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• Jeramy M. Eckenrode

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• Tecnología energética
• Química
• Ingeniería mecánica
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Preliminary Design and Economic Analysis Project

Maple Syrup Production Process

Youngstown State University Process and Plant Design 2 Jeramy M. Eckenrode 5/3/2013

Contents Abstract ........................................................................................................................................... 3 Process Flow Diagram .................................................................................................................... 4 Flow Summary Table ...................................................................................................................... 5 Flow Summary Table (Continued) ................................................................................................. 6 Preliminary Equipment Design ....................................................................................................... 8 Heat Exchangers and Fired Heaters ............................................................................................ 8 Vessels ........................................................................................................................................ 8 Piping .......................................................................................................................................... 9 Compressors and Pumps ............................................................................................................. 9 Safety Analysis ............................................................................................................................. 10 Safety Data Sheets .................................................................................................................... 10 Piping & Instrumentation Diagram ............................................................................................... 11 Economic Evaluation .................................................................................................................... 12 Discounted Cash Flow Diagram ............................................................................................... 12 Monte Carlo Analysis of Net Present Value ............................................................................. 13

Abstract Maple syrup has many uses including, but not limited to, food and medicinal purposes. Canada produces approximately 80% of the world’s maple syrup production, with the United States producing the remaining 20%. The purpose of this project is to design a maple syrup chemical process which attempts to produce a profit within twelve years. The plant costs were estimated using a CapCost program, whereas the cost of the capital equipment, raw materials, utilities, labor and the net present value at an interest rate of 10% were determined. The total cost of manufacturing was calculated as $5,522,133 and the fixed capital investment totaled $6,180,000. Also, the cost of the raw materials and labor costs were calculated as $2,183,159 and $335,204, respectively. Finally, the net present value of the process is-$1,500,000. As such, the process is losing 1.5 million dollars in twelve years. Many adjustments were made and attempted in order to optimize the process so as to earn a profit in twelve years. However, the attempts were unsuccessful. Therefore, the recommendation is to consult other chemical engineers in order to produce a result that earns a profit, however, if these attempts continue to fail, it is recommended to dismiss the project as a failure.

Process Flow Diagram

Flow Summary Table Stream Temperature (°C) Pressure (atm) Vapor Fraction (basis) Mass Flow (kg/h) Mole Flow (kmol/h) Component Flow rates (kg/h) Sucrose Water

1 70 14.7 0 2268 124

2 70 14.7 0 2268 124

3 70 14.7 0 2268 124

4 70 14.7 0 2268 124

5 212 17.0 0 3841 463

6 212 17.0 0 3841 463

7 213 116 0 2841 463

8 213 116 0 2968 358

9 212 14.7 0 2968 358

10 212 14.7 0 2968 358

11 212 14.7 0 2968 358

12 212 116 0 872 105

27 2241

27 2241

27 2241

27 2241

58 3782

58 3782

58 3782

45 2923

45 2923

45 2923

45 2923

13 859

Stream Temperature (°C) Pressure (atm) Vapor Fraction (basis) Mass Flow (kg/h) Mole Flow (kmol/h) Component Flow Rates (kg/h) Sucrose Water

13 213 40 0 872 105

14 213 40 0 872 105

15 290 38 1 857 103

16 212 14.7 1 540 66

17 212 14.7 1 540 66

18 70 14.7 0 8171 1000

19 70 45 0 8171 1000

20 300 35 1 8171 1000

21 259 35 0.9 8171 1000

22 212 14.7 0 394 43

23 212 29.4 0 394 43

24 212 19.4 0 394 43

13 859

13 859

13 843

0 540

0 540

0 8171

0 8171

0 8171

0 8171

45 349

45 349

45 349

Stream Temperature (°C) Pressure (atm) Vapor Fraction (basis) Mass Flow (kg/h) Mole Flow (kmol/h) Component Flow Rates (kg/h) Sucrose Water

25 315 19.4 0.99 394 43

26 259 35 0 183 17

27 259 50 0 183 17

28 259 40 0 183 17

29 240 25 0.90 2580 315

30 249 29.4 0.99 211 12

31 240 25 0.91 2790 155

32 212 14.7 1.0 2580 143

33 324 25 1.0 2580 143

34 259 35 1.0 211 12

35 249 29.4 0.99 183 12

36 259 38 0.0 183 8

45 349

45 138

45 138

45 138

0 2580

0 211

0 2790

0 2580

0 2580

0 211

0 183

45 138

Flow Summary Table (Continued) Stream Temperature (°C) Pressure (atm) Vapor Fraction (basis) Mass Flow (kg/h) Mole Flow (kmol/h) Component Flowrates (kg/h) Sucrose Water

37 212 14.7 1 115 6

38 212 14.7 0 68 1

39 212 14.7 0 68 1

0 115

45 23

45 23

Major Equipment Summary Table Equipment Item

Material of Construction

Pump

Stainless Steel

Drive

Stainless Steel

Fired Heater

Stainless Steel

Compressor

Stainless Steel

Heat Exchanger

Stainless Steel/Carbon Steel

Vessel

Stainless Steel Clad

Critical Design Specifications Max. Temperature = 126⁰C Max. Pressure = 3.4atm Max. Temperature = 126⁰C Max. Pressure = 3.4atm Max. Temperature = 149⁰C Max. Pressure = 3.1atm Max. Temperature = 162⁰C Max. Pressure = 2.4atm Max. Temperature = 162⁰C Max. Pressure = 2.4atm Max. Temperature = 159⁰C Max. Pressure = 2.4atm

Preliminary Equipment Design Heat Exchangers and Fired Heaters Equipment Type Duty (MJ/h) Area (m2) Shell Side Max Temp. (⁰C) Pressure (atm) Phase MOC Tube Side Max Temp. (⁰C) Pressure (atm) Phase MOC

E-201 Fixed, Sheet, U-Tube 5609

E-202 Fixed, Sheet, U-Tube 638

91.6

25.8

149 2.4 Vapor Stainless Steel/Carbon Steel

162 1.7 Vapor Stainless Steel/Carbon Steel

69 2.0 Liquid Stainless Steel/Carbon Steel

159 1.3 Vapor Stainless Steel/Carbon Steel

E-203 Fixed, Sheet, U-Tube 1.4 1.12

H-201 Stainless Steel 5610 -

126 2.7 Liquid Stainless Steel/Carbon Steel 126 2.7 Liquid Stainless Steel/Carbon Steel

Vessels Equipment MOC Diameter (m) Height/Length (m) Orientation Pressure (atm)

V-201 Stainless Clad 0.61 1.93 Vertical 1.0

V-202 Stainless Clad 0.457 1.91 Vertical 2.4

V-203 Stainless Clad 0.457 1.85 Vertical 2.6

V-204 Stainless Clad 2 10 Vertical 2.6

Piping Equipment MOC Type

Piping Insulated Stainless Steel Schedule 40

Compressors and Pumps Equipment MOC Power (Shaft) (kW) Efficiency Type/Drive Temperature (⁰C) Pressure in (atm) Pressure out (atm)

Equipment MOC Power (Shaft) (kW) Efficiency Type/Drive Temperature (⁰C) Pressure in (atm) Pressure out (atm)

C-201 Stainless Steel 12.5 0.9 Centrifugal 162 2.0 1.7

P-201 Stainless Steel 1.5 0.5 Centrifugal 100 1.2 7.8

C-202 Stainless Steel 2.68 0.9 Centrifugal 126 2.4 2.0

P-202 Stainless Steel 0.6 0.8 Centrifugal 21 1.0 3.0

P-203 Stainless Steel 0.001 0.8 Centrifugal 100 1.0 2.0

P-204

P-205

P-206

Stainless Steel 0.01 0.8 Centrifugal 100 1.0 2.0

Stainless Steel 0.006 0.8 Centrifugal 126 2.4 3.4

Stainless Steel 0.001 0.8 Centrifugal 100 1.0 1.0

Safety Analysis Safety Data Sheets Chemical Water Maple Syrup

Safety Data Sheet Appendix A Appendix B

Piping & Instrumentation Diagram Utility Connections 1. Sample Port 2. 14.7 Psia Steam 3. Condensate 4. Vent to Atmosphere

Economic Evaluation Fixed Capital Investment $6,180,000

Labor Costs $335,204

Raw Material Costs $2,183,159

Utility Costs $658,000

Total Cost of Manufacturing $5,522,133

Discounted Cash Flow Diagram

Cash Flow Diagram

Project Value (millions of dollars)

0.0 -1.0 -2.0 -3.0 -4.0 -5.0 -6.0 -7.0

-8.0 -9.0

-10.0 -1

0

1

2

3

4

5 6 7 8 9 Project Life (Years)

10

11

12

13

Net Present Value -$8,790,000

Monte Carlo Analysis of Net Present Value