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Protein Purification to Produce Edible Soybean Protein Miyu Ono | Gracelynn Soesanto | Alia Wallenstrom

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Protein Purification to Produce Edible Soybean Protein Miyu Ono | Gracelynn Soesanto | Alia Wallenstrom University of Pennsylvania ScholarlyCommons Department of Chemical & Biomolecular Senior Design Reports (CBE) Engineering 4-20-2021 Protein Purification ot Produce Edible Soybean Protein Miyu Ono University of Pennsylvania Gracelynn Soesanto University of Pennsylvania Alia Wallenstrom University of Pennsylvania Follow this and additional works at: https://repository.upenn.edu/cbe_sdr Part of the Biochemical and Biomolecular Engineering Commons Ono, Miyu; Soesanto, Gracelynn; and Wallenstrom, Alia, "Protein Purification ot Produce Edible Soybean Protein" (2021). Senior Design Reports (CBE). 130. https://repository.upenn.edu/cbe_sdr/130 This paper is posted at ScholarlyCommons. https://repository.upenn.edu/cbe_sdr/130 For more information, please contact [email protected]. Protein Purification ot Produce Edible Soybean Protein Abstract This project recommends a design for a soy processing facility to produce soy protein concentrates (SPC), soy oil and soy molasses from dehulled soybeans. Utilities were minimized, wherever possible by evaluating whether streams within the system had the capacity to heat or cool other processes. The plant has a production capacity of 170 MM lb soy protein concentrate/year and will be located in Decatur, IL. The proposed design also yields 114 MM lb soy oil/year and 62 MM lb soy molasses/year. The SPC, soy oil and soy molasses have less than 2 PPM residual solvent concentrations and comply with FDA regulations. The plant is running with an uptime of 80% and economic analysis shows an estimated IRR of 41% with an ROI of 59%. Disciplines Biochemical and Biomolecular Engineering | Chemical Engineering | Engineering This working paper is available at ScholarlyCommons: https://repository.upenn.edu/cbe_sdr/130 1 University of Pennsylvania School of Engineering and Applied Science Department of Chemical and Biomolecular Engineering 220 South 33rd Street Philadelphia, PA 19104 April 20, 2021 Dear Dr. Allen, Professor Vrana and Dr. P.C. Gopalratnam, Enclosed you will find a proposed design for the soybean processing facility, specified in the problem statement provided by Dr. Gopalratnam. The proposed plant is for the industrial production of 170 MM lb/year of food-grade soy protein concentrate (163 MM lb/year on a dry basis), as well as 114 MM lb/yr of soy molasses, and 62 MM lb/yr unrefined soybean oil from dehulled soybeans in Decatur, Illinois. The process implements both hexane solvent extraction technology and ethanol solvent extraction technology. Dehulled soybeans are processed via conditioning and grinding. The soybeans are then taken through hexane extraction and ethanol extraction as well as desolventization. Production was assumed at 80% uptime, and rigorous profitability analysis was performed to determine plant feasibility. The proposed plant is found to be economically feasible given a permanent investment of the plant of $170 MM, with an expected NPV of $395 MM by 2038. It has an estimated IRR of 41% and ROI of 58%. The following report contains a detailed process design and profitability analysis of the proposed plant, including rationale for key design decisions. It is recommended to pursue plant production using the outlined process design, but continue to research into other potential solvent extraction methods. Sincerely, Miyu Ono Gracelynn Soesanto ________________________ ________________________ Alia Wallenstrom ________________________ 2 Protein Purification to Produce Edible Soybean Protein Miyu Ono | Gracelynn Soesanto | Alia Wallenstrom Project Proposed by: Dr. P.C. Gopalratnam Project Submitted to: Prof. Bruce Vrana Advised By: Dr. Sue Ann Bidstrup Allen University of Pennsylvania School of Engineering and Applied Sciences Department of Chemical and Biomolecular Engineering April 20, 2021 3 Contents Section 1: Abstract .......................................................................................................................... 5 Section 2: Introduction and Objective ............................................................................................ 6 2.1 Introduction ........................................................................................................................... 6 2.2 Objective Time Chart ............................................................................................................ 8 Section 3: Market and Competitive Assessment ............................................................................ 9 3.1 Market Analysis .................................................................................................................... 9 3.2 Competitive Analysis .......................................................................................................... 11 3.3 Value Proposition................................................................................................................ 12 Section 4: Customer Requirements ............................................................................................... 13 4.1 Customer Requirements ...................................................................................................... 13 Section 5: Preliminary Process Synthesis ..................................................................................... 16 5.1 Preliminary Process Synthesis ............................................................................................ 16 5.2 Assembly of Database......................................................................................................... 22 Section 6: PFDs and Material Balances ........................................................................................ 25 Section 6.1 Pre-Treatment ........................................................................................................ 26 Section 6.2 Hexane Extraction .................................................................................................. 30 Section 6.3 Hexane Recycle ..................................................................................................... 33 Section 6.4 Ethanol Extraction ................................................................................................. 37 Section 6.5 Ethanol Recycle ..................................................................................................... 41 Section 7: Energy Balance and Utility Requirements................................................................... 44 7.1 Heat Integration Strategy .................................................................................................... 44 7.2 Process Utilities .................................................................................................................. 44 Section 8: Equipment List and Unit Description .......................................................................... 48 8.1 Unit Descriptions ................................................................................................................ 48 8.2 Unit Specification Sheets .................................................................................................... 65 Section 9: Cost Summary............................................................................................................ 104 9.1 Equipment Costs ............................................................................................................... 104 9.2 Operating Cost - Cost of Manufacture .............................................................................. 106 Section 10: Profitability Analysis - Business Case ................................................................. 107 10.1 Sensitivity Analysis ........................................................................................................ 107 10.2 Economic Analysis ......................................................................................................... 109 Section 11: Other Important Considerations ............................................................................... 119 11.1 Process Safety Concerns ................................................................................................. 119 4 11.2 Environmental Considerations ........................................................................................ 121 11.3 Global, Cultural, Social and Ethical Concerns ............................................................... 121 Section 12: Conclusions and Recommendations ........................................................................ 124 Section 13: Acknowledgements .................................................................................................. 125 Section 15: References ................................................................................................................ 126 Section 15: Appendices ............................................................................................................... 131 Appendix 1: Hexane Recovery ............................................................................................... 131 A.1.1. Hexane Recovery Flow Diagram ............................................................................. 131 A.1.2. Input Summary ......................................................................................................... 132 A.1.3. Block Summary........................................................................................................ 136 A.1.4. Binary Interactions ..................................................................................................
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