Mat'l Balance -Jan10
-
Upload
marc-vincent-romero -
Category
Documents
-
view
23 -
download
2
Transcript of Mat'l Balance -Jan10
Summary of Assumptions
A. Summary of Assumptions for Mass Balance
For Washing Tank (T-2)
Forty percent of the C2H5OH solution is used to wash the feather
1.5 gallons of C2H5OH solution per pound of feather is used as a washing agent
All dirt are removed
For Filter Press (F-1)
No keratin feather is carried at the filtrate All fats are dissolved in C2H5OH All dirt are removed 1% of the liquids adhered on the cake 0.5% lost due to accumulation in the equipment
For Dryer (D-1)
100% of ethanol is evaporated since temperature is carried out at 140-160⁰C
0.50% moisture content/keratin feather
For Grinder (G-1)
The size of feather fiber length will be reduced to ≥ 0.20
mm
For Separator (C-1)
40% keratin fiber in feather will be separated Negligible amount of water
For Rotary Grinder (G-2)
The size of feather fiber length will be reduced to
<0.020 mm
For Screener (S-1)
10% (oversize) of the ground fiber will be recycled back to the prior grinder
For Plasticizer Mixing Tank (T-3)
The ratio of the feed (keratin : Additive) is 3:2
For Air Cooler (C-2)
Only heat transfer will occur
Material Balance Per Equipment
Equipment: WASHING TANK
Chicken Feathers = 20, 955.40 kg
C2H5OH Solution = 244, 846.32 kg
TOTAL IN = 265, 801. 72 kg TOTAL OUT = 265, 801. 72 kg
T-2
P = 1 atm
C2H5OH = 97 938. 53 kg
H2O = 146 907. 79 kg
TOTA = 244, 846.32 kg
Dirt = 2 095.55 kg
Feather = 18 859.86 kg
C27H46O = 207.46 kg
H2O = 1 489.93 kg
Keratin Feather = 17 162.47
kg
C2H5OH Solution = 244, 846.32 kg
TOTAL = 265, 801. 72 kg
Washed Feather Chicken Feathers
C2H5OH Solution
Dirt = 2 095.55 kg
Feather = 18 859.86 kg
C27H46O = 207.46 kg
H2O = 1 489.93 kg
Keratin Feather = 17 162.47
kg
TOTAL = 20, 955.40 kg
Assumptions:
All dirt are removed
1.5 gallons of C2H5OH solution per pound of feather is used as a
washing agent
Forty percent of the C2H5OH solution is used to wash the feather
(Ref: Gassner, III et al., 1995. Fiber and Fiber Products
Produced from Feathers.)
Basis: 20 955. 40 kg/day
Computations:
Feed:
Dirt = 0.1 (20955.40 kg) = 2 095. 54 kg
Feather = 0.9 (20955.40 kg) = 18 859. 86 kg
C27H46 = 0.0099 (207. 46) = 207. 46 kg
H2O = 0.0711 (207. 46) = 1 489.93 kg
Keratin Feather = 0.819 (207. 46) = 17 162.47 kg
C2H5OH Solution Added:
Volume 40% C2H5OH = 262. 09 m3
Average Density of C2H5OH Solution = 934. 21 kg/ m3
40% C2H5OH solution Added = (262. 09 m3) (934.21 kg/ m3)
= 244 846.32 kg
C2H5OH = 0.4 (244 846.32 kg) = 97 938. 53 kg
H2O = 0.6 (244 846.32 kg) = 146 907. 79 kg
Product:
Dirt = 2 095.55 kg
Feather = 18 859.86 kg
C27H46 = 0.0099 (207. 46) = 207. 46 kg
H2O = 0.0711 (207. 46) = 1 489.93 kg
Keratin Feather = 0.819 (207. 46) = 17 162.47 kg
C2H5OH Solution = 244 846.32 kg
Dirt Balance: Dirt In = Dirt Out
Dirt Out = 2 095. 54 kg
Feather Balance: Feather In= Feather Out
Feather Out = 18 859.86 kg
Feather Composition Balance:
C27H46O Balance: C27H46O In = C27H46O Out
C27H46O Out = 207. 46 kg
Keratin Feather Balance: Keratin Feather In = Keratin Feather Out
Keratin Feather Out = 17, 162.47 kg
H2O Balance:
H2O in Chicken Feathers+H2O in C2H5OH solution = H2O Out
1 489.93 kg + 146 907. 79 kg = H2O Out
H2O Out = 146 907. 79 kg
C2H5OH Balance: C2H5OH In = C2H5OH Out
C2H5OH Out = 97 938. 53 kg
C2H5OH = 489. 69 kg
H2O = 734. 54 kg
Dirt = 10. 48 kg
C27H46O = 1.04 kg
Keratin Feather = 85. 82 kg
Equipment: FILTER
FiltrateF-1
Washed Feather
Cake
C2H5OH = 96 469.45 kg
H2O = 144 704.18 kg
Dirt = 2 085.06 kg
C27H46O = 206. 42 kg
TOTAL = 243, 465. 11 kg
Keratin Feather = 17 076.66 kg
Adhering Amount
H2O = 2 959. 01 kg
C2H5OH = 979.39 kg
21 015. 05 kg
Losses = 1321. 56 kg
Dirt = 2 095.55 kg
Feather = 18 859.86 kg
C27H46O = 207.46 kg
H2O = 1 489.93 kg
Keratin Feather = 17 162.47
kg
C2H5OH Solution = 244, 846.32 kg
TOTAL = 265, 801. 72 kg
TOTAL IN = 265, 801. 72 kg TOTAL OUT = 265, 801. 72
kg
Assumptions:
No keratin feather is carried at the filtrate
All fats are dissolved in C2H5OH
All dirt are removed
1% of the liquids adhered on the cake
0.5% lost due to accumulation in the equipment
(Ref: Plant Design and Economics for Chemical Engineers by Peter and Timmerhaus, 5th Edition, p.855)
Computations:
Feed (Washed Feather):
Dirt = 2 095.55 kg
Feather = 18 859.86 kg
C27H46O = 0.0099 (207. 46) = 207. 46 kg
H2O = 0.0711 (207. 46) = 1 489.93 kg
Keratin Feather = 0.819 (207. 46) = 17 162.47 kg
C2H5OH Solution = 244 846.32 kg
Cake:
Keratin Feather = 17 162.47 (1-0.005) = 17076.66 kg
Adhering amount
H2O = 1 489.93 kg + (146 907. 79 kg) (0.01) = 2959.01 kg
C2H5OH = (97 938. 53 kg) (0.01) = 979. 39 kg
Filtrate:
C2H5OH = (97 938. 53 kg)(0.985) = 96 469.45 kg
H2O = (146 907. 79 kg) (0.985) = 144 704.18 kg
Dirt = 2 095.55 kg - 10. 48 kg = 2 085. 06 kg
C27H46O = 207.46 kg - 1.04 kg = 206.42 kg
Lost Amount:
C2H5OH = (97 938. 53 kg)(0.005) = 489.69 kg
H2O = (146 907. 79 kg) (0.005) = 734.54 kg
Dirt = kg = (2 095.55 kg) (0.005) = 10.48 kg
C27H46O = (17 162.47 kg) (0.005) = 1.04 kg
Dirt Balance: Dirt In = Dirt Out
Dirt In = Dirt in Cake + Dirt in Filtrate + Dirt Lost
2 095.55 kg = 0 + 2 085. 06 kg + Dirt Lost
Dirt Lost = 10.48 kg
C27H46O Balance: C27H46O In = C27H46O Out
C27H46O In = C27H46O in Filtrate + C27H46O Lost
207. 46 kg = 206. 42 kg + C27H46O Lost
C27H46O Lost = 1. 04 kg
H2O Balance: H2O In = H2O Out
H2O In = H2O in Cake + H2O in Filtrate + H2O Lost
148 397. 72 kg = 2959. 01 kg + 144 704.18 kg + H2O Lost
H2O Lost = 734.54 kg
Keratin Feather Balance:
Keratin Feather In = Keratin Feather Out
Keratin Feather In = Keratin feather in Cake + Keratin Feather in Filtrate + Keratin Feather Lost
17 162.47 kg = 17076.66 kg + 0 + Keratin Feather Lost
Keratin Feather Lost= 85. 81 kg
C2H5OH Balance:
C2H5OH In = C2H5OH Out
C2H5OH In = C2H5OH in Cake + C2H5OH in Filtrate + C2H5OH Lost
97 938. 53 kg = 979. 39 kg + 96 469.45 kg + C2H5OH Lost
C2H5OH Lost = 489. 69 kg
Evaporated Liquid = 2, 377. 98 kg
Dried Feather = 17, 162. 04 kg
TOTAL OUT = 19 540. 02 kg
Equipment: Dryer
D-1
Keratin Feather = 17076. 66 kg
H2O = 1483. 98 kg
C2H5OH = 979. 39 kg
TOTAL = 19540.02 kg
Cake
Evaporated Liquid
H2O = 1398. 59 kg
C2H5OH = 979. 39 kg
TOTAL = 2, 377. 98 kg
Keratin Feather= 17 076. 66 kg
H2O = 85. 38 kg
C2H5OH = 0 kg
TOTAL = 17, 162. 04 kg
Drier Feather
TOTAL IN = 19540. 02 kg
Assumptions:
100% of ethanol is evaporated since temperature is carried out at 140-160⁰C
0.50% moisture content/keratin feather
(Ref: Plant Design and economics for Chemical Engineers, 5th edition)
Computations:
H2O in Drier Feather = 0.0050 (17076. 66 kg) = 85.38 kg
C2H5OH Evaporated = 1 (979. 39 kg) = 979. 39kg
Keratin Feather Balance: Keratin Feather In = Keratin Feather Out
Keratin Feather Out = 17 076. 66 kg
H2O Balance: H2O In = H2O Out
H2O in Cake = H2O Evaporated + H2O in Drier Feather
1483. 98 kg = H2O Evaporated + 85. 38 kg
H2O Evaporated = 1398. 59 kg
C2H5OH Balance: C2H5OH In = C2H5OH Out
C2H5OH in Cake = C2H5OH Evaporated + C2H5OH in Dried Feather
979. 39 kg = 979. 39 kg + C27H46O Drier Out
Evaporated C2H5OH = 0 kg
Moisture Content = (1483.98kg+979.39 kg)
17076.66kg
Moisture Content = 0. 1443
Equipment: Grinder
Assumptions:
The size of feather fiber length will be reduced to ≥ 0.20 mm
(Ref: Gassner, III et al., 1995. Fiber and Fiber Products Produced
from Feathers.)
Computations:
Keratin Feather Balance: Keratin Feather In = Keratin Feather Out
Keratin Feather Out = 17 076. 66 kg
H2O Balance: H2O In = H2O Out
H2O Out = 85. 39 kg
Ground Fiber:
Keratin Feather = 17 076. 66 kg = 99.50%
H2O = 85. 39 kg = 0.50%
G-1 Dried Feather
Keratin Feather = 17 076. 66 kg
H2O = 85. 39 kg
TOTAL IN = 17, 162. 04 kg
Ground Fiber
Keratin Feather = 17 076. 66 kg
H2O = 85. 39 kg
TOTAL OUT = 17, 162. 04 kg
QUILL = 10 246 kg
Keratin Fiber = 6 830.66 kg
TOTAL OUT = 17 076. 66
Equipment: Separator
Assumptions:
40% keratin fiber in feather will be separated
Negligible amount of water (Ref: Gassner, III et al., 1995.
Fiber and Fiber Products Produced from Feathers.)
Computations:
Keratin Fiber = 0.40 (17 076 .66 kg)
= 6830. 66 kg
Over-all Material Balance: Ground Fiber = Quill + Keratin Fiber
17076 .66 kg = Quill + 6830.66 kg
Quill = 10 246 kg
C-1 Ground Fiber
Keratin
Feather
Keratin Fiber
TOTAL IN = 17076 .66 kg
QUILL = 10 246 kg
Keratin
Feather
Ground Fiber = 6830.66 kg
TOTAL OUT = 6830.66 kg
Equipment: Rotary Grinder
Assumption:
The size of feather fiber length will be reduced to < 0.020 mm
(Ref: Barone, J.R., Liebner, C. & Schmidt, W.F., 2004. Thermally Processed Keratin Films.
Computations:
Keratin Balance: Keratin Fiber In = Keratin Fiber Out
Keratin Fiber Out = 6830.66 kg
G-2Keratin Fiber
Keratin Fiber = 6830.66
kg
Ground Fiber
Keratin Fiber = 6830.66 kg
TOTAL IN = 6830.66 kg
Keratin Fiber = 6147. 60 kg
Quill = 6830.66 kg
Equipment: Screener
Assumptions:
10% (oversize) of the ground fiber will be recycled back to the prior grinder
Computations:
Oversize (back to G-2) = 0.10 (6830.66 kg)
= 683.07 kg
Keratin Fiber Out = 6830.66 kg – 683.07 kg = 6 147. 60 kg
S-1 Ground Keratin Fiber
Keratin Feather = 6830.66
kg
Keratin Fiber
Keratin Fiber = 6147. 60 kg
TOTAL IN = 6830.66 kg
Oversize = 683.07 kg
Keratin Fiber = 6 147. 60 kg
Additive = 4 098. 40 kg
Equipment: Plasticizer Mixing Tank
Keratin Fiber
Keratin Fiber = 6 147. 60 kg
Paste
TOTAL OUT = 10 246 kg
Additive
C3H8O3 = 3 073. 80 kg
NA2SO3 = 204. 92 kg
H2O = 819. 70 kg
TOTAL = 4 098. 40 kg
Keratin Fiber = 6 147. 60 kg
C3H8O3 = 3073. 80 kg
NA2SO3 = 204. 92 kg
H2O = 819. 68 kg
TOTAL = 10 246 kg
T-3
Assumptions:
The ratio of the feed (keratin : Additive) is 3:2
(Ref: Barone, et.al, Extrusion of Keratin, p. 2)
Computations:
Additive added = 6 147. 60 keratin ( 2additive3keratin
)
= 4 098. 40 kg
Additives composition:
75% C3H8O3
5% Na2SO3
20% H2O
C3H8O3 added= 0.75 (4 098. 40 kg)
= 3 073. 80 kg
Na2SO3 added = 0.05 (4 098. 40 kg)
= 204. 92 kg
H2O added = 0.20 (4 098. 40 kg)
= 819. 70 kg
Over-all Material Balance: Fiber Keratin + Additive = Paste
6 147.60 kg + 4 098. 40 kg = Paste
Paste = 10 246 kg
Keratin Fiber Balance : Keratin Fiber In = Keratin Fiber Out
Keratin Fiber Out = 6 147. 60 kg
H2O Balance : H2O In = H2O Out
H2O in Additive = H2O Paste
819. 70 kg = H2O Paste
H2O Paste = 819. 68 kg
C3H8O3 Balance: C3H8O3 In = C3H8O3 Out
C3H8O3 in Additive = C27H46O Paste
3 073. 80 kg = C27H46O Paste
C3H8O3 Paste = 3 073. 80 kg
Na2SO3 Balance: NA2SO3 In = NA2SO3 Out
NA2SO3 in Additive = NA2SO3 Paste
204. 92 kg = Na2SO3 Paste
NA2SO3 Paste = 204. 92 kg
Film = 9 457. 05 kg
H2O Evaporated = 788.94 kg
Equipment: Extruder
Paste Film
TOTAL IN = 10 246 kg
E-1
Keratin Fiber = 6 147. 60 kg
C3H8O3 = 3 073. 80 kg
NA2SO3 = 204. 92 kg
H2O = 30. 74 kg
TOTAL = 9 457. 05 kg
H2O Evaporated = 788.94 kg
Keratin Fiber = 6 147. 60 kg
C3H8O3 = 3073. 80 kg
NA2SO3 = 204. 92 kg
H2O = 819. 68 kg
TOTAL = 10 246 kg
Computations:
Paste:
Keratin Fiber = 6 147. 60 kg = 60%
C3H8O3 = 3 073. 80 kg = 30%
Na2SO3 = 204. 92 kg= 2%
H2O = 819. 68 kg = 8%
H2O Evaporated = (0.9625) (819.68 kg)
= 788.94 kg
Over-all Material Balance: Paste = H2O Evaporated + Film
10 246 kg = 788.94 + Film
Film = 9 457. 05 kg
Keratin Fiber Balance : Keratin Fiber In = Keratin Fiber Out
6 147.60 kg = Keratin Fiber Out
Keratin Fiber Out = 6 147. 60 kg
H2O Balance : H2O In = H2O Out
H2O in Paste = H2O Evaporated + H2O in Film
819.68 kg = 788.94 + H2O in Film
H2O in Film = 30.74 kg
C3H8O3 Balance: C3H8O3 In = C3H8O3 Out
3 073. 80 kg = C3H8O3 Out
C3H8O3 in Film = 3 073. 80 kg
Na2SO3 Balance: Na2SO3 In = Na2SO3 Out
204. 92 kg = Na2SO3 Out
Na2SO3 in Film = 204. 92 kg
Equipment: Air Cooler
Film = 9 457. 05 kg
TOTAL OUT = 9 457. 05 kg
Assumption:
Only heat transfer will occur
Computations:
Over-all Material Balance : Film In = Film Out
9 457. 05 kg = Film Out
Film Out =9 457. 05 kg
C-2Film Film
TOTAL IN = 9 457. 05 kg
Keratin Fiber = 6 147. 60 kg
C3H8O3 = 3 073. 80 kg
NA2SO3 = 204. 92 kg
H2O = 30.74 kg
TOTAL = 9 457. 05kg
Keratin Fiber = 6 147. 60 kg
C3H8O3 = 3 073. 80 kg
NA2SO3 = 204. 92 kg
H2O = 30. 74 kg
TOTAL = 9 457. 05 kg
Keratin Fiber Balance : Keratin Fiber In = Keratin Fiber Out
6 147. 60 kg = Keratin Fiber Out
Keratin Fiber Out = 6 147. 60 kg
C3H8O3 Balance : C3H8O3 In = C3H8O3 Out
3 073. 80 kg = C3H8O3 Out
C3H8O3 in Film = 3 073. 80 kg
Na2SO3 Balance: Na2SO3 In = Na2SO3 Out
204. 92 kg = Na2SO3 Out
Na2SO3 in Film = 204. 92 kg
H2O Balance : H2O In = H2O Out
30. 74 kg = H2O Out
H2O in the film = 30. 74 kg
Film = 9 457. 05 kg
TOTAL OUT = 9 457. 05 kg
Equipment: Flattening Rolls
Computations:
Over-all Material Balance : Film In = Film Out
9 457. 05 kg = Film Out
Film Out =9 457. 05 kg
Keratin Fiber Balance : Keratin Fiber In = Keratin Fiber Out
6 147. 60 kg = Keratin Fiber Out
Keratin Fiber Out = 6 147. 60 kg
Film Film R-2
Keratin Fiber = 6 147. 60 kg
C3H8O3 = 3 073. 80 kg
NA2SO3 = 204. 92 kg
H2O = 30. 74 kg
TOTAL = 9 457. 05 kg
Keratin Fiber = 6 147. 60 kg
C3H8O3 = 3 073. 80 kg
NA2SO3 = 204. 92 kg
H2O = 30. 74 kg
TOTAL = 9 457. 05 kg
TOTAL IN = 9 457. 05 kg
C3H8O3 Balance : C3H8O3 In = C3H8O3 Out
3 073. 80 kg = C3H8O3 Out
C3H8O3 in Film = 3 073. 80 kg
Na2SO3 Balance: Na2SO3 In = Na2SO3 Out
204. 92 kg = Na2SO3 Out
Na2SO3 in Film = 204. 92 kg
H2O Balance : H2O In = H2O Out
30. 74 kg = H2O Out
H2O in the film = 30. 74 kg