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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