1. ERT 455 MANUFACTURING & PRODUCTION OF BIOLOGICAL PRODUCT LECTURES: CIK MUNIRA BT MOHAMED NAZARI PROF. MADYA DR. DACHYAR ARBAIN

2. PRESENTATION OUTLINE Teaching Plan What is Manufacturing? What is Production means? Example of Biological Products. Introduction to Engineering Calculation –Basic principles –Units of operations –Conservation of mass –Material balances 2ERT 455 Session 2012/2013

3. “ Is the process of converting raw materials into products; it encompasses the design and manufacturing of goods using various production methods and techniques.” ERT 455 Session 2012/20133 Manufacturing??

4. ERT 455 Session 2012/20134 Production?? Production is a process of converting inputs into outputs. Process layout (flowsheet), process unit spec, operating variable

5. ERT 455 Session 2012/20135 Biological Product Biological products or in others term Bioproducts or bio-based products are materials, chemicals and energy derived from renewable biological domestic agricultural materials (including plant, animal, and marine materials). Biological resources include agriculture, forestry, and biologically-derived waste, and there are many other renewable bioresource examples. Some examples of agricultural resources that make up many biobased products include: soybeans, corn, kenaf, and numerous other types of crops that are harvested. Current applications of these agricultural resources create products such as ethanol (corn-based), soy candles, soy-based lubricants, kenaf office paper, and bioplastics.

6. INTRODUCTION TO ENGINEERING CALCULATIONS ERT 455 Session 2012/20136

7. Many problems that arise in connection with the design of new process or the analysis of an existing one are of a certain type of given amounts and properties of the raw materials, calculate amounts and properties of the products; or vice versa. ERT 455 Session 2012/20137

8. BASIC PRINCIPLES CONVERSION OF UNITS SYSTEMS OF UNITS ERT 455 Session 2012/2013 8

9. CONVERSION OF UNITS A measured quantity can be expressed in terms of any units having the appropriate dimension. Example: Velocity - may be expressed in unit of ft/s, miles/hr, cm/yr or any other ratio of a length unit to a time unit. The equivalence between two expressions of the same quantity may be defined in terms of a ratio or conversion factors. ERT 455 Session 2012/20139

10. Example: ERT 455 Session 2012/201310

11. ERT 455 Session 2012/201311 Conversion Factor A ratio of equivalent values of a quantity expressed in different units. To convert a quantity expressed in terms of one unit to its equivalent in terms of another unit by multiply the given quantity by the conversion factor (new unit/old unit).

12. Example: –To convert 36 mg to its equivalent unit in grams (g). – or ERT 455 Session 2012/201312 36 mg 1 g 1000 mg = 0.036 g Vertical line Multiplication symbol

13. Example: –Convert an acceleration of 1 cm/s 2 to its equivalent in km/h 2. –Convert 554 m 4 /(day.kg) to cm 4 /(min.g). ERT 455 Session 2012/201313 Answer = 129.6 km/h 2 Answer = 3.85 x 10 4 cm 4 /min.g

14. SYSTEMS OF UNITS The official international system of units is SI. –Kilogram-meter-second –Older systems of units centimeter-gram-second (cgs) system and foot- pound-second (fps) system. A system of units has the following components; –Base units – length, mass, time –Multiple units – mega, kilo, centi, mili –Derived units – volume, force, pressure, energy ERT 455 Session 2012/201314

15. FORCE AND WEIGHT According to Newton’s second law of motion, force is proportional to the product of mass and acceleration (length/time 2 ). In SI, 1 newton (N) =1 kg.m/s 2 Equation above define conversion factors between natural and derived force units. Example: –The force in newtons required to accelerate a mass of 4 kg at a rate of 9 m/s 2 is ERT 455 Session 2012/201315 Derived force units Natural force units 36 N.

16. FORCE AND WEIGHT The weight of an object is an object of mass (m) is subjected to a gravitational force W. W = mg, g = 9.81 m/s 2 or 32.174 ft/s 2 (at sea level) Test yourself, Suppose an object weights 9.8 N at sea level. What is its mass? Would its mass be greater, less, or the same on the moon? How about its weight? ERT 455 Session 2012/201316

17. OTHERS DIMENSIONS UNIT VELOCITY = length travelled per unit time ACCELERATION = rate of change of velocity PRESSURE = force per unit area DENSITY = mass per unit volume ENERGY = force x length POWER = energy per unit time ERT 455 Session 2012/201317

18. UNITS OF OPERATIONS Unit operation is a basic step in a process. In chemical/process/food engineering, unit operations are largely used to conduct the primarily physical steps of preparing the reactants, separating and purifying the products, recycling unconverted reactants, and controlling the energy transfer into or out of the chemical reactor. For example, in milk processing, homogenization, pasteurization, chilling, and packaging are each unit operations which are connected to create the overall process. A process may have many unit operations to obtain the desired product. ERT 455 Session 2012/2013 18

19. ERT 455 Session 2011/201219

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21. Chemical engineering unit operations consist of five classes: –Fluid flow processes, including fluids transportation, filtration, solids fluidization. –Heat transfer processes, including evaporation, condensation. –Mass transfer processes, including gas absorption, distillation, extraction, adsorption, drying. –Thermodynamic processes, including gas liquefaction, refrigeration. –Mechanical processes, including solids transportation, crushing and pulverization, screening and sieving. Chemical engineering unit operations also fall in the following categories: –Combination (mixing) –Separation (distillation) –Reaction (chemical reaction) ERT 455 Session 2012/2013 21

22. Important unit operations in the food industry are; – fluid flow, –heat transfer, –drying, –evaporation, –contact equilibrium processes (which include distillation, extraction, gas absorption, crystallization, and membrane processes), –mechanical separations (which include filtration, centrifugation, sedimentation and sieving), –size reduction and –mixing.. ERT 455 Session 2012/2013 22

23. Two very important laws which all unit operations obey are the laws of conservation of mass and energy. MASS –The mass of an object is a fundamental property of the object; a numerical measure of its inertia; a fundamental measure of the amount of matter in the object. ENERGY OF A SYSTEM –3 components Kinetic energy Potential energy Internal energy ERT 455 Session 2012/2013 23

24. CONSERVATION OF MASS The law of conservation of mass states that mass can neither be created nor destroyed. Thus in a processing plant, the total mass of material entering the plant must equal the total mass of material leaving the plant, less any accumulation left in the plant. If there is no accumulation, then the simple rule holds that "what goes in must come out". Similarly all material entering a unit operation must in due course leave. ERT 455 Session 2012/2013 24

25. ERT 455 Session 2011/201225 PROCESS UNIT m in (kg) m out (kg) INPUTOUTPUT

26. For example, if milk is being fed into a centrifuge to separate it into skim milk and cream, under the law of conservation of mass the total number of kilograms of material (milk) entering the centrifuge per minute must equal the total number of kilograms of material (skim milk and cream) that leave the centrifuge per minute. Similarly, the law of conservation of mass applies to each component in the entering materials. For example, considering the butter fat in the milk entering the centrifuge, the weight of butter fat entering the centrifuge per minute must be equal to the weight of butter fat leaving the centrifuge per minute. A similar relationship will hold for the other components, proteins, milk sugars and so on. ERT 455 Session 2012/2013 26

27. CONSERVATION OF ENERGY The law of conservation of energy states that energy can neither be created nor destroyed. The total energy in the materials entering the processing plant, plus the energy added in the plant, must equal the total energy leaving the plant. ERT 455 Session 2011/2012 27

28. This is a more complex concept than the conservation of mass, as energy can take various forms such as kinetic energy, potential energy, heat energy, chemical energy, electrical energy and so on. During processing, some of these forms of energy can be converted from one to another. Examples: –Mechanical energy in a fluid can be converted through friction into heat energy. –Chemical energy in food is converted by the human body into mechanical energy. ERT 455 Session 2012/2013 28

29. For example, consider the pasteurizing process for milk, in which milk is pumped through a heat exchanger and is first heated and then cooled. The energy can be considered either over the whole plant or only as it affects the milk. For total plant energy, the balance must include: the conversion in the pump of electrical energy to kinetic and heat energy, the kinetic and potential energies of the milk entering and leaving the plant and the various kinds of energy in the heating and cooling sections,as well as the exiting heat, kinetic and potential energies. To the food technologist, the energies affecting the product are the most important. In the case of the pasteurizer, the energy affecting the product is the heat energy in the milk. Heat energy is added to the milk by the pump and by the hot water passing through the heat exchanger. Cooling water then removes part of the heat energy and some of the heat energy is also lost to the surroundings. ERT 455 Session 2012/2013 29

30. The heat energy leaving in the milk must equal the heat energy in the milk entering the pasteurizer plus or minus any heat added or taken away in the plant. Example: ERT 455 Session 2012/2013 30 Heat energy leaving in milk Heat energy leaving in milk initial heat energy + heat energy added by pump + heat energy added in heating section - heat energy taken out in cooling section - heat energy lost to surroundings. initial heat energy + heat energy added by pump + heat energy added in heating section - heat energy taken out in cooling section - heat energy lost to surroundings. =

31. The law of conservation of energy can also apply to part of a process. For example in milk production, –considering the heating section of the heat exchanger in the pasteurizer ERT 455 Session 2012/2013 31 Unit operation Heat lost by the hot water Heat lost by the hot water Heat gained by the milk + Heat lost from the heat exchanger to its surroundings Heat gained by the milk + Heat lost from the heat exchanger to its surroundings =

32. From these laws of conservation of mass and energy, a balance sheet for materials and for energy can be drawn up at all times for a unit operation. These are called material balances and energy balances. Using a material balance and an energy balance, a engineering process can be viewed overall or as a series of units. Each unit is a unit operation. The unit operation can be represented by a box as shown below. ERT 455 Session 2012/2013 32

33. ERT 455 Session 2011/201233 NEXT CLASS How to write material balances for a process system How to write energy balances for a process system Exercises on material and energy balances

34. THANK YOU To be continue… ERT 455 Session 2011/201234