzene obtained from a non-renewable source (petroleum). Within this context, the objective of this plant is to design the plant of vanillin production from lignin and its implementation in

7


Indonesia. The source of lignin should be black liquor from pulp and paper industries using the Kraft process. In this work it was used lignin from softwood Pinus spp., kindly supplied by PT Riau Andalan Pulp and Paper. The target of

vanillin production per day is 4500 kg or 1750 ton per year. Needs of vanillin in Indonesia until this plant design was done is still filled with synthetic vanillin imported from China. This vanillin factory has a useful life 20 years. We assume that vanillin needs always grow every years according to projections import data we have collected. Until 2022 the vanillin needs of Indonesia is still below 1750 ton / year. That’s way until that year this plant can

fulfill all of vanillin needs in Indonesia. Otherwise, in 2035 vanillin needs of Indonesia can reach 12000 ton / year, and we predict that there will be another vanillin plant from lignin to fulfill needs of vanillin, but with keeping the best quality of vanillin this plant won’t lose the customer. 1.3

Plant Development Analysis

1.3.1

Raw Material Analysis

Vanillin (4-hydroxy-3-methoxybenzaldehyde) is organoleptically the characteristic aroma component of the cured vanilla pod, where it contributes to about 2% (w/w) of the dry matter (Priefert, H., Rabenhorst, J., & Steinbüchel, A., 2001). It is used in a broad range of flavors for foods, confectionery, and beverages (approximately 60%), as a fragrance ingredient in perfumes and cosmetics (approximately 33%), and for pharmaceuticals (approximately 7%). From the annual consumption of the world flavor market, only about 0.2% originates from botanical sources (Krings and Berger 1998). There are 2 types of commercially available vanillin. The first one is a natural vanillin extracted from the vanillin pods and the second type is a pure vanillin chemically synthesized from various chemical substrates. The price of the chemically synthesized “nature-identical” vanillin is very low (about US$15 kg– 1), compared to the price

of cured vanilla pods [between US$30 kg – 1 and US$120 kg – 1 (actual price)], which usually contain about 2% (w/w) vanillin. The high price of “natural”

vanillin is mainly due to the limited availability of vanilla pods depending on climate-associated fluctuations of harvest yields, economical and political

8


decisions, and last but not least to the labor-intensive cultivation, pollination, harvesting and curing of vanilla pods. Vanillin can be produced from phenolic compounds such as phenolic stibenes, guaiacol, lignin, isoeugenol, eugenol, ferulic acid, vanillic acid, aromatic amino acid, sugar beet pulp, wheat straw and biomass substances (Vaithanomsat, P., & Apiwatanapiwat, W. , 2009). The main portion is produced by chemical synthesis from guaiacol and lignin (Priefert, H., Rabenhorst, J., & Steinbüchel, A., 2001). 1. Guaiacol

Guaiacol is one of the raw material to produce vanillin which is derived from petroleum. Rhone- Poulenc is the World’s largest producer of vanillin and ethyl vanillin with a $60m turnover in these two products. The company has concentrated on the guaiacol route. Production facilities are situated in Saint Frons (France), which has been in operation since 1978 and in Baton Rouge, Louisiana (USA), which was commissioned over a two-year period ending in mid-1992. Combined capacities for vanillin and ethyl vanillin are estimated to be 3 000t and 5 000t respectively. Ube Industries in Japan also use the guaiacol route to vanillin and ethyl vanillin. The company recently expanded their 1 000t manufacturing facility by 400t and are understood to produce more or less equal volumes of both vanillin and ethyl vanillin. Chinese producers are thought to produce only vanillin, mostly via the guaiacol route (total capacity 2 000t). Rhodia acquired in 2000 the existing business of the Chinese company Xuebao Fine Chemicals Co. Ltd, one of the most recent vanillin plant at that time. Rhodia shares its experience in vanillin manufacture about environmental problem, involved higher toxicity of the raw materials (guaiacol), unfavourable ecobalance (3 to 5 more tars and COD Chemical Oxygen Demand, and 5 times more VOC - Volatile Organic Compounds, 1/3 of which benzene), non compliance with environmental standards, high health & safety risks and unacceptable standards for a flavor. Therefore, many manufacturers are trying to produce vanillin with raw materials that are environmentally friendly and renewable, likes lignin.

9


2. Lignin

The term lignin is derived from the Latin word for wood lignum. Lignin is a major constituent in structural cell walls of all higher vascular land plants. Its polyphenolic structure is well known for its role in woody biomass to give resistance to biological and chemical chemical degradation. degradation. Lignin is third component component macromolecule of wood wood associated kovalen with cellulose and hemicellulose. At At this time and future, the application of lignin has prospect. Lignin commercially can be used as binder, filler, surfactant, polymer product, disperser and others chemical raw, especially benzene derivate.

Figure 1.4 Sustainable industrial wood biorefinery operated by Borregaard, Norway (2010).

Lignin is a renewable raw material that could potentially be used as a raw material in the manufacture of vanillin. This sustainable resource is to be used within the biobased economy which is expected in the years to come to gradually take a larger share compared to the fossil-based economy. The biobased economy is not just the implementation of innovative technologies using renewable resources, but it will be a real transition with a broad and high impact on society at different levels (Langeveld and Sanders 2010). The use of lignin as a raw material has the advantage in terms of availability of raw material is abundant, especially in Indonesia. Lignin is an organic compound produced by woody plants and Indonesia are rich of it. One of lignin source which has abundant availability in Indonesia are oil palm empty fruit bunches (PEFB). At present and for the future, Indonesia is one of the largest palm oil producing country in the world that automatically as well as the world's largest producer of PEFB. However, in the manufacture of vanillin, PEFB 10


ineffective if used as a raw material because of the process is not possible. Initial pre-treatment to get lignin from PEFB not support passage of vanillin plant. This is because the process of getting lignin is too complicated and a lot of equipment needed. Moreover, Moreover, until now there has has been none of plant that utilizes utilizes PEFB as raw materials in Indonesia. Another alternative that can be used as raw material is black liquor. Black liquor is the waste produced by the pulp and paper plant. Black liquor availability is very abundant in Indonesia because Indonesia is one of the largest paper producers in Southeast Southeast Asia. Therefore, Therefore, black liquor can be used as renewable renewable raw materials in the vanillin manufacture. PT. Riau Andalan Pulp and Paper is a pulp and paper plant that produced black liquor in Indonesia. The plant can produce 4.92 million tons of black liquor per year. 10% of black liquor produced by this plant can support support the needs of vanillin vanillin for 20 years. Not only that, the processing of black liquor into lignin is much more economical compared with the processing of PEFB into lignin. Based on the explanation above, it was concluded that the raw materials used to produce lignin vanillin was obtained from black liquor. Table1.2 Analysis of Selection Raw Material

No

Considerations Factor

PEFB

Black Liquor Liquor

1

Raw material

5

4

5

5

4

3

1

4

4

5

availability 2

Distance traveled raw materials

3

Substances in the material and the quality of the products

4

Materials processing efficiency

5

Material prices

11


1.3.2

Location Analysis

1.3.2.1 Raw Material Availability Aspect

Raw material availability aspect is the most influence aspect to decide the location of the plant that we want to build. Relating to this aspect, plant construction must near with the source of raw material to minimize the transportation cost and also avoid production obstacle due to raw material supply. Main raw material of vanillin plant is black liquor as waste of pulp and paper production plant. In Indonesia, The biggest pulp and paper industry is Riau Andalan Paper and Pulp (RAPP) with production capacity about two million tonnes a year. As one of the largest integrated pulp and paper mill in the world, black liquor as the waste production is so much, around 4.920.000 m 3 a year. RAPP locates in PangkalanKerinci village, Langgam sub-district, Pelalawan Regency, Riau, Sumatra. Based on black liquor availability, we choose to build our plant in Pelalawan Regency, Riau near RAPP plant. Actually, the black liquor of this plant is used to production methanol as renewable energy and reduced consumption of fossil fuel for their plant. On the other side, total mass of black liquor that we need per day is 1000.5 tonnes t onnes or just about 0.007% from the total black liquor waste production per day from RAPP. Therefore, we sure that RAPP will give the black liquor as our raw material plant. Figure 1.5, 1.6, and 1.7 show the location of RAPP and also location of vanillin plant that we want to build in Riau. 1.3.2.2 Utility Needs Availability Aspect

The utility needs for vanillin plant is water, electricity, and fuel. The water need is obtained PDAM and Kampar Kiri River near the plant. Meanwhile energy fuel resource is obtained from Pertamina RU II Dumai which is distributed through piping.Te electricity need is obtained from PLTA.

12


Vanillin Plant Riau Andalan Pulp & Paper (Sumber Black Liquor)

Figure 1.5. Location of raw material avaibility and plant building

Source: BadanKoordinasi Survey danPemetaanNasional, 2002

Vanillin Plant

Riau Andalan Pulp & Paper (Sumber Black Liquor)


Source : googlemap.com

13


Vanillin Plant



Source : googlemap.com

1.3.2.3 Product Marketting Aspect

Our consumer is food companies especially milk, chocolate, and ice cream industy. Most of that company locates in Cikarang industrial area.Some of the biggest company are Unilever, Nestle, Diamond, and Campina.Vanillin product will be distributed via land and sea transportation.Based on market place above, vanillin plant in Pekanbaru, Riau is not too strategic because far from food company target. We need more cost to distribute vanillin product. However, if we compare with choosing to build vanillin plant near the market target, cost for distribute vanillin product from Riau to Cikarang is lower than cost for deliver raw material from riau to Cikarang.

14


1.3.2.4 Transportation Aspect

Transportation in our plant is need to support our process production plant, mainly for supply the supporting material and distribution the vanillin to the target marketing. From the figure 1.4.3, we can looked that our plant is near with east main road Jambi-Riau. Our plant also near with the Kampar Kiri River. For, the air transport, our plant is near with the Sultan SyarifKasim II Airport in Pekanbaru. Therefore, from the transportation aspect, our plant location is strategic. 1.3.2.5 Social and Environment Aspect 1. Geographic Aspect

Pelalawan regency is one of ten regency in Riau Province and located at 00 o46,24’ LU - 00o24,34 LS dan 101 o 30,37’-103o21,36’ BT.Pelalawan has area about 13.256,7 km 2danborders to the following area. a. North : Siak regency b. South :IndragiriHuluand Indragiri Hilirregency c. West : Kampar danIndragiriHulurengency d. East :Karimun, Kepulauan Riau province, Bengkalis regency Pelalawan regency topography consist of lowland and hill, which the lowland is about 93% from total area of Pelalawan Regency. Ground characteristic from certain parts are organic ground and acidic with brackish ground water. The humidity and temperature quite high. In general, Pelalawan regency is suitable use for plant construction because the ground structur is flat, not bumpy, and near with water resource. 2. Social Aspect

The number of residents in regency Pelalawan based on survey in 2009 (BPS, 2009) is 280.197, consist of 145.442 are men (51,54%) and 134.775 are women (48,46%). Majority residents are moslem (257.447 people) and the others are Protestan, Katolik, Hindu, and Budha. 3. Labor Aspect

The occupation of Pelalawan regency residents is quite diverse. There are businessman, farmer, fisherman, labor, and others. The

15


availability of labor is quite big due to Riau province have many Industry and residents. Therefore we can quite easily get the labor. 1.3.3

Market & Capacity Analysis

Vanillin is a versatile, well-established aroma chemical used mostly as a flavourcompound. The total world market is estimated at 10,500 tons per annum. Themajor applications are in the manufacture of chocolate and ice cream, with smallerquantities used in baked goods and confectionery. Vanillin can also be used as a fragrance and fixative in perfumes, cosmetics and other fragrance mixtures. It is alsoused as a pharmaceutical intermediate.Commercial users can choose between natural vanilla (very expensive and used onlyin niche markets), nature-identical vanillin (guaiacol or lignin vanillin), and artificialvanilla flavour (ethyl vanillin).

Figure 1.8 Vanillin Use for Flavour Market

Source : www.nedlac.org.za/media/5959/industry.pdf

Natural vanilla flavouring, produced from the pod of the vanilla orchid by extraction of the aroma compounds with ethanol, constitutes less than 5% of the world market. Natural vanilla contains both vanillin and a range ofother aroma chemicals, which in total are responsible for the full flavour of true vanilla. Natural vanilla is considerably more expensive than synthetic vanillin by afactor of 10. Synthetic vanillin is produced on a commercial scale using two distinct technologies.Vanillin produced by the different process routes has different flavour profiles.Consumer preference ultimately drives demand for the different vanillin products. Incertain applications, particularly the perfume industry, 16


European chocolate manufacturers, and the Japanese market, lignin vanillin is preferred over guaiacolvanillin. As is the case with most aroma chemicals used in the flavour industry,companies are reluctant to change from current suppliers as the organoleptic profilewill also change. The world demand for vanillin in its major applications is as follows: The world demand for vanillin in its major applications is as follows: Table 1.3 Vanillin World Demand Applications

Source : www.nedlac.org. za/media/5959/industry.pdf

Vanillin is a mature market, and the market is growing steadily, anticipated to be 2 – 3% over the next few years. Flavour and fragrance applications continue to expandin line with demographics and increases with disposable income. As a result, thegrowth in consumption of vanillin in flavour and fragrance products is growing at 4%in developing nations, in comparison to 2% in developed regions.Vanillin for many years was used as an intermediate for 2,3,5-trimethoxybenzaldehyde, which itself is an intermediate for the drug trimethoprim.This product is now however manufactured almost exclusively in China using thecheaper gallic acid route. In the 1980’s the use of vanillin as a

pharmaceuticalintermediate in the production of drugs such as L-methyl dopa declined. It has nowlevelled to approximately 10% of total vanillin demand. In Europe, the use of vanillinas a pharmaceutical intermediate appears to be captive to Rhodia. The globaldemand for vanillin is estimated as follows:

17


Tabel 1.4 World Demands for Vanillin

Source : www.nedlac.org.za/media/5959/industry.pdf

The high cost of production and natural vanillin causes the industries of vanillin consumer (foods and drinks, pharmaceuticals, and perfumes) in Indonesia prefer to choose using synthetic vanillin which is imported from other countries. Based on literature that we have learned, there is several reasons Indonesia has to import synthetic vanillin. Firstly, in agricultural areas that producing vanilla beans such as Jawa Tengah, Jawa Timur, Bali, Nusa Tenggara Timur, Sulawesi Utara, Lampung, and Sumatra are found the pest of vanillin called Busuk Batang Vanili (BBV). It is the primary diseases and became one of problems in Indonesia’s

vanillin production since 1960 (Soetono 1962; Hadisutrisno et al. 1967; Risfaheri et al. 1998). BBV has destroyed vanilla plants in production areas so it causes loosing of billions of rupiahs every years. The loss that caused by BBV in 1991 is predicted almost Rp 32 billions (Untung, 1992). The damage of vanillin plants caused by BBV In Bali is almost 80% (Sedhana, 1996). The consequences are the cost of vanillin natural is so much expensive and not sold in Indonesia’s markets

so the natural vanillin products is exported to many countries. In the other hand, vanillin needs in Indonesia is fulfilled by synthetic vanillin product import that much cheaper. Literally, the good or bad market qualities from vanillin commodities, is not only determined by the vanilla qualities. There is many things that determine the vanillin quality markets, they are farmer, collector, wholesaler, processor, importir and also the marketing models that used in market systems. This case also causes synthetic vanilin cost that imported by Indonesia is so expensive. Price of natural vanillin producton the marketis 3-4 times the price of synthetic vanillin . Price

18


of natural vanilla extract U.S.$ 30-60 per gallon , while the priceof synthetic vanillin U.S.$10-15 pergallon( Schultz, 2005, referenced inMelawati2006).

Synthetic vanillin prodution is predicted about 3000 tonnes per year, whereas the global market demand of synthetic vanillin reaches 3500 tonnes. Along with the development of food and drink and pharmaceutical industries, the demand of synthetic vanillin will always increase with velocity 8-9% per year with the market target in USA 27 %, Eropa 45 %, Asia 21 % and others 7 %. For saving the foreign exchange and decreasing the dependence of vanillin import, so the production of synthetic vanillin with efficien process technology and high quality product is needed. This indicates that the vanillin market in Indonesia is big enough. In the future, we predict that the interest of people in Indonesia for the products such as ice cream, chocolate and the others semi-luxury foods FMCG owns like Wall’s, Campina, Diamond, Nestle and others will increase too.

Moreover, today, the cake factories in big cities have increased so big. This case is supported with three reasons. Firstly, the facts that the economic growth is stable enough and will increase straightly. It will effect the amounts of middle class people in Indonesia which has high purchasing power is increased too. Finally, the semi-luxury food products that contains vanilla will be more affordable and demand will increase continously. Secondly, the aggresiveness of large FMCG campanies in Indonesia causes their volume increases continously. As a result , demand forvanillaas one of theraw materialswould be even greater . The last reasonis that Indonesiais havingstyle trendsof consumerismwhere the need forfood and beverageis notanymorelimited tostaplefoods anddrinksbut also thesemi- luxury foods and drinksthat tendimpulsive. Wetried tomap thelocation ofplant semi-luxuryfood and beverage productsthat wil be our prospective customers. Someof these companiesare listed in Table 1.5 below.

19


Table 1.5 FMCG Companies

No

Companies

Products

Ice Creams : Magnum, Paddle Pop, 1 Wall's

Vienetta, Cornetto, Buavita, etc Ice Creams: Concerto, Hula-Hula,

2 Campina

Tropicana, Bazooka, etc

3 Diamond

Ice Creams

4 PT IndoMeiji Diary Food

Ice Creams

5 PT Ceres

Chocolates

6 PT Cadbury Indonesia

Chocolates Coffees (Nescafe), Milk (Milo,

7 PT Nestlé Indonesia

Carnation), Candies (FOXS)

Needs of vanillin in Indonesia until this plant design was done is still filled with synthetic vanillin imported from China. This vanillin factory has a useful life 20 years. We assumed that vanillin neededs always grow every years according to projections import data we have collected. Thus the amount of vanila needed each year until 2035 (according to the useful life on the plant) can be calculated. Table 1.6 Vanillin Needs in Indonesia

Code

Commodity

2007

2008

2009

2010

2011

Trend

291241 Vanillin (4-hydroxy-3- 2,413.8 3,320.5 3,165.4 4,564.1 3,873 13.47 methoxybenzaldehyde)

20


6000 5000 4000 3000 2000 1000 0 2006.5

y = 4E-133e0.1559x R² = 0.8783 2007

2007.5

2008

2008.5

2009

2009.5

2010

2010.5

2011

2011.5

Figure 1.9 Curve Vanillin Needs in Indonesia

Prediction and calculation needs vanillin until 2035 are shown in Table 1.7 below. Table 1.7 Value of Imported Vanillin in 2015-2035

Indonesian Years

Imported

Years

Vanillin (ton)

Indonesian Imported Vanillin (ton)

2011

288

2023

1868

2012

336

2024

2183

2013

393

2025

2551

2014

459

2026

2981

2015

537

2027

3484

2016

627

2028

4072

2017

733

2029

4759

2018

857

2030

5562

2019

1001

2031

6501

2020

1170

2032

7597

2021

1367

2033

8879

2022

1598

2034

10377

2035

12128

Vanillin factory will be built in 2013-2015 and began operating in 2015. The factory is designed to meet 53% requirement of vanilla in 2025. Because production in 2015-2035 produced about 4.5 tons per day. Amount of excess vanillin

21


which we produce will be exported to Australia so the factory will not be lossin the beginning of the operation. The production capacity of the factory is shown in the table 1.8 below. Table 1.8 Production Capacity 2015-2035

Years

Demand of Vanillin in Indonesia (ton)

2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032 2033 2034 2035

393 459 537 627 733 857 1001 1170 1367 1598 1868 2183 2551 2981 3484 4072 4759 5562 6501 7597 8879 10377 12128

Plant Production Capacity (ton)

Excess of Production (ton)

Building Plant Building Plant 1350

813

1350

723

1350

617

1350

493

1350

349

1350

180

1350 1350 1350 1350 1350 1350 1350 1350 1350 1350 1350 1350 1350 1350 1350

Thus, the plant design for the production of synthetic vanillin from lignin can bedone, because the assessment can be realized technically and financially feasible. Feasibility is a projection that could change if the price of raw material or product prices fluctuate, so it is recommended to do innovation processes to reduce production costs and still prioritize the qualities of synthetic vanillin.

22


CHAPTER 2 PROCESS DESIGN 2.1

Process Technology Selection

In the manufacture of vanillin, a process that is needed is a method of decision LignoBoost. Lignin from black liquor and high temperature oxidation process in a reactor that will produce vanillin. In addition to the method above methods, other ways that are often used in the making of the balck liquor lignin, which Organosolv method using alcohol. Organosolv method is the technology used to convert biomass into compounds lignosellulosic the compound cellulose, lignin, and hemicellulose (Mosier et al., 2005). These technologies include enzymatic fractionating by cellulases and chemical hydrolysis by hot water treatment, steam explosion, ammonia fiber explosion, dilute or concentrated acid hydrolysis, alkaline treatment and organosolv processes. While Organosolv process itself means the t he use of ethanol in the pre-treatment process in i n biorefinery useful to recover the desired multiple multi ple lignin products. While LignoBoost is a method of making lignin extraction from black liquor using a compact cake or pellets and products can be used for biofuels or raw material for the chemical industry. LignoBoost works in conjunction with evaporation. It all starts with being precipitated lignin from the black liquor by lowering the pH with CO 2. The precipitate is then dewatered using a filter press. LignoBoost then overcomes conventional sodium filtering and separation problems by redissolving the lignin in spent wash water and acid. The resulting slurry is dewatered and washed once again, with acidified wash water, to produce virtually pure lignin cakes. The lignin can be exported or, after the final drying, dr ying, be used as fuel in the lime kiln.

23


Figure 2.1 Proses Lignoboost

Table 2.1 Scoring Process of Lignin Production

Retention Time

Process Handling

(30%)

(10%)

Organosolv Process

1

1

3

1

1.8

LignoBoost Process

4

3

1

4

2.7

Parameter

Cost (40%)

Concentration Obtained

Total

(20%)

Retention time is the length of time used in the process of making lignin. The greater nilainy, means less time spent in the process. Conversely, the more time spent, indicating the smaller value given. In the references we get, the time used to process more than one day Organosolv in a single batch. Meanwhile, LignoBoost Process only requires 4 hours in a single batch. Handling Process is how easy the process was done. In a reference point that we get, Organosolv mixing process using the process at every stage of the process used to be done so that the guard is large enough. Meanwhile, LignoBoost Process conducted in a reactor so that maintenance is done not so great. Cost is

24


how inexpensive process. Process Organosolv use only simple tools are used so the cost is not expensive. Otherways, LignoBoost Process using a mixing tank used so the cost is very expensive. Obtained Concentration is how much product. With a very high price, LignoBoost Process can use the tank so that the results can be produced very much. The next process is the process of making lignin into vanillin. In the manufacture of vanillin tool used is oxidation reactor. Reactor oxidation can be used in a continuous or batch mode. Continuous process is usually done to reduce the area of the plant so that the plant will be used more efficiently. In contrast, batch processes are used to meet the needs of the production of very large so the existing plant will be larger wide area. Table 2.2 Scoring process in Oxidation Reactor

Parameter Batch System Continous System

Process

Process

Time

Handling

(30%)

(10%)

2

2

3

3

Cost (20%)

Concentration Obtained

Mass Transfer Total

(30%)

(10%)

2

3

3

2.4

3

1

1

2.2

According to the tables above our team will choose is a batch process Because of five parameters. Parameters that we choose is big factor in building a plant. There are Process time, process handling, cost, consentration obatained, and mass transfer. If the value of retention time is high, it means retention time of that process happen in not a long time. Otherwise we if the retention time is low, it means we need a long time in the process. In a batch system, process time need 12 hours a day. While in Continuous System, it takes time in one process can not be calculated Because every second of BCR will produce. If the value of the cost is high, it means the process is cheap and if low, it means the process is expensive. Batch system is more expensive than continuous process Because in batch system, the area will be very huge to cover capacity of the plant. If the value of concentration obtained is high, it means we have a big 25


product in that process, and if low it means the product is small amount. Batch system will produce until 0871 amounted to 0.7 g / L, while, for the continuous process is 0.56 until 0.67 g / L. Mass transfer describe the amount of movement of a substance that will the make the process efficient. High value is big mass transfer, low mass transfer value is small. Batch system will result in a greater mass transfer due to the mass of those who dwell in the reactor. 2.2

Process Description

2.2.1

Type Of Process

In vanillin production process, there are two primary stages to producevanillin from black liquor. Black liquor contains typically 30 to 34% of lignin in dry solid weight basis. Lignin should be extracted from black liquor with LignoBosstprocess and continued with conversion of lignin to vanillin.

Figure 2.2 Diagram of vanillin production process

2.2.1.1

Lignin Extraction from Black Liquor

LignoBoost is a complete system that extracts ligninfrom Kraft black liquor .LignoBoost works in conjunction with evaporation.In the LignoBoost process, a stream of black liquor is taken from the black liquor evaporation plant (Fig. 2.2), then lignin is precipitated by acidification (the preferred acid is CO 2) and filtered (“chamber press filter 1”, Fig. 2.2).Instead of washing lignin

immediately after filtration, as in traditional processes, the filter cake is redispersed and acidified (“cake re-slurry”, Fig. 2.2). The resulting slurry is then

26


filtered and washed by means of displacement washing (“chamber press filter 2”,

Fig. 2.2). When the filter cake is re-dispersed in a liquid, at pH level and temperature values approximately equal to those of the final washing liquor, the concentration gradients during the washing stage will be low. The change in the pH level, most of the change in ionic strength and any change in lignin solubility will then take place in the slurry, and not in the filter cake or in the filter medium during washing.The filtrate fromchamber press filter 2 (filtration, washingand dewatering stages) should be recycled tothe weak black liquor. The resulting slurry is once again dewatered and washed, with acidified wash water, to produce virtually pure lignin cakes.In some cases, thisfiltrate can be also used for washing theunbleached or oxygen delignified pulp.The LignoBoost process therefore makesit possible to extract lignin efficiently fromthe black liquor in kraft mills. The majoradvantages, compared to the previoustechnology, are the following:the filter area and the volume of acidicwashing water can be kept at lowervalues, resulting in lower investmentcosts,the addition of sulfuric acid can be alsokept at a lower level, resulting in loweroperational costs,the yield of lignin is higher, the lignin has a lower ash and carbohydrate content, the lignin has a higher content of dry solids.

Figure 2.3General layout of the LignoBoost lignin removal process (post-treatment,

drying and pulverizingare excluded)

2.2.1.2 Lignin Oxidation in Batch Process

Production of vanillin lignin based must be made in alkaline conditions. Alkaline conditions is made to achieve a very high pH nearing pH 14, in addition 27


to high temperature conditions also are 150 0C and 10 bar.The purpose of this process is to break the bond position position of alpha-and beta-carbon beta-carbon of fenilpropane and breaking bonds in the carbon chain in the phenyl propane propanoid. Lignin oxidation process in batch mode formed in a jacketed reactor with controlled temperature and pressure. The reactor is under stirring and oxygen was fed to the reactor. LigninLingoboost outcome enter into a reactor that has a temperature operating conditions of 150 0C and pressure of 10 bar.Alkaline conditions created by inserting NaOH pH 14 into reactor first. Then lignin lignoboost enter to the input process. After that, the solution oxidaze with O2 gas 50% N2 50%.Lignin reaction occurred with O2 being described at the beginning of the bond that ties will occur. NaOH will react also with lignin to form Sodium Vanilate.Sodium Vanilate is salt vanillin mixed with Na+ ions. In addition it also produced some of the content of impurity content to be separated. Lignin is not transformed to Sodium Vanilate 100% m. 2.2.1.3 Membrane Ultrafiltration Separation Separation

In the filtration process, the tool used is membrane ultrafikasi. Membraneultrafikasi used has a large cut-off membrane of 15 kDa, or about 1.6 nm and the pressure used is 0-4 bar. Vanillin has large molecules 152 Da MW, making vanillin will pass with the existing pores. This process begins with the entry of sodium vanilate and other impurities. This process aims to separate Sodium vanilate with other impurities by using the principle of molecular size difference. Sodiumvanilate is outflow and by product is lignin and impurities. Lignin obtained from the by-product will in turn go back to the oxidation tank to re reacted with O 2. 2.2.1.4.

Spray Dryer

Spray drying is a method of producing a dry powder from a liquid or slurry by rapidly drying with a hot gas. This is the preferred method of drying of many thermally-sensitive materials such as foods and pharmaceuticals. A consistent particle size distribution is a reason for spray drying some industrial products such as catalysts. catalysts. Air is the heated drying medium; however, however, if the liquid

28


is a flammable solvent such as ethanol or the product is oxygen-sensitive then nitrogen is used. All spray dryers use some type of atomizer or spray nozzle to disperse the liquid or slurry into a controlled drop size spray. The most common of these are rotary disks and single-fluid high pressure swirl nozzles. Alternatively, for some applications two-fluid or ultrasonic nozzles are used. Depending on the process needs, drop sizes from 10 to 500 µm can be achieved with the appropriate choices. The most common applications are in the 100 to 200 µm diameter range. The dry powder is often free-flowing The most common spray dryers are called single effect as there is only one drying air on the top of the drying. In most cases the air is blown in co-current of the sprayed liquid. The powders obtained with such type of dryers are fine with a lot of dusts and a poor flowability. In order to reduce the dusts and increase the flowability of the powders, there is since over 20 years a new generation of spray dryers called multiple effect spray dryers. Instead of drying the liquid in one stage, the drying is done through two steps: one at the top (as per single effect) and one or an integrated static bed at the bottom of the chamber. The fine powders generated by the first stage drying can be recycled in continuous flow either at the top of the chamber (around the sprayed liquid) or at the bottom inside the integrated fluidized bed. The drying of the powder can be finalized on an external vibrating fluidized bed. The hot drying gas can be passed as a co-current or counter-current flow to the atomiser direction. The co-current flow enables the particles to have a lower residence time within the system and the particle separator (typically a cyclone device) operates more efficiently. The counter-current flow method enables a greater residence time of the particles in the chamber and usually is paired with a fluidized bed system.

29

Preliminary Des Design of Vanil lin Production Production Plant Fr om Black Liquor

2.2.2

BFD and Description

CO2

NaOH

H2SO4

Vanillin + Others

Black Liquor Lignin Extraction (LignoBoost)

Lignin Lignin Oxidation

Powdered Vanillin

Vanillin Solution Filtration

Drying

O2, N2 (50%,50%) Waste Liquor

VANILLIN PLANT FROM LIGNIN BLOCK FLOW DIAGRAM Drawn By :

Date :

Checked By :

Date :

Revised By : Darwing No. :

Wi thou t Sca le Note :

Figure 2.4 Block Flow Diagram Vanillin Plant from Lignin

30


Two main process in Vanillin Plant from Lignin is lignin extraction from black liquor and vanillin oxidation from lignin itself. From this BFD the raw material, which is black liquor is treated with acid. lignin is precipitated by acidification (the preferred acid is CO2) and filtered. Instead of washing lignin immediately after filtration, as in traditional processes, the filter cake is redispersed and acidified (using H 2SO4). The resulting slurry is then filtered and washed by means of displacement washing. After the slurry is filtered, the next process is blending with NaOH to make a base condition of solution before entering bubble column reactor. In bubble column reactor there will be oxidation reaction between lignin and oxygen. It will result the vanillin solution and the other compounds. To get vanillin, this solution must be separated using ultrafiltration, so the other compounds can be impeded at filter, and the filtrate contains only vanillin. The vanillin solution from ultrafiltration must be dried using spray dryer before it will be packed and distributed.

A4


Two main process in Vanillin Plant from Lignin is lignin extraction from black liquor and vanillin oxidation from lignin itself. From this BFD the raw material, which is black liquor is treated with acid. lignin is precipitated by acidification (the preferred acid is CO2) and filtered. Instead of washing lignin immediately after filtration, as in traditional processes, the filter cake is redispersed and acidified (using H 2SO4). The resulting slurry is then filtered and washed by means of displacement washing. After the slurry is filtered, the next process is blending with NaOH to make a base condition of solution before entering bubble column reactor. In bubble column reactor there will be oxidation reaction between lignin and oxygen. It will result the vanillin solution and the other compounds. To get vanillin, this solution must be separated using ultrafiltration, so the other compounds can be impeded at filter, and the filtrate contains only vanillin. The vanillin solution from ultrafiltration must be dried using spray dryer before it will be packed and distributed.

31


The main process of this plant consists of LignoBoost process which is the lignin separation process from black liquor, and the core of this plant is vanillin oxidation from lignin extract from LignoBoost process. The LignoBoost process is started from black liquor solid separation from black liquor in V-101 until the filtration process of black liquor solid so the lignin is separated from black liquor solid. Otherwise the vanillin oxidation process is started while solid lignin resulted by filtration F-102 entering the blending storage V-103 and NaOH is also added in that storage, oxidation in bubble column reactor, ultrafiltration, until drying process of vanillin to be vanillin powder in spray dryer. From the PFD it can be seen that the black liquor from PT Riau Andalan Pulp and Paper flowing through the pipe and pumped by P-101 pump to the black liquor storage S-101. And then the black liquor is kept until the batch is started. The black liquor than is pumped through P-102 pump to be precipitated in black liquor treatment vessel V-101, CO 2 is added to the storage. The slurry from V-101 is pumped to press chamber filter (Plate and frame) PF-101, and water is pumped by P-108 as washing eluent in filtration. As the result, solid black liquor is


The main process of this plant consists of LignoBoost process which is the lignin separation process from black liquor, and the core of this plant is vanillin oxidation from lignin extract from LignoBoost process. The LignoBoost process is started from black liquor solid separation from black liquor in V-101 until the filtration process of black liquor solid so the lignin is separated from black liquor solid. Otherwise the vanillin oxidation process is started while solid lignin resulted by filtration F-102 entering the blending storage V-103 and NaOH is also added in that storage, oxidation in bubble column reactor, ultrafiltration, until drying process of vanillin to be vanillin powder in spray dryer. From the PFD it can be seen that the black liquor from PT Riau Andalan Pulp and Paper flowing through the pipe and pumped by P-101 pump to the black liquor storage S-101. And then the black liquor is kept until the batch is started. The black liquor than is pumped through P-102 pump to be precipitated in black liquor treatment vessel V-101, CO 2 is added to the storage. The slurry from V-101 is pumped to press chamber filter (Plate and frame) PF-101, and water is pumped by P-108 as washing eluent in filtration. As the result, solid black liquor is impeded above the filter as a cake. Then cake is brought using conveyor C-101 to Acidification vessel V-102 to be re-dispersed so the lignin can be extracted. It needs H2SO4 as an acid liquid at pH 4 to extract that lignin. When the filter cake is re-dispersed in a liquid, at pH level and temperature values approximately equal to those of the final washing liquor, the concentration gradients during the washing stage will be low. The change in the pH level, most of the change in ionic strength and any change in lignin solubility will then take place in the slurry, and not in the filter cake or in the filter medium during washing. From V-102 the extract is pumped by P-107 to press chamber filter (Plate and frame) PF-102, and water is pumped by P-110 as washing eluent in filtration. The lignin is in the cake then is brought to blending storage V-103 with NaOH by conveyor C-102. In blending storage lignin is dissolved in NaOH before it is added to bubble column reactor. NaOH will give a base condition as the optimum condition in this reaction. Before entering bubble column reactor, the lignin solution is pumped by P-105 pump. During the process, the lignin solution is heated to increase the temperature through the heat exchanger HE-101, the heat 33


exchanger agent is steam from boiler B-101 at 220 oC. The output temperature of lignin slurry is 170oC and then it enter the bubble column reactor CS-101. The operation condition of bubble column reactor itself is 170 oC and 10 bar pressure. In BCR lignin is reacted with O 2 resulting vanillin and other compounds. The reaction can be explained below. Lignin oxidation : 0.5 L + 1.56 O 2  V + 114 X Vanillin oxidation : V + O2  D Stoichiometry 1

Conversion

70%

Lignin Oxidation : 0.5 L + 1.56 O2 --> V + 114 X

Initial (mol) Change (mol) Remaining (mol)

2350.242 10781.25 -1645.17 -7332.75 4700.483 705.0725 3448.496 4700.483 Stoichiometry 2 Vanilin Oxidation : V + O2 --> Product

Initial (mol) Change (mol) Remaining (mol)

4700.483 3448.496 -3290.34 -3290.34 3290.338 1410.145 158.1582 3290.338 massa 500592.048 gram 0.50059205 ton 500.592048 kg

                                          Where : -

A is Lignin B is Oxygen C is Vanillin D is Vanillin Acid Product

34


Rate Law :

              The product from CS-101 is pumped using P-106 through HE-103 to Ultrafiltration membrane UF-101. The filtrate then pumped to spray dryer SD-101 (80oC). In SD-101 the liquid vanillin is powdered with hot air after passing the HE-102 at 120 oC. Vanillin powder then is brought to packing building to be packaged. The cake from UF-101 is pumped to waste storage.

35


CHAPTER 3 MASS AND ENERGY BALANCE 3.1

Mass Balance

3.1.1

Overall Mass Balance

Overall mass balance in this system is explained in table 3.1 below : Table. 3.1 Mass Balance in Entire Process

OVERALL

Input (ton)

Output (ton)

Black Liquor

111.17

CO2

1.10

0 0

Water H2SO4

14.54 0.88

NaOH

6.67

0 0

O2

0.16

0

N2

0.16

0.16

1.02

68.92 25.48 5.29 10.14 2.22

Vanillin

-

0.50

TOTAL

135.70

135.70

FEED

22.98

Waste

Lean liquor Liquid acid Alkali sulfat Filtrate cake Hot air PRODUCT

While the composition of the black liquor and its content found in Figure 3.2 Table. 3.2 Black Liquor Composition

Black Liquor Composition

Total mass (ton)

Lignin (4.5%)

5

Water (8%)

8.89

Lean liquor (87,5%)

97.27

36


3.1.2

Mass Balance Process Units

Primary Process Description and Mass Balance in Every Process Units are explained in the table below : Table. 3.3 Mass Balance in Storage

STORAGE

Input 1 (ton)

Output 2 (ton)

Lignin Alkali

10.01

10.01

Water

8.89

8.89

Lean liquor

92.27

92.27

TOTAL

111.17

111.17

Table. 3.4 Mass Balance in Acidification Process

ACIDIFICATION I

Input 2 (ton)

Input 3 (ton)

Output 4 (ton)

Lignin Alkali

10.01

0

10.01

Water

8.89

0

8.44

Lean Liquor CO2 Liquid Acid

92.27 0 0

0 1.10 0

92.27 0 1.55

111.17

1.10

112.27

TOTAL

112.27

112.27

Table. 3.5 Mass Balance in Filtration Process

FILTRATION I

Input 4 (ton)

Input 5 (ton)

Output 6 (ton)

Output 7 (ton)

Lignin Alkali Water Lean Liquor Liquid Acid lean liquor solid

10.01 8.44 92.27 1.55 0

0 11.12 0 0 0

10.01 0 0 0 23.35

0 19.56 68.92 1.55 0

112.27

11.12

33.35

90.03

TOTAL

123.38

123.38

37


Table. 3.6 Mass Balance in Acidification Process

ACIDIFICATION II

Input6 (ton)

Input 8 (ton)

Output 9 (ton)

Lignin Alkali Lean liquor solid

10.01 23.35

0

0 0

H2SO4 Lignin Alkali Sulfat Liquid acid

0 0 0 0

0.88 0 0 0

0 5 5.29 23.93

33.35

0.88

34.23

TOTAL

34.23

34.23

Table. 3.7 Mass Balance in Filtration Process

FILTRATON II

Input 9 (ton)

Lignin Alkali sulfat Liquid acid Water TOTAL

Input 10 (ton)

Output 11 (ton)

Output 12 (ton)

5 5.29 23.93 0

0 0 3.42

5 0 0 0

0 5.29 23.93 3.42

34.23

3.42

5.00

32.65

37.65

37.65

Table. 3.8 Mass Balance in Blending Process

BLENDING

Input 11 (ton)

Input 13 (ton)

Output 14 (ton)

Lignin NaOH Lignin slurry

5 0 0

0 6.67 0

0 0 11.67

TOTAL

11.67

11.67

38


Table. 3.9 Mass Balance in Storage Lignin slurry

STORAGE

Input 13 (ton)

Input 14 (ton)

Output 15 (ton)

Lignin NaOH Lignin slurry

5 0 0

0 6.67 0

0 0 11.67

TOTAL

11.67

11.67

Table. 3.10 Mass Balance in Oxidation Process

REACTOR OXIDATION

Input 15 (ton)

Input 16 (ton)

Output 18 (ton)

Output 19 (ton)

Lignin slurry N2

11.67 0

0 0.16

0 0

0 0.16

O2 Alkali Ligin Slurry Water Vanillin Others

0 0 0 0 0 11.67

0.16 0 0 0 0 0.33

0 5.36 1.20 0.50 4.78 11.84

0 0 0

TOTAL

0 0

0.16

12.00

12.00

Table. 3.11 Mass Balance in Ultrafiltration Process

Input 18 (ton)

Output 20 (ton)

Output 21 (ton)

Vanillin Alkali Lignin Slurry water Others Filtrate Cake

0.50 5.36 1.20 4.78 0 11.84

0.50 0 1.20 0 0 1.70

0 0 0 0 10.14 10.14

TOTAL

11.84

ULTRAFILTRATION

11.84

39


Table. 3.12 Mass Balance in Drying Process

DRYING

Input 20 (ton)

Input 26 (ton)

Output 28 (ton)

Output 29 (ton)

Vanillin water Hot Air Vanillin Powder

0.50 1.20 0 0 1.70

0 0 1.02 0 1.02

0 0 2.22 0 2.22

0 0 0 0.50 0.50

TOTAL

3.2

2.72

2.72

Energy Balance Table. 3.3.1 Mass Balance in Storage

STORAGE

Input 1 (ton)

Output 2(ton)

Energy In (Joule)

Energy Out (Joule)

Lignin Alkali

10.01

10.01

0

0

Water

8.89

8.89

0

0

Lean liquor

92.27

92.27

0

0

TOTAL

111.17

111.17

0

0

Table. 3.3.2 Mass Balance in Acidification Process

ACIDIFICATION I

Input 2 (ton)

Input 3 (ton)

Output 4 (ton)

Energy In (Joule)

Energy Out (Joule)

Lignin Alkali

10.01

0

10.01

0.00

0.00

Water

8.89

0

8.44

141.31

134.15

Lean Liquor

92.27

0

92.27

0.00

0.00

CO2

0

1.10

0

27.64

Liquid Acid

0

0

1.55

111.17

1.10

112.27

TOTAL

112.27

112.27

34.79

168.94

168.94

40


Table. 3.3.3 Mass Balance in Filtration Process

Output 7 (ton)

Energy In (Joule)

Energy Out (Joule)

10.01

0

0

0

11.12

0

19.56

0

0

92.27

0

0

68.92

0

0

Liquid Acid

1.55

0

0

1.55

0

0

lean liquor solid

0

0

23.35

0

-

-

TOTAL

112.27

11.12

33.35

90.03

0

0

0

0

Input 4 (ton)

Input 5 (ton)

Output 6 (ton)

Lignin Alkali

10.01

0

Water

8.44

Lean Liquor

FILTRATION I

TOTAL

123.38

123.38

Table. 3.3.4 Mass Balance in Acidification Process

ACIDIFICATION II

Input6 (ton)

Input 8 (ton)

Output 9 (ton)

Energy In (Joule)

Energy Out (Joule)

Lignin Alkali

10.01

0

0

49689.61

-

Lean liquor solid

23.35

0

-

-

H2SO4

0

0.88

0

138.50

-

Lignin

0

0

5

24844.81

Alkali Sulfat

0

0

5.29

24494.23

Liquid acid

0

0

23.93

489.08

TOTAL

33.35

0.88

34.23

49828.12

49828.12

34.23

49828.12

49828.12

TOTAL

34.23

41


Table. 3.3.5 Mass Balance in Filtration Process

Output 11 (ton)

Output 12 (ton)

Energy In (Joule)

Energy Out (Joule)

5

0

0

0

0

0

5.29

0

0

23.93

0

0

23.93

0

0

0

3.42

0

3.42

0

0

34.23

3.42

5.00

32.65

0

0

FILTRATON II

Input 9 (ton)

Lignin

5

Alkali sulfat

5.29

Liquid acid Water

TOTAL

Input 10 (ton)

37.65

37.65

Table. 3.3.6 Mass Balance in Blending Process

BLENDING

Input 11 (ton)

Input 13 (ton)

Output 14 (ton)

Energy In (Joule)

Lignin

5

0

0

0

NaOH

0

6.67

0

0

Lignin slurry

0

0

11.67

0

11.67

0

TOTAL

11.67

Energy Out (Joule)

Table. 3.3.7 Mass Balance in Storage Lignin Slurry

STORAGE

Input 11 (ton)

Input 13 (ton)

Output 14 (ton)

Energy In (Joule)

Lignin

5

0

0

0

NaOH

0

6.67

0

0

Lignin slurry

0

0

11.67

0

11.67

0

TOTAL

11.67

Energy Out (Joule)

42


Table. 3.3.8 Mass Balance in Oxidation Process

REACTOR OXIDATION

Input 15 (ton)

Input 16 (ton)

Output 18 (ton)

Output 19 (ton)

Energy In (Joule)

Energy Out (Joule)

Lignin slurry

11.67

0

0

0

57971.22

0

N2

0

0.16

0

0.16

0

0

O2

0

0.16

0

0

0

0

Alkali Ligin Slurry

0

0

5.36

0

0.00

0

Water

0

0

1.20

Vanillin

0

0

0.50

0

Others

0

0

4.78

0

Total

11.67

0.33

11.84

0.16

TOTAL

12

0 0

12

57971.22

2811317971.22

57971.22

2811317971.22

Q masuk tambahan : 2811260000 J

Table. 3.3.9 Mass Balance in Ultrafiltration Process

ULTRAFILTRATION

Energy In (Joule)

Energy Out (Joule)

Input 18 (ton)

Output 20 (ton)

Output 21 (ton)

Vanillin

0.50

0.50

0

0

0

Water

5.36

0

0

0

0

Alkali Lignin Slurry

1.20

1.20

0

0

0

Others

4.78

0

0

0

0

0

0

10.14

0

0

11.84

1.70

10.14

0

0

Filtrate Cake

TOTAL

11.84

11.84

43


Table. 3.3.10 Mass Balance in Drying Process

DRYING

Input 20 (ton)

Input 26 (ton)

Output 28 (ton)

Output 29 (ton)

Energy In (Joule)

Energy Out (Joule)

Vanillin

0.50

0

0

0

-

4445.67

Hot Air

1.20

0

0

0

142800

Water

0

1.02

2.22

0

Vanillin Powder

0

0

0

0.50

0.00

0.00

1.70

1.02

2.22

0.50

142800

291296.34

TOTAL

2.72

286850.67

2.72

Q masuk tambahan dari steam : 148496.34 J So, Total of the heat steam that we need is = 2811408496.34 = 2811.41 MJ

44


CHAPTER 4 UTILITIES 4.1

Water Utility

Water availability system in this vanillin plant is really needed to support the whole plant production. The water utility in this plant is needed as processes water, water for equipment washing, domestic water availability and fire extinguishing water. The water source design based on the water collection, processing system efficiency and economical factor. The explanation about this water utility consist as follows : 4.1.1

Water Utility Classification

4.1.1.1 Process Water

Process water that used in this plant is used to solute NaOH that will enter oxidation reactor and for washer in filtration. In the whole process for this plant, water is not too needed because water component in the main raw material (black liquor) is 26% and the most of others materials is liquid solution. The water process needs in this plant reach 123,40 m 3 per day. The details about the needs of water describes as follows : Table 4.1 Total Process Water Needs in Plant

Unit

Water (kg)

Filtration 1

11120

Filtration 2

3420

Blending

730

Total

15270

4.1.1.2 Domestic Water

This water is used to fulfill water needs for staff and other employers. Domestic water include toilet facilities, drinking water, water for watering gardens and many more. Assuming the total domestic water everyone is 100 litre/day. So, total water for domestic water if there is 100 persons in this plant is 10.000 litre/day.

45


4.1.1.3 Fire Extinguishing Water

Fire Extinguishing Water is used to extinguish fire if one day there is fire. This water is reserved to be used anytime. The firefighting water used was water with the low specs , but has under gone treatment first. The amount of water required for fire is assumed to10,000 kg/day . 4.1.1.4 Total Water Requirements

Total water requirements needed for this plant per day covers the water needed for process water , cooling water , water heater , boiler feed water , domestic water and fire water . Total water requirement is shown in the table 5.1 below: Table 4.2 Total Water Needs in Plant

Using water

Total (Kg/day)

Processing Water

15270

Domestic water

10000

Fire Extinguishing Water Total

1000 26270

4.1.1.5 Water Sources

Water supply to the plant will be taken from PT. Riau Andalan industrial area. PT Riau Andalan independently manage all water providers to the needs of industries that exist within the industry. Water supplied by PT Riau Andalan is considered clean enough and qualify for use as water for industrial plants . So in the factory there is no clean water management facilities further. 4.2

Electric Utility

As the plant in general , to run the equipment contained in the plant Vanillin, energy required is not small. Equipment that requires a supply of energy , among others: 

Pump



Agitator Mixing Tank

Electricity need for vanillin production in this vanillin plant can be seen in the following table.

46


Table 4.3 Total Electricity Needs in Plant

Item No.

Process unit

Kwh/ day

Kwh/year

V-101

Agitator CO2 precipitation tank

36.32

10897

V-102

Agitator H2SO4 precipitation tank

1.58

474.83

V-103

Agitator lignin slurry tank

0.09

26.68

P-101

Black liquor pump

19.31

5792.45

P-102

Black liquor pump

258.99

77696.04

P-103

CO2 precipitation pump

56.18

16854.27

P-104

Slurry pump

2.89

865.74

P-105

Slurry pump

0.53

157.70

P-106

Slurry pump

3.86

1157.32

P-107

Slurry pump

0.18

53.46

P-108

Water pump

14.19

258.08

P-109

H2SO4 precipitation pump

0.28

84.69

P-110

Water pump

10.38

3113.53

P-111

NaOH pump

1.78

533.65

C-101

Alkali lignin cake conveyor

7.44

2232

C-102

Black liquor solid conveyor

7.44

2232

C-103

Lignin solid conveyor

5.95

1785

C-104

Vanillin conveyor

5.95

1785

433.34

125999.44

TOTAL

47


Electricity need at vanillin plant is AC (accuired current) power type. Total electricity needs for processes of this plant is equal to 433.34 kWh/day. While the need support for lighting and other assumed 30% of the total energy is 130 kWh/day. So the total electricity need of vanillin plant is 125999.44 kWh/year.

Electrical power is largely used for two purposes primary. The first necessity is requiring electrical power needs the production process. The second purpose is to use electrical power production support facilities. Electricity used for support facilities for the needs of lighting and air-conditioning (AC) in the office, laboratories, workshops, as well as the control room, air supply (tap and clean), water supply (and the net), and the sewage treatment plant. 4.3

Steam Utility

In this vanillin plant, steam utility is needed for heating the reactor through the jacket. Reaction temperature needed in that process is 170 oC. Based on calculation, it is obtained that heat needed for reactor is 253.01 MJ per day. It is assumed that steam needed is provided from diesel as fuels. Assuming that efficiency from boiler is 40%. So, the diesel as fuels to produce steam in this vanillin plant is :

              m = 303 litre per day

48


BAB 5 SIZING 5.1 Vessel 5.1.1

Black Liquor Storage Tank (S-101)

STORAGE TANK

Identification:

Item

Black Liquor Storage Tank

Item no.

S-101

No. required

3

Function:

Storage black liquor to keep it from microorganism and algae

Operation:

Discrete

Material handled:

Black Liquor

Composition (%):

Black Liquor

100

Design data

Capacity (kg)

333500

Feed quantity (m /h)

326.57

Operating temperature (K) Operating pressure (psi)

333 14.70

Storage Tank Specification

Flat-bottomed cylindrical vessel

Type Material of construction

Controls:

Stainless steel 316

Diameter (m)

7.16

Height (m)

9.55

Thickness of shell (cm)

2.97

Thickness of Roof (cm)

2.97

S-101 for controlling Black liquor solution

49


5.1.2

Acidification Tank (V-101) MIXER TANK

Identification:

Item

Mixer Tank

Item no.

V-101

No. required

5

Function:

To precipitation black liquor with CO 2

Operation:

Discrete

Material handled:

Black Liquor slurry

Composition (%):

Black Liquor

100

Slurry Design data

Capacity (kg)

22230


21.773

Operating temperature (K)

333

Residence time (h)

1

Operating pressure (psi)

14.7

Mixer Tank Specification

Type

Flat-bottom cylindrical vessel

Material of construction

Stainless steel 316

Diameter(m)

2.90

Height (m)

3.87


2.12

Thickness of roof (cm)

2.12

Impeller Design

Type

Flow turbine with 4 blades

Diameter (m)

1.16

Agitator space from based (m)

0.55

Blade width (m)

0.15

Impeller speed (rpm) Power (kWh) Controls:

60 0.81

V-101 for precipitation black liquor slurry

50


5.1.3

Acidification Tank (V-102) MIXER TANK

Identification:

Item

Mixer Tank

Item no.

V-102 (A)

No. required

1

Function:

Acidification process of black liquor slurry

Operation:

Discrete

Material handled:

Black Liquor slurry

Composition (%):

Black Liquor

100

Slurry Design data

Capacity (kg)

20540


21.58


333

Residence time (h)

0.5


14.7


Type



Stainless steel 316

Diameter(m)

2.30

Height (m)

3.06


2.06


2.06

Impeller Design

Type


Diameter (m)

0.92


0.43

Blade width (m)

0.12

Impeller speed (rpm) Power (kWh) Controls:

60 0.23

V-102 for precipitation black liquor slurry

51


MIXER TANK

Identification:

Item

Mixer Tank

Item no.

V-102 (B)

No. required

1

Function:

Acidification process of black liquor slurry

Operation:

Discrete

Material handled:

Black Liquor slurry

Composition (%):

Black Liquor

100

Slurry Design data

Capacity (kg)

13690


14.38


333

Residence time (h)

0.5


14.7


Type



Stainless steel 316

Diameter(m)

2.01

Height (m)

2.68


2.02


2.02

Impeller Design

Type


Diameter (m)

0.80

Agitator space from based (m) Blade width (m) Impeller speed (rpm) Power (kWh) Controls:

0.38 0.10 60 0.12

V-102 for precipitation black liquor slurry 52


5.1.4

Blending Tank (V-103)

MIXER TANK Identification:

Item

Mixer Tank

Item no.

V-103

No. required

1

Function:

To make lignin slurry

Operation:

Discrete

Material handled:

Lignin slurry

Composition (%):

100

Lignin Slurry Design data

Capacity (kg)

150075


6.89


333

Residence time (h)

0.167


13.24


Type



Plate steels SA-283 grade C

Diameter(m)

4.53

Height (m)

6.04


0.70


0.70

Impeller Design

Type

Controls:


Diameter (m)

1.81


0.86

Blade width (m)

0.23

Impeller speed (rpm)

60

Power (kWh)

8.8 V-103 for make lignin slurry 53


5.1.5

Lignin Slurry Storage (S-102)

STORAGE TANK

Identification:

Item

Lignin Slurry Storage Tank

Item no.

S-102

No. required

1

Function:

Storage lignin slurry before enter to bubble column reactor

Operation:

Discrete

Material handled:

Black Liquor

Composition (%):

Lignin Slurry

100

Design data

Capacity (kg)

11670


6.43


333


14.70




Controls:

Stainless steel 316

Diameter (m)

1.93

Height (m)

2.58


2.10


2.10

S-102 for controlling lignin slurry

54


5.1.6

Waste Storage (S-103)

STORAGE TANK

Identification:

Item

Waste Storage Tank

Item no.

S-103

No. required

2

Function:

Waste storage from the process

Operation:

Discrete

Material handled:

Waste from process

Composition (%):

Waste

100

Design data

Capacity (kg)

597670

Feed quantity (m /h) Operating temperature (K) Operating pressure (psi)

13.11 333 14.70




Controls:

Carbon steel

Diameter (m)

7.07

Height (m)

9.43


3.63


3.63

S-103 for controlling waste from process

55


5.1.7

H2SO4 Storage (S-104)

STORAGE TANK

Identification:

Item

H2SO4 Storage Tank

Item no.

S-104

No. required

1

Function:

Storage H2SO4 to keep it before enter to process

Operation:

Discrete

Material handled:

H2SO4

Composition (%):

H2SO4

100

Design data

Capacity (kg)

47273.63

Feed quantity (m /h) Operating temperature (K) Operating pressure (psi)

25.69 333 14.70




Controls:

Stainless steel 316

Diameter (m)

3.07

Height (m)

4.09


2.40


2.40

S-103 for controlling H 2SO4 from process

56


5.1.8

NaOH Storage (S-105) STORAGE TANK

Identification:

Item

NaOH Storage Tank

Item no.

S-105

No. required

1

Function:

Storage NaOH to keep it before enter to process

Operation:

Discrete

Material handled: NaOH Composition (%):

NaOH

100

Design data

Capacity (kg)

360180


169.10

Operating temperature (K) Operating pressure (psi)

333 14.70




Controls:

Stainless steel 316

Diameter (m)

5.75

Height (m)

7.67


2.70


2.70

S-105 for controlling NaOH

57


5.2 Filtration 5.2.1

Plate and Frame Filter (PF-101) Lignin Alkali Press Filter

Identification:

Item

Lignin Press Filter

Item no.

PF-101

No. required

4

Function:

To get lignin alkali solid and lean liquor solid, separate it from lean liquor, liquid acid, and water.

Operation:

batch

Material handled:

Lignin slurry

Design data:


303

Operating pressure (Pa)

7 x 10

Type

Vertical Plate Airblow (VPA)


Stainless steel 316

Effective filtration Area (m2)

345

Filtration area with safety factor 20% (m2)

414

Filter chamber size (m)

2.03 x 2.03

Number of chambers

50

L (m)

15.6

W (m)

4.25

H (m)

4.58

Weight empty (ton)

80

Total press filter required (item)

4

Total plates required

200

58


5.2.2

Plate and Frame Filter (PF-102)

Lignin Press Filter Identification:

Item

Lignin Press Filter

Item no.

PF-102

No. required

1

Function:

To get solid lignin and separate it from alkali suphate, liquid acid, and water.

Operation:

batch

Material handled:

Lignin slurry

Design data:


303

Operating pressure (Pa)

7 x 10

Type

Vertical Plate Airblow (VPA)


Stainless steel 316

Effective filtration Area (m2)

40.06

Filtration area with safety factor 20% (m2)

48.08

Filter chamber size (m)

1.5 x 1.5

Number of chambers

24

L (m)

8.5

W (m)

3.8

H (m)

3.16

Weight empty (ton)

27.5

Total press filter required (item)

1

Total plates required

21

59


5.3 Pump 5.3.1

Black Liquor Pump (P-101)

Function

: Pumping black liquor to acidification tank I

Type

: Centrifugal pump

Number of Unit

: 1 unit

No.

Specification

1

Scope

Double end-Vertical screw pump

2

Service condition

Continuous process

3

Operating condition

4



Capacity (ton/h)

66.77



Suction pressure (Pa)

100,000



Power (kWh)

0.32

Liquid Properties 

Liquid to be handled

Black liqour



Viscosity (cp)

5.091



5

5.3.2

Temperature of liquid at inlet 60 (°C)

Material

Stainles steel

Black Liquor Acidification pump (P-102)

Function

: Pumping black liquor slurry from acidification tank to press

filter I Type

: Centrifugal pump

Number of Unit

: 2 unit

No.

Specification

1

Scope

Centrifugal pump

2

Service condition

Continuous process

3

Operating condition

60


4



Capacity (ton/h)

33.38




105,000



Power (kWh)

2.36



Black liqour



Viscosity (cp)

1.70



5

5.3.3


Material

Stainles steel

Lignin Acidification Pump (P-103)

Function

: Pumping sludge from acidification tank to filter press II

Type

: Piston pump

Number of Unit

: 1 unit

No.

Specification

1

Scope

Screw pump

2

Service condition

Batch process

3

Operating condition

4



Capacity (ton/h)

61.68




105,000



Power (kWh)

2.56



Black liqour



Viscosity (cp)

1.3169



Temperature of liquid at inlet 60

61


(°C) 5

5.3.4

Material

Stainles steel

Lignin Solution Pump (P-104)

Function

: Pumping lignin slurry (lignin+water) from mixing tank to

storage Type

: Screw Pump

Number of Unit

: 1 unit

No.

Specification

1

Scope

Screw pump

2

Service condition

Batch process

3

Operating condition

4



Capacity (ton/h)

35.15




105,000



Power (kWh)

0.07



Lignin Solution



Viscosity (cp)

2.0801



5


Material

Stainles steel

62


5.3.5

Lignin Solution Pump (P-105)

Function

: Pumping lignin slurry (lignin+water) from storage to BCR

Type

: Screw Pump

Number of Unit

: 1 unit

No.

Specification

1

Scope

Screw pump

2

Service condition

Batch process

3

Operating condition

4



Capacity (ton/h)

49.21




105,000



Power (kWh)

0.12



Lignin Solution



Viscosity (cp)

2.0801



5

5.3.6


Material

Stainles steel

Vanillin Slurry Pump (P-106)

Function

: Pumping Vanilin solution from BCR to Ultrafikasi

Type

: Screw pump

Number of Unit

: 1 unit

No.

Specification

1

Scope

Screw pump

2

Service condition

Continous process

3

Operating condition 

Capacity (ton/h)

4.87

63


4




200,000



Power (kWh)

0.32



Vanillin Solution



Viscosity (cp)

5.13



5

5.3.7


Material

Stainles steel

Vanillin Solution Pump (P-107)

Function

: Pumping Vanillin Solution to Spray Dryer

Type

: Screw pump

Number of Unit

: 1 unit

No.

Specification

1

Scope

Screw pump

2

Service condition

Continous process

3

Operating condition

4



Capacity (ton/h)

0.85




105,000



Power (kWh)

0.03



Vanillin Slurry



Viscosity (cp)

1.65



5


Material

Stainles steel

64


5.3.8

Water Pump (P-109)

Function

: Pumping water from the reservoir to filtration Plate and Press

I Type

: Piston Pump

Number of Unit

: 2 unit

No.

Specification

1

Scope

Piston Pump

2

Service condition

Batch process

3

Operating condition

4



Capacity (ton/h)

3.34




105,000



Power (kWh)

0.26



Water



Viscosity (cp)

1.65



5


Material

Carbon steel

65


5.4 Conveyor

Conveyor I and II

Function

:To transfer filtrate from filtrasi to acidification II.

Type

: horizontal belt conveyor

Material

: Stainless steel

Operating Condition

: - Temperature (T) = 30 0 C - Pressure (P) = 1 atm Conveyor I and II

Rate of material Looseness factor Conveyor Capacity

6.67 ton/10 min 52.23 ton/h 54 ton/h

40.18 ton/h

Spesifikasi

Width of Belt Area Normal Belt Speed Maximum Belt Speed Power

Number of Conveyor

18.00 0.02 76.00 107.00 2.50

inch m2 m/min m/min hp

0.46 m 1.27 1.78 1.86 7.44 2,232.00

m/s m/s kW kWh/day kWh/year

2 pieces

66


Conveyor III

Function

: Transfer of Cake of Filtration to mixer tank.

Type

: horizontal conveyor belt

Material

: Stainless steel

Operating conditions : Temperature (T) = 300C Pressure (P) = 1 atm

5.5 Bubble Column Reactor

Equipment Code Operation Mode

CS-101 Batch

Operation o Temperature 170 C Pressure 10 Bar Volume 25.52 m3 Retention Time 2 hours Dimension Height 4.48 M Diameter 2.69 M Thickness 6,44 mM Multiple Ring Sparger Diameter 3 mM Number of Holes 15 Material Stainless Steel 316

67


5.6 Ultrafiltration Vanillin Solution Ultrafilter Identification:

Function:

Item

Vanillin solution ultrafilter

Item no.

UF-101

No. required

6

Separate vanillin solution from lignin alkali solution after oxidation

Operation:

Continuous

Material handled:

Lignin alkali and other by product

Design data:

Operating temperature ( oK)

353

Operating pressure (Psi)

30

Type

Hollow fiber membrane Polyvinylidenefluoride


PVDF (for filter membrane)

Effective filtration Area



(m2) Filtration area with safety factor (m2) Available filter area (m2) Number of fiber in each module

 130 10000

L (m)

2.36

W (m)

0.34

D (m)

0.23

Membrane cut-off rating (kDa)

1

Total equipment required (item)

6

68


5.7 Spray Dryer SPRAY DRYER

Identification:

Item

Spray Dryer

Item no.

SD-101

No. required

2 (1 active, 1 stand by)

Function:

Make vanillin powder from vanillin solution

Operation:

Batch

Material handled:

Vanillin Solution

Composition (%):

Vanillin solution

100

Design Data:

Type

Closed spray dryer


Stainless steel

Atomizer

Centrifugal Disc (Vane)

Volume (m3)

5.52

Height cylindrical (m)

1.47

Column Diameter (m)

2.45

Thickness (m)

0.0025

Volume Cone (m3)

4.05

Cone Angle ( o)

20.57

Max Temp Operating ( oC)

180

Max Press Operating (psi)

600

Power (hp)

116

69


5.8 Heat Exchanger 5.8.1 Heat Exchanger HE-101

Tipe

Shell and Tube

Jenis

Countercurrent Floating Head

Heat transfer area, m 2

273.50

Heat transfer coefficient, W/m 2 0C

900

Agen pemanas

Superheated steam 190 oC

Laju alir pemanas, kg/hari

32000

Jumlah tube

218 Shell Side

Tube Side

Material

SS 304

SS304

Densitas, kg/m3

0.521

1060

Cp,

2.09

2.08

Temperature in, 0C

190

60

Temperature out, 0C

190

170

5.8.2 Heat Exchanger HE-102

Tipe

Shell and Tube

Jenis

Countercurrent Floating Head

Heat transfer area, m 2

202

Heat transfer coefficient, W/m 2 0C

900

Agen pemanas

Superheated steam 190 oC

Laju alir pemanas, kg/hari

32000

Jumlah tube

161 Shell Side

Tube Side

Material

SS 304

SS304

Densitas, kg/m3

0.521

1.02

Cp,

2.09

1.00

Temperature in, 0C

190

25

Temperature out, 0C

190

120

70


CHAPTER 6 PROCESS CONTROL 6.1

Process Control Instrumentation

Process control system is absolutely necessary in a factory to control all the variables such as temperature, pressure, level, and more so the process runs. Some process control objective to be achieved are as follows: a) Avoiding dangerous circumstances that may occur in the operation (safety) b) Maintaining the quality of the resulting product c) Keeping the equipment is working in a range of operating conditions d) Keeping operations and various byproducts produced run in accordance with environmental standards e) Monitor and diagnose the operation F) Keeping operations running optimally so keep the plant gains At this plant a variety of variables controlled by using a variety of instruments that are available at the P & ID. Here is an explanation of the control system in the main equipment. 6.2

Process Control on Raw Material Storage Tank

Black liquor storage tank is connected to the acidification vessel. Yield products from this vessel will greatly depend on the composition of the input to the output reactor or storage tank. Flow rate control system of storage tanks needed for the flow rate from the storage tank maintained. The control system used to control the flow rate is bypass control system. The process of controlling the flow rate of the tank using orifice meter as a sensor to measure the flow rate output before entering the control valve. Flow rate measurements made of the difference in pressure at P1 and P2. The output of the orifice meter is then analyzed by the controller based on set point. Then the controller controls the flow rate of the control valve (open when the flow rate is too small and close when the flow rate is too large) to adjust the flow rate to set point.

71


6.3

Process Control on Heat Exchanger

Process control in the heat exchanger also has a similar system of controls for each heat exchanger. Controlled variable is the temperature of the main product output heat exchanger. The parameters are controlled steam flow rate or cooling water into the heat exchanger. Temperature is one of the important variables to be controlled. Heat exchangers are the main components that require temperature control. Heat exchanger serves to exchange heat between the main product with steam / cooling water. Controlling the temperature of the product is required to be maintained in accordance with the main design. The control system used for temperature control are feed back control system. Process control using a thermocouple as a temperature sensor on the output of main products in heat exchangers. The output of the thermocouple is then analyzed by the controller based on set point. Then the controller controls the flow rate of the flow control valve on the pipe steam / cooling water before it enters the heat exchanger. Control valve controlling the flow rate of steam / cooling water to adjust the flow rate of steam / cooling water with a temperature set point to achieve the appropriate design. 6.4

Process Control on Reboiler

Process control more towards the boiler temperature control in steam output. Boiler using diesel fuel to vaporize water into steam. Controlled variable is the temperature of the steam output of the boiler. The parameters were controlled flow rate of diesel fuel and water into the boiler. And also controlling the pressure in boiler so it can result the high steam pressure needed. 6.5

Process Control on Black Liquor Treatment Vessel

Process control in black liquor treatment vessel is a control process that involves more than one variable that needs to be controlled. Variables that are controlled from the oxidation reactor is the flow rate, height, composition, and pressure. 

Height The height is a variable that must be maintained during the lignin separation from black liquor. The height of the fluid is maintained in order

72


not higher than the feed inlet and not too low. Sensors are deployed using a floating sensor surface fluid in the vessel. The parameters are controlled liquid flow rate at the outlet. 

Pressure The pressure in the black liquor treatment vessel is kept equal to or slightly above atmospheric pressure. Excessive pressure can affect the quality of the product and can also be dangerous when the reactor exploded due to excess pressure. To prevent excess pressure of the reactor is equipped with a relief valve to release the pressure in the reactor. Controlled variable is the pressure inside the reactor. When the pressure exceeds the set point, then the relief valve on the reactor will open thereby releasing the pressure in the vessel.



Composition The composition is a variable that can affect the production yield of the reactor. The process of composition control over the direction of the control fluid homogeneity in the vessel. Controlled variable is the composition of the sample in the vessel. The parameters are speed controlled agitator. Sensor compositions using gas liquid chromatography (GLC). When the results of the GLC analysis are deviations from the set point, the parameters changed by the addition of agitation speed of stirring.

6.6

Process Control on Acidification Vessel and Lignin Solution Vessel

Process control in acidification and liginin solution vessel is a control process that involves more than one variable that needs to be controlled. Variables that are controlled from the oxidation reactor is the flow rate, height, composition, and pressure. 

Height The height is a variable that must be maintained during the lignin separation from black liquor. The height of the fluid is maintained in order not higher than the feed inlet and not too low. Sensors are deployed using a floating sensor surface fluid in the vessel. The parameters are controlled liquid flow rate at the outlet. 73




Pressure The pressure in the acidification vessel is kept equal to or slightly above atmospheric pressure. Excessive pressure can affect the quality of the product and can also be dangerous when the vessel exploded due to excess pressure. To prevent excess pressure of the vessel is equipped with a relief valve to release the pressure in the vessel. Controlled variable is the pressure inside the reactor. When the pressure exceeds the set point, then the relief valve on the reactor will open thereby releasing the pressure in the vessel.



Composition The composition is a variable that can affect the production yield of the reactor. The process of composition control over the direction of the control fluid homogeneity in the reactor. Controlled variable is the composition of the sample in the reactor. The parameters are speed controlled agitator. Sensor compositions using gas liquid chromatography (GLC). When the results of the GLC analysis are deviations from the set point, the parameters changed by the addition of agitation speed of stirring.

6.7

Process Control on Oxidation Reactor

Process control in the manufacture of vanillin making oxidation reactor is a control process that involves more than one variable that needs to be controlled. Variables that are controlled from the oxidation reactor is the input flow rate, height, composition, pressure and temperature. 

Flow rate The flow rate input is an important variable to be controlled in a reactor. The flow rate input into the reactor can affect the composition in the reactor that will also affect the yield of the reactor. In addition flow rate can also affect the height of the liquid in the reactor. Sensors are used to measure the flow rate is orificemeter. Flow rate is then controlled by the controller input based on set point. Control the flow rate by the flow control valve (FCV).

74




Height The height is one important variable but often forgotten in BCR tank. Sensor height is needed in order to know whether the height of the fluid is sufficiently safe for the agitator to operate. The parameters that are controlled from the control height is input flow rate into the reactor. Height sensors are used to using sensors floating in the fluid surface. The height of the fluid in the reactor is controlled by the controller based on set point. Control the flow rate by the flow control valve (FCV) on the same input stream as the flow rate control input.



Composition The composition is a variable that can affect the production yield of the reactor. The process of composition control over the direction of the control fluid homogeneity in the reactor. Controlled variable is the composition of the sample in the reactor. The parameter control is speed of gas O2 through component in BCR. Sensor compositions using gas-liquid chromatography (GLC). When the results of the GLC analysis are deviations from the set point, the parameters changed by the addition of flow rate O2 from gas sparger to BCR.



Pressure Pressure is an important variable in the reactor. The pressure in the reactor was kept at pressure of 10 bar above atmospheric pressure, but do not be too excessive. It is intended that the oxidation of lignin into vanillin could happen. Pressure changes can occur due to the continuous input reactor and the reaction in the reactor. Excessive pressure can affect the quality of the product and can also be dangerous when the reactor exploded because excess pressure. To prevent excess pressure of the reactor is equipped with a relief valve to release the pressure in the reactor. Controlled variable is the pressure inside the reactor. When the pressure exceeds the set point, then the relief valve on the reactor will open thereby releasing the pressure in the reactor.

75




Temperature Temperature is the most variable can change in the reactor. The process of oxidation reaction produces heat which can change the temperature in the reactor. The reaction in the reactor must be on guard at 170° C for the reaction to occur and produce vanillin. To keep the temperature inside the reactor is used jackets. The temperature sensor used is a thermocouple. Controlled variable is the temperature in the reactor.

6.8

Process Control on Spray Dryer

Process control in the spray drayer is a control process that involves more than one variable that needs to be controlled. Variables that are controlled from the spray dryer is the input flow rate, composition, and pressure. 

Flow rate The flow rate input is an important variable to be controlled in a spray dryer. The flow rate input can affect timing and composition amount. Sensors are used to measure the flow rate is orificemeter. Flow rate is then controlled by the controller input based on set point. Control the flow rate by the flow control valve (FCV).



Composition The composition is a variable that can affect the vanillin powder production of spray dryer. The process of composition control is over the direction of the contain of vanillin. Controlled variable is the composition of the sample in the spray dryer. The parameters controlled is rate of evaporation. Sensor compositions using gas-solid chromatography (GSC). When the results of the GSC analysis are deviations from the set point, the parameters changed by the addition of rate of hot air into spray dryer.



Pressure Pressure is an important variable in the reactor. The pressure in spray dryer was kept at atmospheric pressure or above atmospheric pressure, but do not be too excessive. Pressure changes can occur due to the continuous input to spray dryer. Excessive pressure can affect the quality of the product and can also be dangerous when the spray dryer exploded because excess pressure. To prevent excess pressure of the spray dryerr is equipped 76


with a relief valve to release the pressure in the reactor. Controlled variable is the pressure inside. When the pressure exceeds the set point, then the relief valve will open thereby releasing the pressure in the spray dryer.

77

Preliminary Design of Vanil lin Production Plant Fr om Black Liquor

S-101 BL Storage

P-102 BL Pump

V-101 BL Solid Treatment Vessel

F-101 CO2 Fan

P-103 Slurry Pump

PF-101 Plate & Frame Filter

P-105 Water Pump

FIC 106

FT 106

Water P-108

Lean Liquor

FT 101

LT 101

FIC 101

AC 101 FIC 102

PT 101

AT 101

PIC 101

V-19 LT 102

FT 102

Black Liquor

FT 104

FIC 104

P-101

P-14

S-101 P-102

V-101

P-103

PF-101

To V-102

FT 103

FIC 103

CO2

VANILLIN PLANT FROM LIGNIN PIPING AND INSTRUMENTATION DIAGRAM Drawn By :

Group 6

Checked By

Date : Date :

Revised By :

W it ho ut S ca le

Drawing No :

Notes :

Figure 6.1 Piping and Instrumentation Diagram - 1

78


V-102 Acidification Vessel

P-105 H2SO4 Pump

P-106 H2SO4 Pump

P-107 Lignin Slurry Pump

FT 107


P-108 Water Pump

V-103 Lignin Solution Vessel

P-109 Lignin Solution Pump

FIC 107

Water P-106

Alkali sulfat

PT 102

AC 102 AT 102

PIC 102

V-23

From PF-101

LT 103

FT 105

FIC 105

TO V-104 P-4 V-5

V-102 FT 105

P-107 PT 103

AC 103

PF-102

FIC 105

PIC 103

FC 109

AT 103 V-22 LT 104

H2SO4

FT 109

P-109

P-104

V-103

FT 108

FIC 108

NaoH VANILLIN PLANT FROM LIGNIN PIPING AND INSTRUMENTATION DIAGRAM

P-111 Drawn By :

Group 6

Checked By Drawing No :

Date : Date :

Revised By :

W it ho ut S ca le

A4

Notes :


79

A4


V-102 Acidification Vessel

P-105 H2SO4 Pump

P-106 H2SO4 Pump

P-107 Lignin Slurry Pump

FT 107


P-108 Water Pump

V-103 Lignin Solution Vessel

P-109 Lignin Solution Pump

FIC 107

Water P-106

Alkali sulfat

PT 102

AC 102 AT 102

PIC 102

V-23

From PF-101

LT 103

FT 105

FIC 105

TO V-104 P-4 V-5

P-107

V-102 FT 105

PT 103

AC 103

PF-102

FIC 105

PIC 103

FC 109

AT 103 V-22 LT 104

H2SO4

FT 109

P-109

P-104

V-103

FT 108

FIC 108

NaoH VANILLIN PLANT FROM LIGNIN PIPING AND INSTRUMENTATION DIAGRAM

P-111 Drawn By :

Group 6

Date :

Checked By

Date :

Revised By :

W it ho ut S ca le

A4

Notes :

Drawing No :


79


H-101 Heat Exchanger

C-101 O2 and N2 Compressor

CS-101 Oxidation Reactor

F-102 Air Blower


P-112 Water Pump

B-101 Steam Reboiler


FT 110a

FIC 110a

N2 PT 104

AC 104

PIC 104

FT 110

LT 106

FIC 110

PIC 106

PT 106

AC 104

AT 104

P-30

AT 104

LT 105

TT 101

P-33

From P-109

H-101

P-105 V-104 FT 110

FIC 110

To UF-101 TIC 101

H-102 P-106

FIC 104

O2 & N2

CS-101

FT 114

Steam FT 114

TIC 103

FIC 114

To SD-101 Air H-103

F-102 TIC 102

PIC 105 FT 115

PT 105

TT 103

TT 102

FIC 115

VANILLIN PLANT FROM LIGNIN PIPING AND INSTRUMENTATION DIAGRAM

O2 & N2 B-101

Drawn By :

Group 6

Checked By

P-112

Drawing No :

Date : Date :

Revised By :

W it ho ut S ca le Notes :


80

A4



C-101 O2 and N2 Compressor

CS-101 Oxidation Reactor

F-102 Air Blower


P-112 Water Pump

B-101 Steam Reboiler


FT 110a

FIC 110a

N2 PT 104

AC 104

PIC 104

FT 110

LT 106

FIC 110

PIC 106

PT 106

AC 104

AT 104

P-30

AT 104

LT 105

TT 101

P-33

From P-109

H-101

P-105 V-104 FT 110

FIC 110

To UF-101 TIC 101

H-102 P-106

FIC 104

O2 & N2

CS-101

FT 114

Steam FT 114

TIC 103

FIC 114

To SD-101 Air H-103

F-102 TIC 102

PIC 105 FT 115

PT 105

TT 103

TT 102

FIC 115

VANILLIN PLANT FROM LIGNIN PIPING AND INSTRUMENTATION DIAGRAM

O2 & N2 B-101

Drawn By :

Group 6

Checked By

P-112

Date : Date :

Revised By :

W it ho ut S ca le

A4

Notes :

Drawing No :


80


UF-101 Membrane Ultrafiltration

P-111 Filtrate Pump

SD-101 Spray Dryer

Others

FIC 111

PT 111

From H-102

FT 112

FIC 112

PT 107

P-111

PIC 107

TT 104 FIC 113

FT 113

AC 105

TIC 103

Air From H-103 AT 105

FT 114

FIC 114

Powder Vanillin


Group 6


Date : Date :

Revised By :



81

A4


UF-101 Membrane Ultrafiltration

P-111 Filtrate Pump

SD-101 Spray Dryer

Others

FIC 111

PT 111

From H-102

FT 112

FIC 112

PT 107

P-111

PIC 107

TT 104 FIC 113

FT 113

AC 105

TIC 103

Air From H-103 AT 105

FT 114

FIC 114

Powder Vanillin


Group 6


Date : Date :

Revised By :



81


CHAPTER 7 PLANT LAYOUT AND PIPING DESIGN

Vanillin plant is subsidiary of Riau Andalan Pulp & Paper. The location of our plant is beside RAPP, in Langgam, Pelalawan Regency, Riau. Our Plant Must near with RAPP because black liquor as vanillin plant raw material sourced from RAPP byproduct. RAPP total land area in langgam is 10,100 Ha with the following boundaries area. North : PT Mitra Unggul Pusaka (rubber) East

: PT Mitra Unggul Pusaka (rubber)

South : PT Siak Raya Timber West

: Rubber plantations

A4


CHAPTER 7 PLANT LAYOUT AND PIPING DESIGN

Vanillin plant is subsidiary of Riau Andalan Pulp & Paper. The location of our plant is beside RAPP, in Langgam, Pelalawan Regency, Riau. Our Plant Must near with RAPP because black liquor as vanillin plant raw material sourced from RAPP byproduct. RAPP total land area in langgam is 10,100 Ha with the following boundaries area. North : PT Mitra Unggul Pusaka (rubber) East

: PT Mitra Unggul Pusaka (rubber)

South : PT Siak Raya Timber West

: Rubber plantations

Vanillin Plant


Figure 7.1. Location of vanillin plant building

82


Our vanillin plant is divided into several areas. The first area is the main area of the factory, which is the production area adjacent to a black liqour storage tank. Additionally, there are utility area at the back of the factory. For the purposes of administration and personnel, there is a 3-storey office and other facilities such as clinics, mosque, cafeteria, and athletic fields. For the power source, there is an electric generator room adjacent to the living room maintanance tools and fire safety. Vanillin plant construction is based on safety considerations, ease of distribution of raw materials, utilities, land availability, ease of marketing and transportation of goods. Vanillin plant layout and process equipment layout can be seen in the following figure.

83


155 m wastewater Storage

65 m

Black Liquor Storage

CHEMICALENGINEERING DEPARTMENT ENGINEERING FACULTY UNIVERSITASINDONESIA

INFORMATION Room or Area: - Black Liquor storage tank - Raw material storage - Control Room - Production Process Area - laboratorium - Utility Area - Security Post - Meeting point - Fire Safety - Maintenance Room - Electric Generator Room - Vehicle Parking Area - Main Office

Process Production Area m 0 7

Raw Material Storage

Security post

Laboratorium

Control Room

Product Storage

OWNER PROJECT GROUP 6 PLANT DESIGN 2012

Truck Parking Area

1 2 5 m

Truck Parking Area

SKALA 1:5 Fire Station

Main Road

Main Road

Pedistrian road

Pedistrian road

P e d i s t r i a n r o a d

Meeting Point

Pedistrian road

clinic

Mosque

Project

MASTER PLANT OF VANILLIN PLANT

PICTURE

50 m Parking Area

Utility room

DESIGN LAYOUT OF VANILLIN PLANT

Electric generator room

Main Office

PICTURE NO:

Sport Field

m 0 3

NO. Page

1

Maintenance room

canteen

PL 001/2012

Total Page

1

Figure 7.2. Design Layout of Vanillin Plant

84


160 m 65 m

CHEMICAL ENGINEERING DEPARTMENT ENGINEERING FACULTY UNIVERSITAS INDONESIA

8.7 m

2.9 m

2.36 m

7.16 m

2.5 m

INFORMATION 2.83 m

1.5 m

2m

4m 15 m 1.35 m

2.34 m

m 0 7

2.5 m 8m m 6 . 5 1

1m 1.86 m

Utility room

30 m

15 m

8.5 m 4.25 m


125 m

15 m

m 5 1

Laboratorium

m 0 1

15 m

3.8 m

Control Room

m 0 1

15 m

Product Storage

m 0 1

Equipment: - Raw material storage tank - Acidification Vessel 1 - Plate & Frame Filtration - Belt Conveyor - Elevator - Acidification Vessel 2 - Solution lignin Vessel - Heat Exchanger - Ultrafiltration - Spray Drying - Wastewater tank - Air tank - Compressor

m 5 1


15 m

SKALA 1:5 Project


PICTURE DESIGN LAYOUT OF VANILLIN PLANT EQUIPMENT PROCESS

PICTURE NO: NO. Page

PL 002/2012 Black Liquor Storage

Acidification vessel 1

Plate & Frame filtration

Elevator, acidification vessel 2, plate&frame filtration

Vessel, storage, Heat exchanger, reactor, ultrafiltation, spray drying

Total Page

1

1

wastewater Storage

Figure 7.3. Design Layout of Vanillin Plant Equipment Process

85


160 m 65 m

CHEMICAL ENGINEERING DEPARTMENT ENGINEERING FACULTY UNIVERSITAS INDONESIA

8.7 m

2.9 m

2.36 m

7.16 m

2.5 m

INFORMATION 2.83 m

1.5 m

2m

4m 15 m 1.35 m

2.34 m

m 0 7

2.5 m 8m m 6 . 5 1

1m 1.86 m

Utility room

30 m

15 m

8.5 m 4.25 m


125 m

15 m

m 5 1

Laboratorium

m 0 1

15 m

3.8 m

Control Room

m 0 1

15 m

Product Storage

m 0 1

Equipment: - Raw material storage tank - Acidification Vessel 1 - Plate & Frame Filtration - Belt Conveyor - Elevator - Acidification Vessel 2 - Solution lignin Vessel - Heat Exchanger - Ultrafiltration - Spray Drying - Wastewater tank - Air tank - Compressor

m 5 1


15 m

SKALA 1:5 Project


PICTURE DESIGN LAYOUT OF VANILLIN PLANT EQUIPMENT PROCESS

PICTURE NO: NO. Page

PL 002/2012 Black Liquor Storage

Acidification vessel 1

Plate & Frame filtration

Elevator, acidification vessel 2, plate&frame filtration

Vessel, storage, Heat exchanger, reactor, ultrafiltation, spray drying

Total Page

1

1

wastewater Storage

Figure 7.3. Design Layout of Vanillin Plant Equipment Process

85

Preli minary Design of V anill in Production Plant Fr om Black L iquor

CHAPTER 8 HEALTH, SAFETY, AND ENVIRONMENT MANAGEMENT

Health, Safety, and Environment Program (HSE) is a standard for industries in Indonesia in order to protect workers' rights. Safety and good health can improve safety and morale for employees or labor in general. A sense of safety and employee morale which is great significance for the improvement of labor productivity is the key to the success of a company or factory. In order to implement the good HSE program, in the factory applied some policies regarding work place safety and health. The purpose of the HSE policy implementation include : 1. Set a target of increasing annual health and safety and make sure everything is fulfilled by conducting regular audits 2. Prevent personal injury and health risks for all people who are in the factory 3. Develop, design, build, set up, operate and maintain the process, plant,


CHAPTER 8 HEALTH, SAFETY, AND ENVIRONMENT MANAGEMENT

Health, Safety, and Environment Program (HSE) is a standard for industries in Indonesia in order to protect workers' rights. Safety and good health can improve safety and morale for employees or labor in general. A sense of safety and employee morale which is great significance for the improvement of labor productivity is the key to the success of a company or factory. In order to implement the good HSE program, in the factory applied some policies regarding work place safety and health. The purpose of the HSE policy implementation include : 1. Set a target of increasing annual health and safety and make sure everything is fulfilled by conducting regular audits 2. Prevent personal injury and health risks for all people who are in the factory 3. Develop, design, build, set up, operate and maintain the process, plant, equipment, including disposal in accordance with company guidelines and regulations on occupational safety and health, and document process control methods are classified as hazardous 4. Provide and maintain a safe system of work and prepare all necessary plans to tackle any kind of disturbance or damage 5. Ensure that all employees at the location of the company to realize responsibility for occupational safety and health 6. Ensures staff provide guidance on occupational safety, health and environmental issues receive adequate training 7. Involve all employees in the implementation of policies and procedures using advice and training to facilitate the emergence of a sense of involvement and responsibility 8. Ensuring and summarizes all the experience of occupational safety and health hazards that are relevant and disseminate the conclusions for the business as a whole 9. Reviewing periodically and health policy in line with central policy

86


8. 1

Health Aspects

Health factor is one of the main supporters milling operations. With good health in the factory, all the factors supporting plant performance, especially the employees will be more productive at work. To prevent disruption of the environmental health aspects of plant it is necessary to consider what are the factors that could potentially endanger the health aspects in plant environments. Danger to the health aspects can be avoided by analyzing the potential hazards affecting the environmental health aspects of the plant. 8. 2

Safety Aspects

Safety is a very important factor in a factory. Analysis of the factors of potential harm occurred in this plant needs to be done so that we get the data and considerations necessary for handling. Hazard Analysis is an analysis of the composition of the dangers of a place that has the potential dangers. 

Identify Adverse events leading to a hazard material



Mechanism analysis of opportunities possible unexpected events



The estimated magnitude of the dangers that may arise. Hazard analysis can be divided into two, namely: 1. HIRA (Hazard Identification and Risk Assessment) 2. HAZOP (Hazard and Operability Study)

8.2.1

Hazard Identification and Risk Assessment (HIRA)

HIRA is the identification of risks to an activity. Hazard Identification and Risk Assessment (Hazard Identification and Risk Assessment), analysis carried out in daily activities and in the factory. In determining HIRA, there are several steps that must be done. The stages are as follows: 

Sorting activities to be carried out into smaller sub-activities and specific



Identify potential hazards for each sub-activity



Determination of the risks that might occur (hazard effects and the possibilities)



Determining how to prevent and control the risk of harm



Conclusion potential hazards and risks involved for each activity



Conclusion to overall job



Risk = Hazard x Exchange Rate Possible Dangers 87


o

Harmful effects are still composed of HIGH, MEDIUM and LOW

o

The possible dangers consist of HIGH, MEDIUM and LOW Table 8.1 Parameter in Counting Dangers Possibilities

PARAMETER

HIGH

MEDIUM

LOW

Frequency of harm

Each time the work was done

Once in 10-100

One time during the job done

Frequency of adverse danger

Almost every time the work is done

Once in 10-100

Once in 100 or more

Ability level executive jobs

Without experience, never done before work

Less experienced

Experienced, have good ability and often do the work

Table 8.2 Parameter in Counting Danger Effects PARAMETER

HIGH

MEDIUM

LOW

Human Resources

Death, disability, body dysfunction, severe injuries

Medium wounds, the body can still work

minor injuries

The damage causes decreased production levels

Little damage, does not affect the production of protection tool

Asset

Damage to the equipment, production halted

Protection Tool

No protective devices are in an environment with the presence of a flammable substance

Minimal protection device

Tools available with sufficient protection, installation of insulated

Evacuation time availability

Less than 1 minute

Between 1-30 minutes

More than 30 minutes

88

Prelimin ary Design of Vanil lin Production Plant Fr om Black Liquor

Table 8.5 Hazard Identification and Risk Assessment (HIRA) Types of Activities

Plant Building

Installation Tool

Danger Possible Rate Risks Rate Effects Pre-Operational Stage

Potential Danger

Dangers

Prevention and Management

Final Risks

Falling from Height

Permanent Injuries Death

M

Work on construction activities in accordance with SOP and using PPE safety belt

L

Objects falling from height

Moderate to severe injuries

M

Work on construction activities in accordance with SOP and using PPE safety helmet

L

Tripped up by construction equipment scattered

Mild to moderate injuries

M

M

Work on construction activities in accordance with SOP and using PPE safety shoes

M

L

Falling or pinched tool

Death and organ dysfunction

H

M

M

Using PPE and safety belt

L

Hit or tripped work equipment

Non permanent injuries

M

M

M

Checking the condition of the tool to be used to start a job

L

H

L

M

L

89


Electrical installation

Death, Electric shock permanent injury

H

L

M

Using rubber boots, gloves and other tools that are insulators

L

Fall at the Death and time of organ installation of dysfunction the high

H

M

M


L

M

Wearing PPE such as gloves and masks when filling the tank of raw materials

L

L

L

Plant Operation Stage

Exposure to chemicals Charging of raw materials in tanks

The operation of the process

Irritation and minor injuries

L

H

Permanent Slip away due injuries and to chemicals death

H

L

M


Permanent Electric shock injuries and at the pump death

H

L

M

Perform regular checks and maintenance of the pump according to SOP

90


Electrical installation

Death, Electric shock permanent injury

H

L

M

Using rubber boots, gloves and other tools that are insulators

L

Fall at the Death and time of organ installation of dysfunction the high

H

M

M


L

M


L

L

L

Plant Operation Stage

Exposure to chemicals Charging of raw materials in tanks

The operation of the process


L

H

Permanent Slip away due injuries and to chemicals death

H

L

M


Permanent Electric shock injuries and at the pump death

H

L

M

Perform regular checks and maintenance of the pump according to SOP

90


Exposure to heat flow and heat exchange equipment boiler

Injuries caused by the heat of the skin

M

M

M

Workers doing the work in accordance with SOP

L

L

Irritation Exposure to and injury chemicals in a by heat on leaky pipe the skin.

M

L

M

Perform regular checks on the piping system and start planning a better pipeline

Bumped by pipelines & reactors

Non permanent minor injuries

M

L

M

Workers work carefully and in accordance with SOP

L

Exposure to chemicals directly


M

Carry out work in accordance with the SOP and training employees periodically

L

M

Implementation and maintenance work as per SOP tank periodically

L

Storage of raw materials / Contamination product in the end product storage

Decline in value and product quality

L

M

M

M

91


Exposure to heat flow and heat exchange equipment boiler

Injuries caused by the heat of the skin

M

M

M

Workers doing the work in accordance with SOP

L

L

Irritation Exposure to and injury chemicals in a by heat on leaky pipe the skin.

M

L

M

Perform regular checks on the piping system and start planning a better pipeline

Bumped by pipelines & reactors

Non permanent minor injuries

M

L

M

Workers work carefully and in accordance with SOP

L

Exposure to chemicals directly


M

Carry out work in accordance with the SOP and training employees periodically

L

M

Implementation and maintenance work as per SOP tank periodically

L

Storage of raw materials / Contamination product in the end product storage

Decline in value and product quality

L

M

M

M

91


Factory Maintenance Stages

Maintenance Process

Stumble and fall

Non permanent injuries to permanent

M

M

M

Maintenance jobs done mentati applicable SOPs

L

Pinched or scratched appliance


M

M

M

Using PPE and safety belt Obey SOP jobs

L

Exposure to chemicals


L

M

M


L

M

Perform maintenance and replacement electrical equipment periodically and perform maintenance work on a regular basis

L

M

Perform maintenance work in accordance with the procedures and PPE safety belt

L

Electric shock Permanent on job-related injuries to electrical farm installation

Treatment Plant Facilities

Falling from a height

Permanent injuries to death

H

H

L

L

92


Factory Maintenance Stages

Maintenance Process

Stumble and fall


M

M

M


L

Pinched or scratched appliance


M

M

M

Using PPE and safety belt Obey SOP jobs

L

Exposure to chemicals


L

M

M


L

M


L

M

Perform maintenance work in accordance with the procedures and PPE safety belt

L

Electric shock Permanent on job-related injuries to electrical farm installation

Treatment Plant Facilities

Falling from a height


H

H

L

L

92


Electric shock


H

L

M


L

93


Electric shock


H

L

M


L

93


8.2.3 Hazard Operability Study (HAZOP) of Vanillin Plant Operation

Equipment

Unit

Code

Vessel

S-101 S-102 S-103 S-104 S-105 V-101 V-102 V-103

Parameter

Deviation

Causes

Effects

Prevention

Less

Blocking of raw material supplies and not suitable with the equipment capacity

Vessel doesn't work efficiently

Ensure that raw material capacity must suitable with equipment capacity

More

Raw material capacity more than machine capacity

Vessel will be damaged easily

Less

Power resources is low

More

Agitator velocity isn't appropriate

No

Blocking in pump

Flow rate

Agitator Velocity

Pump

P-101 P-102 P-103 P-104 P-105

Flow rate

Control

Flow control (FC) Installing controller such as valve at the input of reactor to adjust raw material capacity which entering the equipments

Reaction doesn't work Giving extra power such perfectly and as electrical power Flow too long control (FC) Making bubble Determine agitator in the agitating velocity value (rpm); process Controlling regularly Pump heat and damaged easily

Pump cleaning and controlling regularly

Flow control (FC)

94


8.2.3 Hazard Operability Study (HAZOP) of Vanillin Plant Operation

Equipment

Unit

Code

Vessel

S-101 S-102 S-103 S-104 S-105 V-101 V-102 V-103

Parameter

Deviation

Causes

Effects

Prevention

Less

Blocking of raw material supplies and not suitable with the equipment capacity

Vessel doesn't work efficiently


More


Vessel will be damaged easily

Less

Power resources is low

More

Agitator velocity isn't appropriate

No

Blocking in pump

Flow rate

Agitator Velocity

Pump

P-101 P-102 P-103 P-104 P-105

Flow rate

Control

Flow control (FC) Installing controller such as valve at the input of reactor to adjust raw material capacity which entering the equipments

Reaction doesn't work Giving extra power such perfectly and as electrical power Flow too long control (FC) Making bubble Determine agitator in the agitating velocity value (rpm); process Controlling regularly Pump heat and damaged easily

Pump cleaning and controlling regularly

Flow control (FC)

94


P-106 P-107 P-108 P-109 P-110 P-111

Less

Blocking or leaking in pump

Low supply

Pump cleaning and controlling regularly, installing valve and flow indicator

More

Overload stirring performance

Pump damaged easily

Controlling regularly

Less

Blocking or leaking in HE

Supply will be clogged


Flow rate More

Input flow rate increase

Less

Steam supply will decrease

H-101

Temperature

Heat Exchanger

H-102

HE-103

More

Steam supply will increase

Less


Temperature

Flow rate

More


Less

Blocking or

HE will be damaged easily Temperature process will increase too long Encrement of temperature will be excessed Temperature process will increase too long Encrement of temperature will be excess Supply will be

Controlling regularly and installing valve in HE input

Flow control (FC)

Increasing steam to HE Temperature control (TC) Decreasing steam to HE

Increasing steam to HE Temperature control (TC) Decreasing steam to HE Controlling regularly

Flow 95


P-106 P-107 P-108 P-109 P-110 P-111

Less

Blocking or leaking in pump

Low supply

Pump cleaning and controlling regularly, installing valve and flow indicator

More

Overload stirring performance

Pump damaged easily


Less

Blocking or leaking in HE

Supply will be clogged


Flow rate More


Less


H-101

Temperature

Heat Exchanger

H-102

HE-103

More


Less


Temperature

Flow rate

More


Less

Blocking or

HE will be damaged easily Temperature process will increase too long Encrement of temperature will be excessed Temperature process will increase too long Encrement of temperature will be excess Supply will be

Controlling regularly and installing valve in HE input

Flow control (FC)

Increasing steam to HE Temperature control (TC) Decreasing steam to HE

Increasing steam to HE Temperature control (TC) Decreasing steam to HE Controlling regularly

Flow 95


leaking in HE

Temperature

More


Less

Chilling water supply increase

More

Less Boiler

B-101

Flow rate More

Less Bubble column reactor

CS-101

Chilling water supply is less Blocking or leaking in Boiler The result of combustion increase Raw material input is blocked and unsuitable with equipment capacity

clogged HE will be damaged easily The temperature reduction will be excess Temperature reduction process will too long

Decreasing water supply to HE

Heating will be blocked

Lean liquor flow rate setting

Damaged equipment

Installing pressure valve

Reactor doesn't work efficiently


reactor damaged easily and liquid spilled

Flow Installing controller control (FC) such as valve at the input of reactor to adjust raw material capacity which entering the equipments

Flow rate More


control (FC) Controlling regularly and installing valve in HE input

Temperature control (TC) Increasing water supply to HE

Flow control (FC)

96


leaking in HE

Temperature

More


Less

Chilling water supply increase

More

Less Boiler

B-101

Flow rate More

Less Bubble column reactor

CS-101

Chilling water supply is less Blocking or leaking in Boiler The result of combustion increase Raw material input is blocked and unsuitable with equipment capacity

clogged HE will be damaged easily The temperature reduction will be excess Temperature reduction process will too long

Decreasing water supply to HE

Heating will be blocked

Lean liquor flow rate setting

Damaged equipment

Installing pressure valve

Reactor doesn't work efficiently


reactor damaged easily and liquid spilled

Flow Installing controller control (FC) such as valve at the input of reactor to adjust raw material capacity which entering the equipments

Flow rate More


control (FC) Controlling regularly and installing valve in HE input

Temperature control (TC) Increasing water supply to HE

Flow control (FC)

96


Less Blower

F-101

Flow rate More

Less Plate and Frame Filtration

PF-101 PF-102

Flow rate More

Less Conveyor

CON-101 CON-102 CON-103 CON-104

Acidification process doesn't Giving extra power such work as electrical power Flow effectively control (FC) Overload Blower/fan stirring damaged Controlling regularly performance easily Controlling pump and Blocking or Supply will be flow regularly; leaking in pump decreased Installing flow rate controller Flow rate Control Overload Filtration Controlling pump and stirring process will flow regularly; performance in take time too Installing flow rate pump long controller Low power supply

Low driving force

Belt Speed

More

Incorrectness set point

Materials which will be streamed from one place to another would pile on operations

Provide additional power in the form of electric power

Supply products are expected to be the product will be too big

Determining the value of a new set point and controlled on a regular basis

Flow Control (FC)

97


Less Blower

F-101

Flow rate More

Less Plate and Frame Filtration

PF-101 PF-102

Flow rate More

Less Conveyor

CON-101 CON-102 CON-103 CON-104

Acidification process doesn't Giving extra power such work as electrical power Flow effectively control (FC) Overload Blower/fan stirring damaged Controlling regularly performance easily Controlling pump and Blocking or Supply will be flow regularly; leaking in pump decreased Installing flow rate controller Flow rate Control Overload Filtration Controlling pump and stirring process will flow regularly; performance in take time too Installing flow rate pump long controller Low power supply

Low driving force

Belt Speed

More

Incorrectness set point

Materials which will be streamed from one place to another would pile on operations

Provide additional power in the form of electric power

Supply products are expected to be the product will be too big

Determining the value of a new set point and controlled on a regular basis

Flow Control (FC)

97


Less Temperature of the Hot air More Spray Drying

SD-101 Less Flow rate input

More

Less Ultrafiltration

UF-101

Flow rate More

Hot air temperature which use to atomized is too small Hot air temperature which use to atomized is too big Input flow rate is too small Input flow rate is too large Blocking of material supplies and not suitable with the equipment capacity Raw material capacity more than machine capacity

vanillin still contain a water Vanillin may participate evaporate

Increase temperature of hot air Temperature Control (TC) Decrease flow rate and temperature steam

Decreases debit fluid Flooding, crystalization cannot maximum running

Increasing the flow rate input

Ultrafiltration doesn't work efficiently

Ensure that material capacity must suitable with equipment capacity

Ultrafiltration will be damaged easily

Installing controller such as valve at the input of ultrafiltration to adjust raw material capacity which entering the equipments

Reducing the flow rate input

Flow rate Control (LC)

Flow control (FC)

98


Less Temperature of the Hot air More Spray Drying

SD-101 Less Flow rate input

More

Less Ultrafiltration

UF-101

Flow rate More

Hot air temperature which use to atomized is too small Hot air temperature which use to atomized is too big Input flow rate is too small

vanillin still contain a water Vanillin may participate evaporate

Increase temperature of hot air Temperature Control (TC) Decrease flow rate and temperature steam

Decreases debit fluid Flooding, crystalization cannot maximum running

Increasing the flow rate input

Blocking of material supplies and not suitable with the equipment capacity

Ultrafiltration doesn't work efficiently

Ensure that material capacity must suitable with equipment capacity


Ultrafiltration will be damaged easily

Input flow rate is too large

Reducing the flow rate input

Installing controller such as valve at the input of ultrafiltration to adjust raw material capacity which entering the equipments

Flow rate Control (LC)

Flow control (FC)

98

Vanillin Production from Lignin

8. 3.

Environmental Aspects

An industrial process can have a negative impact on the environment if not handled properly. The negative impact on the environment can affect the sustainability of production and the local environment. In this section, we discuss some of the environmental impacts that may result from the presence of the vanillin plant is that the manufacturing process produces substances called residual waste. Based on his form, the waste produced by the plant can be grouped into four types, namely: 8. 3. 1. Liquid Waste

Wastewater produced by this plant are lean liquor that will be recycled by PT Riau Andalan Pulp and Paper and water which is reused for chilling water in heat exchanger. 8. 3. 2. Solid Waste

No solid waste is removed from the production process of this vanillin plant. 8. 3. 3. Waste Gas

Majority of the waste gas produced is CO2 emissions resulting from the generator. 8. 3. 4. Waste Sound (Noise)

Possible noise pollution generated by tools such as pumps and motors drive stirrer.


8. 3.

Environmental Aspects

An industrial process can have a negative impact on the environment if not handled properly. The negative impact on the environment can affect the sustainability of production and the local environment. In this section, we discuss some of the environmental impacts that may result from the presence of the vanillin plant is that the manufacturing process produces substances called residual waste. Based on his form, the waste produced by the plant can be grouped into four types, namely: 8. 3. 1. Liquid Waste

Wastewater produced by this plant are lean liquor that will be recycled by PT Riau Andalan Pulp and Paper and water which is reused for chilling water in heat exchanger. 8. 3. 2. Solid Waste

No solid waste is removed from the production process of this vanillin plant. 8. 3. 3. Waste Gas

Majority of the waste gas produced is CO2 emissions resulting from the generator. 8. 3. 4. Waste Sound (Noise)

Possible noise pollution generated by tools such as pumps and motors drive stirrer. Noise can also be caused due to the damage to the mechanical system on the appliance. To reduce the noise level equipment necessary regular maintenance schedule has been determined. For workers who are diarea that generate noise should be equipped with ear protection (ear plugs). Meanwhile, for tools that can generate noise can be added by means of dampening noise. Noise standards set by the minister of health is 60 -70 dB, while the minister of labor is a maximum of 85 dB for 8 hours. Expected kenisingan of indigo dye plant is not too large because the pump used is not too large, as well as other tools. 8. 4.

Risk Management

Risk Management aims to solve the problem even prevent accidents. A particular effort is needed to reduce or eliminate potential risks. Risk is a condition where there is the possibility of an accident or occupational disease because of the presence of a hazard. The danger is of a material nature, administration of a tool, how to do a job or work

99


Vanillin Production from Lignin environment that can lead to property damage, occupational disease, or the loss of human lives. To avoid the danger of necessary control components with potential risks such as human factors, equipment and materials, as well as the methods and sources of danger. Risk management system is a management process carried out with the intention of minimizing the risk or the extent possible to avoid the risk altogether. In a risk management system, which required the application of the hierarchy of control measures against the risk of a hazard, with the following steps: 

Elimination (eliminate the hazard)



Substitution (use raw materials more secure)



Engineering (redesign existing processes to make it more secure)



Administrative control (changing methods or procedures work in a more secure)



Personal protective equipment (using the appropriate protective equipment to isolate the body from harm) To meet risk management will require tools and backup facilities to prevent or

overcome danger danger that occurs in plants. The tools and means necessary including body protective gear for employees, fire extinguishers, MSDS (Material Safety Data Sheet), and Account Head Point (local assembled) for all employees if fire occurs. 8.4.1. Personal Protection Equipment

Equipment protection for employees is the main standard for a company to protect its employees from the threat of disruption to the aspects of safety and health at work. Based on the major needs in the field of personal protective equipment can be divided into:

a. General Personal protective equipment as a minimum requirement to enter the plant, ie safety helmet, googles, and safety shoes. b. Special

100


Vanillin Production from Lignin PPE is used in accordance with the needs of employees in the workplace each based on hazard and risk. For example: safety goggles, respirators, ear protection, gloves, earplugs, etc. Here are some of the personal protective equipment used in the factory: a. Protective equipment fall

Fall protective equipment used in the petrochemical industry is the seat belt / safety belt is one of safety for the protection of workers in performing work activities in high places where workers are likely to fall. Things that need to be considered for fall protection equipment, namely: 

Safety belt used to be in high places over 4 ft, the rope should be tied firmly on building / sustaining a capable Defence weight



Ensure seat belt component in a condition to be good



To keep the belt remains in good condition, the equipment belt should be cleaned with hot water and soap, and stored away from the sun and ultaviolet very strong, also the chemical that causes the fibers to become brittle and weak belt

Type of fall protection equipment consists of: 

Belts or harnesses are equipped components stitching, buckles, D-rings, cuts and abration



The rope is made up of components rot, proper hook and knots, frayed strands or broker.

b. Respiratory protection

The usefulness of this protection tool, especially in an emergency, eg labor should help others who suffer accidents / when must escape a sudden atmospheric air composition changes such that endanger his soul / when should perform repairs equipment in where very high levels of contaminants. Respirator or air purifying respirator which serves to clean the air that has been contaminated in the form of dust, gases, metal vapors, smoke and fog, and protect the work force has been a breath of danger, composed of chem respirator (steam and gas

101


Vanillin Production from Lignin contaminants), mech filter respirators (dust, mist, vapor metallic, sour) and cartridge / canister respirator (mixed gas / vapor with solid particles equipped with a filter). Breathing apparatus (air supply respirator), which supplies clean air or oxygen to the wearer. Respirator is not equipped with a filter or cartridge, but supplies the user with compressed air / air cleaner / from an oxygen tank.

Figure 8.1. Respirator

c. Hand protection tool

To protect from possible dangers that occur, it is expected that workers in work activities always wore gloves, which must be adjusted to the working conditions and in the absence of injured / contamination of the hands. Various kinds of gloves according to the types of hazards that must be prevented: 

Asbestos gloves, leather, PVC should be used when heat is caused by the heat generated in the factory work, eg welding gloves to be used must pass through the wrist



Rubber gloves, made of synthetic material, vinyl as well as natural, to protect hands from chemicals caustic acids, alkalis and various types of other solvents



Gloves canvas / leather, wear gloves of canvas or heavy cotton is typically used when the main danger is very high heat caused by friction



Gloves with chrome leather or PVC material with special design, to reduce the hazard when in contact with sharp objects

102



Figure 8.2. Gloves

d. The tool foot protector

Safety shoes should protect workers against accidents caused by heavy items falling to the feet, protruding nails, liquid metal, and so on. The types of tools used: Protective Footwear, used in good condition should provide some protection against the impact of falling objects or punctures caused by sharp objects to be secure, end-coated steel in a protective layer of skin shoes worn feet will not slip or high heels at least 3 / 8 inch, 1-1/2 inch maximum.

Figure 8.3. Safety Shoes

e. Eye protection

Use eye protection of workers flake delicate objects and spray chemicals that can enter and cause irritation to the eyes or even injure the eyes. This tool can also protect your

103


Vanillin Production from Lignin eyes from impact workers against a hard object. For eye protection, personal protective equipment supplied googles or safety glasses for workers.

Figure 8.4. Goggles

f. Ear protective devices

Ear protective devices commonly used in the area located the tools that may cause loud noises such as compressors, pumps, steam generators, conveyors and other tools that use motors for propulsion. For protection against ear every employee who deals with the tools required to use earplug process provided by the company.

Figure 8.5. Earplugs

g. Protective equipment head

The tool used in the form of head protection safety helmet. This headwear is a protective device that is used to protect the head from impact by hard objects while working in the field. h. The tool body armor

104


Vanillin Production from Lignin Personal protective equipment such as protective clothing body safe. Clothing was named coverall which serves to avoid the possibility of a leak or spill liquid products in bulk, so it can protect the body and to avoid direct contact with the skin of workers. To clean up the spill using absorbent material must be non-combustible inorganic. In addition, protective clothing or clothing that workers should not be used that has a crease on the bottom of his pants. 8.4.2. Fire extinguisher

Determining the type of fire extinguishers are provided to extinguish the fire and fire prevention and control efforts tailored to the classification of fire, state buildings and items that exist in the building. Classification of types of fires, as follows: Types of fire extinguishers, among others: a. Water type fire extinguishers, consists of two types: 

Soda Acid



Water CO2 Fire extinguisher soda acid type is not used anymore because it is dangerous to humans. Water type fire extinguisher was used to extinguish the fire Class-A and has the following specifications:



Red tube.



Distance sprays to tubes 9 liters (12-15 kg) is 6 meters.



When usage is 1-2 minutes depending on the size of the tube

b. Fire extinguisher types of dry dust, consisting of three types: 

BC-class Dry Dust Fire Class - B and C



Class ABC dry dust Fire Class - A, B and C



Dry Dust class D Fire Class - D fire extinguishers dry dust types have the following specifications: a. Light blue tube b. Consists of chemicals such as:

105



o

Sodium Bicarbonate (97%)

o

Magnesium Stearate (1.5%)

o

Magnesium Karbinat (1%)

o

Tricalcium phosphate (0.5%)

c. Tube size 1-12 kg d. Distance 9 liters spray tube is 4-6 meters e. Long time usage depending on size, to the size of 14-16 kg is 15 seconds c. Types of fire extinguishers carbon dioxide (CO2) Extinguisher was used to extinguish the fire Class-B and C and has the following specifications: o

o

o

black tube distance 4.5-8 kg spray tube is 2 meters spending time is 14 seconds

o

gas CO2 in liquid tube.

o

the level of development is 450:1

d. The type of fire extinguisher foam (foam), consists of three types: o

Scum Chemistry

o

Self-Aspirating

o

Non-Aspirating AFFF The type of fire extinguisher foam or foam used to extinguish the fire classes A and B. Specifications of this type extinguishers are: o

Creamy white colored tube

o

Distance sprays to tubes 9 liters (14-16kg) is 4-5 meters

o

The duration is 30 seconds spending

o

The level of development is 1:8

106



8.4.3. MSDS (Material Safety Data Sheet)

MSDS are data from material or plant material in the interests of health and safety. Any material or chemicals present in the plant must have a MSDS which serves as the basis for the use of (material handling). MSDS data serves to communicate and inform everyone working with these materials so that they can use the material properly and act appropriately if there is immediate danger. MSDS of some materials of this plant will be showed in appendix. 8.5. Quality Control in Vanillin Plant

All the food people eat must be absolutely pure and clean. This is one of the most important principles of the food industry. One decisive criterion here is that products leave factory without any metal contaminations and other contaminants. Product manufacturers and service industries have realized that competition in a global market require a continual and committed effort towards the improvement of product and service quality. Quality control process consists of raw materials, process, product and service. Major factors in process that cause variability in quality of finished product are people, equipment and methods or technologies employed in the process. Use of proper statistical process control methods is vital for assurance of the product quality. Statistical quality control comprises the following procedure: – Finished product is measured – Value of quality characteristics is used to provide feedback on how process can be

improved – Sampling occurs for days or weeks – Lot is either accepted or rejected based on information from sample – This procedure provided slow feedback of information.

Recognizing the importance of quality control of food products, Government of Indonesia has legalized the Act No. 7 of 1996 on food and our plant use it as regulation of quality control. The Food Act is intended as a legal basis for the regulations, development, and control on the production activities or process, the circulation, and trade of food. This Act also provides a reference for various legislative regulations related to food, both already in existence and to be established.

107



CHAPTER 9 ECONOMIC ANALYSIS

This chapter gives the economic analysis of vanillin plant from lignin. The steps to analyze the plant economic is explained below. 9.1 Plant Cost Estimation

For total Capital Investment estimation of vanillin plant, we use Guthrie method with the following formula.

C TCI  C TPI  C WC 

1.

C TBM  C site  C buildings  C offsite facilities  C contingenc y  C contractor fee  C WC

Total Bare Modul Cost (C TBM)

Total bare module cost can be calculated using the costs of bare module (CBM) from each equipment manufacturer. Cost of bare module (CBM) for each equipment can be seen in table 9.1 while total bare module cost (CTBM) can be seen in table 6.2.

108


Vanillin Production from Lignin Table 9.1. Recapitulation CBM value for each equipment Code

Unit Amount

Equipment

P-101 BLACK LIQUOR PUMP BLACK LIQUOR ACIDIFICATION P-102 PUMP P-103 LIGNIN ACIDIFICATION PUMP P-104 LIGNIN SOLUTION PUMP P-105 LIGNIN SOLUTION PUMP P-106 VANILLIN SOLUTION PUMP P-107 VANILLIN SLURRY PUMP P-108 WATER PUMP P-109 H2SO4 PUMP P-110 WATER PUMP P-111 NAOH PUMP S-101 BLACK LIQUOR STORAGE V-101 ACIDIFICATION VESSEL V-102 ACIDIFICATION VESSEL 2 (A) V-102 ACIDIFICATION VESSEL 2 (B) V-103 BLENDING VESSEL S-102 LIGNIN SLURRY STORAGE S-103 H2SO4 STORAGE S-104 NaOH STORAGE S-105 WASTE STORAGE PF-101 PLATE AND FRAME FILTRATION PF-102 PLATE AND FRAME FILTRATION E-101 HE E-102 HE E-103 HE UF-101 ULTRAFILTRATION SD-101 SPRAY DRYING B-101 BOILER CS-101 BUBBLE COLUMN REACTOR

Cost $

Year Basis

Cost Index Year Basis

Cost Index in 2013

Cost in 2013 ($)

Source

1

8,565.84

2007

525.4

587.88

9,584.48

sinnot,2009

2

8,401.91

2007

525.4

587.88

18,802.11

sinnot,2009

1 1 1 1 1 2 1 1 1 3 5 1 1 1 1 1 1 2 4 1 1 1 1 2 1 1 1

8,485.19 7,836.77 8,168.08 7,076.06 6,955.41 7,092.47 7,005.95 7,234.38 7,814.68 2,646.54 885.85 586.39 1,892.34 996.13 93,131.21 21,853.70 10,708.90 112,472.97 215,362.25 56,454.18 21,700.00 21,700.00 19,000.00 70,834.40 32,269.54 17,032.24 49,066.96

2007 2007 2007 2007 2007 2007 2007 2007 2007 2004 2004 2004 2004 2004 2004 2004 2004 2004 2004 2004 2007 2007 2007 2000 2000 2000 2004

525.4 525.4 525.4 525.4 525.4 525.4 525.4 525.4 525.4 444.2 444.2 444.2 444.2 444.2 444.2 444.2 444.2 444.2 444.2 444.2 525.4 525.4 525.4 394.0 394.0 394.0 444.2

587.88 587.88 587.88 587.88 587.88 587.88 587.88 587.88 587.88 587.88 587.88 587.88 587.88 587.88 587.88 587.88 587.88 587.88 587.88 587.88 615.40 615.40 615.40 615.40 615.40 615.40 587.88

9,494.24 8,768.70 9,139.42 7,917.54 7,782.54 15,871.81 7,839.09 8,094.69 8,743.99 10,507.74 5,861.90 776.06 2,504.44 1,318.34 123,255.24 28,922.45 14,172.78 297,706.49 1,140,091.49 74,714.73 25,417.17 25,417.17 22,254.66 221,276.60 50,402.72 26,603.14 64,938.06

sinnot,2009 sinnot,2009 sinnot,2009 sinnot,2009 sinnot,2009 sinnot,2009 sinnot,2009 sinnot,2009 sinnot,2009 sinnot,2004 sinnot,2004 sinnot,2004 sinnot,2009 sinnot,2012 sinnot,2009 sinnot,2012 matche,2007 sinnot,2004 sinnot,2004 sinnot,2004 Seider, 2003 Seider, 2003 Seider,2003 Seider, 2003 Seider, 2003 Seider, 2003 sinnot, 2004

109

Vanillin Production from Lignin Table 9.2. Recapitulation CTBM value Code

P-101

Equipment

FOB/unit ammount ($)

Total Module Factor

Bare Modul Cost ($)

P-102

BLACK LIQUOR PUMP BLACK LIQUOR ACIDIFICATION PUMP

9,584.48

3.47

33,258.15

18,802.11

3.47

65,243.33

P-103

LIGNIN ACIDIFICATION PUMP

9,494.24

3.47

32,945.02

P-104

LIGNIN SOLUTION PUMP

8,768.70

3.47

30,427.41

P-105


9,139.42

3.47

31,713.78

P-106

VANILLIN SOLUTION PUMP

7,917.54

3.47

27,473.87

P-107

VANILLIN SLURRY PUMP

7,782.54

3.47

27,005.41

P-108

WATER PUMP

15,871.81

3.47

55,075.17

P-109

H2SO4 PUMP

7,839.09

3.47

27,201.64

Vanillin Production from Lignin Table 9.2. Recapitulation CTBM value Code

P-101

FOB/unit ammount ($)

Equipment

Total Module Factor

Bare Modul Cost ($)

P-102

BLACK LIQUOR PUMP BLACK LIQUOR ACIDIFICATION PUMP

9,584.48

3.47

33,258.15

18,802.11

3.47

65,243.33

P-103

LIGNIN ACIDIFICATION PUMP

9,494.24

3.47

32,945.02

P-104


8,768.70

3.47

30,427.41

P-105


9,139.42

3.47

31,713.78

P-106

VANILLIN SOLUTION PUMP

7,917.54

3.47

27,473.87

P-107

VANILLIN SLURRY PUMP

7,782.54

3.47

27,005.41

P-108

WATER PUMP

15,871.81

3.47

55,075.17

P-109

H2SO4 PUMP

7,839.09

3.47

27,201.64

P-110

WATER PUMP

8,094.69

3.47

28,088.57

P-111

NAOH PUMP

8,743.99

3.47

30,341.66

S-101

BLACK LIQUOR STORAGE

10,507.74

1.41

14,815.92

V-101

ACIDIFICATION VESSEL

5,861.90

4.2

24,619.97

V-102

ACIDIFICATION VESSEL 2 (A)

776.06

1.5

1,164.08

V-102

ACIDIFICATION VESSEL 2 (B)

2,504.44

1.47

3,681.52

V-103

BLENDING VESSEL

1,318.34

4.2

5,537.01

S-102

LIGNIN SLURRY STORAGE

123,255.24

1.47

181,185.20

S-103

H2SO4 STORAGE

28,922.45

4.2

121,474.31

S-104

NaOH STORAGE

14,172.78

3.37

47,762.27

S-105

WASTE STORAGE

297,706.49

1.5

446,559.73

PF-101 PF-102

PLATE AND FRAME FILTRATION PLATE AND FRAME FILTRATION

1,140,091.49

3.47 3.37

3,956,117.46

110


Vanillin Production from Lignin 74,714.73

251,788.64

E-101

HE

25,417.17

1.5

38,125.75

E-102

HE

25,417.17

2.06

52,359.37

E-103

HE

22,254.66

3.37

74,998.21

UF-101

ULTRAFILTRATION

221,276.60

2.7

597,446.81

SD-101

SPRAY DRYING

50,402.72

2.7

136,087.36

B-101

BOILER

26,603.14

2.24

59,591.04

CS-101

BUBBLE COLUMN REACTOR

64,938.06

1.41

91,562.66

Total Bare Modul Cost ($)

-

6,493,651.30

Csite cost calculation

              

-

C building cost calculation

             

-

Coffsite facilities cost calculation

          

-

Ccontingency cost calculation

          

-

Ccontractor fee cost calculation

                111



-

CWC cost calculation

         (           )  Therefore total capital investment of vanillin plant can be found with following equation.

                                             Table 9.3. Total Cost Investment Component

Value in $

Total Bare Modul Cost (C TBM) ($) Site Development Cost (C site) ($) Building Cost (C building) ($)

Contractor fee ($) Working Capital (C WC) ($) Total Cost Investment ($)

1,298,730.26 1,298,730.26

Offsite Facilities Cost (C offsite facilities) ($) Contingency ($)

6,493,651.30

15,000.00 974,047.70 194,809.54 2,182,403.43 14,306,866.92

112



9.2

Annual Operating Costs

Annual operating costs are divided into two types; fixed and variable cost, this cost will be issued during the plant operating. Some of the assumptions used for calculate the operating costs are as follows: 1. Plant operating life is 20 years. 2. In 1 year, this plant operated for 300 days, 24 hours. 3. The production capacity is 100% since the plant operated. 4. Depreciation is 9%, inflation is 4%, and interest rate is 10% per year. Operating costs are calculated by performing the following details: 9.2.1

Raw Material Costs

Raw material used in this plant consists of: 1. Black Liquor Costs Black liquor is result of the paper mill waste. Black liquor obtained from Riau Andalan Pulp and Paper mill without charge. It because PT. Riau Andalan Pulp and Paper is owner of this plant. Needs for a year

: 200,100 tons/year

Raw material cost

: $ 0 /tons

Raw material cost per year

: 200,100 tons/year X $ 0 /tons = $ 0 /year

2. Carbon Dioxide Needs for a year

: 1,500.30 m3/ year

Raw material cost

: $ 2.04 /m3


: 1,500.30 m3/ year X $ 2.04 /m3 = $ 3,055.53 /year

3. Sulfuric Acid Needs for a year

: 2,362.50 tons/ year

Raw material cost

: $ 412.83 /tons


: 2,362.50 tons/ year X $ 412.83 /tons = $ 975,315.48 /year

4. Sodium Hydroxide

113


Vanillin Production from Lignin Needs for a year

: 450 tons/ year

Raw material cost

: $ 1,767.78 /tons


: 450 tons/ year X $ 1,767.78 /tons = $ 795,500.61 /year

5. Water Needs for a year

: 333,166.50 tons/ year

Raw material cost

: $ 0.13 /tons


: 333,166.50 tons/ year X $ 0.13 /tons = $ 44,604.48 /year

6. Air (O2 and N2) Needs for a year

: 612 m3/ year

Raw material cost

: $ 3.16 /m3


: 612 m3/ year X $ 3.16 /m3 = $ 1,935.21 /year

Thus, the total direct material cost is $ 1,820,411.31 per year. Table 9.4. Raw Material Cost per Year Cost in 2012 ($)

Cost in 2015 ($)

Raw Material Cost Per Year ($)

Materials

Amount

Unit/batch

Needs per year

Water

370.19

ton

333,166.50

0.12

0.13

44,604.48

CO2

1.67

m3

1,500.30

1.90

2.04

3,055.53

H2SO4

50.03

ton

45,022.50

385.14

412.83

975,315.48

NaOH

0.50

ton

450.00

1,649.20

1,767.78

795,500.61

Air (O2 and N2)

0.68

m3

612.00

2.95

3.16

1,935.21

Total Raw Material Cost Per Year

1,820,411.31

114



9.2.2

Operating Labor Costs Table 9.5. Indirect Labor costs

Qualification

Amount

Cost per month ($)

Commissioner President Director

1 1

5000 3500

Cost per year ($)

Total cost per year ($)

60000 42000

60000 42000

24000 18000 10800 18000 10800 18000 10800

24000 18000 21600 18000 21600 18000 21600

24000 18000 10800 18000 10800 18000 10800

24000 18000 21600 18000 21600 18000 21600

FINANCIAL

Financial Director Marketing Department Manager Marketing Department Staff Financial Department Manager Financial Department Staff Budgetary Department Manager Budgetary Department Staff

1 1 2 1 2 1 2

2000 1500 900 1500 900 1500 900

HUMAN RESOURCES

Human Resources Director Public Relation Manager Public Relation Staff Personnel Manager Personnel Staff Education & Training Manager Education & Training Staff

1 1 2 1 2 1 2

2000 1500 900 1500 900 1500 900

OPERATIONAL

Operational Director Engineering Manager Processing Manager HSE Manager Research & Development Manager Research & Development Staff

1 1 1 1

3000 1800 1800 1800

36000 21600 21600 21600

36000 21600 21600 21600

1 3

1800 1200

21600 14400

Fixed Cost of Indirect Labour Variable Cost of Indirect Labour = 20% TIL

21600 43200 553,200.00 110,640.00

Total Indirect Labour

663,840.00

115



Table 9.6. Direct Labor costs

Qualification

Amount

Supervisor Engineering Staff Processing Staff HSE Staff R&D Staff

2 3 3 3 3

Cost per month ($)

1500 1200 1200 1200 1200

Cost per year ($)

Total cost per year ($)

450,000.00 14400 14400 14400 14400

900,000.00 43200 43200 43200 43200 172,800.00 34,560.00 207,360.00

Fixed Cost of Direct Labour Variable Cost of Direct Labour = 20% TDL Total Direct Labour Total Operating Labour (OL)

9.2.3

871,200.00

Utilities Costs

The table below explain the detail of the utilities cost needed per year. Table 9.7. Total Utilities Cost per Year Utilities

Electricity

Amount

Unit

126129.44 kwh/year

Needs per year

Utilities Cost Per Year ($)

Cost in 2012 ($)

Cost in 2015 ($)

126129.44

0.08

0.09

54432.38

Domestic Water

10.00 m3/day

3000.00

0.12

0.13

401.64

Fuel for Steam

210.43 L/batch

568161

1.10

1.18

669913.58

Total Utilities Cost Per Year

681131.08

116



9.2.4

Total Direct Costs Table 9.8. Total Direct Costs per Year

Total Raw Material Costs

$ 1820411.31

Total Operating Labour (OL)

$ 871200.00

Total Utilities Cost

$ 681131.08

Maintanance Cost (10% Fc)

$ 1212446.35

Direct Supervisory (20% Operating Labour)

$ 174240.00

Operating Supplies (1%Fc)

$ 121244.63

Laboratory Charges

$ 87120.00

TOTAL DIRECT COST

9.2.5

$ 4967793.37

Total Fixed Costs Table 9.9. Total Fixed Cost Fixed Cost Local Taxes

3% Fc

$ 363733.90

Insurance

1% Fc

$ 121244.63

Total Fixed Cost

$ 484978.54

9.2.6

Plant Overhead

9.2.7

Total Manufacturing Cost Table 9.10. Total Manufacturing Cost

                       Total direct cost

$ 4967793.37

117


Vanillin Production from Lignin Total Fixed Cost

9.2.8

$ 484978.54



Plant Overhead

$

Total Manufacturing Cost

$ 6281542.17

Expenses Cost

     Here, we can know value of TOC, with the estimating that total manufacturing cost is 85% Total Operating cost. So, the value of TOC is :

         We can get the expenses cost.

          The details of expenses cost is in table 6.11 Table 9.11. Total Expenses Cost EX PEN SES COST

EXPENSES COST = 15% TOC

Administrative Cost = 15% OL Financial Interest = 5% Fc Distribution&Selling + R&D = EC – (AC+FI)

9.2.9

$



$ 130680.00 $ 606223.17 $ 371604.27

Total Operating Cost

             So, total operating cost of this plant is   118



9.3

Equity

The total investment from this vanillin plant is $ 14306866.92 (according to the preliminary equation). The initial capital came from the plant 60% equity and 40% of the bank loan.

Table 9.12. Source investment

Source investment

%

value

Interest / year

Self investment

60%

8584120.15

5%

Bank Loan

40%

5722746.77

10%

Table 9.13. Bank Source Equity Year

2014 2015 2016 2017 2018 2019 2020

Bank Loan

5722747 6295021 6924524 5539619 4154714 2769809 1384905

Interest

0 629502 692452 553962 415471 276981 138490

End Year Payment

Loan remaining

0 0 2077357 1938867 1800376 1661886 1523395

0 6924524 5539619 4154714 2769809 1384905 0

Table 9.14. Self Investment Source Equity Year

2014 2015 2016 2017 2018 2019 2020

Investment Loan

8584120 9442532 9914659 7931727 5948795 3965864 1982932

Interest

0 472127 495733 396586 297440 198293 99147

End Year Payment

Loan Remaining

0 0 2478665 2379518 2280372 2181225 2082078

0 9914659 7931727 5948795 3965864 1982932 0

119



9.4

Investment feasibility Analysis

To determine a project feasible or not to do, it is necessary a feasibility analysis of investment. Investment is called feasible if it gives more profit than the expected. Expected minimum profit are commonly known as the MARR, while profits are calculated on the investment feasibility analysis are known as the IRR. Some of the usual investment parameters analyzed are given below. 9.5.1

Cash Flow

Cash flow can indicate fluctuations in income earned over the life of the plant through net income. The calculation is by subtracting the cash inflow with cash flow out. Calculations of cash inflow involving revenue after taxes cutting, depreciation, rest value of equipment called the after-tax cash flow (ATCF). Meanwhile, out cash flow can be an investment, cost, and loans. Calculations before and after tax cash flow is shown in Table 9.15 and is represented in the cash flow diagram in Figure 9.1

120



After Tax Cash Flow 10000000.00

5000000.00

0.00 1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

-5000000.00

-10000000.00

-15000000.00 ATCF Total

ATCF Bank

ATCF Investor

Figure 9.1. Cash flow diagram

121

Vanillin Production from Lignin Table 9.15 shows the calculation of cash flow that calculated from the initial construction plant. In early 2013, the construction of the plant is beganwhich an investment is for the purchase of the entire instrument. Figure 6.1 shows that the largest investment incurred in the first year. In 2013, the construction is still going on until the middle of 2014, so it is still a cash flow investment. In 2015, our factory started operation. 9.5.2

IRR

To find out how IRR can be obtained from the cash flow in table 6.12 above, it can be calculated that the number of trial IRR values PW = 0, Table 9.16 IRR Calculation

NPV PV Bank

PV Investor

PW

-5334763.94

-7929399.12

-14592249.73

-341252.11

-511878.16

-853130.27

-3605180.83

-5457383.83

-8237587.18

3268169.31

4992616.20

6825122.96

2952272.39

4551412.99

5635018.13

Vanillin Production from Lignin Table 9.15 shows the calculation of cash flow that calculated from the initial construction plant. In early 2013, the construction of the plant is beganwhich an investment is for the purchase of the entire instrument. Figure 6.1 shows that the largest investment incurred in the first year. In 2013, the construction is still going on until the middle of 2014, so it is still a cash flow investment. In 2015, our factory started operation. 9.5.2

IRR

To find out how IRR can be obtained from the cash flow in table 6.12 above, it can be calculated that the number of trial IRR values PW = 0, Table 9.16 IRR Calculation

NPV PV Bank

PV Investor

PW

-5334763.94

-7929399.12

-14592249.73

-341252.11

-511878.16

-853130.27

-3605180.83

-5457383.83

-8237587.18

3268169.31

4992616.20

6825122.96

2952272.39

4551412.99

5635018.13

2666450.82

4148485.59

4651632.90

2407854.71

3780528.12

3839150.13

2173905.94

3444523.34

3167951.53

1962271.72

3137716.59

2613544.42

1770840.74

2857592.27

2155674.62

1597701.86

2601852.57

1777593.30

1441124.77

2368398.15

1465450.68

1299542.74

2155310.70

1207794.80

1171536.95

1960837.02

995156.86

1055822.43

1783374.61

819708.42

951235.31

1621458.53

674977.72

856721.38

1473749.51

555615.10

771325.68

1339023.03

457198.91

694183.17

1216159.45

376074.98

624510.20

1104134.97

309223.76

561596.91

1002013.39

254150.51

504800.24

908938.61

208794.37

122

Vanillin Production from Lignin Based on the trial was obtained IRR = 20.35%. Then, to know the NPV value as one component of determining the feasibility of the realization of the design, PW calculation with i = MARR = 10%, at which NPV = PW.

123

Vanillin Production from Lignin 9.5.3 Net Present Value (NPV)

An investment is feasible to be implemented if the investment has a value of NPV> 0. This value indicates that the value for money of the plant profit not lower than the value of the money spent as an investment in the factory default. Therefore all of the above ATCF then be calculated present value rate of 10% MARR. Table 6.17 shows the calculation of our plant NPV. Table 9.17 NPV Calculation Year

-1 0 1 2 3 4

NPV PV bank

PV Investor

-5334763.94

-7929399.12

-341252.11

-511878.16

-3605180.83

-5457383.83

3268169.31

4992616.20

2952272.39

4551412.99

2666450.82

4148485.59

2407854.71

3780528.12

2173905.94

3444523.34

1962271.72

3137716.59

1770840.74

2857592.27

1597701.86

2601852.57

1441124.77

2368398.15

1299542.74

2155310.70

1171536.95

1960837.02

1055822.43

1783374.61

951235.31

1621458.53

856721.38

1473749.51

771325.68

1339023.03

5 6 7 8 9 10 11 12 13 14 15 16

124

Vanillin Production from Lignin 17 18 19 20 Total NPV

694183.17

1216159.45

624510.20

1104134.97

561596.91

1002013.39

504800.24 5143803.48

908938.61 18242597.62 23386401.11

NPV total

From the table above we can see that the value of the plant NPV is greater than zero. 9.5.4 Pay Back Period

The payback period can be determined where the number of cumulative ATCF to year n is equal to zero. From table 6.15, payback period value is located between 3 and 4 years because in year 3 the value of cumulative ATCF is negative and in year 4 the value of cumulative ATCF is positive. Table 9.18 Pay Back Period Calculation

Year

Payback Bank

Payback Self

Payback overall

investment 3

-1272777.01

-1909165.51

-3181942.52

4

2631173.64

3946760.46

6577934.10

PBP

3.33

3.33

3.33

From the table above, we using the interpolation, we get the payback period is 3,74 years. This shows that the construction of the plant is feasible to be realized. 9.5.5Break Event Point (BEP)

Break Event Point states where the total sales volume of income exactly equal to the total cost, so the company does not make a profit nor suffer a loss. Problems of Break event will appear in the company if it has a Variable Costs and Fixed Costs. A company with a certain production volume may suffer a loss

125

Vanillin Production from Lignin of income due to sales is only able to cover variable costs and can only cover a small portion fixed costs.

                  Where the variable cost is the total of raw material price, labour price, and plant overhead. The data is gotten from table 6.15.

        So, the BEP of this plant is 495,95 tonnes. 9.5.6 Sensitivity Analysis

Sensitivity for product price Table 9.19. Sensitivity analysis for product price

Deviasi Price -0.20 -0.10 -0.05 0.00 0.05 0.10 0.20

14.40 16.20 17.10 18.00 18.90 19.80 21.60

NPV -5658627.61 8863886.75 16125143.93 23386401.11 30647658.29 37908915.46 52431429.82

IRR (%) PBP (tahun) 12.30 4.71 16.58 3.86 18.51 3.57 20.35 3.33 22.11 3.13 23.80 2.96 27.00 2.69

From the table above, we can see that if the price become cheaper, the value of NPV, IRR and the payback period become lower. The payback period is sensitive with deviation -20% or the price of vanillin $ 14.40 because the NPV become a negative value although the PBP below 5 years and IRR still above 10% (below MARR).

126


Product Price Effect 60000000.00 y = 1E+08x + 2E+07 R² = 1

50000000.00 40000000.00 30000000.00

V P N

Series1

20000000.00

Linear (Series1)

10000000.00 0.00 -0.30

-0.20

-0.10 0.00 0.10 -10000000.00 PriceDeviation

0.20

0.30

Figure 9.2. Sensitivity analysis for product price

Sensitivity for Raw material price Table 9.20. Sensitivity analysis for raw material cost effect

Deviasi Raw Material Cost NPV 0.00 1820411.31 23386401.11 0.05 1911431.87 21782327.30 0.10 2002452.44 20178253.37 0.20 2184493.57 16970105.67 0.50 2730616.96 7345662.59

IRR (%) PBP (tahun) 20.35 3.33 19.94 3.38 19.51 3.44 18.66 3.57 16.03 4.02

From the table above, we can see that if the raw material cost become higher, the value of NPV and IRR become smaller while payback period lower. The payback period is sensitive with deviation 50% or raw material cost $ 2730616.96.

127


Operational Cost Effect 25000000.00

y = -3E+07x + 2E+07 R² = 1

20000000.00 15000000.00

V P N

Series1

10000000.00

Linear (Series1)

5000000.00 0.00 0.00

0.20

0.40

0.60

Cost Deviation

Figure 9.3. Sensitivity analysis for raw material

cost effect

128

Vanillin Production from Lignin APPENDIX

1.

Vessel

1.1 Black Liquor Storage Tank (S-101) Calculation

Storage tank functioning as a repository of black liquor that will be used for the production of vanillin. To calculate the dimensions of the tank needs to know the total volume of the tank. The total volume of the tank is calculation of tank working volume and tank head space. In the design of storage tanks, assumptions using are: - Ratio of height to diameter of the tank is 4:3 - Tank working volume is 0.85 of the total volume of tank - residence time is 1 hour.

            

Black liquor flow rate:

Tank working volume :

                           Diameter and height of the tank:         Where; D is diameter of the tank and H is height of the tank. From the results of calculation and rounding up to 0.1 m, height and diameter of the tank is obtained respectively 9.55 m and 7.16 m.

129

Vanillin Production from Lignin Thickness of shell tank:

 x (CA n)     P (psi) = Poperation (psi) + Pstatis + safety factor = 14.7 psi + 21.8 psi + 20 psi = 56.50 S = Allowable stress, for stainless steel 316 = 20000 psi E = Joint efficiency = 0.85 CA= Corrosion Allowance = 0.001 m/year n = equipment life = 20 years

                       

Roof thickness of the tank:

       

1.2 Acidification Tank (V-101) Calculation a. Tank Design

Mixer tank functioning as a tank to mix black liquor slurry with H 2SO4. To design mixer tank, the dimensions of the tank needs to know the total volume of the tank. The total volume of the tank is calculation of tank working volume and tank head space. In the design of storage tanks, the assumptions used are: - Ratio of height to diameter of the tank is 4:3 - Tank working volume is 0.85 of the total volume of tank - residence time is 1 hour.

            



130


                      Diameter and height of the tank:         Where; D is diameter of the tank and H is height of the tank. From the results of calculation and rounding up to 0.1 m, height and diameter of the tank is obtained respectively 3.87 m and 2.90 m. Thickness of shell tank:


                     


        131

Vanillin Production from Lignin b. Impeller Design

Calculated of impeller design are: Diameter (Da) = 0.4 x 2.90 m = 1.16 m Blade width (W) = 0.125 x 1.16 m = 0.15 m Agitator space from based (E) = 0.167 x 3.29 m = 0.55 m

1.3 Acidification Tank (V-102) Calculation a. Tank Design

Mixer tank functioning as a tank to mix black liquor slurry slurr y with H 2SO4. To design mixer tank, the dimensions of the tank needs to know the total volume of the tank. The total volume of the tank is calculation of tank working volume and tank head space. In the design d esign of storage tanks, the assumptions used are: - Ratio of height to diameter of the tank is 4:3 - Tank working volume is 0.85 of the total volume of tank - residence time is 0.5 hour.

                 



         

              Diameter and height of the tank:           132


Where; D is diameter of the tank and H is height of the tank. From the results of calculation and rounding up to 0.1 m, height and diameter of the tank is obtained respectively 3.06 m and 2.30 m. Thickness of shell tank:

 x (CA n)     P (psi) = Poperation (psi) + Pstatis + safety factor = 14.7 psi + 7.05 psi + 20 psi = 41.75 stainless steel 316 = 20000 psi S = Allowable stress, for stainless

E = Joint efficiency = 0.85 CA= Corrosion Allowance = 0.001 m/year m/ year n = equipment life = 20 years

                               


            

b. Impeller Design

Calculated of impeller design are: Diameter (Da) = 0.4 x 2.30 m = 0.92 m Blade width (W) = 0.125 x 0.92 m = 0.12 m Agitator space from based (E) = 0.167 x 2.60 m = 0.43 m 1.4 Blending Tank ( V-103) Calculation

133

Vanillin Production from Lignin c. Tank Design

Mixer tank functioning as a tank to mix black liquor slurry slurr y with H 2SO4. To design mixer tank, the dimensions of the tank needs to know the total volume of the tank. The total volume of the tank is calculation of tank working volume and tank head space. In the design d esign of storage tanks, the assumptions used are: - Ratio of height to diameter of the tank is 4:3 - Tank working volume is 0.85 of the total volume of tank - residence time is 10 minute.

                 



         

               Diameter and height of the tank:           Where; D is diameter of the tank and H is height of the tank. From the results of calculation and rounding up to 0.1 m, height and diameter of the tank is obtained respectively 2.04 m and 1.54 m. Thickness of shell tank:

 x (CA n)     P (psi) = Poperation (psi) + Pstatis + safety factor

134

Vanillin Production from Lignin = 14.7 psi + 4.49 psi + 20 psi = 39.19 S = Allowable stress, for stainless steel 316 = 20000 psi E = Joint efficiency = 0.85 CA= Corrosion Allowance = 0.001 m/year n = equipment life = 20 years

                      


       

c. Impeller Design

Calculated of impeller design are: Diameter (Da) = 0.4 x 1.54 m = 0.61 m Blade width (W) = 0.125 x 0.61 m = 0.08 m Agitator space from based (E) = 0.167 x 1.74 m = 0.29 m

1.5 Lignin Slurry Storage (S-102) Calculation

Storage tank functioning as a repository of alkali lignin slurry before enter to bubble column reactor. To calculate the dimensions of the tank needs to know the total volume of the tank. The total volume of the tank is calculation of tank working volume and tank head space. In the design of storage tanks, assumptions using are: - Ratio of height to diameter of the tank is 4:3 - Tank working volume is 0.85 of the total volume of tank - residence time is 1 hour. Black liquor flow rate:

   135


          Tank working volume :

                           Diameter and height of the tank:         Where; D is diameter of the tank and H is height of the tank. From the results of calculation and rounding up to 0.1 m, height and diameter of the tank is obtained respectively 2.58 m and 1.93 m. Thickness of shell tank:


                      


136


        1.6 Waste Storage (S-103) Calculation

Storage tank functioning as a repository of waste from vanillin production process. To calculate the dimensions of the tank needs to know the total volume of the tank. The total volume of the tank is calculation of tank working volume and tank head space. In the design of storage tanks, assumptions using are: - Ratio of height to diameter of the tank is 4:3 - Tank working volume is 0.85 of the total volume of tank - residence time is 1 hour.

            



                             Diameter and height of the tank:         Where; D is diameter of the tank and H is height of the tank. From the results of calculation and rounding up to 0.1 m, height and diameter of the tank is obtained respectively 9.43 m and 7.07 m. Thickness of shell tank:

137



                       


       

1.7 H2SO4 Storage (S-104) Calculation

Storage tank functioning as a repository of H 2SO4 before used in vanillin production process. To calculate the dimensions of the tank needs to know the total volume of the tank. The total volume of the tank is calculation of tank working volume and tank head space. In the design of storage tanks, assumptions using are: - Ratio of height to diameter of the tank is 4:3 - Tank working volume is 0.85 of the total volume of tank - residence time is 1 hour.

           



138


                             Diameter and height of the tank:         Where; D is diameter of the tank and H is height of the tank. From the results of calculation and rounding up to 0.1 m, height and diameter of the tank is obtained respectively 4.09 m and 3.07 m. Thickness of shell tank:

 x (CA n)     P (psi) = Poperation (psi) + Pstatis + safety factor = 14.7 psi + 9.09 psi + 20 psi = 43.79 psi S = Allowable stress, for stainless steel 316 = 20000 psi E = Joint efficiency = 0.85 CA= Corrosion Allowance = 0.001 m/year n = equipment life = 20 years

                       


       

139

Vanillin Production from Lignin 1.8 NaOH Storage (S-105) Calculation

Storage tank functioning as a repository of NaOH before used in vanillin production process. To calculate the dimensions of the tank needs to know the total volume of the tank. The total volume of the tank is calculation of tank working volume and tank head space. In the design of storage tanks, assumptions using are: - Ratio of height to diameter of the tank is 4:3 - Tank working volume is 0.85 of the total volume of tank - residence time is 1 hour.

              



                             Diameter and height of the tank:         Where; D is diameter of the tank and H is height of the tank. From the results of calculation and rounding up to 0.1 m, height and diameter of the tank is obtained respectively 7.67 m and 5.75 m. Thickness of shell tank:

 x (CA n)     P (psi) = Poperation (psi) + Pstatis + safety factor

140

Vanillin Production from Lignin = 14.7 psi + 19.72 psi + 20 psi = 54.42 psi S = Allowable stress, for stainless steel 316 = 20000 psi E = Joint efficiency = 0.85 CA= Corrosion Allowance = 0.001 m/year n = equipment life = 20 years

                       


       

2.

Plate and Frame Filter

2.1 Plate and Frame Filter (PF-101)

Sizing Calculation : 1. Component mass and volume Component

input mass (ton)

output mass (ton)

Density 3 (ton/m )

input volume 3 (m )/ batch

output volum (m3)/ batch

2 3.91 18.45 0.31 0 24.68

2 3.91 13.78 0.31 4.67 24.68

1.3 1 1 1 1 13.35

1.54 3.91 18.45 0.31 0 24.22

1.54 3.91 13.78 0.31 4.67 24.22

Total VolumFiltrat

18.01

Lignin Alkali Water Lean Liquor Liquid Acid lean liquor solid Total Total Mass Filtrate Total Mass Cake

18.01 6.67

2. Filtrate density

         

3. Cake density

141


        4. Thickness of cake (L) Estimated thickness of cake is = 0.06 m 5. Estimated cake porosity



Cake porosity ( ) of black liquor with pH 9 at 30°C = 0.7 6. Dry solid per unit area (



       kg/m 2

7. Effective filtration area (A)

         m 2

8. Safety factor = 20% 9. Filtration area (A)

         10.In this design, we use press filter with the filter area 2 x 2 m (4 m 2) and have 50 chambers. So, total press filter that we need for this process is:

         And total minimum plate required is:

          142

Vanillin Production from Lignin 2.2 Plate and Frame Filter (PF-102)

Sizing Calculation: 1. Component of lignin Slurry

Component

input mass (ton)

output mass (ton)

Density 3 (ton/m )

input 3 volume (m )/ batch

output volum (m3)/ batch

Lignin

5

5

1.3

3.85

3.85

alkali sulfate

5.29

5.29

2.66

1.99

1.99

Liquid Acid

23.93

23.93

1

23.93

23.93

water

3.42

3.42

1

3.42

3.42

total

37.64

37.64

33.18

33.18

total mass filtrate

32.64 2.5

total mass cake

Volume filtrate

29.34

2. Filtrate density

          

3. Cake density

    4. Thickness of cake (L) Estimated thickness of cake is = 0.06 m 5. Estimated cake porosity



Cake porosity ( ) of black liquor with pH 3 at 30°C = 0.33 6. Dry solid per unit area (



       kg/m 2

143

Vanillin Production from Lignin 7. Effective filtration area (A)

         m 2

8. Safety factor = 20% 9. Filtration area (A)

         10.In this design, we use press filter with the filter area 1.5 x 1.5 m (2.25 m 2) and have 24 chambers. So, total press filter that we need for this process is:

             And total minimum plate required is:

             3

Pump

3.1 Black Liquor Pump (P-101)&(P-102)

Operation Condition : P suction= 100,000 Pa Pdischarge= 105,000 Pa T = 600 C Mass Rate = 66.77 ton/h Density = 1818.2kg/m 3 Liquid Viskosity = 5.09 cP

Pump design :

 

(Timmerhaus, 2004)

144


       From tabel A.3 buku Noel de Nevers (1991), we choose pipe with spesification: Nominal Measure: 6 inch Schedule number : 40

Inner Diameter (ID) : 6.065in Outer Diameter (OD) : 6.625 in Inside sectional area : 28.9 inch 2

Velocity,

     Reynold Number:

     (aliran turbulen) To get the value of the friction factor, used 6:10 on the book charts Noel de Nevers (1991), in which the first note ε / D. To pipe the design of this plant, used

types of commercial steel. From table 6.2 on the book Noel de Nevers (1991), is known for stainless steel pipes , value ε = 0,000046 m. So, value ε/D = 0.0029

From 6:10 charts Noel de Nevers book (1991), the value of the friction factor (f) = 0,0034

Assumption of friction loss in the pipe is relatively the same. Friction loss :

Number of Velocity

Equivalent pipe diameter

Tank outlet

0.5

25

Tank inlet

1

50

145

Vanillin Production from Lignin Gate valve

0.3

15

4 elbow

9

450

Total

10.8

540

Extra Length of Pipe:

        Total Length

      Pressure Drop

Pressure Drop = 4381.08 N/m 2

Head

: 3.87 m

Pressure Differences : 5000 N/m 2 Efficiency

Eff = 82.77%

From Energy Balance, So we can get, W

: 43.08 J/kg

Power : 0.32 kWh/operation 3.2 Black Liquor Acidification Pump (P-102)

Operation Condition : P suction= 105,000 Pa 146

Vanillin Production from Lignin Pdischarge= 700,000 Pa T = 600 C Mass Rate = 33.38 ton/h Density = 1020kg/m 3 Liquid Viskosity = 1.7 cP

Pump design :

  (Timmerhaus, 2004)        From tabel A.3 buku Noel de Nevers (1991), we choose pipe with spesification: Nominal Measure: 6 inch Schedule number : 40


Velocity,

    

Reynold Number:

     (Turbulen Stream) To get the value of the friction factor, used 6:10 on the book charts Noel de Nevers (1991), in which the first note ε / D. To pipe the design of this plant, used


From 6:10 charts Noel de Nevers book (1991), the value of the friction factor (f) = 0,0034 Assumption of friction loss in the pipe is relatively the same.

147

Vanillin Production from Lignin Friction loss :

Number of Velocity Tank outlet Tank inlet Gate valvle 4 elbow

Equivalent pipe diameter 0.5 1 0.3 6 7.8

Total

25 50 15 300 390


        Total Length

      Pressure Drop

Pressure Drop = 1271.13 N/m 2 Head

: 4.58 m

Pressure Differences : 595,000 N/m 2 Efficiency

Eff = 82.49% From Energy Balance, So we can get, W

: 629.46 J/kg

Power

:2.35 kWh/operation

3.3 Lignin Acidification Pump (P-103)

Operation Condition : P suction= 105,000 Pa Pdischarge= 700,000 Pa T = 600 C

148

Vanillin Production from Lignin Mass Rate = 61.68 ton/h Density = 1774.71kg/m3 Liquid Viskosity = 1.32 cP

Pump design :

  (Timmerhaus, 2004)        From tabel A.3 buku Noel de Nevers (1991), we choose pipe with spesification: Nominal Measure: 6 inch Schedule number : 40


Velocity,

    

Reynold Number:

     (Turbulen Stream) To get the value of the friction factor, used 6:10 on the book charts Noel de Nevers (1991), in which the first note ε / D. To pipe the design of this plant, used


From 6:10 charts Noel de Nevers book (1991), the value of the friction factor (f) = 0,0034 Assumption of friction loss in the pipe is relatively the same. Friction loss :

Number of Velocity

Equivalent pipe diameter

149

Vanillin Production from Lignin Tank outlet Tank inlet Gate valvle 4 elbow

0.5 1 0.3 9 10.8

Total

25 50 15 450 540


        Total Length

      Pressure Drop


: 3.16 m


Eff = 81.98% From Energy Balance, So we can get, W

: 368.26 J/kg

Power

: 2.56 kWh/operation

3.4 Lignin Solution Pump (P-104)

Operation Condition : P suction= 105,000 Pa Pdischarge= 105,000 Pa T = 600 C Mass Rate = 35.15 ton/h Density = 1814.6kg/m 3

150

Vanillin Production from Lignin Liquid Viskosity = 2.08cP

Pump design :

  (Timmerhaus, 2004)        From tabel A.3 buku Noel de Nevers (1991), we choose pipe with spesification: Nominal Measure: 4inch Schedule number : 40

Inner Diameter (ID) : 4.026in Outer Diameter (OD) : 4.5 in Inside sectional area : 28.9 inch

Velocity,

2

    

Reynold Number:

     (Turbulen Stream) To get the value of the friction factor, used 6:10 on the book charts Noel de Nevers (1991), in which the first note ε / D. To pipe the design of this plant, used



Number of Velocity Tank outlet Tank inlet Gate valvle

Equivalent pipe diameter 0.5 1 0.3

25 50 15

151

Vanillin Production from Lignin 4 elbow

3 4.8

Total

150 240


        Total Length

      Pressure Drop


: 3.12 m


Eff = 79.83 % From Energy Balance, So we can get, W

: 32.32 J/kg

Power


3.5 Lignin Solution Pump (P-105)

Operation Condition : P suction= 105,000 Pa Pdischarge= 105,000 Pa T = 600 C Mass Rate = 49.21 ton/h Density = 1814.6kg/m 3 Liquid Viskosity = 2.08cP

152


Pump design :

  (Timmerhaus, 2004)        From tabel A.3 buku Noel de Nevers (1991), we choose pipe with spesification: Nominal Measure: 6 inch Schedule number : 40


Velocity,

    

Reynold Number:

     (Turbulen Stream) To get the value of the friction factor, used 6:10 on the book charts Noel de Nevers (1991), in which the first note ε / D. To pipe the design of this plant, used



Number of Velocity Tank outlet Tank inlet Gate valvle 4 elbow Total


25 50 15 150 240

153



        Total Length

      Pressure Drop


: 4.48 m



: 44.53 J/kg

Power


3.6 Vanillin Slurry Pump (P-106)

Operation Condition : P suction= 105,000 Pa Pdischarge= 200,000 Pa T = 600 C Mass Rate = 4.87 ton/h Density = 1609kg/m 3 Liquid Viskosity = 5.13cP

Pump design :

154


  (Timmerhaus, 2004)        From tabel A.3 buku Noel de Nevers (1991), we choose pipe with spesification: Nominal Measure: 1.5inch Schedule number : 40


Velocity,

2

    

Reynold Number:

     (Turbulen Stream) To get the value of the friction factor, used 6:10 on the book charts Noel de Nevers (1991), in whic h the first note ε / D. To pipe the design of this plant, used types of commercial steel. From table 6.2 on the book Noel de Nevers (1991), is known for stainless steel pipes , value ε = 0,000046 m. So, value ε/D = 0.0011


Number of Velocity Tank outlet Tank inlet Gate valvle 4 elbow Total


25 50 15 150 240


155


        Total Length

      Pressure Drop

Pressure Drop = 52,223 N/m 2 Head

: 0.34 m



: 94.83 J/kg

Power


3.7 Vanillin Solution Pump (P-107)

Operation Condition : P suction= 105,000 Pa Pdischarge= 150,000 Pa T = 600 C Mass Rate = 0.85 ton/h Density = 1015.67kg/m3 Liquid Viskosity = 1.65cP

Pump design :

  (Timmerhaus, 2004)        156

Vanillin Production from Lignin From tabel A.3 buku Noel de Nevers (1991), we choose pipe with spesification: Nominal Measure: 1.5 inch Schedule number : 40


Velocity,

2

    

Reynold Number:

     (Turbulen Stream) To get the value of the friction factor, used 6:10 on the book charts Noel de Nevers (1991), in which the first note ε / D. To pipe the design of this plant, used





Total

25 50 15 150 240


        Total Length

157


      Pressure Drop

Pressure Drop = 52,223 N/m 2 Head

: 0.34 m



: 50.12 J/kg

Power


3.8 Water Pump (P-108)

Operation Condition : P suction= 105,000 Pa Pdischarge= 700,000 Pa T = 600 C Mass Rate = 3.33 ton/h Density = 1000kg/m 3 Liquid Viskosity = 0.89cP

Pump design :

  (Timmerhaus, 2004)        From tabel A.3 buku Noel de Nevers (1991), we choose pipe with spesification: Nominal Measure: 1.5 inch Schedule number : 40 158

Vanillin Production from Lignin Inner Diameter (ID) : 1.9in Outer Diameter (OD) : 1.61 in Inside sectional area : 2.04 inch

Velocity,

2

    

Reynold Number:

     (Turbulen Stream) To get the value of the friction factor, used 6:10 on the book charts Noel de Nevers (1991), in which the first note ε / D. To pipe the design of this plant, used





Total

25 50 15 300 390


        Total Length

      Pressure Drop

159

Vanillin Production from Lignin Pressure Drop = 91.87 N/m 2 Head

: 4.58 m



: 639.97 J/kg

Power


      


                             Diameter and height of the reactor:         Where; D is diameter of the tank and H is height of the tank.From the results of calculation and rounding up to 0.1 m, height and diameter of the tank is obtained respectively 1.89 m and 1.134 m. Thick walls of the tank:

160


      P (psig) = P operation (psia) + Pstatis + safety factor = 159,7 psia + 14.7 psia + 25 psia = 199,4 psia = 184,7 psig S = Allowable stress, for Stainless Steel 316 = 74500 psig E = Joint efficiency = 0.8 (Walas, 1988) R = D/2 = 0,8465 m = 33,32 in Corrosive factor = 0.15 in

                   

4

Bubble Column Reactor

Stoichiometry 1

Conversion 70%

Lignin Oxidation : 0.5 L + 1.56 O2 --> V + 114 X Initial (mol)

2350.242 10781.25

Change (mol)

-1645.17 -7332.75 4700.483

Remaining (mol)

705.0725 3448.496 4700.483

Stoichiometry 2 Vanilin Oxidation : V + O2 --> Product Initial (mol)

4700.483 3448.496

Change (mol)

-3290.34 -3290.34 3290.338

Remaining (mol)

1410.145 158.1582 3290.338 massa

500592.048 gram

161

Vanillin Production from Lignin 0.50059205 ton 500.592048 kg

        Reactor Volume = 25.51 m 3 Reactor functioning as a tank to mix and react lignin slurry with oxygen in alkaline condition. To design bubble column reactor, the dimensions of the reactor needs to know the total volume of the reactor. In the design of reactor, the assumptions used are: - Ratio of height to diameter of the bubble column reactor is 5:3 - residence time is 2 hour. Diameter and height of the reactor:

        Where; D is diameter of the tank and H is height of the tank. From the results of calculation and rounding up to 0.1 m, height and diameter of the tank is obtained respectively 4.48 m and 2.69 m.

Thickness of shell tank:

 x (CA n)     162

Vanillin Production from Lignin P (psi) = Poperation (psi) + Pstatis + safety factor = 145 psi + 6787 psi + 20 psi = 174.84 S = Allowable stress, for stainless steel 316 = 20000 psi E = Joint efficiency = 0.85 CA= Corrosion Allowance = 0.001 m/year n = equipment life = 20 years

                      Roof thickness of the tank:

       5

Ultrafiltrasi

Sizing Calculation : Component mass and volume Component

Input mass

Output

Density

(ton)

mass (ton)

(ton/m )

3

Input

Output

volume

volume

(m )/

3

(m3)/

batch

batch

Vanillin

0.500

0.500

1.05

0.476

0.476

Alkali Lignin Slurry

5.360

0.000

1.22

4.393

0

Water

1.200

1.200

1

1.200

1.200

163

Vanillin Production from Lignin Others

4.780

0.000

1

4.780

0

Filtrate Cake

0.000

10.140

1.3

0

7.800

Total

11.840

11.840

10.849

9.476

1.700

volum

1.676

total mass filtrate

filtrat

Filtrate density

         3. Cake density

        4. Thickness of cake (L) Estimated thickness of cake is = 0.03 m 5.

Estimated cake porosity



Cake porosity ( ) of product = 0.2 6.

Dry solid per unit area (



        kg/m 2

7.

Effective filtration area (A)

      164


   m

2

8.

Safety factor = 20%

9.

Filtration area (A)

          10.In this design, we use hollow fiber ultrafiltration with the filter area 190 m 2 and have 10000 fibers per module. So, filter that we need for this process is:

        6

Spray Dryer

Surface moisture is removed in about 5 sec, and most drying is completed in less than 60 sec. Parallel flow of air and stock is most common. Atomizing nozzles have openings 0.012-0.15 in. and operate at pressures of 300-4000 psi. Atomizing spray wheels rotate at speeds to 20,000rpm with peripheral speeds of 250-600 ft/sec. With nozzles, the length to diameter ratio of the dryer is 4-5; with spray wheels, the ratio is 0.5-1.0. For the final design, the experts say, pilot tests in a unit of 2 m dia should be made.

Diameter of particle,

   = 55,65 μm

T air inlet = 120oC T air oulet = 110oC T feed inlet = 80 oC T feed outlet = 90 oC

165

Vanillin Production from Lignin Design aspect include : Atomizer : its type & design, flow rate of the heated inlet air, settling velocity, solid & Gas operating velocity, chamber Diameter, residence time, design of Conical bottom.

Atomizer : Centrifugal disk atomization is particularly advantageous for atomizing suspensions and pastes that erode and plug nozzle. Type of Disk atomizer (Vane, Kesner, Pin) Ref. patent US20040139625. Diameter of the disk atomizer 5-45 cm. Rotational speed 33.000 rpm, peripheral speed 6000 m/min. Mean particle size 55 micron.

Feed Rate = 730 kg/hr = 24 lb/min Peripheral speed is got from Herring and Marshal chart (peripheral speed vs. mean particle diameter, with feed rate as parameter). On interpolation we get 473 ft/s (v =8952 m/min).

Disk Selection Disk selected = B-1, with diameter 0,59 ft. Vane height= 0,406 ft, vane length = 1 ft, number of vanes = 60. Rotational speed (N) =

      

N = 473 * 60 = 15800 rpm So, power consumption of atomizer can be calcaulated below

      166

Vanillin Production from Lignin Spray Chamber design

167


X1 = 0.015, X 2 = 0.003 Y1 = 0.01317 (by psychometric chart at given DB & WB) humidity air HL1= 112.2 kJ/kg of dry solid, H L2= 121.68 kJ/kg of dry solid H1= 134.29 kJ/kg dry air Simultaneously solving mass balance and enthalpy balance eq (1) and (2) we get Y2= 0.0206 Evaporation rate of water = (0.015-0.003)*1500 kg/hr = 18 kg Assumed chamber efficiency is 70%, therefore net evaporation rate of water is 18/0.7 =25.71 kg water /hr. Moisture removed per kg of dry air = (0.0206-0.01317)=0.00743 kg water per kg of dry air. Gs = 25.71/0.00743 = 3460 kg/hr.

After this we must calculate humid volume

168


Humid volume inlet (Vin) = 0.283 m3/kg dry air Humid volume outlet (Vout) = 0.281 m3/ kg dry air Vavg = (Vin + Vout)/2 = 0.282 m3 / kg dry air Assume Dp = 100 micron And then we calculate operating velocity. The operating velocity in the case of non-dusting spray dryer is taken as two times the settling velocity of the drop.

Settling velocity didapatkan berdasarkan perhitungan adalah sebesar 0.25 m/s. Stoke’s law is applicable if Re < 2. So we must check the reynold number

    So we can get operating velocity, va= 2vs = 2*0.25 = 0.5 m/s

Column Area:

     = 3.1 m2 169


Column diameter :

    = 1,974 m, for safety, assuming 15 % safety

factor, Dc = 2.1 m. Residence time :

√    

Time required to evaporate moisture from droplet :

Өp = 0.00969 sec, Өp < td, design is acceptable

Chamber is a cylindrical with a conical bottom Total volume of chamber (Vt) = Gs*Vav*td = 5.2 m3 Minimum height of cylindrical portion (hmin) = vs*Өp = 0.00068 m

Recommended height of cylindrical portion (hcyl) = 0.6 *Dc = 1.47 m

   = 3.1 m3   m Height of cone (hcone) =    Volume Cone =

Cone angle : tan(a/2) = Dc/2hcone a = 20.57 degree Thickness of chamber : tmin = (Dc+100)/1000 = 0.11 inch

170

Vanillin Production from Lignin 7.

Material Safety Data Sheet (MSDS) 1. Black Liquor Properties

Information

Molecular Weight (g/mol)

Not available

Melting Point ( C)

Not available

Boiling Point ( C)

Variable

Form

Slurry

Odor

rotten egg odor

pH

Typical Range 10-12

Color

Black liquid

Solubility

Soluble in cold and hot water

Flammability

Not flammable, will burn at very high temperatures

Materials to avoid

Aluminum and acids. Contact with acids and oxidizing agents can result in release of potentially lethal concentrations of hydrogen sulfide (H2S) gas Corrosive with aluminum Causes eye and skin irritation and corrosion; respiratory airways irritation if ingested in large amounts : digestive tract irritation and corrosion, vomiting, diarrhea, and death (possible) Do not contact with eyes, skin, and clothing. Do not be inhaled Do not contact with the acid Keep away from acids and aluminum Gloves, respirator, eye protection, goggles and footwear Open ventilation and insulation use

Corrosivity Toxic effect

Handling

Storage Personal protective equipment Spill procedures

171

Vanillin Production from Lignin a shovel to dispose of spill 2. H2SO4 Properties

Information


98

Melting Point ( C)

10.36

Boiling Point ( C)

100

Form

Liquid

Odor

Odorless

pH

Typical Range 2-3

Color

Transparent

Solubility

Soluble in cold and hot water

Flammability Materials to avoid

Easy to flammable Organic material, metal, acids, and alkali Corrosive with aluminum, stainless steel (304,316), not corrosive with glass Causes eye irritation and burn if contact with skin. Do not contact with eyes, skin, and clothing. Keep in closed container, cool, and good ventilated Gloves, respirator, eye protection, goggles and footwear Spare with soil, sand, and not flammable material

Corrosivity

Toxic effect Handling Storage Personal protective equipment Spill procedures

172


3. NaOH Properties

Information


40

Melting Point ( C)

323

Boiling Point ( C)

1388

Form

Solid

Odor

Odorless

pH

13.5 (Basic)

Color

White

Solubility

Easily soluble in cold water

Flammability Materials to avoid Corrosivity

Not flammable Aluminum Very caustic to aluminum and other metals in presence of moisture. Causes damage to the following organs: lungs Do not contact with eyes, skin, and clothing. Keep in closed container and cool Gloves, respirator, eye protection, goggles and footwear Insulation use a shovel to dispose of spill

Toxic effect Handling Storage Personal protective equipment Spill procedures

173

Vanillin Production from Lignin REFERENCE

A, m. Z., silva, e. B., & rodrigues, a. (2007). Recovery of vanillin from lignin/vanillin mixture by using tubular ceramic ultrafiltration membranes. Journal of membrane science , 221 – 237.

Araújo, j. D. (2008). Production of vanillin from lignin present in the kraft black liquor of the pulp and paper industry. Biological and chemical engineering . Araújo, j. D., grande, c. A., & rodrigues, a. E. (2010). Vanillin production from lignin oxidation in a batch reactor. Chemical engineering research and design , 1024 – 1032.

Heradewi. (2007). Isolasi lignin dari lindi hitam proses pemasakan organosolv serat tandan kosong kelapa sawit (tkks). Bogor: institut pertanian bogor.

Jo, j. D., grande, c. A., & rodrigues, a. E. (2009). Structured packed bubble column reactor for continuous production of vanillin from kraft lignin oxidation. Journal of catalysis today , s330-335. Peters, m. S., & timmerhaus, k. D. (1991). Plant design and economics for chemical engineers. New york: mcgraw-hill.

Priefert, h., rabenhorst, j., & steinbüchel, a. (2001). Biotechnological production of vanillin. Appl microbiol biotechnol , 56:296 – 314. Silvaa, e. B., zabkovaa, m., araújoa, j., c.a. Catetob, c., & barreirob, m. (2009). An integrated process to produce vanillin and lignin-based polyurethanes from kraft lignin. Chemical engineering research and design , 1276 – 1292. Sinnott, R. K. (2005). Chemical Engineering Design, Vol. 6. ButterworthHeinemann: Elsevier. Tomani, p. (2009). The lignoboost process. Cellulose chemistry and technology .

174

Final Report Group 6

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