Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

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Design of a High Fructose Corn Syrup pilot Plant Tasneem Mufareeh Ali Mahmoud B.Sc. (Hons.) in Chemical Engineering Technology University of Gezira (2011) A Dissertation Submitted to the University of Gezira in Partial Fulfillment of Requirement for the Award of the Degree of Master of Science in Chemical Engineering Department of Applied Chemistry and Chemical Technology Faculty of Engineering and Technology January 2014

Transcript of Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Page 1: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Design of a High Fructose Corn Syrup pilot Plant

Tasneem Mufareeh Ali Mahmoud

B.Sc. (Hons.) in Chemical Engineering Technology

University of Gezira (2011)

A Dissertation

Submitted to the University of Gezira in Partial Fulfillment of

Requirement for the Award of the Degree of Master of Science

in

Chemical Engineering

Department of Applied Chemistry and Chemical Technology

Faculty of Engineering and Technology

January 2014

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Design of a High Fructose Corn Syrup pilot Plant

Tasneem Mufareeh Ali Mahmoud

Supervision committee:

Name: Position Signature Dr. Babiker Karama Abdalla Main Supervisor …………….

Dr. Imad Abdalmonem Mahagoub Co-supervisor …………….

Date: January, 2014

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Design of a High Fructose Corn Syrup pilot Plant

Tasneem Mufareeh Ali Mahmoud

Examination committee:

Name: Position Signature

Dr. Babiker Karama Abdalla Chair person .…….…….

Pror. Hamid Mohamed Mustafa External Examiner ......……….

Dr. Abdalla Mohamed Ahmed slman Internal examiner .…………

Date of Examination: 28-1-2014

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Dedication

This work is dedicated for all the great men and women

This work is dedicated for my mother and my father who gave my live many of its

meanings and means.

To my brothers and sisters, and friends, who share me the voyage and path…

My supervisor Dr; Babiker Karama Abdalla,

To; Mohamed Mufarreh…

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Acknowledgement

The Researcher wish to acknowledge with gratitude everyone who helped in the preparation and

publication of this research.

Great thanks are due to Mohamed Mufareeh, for helping me.

Thanks are due to Dr. Imad Eldeen Abdulmoniem.

The researcher also wish to acknowledge those who supported the practical arm of this study:

Prof; Babiker Karama Abdalla,

Thanks are also to my family and my friends who supported me in this study to be accomplished.

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Design of High Fructose Corn Syrup (HFCS) pilot Plant

Tasneem Mufareeh Ali Mahmoud

Abstract

High fructose corn syrup (HFCS) is widely used in industry for the production of foods and beverages.

Our MyThis study objective is to design a plant for the production of HFCS from corn waste to

participate in the provision of HFCS needed in Sudan. This HFCS production plant project is to meet

the need for HFCS in Sudan. The annual consumption of HFCS in Sudan is 9000 tones. This plant will

produce HFCS using acid hydrolysis followed by glucose isomerase enzyme hydrolysis of corn waste,

and yields ethanol as a by-product. This is a full design and feasibility study. The project requires

2861.1 tons/day of corn waste, 1.14 tons /day sulfuric acid (H2SO4), 44.06 tons /day, of ethanol,

15.9*103 tons /day Glucose isomeraise and 1000 tonestons/day from (HCl). The cost of the raw

material used by the project will be 58.72 Million $/year. The planned annual HFCS production of the

project is about 10000 tones.The project will produce 171.7 tons of ethanol per day. Total capital

investment cost is seven Million $.The estimated profite is 1.4 Million $ /year. The Ppayout period

backe of the project (Payout time) is four years. A part of the energy needed by the plant is to be

provided by steam boilers. The remaining will be provided as regular electricity. The plant is's proposed

location in Sudan is in Al-Bbagir in Sudan, as because of the availability of appropriadte conditions

for the cultivation of corn. The location of the plant also provides, security, labour, transportation, and

facilitates guarantees the feasibility and effectiveness of the project. The plant complex consists of

different specialized unitse. There are is a processing area, areas for utillities (like boilers and

compressor), administration offices, hospitals , super market, schools, and social and sports clubs.

According to my estimates, the project could probably pay back the investment capital in four years. This number

may be overly optimistic, ; however, this project has all the requirements for success.

The implementation of this project in Sudan has the potential of eliminating the reliance on imported

HFCS by the food and beverage manufacturers and therefore significantly reduces the cost of

production and enhances competitiveness, maintaining similar product quality.

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عالي الفركتوزتصميم وحدة لانتاج السكر

تسنيم مفرح علي محمود

الدراسة ملخص

الهدف .خاصه وصناعة المشروباتعموما الاستخدم في الصناعات الغذائية ةز واسعكتوبالفر ةالسكر الغني ارةعص تأصبح

الاستهلاك في السودان. حجم همن هذا البحث هو تصميم مصنع لانتاج السكر الغني بالفركتوز من بقايا الذرة للمساهمة في توفير

الدراسة هي تصميم ودراسة جدوى وهذه ا.طن تقريب 9000السنوي من عصير السكر الغني بالفركتوز في السودان هي

قوم التحليل باستخدام انزيم الجلكوز ايزومريس الذي ي هم التحليل باستخدام الاحماض ويليالطريقة المستخدمة هي عملية استخداو

ن/يوم من ط 2861.1والفركتوز وينتج الايثانول كمنتج جانبي .يتطلب هذا المشروع حوالي بالتحول بين المتماكبين الجلكوز

طن/يوم من انزيم 15900طن/يوم من الايثانول و 44.06طن/يوم من حمض الكبريتيك وحوالي 1.1بقايا الذرة وحوالي

مليون دولار خلال 58.72طن من حمض الهيدروكلوريك, وتعتبر تكلفة المواد الخام حوالي 1000جلكوز ايزومريس و

ذلك ينتج من السكر الغني بالفركتوز وبجانب سنويا طن 10000انتاج هذا المشروع هو العام.ويعتبر الهدف الاساسي من

مليون دولار سنويا. ويقوم 1.4مليون دولار ويعتبر الربح 7طن من الايثانول في اليوم.وتعد تكلفة رأس المال حوالي 171.7

لمصنع فجزء منها يوفر من خلال استحدام سنوات. أما بالنسبة للطاقة التي يستخدمها ا 4المشروع باعادة تكلفة انشائه في حوالي

في مدينة الباقير، وذلك لتوفر الظروف ان يقوم المصنع في السودان في اقتراحي المراجل البخارية و المتبقي من الكهرباء.

نعداخل المص تتكون المنطقة ل مهرة و قريبة في موقعها لنقل البضائع.اوايضاهي مدينة آمنة وبها عم ,لزراعة الذرة المناسبة

محلات المن عدد من الوحدات المختلفة والمتخصصة التي تتم المعالجة فيها مثل الغلايات ومكاتب الإدارة والمستشفيات و

لما ذكر من ميزات لهذا المشروع وهو ايضا يعيد تكاليف انشائه بالاضافةالنوادي الاجتماعية والرياضية. والمدارس و التجارية

ا.واخيرا تنفيذ مثل هذا المشروع في السودان تحد من استيراد السكر الغني بالفركتوز حخلال سنوات فهذا يجعل منه مشروعا ناج

ودة سة محافظا على نفس مستوى جمن قبل مصنعي الاغذية والمشروبات وبالتالي هذا يقلل من التكلفة الانتاج ويشجع المناف

المنتجات.

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Table of Contents

CHAPTER ONE 1

Sweeteners 1

HFCS around the world 1

Justification of the problem 2

Objectives 3

CHAPTER TWO 4

Advantages of HFCS 4

Importance and uses of HFCS 4

Comparison between HFCS and other sweeteners 5

Types of HFCS and Usage 7

Properties of HFCS 7

Concern about relation between HFCS, obesity, diabetes 9

High fructose corn syrup: Production and uses 10

CHAPTER THREE 13

Comparison between the Types of reactions which produce HFCS 13

Production of HFCS 13

Material balance 23

The amount of substance use in the process 24

Material balance around equipment’s 24

Over all material balance 39

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Energy balance 41

General equation for energy balance 41

Energy balance around equipments 41

Economical Evaluation 46

Introduction 46

Capital Investment 46

Pay pack period 48

Calculation 48

CHAPTER FOUR

Possibility of the project 53

CHAPTER FIVE 55

Conclusion 55

References 56

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List of tables

Table (2.1): examples for uses of HFCS in some industries

Table (2.2): Comparison of Caloric Sweetener Compositions

Table (2.3):Carbohydrate Composition (Dry Basis)

Table (2.4): Physical & Chemical Properties

Table (2.5) :Viscosities (Centipoises')

Table (2.6):Weight/Volume Factors (100°F)

Table (2.7): Microbiological Standards

Table (2.8): Nutritional Data/100g

Table (2.9): Nutritional values calculated per 100 g of HFCS

Table (3.1): Molecular weight of component

table(3.2)ــــــــــــtable(3.56)Material balance

Table (3.57): Cost of the equipment

Table (3.58): Total capital investment

Table (3.95): row material cost

Table (3.60) :Operation labor cost

Table(3.61): Total production cost

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Table of figures

Fig (2.1)The formulae of fructose and glucose

Figure(2.2): Sweetener consumption in the United States

Fig (2.3) block diagram of HFCS production

Fig (3.1) Block diagram of production HFCS 55

Fig (3.2)Production of High-Fructose Corn Syrup

Fig (3.3) flow chart of HFCS

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Chapter one

Introduction

1.1 Sweeteners:

Liquid and solid sweeteners are produced around the world from several starch sources including corn,

wheat, tapioca, potatoes and even cellulose hydrolyzed. The most widely used of Liquid sweeteners is

corn.

Sugars are found in the tissues of most plants but are only present in sufficient concentrations for efficient

extraction in sugar cane and sugar beet.

High-fructose syrups are sweeteners produced from several starches, but corn is the primary starch used

to produce HFS (Starch is a polymer made of glucose molecules linked into long chains). High fructose

corn syrup (HFCS) is the largest single sweetener syrup produced. (Marc J.E.C. van der Maarel et.al,

2001)

High fructose corn syrup (HFCS) is a sweetener made from corn and can be found in numerous foods and

beverages. HFCS is composed of either 42 percent or 55 percent fructose, with the remaining sugars

being primarily glucose and higher sugars. In terms of composition, HFCS is nearly identical to cane

sugar (sucrose), which is composed of 50 percent fructose and 50 percent glucose. Glucose is one of the

simplest forms of sugar that serves as a building block for most carbohydrates. Fructose is a simple sugar

commonly found in fruits and honey. (Kay Parker et.al, 2010).

High-fructose corn syrup started to take over the market and replace cane sugar in the 1980s. Compared

to sucrose, HFCS provides foods with better flavor enhancement, stability, freshness, texture, color,

durability, and consistency, also It is cheaper and more versatile ingredient that can be used not only to

sweeten foods, but also to extend shelf life, prevent freezer burn and, in the case of baked goods, get them

brown and keep them soft. It is now in all sorts of products you wouldn't necessarily expect, including

frozen foods and breads.

HFCS consists of 24% water, and the rest sugars. The most widely used varieties of high-fructose corn

syrup are: HFCS 55 (mostly used in soft drinks), approximately 55% fructose and 42% glucose.

1.2 HFCS around the world:

1.2.1United States

US sweetener consumption, 1966–2012, in dry pounds. It is apparent from this graph that overall

sweetener consumption, and in particular glucose-fructose mixtures, has increased since the introduction

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of HFCS. Thus, the amount of fructose consumed in the United States has increased since the early

1980s. This would be true whether the added sweetener was HFCS, table sugar, or any other glucose-

fructose mixture

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A system of sugar tariffs and sugar quotas imposed in 1977 in the United States significantly

increased the cost of imported sugar, and U.S. producers sought cheaper sources. HFCS derived

from corn is more economical because the domestic U.S. prices of sugar are twice the global price

and the price of corn is kept low through government subsidies paid to growers.

HFCS became an attractive substitute and is preferred over cane sugar by the vast majority of

American food and beverage manufacturers Soft drink makers such as Coca-Cola and Pepsi use

sugar in other nations but switched to HFCS in the U.S. in 1984. Large corporations, such

as Archer Daniels Midland, lobby for the continuation of government corn subsidies.

1.2.2 Mexico

Other countries, including Mexico, typically use sugar in soft drinks. Some Americans seek

out Mexican Coca-Cola in ethnic groceries because they prefer the taste compared to Coke in the

U.S. which is made with HFCS. Kosher for Passover Coca-Cola sold in the U.S.

1.2.3 European Union

In the European Union (EU), HFCS, known as isoglucose in sugar regime, is subject to

a production quota. In 2005, this quota was set at 303,000 tons; in comparison, the EU produced

an average of 18.6 million tons of sugar annually between 1999 and 2001.[38] Wide-scale

replacement of sugar with HFCS has not occurred in the EU. For labeling purpose, syrup with

more than 50% of glucose, like HFCS 42, called Glucose-Fructose Syrup (GFS), and more than

50% of fructose, like HFCS 55, called Fructose-Glucose Syrup (FGS), although production within

Europe is minimal.

1.2.4 Japan

In Japan HFCS consumption accounts for one quarter of total sweetener consumption. In Japanese

Agricultural standard it is called (lit, isomerized sugar). If a syrup contains more than 50% of

glucose, it is called (lit. glucose fructose syrup); if syrup contains 50% to 90% of fructose, it is

called (lit. fructose glucose syrup); and if syrup contains more than 90% of fructose, it is called

(lit, high fructose syrup).

1.3 Justification of the problem

In some products sweetened with sucrose, the covalent bond between the fructose and glucose molecules

breaks down in low acid environments, such as those found in soft drinks, as well as at high temperatures,

such as during storage in hot climates, the sucrose content of a cola beverage decreased from 36% of total

sugars to only 10% of sugars 3 months after manufacture, and the free fructose content increased from

32% to 44% of total sugars. This creates variability in the taste profile of the product. In contrast, HFCS

maintains its structural stability over a range of temperatures and acidic conditions.

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1.4 Objectives

1.4.1General objective:

Design of a Novel Plant for High-fructose corn syrup (HFCS) Production from corn.

1.4.2 Specific objectives:

To optimize this design I need to do:

Material balance: to calculate the amount of material which I need in the plant.

Energy balance: to calculate the amount of energy which pilot plant need it to operate and produce the

HFCS.

Economic evaluation: to knew the possibility of the project.

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Chapter two

Literature review

2.1 Introduction:

People used to drink soft drinks extravagantly, every day 1.6 billion bottles sold around the world, So

that it has become the largest brand on the level.

2.2 Advantages of HFCS:

HFCS is commonly used to make sodas, fruit drinks, chips and candy bars. However, many other foods

also contain HFCS, such as bread, fruit-flavored yogurt, and cereal, condiments like ketchup, canned

vegetables, salad dressings and granola bars. (Kay Parker et.al, 2010)

Cheaper for farmers to grow corn than sugar cane. Foreign sugar makes the price of HFCS

substantially lower than the price of sugar. So a lot of food producers choose HFCS to

reduce their production costs and maximize profit.

HFCS is made when corn syrup is treated with enzymes to convert some of its glucose into

fructose, resulting in syrup that is 42 percent or 55 percent fructose. Sucrose contains one

molecule of glucose and one molecule of sucrose. Although its producers argue that HFCS

and table sugar have the same composition and the same calorific value, glucose and

fructose are bound differently in each one. In cane sugar, or sucrose, the two molecules are

linked by a chemical bond. When you eat table sugar, your body separates the two

molecules during digestion before they are absorbed into the body. In HFCS the molecules

are not liked, they are "free molecules.

2.3 Importance and uses of HFCS

As the result of improvement of our life we need more products Compatible with this improvement.

HFCS alternate sugar as the result of his Superiority and make product better.

2.3.1 Uses in Beverages and Frozen Foods

HFCS raises the freezing point in frozen beverage mixes which, According to the Sweet Surprise website,

makes them easier and quicker to thaw and mix with water. Manufacturers also use it as a flavor stabilizer

to ensure a longer shelf life in soft drinks, such as colas and fruit drinks. The Sweet Surprise website also

states that HFCS provides greater stability in carbonated sodas than cane sugar. In frozen fruits, it

enhances the flavor of the fruit, regulates tartness and helps maintain the texture and integrity of the fruit.

It also helps reduce freezer burn.

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2.3.2 Uses in baked Goods

In addition to its sweetening properties, HFCS also acts as a browning agent, which creates the golden

brown crust on baked goods. Additionally, according to the Corn Refiners Association, HFCS provides

sugar to complete the yeast fermentation process, which allows dough to rise. It also helps keep baked

goods moist by preventing sugar crystallization during the baking process. HFCS enhances the flavor of

fruit fillings and manufacturers also use it as a preservative. Common baked goods with HFCS include

unsweetened items such as breads, biscuits and dinner rolls, and sweetened items such as cookies and

cakes.

2.3.3 Uses in Creams, Sauces and Meats

HFCS provides sugar for the fermentation process in yogurt. It is also used as a thickener to create a

creamy texture in low-fat and non-fat dairy products such as cottage cheese, yogurt and sour cream. In

savory sauces, such as spaghetti sauce, HFCS enhances the spices and cuts the acidity of tomatoes. HFCS

acts as a thickener in sauces, such as barbecue, teriyaki and tomato-based products, which allows them to

cling to the surface of foods. HFCS also appears in meat products, such as sausages and processed lunch

meats, as a stabilizer, binding agent and flavor enhancer.

2.4 Some examples for uses of HFCS in some industries:

Table (2.1) examples for uses of HFCS in some industries

Beverages HFCS provides greater stability in acidic carbonated sodas than sucrose;

flavors remain consistent and stable over the entire shelf-life of the product.

Baked goods HFCS gives a pleasing brown crust to breads and cakes; contributes

fermentable sugars to yeast raised products; reduces sugar crystallization

during baking for soft-moist textures; enhances flavors of fruit fillings.

Yogurt HFCS provides fermentable sugars; enhances fruit and spice flavors; controls

moisture to prevent separation; regulates tartness

Spaghetti sauces, ketchup

and condiments

HFCS enhances flavor and balance – replaces the “pinch of table sugar

grandma added” to enhance spice flavors; balances the variable tartness of

tomatoes.

Granola, breakfast and

energy bars

HFCS enhances moisture control, retards spoilage and extends product

freshness; provides soft texture; enhances spice and fruit flavors.

2.5 Comparison between HFCS and other sweeteners:

Sugar and HFCS have the same number of calories as most carbohydrates; both contribute 4 calories per

gram. They are also equal in sweetness.

2.5.1 Cane and beet sugar

Cane sugar and beet sugar are both relatively pure sucrose. While glucose and fructose, which are the two

components of HFCS, are monosaccharide, sucrose is a disaccharide composed of glucose and fructose

linked together with a relatively weak glycoside bond. The fact that sucrose, glucose and fructose are

unique, distinct molecules complicates the comparison between cane sugar, beet sugar and HFCS. A

molecule of sucrose (with a chemical formula of C12H22O11) can be broken down into a molecule of

glucose (C6H12O6) plus a molecule of fructose (also C6H12O6 — an isomer of glucose) in a weakly acidic

environment by a process called inversion. Sucrose is broken down during digestion into a mixture of

50% fructose and 50% glucose through hydrolysis by the enzyme sucrose.

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Fig (2.1) the formulae of fructose and glucose

2.5.2 Honey

Honey is a mixture of different types of sugars, water, and small amounts of other compounds. Honey

typically has a fructose/glucose ratio similar to HFCS 55, as well as containing some sucrose and other

sugars. Like HFCS, honey contains water and has approximately 3 cal per gram. Because of its similar

sugar profile and lower price, HFCS has been used illegally to "stretch" honey. As a result, checks for

adulteration of honey no longer test for higher-than-normal levels of sucrose, which HFCS does not

contain, but instead test for small quantities of proteins that can be used to differentiate between HFCS

and honey.

Table (2.2) Comparison of Caloric Sweetener Compositions

Component Percentage HFCS-55 Sugar Honey

Fructose 55 50 49

Glucose 42 50 43

Other Sugars 3 0 5

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Figure (2.2): Sweetener consumption in the United States (Daniel Finnie, et.al, 2008)

2.6 Types of HFCS and Usage

- HFCS 42:

The percentage of glucose is 58% and fructose is 42%.

Which use in some beverages, beer, confectionary products canned goods, HFCS55

- HFCS 55:

The percentage of glucose is 45% and fructose is 55%.

Which use in soft drinks, ice cream, yogurt, processed foods, feed for honey bees for crop pollination

- HFCS 90:

The percentage of glucose is 10% and fructose is 90%.This used to make HFCS 55. (Blaise W. Leblanc,

2008)

2.7 Properties of HFCS:

HFCS is a viscous, colorless and odorless liquid. Nutritionally, is a carbohydrate containing percentages

of glucose and fructose. The fructose is combined with regular corn syrup to achieve the desired level of

sweetness and viscosity; Because HFCS is usually created to be several degrees sweeter than sugar.

HFCS does not tend to form crystals, as sucrose syrups do.

Table (2.3) Carbohydrate Composition (Dry Basis)

Fructose > 55%

Dextrose + Fructose > 95%

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Higher Saccharides < 5%

Table (2.4) Physical & Chemical Properties

Dry Substance % 76.5 – 77.5

pH 3.3 - 4.3

Ash % Trace

SO2 ppm <10

Moisture % 22.5 – 23.5

Appearance Clear to light straw liquid

Odor No detectable foreign odors

Table (2.5) Viscosities (Centipoises')

80 °F 700

100 °F 250

120 °F 100

Table (2.6) Weight/Volume Factors (100°F g)

Specific Gravity 1.372

Pounds/Gallon 11.45

Table (2.7) Microbiological Standards Total Plate Count <200 cfu/10g DSE

Yeast <10cfu/10g DSE

Mold <10 cfu/10g DSE

Listeria Absent

Salmonella Absent/25g

DSE= Dry Solids Equivalent

Table (2.8) Nutritional Data/100g Calories 308

Carbohydrates (g) 77

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Sugars (g) 75

Other Carbohydrates (g) 2

There are no fat, protein, fiber, vitamins, or minerals (including sodium) of dietary significance

2.8 Fructose and Adverse Health Outcomes

Many of the concerns about HFCS are, in fact, concerns about the role of fructose in appetite and

metabolism. Fructose is more quickly emptied from the stomach compared with other sugars and is

absorbed in the intestines more slowly and less completely than glucose. Unlike glucose, fructose intake

does not stimulate insulin secretion, which is likely due to the lack of fructose transporters (Glut-5) in the

β cells of the pancreas. Insulin is believed to directly and indirectly (though effects on leptin secretion)

inhibit food intake. The brain and central nervous system also lack Glut-5 transporters, further inhibiting

the ability of fructose to provide satiety signals. In addition, fructose can be more easily incorporated into

phospholipids and triacylglycerols than glucose, as fructose metabolism bypasses the key rate-limiting

step in the liver that slows glucose metabolism. Thus, consumption of excess amounts of fructose, but not

the same amount of glucose, has significantly increased rates of lipogenesis. In addition, fructose

consumption does not increase leptin or decrease ghrelin levels, in contrast to the hormonal response after

glucose ingestion.

2.9 Concern about relation between high fructose corn syrup,

obesity, diabetes

At present, insufficient evidence exists that HFCS consumption has contributed to obesity more than

sucrose, increased consumption of total calories (from any source), or decreased physical activity has.

Obesity is a serious and complex public health issue facing our nation and the rest of the world, it caused

by an imbalance between calories consumed from all foods and beverages if there is no balance, it is not

uniquely caused by any single food or beverage.

HFCS-sweetened beverages are not driving obesity, but play a small and declining role in the diet.

Both beverages sweetened with HFCS and those sweetened with sucrose contribute to the

overconsumption of calories compared with a diet beverage or no beverage. In addition, men and women

may respond to the sweeteners differently, as one study found that men experienced significantly less

hunger after consuming HFCS than sucrose, while women experienced less hunger after consuming

sucrose-sweetened beverages. However, another study found increased hunger in women the day after

consuming 30% of calories from sucrose as compared with HFCS.

Diabetes is a complex disease with many underlying factors. It is highly unlikely that one component of

the diet is uniquely related to diabetes. There are well-established links between obesity and diabetes.

HFCS and sugar are nutritionally equivalent, there is broad scientific consensus that HFCS and cane

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sugar are nutritionally and metabolically equivalent, and the American Medical Association has

concluded that HFCS is not a unique cause of obesity.

2.10 High fructose corn syrup: Production and uses

High fructose corn syrup (HFCS) is a liquid alternative sweetener to sucrose that is made from corn, the

“king of crops” using chemicals (caustic soda, hydrochloric acid) and enzymes (-amylase and

glucoamylase) to hydrolyze corn starch to corn syrup containing mostly glucose and a third enzyme

(glucose isomerase) to isomerize glucose in corn syrup to fructose to yield HFCS products classified

according to their fructose content: HFCS-90, HFCS-42, and HFCS-55. HFCS-90 is the major product of

these chemical reactions and is blended with glucose syrup to obtain HFCS-42 and HFCS-55. HFCS has

become a major sweetener and additive used extensively in a wide variety of processed foods and

beverages ranging from soft and fruit drinks to yogurts and breads. HFCS has many advantages

compared to sucrose that make it attractive to food manufacturers. These include its sweetness,solubility,

acidity and its relative cheapness in the United States (US).

Nutritional values calculated per 100 g of HFCS. Percentages are relative to US

recommendations for adults. Data from USDA nutrient database (USDA.gov).

Table (2.9) Nutritional values calculated per 100 g of HFCS

Nutritional Items Value

Energy 1,176 kJ (281 kcal)

Carbohydrates 76 g

Dietary fiber 0 g

Fat 0 g

Protein 0 g

Water 24 g

Riboflavin (Vitamin B 2) 0.019 mg (1%)

Niacin (Vitamin B3) 0 mg (0%)

Pantothenic acid (Vitamin B5) 0.011 mg (0%)

Vitamin B6 0.024 mg (2%)

Folic acid (Vitamin B9) 0 _g (0%)

Vitamin C 0 mg (0%)

Calcium 6 mg (1%)

Iron 0.42 mg (3%)

Magnesium 2 mg (1%)

Phosphorus 4 mg (1%)

Potassium 0 mg (0%)

Sodium 2 mg (0%)

Zinc 0.22 mg (2%)

2.11 PRODUCTION AND USES OF HFCS

The corn grain undergoes several unit processes starting with steeping to soften the hard corn kernel

followed by wet milling and physical separation into corn starch (from the endosperm); corn

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hull (bran) and protein and oil (from the germ). Corn starch composed of glucose molecules of infinite

length, consists of amylose and amylopectin and requires heat, caustic soda and/or hydrochloric acid plus

the activity of three different enzymes to break it down into the simple sugars glucose and fructose

present in HFCS. An industrial enzyme, -amylase produced from Bacillus spp., hydrolyzes corn starch to

short chain dextrin and oligosaccharides. A second enzyme, glucoamylase (also called amyloglucosidase),

produced from fungi such as Apergillus, breaks dextrins and oligosaccharides to the simple sugar glucose.

The product of these two enzymes is corn syrup also called glucose syrup. The third and relatively

expensive enzyme used in the process is glucose isomerase (also called D-glucose ketoisomerase or D-

xylose ketolisomerase), that converts glucose to fructose. While -amylase and glucoamylase are added

directly to the processing slurry, pricey glucose isomerase is immobilized by package into columns where

the glucose syrup is passed over in a liquid chromatography step that isomerizes glucose to a mixture of

90% fructose and 10% glucose (HFCS-90). Whereas inexpensive -amylase and glucoamylase are used

only once, glucose isomerase is reused until it loses most of its enzymatic activity. The - amylase and

glucoamylase used in HFCS processing have been genetically modified to improve their heat stability for

the production of HFCS. In the US, four companies control 85% of the $2.6 billion HFCS business—

Archer Daniels Midland, Cargill, Staley Manufacturing Co, and CPC International.

With clarification and removal of impurities, HFCS-90 is blended with glucose syrup to produce HFCS-

55 (55% fructose) and HFCS-42 (42% fructose). Both HFCS-55 and HFCS-42 have several functional

advantages in common, but each has unique properties that make them attractive to specific food

manufacturers. Because of its higher fructose content, HFCS-55 is sweeter than sucrose and is thus used

extensively as sweetener in soft, juice, and carbonated drinks. HFCS-42 has a mild sweetness and does

not mask the natural flavors of food. Thus it is used extensively in canned fruits, sauces, soups,

condiments, baked goods, and many other processed foods. It is also used heavily by the dairy industry in

yogurt, eggnog, flavored milks, ice cream, and other frozen desserts. The use of HFCS has increased

since its introduction as a sweetener. Although, its use peaked in 1999, it rivals sucrose as the major

sweetener in processed foods. The US is the major user of HFCS in the world, but HFCS is manufactured

and used in many countries around the world (Vuilleumier, 1993). HFCS has functional advantages

relative to sucrose. These include HFCS’s relative cheapness (at 32 cents/lb versus 52 cents/lb for

sucrose); greater sweetness with HFCS being sweeter than sucrose, better solubility than sucrose and

ability to remain in solution and not crystallize as can sucrose under certain conditions. Moreover, HFCS

is liquid and thus is easier to transport and use in soft drink formulations (Hanover and White, 1993). It is

also acidic and thus has preservative ability that reduces the use of other preservatives. HFCS has little to

no nutritional value other than calories from sugar. Analysis of food consumption patterns using USDA

(2008) food consumption tables for the US from 1967 to 2000 (Bray et al., 2004) showed that HFCS

consumption increased major source of dietary fructose.

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Fig (2.3) block diagram of HFCS production

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Chapter three

Material and methods

3.1 Process design and flow diagram

In order to produce HFCS, corn starch must first be broken down into glucose molecules. By adding

glucose isomerase (also called D-glucose ketoisomerase or D-xylose ketolisomerase) to converts glucose

to high fructose corn syrup (mixture of about 42% fructose and 50–52% glucose with some other sugars

mixed in).

3.2 Production High-fructose corn syrup (HFCS):

Starch is the most common digestible polysaccharide found in foods, and is therefore a major source of

energy in our diets. In its natural form starch exists as water-insoluble granules (3 - 60 mm), but in many

processed foods the starch is no longer in this form because of the processing treatments involved (e.g.,

heating). It consists of a mixture of two glucose homopolysaccharides. Starch has become an important

raw material for the sugar industry which, for centuries, relied exclusively on sugar beet and sugar cane

for the production of natural sweeteners. HFCS is food syrup, made from the hydrolysis of starch, it

obtained by controlled partial hydrolysis of starch, are purified aqueous solutions of nutritive saccharides.

HFCS consists of 24% water, and the rest sugars. The most widely used varieties of high-fructose corn

syrup are: HFCS 55 (mostly used in soft drinks), approximately 55% fructose and 42% glucose; and

HFCS 42 (used in beverages, processed foods, cereals and baked goods), approximately 42% fructose and

53% glucose. HFCS-90, approximately 90% fructose and 10% glucose, is used in small quantities for

specialty applications, but primarily is used to blend with HFCS 42 to make HFCS 55

HFCS produced by two ways as;

1. Enzymic hydrolysis.

2. Acidic hydrolysis followed by enzymic hydrolysis (dual conversion syrups). (IPEK ÇELEBİ, 2006).

3.2.1 Acidic Hydrolysis Followed by Enzymic Hydrolysis

Dual conversion syrups are manufactured by hydrolysis of the starch to a specific DE by acid and

completing the hydrolysis by the use of one or more enzymes.

Firstly, the hydrolysis of starch was achieved by boiling raw starch in H2SO

4 to give sweet syrup.

Hydrolysis of starch has commonly been carried out using hydrochloric acid at temperatures of 130-

170°C with subsequent partial neutralization. In this process, starch slurry is acidified with hydrochloric

acid and pumped through a series of steam-heated pipes where the conversion of starch into sugars

occurs. Temperature, acidity, and retention time are the major factors that govern the extent of the

hydrolysis.

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Using acids in hydrolysis of starch has some disadvantages as inducing formation of coloring and

flavoring substances as well as other contaminants such as furfural, levulinic acid and formic acid (which

of all give in high refining cost), being lack of process control, being an unsafely process and also giving

low yields.

Glucose syrup from starch hydrolysis contains ash, color bodies and proteinaceous materials which

produce an unacceptable color, taste or odor quality in the finished product and reduce isomerization

enzyme performance. Whether the syrup will be evaporated and sold as a finished product or continue on

in the refining process to isomerization, demineralization is required to remove objectionable soluble

components. Color stability of some corn syrups is obtained through the addition of sulfur dioxide, but

due to human sensitivity to sulfites, this practice has partly been replaced with ion exchange. The ash

content of glucose syrups is typically 0.25-0.45% by weight of total syrup dry Solids and predominantly

contains the following ions:

• Sodium Na+

• Calcium Ca++

• Magnesium Mg++

• Chloride Cl-

• Sulfate SO4

These salts must be removed prior to final evaporation. The ash content of 42 HFCS is typically 0.15-

0.25% by weight of total syrup dry solids and consists primarily of:

• Sodium Na+

• Magnesium Mg++

• Sulfate SO4

• Sulfite SO3

As the dextrose or fructose syrup solution passes through the resin bed, the sugars, ash, color bodies and

proteins diffuse into the resin beads and can be exchanged or adsorbed onto the resin. In the strong acid

cation bed, sodium, calcium, magnesium and other cations will replace the hydrogen ions on the resin due

to their greater affnity for the resin than hydrogen ion. The hydrogen ions displaced from the resin by

other cations cause a drop in the solution pH to a level of about 1.5-2.0 in the “primary” cation column

and 3.0-3.5 in the “secondary” cation column. Thus, neutral salts are changed to their corresponding

mineral acids. Proteinaceous compounds, at low pH, may be sorbed onto the cation resin either by ion

exchange or adsorption on the resin matrix.

The syrup then passes through a bed of weak base anion resin where the mineral acids, organic acids and

color bodies diffuse into the resin beads and are adsorbed onto the tertiary amine functional groups.

The chemical equations depicting the service ion exchanges are shown below:

Strong Acid Cation Service Exchange Reaction

RSO3–H+ + Na + Cl– ➔ RSO3–Na+ + H +Cl– (Produces mineral acids)

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Weak Base Anion Service Exchange Reaction

RCH2 N (CH3)2 + H +Cl– ➔ RCH2NH+Cl–(CH3)2

(Acid absorber). (IPEK ÇELEBİ,2006).

3.2.2 Block diagram of production HFCS 55:

Fig (3.1) Block diagram of production HFCS 55

3.2.3 Process of produce HFCS:

3.2.3.1 Preparation

The starch content of most foods cannot be determined directly because the starch is contained within a

structurally and chemically complex food matrix. In particular, starch is often present in a semi-crystalline

form (granular or retrograded starch) that is inaccessible to the chemical reagents used to determine its

concentration. It is therefore necessary to isolate starch from the other components present in the food

matrix prior to carrying out a starch analysis.

Dry kernels are cleaned and then steeping for (30 to 40 hours to begin breaking the starch and Protein

bonds) in a weak solution of sulfurous acid to soften the kernel before the protein, fiber and oil are

separated from the starch by a series of grinding and screening steps. The raw starch is further refined by

washing.

Corn

Preparation Separation Gelatinization

Acid hydrolysis Clarification Evaporation Glucose Syrup

HFCS 90 HFCS 55

Glucose isomerase

Milling

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3.2.3.2 Separation

The starch granules are water-insoluble and have a relatively high density (1500 kg/m3) so that they will

tend to move to the bottom of a container during centrifugation, where they can be separated from the

other water-soluble and less dense materials.

Before conversion of starch to glucose can begin, the starch must be separated from the plant material.

This includes removing fiber and protein (which can be valuable by-products), Protein produces off-

flavors and colors due to the Millard reaction, and fiber is insoluble and has to be removed to allow the

starch to become hydrated.

3.2.3.3 Milling

The most common process is the “tempering-degerming.” in this process is to dry clean the corn,

separating fines and broken from the whole corn. Occasionally wet cleaning follows to remove surface

dirt, dust and other matter. The clean corn is tempered to 20 percent moisture. While moist, the majority

of the outer bran or pericarp, germ, and tip cap are removed, leaving the endosperm.

3.2.3.4 Gelatinization

Gelatinization is the process of breaking down the intermolecular bonds if starch molecules in the

presence of water and heat. the intermolecular bonds of the starch molecules are broken down, allowing

the hydrogen bonding sites to engage more water. This irreversibly dissolves the starch granule, so the

chains begin to separate into an amorphous form. This prepares the starch for hydrolysis. (Sheri Miraglia,

1998).

3.2.3.5 Acid hydrolysis

Glucose syrup produce by combining corn starch with dilute hydrochloric acid, and then heating the

mixture at temperatures of 130-170°C under pressure, acidic condition (pH 4.5-5).the amount of HCL

need is 35% from the amount of starch entered. (Barnali Bej, R.K. Basu and S.N. Ash, 2008

3.2.3.6 Clarification

After hydrolysis, the dilute syrup can be passed through columns to remove impurities, improving its

color and stability.

3.2.3.7 Evaporation

The dilute glucose syrup is finally evaporated under vacuum to raise the solids concentration.

3.2.3.8 Glucose isomerase

Glucose isomerase is enzyme which converts glucose to high fructose corn syrup 90 and the enzyme

comes in solid form, because of the high cost of glucose isomerase (about $5.05 per gram in low

quantities),the enzyme must be reused HFCS-90 blending with glucose syrup to produce HFCS-55

(55%fructose). (Daniel Finnie, et.al, 2008)

It's preferred use of stirred tank reactors, continuous stirred reactors (CSTR) or a jet cooker.

3.2.4 Enzyme Hydrolysis

Since enzymes have efficiency, specific action, ability to work under mild conditions, increasing reaction

rate, operation without contamination by microorganisms and having high purification and

standardization, they are ideal catalysts for the food industry. Enzyme reactions, requiring simple

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equipment, are easily controlled and can be easily stopped when the desired degree of conversion is

reached.

3.2.4.1 Step 1 - Starch Extraction

The major components of the maize kernel (protein, germ oil, fibre and starch) are separated during starch

extraction. The starch is further processed and the other components sold as by-products. Starch

extraction begins with steeping the maize grains in a weak solution of sulfurous acid to soften the kernel

and help break the chemical bonds between the proteins and the starch. The soluble solids are leached

from the grain, concentrated through evaporation and sold to feed compounders and fertiliser companies

as a high protein concentrate. Next, oil is expelled from the germ to produce a crude maize oil which is

sold for further refining before being used in the food industry. The starch and gluten are then separated

from the fiber and from each other. The fiber is used in the animal feeds industry and the gluten is sold as

corn flour. The starch is washed and concentrated to 40 % solids. About half of it is sold as either

unmodified or chemically modified starch, and the remainder is converted to sugar syrups.

3.2.4.2 Step 2 - Liquefaction

Liquefaction is the hydrolysis of the starch to oligosaccharides: glucose polymers of up to ten glucose

residues. This is done by holding the starch slurry at 105oC for seven minutes at pH 6.0 - 6.5 in the

presence of a heat stable alpha amylase enzyme. Small quantites (ca. 50 ppm) of a calcium salt are also

added to the jet cooker to help stabilize the enzyme. During the seven minutes the starch hydrates and is

broken down both by the shearing forces in the jet cooker (Corn Starch and the enzyme α-amylase are fed

into a stirred tank reactor) and by the action of the enzyme:

(C6H10O5) n +n H2O → nC6H12O6

Starch

oligosaccharides (D-glucose)

After this initial liquefaction the mixture is cooled to 97°C and transferred to a multi chamber reactor,

where the solution is held for 90 minutes to reach a dextrose equivalent of 10 – 12 units. As the name

implies, liquefaction lowers the viscosity of the solution. By this means the more specialized reactions

occurring in the next step can be more easily controlled. (Barnali Bej, R.K. Basu and S.N. Ash, 2008)

3.2.4.3 Step 3: Saccharification

After liquefaction the pH is lowered to between 4 and 5 and the liquid is cooled to around 60°C. This

inactivates the liquefaction enzyme and creates conditions suitable for the saccharification enzymes. A

specialized enzyme or enzymes are then added. The enzymes added depend on the type of syrup that is to

be produced, i.e. how much of the free sugar should be glucose, how much should be maltose etc. For

example, if a high glucose syrup is required then an amyloglucosidase is added, but if a high maltose

syrup is preferred then a fungal alpha amylase could be added. If a high sugar syrup including both these

sugars is required then both enzymes will be added. The reaction occurring follows the equation below:

Oligosaccharides + H2O → glucose/maltose mixture

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3.2.4.4 Step 4 - Refining

The raw sugar syrup requires refining to remove impurities such as residual proteins and fats. This is done

by passing the solution through a rotating vacuum filter coated with diatomaceous earth then

decolourising it with activated carbon. The product is then concentrated to the desired solids level

(typically 75 - 85 % solids) and packaged for sale.

3.2.2.5 Convert into HFCS

The next step in the process is converting glucose into a mixture of fructose and glucose. This is done by

suspending the enzyme glucose isomerase in a gel column and running the glucose through the enzyme.

Glucose isomerase is suspended so that multiple batches of glucose can be run through the gel column.

This is in contrast to the relatively inexpensive enzymes α-amylase and glucoamylase which are mixed

with the reactants and then thrown out. Once the glucose is run through the gel column a mixture

containing approximately 42% fructose and 52% glucose, known as HFCS-42, is produced. This happens

because converting glucose into fructose is a reversible reaction; meaning that at a certain point fructose

will begin to convert into glucose. At equilibrium, which occurs when 42% fructose is produced, fructose

will convert into glucose and glucose will convert into fructose simultaneously. The problem is that

HFCS-42 is not comparable to the taste of the sucrose that is has replaced.

A mixture containing 55% fructose, known as HFCS-55, is considered to have the same taste as sucrose.

To produce HFCS-55, some of the HFCS-42 is converted into HFCS-90 by liquid chromatography.

Liquid chromatography separates the glucose and fructose molecules by distinguishing between their

different structures. The separated glucose is discarded and the HFCS-90 is mixed with the remaining

HFCS-42 to produce HFCS-55. Carbon Adsorption is then used to remove any impurities that may be

left in the HFCS-55. These impurities can be anything ranging from left over enzymes to other sugars

accidently produced in the process.

3.3 Summary – Basic Steps

Here is a summary of the basic engineering steps used to produce HFCS:

- Mix corn starch and α-amylase to produce maltose and glucose

- Separate α-amylase out of mixture using a filter

- Add glucoamylase to the maltose and glucose mixture to produce pure glucose

- Separate glucoamylase from glucose using a filter

- Run glucose mixture through the enzyme glucose isomerase to produce

HFCS-42

- Mix HFCS-42 and HFCS-90 to produce HFCS-55

- Use Carbon Adsorption to remove impurities

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3.4 Chemical reactions:-

CH2OH

OH

OH

O

O

OH

OH

CH2OH

O

O

CH2OH

OH

OH

OH

O

O

H

O

CH2OH

CH2OH

O

HCL

OH

O

CH2OH

OH

OH OH

OH

O

O

H

H

H

O

H

H CH2OH

H CH2OH

Glucose Fructose

O

Glucoseisomarise

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(İPEK ÇELEBİ, 2006)

O-H-CHO-(CHOH)2-(CH2)3-O- H-CHO-(CHOH)2-(CH2)3-O +HCL

O-H-CHO-(CHOH)2-(CH2)3-

Fig (3.2) Production of High-Fructose Corn Syrup

3.5 Factors That Affect Enzymic Hydrolysis

The enzymatic hydrolysis of starch is mainly affected by botanic sources of starch including

amylose/amylopectin ratio, crystallinity and size of granules. Not only botanic source has an importance

on the hydrolysis but also operating conditions as starch concentration, temperature, pH, enzyme type,

enzyme concentration.

The effect of time on hydrolysis and enzyme stability was reported by Apar and Özbek, (2005). It was

found that; when rice starch was hydrolyzed by α-amylase derived from B.subtilis with processing time

(from 0 to 90 min), a decrease in the activity of α-amylase was observed with the time of exposure. The

degree of hydrolysis reached a value of 84.51% and 81.82% the efficiency of α-amylase was lost after 90

Glucoseisomarise O-H-CHO-(CHOH)2-(CH2)3-

Glucose

+

O-(CHOH)2-CH2-CHO-CH3

Fructose

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min. Not only sole effect of these parameters but also interactions between them should also be taken into

account on hydrolysis of starch.

3.6 Industrial Starch Hydrolysis

Conversion of starch into sugar syrups and dextrins forms the major part of the starch processing industry.

Sugar syrups obtained by starch are sweet edible products that are widely used in confectionery and other

food products, also solid glucose can be prepared by crystallization from completely hydrolyzed liquors.

In United States these syrups are known as corn syrups since they are produced by acidic/enzymatic

hydrolysis of corn starch. Other starches, such as those from wheat, potato and rice can, of course, be

used to manufacture such products. In our country since wheat starch production is widespread, and it is

produced as a by-product of gluten manufacture, production of them from wheat starch gains importance.

The industrial hydrolysis of starch into glucose syrups is generally performed in two following steps as

liquefaction and saccharification. After saccharification, fructose syrups are obtained from glucose syrups

by isomerization if desired.

Liquefaction is a process of dispersion of insoluble starch granules in an aqueous solution followed by

partial hydrolysis using thermostable amylases. α-amylase behaves as a thinning agent which results in

reduction in viscosity and partial hydrolysis of starch.

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Fig (3.3) flow chart of HFCS

E - 2

E-2

E-2

E-4

E - 1

Tank Washing

basin

Screening

Centrifugal

Tank Dryer

Mill

Pre-heater

Reactor Pre-heater

Colum

n

Tank

Storage tank

Glucose

isomerase

H2O

Ethanol

HCL

H2SO4 H2O

H2O Corn

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3.7 Material balance

Material balances are important first step when designing a new process or analyzing an existing one.

They are almost always prerequisite to all other calculations in the solution of process engineering

problems.

Mathematically the mass balance for a system without a chemical reaction is as follows:

Input = Output + Accumulation

Particle material balance

Input+ Generation = Output + Accumulation + Consumption (Per warfving)

Typically, "sweet" corn is roughly 9-14% glucose and other sugars. The highest concentration of sugars

in corn is in the "super sweet" hybrid that tops out around 44% concentrations of sugars.

HFCS contain about 5-10% sugar by weight.

3.7.1 Molecular weight of starch

Starch is a polymer of glucose. The molecular formula of glucose in starch is C6H12O6 that mean the

molecular weight of glucose is (C6H12O6) is (72.06+12.1+96) = 180.16 g/mole.

To calculate the molecular mass of starch you need to know how many molecules of glucose (n) are

linked together and multiply that by the molecular mass of each residue. (C6H12O6)*n = 180.16 * n (n is

the number of residues in the polymer)

However, some sources claim that the average molecular mass of starches is around 250000 g/mole. But

it really depends on what the starch is from.( R.G. Gilbert et.al)

Obviously, the amount of HFCS required to be produced by the HFCS production plant governs the

amount of the corn in put into the HFCS production process.

The objective of this planned HFCS production plant project is to meet 10000 Tones of HFCS from the

need for HFCS in Sudan per year.

1kg of corn contain 0.1 ـــــــــــــــــــــــــــــــــــــــــــــــــــــــــ kg of Glucose

X kg of corn contain 106*.103 ـــــــــــــــــــــــــــــــــــــــــــــــــ Kg of glucose

X = 103*107 kg corn

The amount of corn need is 103000 Tons of corn

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Table (3.1) molecular weight of component

Component molecular weight

Corn (starch) 250000

H2O 18

H2SO4 98

HCL 36.5

Ethanol 46

Glucose isomerase 171000

Glucose 180.16

HFCS 180.16

3.7.2 The amount of substance use in the process:

2.7.2.1 Gelatinization

Amount of water need for Gelatinization process:-

1.2Kg of starch need218ـــــــــــــــــــــــــــــــــــــــــــ liter

1.03*107 Kg of starch needــــــــــــــــــــــــــــــــــــــX liter of water

The amount of water needed is 1.87*1011 liters

3.7.2.2 Acid hydrolysis

Amount of HCL need is 35% from the amount of starch entered = 360500000Kg

The Temperature need must be between (130-170°C) under pressure and acidic condition (pH 4.5-5).

(Barnali Bej, R. K. Basu and S. N. Ash)

3.7.2.3 Amount of glucose isomerise need:

1kg of enzyme convert 18000ـــــــــــــــــــــــــــــــــــــــــــ kg of glucose

X of enzyme convert 107*103 ــــــــــــــــــــــــــــــــــــــ kg of glucose

The amount of enzyme (glucose isomerise) convert 103*107 kg of glucose into fructose = 5722222.2 kg.

(S H Bhosale, M B Rao, and V V Deshpande)

3.7.2.4 Amount of H2SO4

Amount of H2SO4 need is 0.04% from the amount of starch entered= 412000 liters

3.7.2.5 Amount of ethanol need

Amount of ethanol need is 1.54% (K. Lorenz, and J.A. Johnson) from the amount of starch entered=

15.86*106 liters

3.7.2.6 Amount of HFCS produce

Amount of HFCS produce is 97% from the amount of glucose add to the reactor and the other 1.5% is

maltose, 0.5% iso maltose and 1% other oligosaccharides.

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3.7.3 Material balance around equipment’s:

3.7.3.1 Material balance around washing basin:

Feed contains corn, fibers, proteins and other wastes.

The base is to obtain 10.000 ton of HFCS.

Table (3.2) S1

Table (3.3) S2

component

Weight(Kg)

water

100*109

Table (3.4) S3

component

Weight(Kg)

Corn

1.12167*109

component Weight(Kg)

Feed 1.133*109

S1

S2

S3

S4

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Table (3.5) S4

component

Weight(Kg)

water

100*109

Wastes 0.01133*109

Total 100.01133*109

Table (3.6) over all Material balance around the washing basin:

Weight(Kg)

Inputs 101.133*109

Outputs 101.133*109

3.7.3.2 Material balance around steeping steeping tank:

E-1

S3

S5

S6

S7

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Table (3.7) S3

component

Weight(Kg)

Corn

1.12167*109

Table (3.8) S5

component

Weight(Kg)

Water 0.0103*109

H2SO4 0.000412*109

Table (3.9) S6

component

Weight(Kg)

Corn

1.097336*109

Table (3.10) S7

component

Weight(Kg)

Fibers

0.024334*109

Water

0.0103*109

H2SO4

0.000412*109

Total

0.035046*109

Table (3.11) over all Material balance around the steeping tank:

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Weight(Kg)

Inputs 1132382*109

Outputs 1.132382*109

3.7.3.3 Material balance around Screening:

Table (3.12) S6

component

Weight(Kg)

Corn

1.097336*109

Table (3.13) S8

component

Weight(Kg)

Corn

1.07538928*109

Table (3.14) S9

component

Weight(Kg)

Fibers

0.02194672*109

S6 S8

S9

Page 41: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Table (3.15) over all Material balance around the Screening:

Weight(Kg)

Inputs

1.097336*109

Outputs

1.097336*109

3.7.3.4 Material balance around Centrifugal:

Table (3.16) S8

component

Weight(Kg)

Corn

1.07538928*109

Table (3.17) S10

component

Weight(Kg)

Corn

1.043127602*109

Table (3.18) S11

component

Weight(Kg)

Fibers

0.322616784*109

S8 S10

S11

Page 42: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Table (3.19) over all Material balance around the Centrifugal:

Weight(Kg)

Inputs

1.07538928*109

Outputs

1.07538928*109

3.7.3.5 Material balance around tank:

E-1

Table (3.20) S10

component

Weight(Kg)

Corn

1.043127602*109

Table (3.21) S12

component

Weight(Kg)

Ethanol

0.015862*109

S10

S12

S13

S14

Page 43: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Table (3.22) S13

component

Weight(Kg)

Corn

1.02226505*109

Table (3.23) S14

component

Weight(Kg)

Ethanol

0.015862*109

Proteins 0.02086255204*109

Total

0.03672455204*109

Table (3.24) over all Material balance around the tank:

Weight(Kg)

Inputs

1.058989602*109

Outputs

1.058989602*109

3.7.3.6 Material balance around dryer:

S17

Page 44: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

E-2

Table (3.25) S13

component

Weight(Kg)

Corn

1.02226505*109

Table (3.26) S15

component

Weight(Kg)

Dry air

70.45*109

Table (3.27) S16

component

Weight(Kg)

Corn

1.02226505*109

Table (3.28) S17

component

Weight(Kg)

Humidity air

70.45*109

Table (3.29) over all Material balance around the dryer:

S13 S16

S15

Page 45: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Weight(Kg)

Inputs

71.472265505*109

Outputs

71.472265505*109

3.7.3.7 Material balance around mill:

Table (3.30) S16

component

Weight(Kg)

Corn

1.02226505*109

Table (3.31) S18

component

Weight(Kg)

Corn

1.02226505*109

Table (3.32) over all Material balance around the mill:

Weight(Kg)

S18

S16

Page 46: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Inputs

1.02226505*109

Outputs

1.02226505*109

3.7.3.8 Material balance around pre-heater:

E-2

Table (3.33) S18

component

Weight(Kg)

Corn

1.02226505*109

Table (3.34) S19

component

Weight(Kg)

water

187*109

Table (3.35) S20

component

Weight(Kg)

Corn slurry

188.0222651*109

S18

S19

S20

Page 47: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Table (3.36) over all Material balance around the pre-heater:

Weight(Kg)

Inputs

188.0222651*109

Outputs

188.0222651*109

3.7.3.9 Material balance around hydrolyses tank:

E-1

Table (3.37) S20

component

Weight(Kg)

Corn slurry

188.0222651*109

Table (3.38) S21

component

Weight(Kg)

HCL

0.3605*109

S20

S21

S22

S23

Page 48: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Table (3.39) S22

component

Weight(Kg)

Glucose syrup

187.1878478*109

Table (3.40) S23

component

Weight(Kg)

HCL

0.270375*109

Oligosaccharides.

0.920038545*109

Total

1.190413545*109

Table (3.41) over all Material balance around the pre-heater:

Weight(Kg)

Inputs

188.3827651*109

Outputs

188.3827651*109

Page 49: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

3.7.3.10 Material balance around Column:

E-1

Table (3.42) S22

component

Weight(Kg)

Glucose syrup

187.1878478*109

Table (3.43) S24

component

Weight(Kg)

Glucose syrup

187.0977228*109

Table (3.44) S25

S22

S24

S25

Page 50: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

component

Weight(Kg)

HCL

0.090125*109

Table (3.45) over all Material balance around the Column:

Weight(Kg)

Inputs

187.1878478*109

Outputs

187.1878478*109

3.7.3.11 Material balance around pre-heater:

E-2

Table (3.46) S24

component

Weight(Kg)

Glucose syrup

187.0977228*109

S24

S26

S27

Page 51: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Table (3.47) S26

Component

Weight(Kg)

Glucose syrup

0.102226505*109

Table (3.48) S27

component

Weight(Kg)

Water

186.9954963*109

Table (3.49) over all Material balance around the pre-heater:

Weight(Kg)

Inputs

187.0977228*109

Outputs

187.0977228*109

3.7.3.12 Material balance around reactor

S27

Page 52: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

E-4

Table (3.50) S26

Component

Weight(Kg)

Glucose syrup

0.102226505*109

Table (3.51) S27

Component

Weight(Kg)

Glucose isomarise

0.0057222222*109

Table (3.52) S28

Component

Weight(Kg)

HFCS

0.09915970985*109

Table (3.53) S29

Component

Weight(Kg)

Glucose isomarise

0.0057222222*109

S26

S28

S29

Page 53: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

maltose

0.001533397575*109

isomaltose

0.000511132525*109

Other oligosaccharides.

0.00102226505*109

Total 0.00878901735*109

Table (3.54) over all Material balance around the reactor:

Weight(Kg)

Inputs

0.1079487272*109

Outputs

0.1079487272*109

Page 54: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

3.7.3.13 over all material balance:

Table (3.55) over all input streams:

Stream Weight(Kg)

Corn(starch) 11.33*108

H2O 18.7*1010

H2O

H2SO4

HCL

Ethanol

Glucose

isomerase

HFCS

Others

Corn

Page 55: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

H2SO4 00.04*107

HCL 36.05*107

Ethanol 01.59*107

Glucose isomerase 00.57*107

Total 18.85*1010

Table (3.56) overall output streams:

Stream Weight(Kg)

HFCS 09.92*1011

Oligomers 10.34*1010

H2O 18.70*1010

H2SO4 00.04*107

HCL 36.05*107

Ethanol 01.59*107

Glucose isomerase 00.57*107

Total 18.85*1010

Page 56: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

3.8 Energy balance

3.8.1 Introduction: Enthalpy is a measure of the total energy of a thermodynamic system. It includes the system's internal

energy or thermodynamic potential

The enthalpy is the preferred expression of system energy changes in many chemical, biological, and

physical measurements, because it simplifies certain descriptions of energy transfer. Enthalpy change

accounts for energy transferred to the environment at constant pressure through expansion or heating.

The total enthalpy, H, of a system cannot be measured directly. The same situation exists in classical

mechanics: only a change or difference in energy carries physical meaning. Enthalpy itself is a

thermodynamic potential, so in order to measure the enthalpy of a system, we must refer to a defined

reference point; therefore what we measure is the change in enthalpy, ΔH. The change ΔH is positive in

endothermic reactions, and negative in heat-releasing exothermic processes. ΔH of a system is equal to

the sum of non-mechanical work done on it and the heat supplied to it.

Increasing cost of energy has caused the industries to examine means of reducing energy consumption in

processing. Energy balances are used in the examination of the various stages of a process, over the whole

process and even extending over the total production system from the raw material to the finished

product.

3.8.2 General equation for energy balance:

Energy out = Energy in +generation – consumption – accumulation

Heat enters and leave the system = the enthalpy of inlet and out let stream components.

Steady state

Q = H out – H in

Q = Fin * Cpi

Cp = a + bT + cT2

ΔH = [(aT) + (bT2) /2+ (cT3)/3 + (dT4)/4]

Also Q = M*Cp* ΔT

3.8.3 Energy balance around equipment’s:

3.8.3.1 Energy balance around washing basin

S2

S3

Page 57: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Q washing basin = Q4 + Q3 – Q2 –Q1

Q4 = M*Cp* ΔT

ΔT = 0

And Q3, Q2 , Q1 =0 (there is no change in temperature in washing basin)

Q washing basin =0

3.8.3.2 Energy balance around steeping tank:

E-1

Q tank = Q6 + Q7– Q3 –Q5

No heating

Q tank = 0

3.8.3.3 Energy balance around centrifugal:

S1

S4

S3

S5

S6

S7

Page 58: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Q centrifugal = Q10 + Q11 – Q8

Q = M*Cp* ΔT

M= 43015.6 Kmols

ΔT = (333-298)= 35

Specific heat of starch:

Formula for calculating the specific heat of foods. Cp = 4.180 x.w + 1.711 x.p + 1.928 x f + 1.547 x c +

0.908 x a is the equation used for finding the specific heat of foods where "w" is the percentage of the food

that is water, "p" is the percentage of the food that is protein, "f" is the percentage of the food that is fat, "c"

is the percentage of the food that is carbohydrate, and "a" is the percentage of the food that is ash. This

equation takes into account the mass fraction (x) of all the solids that make up the food. The specific heat

calculation is expressed in kJ/(kg-K). http://www.chemteam.info/Thermochem/Determine-Specific-

Heat.html)

For Corn:

Cp = 4.180 x w + 1.711 x p + 1.928 x f + 1.547 x c + 0.908 x a

Cp =349.68

Q10 = M*Cp* ΔT

Q centrifugal = (43015.6)*(349.68)*(35)

Q centrifugal = 15.04173*106 KJ

S8 S10

S11

Page 59: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

3.8.3.4 Energy balance around dryer:

E-2

The clean corn is tempered to 20 percent moisture

For a (hot air) dryer, the heater duty for the inlet air heat exchanger is given by:

Q heater = Wg CP,g (Tg,in-Tg,a)

Q heater = Ws (Xin- Xout) ΔHv

Q heater = (Tg,in - Tg,a)/(Tg,in –Tg,out) {Ws (Xin- Xout) ΔHv}

The clean corn is tempered to 20 percent moisture

Q heater = (298-423)/ (298-333)*{5 *0.5*(40890.6*349.68*90)}

Q heater = 114.9*109 KJ

3.8.3.5 Energy balance around pre-heater:

E-2

Q pre-heater = Q20 + Q18– Q19

Q = M*Cp* ΔT

S18

S19

S20

S13

S17

S16

S15

Page 60: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Q = 7.53*106*349.68*(473-298)

Q pre-heater = 460.79*109 KJ

3.8.3.6 Energy balance around hydrolyses tank:

E-1

Q tank = Q23+ Q22– Q20 –Q21

Q = M*Cp* ΔT

Q = 7.53*106*349.68*(473-298)

Q = 1.73*109*349.68*(443-373)

Q tank = 4234.6*109KJ

3.8.3.7 Energy balance around pre-heater:

E-2

S24

S26

S27

S20

S21

S22

S23

Page 61: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Q pre-heater = Q27 + Q26– Q24

Q = M*Cp* ΔT

Q = 6.12*106*349.68*(373-298)

Q pre-heater = 160.5*109 KJ

Page 62: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

3.8.3.8 Material balance around reactor:

E-4

2 O-H-CHO-(CHOH)2-(CH2)3-

∆𝐻r =∆𝐻r˚+∆𝐻product -∆𝐻reactant

Where:-

∆𝐻r, t= Heat of reaction at temperature r.

∆𝐻r˚= Heat of reaction at 25 C °(298K)

∆𝐻React = enthalpy change to bring products to reaction temperature, t.

∆𝐻r°= ∑∆𝐻°f, product - ∑∆𝐻°f, reactants

= - (1*2337.2)-(2*4373323.5) = -8748984.2 KJ

∆𝐻Reactent = (n Cp ∆𝑡)reactant

2*349.68*(338-298) =27974.4

∆𝐻Product = (n Cp∆𝑡) product

1*0.74*(338-298) = 29.6 KJ

Q = M*Cp* ΔT

S26

S27

S28

S29

Glucoseisomarise O-H-CHO-(CHOH)2-(CH2)3-

Glucose

+

O-(CHOH)2-CH2-CHO-CH3

Fructose

Page 63: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Q = 55.03980*104 *0.74*(338-298)

∆𝐻r =- 902929 KJ

QR =Q29-Q28-Q27 + ∆𝐻r

Q reactor = 16.291780*106 KJ - 902929 KJ

Q reactor = 15.388851*106 KJ

Over all energy required is = 4.971*1012 KJ

Component Heat formation KJ/mol

HFCS -2337.32

Total -2337.32

Total energy required is 4.3704*106 KJ/mol

ΔH of reaction=∑ΔH of (products) −∑ΔH of (Reactants)

Energy balance:

Steady state

Q = H out – H in

Q = Fin * Cpi

Cp = a + bT + cT2

ΔH = [(aT) + (bT2) /2+ (cT3)/3 + (dT4)/4]

Also Q = M*Cp* ΔT

Energy balance around washing basin

Q washing basin = Q4 + Q3 – Q2 –Q1

S1

S2

S3

S4

Page 64: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Q4 = M*Cp* ΔT

ΔT = 0

And Q3 , Q2 , Q1 =0 (there is no change in temperature in washing basin)

Q washing basin =0

Energy balance around steeping tank:

E-1

Q tank = Q6 + Q7– Q3 –Q5

No heating

Q tank = 0

Energy balance around centrifugal:

Q centrifugal = Q10 + Q11 – Q8

Q = M*Cp* ΔT

M= 43015.6 Kmols

ΔT = (333-298)= 35

Specific heat of starch:

Formula for calculating the specific heat of foods. Cp = 4.180 x.w + 1.711 x.p + 1.928 x f + 1.547 x c +

0.908 x a is the equation used for finding the specific heat of foods where "w" is the percentage of the food

S3

S5

S6

S7

S8 S10

S11

Page 65: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

that is water, "p" is the percentage of the food that is protein, "f" is the percentage of the food that is fat, "c"

is the percentage of the food that is carbohydrate, and "a" is the percentage of the food that is ash. This

equation takes into account the mass fraction (x) of all the solids that make up the food. The specific heat

calculation is expressed in kJ/(kg-K). http://www.chemteam.info/Thermochem/Determine-Specific-

Heat.html) For Corn:

Cp = 4.180 x w + 1.711 x p + 1.928 x f + 1.547 x c + 0.908 x a

Cp =349.68

Q10 = M*Cp* ΔT

Q centrifugal = (43015.6)*(349.68)*(35)

Q centrifugal = 15041730 KJ

Energy balance around dryer:

E-2

The clean corn is tempered to 20 percent moisture

For a (hot air) dryer, the heater duty for the inlet air heat exchanger is given by:

Q heater = Wg CP,g (Tg,in-Tg,a)

Q heater = Ws (Xin- Xout) ΔHv

Q heater = (Tg,in - Tg,a)/(Tg,in –Tg,out) {Ws (Xin- Xout) ΔHv}

The clean corn is tempered to 20 percent moisture

Q heater = (298-423)/ (298-333)*{5 *0.5*(40890.6*349.68*90)}

Q heater = 114.9*109 KJ

S13

S17

S16

S15

Page 66: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Material balance around pre-heater:

E-2

Q pre-heater = Q20 + Q18– Q19

Q = M*Cp* ΔT

Q = 7.53*106*349.68*(473-298)

Q pre-heater = 460.79*109 KJ

Energy balance around hydrolyses tank:

E-1

Q tank = Q23+ Q22– Q20 –Q21

Q = M*Cp* ΔT

Q = 7.53*106*349.68*(473-298)

Q = 1.73*109*349.68*(443-373)

Q tank = 4234.6*109KJ

Energy balance around pre-heater:

S18

S19

S20

S20

S21

S22

S23

Page 67: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

E-2

Q pre-heater = Q27 + Q26– Q24

Q = M*Cp* ΔT

Q = 6.12*106*349.68*(373-298)

Q pre-heater = 160.5*109 KJ

Material balance around reactor

E-4 Q reacter = Q23+ Q22– Q20 –Q21

∆𝐻r =∆𝐻r˚+∆𝐻product -∆𝐻reactant

Where:-

∆𝐻r, t= Heat of reaction at temperature r.

∆𝐻r˚= Heat of reaction at 25 C °(298K)

∆𝐻React = enthalpy change to bring products to reaction temperature, t.

S24

S26

S27

S26

S27

S28

S29

Page 68: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

∆𝐻r°= ∑∆𝐻°f, product - ∑∆𝐻°f, reactants

∆𝐻reacter =(nCp ∆𝑡)reactant

∆𝐻product = (nCp∆𝑡)product

QR =Q29-Q28-Q27 + ∆𝐻r

S25

Component

Weight(Kg)

Glucose syrup

0.102226505*109

S27

Component

Weight(Kg)

Glucose isomarise

0.0057222222*109

S28

Component

Weight(Kg)

HFCS

0.09915970985*109

Page 69: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

S29

Component

Weight(Kg)

Glucose isomarise

0.0057222222*109

maltose

0.001533397575*109

isomaltose

0.000511132525*109

Other oligosaccharides.

0.00102226505*109

Total 0.00878901735*109

Page 70: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

3.8 Economical Evaluation

3.8.1 Introduction:

Cost estimating is one of the most important steps in project management. A cost estimate establishes the

base line of the project cost at different stages of development of the project. A cost estimate at a given

stage of project development represents a prediction provided by the cost engineer or estimator on the

basis of available data. According to the American Association of Cost Engineers, cost engineering is

defined as that area of engineering practice where engineering judgment and experience are utilized in the

application of scientific principles and techniques to the problem of cost estimation, cost control and

profitability.

3.8.2 Capital Investment:

The capital needed to supply the necessary manufacturing and plant facilities is called fixed capital

investment, and the necessary for the operation is called working capital. The total of capital investment is

the sum of the fixed and working capital.

The fixed capital investment is divided into:

Manufacturing fixed capital investment (direct cost).

Non manufacturing fixed capital investment (indirect cost).

3.8.2.1 Fixed capital cost:

Direct cost:

The direct cost determines the capital necessary for the installed process with all components that are

needed for the complete process operation and include:

Purchase equipment.

Purchase equipment installs.

Instrumentation and control.

Piping.

Services facilities.

Land.

Indirect cost:

It is the capital required for construction overhead and for all plant components and are not directly

related to the process operation, and includes:

Engineering and supervision.

Legal expenses.

Construction.

Contractor fee.

Contingency.

The fixed capital investment = Direct cost + Indirect cost

Page 71: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

3.8.2.2 Working capital investment:

It is consisting of the total amount of money invested in:

Raw material.

Finished products and semi finished products in the process of being manufactured.

Account receivable.

Cash kept on hand for monthly payment of operating expenses, such as salaries, wages and raw material

purchases.

Total Capital = Fixed Capital Investment + Warking capital investment Account payable.

Most of chemical plants use an initial working capital about 10 – 12 % of the total capital

investment.

3.8.3 Production cost:

The total production cost is the total of all costs of operating the plant, selling the products. Recovering

the capital investment, and distribution the corporate functions such management and development. And

it is divided into two categories:

3.8.4 Manufacturing costs:

They are costs referred to as operating or production costs and are divided to:

Variable cost:

Raw material.

Operating labor.

Land.

Direct supervisory.

Patent and royalties.

Utilities.

Laboratory charges.

Maintenance and repair.

Operating supplies.

3.8.5 Fixed charges:

This is include the

Depreciation

Local taxes

Plant overhead:

Genral plant up keep and overhead

Payroll over head

Packing

Medical

Safety and protection

Restaurants

Page 72: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Laboratories

Storage facilities

Page 73: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

3.8.6 General expenses:

This is included the:

Administrative cost

Distribution and marketing

Research and development

Total production cost =Manufacturing cost+General cost

Total profit = total income-total production cost

3.8.7 Pay pack period:

It is the length of time necessary for the total return to equal the capital investiment.

Pay pack period = fixed capital investiment / Annual profit

3.8.8 Calculation:

Table (3.57) cost of the equipment:-

Equipment Cost per $ in 2010

Reacter 270*103

Dryer 240*103

Screan 18.7*103

Column 18.63*103

3 Tanks 146.7*103

Centrifugal 12.9*103

Washing base 2.568*103

2 Pre-heaters 59.88*103

Mill 8*103

Total 777.5*103

Total capital cost = work + fixed capital cost

PPC = PCE (1 + F1 + F2 ………. + Fa)

PPC = 777.5*103*0.25 = 194.14*103$

(=420.1*103+ 777.5*103) *3.40

PPC = 3.87*106$

Fixed capital = PPC *1.45 = 5.6*106$

Working capital cost:

The fixed capital cost = 80% of total capital investment cost

Working capital investment cost 20% of total capital investment cost

Page 74: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

The working capital cost = fixed investment cost * 0.2/0.8

1.4*106$

Total capital cost = 7*106$

Page 75: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Table (3.58) Total capital investment:-

Fixed capital investment cost 5.6*106$

Work capital investment cost 1. 4*106$

Total capital investment cost 7*106$

Direct production cost:

Row material cost (corn waste, Ethanol,water, HCl and H2SO4)

Starch cost:

The cost of ton of corn waste = 10$= 1030000*10$ =10.03*106$

H2SO4 cost:

The cost of 1 ton of H2SO4 = 100$

412*100 = 41.2

The amount of ethanol need

15.862*103 ton

The cost of 1 ton of ethanol = 900$

15.862*103*900=14.3*106

Water cost:

The cost of 1 ton of water = 0.05 $

2369 *103 ton* 0. 05 = 118.45*103$

HCl cost:

The cost of 1 ton of HCl = 80$

360500*80= 28.8*106

Glucose isomerise cost:

The amount of glucose isomarise is 5.72*106/year

But we buy 10% of the amount and we can make re-generative of the enzyme and re used it.

The cost of enzyme is 10$/Kg

572*103 *10= 5.72*106

Page 76: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Table (3.59) row material cost

Material Cost $/year

Corn starch 10.03*106

H2SO4 41.2*103

HCl 28.8*106

Water 118.45*103

Ethanol 14.3*106

glucose isomarise 5.72*106

Total 58.72*106

Total row material cost = 58.72*106$

Table (3.60) operation labor cost

Labor No. of labor/3shift Cost$/month

Manager 1 3500

Senior Engineering 3 7500

Chemical Engineering 6 10500

Electrical Engineering 3 5250

Mechanical Engineering 4 7000

Electronic &Instrumentation

Engineering

5 8750

Technicians 20 18000

Operation and labor cost

$/month

42.5*103

Operation labor cost per year:

510*103 $/year

Utilities = Energy = 4.3704*106 KJ/hr

Utilities cost =88.9*103$/year

Maintenance cost

= fixed investment *0.02 = 112*103$/year

Operation suplies cost

= maintenance cost *0.15 =16.8*103$/year

Page 77: Design of a High Fructose Corn Syrup pilot Plant Tasneem ...

Direct supervision and clearical cost:

= Operation labor cost*0.15 =76.5*103 $/year

Labloratory charge cost

Labloratory charge cost = Operating labor cost *0.15

= 76.5*103 $/year

Fixed charge cost:

Depreciation cost:

Depreciation cost = fixed capital cost *0.05 = 280*103$/year

Insurance cost:

Insurance cost = fixed capital cost * 0.01 = 56*103$/year

Plant overhead cost:

Plant overhead cost = Operating labor cost *0.05 = 25.5*103$/year

General cost:

Administration cost

Administration cost = Operating labor cost *0.02 = 10.2*103$/year

Financing cost:

Financing cost = total capital investment *0.01 = 70*103$/year

Table (3.61) Total production cost

Item $ cost

Manufacturing cost Direct production cost

Row material

Operation labor

Maintenance

Utilities

Operation supplies

Direct supervision and clerical labor

Laboratory charge

58.72*106

510*103

112*103

88.9*103

16.8*103

76.5*103

76.5*103

Total 43.88*106

Fixed charge cost Depreciation

Insurance

280.5*103

56*103

Total 336.5*103

Plant overhead cost 25.5*103

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General expense cost Administration

Financing

10.2*103

70*103

Total 80.2*103

Total production cost 59.2*106

3.8.9 Income of production

-HFCS:

One ton of HFCS is 500$

10000*500 =5*106$/year

- Ethanol:

The amount of ethanol produced is 61.8*103ton/year

One ton of ethanol is 900$

61.8*103ton *900= 55.6*106$/year

55.6*106

- Total income of production:

5*106$+55.6*106=60.6*106

3.812 Profit

Profit = income – total production cost

60.6*106- 59.2*106= 1.4*106 $/year

3.8.14 Payback period (Payout time):

= Fixed/ profit =

(5.6*106$)/( 1.4*106) = 4 years.

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Chapter four

Result and discussion

4.1 Possibility of the project:

Fructose syrup is one of the essential components in the manufacturing of many different food products.

It is used in the production of beverages, sweets and candies, ice creams, etc.

Currently, all Sudan’s need for fructose syrup is met by importation from countries like the United States.

There are no official or even reliable estimates for the amount of fructose syrup consumed in Sudan. The

numbers vary in different sources from as little as 4000 to as high as 9000 tons.

Importation of fructose syrup from the US is met with many obstacles. The lack of normal and direct

diplomatic and commercial ties between Sudan and the US, as well as the economic sanctions against

Sudan taken unilaterally by the US force importers to exert extra effort, cash, and time to finalize their

deals. This definitely contributes to the net cost of the purchase and raises the prices significantly.

Furthermore, the sharp and marked decline in the value of the Sudanese currency as a result of the

economic collapse, and the disruption of the trade balance due to the loss of the oil revenue after the

secession of South Sudan, and the total reliance on imported goods and the lack of local production have

all led to the multiplication of prices and serious constraints to the importation business in general. Since

these increases in the cost and therefore the prices are not accompanied by increases in the income of

most people, this has affected the demand of many of the imported goods as their prices have, in some

cases, tripled as is the case in beverages during this year alone. Unless the affordability of these goods is

improved as by the localization of the production in a more fundamental way, this could end in the loss of

competitiveness to local rivals despite their markedly lower quality.

This economic model which relies completely on importation from abroad has proved its unsustainability

as manifested by the current crises and puts a detrimental burden on the economy. Therefore whenever

possible, production of raw materials – mostly agricultural – and completion of the manufacturing process

in as many stages as possible should be performed within the country.

Sudan has all the requirements for the production of high fructose corn syrup. The vast lands that can

support the cultivation of the maize plants in many parts of the country allows the easy installation of the

project. Sudan has vast resources of fresh surface and ground water and fertile soils which encourage

agriculture and make it the obvious economic driver of the country.

Therefore, the corn can be produced with low costs in a sustainable way, providing a constant supply for

the production of high fructose corn syrup.

Besides corn, the production of the fructose syrup requires hydrochloric acid, sulphuric acid, ethanol, as

well as the recombinant glucose isomerase enzyme. Aside from the latter, these are all readily available

mostly through local production. The recombinant enzyme is the only input material that can be obtained

strictly through importation from abroad.

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In total, the establishment of this plant for the production of high fructose corn syrup costs 59.2*106

dollars. This plant produces 10.000 tons annually which is more than the largest estimates of Sudan’s

need of corn syrup.

The low cost of production, the lack of local competitors and the artificially high cost of importation due

to the currency devaluation, the production of ethanol as a by-product, and the diverse uses of the syrup

promise to make the project very profitable. In fact, according to my estimates, the project could probably

pay back the investment capital in four years. This number may be overly optimistic, however, this

project has all the requirements for success; and its low cost and its novelty coupled with the high demand

for the product make it a safe investment. The net profit of this project exceeds 1.4 million dollars

annually.

Even if this project meets its expectations, the prospect for expansion and exportation to other countries in

the region make it a potential contributor to development and a source of hard currency.

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CHAPTER FIVE

Conclusion and Recommendations

5.1 Conclusion

As a result of lifestyle change, speed and people need to juices and soft drinks, which need to corn sugar.

In some products sweetened with sucrose, the covalent bond between the fructose and glucose molecules

breaks down in low acid environments, such as those found in soft drinks, as well as at high temperatures,

such as during storage in hot climates, the sucrose content of a cola beverage decreased from 36% of total

sugars to only 10% of sugars 3 months after manufacture, and the free fructose content increased from

32% to 44% of total sugars. This creates variability in the taste profile of the product. In contrast, HFCS

maintains its structural stability over a range of temperatures and acidic conditions.

This project assessed the case for corn and HFCS production from the prospective benefits for each actor:

the production of HFCS with less expensive feedstock for private enterprises, access to alternative

sources for the table sugar, HFCS as an alternative income source for smallholder farmers, ethanol is by-

products and is very valuable. It offers business possibility to agricultural enterprises and rural

employment.

5.2 Recommendations

1- I recommend to take this study in the list of important in Sudan.

2- I propose government share with the private sectors in Sudan which manufacture of food

products.

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