Conté: Part 1, The company / Laura Castañeda Pajuelo. Part 2, The process / Joan Carrasco Vidiella. Part 3, The analysis / Vedruna Francès de Ma

Carrasco Vidiella, Joan

Castaneda Pajuelo, Laura

Francès de Mas, Vedruna

Universitat Autònoma de Barcelona. Facultat de Biociències

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Item Value Total capital investment 18 051 000 € Total plant direct cost 9 330 000 € Equipment purchase cost 2 854 000 € Installation 1 111 000 € Piping 999 000 € Instrumentation 1 142 000 € Insulation 86 000 € Electrical 285 000 € Buildings 1 284 000 € Yard improvement 428 000 € Auxiliary facilities 1 142 000 € Total plant indirect cost 5 598 000 € Engineering 2 332 000 € Construction 3 265 000 € Others 2 239 000 € Contractor’s fee 746 000 € Contingency 1 493 000 € Working capital 26 000 € Start-up cost 858 000 € Annual operating cost 919 000 € Raw materials 26 000 € Labour dependent 208 000 € Laboratory/QC/QA 31 000 € Consumables 4 000 € Utilities 649 000 € Annual production 32.11 kg/year Unit production cost 28 608.37 €/kg Unit price 38 €/kg Revenues 1 000 €/yr Payback time 25.38 years A. Biwer and E. Heinzle. Environmental assessment in early process development. J Chem Technol Biotechnol 79:597–609 (2004) E. Heinzle, A. Biwer, C. Cooney. Development of sustainable bioprocesses. Wiley (2006) R. Turton et al. Analysis, synthesis, and design of chemical processes. 3rd ed. Prentice Hall (2009) Gaseous emissions: Water, Carbon Dioxide, Nitrogen and Oxygen  640  tons / year Emitted directly to the atmosphere. No hazardous gases are emitted  Liquid waste: Water with  salts for the most part.  Some biomass  is present.  Aspergillus Niger of the variety  we are using is considered GRAS, so no further  measures need to be  taken.  2400 tons / year Local water treatment will be used. An additional fee might need to be paid for the high amount of salts that water contains  Industrial Process Design 3. The analysis •The most important items in our  annual operating cost are the labour (22.63%) and the utilities (70.62%).  We annually spend 644 240 €  on electrical power, which represents the 99.25% of the utilities cost. •It is difficult to improve the cost of the labour and the power because both the operators minimum salary  and the power price are defined by law. •The use of more efficient equipment might be a solution, but that would come with an increase of cost. Due to SuperPro Designer limitations, we had to make some assumptions:  •SPD does not count the price of the land, which is 874,617.0 € •Some equipment prices are not given by the program  and they are counted as zero; we know them, but their value in the program can can’t be modified •Also, only the  power consumption of some equipment is available and the calculus is an approximation •The price of xylanase is calculated using only the annual operating cost (919 000 / 32.11 = 28 608) •Prices are taken from the year 2013 Solid waste: Mainly from the SSF fermentation. It’s rich in biomass and proteins, bran and other organic waste.  133 tons / year To be released into the local landfill for its incineration or dumping  Item Input Mw Output Mw Input Mult Output Mult Kg/KgP Enviromental Index Mw Environmental Index Mult Environmental Index Mw output Environmental Index Mult output Water 0 0 1 1 77000 0 0 77000 77000 KH2PO4 0.08 0.33 5.2 1.3 168 13.44 55.44 873.6 218.4 Amm.sulfate 0.15 0.33 5.2 1.69 109 16.35 35.97 566.8 184.21 Carb Dioxide 1 0.08 1.3 1 2278 2278 182.24 2961.4 2278 Mag.Sulfate 0.08 0 1 1.3 0.126 0.01008 0 0.126 0.1638 Total 79555.126 2307.80008 273.65 81401.926 79680.7738 Joan Carrasco Vidiella, Laura Castañeda Pajuelo, Vedruna Francès de Mas Professor: Carles Solà Ferrando Facultat de Biociències, Universitat Autònoma de Barcelona, June 2013 Introduction To evaluate the performance of our project, three analysis were done. The economical analysis allowed us to see which were the major costs and investments. The environmental analysis pointed out the potential concerns our project might have to consider to become a sustainable process. Finally, the social analysis describes the labour and management organization.    Growing concerns in environmental problems such as climate change, energy consumption and water usage make the environmental analysis of a process a very important . The main problem in our process is the big amount of residual water  and solid waste that it generates.   To do the environmental analysis, the amount of one substance per kilogram of desired product is calculated. Afterwards, every one of this substances is associated with one Environmental Factor, which when combined with the matter balance give us an approximation of the process’s environmental performance.    Plant manager •Engineer profile •He handles the plant control Operators •Three 8 hours shifts •Two operators each shift Temporary workers •Additional workers will be temporarily contracted in times of higher workload Chief manager •He is part of the main company  •He works on our section once a week •He deals with administration and finances External services •Cleaning service •Maintenance •Transport of raw materials, rice bran, salts, utilities... Operators need profile Conclusions  •We conceived, designed and structured a project from the start. Our work was not one of bibliographic revision (even though bibliographic support was needed) but one of development of an idea using the knowledge acquired throughout the degree.  •Finally, the process is not economically feasible. The main problems are the equipment cost, the electrical power cost and the labour.   •To overcome these obstacles, genetic engineering of Aspergillus niger to achieve a higher yield of xylanase per batch could be performed. Also, targeting a bigger market (e.g. other industries, other countries) could result in more benefits with the same cost, as the equipment  can produce higher amounts of xylanase without further investments.  •Pilot plant studies and further optimization studies are the logical next steps in making this project a reality.   Item Input Output Mass Index [kg kg−1 P] 79555,126 79555,126 Number of A components 0 0 Environmental Index [Index points kg−1 P] 2307,80008 273,65 Environmental Index  [Index points kg−1 P] 81401,926 79680,774 General Effect Index (0–1) 0,02900882 0,0034398 General Effect Index (1–256) 1,02321409 1,0015794   Environmental Economical Social 

Industrial Process Design

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Industrial Process Design

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