CHAPTER THREE OF A DESIGN PROJECT FOR

DESIGN OF A PLANT FOR THE PRODUCTION OF 240,000 CUBIC METRES OF

LIQUEFIED BIOGAS PER ANNUM FROM AGRO WASTES

PRESENTED TO THE DEPARTMENT OF CHEMICAL ENGINEERING

BY
GROUP G
IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE COURSE
CHG 531: CHEMICAL ENGINEERING PROCESS DESIGN I

GROUP MEMBERS & THEIR INDIVIDUAL CONTRIBUTIONS

NAMES MATRIC CONTRIBUTION TO SIGNATURE

NUMBER CHAPTER

ADETUNMIBI, PEACE ADEGBOYEGA 170401017 Compilation and general material

balance calculation

EZEOKOYE, IFUNANYA BENEDICTA 170401044 Compilation and general material

balance calculation

ORIMOLOYE, ARAMIDE DESOLA 170401032 Biodigester Material Balance

KABIAWU, ANJOLAIYA INNOCENT 170401047 Driers and Miller material

Balance

DADA, TAIWO OLAMIDE 170401072 Scrubber Material Balance

ADEDEJI, ADETILEWA 170401061 Mixer Material Balance

OLUWAFUNMILAYO

AMODU, SULEMAN BABANGIDA 170401075 Liquefaction material balance

UDOH, IMMAOBONG ESSIEN 180401505 Pumps and compressors material

balance

NNABUIHE OLISEMEKA VICTOR 180401510 Mixer material balance

OKUNLOLA, JOSEPH KAYODE 170401048 Liquefaction material balance

 CHAPTER 3

3.0 MATERIAL BALANCE

In this chapter, we will perform material balances on the process that was proposed in
Chapter 2. These balances are essential to check whether the process as described is in
agreement with the laws of conservation of mass. Since the given basis is the volume of
product per annum, we will determine the feed mass flow rate mathematically. To facilitate
mathematical calculations and describe a feasible process, we have made certain assumptions
and specifications. These have been based on cited literature and are stated with reasoning
provided wherever necessary. We will perform material balances around each unit operation,
and then a total material balance around the entire process will be done.

Material balances are based on the law of conservation of mass. According to this principle,
if no mass is accumulated, the mass entering a proc

ess is equal to the mass exiting the process. This holds for batch processes and continuous
processes over a given time interval. Material balances may be expressed mathematically and
are usually of the form:
Mass In = Mass Out + Mass Retained
Feed Materials = Products + Wastes + Materials Retained.

The diagram of the proposed process is provided below for reference.

Figure 3.1 Process Flow Diagram of the Proposed Process

3.1 DETERMINATION OF FEED MASS FROM OUTPUT BASIS
AIM: 240,000 m3 of liquified CH4 (liquid) is produced per annum
From literature, Liquefied CH4 is 1/600 the volume of Gaseous CH4
Therefore, volume of CH4 Gas before the liquefaction process = 600×240,000 m3
Volume of Gas CH4 per annum = 144 ×106 m3
Density of Liquified biomethane CH4 (IEA, 2021) = 424.4 kg/ m3
Mass of Gas CH4 = 5.36 kg/s

Factoring a total downtime of 35 days due to plant maintenance per year, Plant Calendar year
= 330 days

TABLE 3.1: Typical Biogas Composition

SUBSTANCE SYMBOL CONCENTRATION
Methane CH4 55 – 70 %
Carbon Dioxide CO2 30 – 40 %
Water Vapour H2O 2–7%
Hydrogen Sulphide H2S 20 – 20,000 ppm (2%)
Oxygen O2 0–2%
Nitrogen N2 0–2%
Source: (Okoro et al., 2018)

Assuming the following composition for raw biogas leaving the anaerobic digester:
Basis : 1s of Operation
TABLE 3.3: Mass of Individual Components of Raw Biogas from the Digester
S/N COMPONENT
MASS % MASS COMPOSITION
1 Methane 0.666 3.572
2 CO2 0.276 1.480
3 NH3 0.013 0.070
4 H2O 0.03 0.161
5 H2S 0.001 0.005
6

O2 0.006 0.032
7

N2 0.008 0.043
TOTAL MASS FLOWRATE OF RAW 5.363 kg/s
BIOGAS FROM DIGESTER

TABLE 3.4: Assumed Composition of Manure Feed

PROPERTY WEIGHT FRACTION (%)
Moisture content 83%
Total Solid content (TS) 17%
Volatile Solid content (VS) (84.3% of TS)
Basis: 1 second operation.

For a Biodigester yield of 356mL Biogas/g VS

(Corn cob +Cow dung +Water to the ratio 2:1:8), according to literature (Ona et al., 2019):
Biogas Mass Produced = 5.36 kg/s
Biogas density = 0.00115 kg/L
5.364
Biogas volume = = 4664.34 L
0.00115
Yield = 0.356 m3 biogas/kg VS

● (Biogas density under mesophilic conditions = 1.15 kg/m3)

Yield = 0.4094 kg biogas/kg VS

1 kg VS 0.4094 kg gas

x kg VS 5.36 kg gas

x = 13.09 kg VS.

According to Li et al. (2009), 53% of volatile solids in biomass become biogas which is equal
to 13.09 kg.

Mass VS in Slurry = 13.09/0.53 = 24.70 kg.

Component balance on VS:

VS in Slurry = VS in Digestate + Mass of biogas

VS in Digestate = 24.7 - 13.09 = 11.61 kg.

Digestate Balance:

VS in Digestate = 11.61 kg = 47% TS = 0.47(55% kg biomass)

11.35 kg = 0.2585(kg biomass)

kg biomass in Digestate = 11.61/0.2585 = 44.91 kg.

Hence,

● TS in Digestate = 0.55(44.91) = 24.7 kg.

● VS in Digestate = 0.47(24.7) = 11.61 kg.
 ● Moisture in Digestate (biomass only) = 0.45(44.91) = 20.21 kg.

Biomass in Slurry Balance:

VS in slurry = 24.7kg = 46.76% total biomass = 0.4676(kg biomass in Slurry)

kg biomass in Slurry = 24.7/0.4676 = 52.83 kg.

Assuming that the ratio of corn cobs to manure to water is 2:1:8 (Ona et al., 2019),

Cobs : Manure = 2:1

Therefore,

● Mass of corn cobs = ⅔ * (52.83 kg) = 35.22 kg.

● Mass of manure = ⅓ * (52.83 kg) = 17.61 kg.

Slurry Balance:

The ratio of Biomass to Water = 3:8 (Ona et al., 2019).

Mass of biomass = 52.83 kg = 3/11 * (kg slurry)

3
Mass of Slurry, F = 52.83 / /11 = 193.71 kg.

Hence,

● Mass of water in Slurry = 8/11 * (193.71 kg) = 140.64 kg.

Component Balance on Water:

Mass of water in Slurry = Mass of water in Digestate + Mass of water in Raw Biogas

Where,

Mass of water in Slurry = 140.64 kg,

Mass of water in Raw Biogas = 0.03 * (kg biogas) = 0.03 * 5.36kg = 0.1608 kg

Mass of water in Digestate = 140.64 - 0.1608 = 140.479 kg.

Plant Calendar year = 330 days

3.2 MATERIAL BALANCE AROUND THE ROTARY DRUM

DRYER
Operating Conditions: Temperature = 55 °C, Pressure = 1 atm

Moisture
Removed
6.833 kg/s
Water : 100%

ROTARY DRUM F2
F1 DRYER Dried Corn Stalk
Fresh Corn Stalk 37.46 kg/s
44.31 kg/s Dry solids : 97%
Dry Solids : 82% Water : 3%
Water : 18%

Assumptions:
1. The efficiency of the dryer is 88%
2. No loss of mass in the dryer (no retention)

Overall material balance

Mass In = Mass Out + Mass Retained + Moisture Removed
∴ F1 = F2 + W
Where F1 = 44.31 kg/s
Component balance on water:
xF1F1 = xF2F2 + xWW
xf1F1 = 0.18 × F1 = 7.9758 kg/s
xf1F2 = (1-0.88) × xf1F1 = 0.9571 kg/s
W = xf1F1 - xF2F2 = 7.0187 kg/s

F2 = F1 - W = 37.46 kg/s
3.3 MATERIAL BALANCE AROUND THE HAMMER MILL

HAMMER MILL
F2 F3
Corn stalk Dried Grinded Corn Stalk
37.46 kg/s 35.22 kg/s
Dry solids: 97% Dry Solids: 97%
Moisture Content: Moisture Content:
3%
F3 3%
Grinded Corn stalk Assumptions:
35.22 kg/s
1. Corn cob Dried is properly milled to achieve completely
homogenous
2. 0.06 retention of Feed in the hammer mill

Mass In = Mass Out + Mass Retained

∴ F2 = F3 + R
Where F2 = 37.46 kg/s
R = 0.06 of F2 = 0.06 X 37.46
R = 2.24 kg/s
F3 = F2 - R
F3 = 35.22 kg/s
3.4 MATERIAL BALANCE AROUND THE PRE-MIXER
Operating Conditions: Temperature `25 °C, Pressure = 1 atm

W1
Water
27.93

Propeller Mixer
1

F4
Corn stalk Slurry
63.15 kg/s
Water 54.5%

Assumptions:
1. No loss of mass in the Mixer
2. There is perfect mixing in the mixer

Mass In = Mass Out + Mass Retained

∴ F3 + W1 = F4
Where F3 = 35.22 kg/s
W1 = 27.93 kg/s
∴ F4 = 63.15 kg/s
3.5 MATERIAL BALANCE AROUND THE MIXER
W2
P1
Water
Peroxide
14.26 kg/s

/
F4
Corn slurry Propeller
63.15 kg/s Mixer F6
2 Biomass Slurry
F5 193.71 kg/s
Fresh Cow dung Water 72.7%
17.61 kg/s

From previous literature, the ratio of cow dung to corn stalk and water is 1:2:8.
Assumptions:
1) No retention in the mixer, that is the rate of accumulation=0
2) No reaction occurs during mixing.
3) All peroxide as used up in the mixer
Peroxide percentage of 7.36% of biomass as cited by Rabelo et al., 2013

Overall mass balance around the mixer:

Input= Output + Accumulation

F4+F5+ W2+P1= F6

Where: F4 = 63.15 kg/s

F5= 17.61 kg/s
W2= 98.69 kg/s
F6 = 193.71 kg/s
P1 = 14.26
Therefore, the amount of slurry(F6) leaving the mixer is 193.71 kg/s

3.6 MATERIAL BALANCE AROUND THE HEAT

EXCHANGER

Heat Exchanger
1
F6 HF6
Biomass slurry Biomass Slurry
193.71 kg/s 193.71 kg/s
H2O: 72.7% H2O: 72.7%
TS: 17.3% TS: 17.3%
VS: 10% VS: 10%

Assumptions:
1. No loss of mass in the Exchanger (no retention)

Mass In = Mass Out + Mass Retained

∴F=P
Where F = 193.71 kg/s
∴ P = 193.71 kg/s
All compositions remain the same.

3.7 MATERIAL BALANCE AROUND CENTRIFUGAL PUMP 1

Operating Conditions: Temperature = 35 °C, Pressure = 1 bar

Centrifugal Pump PF6

1 Biomass Slurry
193.71 kg/s
H2O: 72.7%
TS: 17.3%
VS: 10%
 HF6
Biomass Slurry
193.71 kg/s
H2O: 72.7%
TS: 17.3%
VS: 10%

Assumptions:
1. No loss of mass in the pump (no retention)

Mass In = Mass Out + Mass Retained

∴ HF6 = PF6
Where PF6 = 193.71 kg/s
∴ PF6 = 193.71 kg/s

All compositions remain the same.

3.8 MATERIAL BALANCE ON BIODIGESTER

Operating Conditions: Temperature = 40 °C, Pressure = 1 atm

F7
Raw Biogas
5.36kg/s
CH4: 66.6% mass
CO2: 27.6% mass
H2O: 3.0% mass
H2S:0.1% mass
O2: 0.6% mass
N2: 0.8% mass
NH3: 1.3% mass
PF6
D1
Biogas Slurry
Digester Effluent
193.71 kg/s Anaerobic Digester 188.35 kg/s
H2O: 72.7%
H2O: 91.00.%
Total solids: 27.3%
TS: 9.00%
VS: 6.75%
Assumptions:
1. No loss of mass in the digester (no retention)
2. No other impurities present (or are negligible)

Mass In = Mass Out + Mass Retained``

∴ PF6 + P1= F7 + D1
Where PF6 = 193.71 kg/s
P1 = 0.0736(PF6) = 14.257 kg/s
F7 = 5.36 kg/s

∴ D1 = PF6 + P1- F7 = (193.71 ) +(14.257) – (5.36 ) = 188.35 kg/s of Digester Effluent

3.9 MATERIAL BALANCE AROUND THE COMPRESSOR 1

Operating Conditions: Temperature = 45 °C, Pressure = 10 bar

Biogas
Compressor
F7 CF7
Raw Biogas CompressedBiogas
5.364 kg/sec 5.364 kg/sec
CH4: 66.6% mass CH4: 66.6% mass
CO2: 27.6% mass CO2: 27.6% mass
H2O: 3.0% mass H2O: 3.0% mass
H2S:0.1% mass Assumptions: H2S:0.1% mass
O2: 0.6% mass O2: 0.6% mass
No loss of mass in the
N2: 0.8% mass N2: 0.8% mass
NH3: 1.3% mas compressor (no NH3: 1.3% mas
retention)

Mass In = Mass Out +

Mass Retained
∴ F7 = CF7
Where F = 5.364 kg/sec of raw biogas
∴ CF7 = 5.364 kg/sec of compressed raw biogas
All compositions remain the same.
3.10 MATERIAL BALANCE AROUND THE SCRUBBER
Operating Conditions: Temperature = 20 °C, Pressure = 10 bar

Assumptions:
1. All Biomethane is recovered from B1
2. All waste gas is removed by the water coming to the scrubber

B1
Biomethane
3.572 Kg/sec

DEA
3.583 kg/sec

Scrubber
Scrubber Effluent
5.374 kg/s
HF7
CompressedBiogas
5.364 kg/sec
CH4: 66.6% mass
CO2: 27.6% mass
H2O: 3.0% mass
H2S:0.1% mass
O2: 0.6% mass
N2: 0.8% mass
NH3: 1.3% mas
N2:0.8%
Overall Material Balance around the Scrubber
Input= Output + Accumulation- Generation
Accumulation = 0, Generation = 0.
Hence, Input = Output
F + W = E1+ B1

Inlet Biogas Composition and Mass Flow Rates:

Given:
- Total mass flow rate of biogas inlet stream: = 5.364 kg/s

Component mass fractions and their corresponding mass flow rates:

- CH₄: 66.6% mass
= 5.364 * 0.666 = 3.572104 kg/s

- CO₂: 27.6% mass

= 5.364*0.276 = 1.480464 kg/s
- H₂O: 3.0% mass
= 5.364*0.03 = 0.16092 kg/s
- H₂S: 0.1% mass
= 5.364*0.001 = 0.005364 kg/s
- O₂: 0.6% mass
= 5.364*0.006 = 0.032184 kg/s
- N₂: 0.8% mass
= 5.364*0.008 = 0.042912 kg/s
- NH₃: 1.3% mass
= 5.364*0.013 = 0.069732 kg/s

Total Impurities to be Removed by DEA= 1.791576 kg/s

Mass Flow Rate of Biomethane Exiting the Scrubber

Since all CH₄ exits the scrubber:

Mass of CH4 = 3.572104 kg/s

DEA Requirement Calculation:

The specific absorption capacity of DEA for each impurity should be considered.

DEA Loading (mol gas /

mol DEA) at 25°C and 1
Gas atm
CO2 0.50 - 0.80
H2S 0.20 - 0.35
H2O 0.10 - 0.20

Taking an average of 0.5 for the absorption, Mass of DEA

= 1.791576 /0 .5 = 3.583152 kg/s

3.11 MATERIAL BALANCE AROUND THE FLASH DRUM

Off Gas

E1
Rich DEA W4
Flash Drum
Lean DEA

Assumptions
1. All gases are removed from the DEA

Mass of off Gas = 1.791576 Kg/s

Mass of Lean DEA = 3.5831 Kg/s
Mass of rich DEA = 5.3747 Kg/s

3.12 RECIPROCATING COMPRESSOR

Operating Conditions: Temperature = 35 °C, Outlet pressure = 10bar

F8 CF8
Biomethane Biomethane
Compresso 3.752Kg/sec
3.572Kg/sec
r CH: 99.9%
CH: 99.9%
N2: 0.1 % N2: 0.1 %

Assumptions:
1. No loss of mass in the compressor (no retention)

Mass In = Mass Out + Mass Retained

∴F=P
Where F = 3.572 Kg/sec of Biomethane gas
∴ P = 3.572 Kg/sec of Wet Biomethane gas
All compositions remain the same.
3.13 LIQUEFACTION PROCESS

Liquefaction Stage:

● After pre-cooling, natural gas moves through a tube circuit in the main cryogenic heat
exchanger (MCHE) where it is liquefied and sub-cooled to between -238°F (-150°C)
to -260°F (-162°C) by mixed refrigerant (MR)
 Nitrogen
Kg/s

F Liquefaction F
Biomethane Stage Biomethane
3.572 Kg/sec 3.572 Kg/sec
Mass of
Biomethane Nitrogen
before and Kg/s
after
liquefaction =
3.572 kg/s
Assuming 100% purity for the product streams and 330
days calendar year.

Confirmation of agreement with basis:

Density of liquified biomethane at -162oC and 2 Mpa = 424.4 kg/m3
Mass of liquefied biomethane per year = 3.572*24*60*330 = 101856000 kg/yr
Volume of Liquefied Biomethane produced = 101856000 / 424.4 = 2400000 m3/yr
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