maple syrup production report
TRANSCRIPT
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Preliminary Design and
Economic Analysis Project
Maple Syrup Production Process
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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
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Abstract
Maple syrup has many uses including, but not limited to, food and medicinal purposes. Canada produces approximately 80% of theworlds 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.
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Process Flow Diagram
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Flow Summary Table
Stream 25 26 27 28 29 30 31 32 33 34 35 36
Temperature (C) 315 259 259 259 240 249 240 212 324 259 249 259Pressure (atm) 19.4 35 50 40 25 29.4 25 14.7 25 35 29.4 38
Vapor Fraction (basis) 0.99 0 0 0 0.90 0.99 0.91 1.0 1.0 1.0 0.99 0.0
Mass Flow (kg/h) 394 183 183 183 2580 211 2790 2580 2580 211 183 183
Mole Flow (kmol/h) 43 17 17 17 315 12 155 143 143 12 12 8
Component Flow Rates (kg/h)
Sucrose 45 45 45 45 0 0 0 0 0 0 0 45
Water 349 138 138 138 2580 211 2790 2580 2580 211 183 138
Stream 1 2 3 4 5 6 7 8 9 10 11 12
Temperature (C) 70 70 70 70 212 212 213 213 212 212 212 212
Pressure (atm) 14.7 14.7 14.7 14.7 17.0 17.0 116 116 14.7 14.7 14.7 116Vapor Fraction (basis) 0 0 0 0 0 0 0 0 0 0 0 0
Mass Flow (kg/h) 2268 2268 2268 2268 3841 3841 2841 2968 2968 2968 2968 872
Mole Flow (kmol/h) 124 124 124 124 463 463 463 358 358 358 358 105
Component Flow rates (kg/h)
Sucrose 27 27 27 27 58 58 58 45 45 45 45 13
Water 2241 2241 2241 2241 3782 3782 3782 2923 2923 2923 2923 859
Stream 13 14 15 16 17 18 19 20 21 22 23 24
Temperature (C) 213 213 290 212 212 70 70 300 259 212 212 212
Pressure (atm) 40 40 38 14.7 14.7 14.7 45 35 35 14.7 29.4 19.4
Vapor Fraction (basis) 0 0 1 1 1 0 0 1 0.9 0 0 0
Mass Flow (kg/h) 872 872 857 540 540 8171 8171 8171 8171 394 394 394
Mole Flow (kmol/h) 105 105 103 66 66 1000 1000 1000 1000 43 43 43
Component Flow Rates (kg/h)
Sucrose 13 13 13 0 0 0 0 0 0 45 45 45
Water 859 859 843 540 540 8171 8171 8171 8171 349 349 349
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Flow Summary Table (Continued)
Stream 37 38 39
Temperature (C) 212 212 212
Pressure (atm) 14.7 14.7 14.7
Vapor Fraction (basis) 1 0 0
Mass Flow (kg/h) 115 68 68
Mole Flow (kmol/h) 6 1 1
Component Flowrates (kg/h)
Sucrose 0 45 45
Water 115 23 23
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Major Equipment Summary Table
Equipment Item Material of Construction Critical Design Specifications
Pump Stainless Steel
Max. Temperature = 126C
Max. Pressure = 3.4atm
Drive Stainless Steel
Max. Temperature = 126C
Max. Pressure = 3.4atm
Fired Heater Stainless Steel
Max. Temperature = 149C
Max. Pressure = 3.1atm
Compressor Stainless Steel
Max. Temperature = 162C
Max. Pressure = 2.4atm
Heat Exchanger Stainless Steel/Carbon Steel
Max. Temperature = 162C
Max. Pressure = 2.4atm
Vessel Stainless Steel Clad
Max. Temperature = 159C
Max. Pressure = 2.4atm
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Preliminary Equipment Design
Heat Exchangers and Fired Heaters
Equipment E-201 E-202 E-203 H-201
Type Fixed, Sheet, U-Tube Fixed, Sheet, U-Tube Fixed, Sheet, U-Tube Stainless Steel
Duty (MJ/h) 5609 638 1.4 5610
Area (m2) 91.6 25.8 1.12 -
Shell Side
Max Temp. (C) 149 162 126
Pressure (atm) 2.4 1.7 2.7
Phase Vapor Vapor LiquidMOC Stainless Steel/Carbon Steel Stainless Steel/Carbon Steel Stainless Steel/Carbon Steel
Tube Side
Max Temp. (C) 69 159 126
Pressure (atm) 2.0 1.3 2.7
Phase Liquid Vapor Liquid
MOC Stainless Steel/Carbon Steel Stainless Steel/Carbon Steel Stainless Steel/Carbon Steel
Vessels
Equipment V-201 V-202 V-203 V-204MOC Stainless Clad Stainless Clad Stainless Clad Stainless Clad
Diameter (m) 0.61 0.457 0.457 2
Height/Length (m) 1.93 1.91 1.85 10
Orientation Vertical Vertical Vertical Vertical
Pressure (atm) 1.0 2.4 2.6 2.6
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Piping
Equipment Piping
MOC Insulated Stainless Steel
Type Schedule 40
Compressors and Pumps
Equipment C-201 C-202
MOC Stainless Steel Stainless Steel
Power (Shaft) (kW) 12.5 2.68
Efficiency 0.9 0.9
Type/Drive Centrifugal Centrifugal
Temperature (C) 162 126
Pressure in (atm) 2.0 2.4
Pressure out (atm) 1.7 2.0
Equipment P-201 P-202 P-203 P-204 P-205 P-206
MOC Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel
Power (Shaft) (kW) 1.5 0.6 0.001 0.01 0.006 0.001
Efficiency 0.5 0.8 0.8 0.8 0.8 0.8
Type/Drive Centrifugal Centrifugal Centrifugal Centrifugal Centrifugal Centrifugal
Temperature (C) 100 21 100 100 126 100
Pressure in (atm) 1.2 1.0 1.0 1.0 2.4 1.0
Pressure out (atm) 7.8 3.0 2.0 2.0 3.4 1.0
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Safety Analysis
Safety Data Sheets
Chemical Safety Data Sheet
Water Appendix A
Maple Syrup Appendix B
http://e/water.pdfhttp://c/Users/jmeckenrode/Desktop/MSDS%20Maple%20Syrup.dochttp://c/Users/jmeckenrode/Desktop/MSDS%20Maple%20Syrup.dochttp://e/water.pdf -
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Piping & Instrumentation Diagram
Utility Connections1. Sample Port
2. 14.7 Psia Steam
3. Condensate
4. Vent to Atmosphere
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Economic Evaluation
Fixed Capital Investment Labor Costs Raw Material Costs Utility Costs Total Cost of Manufacturing Net Present Value
$6,180,000 $335,204 $2,183,159 $658,000 $5,522,133 -$8,790,000
Discounted Cash Flow Diagram
-10.0
-9.0
-8.0
-7.0
-6.0
-5.0
-4.0
-3.0
-2.0
-1.0
0.0
-1 0 1 2 3 4 5 6 7 8 9 1 0 11 12 13Proje
ctValue(millionsofdollars)
Project Life (Years)
Cash Flow Diagram
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Monte Carlo Analysis of Net Present Value