# -*- coding: utf-8 -*-
# BioSTEAM: The Biorefinery Simulation and Techno-Economic Analysis Modules
# Copyright (C) 2020-2023, Yoel Cortes-Pena <yoelcortes@gmail.com>
#
# This module is under the UIUC open-source license. See
# github.com/BioSTEAMDevelopmentGroup/biosteam/blob/master/LICENSE.txt
# for license details.
"""
This module contains unit operations for the separation of solids
(e.g. centrifugation, expression, filtration).
.. contents:: :local:
.. autoclass:: biosteam.units.solids_separation.SolidsSeparator
.. autoclass:: biosteam.units.solids_separation.SolidsCentrifuge
.. autoclass:: biosteam.units.solids_separation.RotaryVacuumFilter
.. autoclass:: biosteam.units.solids_separation.PressureFilter
.. autoclass:: biosteam.units.solids_separation.ScrewPress
References
----------
.. [1] Seider, Warren D., et al. (2017). "Cost Accounting and Capital Cost
Estimation". In Product and Process Design Principles: Synthesis, Analysis,
and Evaluation (pp. 481-485). New York: Wiley.
.. [2] Humbird, D., Davis, R., Tao, L., Kinchin, C., Hsu, D., Aden, A.,
Dudgeon, D. (2011). Process Design and Economics for Biochemical
Conversion of Lignocellulosic Biomass to Ethanol: Dilute-Acid
Pretreatment and Enzymatic Hydrolysis of Corn Stover
(No. NREL/TP-5100-47764, 1013269). https://doi.org/10.2172/1013269
"""
from .decorators import cost
from .splitting import Splitter
from .design_tools import compute_vacuum_system_power_and_cost
from warnings import warn
from ..exceptions import lb_warning, InfeasibleRegion
from .decorators import cost
from biosteam.utils import remove_undefined_chemicals, default_chemical_dict
import numpy as np
import biosteam as bst
from thermosteam import separations
from math import exp, log, ceil
__all__ = ('SolidsSeparator', 'RotaryVacuumFilter', 'CrushingMill',
'PressureFilter', 'SolidsCentrifuge', 'RVF',
'ScrewPress',)
[docs]
class SolidsSeparator(Splitter):
"""
Create SolidsSeparator object.
Parameters
----------
ins :
Inlet fluids with solids.
outs :
* [0] Retentate.
* [1] Permeate.
split : array_like
Component splits to 0th output stream
moisture_content : float
Fraction of water in solids
"""
_N_ins = 1
_ins_size_is_fixed = False
def _init(self, split,
order=None, moisture_content=None,
moisture_ID=None,
strict_moisture_content=None
):
Splitter._init(self, order=order, split=split)
#: Moisture content of retentate
self.moisture_content = moisture_content
self.strict_moisture_content = strict_moisture_content
if moisture_content is not None:
self.moisture_ID = moisture_ID
if moisture_ID is None: moisture_ID = '7732-18-5'
self.isplit[moisture_ID] = 0.
def _run(self):
if self.moisture_content is None:
separations.mix_and_split(
self.ins, *self.outs, self.split,
)
else:
separations.mix_and_split_with_moisture_content(
self.ins, *self.outs, self.split, self.moisture_content, self.moisture_ID,
self.strict_moisture_content,
)
[docs]
class SolidsCentrifuge(SolidsSeparator):
"""
Create a solids centrifuge that separates out solids according to
user defined split. Capital cost is based on [1]_.
Parameters
----------
ins :
Inlet fluid with solids.
outs :
* [0] Solids-rich stream.
* [1] Liquid-rich stream.
split : array_like or dict[str, float]
Component splits.
order=None : Iterable[str]
Species order of split. Defaults to Stream.chemicals.IDs.
solids : tuple[str]
IDs of solids.
moisture_content : float
Fraction of water in stream.
centrifuge_type : str
Type of the centrifuge, either 'reciprocating_pusher' (1-20 ton/hr solids)
or 'scroll_solid_bowl' (2-40 ton/hr solids).
"""
_units = {'Solids loading': 'ton/hr',
'Flow rate': 'm3/hr'}
solids_loading_range = {
'reciprocating_pusher': (1, 20),
'scroll_solid_bowl': (2, 40)
}
kWhr_per_m3 = 1.40
def _init(self, split, order=None, solids=None, moisture_content=0.40,
centrifuge_type='scroll_solid_bowl', moisture_ID=None,
strict_moisture_content=None):
SolidsSeparator._init(
self, moisture_content=moisture_content,
split=split, order=order, moisture_ID=moisture_ID,
strict_moisture_content=strict_moisture_content
)
if solids is None:
solids = [i.ID for i in self.chemicals if i.locked_state == 's']
self.solids = solids
self.centrifuge_type = centrifuge_type
@property
def solids(self):
return self._solids
@solids.setter
def solids(self, solids):
self._solids = tuple(solids)
@property
def centrifuge_type(self):
return self._centrifuge_type
@centrifuge_type.setter
def centrifuge_type(self, i):
if not i in ('reciprocating_pusher', 'scroll_solid_bowl'):
raise ValueError('`centrifuge_type` can only be "reciprocating_pusher" or '
f'"scroll_solid_bowl", not {i}.')
self._centrifuge_type = i
def _design(self):
solids, centrifuge_type = self._solids, self.centrifuge_type
ts = sum([s.imass[solids].sum() for s in self.ins if not s.isempty()]) # Total solids
ts *= 0.0011023 # To short tons (2000 lbs/hr)
self.design_results['Solids loading'] = ts
lb, ub = self.solids_loading_range[centrifuge_type]
if ts < lb:
lb_warning(self, 'Solids loading', ts, 'ton/hr', lb)
self.design_results['Number of centrifuges'] = ceil(ts/ub)
cost = 68040*(ts**0.5) if centrifuge_type else 170100*(ts**0.3)
cost *= bst.CE / 567
self.baseline_purchase_costs['Centrifuges'] = cost
self.F_BM['Centrifuges'] = 2.03
self.design_results['Flow rate'] = F_vol_in = self.F_vol_in
self.power_utility(F_vol_in * self.kWhr_per_m3)
[docs]
class RotaryVacuumFilter(SolidsSeparator):
"""
Create a RotaryVacuumFilter object.
Parameters
----------
ins :
* [0] Feed
* [1] Wash water
outs :
* [0] Retentate
* [1] Permeate
split : array_like or dict[str, float]
Component splits.
moisture_content : float
Fraction of water in retentate.
"""
auxiliary_unit_names = ('vacuum_system',)
_F_BM_default = {'Vessels': 2.32,
'Vacuum system': 1.0}
#: Revolutions per second
rps = 20/3600
#: Radius of the vessel (m)
radius = 1
#: Suction pressure (Pa)
P_suction = 1500.
#: For crystals (lb/day-ft^2)
filter_rate = 6000
_kwargs = {'moisture_content': 0.80} # fraction
_bounds = {'Individual area': (10, 800)}
_units = {'Area': 'ft^2',
'Individual area': 'ft^2'}
def _design(self):
flow = sum([stream.F_mass for stream in self.outs])
self.design_results['Area'] = self._calc_Area(flow, self.filter_rate)
def _cost(self):
Design = self.design_results
Area = Design['Area']
ub = self._bounds['Individual area'][1]
N_vessels = np.ceil(Area/ub)
iArea = Area/N_vessels # individual vessel
self.parallel['self'] = N_vessels
self.parallel['vacuum_system'] = 1
Design['Individual area'] = iArea
self._load_vacuum_system(Area, N_vessels)
logArea = np.log(iArea)
Cost = np.exp(11.796 - 0.1905 * logArea + 0.0554 * logArea**2)
self.baseline_purchase_costs['Vessels'] = Cost * bst.CE/567
def _load_vacuum_system(self, area, N_vessels):
s_cake, s_vacuumed = self.outs
radius = self.radius
Area = self.design_results['Individual area']
N = self.parallel['self']
vacummed_air = s_vacuumed.F_vol # Flow rate sucked-in displaces air
air_density = 1.2754 # kg /m3
self.vacuum_system = bst.VacuumSystem(
F_mass=vacummed_air * air_density,
F_vol=vacummed_air,
P_suction=self.P_suction,
vessel_volume=N * radius * Area * 0.0929 / 2., # m3
)
@staticmethod
def _calc_Area(flow, filter_rate):
"""Return area in ft^2 given flow in kg/hr and filter rate in lb/day-ft^2."""
return flow * 52.91 / filter_rate
RVF = RotaryVacuumFilter
@cost('Flow rate', units='kg/hr', cost=1.5e6, CE=541.7,
n=0.6, S=335e3, kW=2010, BM=2.3)
class CrushingMill(SolidsSeparator):
"""
Create crushing mill unit operation for the
separation of sugarcane juice from the bagasse.
Parameters
----------
ins :
* [0] Shredded sugar cane
* [1] Recycle water
outs :
* [0] Bagasse
* [1] Juice
split : array_like or dict[str, float]
Splits of chemicals to the bagasse.
moisture_content : float
Fraction of water in Bagasse.
"""
_hp2kW = 0.7457
[docs]
@cost('Retentate flow rate', 'Flitrate tank agitator',
cost=26e3, CE=551, kW=7.5*_hp2kW, S=31815, n=0.5, BM=1.5)
@cost('Retentate flow rate', 'Discharge pump',
cost=13040, CE=551, S=31815, n=0.8, BM=2.3)
@cost('Retentate flow rate', 'Filtrate tank',
cost=103e3, S=31815, CE=551, BM=2.0, n=0.7)
@cost('Retentate flow rate', 'Feed pump', kW=74.57,
cost= 18173, S=31815, CE=551, n=0.8, BM=2.3)
@cost('Retentate flow rate', 'Stillage tank 531',
cost=174800, CE=551, S=31815, n=0.7, BM=2.0)
@cost('Retentate flow rate', 'Mafifold flush pump', kW=74.57,
cost=17057, CE=551, S=31815, n=0.8, BM=2.3)
@cost('Retentate flow rate', 'Recycled water tank',
cost=1520, CE=551, S=31815, n=0.7, BM=3.0)
@cost('Retentate flow rate', 'Wet cake screw', kW=15*_hp2kW,
cost=2e4, CE=521.9, S=28630, n=0.8, BM=1.7)
@cost('Retentate flow rate', 'Wet cake conveyor', kW=10*_hp2kW,
cost=7e4, CE=521.9, S=28630, n=0.8, BM=1.7)
@cost('Retentate flow rate', 'Pressure filter',
cost=3294700, CE=551, S=31815, n=0.8, BM=1.7)
@cost('Retentate flow rate', 'Pressing air compressor receiver tank',
cost=8e3, CE=551, S=31815, n=0.7, BM=3.1)
@cost('Retentate flow rate', 'Cloth wash pump', kW=150*_hp2kW,
cost=29154, CE=551, S=31815, n=0.8, BM=2.3)
@cost('Retentate flow rate', 'Dry air compressor receiver tank',
cost=17e3, CE=551, S=31815, n=0.7, BM=3.1)
@cost('Retentate flow rate', 'Pressing air pressure filter',
cost=75200, CE=521.9, S=31815, n=0.6, kW=112, BM=1.6)
@cost('Retentate flow rate', 'Dry air pressure filter (2)',
cost=405000, CE=521.9, S=31815, n=0.6, kW=1044, BM=1.6)
class PressureFilter(SolidsSeparator):
"""
Create a pressure filter for the separation of structural carbohydrates,
lignin, cell mass, and other solids. Capital costs are based on [2]_.
Parameters
----------
ins :
Contains structural carbohydrates, lignin, cell mass, and other solids.
outs :
* [0] Retentate (i.e. solids)
* [1] Filtrate
split : array_like or dict[str, float]
Splits of chemicals to the retentate. Defaults to values used in
the 2011 NREL report on cellulosic ethanol as given in [2]_.
moisture_content : float, optional
Moisture content of retentate. Defaults to 0.35
"""
_units = {'Retentate flow rate': 'kg/hr'}
def _init(self, moisture_content=0.35, split=None):
if split is None:
chemicals = self.chemicals
split = dict(
Furfural=0.03571,
Glycerol=0.03714,
LacticAcid=0.03727,
SuccinicAcid=0.03714,
HNO3=0.03716,
Denaturant=0.03714,
DAP=0.03716,
AmmoniumAcetate=0.03727,
AmmoniumSulfate=0.03716,
NaNO3=0.03716,
Oil=0.03714,
HMF=0.03571,
Glucose=0.03647,
Xylose=0.03766,
Sucrose=0.0359,
Mannose=0.0359,
Galactose=0.0359,
Arabinose=0.0359,
Extract=0.03727,
Tar=0.9799,
CaO=0.9799,
Ash=0.9799,
NaOH=0.03716,
Lignin=0.98,
SolubleLignin=0.03727,
GlucoseOligomer=0.03722,
GalactoseOligomer=0.03722,
MannoseOligomer=0.03722,
XyloseOligomer=0.03722,
ArabinoseOligomer=0.03722,
Z_mobilis=0.9799,
T_reesei=0.9799,
Protein=0.98,
Enzyme=0.98,
Glucan=0.9801,
Xylan=0.9811,
Xylitol=0.03714,
Cellobiose=0.0359,
DenaturedEnzyme=0.98,
Arabinan=0.9792,
Mannan=0.9792,
Galactan=0.9792,
WWTsludge=0.9799,
Cellulase=0.03727
)
remove_undefined_chemicals(split, chemicals)
default_chemical_dict(split, chemicals, 0.03714, 0.03714, 0.9811)
bst.SolidsSeparator._init(self, moisture_content=moisture_content, split=split)
def _design(self):
self.design_results['Retentate flow rate'] = self.outs[0].F_mass
PressureFilter._stacklevel += 1
#: TODO: Check BM assumption. Use 1.39 for crushing unit operations for now.
[docs]
@cost('Flow rate', units='lb/hr', CE=567, lb=150, ub=12000, BM=1.39,
f=lambda S: exp((11.0991 - 0.3580*log(S) + 0.05853*log(S)**2)))
class ScrewPress(SolidsSeparator):
"""
Create screw press unit operation for the
expression of liquids from solids. Capital cost is based on [1]_.
Parameters
----------
ins :
* [0] Solids + liquid
outs :
* [1] Solids (retentate)
* [0] Liquids (permeate)
split : array_like or dict[str, float]
Component splits.
moisture_content : float
Fraction of water in solids.
"""
kWh_per_bmt = 37.2 # From Perry's Handbook, 18-126
# Energy consumption may be drastically different depending on the application
# - 5 to 12 bdmt (tonne dry biomass) https://www.andritz.com/products-en/group/pulp-and-paper/service-solutions/screw-press-service/screw-press-upgrade-case-study-1-less
def _cost(self):
self._decorated_cost()
biomass = self.ins[0]
bmt = biomass.F_mass * 0.001
self.add_power_utility(bmt * self.kWh_per_bmt)