CHAPTER VII
ENERGY BALANCE AND UTILITY REQUIREMENTS
ENERGY BALANCE
Table 7.1. Summary of Power Requirements for Equipments
SUMMARY OF ENERGY REQUIREMENT OF EQUIPMENT
ENERGY REQUIREMENT (kW)
CODES EQUIPMENT CHEMICAL MECHANICAL
COOLING HEATING
ENERGY ENERGY
AREA 100
Spray Washer with
U - 10001 - 45.8820 - -
Vibrating Screen
V - 10001 Vacuum Dryer - 0.9031 - 485.3424
E - 10001 Cooling Conveyor - 0.0717 6.7314 -
FL - 10002 Vibrating Screen - 0.0651 - -
U - 10002 Hammer Mill - 2.5391 - -
AREA 200
TK - 20001 UAE Stirred Tank - 26.3882 23.7500 -
U - 20001 Basket Centrifuge - 30.0000 - -
FL - 20001 Press Filter - 13.9721 - -
V - 20001 Vacuum Evaporator - 234.0622 - 554.0041
FL - 20002 Cartridge Filter - 0.2049 - -
E - 20001 Condenser - - 551.5365 -
AREA 300
A - 30001 Mixer - 12.1726 - -
Jacketed Stirred Batch
R - 30001 60.2043 60.2359 - 3.9753
Reactor
FL - 30001 Rotary Filter - 0.0082 - -
A - 30002 Mixer - 93.9991 - -
FL - 30002 Press Filter - 43.9489 - -
TK - 30002 Acidification Tank 0.1112 - -
FL - 30003 Filter - 0.8189 - -
V - 30001 Vacuum Evaporator - 61.8721 - 162.6605
E - 30001 Condenser - - 162.6528 -
AREA 400
A - 40001 Mixer - 0.0134 - -
Jacketed Stirred Batch
R - 40001 0.0482 0.0061 - 3.3350
Reactor
TK - 40001 Fermentation Tank - 0.2263 - -
FL - 40001 Ultrafilter membrane - 1.4470 - -
TK - 40002 Ion Exchange Resin Column - 0.0045 - -
V - 40001 Vacuum Evaporator - 9.0981 - 16.6241
U - 40001 Crystallizer - 0.7291 0.0561 -
AREA 500
Jacketed Stirred Batch
R - 50001 - 0.9228 3.7606 2.2317
Reactor
TK - 50001 Vacuum Holding Tank - 0.0061 - -
AREA 600
FL - 60001 Cartridge Filter - 6.0870 - -
U - 60001 Automated Filling Machine - 9.8584 - -
U - 60002 Packaging Machine - 8.2150 - -
AREA 700
TK - 70001 Jacketed Stirred Tank - 0.3954 116.0598
U - 70001 Disc Stack Centrifuge - 0.5068 - -
TK - 70002 Jacketed Stirred Tank - 0.6461 84.2272
U - 70002 Disc Stack Centrifuge - 0.3220 - -
FL - 70001 TFF System - 14.2672 - -
V - 70001 Spray Dryer - 0.0156 - 4.0359
AREA 800
FL - 80001 Microfiltration System - 38.7646 - -
FL - 80002 Reverse Osmosis Unit - 8.4833 - -
AREA 900
TK - 90001 Mixing Tank - 13.7932 - -
FL - 90001 Bar Screen - 0.0041 - -
TK - 90002 Clarifier Tank - 0.0906 - -
TK - 90003 Aeration Tank - 0.3499 - -
FL - 90002 Ultrafiltration Modules - 0.1909 - -
TK - 90004 Chlorination Tank - 0.0117 - -
FL - 90003 Activated Carbon Filter - 0.1904 - -
AREA 1000
MH - 100001 Hopper -
0.2163 - -
TK - 100001 Storage Basin -
9.4875 - -
TK - 100002 Holding Tank -
0.0264 - -
TK - 100003 Holding Tank -
0.1400 - -
TK - 100004 Storage Silo -
106.2018 - -
U - 100001 Solid Bowl Centrifuge -
0.0308 - -
TK - 100003 Holding Tank -
0.5925 - -
TOTAL 60.2525
857.9730 748.4873 1432.4959
GRAND TOTAL 3099.2087
SUMMARY OF ENERGY REQUIREMENT OF EQUIPMENT
Table 7.2. Summary of Energy Requirement for Solid Transportation
SOLID TRANSPORTATION
ENERGY
CODES EQUIPMENT REQUIREMENT
(kW)
MH - 10001 Conveyor Belt 1.7566
MH - 10002 Conveyor Belt 1.6531
MH - 20001 Pneumatic Conveyor 329.3481
MH - 20002 Screw Conveyor 28.6903
MH - 30001 Screw Conveyor 28.6902
MH - 60001 Conveyor Belt 1.6506
MH - 100001 Hopper 0.0000
MH - 100002 Belt Conveyor 1.7013
Table 7.3. Summary of Energy Requirement for Vapor Transportation
VAPOR TRANSPORTATION
ENERGY
CODES EQUIPMENT
REQUIREMENT (kW)
B - 20001 Centrifugal Blower 0.0013
B - 90001 Centrifugal Blower 0.0027
Table 7.4. Summary of Power Requirements for Pumps
LIQUID TRANSPORTATION
ENERGY
CODES EQUIPMENT
REQUIREMENT (kW)
P - 10001 Centrifugal Pump 24.5229
P - 20001 Centrifugal Pump 8.0788
P - 20002 Centrifugal Pump 18.2663
P - 20003 Centrifugal Pump 6.4981
P - 20004 Centrifugal Pump 2.2102
P - 20005 Centrifugal Pump 3.9594
P - 30001 Centrifugal Pump 0.9173
P - 30002 Centrifugal Pump 2.8803
P - 30003 Centrifugal Pump 4.5209
P - 30004 Centrifugal Pump 23.5984
P - 30005 Centrifugal Pump 0.1301
P - 30006 Centrifugal Pump 1.2304
P - 40001 Centrifugal Pump 1.2140
P - 40002 Centrifugal Pump 1.2098
P - 40003 Centrifugal Pump 1.1741
P - 40004 Centrifugal Pump 0.0517
P - 40005 Centrifugal Pump 0.5831
P - 50001 Centrifugal Pump 0.9973
P - 60001 Centrifugal Pump 0.9898
P- 70001 Centrifugal Pump 3.1654
P- 70002 Centrifugal Pump 36.3653
P- 70003 Centrifugal Pump 1.7370
P- 70004 Centrifugal Pump 49.0730
P- 70005 Centrifugal Pump 22.3811
P- 70006 Centrifugal Pump 0.9171
P- 70007 Centrifugal Pump 22.1054
P- 70008 Centrifugal Pump 12.5142
P- 70009 Centrifugal Pump 7.0047
P- 70010 Centrifugal Pump 2.2857
P- 70011 Centrifugal Pump 10.1412
P - 80001 Centrifugal Pump 84.1283
P - 80002 Centrifugal Pump 34.0311
P - 90001 Centrifugal Pump 27.6409
P - 90002 Centrifugal Pump 16.3680
P - 90003 Centrifugal Pump 18.0548
P - 100001 Cavity Pump 0.1101
P - 100002 Cavity Pump 12.4951
P - 100003 Centrifugal Pump 0.2109
P - 100004 Cavity Pump 20.2043
P - 100005 Cavity Pump 12.7207
UTILITY REQUIREMENTS
This section focuses on the utilities required to keep the process operating.
Water
Water will be one of the plant's essential utilities, used in all process areas for washing,
extraction, product formulation, and cleaning. The Metro Iloilo Water District will provide the
primary supply of treated potable water for raw material washing in AREA 100, solvent
preparation and cooling in AREAS 200-400, and compounding processes in AREAS 500-600.
AREA 800's distilled or purified water will be used as a key ingredient in serum formulations
and for sensitive vitamin C and ascorbyl glucoside processing, while service water will support
cleaning-in-place systems, boiler feed, and general plant sanitation, extending to wastewater
treatment in AREA 900 and solid waste handling in AREA 1000.
Electricity
Electricity will power all equipment and control systems, allowing for 24-hour operation
of the plant's production and utility areas. Grid electricity from Iloilo Electric Cooperative I
(ILECO I) will power raw material preparation equipment in AREA 100, extraction and
purification systems in AREAS 200-400, compounding and filling lines in AREAS 500-600, and
auxiliary systems for protein processing, water treatment, and waste management in AREAS
700-1000. Standby generators powered by conventional energy sources will power key loads
including reactors, coolers, control systems, and wastewater treatment units, preventing product
loss and environmental issues during grid outages.
Steam
Steam will be the major thermal utility for regulated heating, sterilizing, and certain
drying operations throughout the plant. The boiler house generates low- to medium-pressure
steam, which is distributed to extraction vessels in AREA 200, purification and concentration
equipment in AREA 300, enzymatic or chemical reactors for ascorbyl glucoside production in
AREA 400, and compounding tanks in AREA 500. This ensures precise temperature profiles to
prevent vitamin C degradation. Steam will be used for hot-water generation and sterilization in
washing systems in AREA 100, as well as for CIP, packaging-line sterilization in AREA 600,
and thermal conditioning of process water and wastewater treatment steps in AREAS 800-900,
where elevated temperatures enhance treatment efficiency.
Air
Air is a necessary utility needed in various stages of manufacturing to provide a regulated
environment for operations and to maintain product quality. Filtered air is required in AREA 500
- Serum Compounding to ensure a sterile environment during serum component mixing.
Furthermore, in AREA 900 - Wastewater Treatment, aeration is an important step that helps in
the decomposition of organic waste, improving the treatment process. Proper air management is
critical for maintaining the efficiency of various operations and complying with environmental
standards.
Table 7.5. Summary of Power Utility Requirements
SUMMARY OF POWER UTILITY REQUIREMENT
Utilities Daily Annually
Water, kg 10662.2655 3358613.6285
Steam, kg 885826.2852 279035279.8271
Electricity, kW 1748.1542 550668.5865
Air, kg 7562.4695 2382177.8929