mat'l balance -jan10

Summary of Assumptions

A. Summary of Assumptions for Mass Balance

For Washing Tank (T-2)

Forty percent of the C2H5OH solution is used to wash the feather

1.5 gallons of C2H5OH solution per pound of feather is used as a washing agent

All dirt are removed

For Filter Press (F-1)

No keratin feather is carried at the filtrate All fats are dissolved in C2H5OH All dirt are removed 1% of the liquids adhered on the cake 0.5% lost due to accumulation in the equipment

For Dryer (D-1)

100% of ethanol is evaporated since temperature is carried out at 140-160⁰C

0.50% moisture content/keratin feather

For Grinder (G-1)

The size of feather fiber length will be reduced to ≥ 0.20

mm

For Separator (C-1)

40% keratin fiber in feather will be separated Negligible amount of water

For Rotary Grinder (G-2)

The size of feather fiber length will be reduced to

<0.020 mm

For Screener (S-1)

10% (oversize) of the ground fiber will be recycled back to the prior grinder

For Plasticizer Mixing Tank (T-3)

The ratio of the feed (keratin : Additive) is 3:2

For Air Cooler (C-2)

Only heat transfer will occur

Material Balance Per Equipment

Equipment: WASHING TANK

Chicken Feathers = 20, 955.40 kg

C2H5OH Solution = 244, 846.32 kg

TOTAL IN = 265, 801. 72 kg TOTAL OUT = 265, 801. 72 kg

T-2

P = 1 atm

C2H5OH = 97 938. 53 kg

H2O = 146 907. 79 kg

TOTA = 244, 846.32 kg

Dirt = 2 095.55 kg

Feather = 18 859.86 kg

C27H46O = 207.46 kg

H2O = 1 489.93 kg

Keratin Feather = 17 162.47

kg


TOTAL = 265, 801. 72 kg

Washed Feather Chicken Feathers

C2H5OH Solution

Dirt = 2 095.55 kg


C27H46O = 207.46 kg

H2O = 1 489.93 kg


kg

TOTAL = 20, 955.40 kg

Assumptions:


1.5 gallons of C2H5OH solution per pound of feather is used as a

washing agent

Forty percent of the C2H5OH solution is used to wash the feather

(Ref: Gassner, III et al., 1995. Fiber and Fiber Products

Produced from Feathers.)

Basis: 20 955. 40 kg/day

Computations:

Feed:

Dirt = 0.1 (20955.40 kg) = 2 095. 54 kg

Feather = 0.9 (20955.40 kg) = 18 859. 86 kg

C27H46 = 0.0099 (207. 46) = 207. 46 kg

H2O = 0.0711 (207. 46) = 1 489.93 kg

Keratin Feather = 0.819 (207. 46) = 17 162.47 kg

C2H5OH Solution Added:

Volume 40% C2H5OH = 262. 09 m3

Average Density of C2H5OH Solution = 934. 21 kg/ m3

40% C2H5OH solution Added = (262. 09 m3) (934.21 kg/ m3)

= 244 846.32 kg

C2H5OH = 0.4 (244 846.32 kg) = 97 938. 53 kg

H2O = 0.6 (244 846.32 kg) = 146 907. 79 kg

Product:

Dirt = 2 095.55 kg


C27H46 = 0.0099 (207. 46) = 207. 46 kg

H2O = 0.0711 (207. 46) = 1 489.93 kg


C2H5OH Solution = 244 846.32 kg

Dirt Balance: Dirt In = Dirt Out

Dirt Out = 2 095. 54 kg

Feather Balance: Feather In= Feather Out

Feather Out = 18 859.86 kg

Feather Composition Balance:

C27H46O Balance: C27H46O In = C27H46O Out

C27H46O Out = 207. 46 kg

Keratin Feather Balance: Keratin Feather In = Keratin Feather Out

Keratin Feather Out = 17, 162.47 kg

H2O Balance:

H2O in Chicken Feathers+H2O in C2H5OH solution = H2O Out

1 489.93 kg + 146 907. 79 kg = H2O Out

H2O Out = 146 907. 79 kg

C2H5OH Balance: C2H5OH In = C2H5OH Out

C2H5OH Out = 97 938. 53 kg

C2H5OH = 489. 69 kg

H2O = 734. 54 kg

Dirt = 10. 48 kg

C27H46O = 1.04 kg

Keratin Feather = 85. 82 kg

Equipment: FILTER

FiltrateF-1

Washed Feather

Cake

C2H5OH = 96 469.45 kg

H2O = 144 704.18 kg

Dirt = 2 085.06 kg

C27H46O = 206. 42 kg

TOTAL = 243, 465. 11 kg

Keratin Feather = 17 076.66 kg

Adhering Amount

H2O = 2 959. 01 kg

C2H5OH = 979.39 kg

21 015. 05 kg

Losses = 1321. 56 kg

Dirt = 2 095.55 kg


C27H46O = 207.46 kg

H2O = 1 489.93 kg


kg


TOTAL = 265, 801. 72 kg

TOTAL IN = 265, 801. 72 kg TOTAL OUT = 265, 801. 72

kg

Assumptions:

No keratin feather is carried at the filtrate

All fats are dissolved in C2H5OH


1% of the liquids adhered on the cake

0.5% lost due to accumulation in the equipment

(Ref: Plant Design and Economics for Chemical Engineers by Peter and Timmerhaus, 5th Edition, p.855)

Computations:

Feed (Washed Feather):

Dirt = 2 095.55 kg


C27H46O = 0.0099 (207. 46) = 207. 46 kg

H2O = 0.0711 (207. 46) = 1 489.93 kg


C2H5OH Solution = 244 846.32 kg

Cake:

Keratin Feather = 17 162.47 (1-0.005) = 17076.66 kg

Adhering amount

H2O = 1 489.93 kg + (146 907. 79 kg) (0.01) = 2959.01 kg

C2H5OH = (97 938. 53 kg) (0.01) = 979. 39 kg

Filtrate:

C2H5OH = (97 938. 53 kg)(0.985) = 96 469.45 kg

H2O = (146 907. 79 kg) (0.985) = 144 704.18 kg

Dirt = 2 095.55 kg - 10. 48 kg = 2 085. 06 kg

C27H46O = 207.46 kg - 1.04 kg = 206.42 kg

Lost Amount:

C2H5OH = (97 938. 53 kg)(0.005) = 489.69 kg

H2O = (146 907. 79 kg) (0.005) = 734.54 kg

Dirt = kg = (2 095.55 kg) (0.005) = 10.48 kg

C27H46O = (17 162.47 kg) (0.005) = 1.04 kg

Dirt Balance: Dirt In = Dirt Out

Dirt In = Dirt in Cake + Dirt in Filtrate + Dirt Lost

2 095.55 kg = 0 + 2 085. 06 kg + Dirt Lost

Dirt Lost = 10.48 kg

C27H46O Balance: C27H46O In = C27H46O Out

C27H46O In = C27H46O in Filtrate + C27H46O Lost

207. 46 kg = 206. 42 kg + C27H46O Lost

C27H46O Lost = 1. 04 kg

H2O Balance: H2O In = H2O Out

H2O In = H2O in Cake + H2O in Filtrate + H2O Lost

148 397. 72 kg = 2959. 01 kg + 144 704.18 kg + H2O Lost

H2O Lost = 734.54 kg

Keratin Feather Balance:

Keratin Feather In = Keratin Feather Out

Keratin Feather In = Keratin feather in Cake + Keratin Feather in Filtrate + Keratin Feather Lost

17 162.47 kg = 17076.66 kg + 0 + Keratin Feather Lost

Keratin Feather Lost= 85. 81 kg

C2H5OH Balance:

C2H5OH In = C2H5OH Out

C2H5OH In = C2H5OH in Cake + C2H5OH in Filtrate + C2H5OH Lost

97 938. 53 kg = 979. 39 kg + 96 469.45 kg + C2H5OH Lost

C2H5OH Lost = 489. 69 kg

Evaporated Liquid = 2, 377. 98 kg

Dried Feather = 17, 162. 04 kg

TOTAL OUT = 19 540. 02 kg

Equipment: Dryer

D-1

Keratin Feather = 17076. 66 kg

H2O = 1483. 98 kg

C2H5OH = 979. 39 kg

TOTAL = 19540.02 kg

Cake

Evaporated Liquid

H2O = 1398. 59 kg

C2H5OH = 979. 39 kg

TOTAL = 2, 377. 98 kg

Keratin Feather= 17 076. 66 kg

H2O = 85. 38 kg

C2H5OH = 0 kg

TOTAL = 17, 162. 04 kg

Drier Feather

TOTAL IN = 19540. 02 kg

Assumptions:

100% of ethanol is evaporated since temperature is carried out at 140-160⁰C

0.50% moisture content/keratin feather

(Ref: Plant Design and economics for Chemical Engineers, 5th edition)

Computations:

H2O in Drier Feather = 0.0050 (17076. 66 kg) = 85.38 kg

C2H5OH Evaporated = 1 (979. 39 kg) = 979. 39kg


Keratin Feather Out = 17 076. 66 kg


H2O in Cake = H2O Evaporated + H2O in Drier Feather

1483. 98 kg = H2O Evaporated + 85. 38 kg

H2O Evaporated = 1398. 59 kg

C2H5OH Balance: C2H5OH In = C2H5OH Out

C2H5OH in Cake = C2H5OH Evaporated + C2H5OH in Dried Feather

979. 39 kg = 979. 39 kg + C27H46O Drier Out

Evaporated C2H5OH = 0 kg

Moisture Content = (1483.98kg+979.39 kg)

17076.66kg

Moisture Content = 0. 1443

Equipment: Grinder

Assumptions:

The size of feather fiber length will be reduced to ≥ 0.20 mm

(Ref: Gassner, III et al., 1995. Fiber and Fiber Products Produced

from Feathers.)

Computations:


Keratin Feather Out = 17 076. 66 kg


H2O Out = 85. 39 kg

Ground Fiber:

Keratin Feather = 17 076. 66 kg = 99.50%

H2O = 85. 39 kg = 0.50%

G-1 Dried Feather

Keratin Feather = 17 076. 66 kg

H2O = 85. 39 kg

TOTAL IN = 17, 162. 04 kg

Ground Fiber

Keratin Feather = 17 076. 66 kg

H2O = 85. 39 kg

TOTAL OUT = 17, 162. 04 kg

QUILL = 10 246 kg

Keratin Fiber = 6 830.66 kg

TOTAL OUT = 17 076. 66

Equipment: Separator

Assumptions:

40% keratin fiber in feather will be separated

Negligible amount of water (Ref: Gassner, III et al., 1995.

Fiber and Fiber Products Produced from Feathers.)

Computations:

Keratin Fiber = 0.40 (17 076 .66 kg)

= 6830. 66 kg

Over-all Material Balance: Ground Fiber = Quill + Keratin Fiber

17076 .66 kg = Quill + 6830.66 kg

Quill = 10 246 kg

C-1 Ground Fiber

Keratin

Feather

Keratin Fiber

TOTAL IN = 17076 .66 kg

QUILL = 10 246 kg

Keratin

Feather

Ground Fiber = 6830.66 kg

TOTAL OUT = 6830.66 kg

Equipment: Rotary Grinder

Assumption:

The size of feather fiber length will be reduced to < 0.020 mm

(Ref: Barone, J.R., Liebner, C. & Schmidt, W.F., 2004. Thermally Processed Keratin Films.

Computations:

Keratin Balance: Keratin Fiber In = Keratin Fiber Out

Keratin Fiber Out = 6830.66 kg

G-2Keratin Fiber

Keratin Fiber = 6830.66

kg

Ground Fiber

Keratin Fiber = 6830.66 kg

TOTAL IN = 6830.66 kg

Keratin Fiber = 6147. 60 kg

Quill = 6830.66 kg

Equipment: Screener

Assumptions:

10% (oversize) of the ground fiber will be recycled back to the prior grinder

Computations:

Oversize (back to G-2) = 0.10 (6830.66 kg)

= 683.07 kg

Keratin Fiber Out = 6830.66 kg – 683.07 kg = 6 147. 60 kg

S-1 Ground Keratin Fiber

Keratin Feather = 6830.66

kg

Keratin Fiber

Keratin Fiber = 6147. 60 kg

TOTAL IN = 6830.66 kg

Oversize = 683.07 kg

Keratin Fiber = 6 147. 60 kg

Additive = 4 098. 40 kg

Equipment: Plasticizer Mixing Tank

Keratin Fiber


Paste

TOTAL OUT = 10 246 kg

Additive

C3H8O3 = 3 073. 80 kg

NA2SO3 = 204. 92 kg

H2O = 819. 70 kg

TOTAL = 4 098. 40 kg


C3H8O3 = 3073. 80 kg

NA2SO3 = 204. 92 kg

H2O = 819. 68 kg

TOTAL = 10 246 kg

T-3

Assumptions:

The ratio of the feed (keratin : Additive) is 3:2

(Ref: Barone, et.al, Extrusion of Keratin, p. 2)

Computations:

Additive added = 6 147. 60 keratin ( 2additive3keratin

)

= 4 098. 40 kg

Additives composition:

75% C3H8O3

5% Na2SO3

20% H2O

C3H8O3 added= 0.75 (4 098. 40 kg)

= 3 073. 80 kg

Na2SO3 added = 0.05 (4 098. 40 kg)

= 204. 92 kg

H2O added = 0.20 (4 098. 40 kg)

= 819. 70 kg

Over-all Material Balance: Fiber Keratin + Additive = Paste

6 147.60 kg + 4 098. 40 kg = Paste

Paste = 10 246 kg

Keratin Fiber Balance : Keratin Fiber In = Keratin Fiber Out

Keratin Fiber Out = 6 147. 60 kg

H2O Balance : H2O In = H2O Out

H2O in Additive = H2O Paste

819. 70 kg = H2O Paste

H2O Paste = 819. 68 kg

C3H8O3 Balance: C3H8O3 In = C3H8O3 Out

C3H8O3 in Additive = C27H46O Paste

3 073. 80 kg = C27H46O Paste

C3H8O3 Paste = 3 073. 80 kg

Na2SO3 Balance: NA2SO3 In = NA2SO3 Out

NA2SO3 in Additive = NA2SO3 Paste

204. 92 kg = Na2SO3 Paste

NA2SO3 Paste = 204. 92 kg

Film = 9 457. 05 kg

H2O Evaporated = 788.94 kg

Equipment: Extruder

Paste Film

TOTAL IN = 10 246 kg

E-1


C3H8O3 = 3 073. 80 kg

NA2SO3 = 204. 92 kg

H2O = 30. 74 kg

TOTAL = 9 457. 05 kg

H2O Evaporated = 788.94 kg


C3H8O3 = 3073. 80 kg

NA2SO3 = 204. 92 kg

H2O = 819. 68 kg

TOTAL = 10 246 kg

Computations:

Paste:

Keratin Fiber = 6 147. 60 kg = 60%

C3H8O3 = 3 073. 80 kg = 30%

Na2SO3 = 204. 92 kg= 2%

H2O = 819. 68 kg = 8%

H2O Evaporated = (0.9625) (819.68 kg)

= 788.94 kg

Over-all Material Balance: Paste = H2O Evaporated + Film

10 246 kg = 788.94 + Film

Film = 9 457. 05 kg


6 147.60 kg = Keratin Fiber Out



H2O in Paste = H2O Evaporated + H2O in Film

819.68 kg = 788.94 + H2O in Film

H2O in Film = 30.74 kg

C3H8O3 Balance: C3H8O3 In = C3H8O3 Out

3 073. 80 kg = C3H8O3 Out

C3H8O3 in Film = 3 073. 80 kg

Na2SO3 Balance: Na2SO3 In = Na2SO3 Out

204. 92 kg = Na2SO3 Out

Na2SO3 in Film = 204. 92 kg

Equipment: Air Cooler

Film = 9 457. 05 kg


Assumption:

Only heat transfer will occur

Computations:

Over-all Material Balance : Film In = Film Out

9 457. 05 kg = Film Out

Film Out =9 457. 05 kg

C-2Film Film

TOTAL IN = 9 457. 05 kg


C3H8O3 = 3 073. 80 kg

NA2SO3 = 204. 92 kg

H2O = 30.74 kg

TOTAL = 9 457. 05kg


C3H8O3 = 3 073. 80 kg

NA2SO3 = 204. 92 kg

H2O = 30. 74 kg

TOTAL = 9 457. 05 kg


6 147. 60 kg = Keratin Fiber Out


C3H8O3 Balance : C3H8O3 In = C3H8O3 Out

3 073. 80 kg = C3H8O3 Out

C3H8O3 in Film = 3 073. 80 kg


204. 92 kg = Na2SO3 Out



30. 74 kg = H2O Out

H2O in the film = 30. 74 kg

Film = 9 457. 05 kg


Equipment: Flattening Rolls

Computations:

Over-all Material Balance : Film In = Film Out

9 457. 05 kg = Film Out

Film Out =9 457. 05 kg


6 147. 60 kg = Keratin Fiber Out


Film Film R-2


C3H8O3 = 3 073. 80 kg

NA2SO3 = 204. 92 kg

H2O = 30. 74 kg

TOTAL = 9 457. 05 kg


C3H8O3 = 3 073. 80 kg

NA2SO3 = 204. 92 kg

H2O = 30. 74 kg

TOTAL = 9 457. 05 kg

TOTAL IN = 9 457. 05 kg

C3H8O3 Balance : C3H8O3 In = C3H8O3 Out

3 073. 80 kg = C3H8O3 Out

C3H8O3 in Film = 3 073. 80 kg


204. 92 kg = Na2SO3 Out



30. 74 kg = H2O Out

H2O in the film = 30. 74 kg

mat'l balance -jan10

Documents

feather fiber

c2h5oh solution

feather

carried

dirt

reduced

summary

assumptions