5_chapters 1-2

1 Chapter 1

INTRODUCTION

Brief Background

The global pectin demand during 2016 was 34,000 metric tons and is expected to reach 48,735 tons at 2026 (FMI, 2016). The main sectors that require the high demand of pectin are cosmetics, pharmaceutical, and food industries. Various drugs are encapsulated with a pectin film to protect the gastric mucosa and allow the sustained release of the active substances into the blood circulation. Manufacturers offer pectin products suitable for pharmaceutical applications. The market challenges for the production of pectin are lack of availability and the high cost of raw materials.

Pectin is produced from various fruits and vegetation. Different sources have different percentages of pectin by weight. It is commonly used as a gelling, thickening agent and stabilizer in food. One source of pectin is from mango peels. Mango peels generally contain 20-35% pectin depending on the ripeness of the fruit. Pectin is the structural binder in fruits (Banerjee, 2016). When it is degraded by the enzyme pectinase, the fruit deforms. According to the Department of Trade and Industry the Philippines, in the year 2011, currently does not produce its own pectin and therefore imports 100% of its pectin from other countries. Pectin demand is increasing exponentially due to the increase in demand from numerous industries.

Mango peels which are usually wastes products from local industries which have mangoes as their raw material are hazards to the environment and also the health of the

2 community if not disposed or treated properly. There are at least 30 fruit processing industries in Cebu that utilize mangoes as their raw material therefore supply of raw material will not be a problem. The Philippine Center for Postharvest Development and Mechanization (PhilMech) published Gragasin’s study about the Utilization of Mango Peels as Source of Pectin in the fourth volume of their technical bulletin. The research (conducted jointly by the Department of Science and Technology and PhilMech) successfully produced pectin from carabao mango peels that conformed to United States Pharmacopeia (USP) standards – the standards set by FDA that covers pharmaceutical and food-grade products. This became our basis and guide for the feasibility study and proposal for plant design.

From the data gathered from the Department of Trade and Industry (2011), about 175,660 kilograms of pectin will be the pectin demand in the Philippines because of the increasing demands from various industries especially the food and beverage industry. In order to greatly decrease the volume of mango peels disposed in various landfills and also meet the demand of pectin in the Philippines due to it being imported from different countries like Mexico, France, and China, the researchers decided to propose a new industry in the Philippines which is the production of pectin utilizing mango peels as the raw material using hot acid extraction method. This proposed plant will provide a solution to the solid waste coming from the disposal of fruit processing industries and also be able to improve the economy of the country because the Philippines relies heavily on imported pectin because of the absence of viable technology. This could also make the country a potential exporter for pectin because of the great abundance in raw material.

3 Objectives of the Study

The main objective of this study is to come up with a plant design for the production of powdered pectin from mango peels using hot acid extraction.

The specific objectives of this study are:

1.

Conduct a market study and evaluate the supply and demand of pectin

production in the Philippines; 2.

Choose a plant location considering the source of raw materials, target

market, and ease of access; 3.

Create a plant scale process to produce USP-grade pectin from mango peels;

4.

Design the equipment required for the production of pectin and treatment of

the waste produced from the process based on the material balances; and 5. Provide financial statements for the frst five years of the operation of the plant.

Scope and Limitations

The study of the production of pectin from mango peels is based on the financial, technical, market, social, and environmental effects of the business. The raw material that will be used in this feasibility study will be waste mango peels acquired from mango processing industries in the Philippines specifically Profood International Corporation and those found in Central Visayas. The proposed manufacturing plant will be in Cebu because of the raw material supply found there and also because the city is one of the

4 main areas of trade in the Philippines. The data used in the design of the equipment and processes are based on ideal plant operations. The estimated duration of the construction of the plant will be two years. The financial analysis will only cover the first five years of operation. The cost of goods, equipment, buildings, facilities, machineries, labor and services used in the financial study are estimates from Chemical Engineering design books and credible sources from the internet.

Significance of the Study

The study of the production of pectin from mango peels is significant to the following:

Mango Fruit Processing Industries

Mango fruit processing industries generate multiple wastes. Some of these are peels, stone, and juice. Utilization of the mango peels to produce pectin can greatly reduce the waste generated by the mango processing industries. They could also make a good amount of money from it by selling their waste mango peels.

Community

During the planning, construction, and operation of this plant, many people will be employed especially those near the location of the plant. Manufacturing plants are usually constructed at remote areas especially when raw materials do not have a long

5 shelf-life. This will bring more opportunities for people in rural areas. Lastly, this will also help for the future industrialization of the chosen area.

Philippine Economy

The Philippines currently imports 100% of its pectin from other countries. According to the Department of Trade and Industry, in 2011 the country imported about 94.95 tons of pectin, valued at $52.38M. In 2018, it is expected to reach at about 200 tons of pectin. The estimated cost of pectin is about Php 27,000 per kilogram (kg). The country can become self-sufficient in terms of producing its own pectin at a much cheaper cost. This will stop the country from being dependent on imported pectin which costs more expensive than producing pectin locally. The country could potentially produce pectin in great amounts because it is one of the top producers of mangoes. Lastly, this could also be exported to other countries.

Environment

The production of pectin from mango peels will greatly reduce the methane formed from biodegradation of waste. Landfills produce 55 million tons of methane gas every year. Reduction of the production of methane from landfills could potentially mitigate the destruction of the ozone layer from greenhouse gases. The amount of methane in the atmosphere might be small compared to carbon dioxide but its heattrapping effects are 34 times stronger than carbon dioxide. This contributes exponentially to the global warming that we are experiencing today.

6

7 MARKET STUDY

The increasing demand in the world and also in the Philippines for pectin by the pharmaceutical, cosmetics, beverages and food processing industries makes the consideration for a pectin manufacturing plant a good business. The proposal to extract pectin from mango peel was due to the fact that the mango production in the Philippines is the third highest in terms of volume, and also because there is no competition in using mango peels as a raw material.

Product Description

Pectin is a high-molecular weight heteropolysaccharride, polymer that is present in all plants. It is a compound which contributes to the structure of the plant. It acts as the intercellular cement in plant tissues because it helps keep the walls of adjacent cells joined together. Citrus peels typically contain 15-30% pectin. Commercially, it is mainly used as a stabilizer and thickening agent because it turns into a sticky gel-like compound when combined with water (Thakandur, 1997). Pectin, once extracted, is a coarse or fine yellowish powder that forms colloidal solutions and is highly soluble in water. There are two types of pectin, namely, high methoxyl pectin and low methoxyl pectin. Naturally, pectin is high methoxyl. It can be modified to produce low methoxyl pectin which has more different applications.

Pectin has numerous uses. In medicine, it is used for high cholesterol, high triglyceride, colon cancer, antidiarrheal drug and many more ailments (Krishnan, 1999). It is also

8 used to prevent poisoning from strontium, lead and other heavy metals. Pectin may be used as a denture adhesive agent. In the food industry, pectin is used as a food stabilizer, confectioner, emulsifier, gelling agent, and thickening agent.

Mango peels consist approximately 20-40% of the total mango processing waste by weight generated in industries. Mango peels typically contain about 20-35% pectin. This amount depends on the ripeness of the fruit. Pectin from fruit and vegetable peels could be extracted using different methods. The one which will be used in this study is Hot Acid Extraction.

The physio-chemical properties of the pectin produced from mango peels will be similar to the properties acquired by the Philippine Center for Postharvest Development and Mechanization because the process of extracting pectin is similar and also several quality assurance tests will be used in order to ensure that the parameters are at optimum levels. Table 1 shows the properties of the pectin produced from mango peels compared with the USP specifications of pectin.

9 Table 1. Physio-chemical properties of pectin produced from mango peel

Values

Parameter

Mango Peel Pectin

USP Specification

Degree of Esterification

76-79

Not specified

Methoxyl Content,%

12.65-12.854

Not less than 6.7%

Galacturonic Acid Content, %

92.82-98.65

Not less than 74%

Total Ash Content,%

3.32

Not more than 10%

Acid-Insoluble Ash,%

0.80

Not more than 1%

Loss on Drying,%

8

Not more than 10%

Total Soluble Solids,%

0.40

Not Specified

Arsenic Content, µg/g

0.0435

3

Lead Content, µg/g

3.27

5

Microbial Limit

Absence of Salmonella Absence of Salmonella

Product Demand

The Philippines relies heavily on imported pectin due to the absence of a viable technology to produce it locally. In 2011, the Philippines’ total pectin importation from various origins reached 94,848.93 tons with total custom value of US$ 52.38M or P2.2 billion (DTI, 2011). Food processing, cosmetics, and pharmaceutical industries in the country account for the bulk importation of pectin. These industries utilize pectin as a thickening, gelling, or stabilizing agent in their products.

10 The global market for pectin has been witnessing significant growth on account of rising demand for food products from developed as well as developing economies (Yogesh, 2017). The industry for pectin is rapidly growing driven by rising demand for processed and convenience foods, growing preference towards functional foods from various health conscious consumers have also played a key role in the growth of the market. In addition, the industry has been witnessing demand for low-calorie and low-fat food products from consumers resulting in more demand for pectin from food manufacturers (Estrella, 2016).

The global pectin market is expected to reach USD 1.9 billion by 2025; growing at an anticipated Compound Annual Growth Rate (CAGR) of 7.1% from 2016 to 2025 according to a new report by Grand View Research, Inc. Asia Pacific is expected to witness the fastest growth rate with an anticipated CAGR of 7.8% from 2016 to 2025.

The demand of pectin in the Philippines is exponentially increasing according to the data presented by the Department of Trade and Industry. Table 2 shows the net mass of pectin imported from numerous countries mainly Mexico, China, and Belgium. The expected amount of pectin to be imported at 2018 is 199, 999.40 kilograms.

11 Table 2. Pectin imported by the Philippines from 2014-2017

Year

Imported Pectin(kg)

2014

75871.70

2015

91452.22

2016

133554.45

2017

159358.45

Product Supply

Germany with exports valued at $186.70 million, Mexico with $69.13 million, Brazil with $46.70 million, Czech Republic with $42.60 million and China with $27.40 million were the top exporters of pectin during crop year -2013. On the other hand, USA with imports valued at $89.60 million, Germany with $74.80 million, Japan with $45.1 million, France with $29.10 million and Russia with $27.20 million were the major importers of pectin during fiscal year-2013. According to information contained in Chemical & Engineering News, a magazine published by the American Chemical Society, around $850 million worth of pectin is sold annually across the world (The Dollar Business, 2017). Key players present in the market are DuPont Nutrition & Health, FMC Corporation, CP Kelco, Cargill, Incorporated, Herbstreith & Fox, Devson Impex Private Limited, Yantai Andre Pectin Co. Ltd., and B&V srl.

12 Demand-Supply Analysis

Future Market Insights (2013) recently conducted an in-depth analysis on pectin a raw ingredient used in manufacturing a wide variety of food products. According to this study, nearly 34,000 metric tons of pectin was globally consumed in 2016. The study further estimates that by the end of 2026, the global pectin consumption would have soared at 7.8% CAGR and reached 48,735 metric tons. This indicates the increase in demand in all countries including the Philippines. Using the estimated increase in demand per year, from 2011 wherein the volume imported was 94,848 kg, it could potentially increase to approximately 199,999.40 kilograms at 2018. A good amount of this demand could be covered by a future local manufacturer of pectin because the Philippines does not produce its own pectin.

Price Study

According to Bingabing (2017), mango presents an opportunity for the country as local production reaches an estimated 884,000 metric tons per year, with most peelings thrown away or composted. Currently, the Philippines imports all of its pectin for different applications such as food, pharmaceuticals, and cosmetics. The price of imported pectin is currently at Php 27,000 per kilogram including the taxes, cost of transportation and all other expenses. In countries near the Philippines, pectin is typically priced from Php 3,000 to 5,000 per kilogram that is why we intend to set the starting price of our pectin to be Php 2,000 per kilogram to make it cheaper compared to other companies selling it from abroad.

13 Marketing Program

The marketing program for the production of pectin from mango peels will be focused on the following:

1. Offer a price lower compared to imported pectin; 2. Establish a local pectin manufacturing plant to refrain from importing expensive pectin; 3. Highlight advantages of the production of pectin from mango peels compared to other sources in terms of cost and quality; 4. Become a pioneer producer of pectin in the Philippines. 5. Establish long term business relationships

14 Chapter 2 TECHNICAL STUDY 2.1 Raw Material

Mango (Mangifera indica, Linn) is a fruit that is eaten as dessert or relish depending on its maturity and can be processed to a number of products. It is one of the most important cultivated fruits in tropical countries like the Philippines. The country considers mango as the national fruit because of its abundance in every island of the archipelago (Mahusay Inc., 2011). The Philippines has been labeled as the seventh leading mango-producer in the world, establishing its credibility in supplying high quality mangoes that has a significant contribution to the export earnings of the country (Mahusay Inc., 2011). According to Philippine Statistics Authority (2016), banana, pineapple, and mango are the most important fruit crops in the country. Among these fruits, mango ranked 3 in volume of production with 902,700 metric tons and ranked 2 with an area of rd

nd

188,400 hectares last 2015. Table 2.1.1 shows the volume of production in the first quarter of 2017.

15 Table 2.1.1 Volume of Production for Mango by Region, October-December: 20152016 and January-March: 2016-2017 PRODUCTION PERCENT CHANGE REGION

October – December

January - March

2015

2016

2016

2017

Oct – Dec

Jan - Mar

33, 127

30, 579

117, 001

107, 827

(7.7)

(7.8)

NCR

-

-

-

-

-

CAR

-

-

484

527

-

8.8

1,483

1,379

62, 205

59,990

(7.0)

(3.6)

-

-

8

6

-

(25.0)

266

243

24,136

19,886

-

(17.6)

-

-

803

295

-

(63.3)

MIMAROPA

154

156

624

597

1.4

(4.4)

Bicol Region

219

219

21

17

(0.2)

(19.0)

Western Visayas

382

349

6,908

6,214

(8.6)

(10.0)

Central Visayas

3,106

2,286

1,838

1,826

(26.4)

(0.6)

Eastern Visayas

134

115

21

19

(14.1)

(9.6)

Zamboanga Peninsula

11,040

9,844

5,773

5,305

(10.8)

(8.1)

Northern Mindanao

4,356

4,304

1,314

1,260

(1.2)

(4.1)

Davao Region

2,615

2,579

2,688

2,612

(1.4)

(2.8)

SOCCSKARGEN

1,653

1,394

6,866

6,117

(15.7)

(10.9)

Caraga

5,797

5,934

999

947

2.4

(5.3)

ARMM

982

935

71

65

(4.8)

(8.1)

NIR

938

842

2,242

2,145

(10.2)

(4.3)

Philippines

Ilocos Region Cagayan Valley Central Luzon CALABARZON

16

Mangoes are suitable on upland areas with abundant sunlight and adequate moisture (Flowerree, 2010). With ideal conditions of the surroundings, mangoes can be harvested 82-88 days after full bloom of its flowers during the summer (regular harvest season). However, mango-farmers in Mindanao can grow mangoes during off-season since the region is outside the country’s typhoon belt hence; the region is relatively drier during “on-season” months. Table 2.1.2 shows that the local mango production has a huge potential to be a raw material source in industrial scale processes.

Table 2.1.2 Mango Production Schedule PERIOD or SCHEDULE FLOWER INDUCTION

HARVEST

Season Production

November to February

March to June

Off Season Production

March to October

July to February

According to Flowerree (2010), mango with yellow-green color, pedicel-end and yellow pulp indicate the maturity of the fruit ready for harvest and eventually, for export. The Philippines exports less than 10% of the total mango production to 48 different countries (BAS, 2004). Mahusay Incorporated (2011) stated that 59% of these exports are fresh mango, 18% mango puree, and 23% are other products like dried mangoes, concentrates and mango juices. The remaining volume of mangoes is for domestic consumption and supplies of the local mango industry. Profood International Corporation is one of the largest mango processing companies in the country. The company has four manufacturing sites that are located in Manila, Iloilo, Cebu, and Davao to guarantee the supply of mangoes that regionally grows in the country.

17 Mango peels and kernels are considered as by–products of mango processing companies. These by-products can be considered as waste other than being used as fertilizers and livestock feed (De la Cruz Medina et al., 2002). According to Jedele et al. (2003) and El-Kholy et al. (2008), it can be estimated that mango processing yields between 150,000 and 400,000 tons of waste worldwide, which may cause environmental problems in the area of the processing plants. Mango peels represent 15 - 20% of the whole fruit weight (Beerh et al., 1976) and generates 20-40% of the total mango processing waste (Banerjee et al., 2016). According to Profood International Corporation (2012), 850 tons of mangoes are processed by the company daily in Cebu City and generates 59.5 to 204 metric tons of mango peels. Mango peels are then collected and dumped for disposal. However, Bernardini et al. (2005) said that mango peels can be potential sources of pectin and phenolic compounds or antioxidants which are evident in Table 2.1.3. The table found below shows the chemical composition of mango peels reflecting the study by Banerjee et al. (2016).

18 Table 2.1.3 Chemical Composition of dried mango peels Components

% weight

Cellulose

15-18%

Hemicellulose

5-11%

Lignin

9-12%

Ash

2-4%

Pectin

20-35%

Extractives

5-10%

Protein

6-10%

2.2 Manufacturing Process To produce pectin from mango peels, Figure 2.2.1 shows the schematic diagram for the processes involved in the production. The maximum production capacity of the plant was derived from the data given by the Department of Trade and Industry (DTI) for the pectin trade in the country for the year 2014-2017. Linear regression for extrapolation became possible because the values in Table 1 (found in the previous chapter) showed an exponential increase.

19 2.2.1 Schematic Diagram MANGO PEELS WASHING

DRYING

H2O

Dried Mango Peel MILLING Mango Peel Powder Acid

HOT ACID EXTRACTION Mango Peel Extract

FILTRATION

Pectic Liquor

Solid Residue

PRECIPITATION

Ethanol

FILTRATION

Filtrate

Solid Residue

NEUTRALIZATION

MILLING

CLARIFICATION

STORAGE

DISTILLATION

PECTIN

Recovered Alcohol

Figure 2.2.1 Schematic diagram for producing pectin from mango

20 2.2.2 Preparation of Mango Peels

The Philippine Center for Postharvest Development and Mechanization (PhilMech) published Gragasin’s study about the Utilization of Mango Peels as Source of Pectin in the fourth volume of their technical bulletin. The research (conducted jointly by the Department of Science and Technology and PhilMech) successfully produced pectin from carabao mango peels that conformed to United States Pharmacopeia (USP) standards – the standards set by FDA that covers pharmaceutical and food-grade products. This became our basis and guide for the feasibility study and proposal for plant design.

In a research study by Sridevi et al. (2015), they have identified the pectindegrading microorganism that depolymerizes the pectin content of mango peels. Efficient bacterial isolate was selected according to the highest pectinolytic activity on the basis of their growth and formation of clearing zones on Citrus Pectin Agar (CPA) medium by using iodine potassium iodide solution and identified as Paenibacillus jamilae (MTCC 10320).

The mango peels will be gathered and collected from Profood International Corporation located in Cebu City. The peels will undergo washing to remove grit and impurities; this will accumulate an estimated moisture content of 60%. The peels will then be dried at an operating temperature of 60ºC to preserve the quality of the raw material because according to Aguilera et al. (2001), P.jamilae can grow at 40ºC but cannot survive at 50ºC.

21

2.2.2.1 Drying

Mango peels with 60% moisture (Mosa, 2015) will undergo drying in a rotary drier that will reduce its moisture to 10%. A counter-current rotary drier utilizes air flowing in opposite direction to the material flow. The material will come in contact with the coolest drying air resulting to a more efficient drying method than that of co-current drier systems (Feeco International, 2017).

The dried mango peels will be stored in a tank with a maximum capacity for six months in order to keep a stock or buffer for the production; as well as preserve the quality of the raw material over time.

2.2.2.2 Milling I

Dried mango peels will undergo size reduction through fine grinding using a crusher mill with an rpm range of 1000-4400.

2.2.3 Hot Acid Extraction

1M Hydrochloric Acid will be added to the mango peel powder and hot water at 100⁰C to maintain a pH range of 1-3 for 60 minutes. The addition of the acid will gelatinize the pectin for easier precipitation. The operator from the control tower will monitor the pH and temperature levels every 20 minutes as a quality control measure. Necessary actions like addition of acid or base and heating or cooling of the tank may be done.

22 2.2.4 Filtration I

The mango peel extract from the extraction method will undergo the initial filtration method which will separate the pectic liquor (filtrate) and the solid residue. The pectic liquor will be further processed through precipitation while the solid residue will be discharged as waste.

2.2.5 Precipitation

The pectic liquor from the first filtration will undergo precipitation by adding 95% Ethanol into the mixture while being continuously stirred at 20⁰ C for 12 hours. The addition of alcohol to the liquor will then form slurry. The operator from the cooling tower will monitor the temperature levels of the reactor tanks. Heating or cooling to 20ºC may be done as a quality control measure.

2.2.6 Filtration II

The slurry from the precipitation method will be filtered using a rotary vacuum filter to separate the filtrate and the solid residue. The filtrate in the second filtration contains the alcohol solvent plus the acid mixture. The filtrate will first be neutralized by adding calcium hydroxide to adjust the pH. Slurry will then proceed to the clarification process wherein the calcium chloride dihydrate will be separated from the alcohol-water mixture.The alcohol-water mixture will then be recovered through the use of a distillation process to revert the diluted alcohol back to its original concentration.

23 The rotary vacuum filter drum is suitable for liquids with high solid content because it will clog other kinds of filter. The drum is pre-coated with a filter medium which is usually diatomaceous earth (DE) or perlite. The drum rotates through the liquid and the vacuum sucks liquid and solids onto the pre-coat surface. The vacuum sucks the liquid portion onto the inner drum while the solids adhere to the outside of the drum which is then scraped as the drum rotates. Utilizing this equipment will greatly reduce the moisture content of the solid residue to 10%.

2.2.7 Milling II

To homogenize the coarse pectin (solid residue from the rotary vacuum filter), size reduction will be done through the use of a grain grinder. The coarse pectin from the second filtration unit will be ground into fine pectin.

2.2.8 Product Storing

Pectin silos will be used to store the final product (sacked pectin). The product quality and bulk volume will be measured daily. Quality assurance will also be enforced to adhere to standards set by the USP (refer to Table 1 in the previous chapter).

2.2.9 Mass Production Flow Rate

Figure 2.2.2 shows the mass flow rate diagram of the entire operation. The material balance across every manufacturing process is shown to account for every material that goes in and out of the production from the processing of raw materials to the end product which is the pectin powder.

24 259.8152 kg of mango peels will be processed into 27.7777 kg of pectin in an hour of operation, producing roughly 667 kg of pectin powder daily. The ethanol (95% v/v) used in the production of pectin will be recycled through distillation. Proper quality control and assurance measures will be done to maintain strict production parameters.

25 (Fig. 2.2.2 Mass Production Flow Rate Diagram)

26 2.2.10 Process Flow Diagrams The process flow diagrams will show the entire operation and processes happening in the plant. There are four diagrams that will illustrate the whole operation; block flow diagram, production flow diagram, power plant diagram, and water treatment plant diagram. Figure 2.2.3 shows the illustration of the block flow diagram that will serve as a guide for the whole operation. The diagram will show how the raw material is converted to the final product. Figure 2.2.4 shows the production flow diagram that shows not only the processes, but also the instruments, equipment, and vessels that the production utilizes.

27 (Fig. 2.2.3 Block Flow Diagram)

28 (Fig. 2.2.4 Production Flow Diagram)

29 2.2.11 Power Plant

This plant will be utilizing the concept of cogeneration which is the simultaneous production of electricity and heat, both of which are being used. Through the utilization of the heat, the efficiency of a cogeneration plant can reach 90% or more. According to Cogen (2017), cogeneration offers energy savings ranging 15-40% when compared to the supply of electricity and heat from conventional power stations and boilers. The total electricity and heat requirements of the whole plant will be satisfied by the cogeneration plant. According to Turbinesinfo (2017) the cogeneration plant will include a highly efficient extraction steam turbine due to its capacity to generate a high amount of electricity and its ability to regulate output as per changing need, it will be driven by the saturated steam produced by a biomass-fired boiler. Demineralized water will be used as the heating medium for the boiler to prevent scaling caused by impurities being precipitated out of the water directly on heat transfer surfaces or by suspended matter in water settling out on the metal and becoming hard and adherent (Lenntech B.V., 2017). The biomass that will be fed into the furnace will be consisting of a combination of rice husk, napier grass, and wood chips. The turbine will be connected to a generator that will convert mechanical work to electrical energy. Low to medium pressure steam exiting the turbine will be sent to process for its heating requirements mainly during the hot-acid extraction while the remaining low pressure steam will be directly sent to a condenser.

30 (Fig. 2.2.5 Power Plant Diagram)

31 2.2.12 Water Treatment Plant

Raw or untreated water will be withdrawn from a deep well injection from an aquifer or groundwater source. The raw water from the deep well will be pumped and stored in a holding tank. From the water holding tank, it will be pumped to a circular clarifier that will remove any suspended solids. Through sedimentation, angled rake arms move the concentrated slurry toward the center of the tank where it is then removed. Clear liquid overflows at the top and is collected in a trough (Fein & Kaplan, 2017). After clarification, the primarily treated water will go through the Dual Media Filter (DMF) that will remove the turbidity and suspended solids (Chemtronics, 2004). The tank is fitted with an inlet distributor that forces the water through the filter media (sand, anthracite, gravel, and pebbles) and a bottom collecting system. Sand is used to remove the suspended particles and anthracite is used to remove the odor and color while the gravel and pebbles are provided to support to both the media. Backwashing will be performed periodically which changes the water flow through the sand-anthracite filter. After the water passed through the DMF, it will then pass through the Activated Carbon Filter (ACT) to remove organic matter by adsorption process with the help of activated carbon. In order to use the water for the processes done in the plant, softening must be done. Water from the initial filters will be pumped to the Softening Tank or the Ion Exchange Unit in order to remove the hardness caused by calcium and magnesium ions. Water is filtered through an ion exchange process utilizing resins like NaCl. The

32 fresh resin contains Na ions in its active sites that causes the Ca and Mg ions to migrate 2+

2+

2+

to these sites, displacing the Na ions. In time, the resin may recharged by adding NaCl to 2+

the tank to refresh the solution with a high concentration of sodium ions (Wikipedia, 2017). To get rid of the mineral ions found in the water, demineralization must be done. Water from the ion exchange unit will be pumped to the Strong Acid Cation (SAC) and Strong Base Anion (SBA) tanks. The SAC tank contains resins that exchange H ions +

with the cation portion (e.g. Ca , Mg , Na , etc.) of the dissolved solids from the water 2+

2+

2+

and are regenerated by a dilute acid solution (e.g. HCl), while the SBA tank resins exchange OH ions with the anion portion (e.g. SO , Cl , etc.) of the dissolved -

4

-2

-

solids and are regenerated by dilute sodium hydroxide (Woolley, 2012). Water from the softening tank will be stored in the Softened Water Tank and will be used for the processes and utilities in the plant. Water from the ACT will be pumped to the Processed Water Tank to be used for heat exchangers, cooling towers, and other utilities. The demineralized water from the SAC and SBA tanks will be stored in the Demineralized Water Tank and will be used for the power plant.

33 (Fig. 2.2.6 Water Treatment Plant Diagram)

34 2.3 Production Schedule

The plant will be designed to run 24 hours a day, 7 days a week. The plant will operate for a total of 300 days a year and the remaining 65 days will be scheduled for maintenance. Throughout the maintenance, the whole plant will be shut down for inspections, repairs, adjustment of machineries, and modification of facilities. In the production and engineering department, the daily 24 hour work schedule will be divided into 3 shifts (8AM-4PM, 4PM-12AM, and 12AM-8AM) ensuring there will be an employee/s and supervisor in each post per shift. The administration personnel will have 8 hours (8AM-5PM) of duty per day with 1 hour of lunch period from 12NOON to 1PM, 6 days a week. The employees will be working on regular days, non-working holidays and will be given leaves. Benefits will be given for those working on a holiday. Tables 2.3.1 and 2.3.2 shows the number of employees under each department. Table 2.3.1 Personnel with Regular Day Schedule (8:00AM-5:00PM) DEPARTMENT

Administrative

POSITION

NUMBER OF PERSONNEL

Plant Manager

1

Administrative Head

1

Human Resource Head

1

Human Resource Staff

2

Attending Physician

1

Accounting and Finance Head

1

Accounting and Finance Staff

2

Sales and Marketing Head

1

Sales and Marketing Staff

2

35 Logistics and Purchasing Head

1

Logistics and Purchasing Staff

2

Production Head

1

Engineering Head

1

Maintenance Head

1

Quality Control Officer

1

Pollution and Control Officer

1

Safety Officer

1

Production

Table 2.3.2 Personnel with Shifting Schedule NUMBER OF PERSONNEL DEPARTMENT

POSITION

SHIFT 1 8:00AM4:00PM

SHIFT 2 4:00PM12:00AM

SHIFT 3 12:00AM8:00AM

Security Guards

4

4

4

Nurse

1

1

1

Maintenance Supervisor

1

1

1

Maintenance Staff

1

1

1

Power plant supervisor

1

1

1

Power plant Operator

2

2

2

Production Supervisor

1

1

1

Dryer and Mill

2

2

2

Raw Materials

1

1

1

Administrative

Maintenance

Production

Engineering

36 Handling WTP

1

1

1

Distilling Column

1

1

1

Quality Control Analyst

2

2

2

Production Helper

3

3

3

Laboratory Sampler

2

2

2

Hot Acid Extraction

1

1

1

Total Number of Employees: 93

2.4 Equipment Design and Specifications

2.4.1 Conveyor Function: For the transportation and handling of solid materials. Capacity: 311.7782 kg/hr No. of units: 5 Type: Belt Conveyor (45º Troughed) Inclination: 20º Width: 3.83 m Length: 3 m

37 Height (lift): 1.5 m Velocity: 30.49 m/min Power (hp) = 0.60153 hp = 0.45 kW

2.4.2 Mill 1 (Ready Made) Type: Crusher Mill

Function: Size reduction of raw material

No. of Units: 1

Brand: Jiangyin Lingling

Model: Model 16

Capacity: 50-300 kg/h

Length: 1.05 m

Width: 0.6 m

Height: 1.6 m

RPM: 1000-4400

Power: 7.5 kW

38 Weight: 250 kg

2.4.3 Drier 1 Function: Reduce the moisture content of the mango peels from 60% to 10%. No. of units: 1 Capacity: 259.8152 kg/hr mango peels Type: Rotary Dryer Material of Construction: 316 Stainless Steel Dimensions: Heating Surface Area: 2.9092 m2 Diameter: 1.9246 m Length: 8.3095 m

2.4.4 Hot Acid Extraction Reactor Tank Equipment: Pitched- blade turbine mixing Reactor Function: To establish the extraction condition that will give the highest Pectin yield Type of Material: Carbon Steel

39 No. of units: 1 Operation: Batch Operating time per batch: 1hour Feed rate: 1039.2606 kg/h Volume per unit: 1.1223 m3 Dimension: Diameter: 1.0456 m Height: 1.5684 m Working Pressure: 100 kPa Wall thickness: 0.003 m Outside diameter, Do = 1.0476 m Agitator Design Impeller diameter, Da

m

Height Above vessel floor, Ha = Da = 0.3492 m Length of Impeller Blade, L Width of the Impeller Blade,W Width of the Baffle, J = 0.10476 m

m m

40 Upper Clearance = 1.0456 m Lower Clearance = 0.3492 m

2.4.4.1 Heat Exchanger Equipment: Double-Pipe Heat Exchanger Function: To cool down the mango peel extract from 100 to 60ºC No. of Units: 1 Material: Schedule 40 stainless steel Dimensions: Heat transfer area: 4.75 m2 Length: 14 ft Inside Pipe Diameter: 1 1/4 in Outside Pipe Diameter: 2 in

2.4.5 Precipitation Equipment: Pitched-blade turbine mixing Reactor Function: To precipitate out pectin from mixture

41 Type of Material used: Carbon Steel Operating Temperature: 30oC Mass flow rate: 10186.6592 kg/hr Operating time per batch: 12 hours Density = 811.9795 kg/m3 Volume = 15.0546m3 Diameter = 2.3379 m Height = 3.5069m Working Pressure= 100 kPa PT = 127.9343 kPa Wall thickness, Tw = 0.0045 m Outside diameter, Do = 2.3424 m Agitator Design Impeller diameter, Da =

m

Height Above vessel floor, Ha = Da = 0.7793 m Length of Impeller Blade, L Width of the Impeller Blade,W

m m

42 Width of the Baffle, J = 0.2338 m Upper Clearance = 2.3379 m Lower Clearance = 0.7793 m

2.4.6 Filter (ready-made) Function: To separate filtrate from residue Filter ring: 5 Power: 11.5 kW Length: 3.3 m Width: 3 m Height: 2.5 m Weight: 4.5 tons

2.4.7 Cooling Tower: Function: Removes excess heat from water coming from Condenser and Heat exchanger No of units: 2 Capacity: 100 m3/hr

43 Type: Counter Current induced draft towers Material of Construction: Type L copper coil with stainless steel casing fiber glass Dimensions: Height of tower: 48 m Concrete Wall: 7.9 - 9.6 cm Operating Conditions: T = 8ºC Air Flow Rate: 2.69 m3/s Water Flow Rate: 7.57x10-4 m3 /s Recirculation Rate: 900m3/hr Cooling Capacity: 9.56 kW

2.4.8 Neutralization Function: For the neutralization of acid-water-ethanol solution Mass Flow Rate=10196.4716 kg/hr Height = 2.5118 m Diameter=2.5118 m Impeller diameter, Da

m

44 Height Above vessel floor, Ha = Da = 0.8373 m Length of Impeller Blade, L Width of the Impeller Blade, W

m m

Width of the Baffle, J = 0.2512 m 2.4.9 Clarifier Function: Removes solid particulates or suspended solids from the saltethanol-water solution Type: Circular Clarifier No. of Unit:1 Material of Construction: Carbon Steel Capacity: 25 m3 Diameter: 1.33 m Height: 1.99 m Operating Conditions Suspended Solids < 25 ppm Turbidity < 25 NTU

45 2.4.10 Grain Grinder (Ready Made)

Type: Grinder/crusher

Function: To yield fine powdered pectin

No. of Unit: 1

Brand: U-FIRST

Model: UF-MF180

Capacity: 10-120 kg/hr

Grinding Disc Diameter: 0.15 m

Length: 0.48 m

Width: 0.52 m

Height: 1.04 m

Power: 2.2 kW

Weight: 75 kg

2.4.11 Rotary Vacuum Drum Filter (Ready made)

Function:

To separate the Pectin from the alcohol-acid solution

Cylinder diameter:

1.6 m

46 Cylinder length:

1.060 m

Revolutions per minute:

0.159-0.625 rpm

Air suction:

0.5-1.5 m3/min· m2

Vacuum:

450-600 mm Hg 20.2-0.4 m3/min· m

Wind volume:

Capacity:

1.5-2 tons/hour

Dimension:

253*245*185 cm3

Moisture content of residue: 10 %

Material of Construction:

304 Stainless Steel

2.4.12 Distillation

2.4.12.1 Distilling Column

Function: To separate ethanol from water

Type: Bubble Cap Tray Distilling Column

Capacity: 10084.9785 kg/hr

No of units: 1

47 Height of Tower: 25.071 m

Diameter of Tower: 1.6714 m

Tray Spacing: 0.4 m

No. of Stages: 11 Feed Tray: 5th

2.4.12.2 Condenser

Function: To condense vapor containing 95% mass ethanol Materials of Construction: Carbon Steel except for plates No. of units: 1 Dimensions: Area: 91.7845 m2 Length: 6 m Diameter of tubes: Outer Diameter = 15.875 mm Inner Diameter = 14.097 mm Surface Area of one tube: 0.2992 m2 Number of tubes: 307 Pitch: 19.844 mm Bundle: 451 mm

48 No. of tubes in Center row: 23 tubes 2.4.12.3 Reboiler

Function: To generate vapors in the bottoms which are returned to the column

No. of units: 1

Material of Construction: Carbon Steel

Material of Construction of tube: 317 stainless steel

Type:Kettle Bell (Shell and Tube)

Dimensions: Area: 69.4498 m2

Nominal Length: 6 m

Number of U: 74

Outside Diameter: 50 mm

Inside Diameter: 45 mm

Pitch: Square pitch at 75 mm

Bundle Diameter: 0.69 m

49 Shell Diameter: 1.38 m

Liquid level from base: 1 m

Freeboard: 0.38 m

2.4.13 Storage Tanks

2.4.13.1 95% Ethanol Storage tank Type: Close Cylindrical Vessel Carbon Steel No. of units: 2 Volume =167.8978 m3 Diameter = 4.4056 m Height = 11.0140 m

2.4.13.2 HCl Storage tank Type: Close Cylindrical Vessel Carbon Steel No. of units: 2 Volume = 13.4326 m3 Diameter = 1.8984 m

50 Height = 4.7459 m

2.4.13.3 Slaked Lime Storage tank Type: Close Cylindrical Vessel Carbon 304 SS No. of units: 1 Volume = 0.4834 m3 Diameter = 0.6267 m Height = 1.5669 m

2.4.13.4 Mango Peel Storage (density=405.77kg/m3) No. of units: 1 Volume = 129.0848 m3 Dimensions: Height = 3 m Length = 3.7872 m Width = 11.3615 m Operating Parameters: Temperature:13oC

51 Controlled Atmosphere:

3% O2 6% CO2 9% N2

Power Requirement = 0.03 kW

2.4.13.5 Biomass Storage

Type: Roofed Structure

Function: To house the biomass

No. of Units: 1

Materials for Construction: Structural steel, Galvanized iron sheets

Dimensions:

Height: 15.89 m

Width: 15.89 m

Length: 50 m

2.4.14 Power Plant

52

2.4.14.1 Turbine

Type: Extraction Steam Turbine

Function: To generate electricity for the plant

No. of Units: 1

Capacity: 5 MW

Materials for Construction: Low and high alloyed steel, globular cast iron

Inlet Pressure: 3000 kPa

Outlet Pressure: 30 kPa Operating Temperature: 500 oC

Steam Capacity: 18,642.00 kg/hr

2.4.14.2 Furnace

Function: To combust fuel to generate heat for the boiler

No. of Unit: 1

Materials for Construction: Refractory bricks

53 Feed Ratio: 50% Rice husk, 30%, Napier grass, 20% Wood chips Capacity: 75.17 m3 Volume: 120.72 m3

Dimensions:

Height: 6 m

Width: 4.9 m

Length: 4.9 m

2.4.14.3 Boiler

Type: Water Tube Boiler

Function: To generate steam for turbine operation

No. of Units: 1

Fuel: Rice Husk, Napier Grass, Wood Chips

Steam Capacity: 18 642.00 kg/hr

Fuel Consumption: 13 329.03 kg/hr Materials for construction: 316 Stainless Steel

54 Working Pressure: 30.60 kg/cm2 Design Pressure: 36.72 kg/cm2

2.4.15 Water Treatment Plant

2.4.15.1 Raw Water Tank Function: This will serve as a storage tank for the raw water from the deep well. No. of Unit/s: 1 Capacity: 276 m3 Type: Storage Tank Material of Construction: Carbon Steel Dimensions: Diameter: 6.41 m Height: 8.55 m

2.4.15.2 Processed Water Tank Function: Storage will be used as one of the utilities in the plant and it will also be used for the heat exchanger, cooling tower and utilities.

No. of unit/s: 1

55 Capacity: 228 m3

Type: Storage Tank

Material of construction: Carbon Steel

Dimensions

Diameter: 6.02 m

Height: 8.02 m

2.4.15.3 Softened Water Tank Function: The softened water that will be used in the distillation and utilities will be stored in this tank from the softening unit. No. of unit/s: 1 Capacity: 90 m3 Type: Storage Tank Material of construction: Carbon Steel Dimensions Diameter: 4.41 m Height: 5.88 m

56

2.4.15.4 Clarifier Function: The clarifier will remove solid particulates or suspended solids from the raw water. No. of unit/s: 1 Capacity: 65 m3 Type: Circular Clarifier Material of Construction: Carbon Steel Dimensions Diameter: 3.5 m Height: 6.76 m Operation Conditions: Suspended solids Turbidity

2.4.15.5 Clarified Water Tank Function: This tank will store the clarified water from the clarifier. No. of unit/s: 1 Capacity: 78 m3

57 Type: Storage Tank Material of Construction: Carbon Steel Dimensions Diameter: 3.5 m Height: 6.76 m

2.4.15.6 Demineralized Water Tank Function: This tank will be used as storage of water from the strong base anion and will be used as feed in the boiler.

No. of unit/s: 1 Capacity: 50 m3

Type: Storage Tank

Material of construction: Stainless Steel with rubber coating inside

Dimensions

Diameter: 3.17 m

Height: 4.23 m

58 2.4.15.7 Dual Media Filter Function: This will serve as a filter that removes the turbidity of the water from the clarified water tank. No. of unit/s: 1 Capacity: 40 m3 Type: Filter Filtering Media: Anthracite Coal and Sand Material of Construction: Carbon Steel Dimensions Diameter: 3 m Height: 5.66 m Operating Conditions Suspended solids < 5ppm

2.4.15.8 Activated Carbon Filter Function: This filter will serve as removal of organic matter from the feed water. No. of unit/s: 1 Capacity: 40 m3

59 Type: Filter Filtering media: Activated Carbon Material of construction: Carbon Steel Dimensions Diameter: 3 m Height: 5.66 m Operating condition: Regeneration: 24 hours Replacement of Filtering Media: Every 120 days

2.4.15.9 Softening Unit Function: this will remove the hardness in the processed water. No. of unit/s: 1 Capacity: 5 m3 Material of construction: Carbon Steel Resin: Tulsion T-40 Polymer matrix: Polystyrene Copolymer

60 Physical form: Moist Spherical Beads Ionic form: Sodium Dimensions Diameter: 1.4 m Height: 3.25 m Operating conditions: Hardness: 5 ppm CaCO3 maximum

2.4.15.10 Strong Acid Cation Function: Calcium, magnesium, and sodium cations will be eliminated by the hydrogen ion. No. of unit/s: 1 Capacity: 40 m3 Material of construction: Carbon Steel Resin: Tulsion T-40 Polymer matrix: Polystyrene copolymer Physical form: Moist spherical beads Ionic form: H+ or Na+

61 Resin regeneration: Hydrochloric Acid, Sodium Chloride and Sulfuric Acid Dimensions Diameter: 3 m Height: 5.66 m

2.4.15.11 Strong Base Anion Function: Anions such as sulfate and chloride ions will be removed by the active amine group and the hydroxide radical. No. of unit/s: 1 Capacity: 40 m3 Material of construction: Carbon Steel Resin: Tulsion A-23P Polymer matrix: Polystyrene Copolymer Physical form: Moist Spherical Beads Ionic form: Chloride Resin regeneration: Sodium Hydroxide Dimensions Diameter: 3 m

62 Height: 5.66 m Operating conditions: pH: 7.0-8.0 Hardness: 2-4 mmol//L

2.5 Piping and Instrumentation Design Figure 2.5.1 shows the Piping and Instrumentation Diagram of the entire production. It illustrates not only the flow of the process but as well as the piping, vessels, and instruments of the operation. It also shows the instrument symbols as well as the controlling devices.

63 (Fig. 2.5.1 Piping and Instrumentation Diagram)

64 2.6 Plant Location The plant will be located in Brgy. Cabadiangan, Liloan City, Cebu. Figure 2.6.1 shows the area that will be occupied by the site is 55,820 m . 30,820 m of the plant will 2

2

be composed of buildings and facilities that will include the administrative building, clinic, laboratory, production facilities, and wastewater and waste treatment facilities. Buffer zone will be allocated to the remaining 20,000 m of the area for future expansion. 2

Figure 2.6.1 Proposed plant site (Google Imagery, 2017)

The plant will be enclosed by four points that has the following location: 1. Latitude:10°45’28.65”N

Longitude: 123°97’59.47”E

2. Latitude:10°45’28.83”N

Longitude: 123°97’75.04”E

3. Latitude:10°44’97.42”N

Longitude: 123°97’76.28”E

4. Latitude:10°44’97.64”N

Longitude: 123°97’60.42”E

65 There are several factors to consider in choosing the location of the plant. These factors are the following:

2.6.1 Availability of Raw Materials

Mango trees are abundant in central visayas that even mango fields are located near the plant site. Profood International Corporation is one of the biggest mango processing industries in Cebu City that generates mango peels as waste. The continuous production of mango big companies can ensure the supply of raw material.

2.6.2 Accessibility to the Market

Production of Pectin from mango peels will lessen the dependence of local industries such as food processing, cosmetics, and pharmaceutical from import. Hauling of the products can be export by land and sea. Roads and highways are readily installed from the plant site for transportation of trucks. Cebu International Port and Cebu Harbor located in Cebu-North Coastal that is 1 hour away from the plant site accessible for shipping.

2.6.3 Transportation Facilities

Roads located near the plant site will make it easier to transport raw materials to the plant and product distribution will be easily achieved. The source of the raw material for this study is located 22.7 km away and will take 1 hour and 1 minute from the proposed plant location site.

66 2.6.4 Water Supply

The water supply for the plant will be from deep well injection and will be processed for the usage of the plant.

2.6.5 Power Supply

The heat and electricity requirement of the whole plant will be provided by the biomass-fired power plant. The biomass-fired power plant will use Napier grass, rice husk, and wood chips as the fuel. The plant will connect to the local power grid if power failure will occur.

2.6.6 Climate

Liloan has a tropical climate. Rainfall is significant most months of the year, and the short dry season has little effect. The average temperature in Liloan is 27.6 °C. Its driest month is April and warmest month is May with an average temperature of 28.6 °C. The average rainfall in Liloan is 1561 mm having October as the heaviest precipitation and January as the coldest month with average temperature of 26.4 °C (Climate-Data.Org, 2012).

2.6.7 Community Factors

The plant location is situated not far from the city proper making it easily accessible to employees and future employees living in the city. Malls, hospitals, schools, and other general needs of the community are existent. The plant is

67 situated that in case of any unforeseen accidents, the living communities will not be affected.

68 (2.7 Plant Layout Fig. 2.7.1 Plant Layout Diagram)

69 2. 8 Buildings and Facilities

2.8.1 Administrative Building

The administrative building will be positioned near the main gate alongside the non-Personal Protective Equipped facilities such as cafeteria and clinic. The building will be also located away from the production site for the safety of the administration employees.

2.8.2 Control Room

The control room will be placed adjacent to the production area so that monitoring of large equipment from different departments will be convenient in terms of accessibility and easy troubleshooting.

2.8.3 Laboratory

The building for laboratory will be located near the production site for accessibility of samples. Laboratory will be for the analysis of raw materials, influents, effluents, product, and by-products involved in the production.

2.8.4 Clinic

The clinic is considered a non-PPE facility which will be located adjacent to the administrative building. A physician will be the head of the facility with registered nurses during operating hours for first aid action of injuries whenever

70 accidents occur. The clinic will be provided with wheelchair, PPE, medicine, immobilization and transport materials, beds, and first-aid kits.

2.8.5 Cafeteria

To avoid contamination of the product from the food and beverages, the cafeteria will be located opposite the administration building. Thus, all employees will only be allowed to eat on this site.

2.8.6 Sanitation

There will be designated comfort rooms in every building including the Laboratory. Janitors will be assigned to clean office rooms and comfort rooms in every building. Septic tanks will be placed below every building except the administrative building and clinic which will have a common septic tank.

2.8.7 Drainage System

Waste water from washroom, canteen kitchen, and other faucets supplied from local water district will go to the drainage system. This will be discharged to Cotcot River, the nearest river in the vicinity the plant site.

2.8.9 Fire and Safety

The fire house will serve as the building for automobiles such as ambulance and firetrucks. It will be located near the operation area and power plant. Firefighting equipment, sprinkler systems, and emergency exits will be

71 installed in every building. The Bureau of Fire and Protection (BFP) and Department of Health’s safety strategies and techniques that include fire drills, first-aid seminars and other safety program will observed and followed to avoid fatalities.

The plant will be provided with safety officers that will handle orientation and seminars for employees. The officers will also strictly implement personal protective equipment usage especially in the zone of operations.

2.9 Raw Material and Supplies

2.9.1 Raw Material

Mango (Mangifera indica, Linn) is a fruit that is eaten as a dessert or relish depending on the maturity of the fruit and can be processed to a number of different kinds of products. It can be processed into a number of unique products such as dried, puree, juice, etc. It is one of the most abundant fruit in the Philippines and is ranked as the third most important fruit crop of the country. The production of mango during the 1 quarter st

of 2017 was about 107,827 MT (Philippine Statistic Authority, 2017). Mango peels constitute about 15 to 20 percent of the total weight of the fruit (Beerh et al, 1976). Mango peel was found to contain polyphenols and dietary fiber (Larrauri et al, 1996) and could be a very useful raw material for the extraction of pectin. Pectin recovery from mango peels is 20.8 percent (Sudhakar et al, 1999) and 39 percent by (Flores-Lopez et al., 2003).

72 An existing study that utilized mango peels as a source of pectin, they were able to produce pectin at an average percent yield of 21.65% dry basis (Gragasin et al, 2014). This proves that producing of pectin from mango peels is possible.

2.9.2 Supplies

To achieve a cost efficient production, source of raw materials and market for the product are both located near the facility to lower transportation cost. Napier grass, Rice husk, and wood chips are used to provide electricity to the plant. Deep well water will be used as the water resource for the plant. Pumped deep well water will pass through water treatment and will be used for the production.

2.10 Waste Disposal

2.10.1 By-Products

2.10.1.1 Calcium Chloride Dihydrate from Neutralization

Calcium Chloride Dihydrate is a by-product of the neutralization reaction and will be separated using the Clarifier. The separated hydrate will be sold by the company.

2.10.1.2 Solid Residue from Filtration

The solid residue mainly composed mainly of Galactose could be used as an aging model and can be donated to scientists who do research on mice and rats.

73 2.10.1.3 Flue Gases from Combustion of Fuel

Flue gases are by-products of the combustion of the biomass in the boiler. These can be critical threats to the environment and health of the community. Wet scrubbers will be used to remove harmful particles and gases from the exhaust steam

2.10.2 Garbage from Waste Bins

Proper disposal of solid wastes is critical in order to mitigate the deadly effects of wastes on to the environment and to the health of the people. There will be individual garbage bins for each type of solid waste including biodegradable, non-biodegradable, residual and special wastes in specific locations in every building in the manufacturing plant. It will be then picked up by dump trucks and then disposed to a dump site.

2.10.3 Wastewater

The bottoms coming from the distillation will be mainly water and partly ethanol. This will be discharged to the lagoon. According to DAO 2016-08 , the parameters for manufacturing plants are temperature, pH, BOD, Total suspended solids, and oil and grease.

2.11 Labor Requirement A plant should have the appropriate personnel to have an efficient operation and production of best quality. The following are qualified personnel to work in a plant:

74

2.11.1 Chemical Engineers

Chemical Engineers design the process of a plant, turning a raw material into a large-scale setting. They are responsible for the design and specifications of equipment to be used in the operation. They are greatly involved with waste management and research due to the impact of industries to the environment. 2.11.2 Environmental Engineers Environmental Engineers are responsible to the waste management and control of the plant. They design equipment for waste treatment to reduce environmental impacts that could affect the health of the community. 2.11.3 Mechanical Engineers Mechanical Engineers are mostly assigned in the power plant. They operate the boiler to produce steam that could generate power for the entire plant and operations. They also maintain and repair machines that are used in the process. 2.11.4 Electrical Engineers Electrical Engineers are responsible for the electrical system of the plant. They design and maintain electrical equipment necessary for the operation. 2.11.5 Civil Engineers Construction of the plant is handled by civil engineers. They ensure the proper material and design to resist natural calamities at its lowest possible cost. 2.11.6 Plant Manager The plant manager supervises the entire plant’s operation. He ensures that everything runs smoothly and efficiently from plant operations, production, product

75 quality, maintenance down to employees. He/she should have the knowledge of the process to assess and improve something in the plant. 2.11.7 Plant Operators Operators are workers that are deployed in utilities and supervision of equipment of a process. 2.11.8 Office Personnel Office works from the administration are usually handled by office personnel. 2.11.9 Maintenance Personnel Maintenance personnel are assigned in the maintenance facility wherein they repair and maintain equipment used in the operation.

2.12 Organizational Structure

Figure 2.12.1 shows the organizational chart which summarizes the hierarchy of the company.

76 (Fig. 2.12.1 Organizational Chart)