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Design and Construction of a Lab-Scale System to Produce

Biodiesel from Waste Oil Using Immobilized Lipase

Team member ID Number

Mubarak Salyem Alsheraifi 200415260Humaid Saeed Alshamsi 200417806Nayef Mohammed Albraik 200416292Abdelaziz Hassan Suwaidi 200215582Saud Abdulaziz Aljahori 200440225

UAE University

College of Engineering

Industrial Training and Graduation Project UnitChemical & Petroleum Engineering Department

Advisor: Dr. Sulaiman Al-Zuhair

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Contents Introduction and Background

Summary of GPI

Detailed Design and Simulation

Lab Scale Experiment

Economics and Cost

HAZOP and Environmental Impact of the process

Conclusion and Way Forward

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Introduction and Background Biodiesel, defined as methyl (or ethyl) ester of long chain

fatty acids, is derived from vegetable oils or animal fats,

for use in compression-ignition (diesel) engine.

Enzymatic transesterification has been proposed recently

to overcome the problems facing conventional chemical

methods without compromising their advantages.

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Introduction and Background The objective of this project is to design and construct a lab-

scale system to continuously produce approximately 1000 g/hrrelatively pure biodiesel by using immobilized lipase as

catalyst.

The design objective of the project is to know how to designthe main equipments of the lab-scale system.

The main equipments in the-lab-scale system are heatexchanger, liquid-liquid extraction, reactor, and distillationcolumn

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Summary of GPI In GPI, literature survey was conducted on biodiesel

production, physical, and chemical properties werecollected.

Different methodologies and processes for biodieselproduction from waste cooking oil have been studied tochoose the suitable process flow diagram.

Then, based on the estimated production capacity,material and energy balances on the whole system as wellas each individual unit had been performed

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Summary of GPI Based on the estimated production capacity, material and

energy balances on the whole system as well as each individualunit had been performed.

Material balance was done in GPI to know the amount ofmaterials needed for the reaction such as amount of the enzymecatalyst, which was achieved using the mass and moleconservation.

The search result from GPI has shown that activity of theenzyme is highest at 45C.

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Process Flow Diagram

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Summary of GPI The energy balance sheet designed in order to calculate

the temperatures in all streams and add heaters or coolers

as needed to make the temperature of the stream entering

the reactor equal to 45C also to operate the distillation at

95 .

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Detailed Design Heat Exchanger.

Liquid Liquid Extraction.

Reactor Design.

Distillation column.

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Factors Involved in Reactor Design

Feedstock composition Single feedstock

Reactant in a solvent

Multi-component feedstock

Scale of process output of product

Process kinetics Effect of composition

(concentration) Effect of temperature

Catalyst

Thermodynamics

Reactor type Batch / continuous

Semi batch / Semicontinuous

Isothermal, non-isothermal,adiabatic

Single pass / recycle

Multiple reactors

Others Materials of construction

instrumentation

safety

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Reactor DesignThe structure parameters mainly include:

1. Reactor diameter.

2. Reactor length.

3. The Volume of the reactor.

4. Weight of the catalyst used in the reactor.

5. Pressure drop inside the reactor.

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Reactor Design

Physical Properties

1. Average Density

2. Average Viscosity

iiavg x

iiavg x

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Reactor Design

Volume of the reactor :

The polymath software program was using to calculatevolume of reactor.

)(reactantsofDensity

reactantsofMass)(reactantsofrateflowVolumetric

average

o

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Reactor Design - Polymath

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Reactor Design

Pressure drop inside the reactor

21

21

o

o

oP

L

P

P

G

DDg

G

PPoc

o 75.1)1(150)1(

3

CA

mG

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Reactor Resultsm36 *10-5Rector volume

g

27Weight of catalystatm0.034Pressure drop

m0.0118Reactor Diameter

m0.54Reactor length

Reactor Design

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Classification of Homogeneous and Heterogeneous

Reactor Models

REACTION PHASE REACTOR MODEL

Homogeneous Plug Flow, CSTR, Batch

Heterogeneous:-

CatalyticTwo Phase

Gas-Catalyst orLiquid-Catalyst

Three Phase

Gas-Liquid-Catalyst

Non-Catalytic

Gas-Liquid

Packed-Bed or Fluidized-Bed

Trickle-bed, Bubble Fixed-BedCSTR Slurry, Bubble Slurry,3-Phase Fluidized

Gas-Liquid CSTR, Gas-LiquidBubble Column

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Multi-phase Reactors- Advantages and

DisadvantagesA packed bed is a hollow tube, pipe, or other vessel that is

filled with a packing material. The packing can be randomly

filled with small objects it is name catalyst.

Packed Bed ReactorAdvantages Disadvantages

High conversion per unit mass of catalyst Undesired thermal gradients may exist

Low operating cost Poor temperature control

Continuous operation Unit may be difficult to service and clean

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Concentric Tube Construction

Parallel FlowParallel Flow

- : :

CounterflowCounterflow

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Heat transfer Area calculations

F.TU.A.Q m

F.TU. QA m

ii

o

i

oo

o

calculated

hr

r

r

r

k

r

h

U1

)()ln(1

1

0.33

h

f

ii .Re.PrjK

.dhNu

1/30.55

shell

e

ho PrR

D

0.36.kh

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Shell and Tube Advantages The configuration gives a large surface area in a small

volume.

Good mechanical layout: a good shape for pressure

operation.

Uses well-established fabrication techniques.

Can be constructed from a wide range of materials.

Easily cleaned.

Well-established design procedures.

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Modified McCabe Thiele

Assumptions:

Ternary components of Glycerol, Biodiesel and Water

Biodiesel & Glycerol are partially miscible

The two-phase region is inside the envelope. The one-phase region is outside the envelope.

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Equilibrium lineEquilibrium Plot

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

1.00

0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18 0.20

Xg Biodiesel Phase

YgWaterPhase

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

1.00

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Equation Used

3.0SpacingTrayTraysofNumberHeight

Height

30

1DiameterTower

LDAreaTower

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Extraction Column Specifications

Equipment Name: (T-101).

Type of Equipment : Liquid Liquid Extraction Column

Data Value Unit

Height 1.4 m

Area 0.22 m2

Diameter 0.05 m

Tube Material Of Construction Carbon steel

Volume 0.003 m3

Number Of Actual Stages 2 Stages

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Simulation Comparison Using HYSYS simulator was not

possible since this equipment runs on a very slow

flow rate which can not be solved or simulated by

HYSYS.

ChemCAD simulator was unable to solve the system

effectively which also lacks the ability to calculateddesign variables for a liquid liquid extraction unit

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Design Alternatives Mixer settlers

Centrifugal

Packed Column

Plate liquid liquid extraction column was chosen the efficiencyof the plate tower is much higher

Plate tower can easily operate with more than one feed and

inside cooling is easier

The presence of solid does not prevent the plate towerperformance.

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Assumption Binary mixture of Tert butanol and water

Total Condenser

Partial Boiler

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Number of Trays Using McCabe Thiele method

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Equation used in Distillation Design

stageTheorticalstageactual

NN

u

VArea

gas

m6.0N*SpacingPlateHeight stageactual

stagesN stageactual 6

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Distillation Column Specification

Equipment Name: (T-102).Type of Equipment : Distillation column

Data Value Unit

Max Vapor Velocity 0.6 m/s

Height 1.2 m

Cross Sectional Area 5.5 * 10-4 m2

Inside Diameter 0.0263 m

Tube Material Of Construction Carbon steel

Volume 6.5*10^-4 m3

Number Of Actual Stages 6 stages

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Design AlternativePacked Tower

The Design of Plate Column is More Equation Reliable.

Trays have Higher Efficacy

Plate Tower is Easier to Operate With More Than One Feed

And Inside Cooling is Easier

The Presence of Solid Does not Prevent the Plate TowerPerformance.

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HAZOP ProcedureHazard Cause Deviation Consequence Impact

Material/energycontained and

controlledduring normal

operation

ToxicityFlammabilityReactivityElevatedpressure

Initiating eventof process

upset; start ofaccident event

sequence

Mechanicalfailure

Proceduralerror

External forceFouling

Excursionbeyond design/operating limits

No flowHigh

temperatureLow levelImpurities

Wrong materialStep omitted

Loss ofcontainment of

processmaterial/ energy

FireExplosionHazardous

material release

Severity ofconsequences;

loss

CasualtiesPropertydamage

Businessinterruption

Environmentaldamage

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Process piping and Insemination Diagram

P k d B d R t

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Equipment Name : R-101

Equipment Type : Packed Bed Reactor

Deviation CausesPotential

ConsequenceSafeguards

Recommendation

s

Low Flow

(Stream 6)

Valve Or Pump

Failure

Low Production

Rate, Not SeriousProblem

Auxiliary Pump

Input A Low Flow

Alarm

High Flow

(Stream 6)

Valve Stuck

Open

Sudden Decrease In

Temperature Of The

Column, LowConversion

Proportional

ValvePressure Alarm

No Flow

(Stream 6)

Pump FailureNot Serious

ProblemsAuxiliary Pump Flow Alarm

Packed Bed Reactor

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Packed Bed ReactorNo Flow

(Stream 7)

Blockage Inside

Packed Bed Reactor

Low Production Rate,

High Pressure Drop,

Building Up Pressure

Up Stream.

Clean With Tert-

Butanol To DissolveWhat Even Blocks

The PBR, Back Flow

For Cleaning

Regular Maintenance,Regular Check Of

7hr/Day

High Pressure(Stream 6)

Oil Or Glycerol

Freezing InsideReactor

Flow, Damage Pump,

Reduction Of Enzyme

Activity

Temperature Alarm Relief Valve In TheVent

Low Temperature

(Stream 5 & 6)

Control Temperature

Failure

Reduction Of Enzyme

Activity, Low

Conversion

Input And Output

Temperature (High

And Low)

Alarm

Hot Water Cycle

(Temperature Control)

High Temperature

(Stream 5 & 6)Valve Stuck

Reduction Of Enzyme

Activity, Low

Conversion

Input And Output

Temperature (High

And Low)

Alarm

Cooling Water Cycle

(Temperature Control)

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Conducting experiments to determine the rate ofenzymatic production of biodiesel.

Detailed design of main units and equipments.

Construction of lab-scale system for continuousproduction.

Testing of the produced biodiesel (physical, chemical andmechanical properties)

Conclusion

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Thanks for Listening