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Assignment 3
GROUP 15
GROUP PERSONNEL:
ANDIKAPUTRA B.W. (1406607893)
FARACITRA AKUWALIFAH (1406607861)
MUSTIKA SARASWATI (1406552906)
NADIRA KAMILIA PERMATASARI (1406607956)
NADYA SAARAH AMELINDA (1406552824)
Our plant produces benzene through the main process called catalytic fast
pyrolysis. Empty fruit bunches (EFB) is use for main raw material. The catalyst that
we used is HZSM-5, an upgrading catalyst of zeolite that can break the carbon-
carbon bonds. Zeolites as catalytic cracking catalysts have been used extensively in
the oil and gas industry in the recent years and the application of HZSM-5 in the
catalytic cracking of hydrocarbons is more than other zeolite types. This is due to
the fact that they have higher activation and specific structure in their pore sizes.
The process in order to produce the benzene starts from the pre-treatment,
the catalytic fast pyrolysis process. The pre-treatment starts with cut the EFB into
small size then hydrolysis EFB with H2SO4. After the pre-treatment process, lignin
will be delivery to reactor fast pyrolysis. Our reactor will be operated in high
temperature.
In order to produces benzene, we need to calculate the size of all the
equipment in our plant. The sizing also related to the economical aspect later. This
sizing is including the dimension and material construction. There are 20 equipment
and 9 types of equipment that we have sized. The types of equipment are tank, belt
conveyor, grinder, pump, compressor, heat exchanger, distillation, reactor, and heat
exchanger.
The sizing of the equipments are done by calculating it using the mass rate,
flow rate, temperature, residence time, fluid properties and other properties.
Eventhough the sizing is not 100% accurate, but it will give more clear picture.
There are different equation used for each equipments. For tanks, the sizing is done
in order to find the dimension by knowing the flow rate or the volume of each batch.
For reactor, the sizing will depends on the kinetic reaction. For utilities such as
pumps and heat exchanger, the sizing will consists of designing the work needed,
material choosen, the heat transfer, head ,etc. For other supporting equipments, the
sizing usually consists of the dimension, temperature, pressure and other thing.
Sizing all of the equipment we need some data from Super Pro 9.0,
simulation software, such as flow rate, temperature, and pressure. The sizing will
make a result in specification table. You can see the detail in Chapter 1 and the
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calculation in Appendix. For material construction, we also determine them by
considering the working fluid that involved in the process and also the operating
condition. We determine whether it is high pressure, high temperature, or corrosive.
Almost all of our equipment is operating in low pressure and low temperature that
is why we choose stainless steel as the main materials. In our process, the most
corrosive fluid that we have is only water.
Not only sizing the equipment but also making Process and Instrumentation
Design (P&ID) for the entire plant and for each process. From P&ID could be
generated controller and valve that we need for each process. P&ID shows all of
piping including the physical sequence of branches, reducers, valves, equipment,
instrumentation and control interlocks. P&IDs play a significant role in the
maintenance and modification of the process that it describes. It is critical to
demonstrate the physical sequence of equipment and systems, as well as how these
systems connect. Controller is designed to make the work easier and to maintain
the process on the designated condition. Controller takes place in three different
types, which are sensor, transmitter, controller and actuator. The sensor is used to
determine if the fixed variable is still in acceptable range, if its not acceptable the
sensor will send signal through the transmitter to the controller to activate the
actuator to activate in order to maintain the wanted variable. Controller is described
by each equipment, sub-process and as a whole.
Our plant needs water utility in the process. The water requirement for the
plant is derived from Way Kuala River which has 1.2 km distance with our plant.
To ensure a continuous supply of water, it was built on the location of the water
reservoir (water intake) which is also a pre-treatment of river water. This processing
includes filtering waste and impurities carried along the water. Furthermore, water
is pumped to the factory to be processed and used as needed.. There is a
specialization of water treatment for raw material, because we need to demineralize
the water first. The steps for water treatment are sedimentation, clarification,
filtration, and demineralization.
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LIST OF FIGURES
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LIST OF TABLES
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CHAPTER 1
EQUIPMENT SIZING
1.1. Reactor
1.1.1. Fast Pyrolysis Reactor
Table 1.1. Fast Pyrolysis Reactor Specification
Equipment Specification
Item Reactor
Name Pyrolysis Reactor
Type Packed Bed Reactor
Code
Function Reacting lignin into BTX
Material SA 283 Grade C
Operation Data
Temperature (OC) 600
Pressure (bar) 1.04
Operation Data
Volume (m3) 116.04
Diameter (m) 4.05
Height (m) 14.19
Shell Thickness (in) 0.344
Catalyst
Type ZSM-5
Volume (m3) 74.27
Weight (kg) 53474.99
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Equipment Specification
Equipment Name Catalyst Regenerator
Equipment Code R-100
Function Regenerate catalyst
Number of Unit 1
Material SS 316
Operation Data
Regenerator Temperature
700
(oC)
Catalyst Circulation Rate
40
(kg/m2s)
Pressure (atm) 1
Dimension
Regenerator Height (m) 6.59
Regenerator Diameter (m) 2.20
Regenerator Volume (m) 24.96
Regenerator Thickness (m) 9.35
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Equipment Specification
Equipment Name Demineralize Water Tank
Equipment Code
Storage Type Liquid Storage
Function Storage for Demineralize Water
Number of Unit 1
Material Carbon Steel SA 167
Table
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Equipment Specification
Cylinder Vertical Concrete
Type of Tank
Foundation
Type od Head Flat Head
Operation Data
o
Temperature ( C) 25
Pressure (atm) 1
Mass Flow (kg/day) 76314
Bulk Density (kg/m )3 1004
Dimension
Capacity (kg/day) 76314
Volume tank (m3) 83.61
Volume of Liquid in Tank
76
(m3)
Tank Diameter (m) 8.53
Tank Height (m) 17.062
Height of Liquid in Tank
(m) 15.335
Design Pressure (bar) 2.88
Hydrostatic pressure (bar) 1.51
Shell Thickness (in) 0.52
Head Thickness (in) 1.84
Equipment Specification
Equipment Name Coagulant Tank
Equipment Code
Number of Vessel 1
Type Rigid Base Circular
Determination of Diameter of the Water Tank
Mass Flow Rate 3197.5 kg/h
Density 1004 kg/m3
Volume 221.73 m3
Height 4.40 m
Diameter 8.40 m
Free board 0.40 m
Wall Thickness 6 mm
Design of Base
Thickness of base 6 mm
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Equipment Specification
Equipment Name Filtration Tank
Equipment Code T-502
Function To Filter Suspended Solid (SS)
Number of Unit 4
Filter Specification
Filter Type Slow Sand Filter
Total Surface Area (m2) 267.1425
Max. Surface Per filter
50
(m2)
Number of Filters 6
Surface Area per Filter
44.53
(m2)
Dimension
Filtration Rate (m/h) 0.2
Required Tank Area (m2) 356.19
Long (m) 25
Width (m) 15
Height (m) 2.4
Equipment Specification
Equipment Name Ion Exchanger
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Equipment Code
Function To remove Cation and
Anion
Number of Unit 2
Operation Data
Cation Concentration 250 mq/L
Use degasifier (Yes/No) Yes
Anion Concentration 150.25 mq/L
Running time 15 h
Throughput Flow rate 19200 m3
Ionic Load
Cation Load 4800000 eq
Anion Load 2884800 eq
Operating Capacity
Cation regeneration with HCl 1 eq/L
Anion regeneration with NaOH 0.5 eq/L
Resin Volumes
SAC 4800000 L
SBA 5769600 L
Specific Flow Rate
SAC 5.1 h-1
SBA 4.72 h-1
Temperature in 123 5 C
Temperature out 243 100 C
Operating pressure 1000 1000 kPa
No. of passes 1 2
Fouling factor 0,00009 0,00009 m2 C/W
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Temperature in 5 486 C
Temperature out 122 50 C
Operating pressure 900 412 kPa
No. of passes 1 2
Fouling factor 0,00009 0,00009 m2 C/W
Heat Duty 429 kW
LMTD 119 C
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1.4. Distillation
1.4.1. Distillation Column
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Equipment Specification
Equipment Name Distillation column
Equipment Code D-200
Function To separate BTX from phenol and
high-boiling aromatics compunds
Operating Data
Feed Flow Rate 16794.70 kg/h
Reflux Ratio 14.6
Column Pressure 9 bar
Number of Actual Tray 27
Condenser Temperature 30 oC
Boiler Temperature 314 oC
Stage Efficiency 80%
Construction Data
Material Carbon Steel
Column Height 16.46 m
Column Diameter 1.09 m
Plate Type SS Sieve tray
Material SA-283 Grade C
Shell Thickness 5.71 cm
Head Type Torispherical
Head Thickness 1.21 cm
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Equipment Specification
Equipment Name Distillation column
Equipment Code D-200
Function To separate Benzene from Toluene
and Xylene
Operating Data
Feed Flow Rate 180899.4 kg/h
Reflux Ratio 0.75
Column Pressure 4.7 bar
Number of Actual Tray 15
Condenser Temperature 14 oC
Boiler Temperature 249 oC
Stage Efficiency 80%
Construction Data
Material Carbon Steel
Column Height 10.67 m
Column Diameter 0.96 m
Plate Type SS Sieve tray
Material SA-283 Grade C
Shell Thickness 5.71 cm
Head Type Torispherical
Head Thickness 1.21Cm
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Equipment Specification
Name Separator
Code V-102
Separate organics aromatics, water and
Function volatile gas
Number of Units 1
Type Vertical 3 Phase Separator
Material SS-304
Operational Data
Pressure (kPa) 900
Temperature (oC) 5
Gas Flowrate
(MMSCFD) 1.40
Oil Flowrate (BOPD) 1.29
Water Flowrate (BWPD) 0.378
Construction Data
Minimum Diameter (m) 2.12
Maximum Diameter (m) 612
Gas Capacity Constraint 580.82
Retention Time
Constraint 674
Diameter (m) 3.1
Height (m) 18.13
L/D 7.76
Vessel Liquid Level -
beta 50%
Vessel Thickness
P (psia) 14.5
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R (in) 0.5
S (psi) 20000
E 0.85
t (in) 0.392
t (m) 0.0099
Vessel Cover
Bottom Flat
Top Torispherical
1.6. Conveyor
1.6.1. Elevator Conveyor
Table 1.18. Elevator Conveyor Specification
Equipment Specification
Equipment Name Elevator Conveyor
Equipment Code
Equipment Specification
Function Delivering biomass feed (empty
fruit bunches) from storage tank to
grinder
Quantity 1
Equipment Type Elevator Conveyor
Material Carbon Steel
Operation Data
Flow rate (ton/h) 416.67
Material Temperature (oC) 25
Pressure (atm) 1 atm
Construction Data
Conveyor Length (ft) 22.96
Belt Width (Inch) 42
Power (hp) 2.815
Conveyor Speed (ft/min) 83.41
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Equipment Specification
Equipment Name Hammer Mill
Equipment Code
Function Grinder
Number of unit 1
Material Carbon Steel
Type Hammer Mill Grinder
Operation Data
Rotate Speed (r/min) 800
Pressure (atm) 1
Capacity (ton/h) 50-70
Output Size (mm) 0.01-1
Power Requirement
377.502 kWh/hour
(kWh/hour)
Dimension
Width (m) 2.1
Height (m) 1.8
Length (m) 1.8
Equipment Specifications
Equipment Name Plate and Frame Filtration
Equipment Code P&F-101
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1.9. Cyclone
1.9.1. Cyclone (Cy-100)
Table 1.22. Cyclone Specification
Equipment Specification
Equipment Name Cyclone
Equipment Code Cy-100
Function Gas-solid separator
Number of unit 1
Material Carbon Steel
Type Cyclone Separator
Operation Data
Pressure (kPa) 1.013
o
Temperature ( C) 600
Volumetric flow rate 626526
Particle diatemer (m) 0.005
Grade efficiency (%) 97
Pressure drop (millibar) 130
Construction Data
D0 (m) 0.15
DB (m) 0.2
W (m) 0.08
S (m) 0.2
Hc (m) 0.3
H (m) 0.8
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A (m) 0.15
B (m) 0.08
Equipment Specification
Equipment Name Cyclone
Equipment Code Cy-101
Function Gas-solid separator
Number of unit 1
Material Carbon Steel
Type Cyclone Separator
Operation Data
Pressure (kPa) 1.013
o
Temperature ( C) 700
Volumetric flow rate 560428
Particle diameter (m) 0.005
Grade efficiency (%) 97
Pressure drop (milibar) 130
Dimension
D0 (m) 0.15
DB (m) 0.2
W (m) 0.08
S (m) 0.2
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Hc (m) 0.3
H (m) 0.8
A (m) 0.15
B (m) 0.08
Equipment Specification
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Equipment Specification
Equipment code P-102
Pump Type Centrifugal Pump
Function Pump for water to Heat Exchanger (B6)
Mode of Operation Continuous
Material Carbon Steel
Operation Data
Water Liquid
Mass flow (kg/s) 83.33
Flow rate (m3/s) 0.082754
Density (kg/m3) 1007
Temperature (C) 5
Differential Pressure (Pa) 420,000
Specification Design
NPSHa (m) 9.37
NPSHr (m) 10.05
Head (m) 60.49
FHP (kW) 43.48
BHP (kW) 49.40
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Equipment Specification
Equipment code P-103
Pump Type Centrifugal Pump
Function Pump for water to Heat Exchanger (B7)
Mode of Operation Continuous
Material Carbon Steel
Operation Data
Water Liquid
Mass flow (kg/s) 257.56
Flow rate (m3/s) 0.255766
Density (kg/m3) 1007
Temperature (C) 5
Differential Pressure (Pa) 312,000
Specification Design
NPSHa (m) 12.49
NPSHr (m) 10.05
Head (m) 48.23
FHP (kW) 91.31
BHP (kW) 121.75
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CHAPTER 2
UTILITY
Operation Controlled
Function Control Procedure
Unit Parameter
To ensure that the optimum temperature for Increase the CV-101 opening if the temperature
the fast pyrolysis is kept maintained because indicator shows the value that is higher that set point so
the pyrolysis reaction is an exothermic the cooling water flow rate to the reactor jacket increase
Temperature reaction and the temperature will always and the heat that can be transferred from reactor to
increase by the heat released while the cooling water will be increased too and vice versa.
Fluidized
reaction occur if the temperature is not
Bed
controlled.
Reactor (R-
The pressure controller will close the PRV-100 if the
101)
pressure indicator shows the value which is below the
To ensure the safety of the reactor. The
maximum pressure allowed in the reactor. If the
Pressure reaction will produce gas phase and gas with
pressure is too high, the PRV-100 will be opened and
high temperature will be very dangerous.
the gas phase will be sent to flare so the pressure in the
reactor can be reduced.
To ensure that the optimum temperature for
When the temperature of the of the CSTR is not fit with
the hydrolysis is kept maintained because the
the wanted condition, the TI will give an electric signal
hydrolysis reaction is an exothermic reaction
Temperature to TC and then transfer that signal into a pneumatic
CSTR and the temperature will always increase by
signal to flow control valve at the cooling water until
Reactor (R- the heat released while the reaction occur if
the condition become normal
100) the temperature is not controlled.
When the pressure of the CSTR is higher than the
Pressure To ensure the safety of the reactor. design pressure, the pressure control valve will open to
reduce the pressure on the CSTR
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Final
Equipment Process Controller Manipulated
Unit Sensor Control Sequence of Instrumentation
Name Variable P/PI/PID Variable
Element
When the outlet pump flow is
Flow Cooling Flow higher than design, the valve
Pump P-100 Flow Element & Flow Control Water Flow Indicator will be closed. But, if the outlet
Flowmeter Rate Controller pump flow is lower than design,
the valve will be opened.
Reduce liquid level in column
Liquid Level
Coagulant Mechanical Proportional by opening the Level Control
T 101 Level Product Flow Indicator
Tank Float Integral LT Valve on the bottom product of
Rate Conttoller
the column.
Reduce liquid level in column
Liquid Level
Filtration Mechanical Proportional by opening the Level Control
V- 100 Level Product Flow Indicator
Tank Float Integral LT Valve on the bottom product of
Rate Conttoller
the column.
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Final
Equipment Process Controller Manipulated
Unit Sensor Control Sequence of Instrumentation
Name Variable P/PI/PID Variable
Element
Reduce liquid level in column
Liquid Level
Kation Mechanical Proportional by opening the Level Control
V-102 Level Product Flow Indicator
Exchanger Float Integral LT Valve on the bottom product
Rate Conttoller
of the column.
Reduce liquid level in column
Liquid Level
Anion Mechanical Proportional by opening the Level Control
V-103 Level Product Flow Indicator
Exchanger Float Integral LT Valve on the bottom product
Rate Conttoller
of the column.
Reduce liquid level in column
Liquid Level
Mechanical Proportional by opening the Level Control
Water Tank T-102 Level Product Flow Indicator
Float Integral LT Valve on the bottom product
Rate Conttoller
of the column.
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CHAPTER 6
CONCLUSION
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REFERENCES
Kern, D. Q., 1965, Process Heat Transfer, McGraw-Hill Book Company, Japan.
Liebermann, N.P., and Liebermann, E.T., 2008, A Working Guide to Process
Equipment, 3ed, McGraw-Hill, New York.
Shuler, M.L. dan Kargi, F., 2002, Bioprocess Engineering, 2, Prentice Hall, New Jersey
Smith, Robin. 2005. Chemical Process Design and Integration, 2nd edition. Centre of
Process Integration, University of Manchester, UK.
Tarleton, E. S. and Wakeman, R.J., 2007, Solid/Liquid Separation : Equipment
Selection and Process Design, Elsevier Ltd., Burlington, Great Britain.
Turton, R., Bailie, R.C., Whiting, W.B., 2009, Analysis, Synthesis, and Design of
Chemical Processes, 3ed., Prentice-Hall Inc., New Jersey.
Vilbrandt, F. C. 1959. Chemical Engineering Plant Design. United State: McGraw-
Hill Inc.
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APPENDIENCES
Appendix A. Fast Phyrolisis Reactor Sizing Calculation
Sizing
Step 1 : Collect Literatures Data
Catalyst ZSM-5
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Flow rate actual this plant is 55730 kg/h and the journal is 46000 kg/hr. By
assuming the actual flow rate is 1.2 times than journals, so the volume actual this
plant is 1.2 bigger than journals as well.
Vtank actual = 1.2Vtank journal
Vtank actual = 1.2 x 8.544 m3
Vtank actual = 116.04 m3
Step 4: Calculate Diameter Actual
= + +
= 0.0847 3 + 0.0847 3 + 0.7854 3
= (0.0847 + 0.0847 + (0.7854 x 4))3
116.04 m3 = (0.0847 + 0.0847 + (0.7854 x 4))3
3 = 66.686 m3
D = 4.055 m
Step 5: Calculate Ls
Ls = 3.5D
Ls = 4 x 1.728 m
Ls = 14.19 m
Step 6: Calculate Volume Liquid
In this case, the tank volume is assumed
100
=
80
So the liquid volume is calculated as below
80
=
100
80
= 116.04
100
= 92.838 m3
Step 7: Calculate Liquid Height on the Tank
= + d
2
92.838 m3 = 4.706 D3 +
4
= 6.827
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= 0.344
Step 10: Calculate Teoritical Volume, Diameter and Length
- Teoritical Volume
Teoritical volume = liquid volume
Teoritical volume = 92.83 m3
- Teoritical Diameter
1
2 =
4
1
2 (3.5) = 92.83 m3
4
D3 = 59.13 m3
DTeoritical = 3.89 m
- Teoritical Length
L = 3.5D
L =3.5 (3.89) m
L = 7.791 m
Step 11: Calculate Catalyst Volume and Weight
Condition :
Catalyst filled 80% of the reactor
Catalyst is ZSM-5
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VCat = 74.27 m3
- Catalyst Weight
WCat = VCat
WCat = 74.27 m3 x 720 kg/m3
WCat = 53474 kg
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a. General Description
The Hydrolysis process will be done in a CSTR. Besides, because this
process will be done in a high temperature, this reactor should have had a jacket to
prevent the heat go outside the system.
b. Material Construction
The material that will be used in here is specified to sugar product and also
the food product. Usually in industry, for those kind of product, the carbon steel
would be used because it will not sticky to the product and will protect the product
from contaminant.
c. Sizing
For hydrolysis tank, used CSTR tank to mix Biomass with H2SO4 as well
within 60 minutes of reaction. In CSTR that are going to used
, there will be a dished head in head and bottom reactor with assumption if the
reaction will undergo in perfect mixing.
- Operating condition
Temperature : 162oC
Pressure : 1 atm
- Volume of CSTR
To calculate the volume of CSTR, the flow rate of each material input to hydrolysis
tank should be known before. As for those flow rate has been calculated in mass
balance and will be written below.
After the flow rate has been known, the entering condition of the fluid like flow
rate, pressure, and temperature is needed. As for the assumptions R is equal to 8,314
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3
kPa.dm /mol K and vo is calculated below
1
= ( )
1 0.4615 0.5384
= +
112 1830
1
= 0.00441512
= 226.494 kg/m3
so, the is
54166,67 /
= = = 66.431 dm3/s
226,494 /3
Assumptions:
From those assumptions above, the volume that needed for the reactor can be
calculated by equation
.
= . =
.
= 0.028 66. 4312 3 s
= 1.860 mol/s
In the calculation above there were no fraction gas (yA0) because in this
reaction there will not be a gas.
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= 0.02054
= . [ ]
.
=
1.860 0.75
=
8.46 105
= (10080)
= 16.478(10080)
= 20.598 3
= 0.0847 3
= 0.0847 3
= 0.7854 3
= + +
3 = 42.597 3
D = 3.492 m = 137.49 in
- Liquid Height
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= +
1
30.63 3 = 0.0847 3 + 2
4
1
33.439.63 3 = 0.0847 (3.497)3 + (3.497)2
4
= 4.032
= 2 = 6.984
= 1.05
- Impeller Sizing
To mix the streams well, the tank uses six-blade 45 open turbine, as for the standard
design for this impeller according to Walas, 1990 is:
Di : Dt = 1 : 3
W : Di = 1 : 8
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C:W=1:3
Where Di = impeller diameter
Dt = tank diameter
W = agitator width
C = distance from bottom of the tank
Impeller diameter = 0.333 x tank diameter
Di = 0.333 x 3.492 m = 1.33 m
Impeller width = 0.125 x impeller diameter
W = 0.125 X 1.33 m = 0.16 m
Impeller distance from the bottom of tank = 0.333 x impeller width
C = 0.333 x 0.16 = 0.055 m
=
4.60 0.86014
=
3.987
= 0.9932 1
Impellers speed = 100 rpm = 1.67 rps
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The reactor is used for catalyst regeneration by combusting the coke in the
pore of the catalyst by hot air. The reactor is modelled as plug flow reactor (Bai,
Zhu, Jin, & Yu, 1998). For this model, the rate law of coke combustion is
= (1 ) )
= 2
Where,
Cc = Coke content on catalyst (%wt)
x = length of the reactor (m)
= cross section average voidage
Gs = total catalyst flowrate (kg/m2s)
PO2 = partial pressure of O2 (atm)
Kc = 1.65 x 108 exp ( -1.612 x 105/RT)
R = 8.314 kJ/kmol K
Initial coke content on catalyst is assumed 0.05%wt and the final is
0.008%wt. Cross-section average voidage is assumed 0.8 and total catalyst flow
rate is 40 kg/m2.s.
The derivation of the equation is:
= 2 (1 ) (64)
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From the polymath, the length of the reactor for coke combustion is 6.586 m
The diameter of the reactor is about 1/3-1/5 L. So that
6.586
= = = 2.195
3 3
= +
( ) (0.6 )
S is allowable stress (74514.7 psi for SS 316). E is joint efficiency 0.8 (Walas 1988).
CA is corrosion allowance. For carbon steel the value of corrosion allowance is
0.00889 m.
14.7 1.0977
= + 0.00889
(74514.7 0.8) (0.6 14.7 )
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= 0.00935 = 9.350
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This warehouse is used for stocking the raw materials (empty fruit bunches).
The raw materials are stocked monthly from the supplier around Way Kuala.
Basic Planning
Construction materials = Concrete
= /
= 100,000 / 30 /
= 3,000,000
= 3,000
=
3,000,000
= = 8450.70 3
355 /3
10%, 90%
1
= 8450.70 3 = 9389.67 3
0.9
= (
Length : Width : Height ratio = 4:3:1
Warehouse Specification
Length = 36.85 m
Width = 27.64 m
Height = 9.21 m
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This warehouse is used for stocking the benzene product. Before we know
the warehouse specifications we have to know some data, which are:
a. Overall density of benzene = 876 kg/m3
b. The process will be done continuously
c. The amount of benzene production is 9271.6 kg/hr
The storage tank for benzene product use cylindrical tanks because cylinder
tank is easier to fabricate and has strong structural shape. The upper end of this
cylindrical tank has ellipsoidal shape, while the bottom end of this cylindrical tank
has flat shape. The material used for the storage tank is stainless steel. Carbon steel
is avoided because it cant withstand acidity and corrosion.
Tank Volume
The first step for sizing the equipment is calculating the tank volume. The
calculation will be done based on the input specified in storage tank. For one day,
the benzene that will produced is 11,125.92 kg. If the storage tank can hold benzene
for 1 weeks, then the mass of benzene that is stored in the storage tank is 77,881.44
kg. By knowing the mass flow rate of benzene, can calculated the volumetric flow
rate for storage tank.
11,125.92 7
= = = 88.90 3
876 3
By considering the safety factor of storage tank which is 10% of the total
volume, it means that the storage tank capacity (working volume) cannot exceed
90% of the total volume. Therefore, the total volume is:
88.90 3
= = 98.78 3
0,9
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1
= 2
4
Based on the rule of thumb of cylindrical storage tank, the ratio of height
and diameter of the tank is 2:1, therefore Hcylinder = 2D, and the cylinder volume
formula can be modified into:
1
= 23
4
The tank total volume is the sum of cylinder volume and ellipsoidal head
volume. The volume of ellipsoidal head is:
1 2
=
4
According to Walas (1990), the ratio between head height and diameter is
1:6, therefore Hh = 1/6 D, and the ellipsoidal head volume formula can be modified
into:
1 2 1 1
= = 3
4 6 24
Therefore, the total tank volume is;
1 1 13
= + = 23 + 3 = 3
4 24 24
By arranging above equation, the tank diameter can be obtained:
3 24
=
13
3 24(406.5 3 )
=
13
= 19.35 762.20
Based on the previous rule of thumb, the tank height can be obtained from
diameter, and it is calculated below:
= 2 6.2 = 38.71
1
= 6.2 = 3.22
6
= 12.4 + 1.03 = 41.94 = 1651.43
Design Pressure
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Where:
t = Material thickness
P = Pressure gauge
R = Shell radius
Di = Shell inner diameter
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1 2
K = ellipsoidal formula factor = 6 [2 + (2) ]
= 0.57 14.478
While the storage tank head thickness is:
1 762.20 2
77.1197 762.20 [2+( ) ]
6 2 1651.43
= + (0.0042 30 ) (100)
(216,250 2 0.85)(0,2 77.11 )
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To sizing the water demine tank produced from the water pre-tereatment process,
followed algorithm as shown in figure above
1. Determine operating condition
The water is processed in atmospheric pressure and room temperature
because of the input is water which do not need pressure for storing the water.
Hence the operating condition is shown on table below
Temperature = 25oC
Pressure = 1 atm = 14.7 psi
2. Determine type and material of tank
Next, needed to choose the material and type that will be used for the tank.
For the material, the consideration is based on the economic aspect. Hence, the
material chosen is carbon steel is chosen due to its competitive price and quality with
other materials. Besides, it also depends on the function which to store water, the non
corrosive fluid and it do not need to store in certain temperature. Another reason is the
good strength of carbon steel and it is easy to get.
For the type of tank, consider the operating condition which do not need
pressure for storing so the type of vessel choosen will be cylinder vertical with concrete
foundation. The type of head is flat head.
To calculate the shell thickness (ts) we use the equation from Brownell, page 254
[ + ]
=
[2 ( 0.6 )]
41.86 336.11 + 0.0042
( ) = = 0.52
2 (16750 0.8 0.6 41.86 )
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The calculation for sizing coagulant tank is based on the data of rigid based
material. The table below shows the data that is used
Then we could calculate the height of the tank with free board data. The
diameter of the coagulant tank we determined is 8.4 m with 4.4 m height. There
will be four tanks due to the big amount of water to be processed in our plant per
day. Hence, we divided the mass flow rate to 4 tanks. The mass flow rate of each
tank would be 3197.5 kg/h.
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Filtration involves the removal of suspended and colloidal particles from the water
by passing it through a layer or bed of a porous granular material, such as sand.
Rate of filtration (loading rate) is the flow rate of water applied per unit area of the
filter. It is the velocity of the water approaching the face of the filter and define as:
=
Where va = face velocity, m/d = loading rate, m3/d.m2
Q = flow rate onto filter surface, m3/d
As = surface area of filter, m2
In this filtration method, we choose Sand Filter as granular material and
Slow Sand Filter (SSF) as the technology. Design criteria for SSF according to UK
expertise is define in this table.
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Before calculate the tank area, the flow rate of water based on water
requirement in our plant is 7631 m3/day. Hence, the required tank area
calculation (Atank) would be as follows
1
= ( )
3 1
7631
= (0.15 ) = 2119.72 2
24
For this area, we can use tank with 25 m long and 15 m wide. From typical
table above, the height of the tank require could be calculated from provided
data
- System underdrain + gravel = 0.4 m
- Filter bed = 0.85 m
- Supernatant water = 1 m
So the total tank height is 2.25 m
Thus, the dimension of the tank become 25 m long, 15 m wide and 2,25 m
height
Finally we can calculate the number (n) of filters by divided surface area of
(A) and maximum surface per filter which known as 50 m2. The total
surface area of filter couldbe calculated fro equation below. The design
loading rate based on the table above. We take 160 m3/m2 day
=
7631 3 /
= = 47.69 2
3
160 2
47.69 2
= = 0.953 1
50 2
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In the sizing calculation of ion exchanger, the result would be the resin volumes. It
is calculated based on the surface area requirement for demineralization process of
total water needed in our plant. Hence, the algorithm calculation will be as follows
Calculate
Examine Water Decide the use
Cation
Analysis of degasifier
Concentration
Consider the
Calculate resin
Calculate ionic aproximate
volume
load per cycle operating
required
capacity
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4800000
= = = 4800000 .
1
2884800
= = = 5769600
0.5
10. At the end of this calculation, we must make sure that the specific flow rate
of both resin columns is compatible with the general recommendations of the resin
producer.
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The specific flow rate in h1 (often expressed in bed volumes per hour
BV/h) is equal to the flow rate in m3/h divided by the resin volume in m3. The usual
range is 5 to 50 h1. For a compact plant with minimum investment cost, use a
specific flow rate around 30 to 35 h1. If the specific flow rates calculated from
the resin volumes Vc and Va are too high, increase the running time t. If they are
too low, reduce the running time t.
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The type of heat exchanger that will be used is shell and tube (STHE),
because STHE can transfer heat with higher efficiency, and also the tube side is
easy to clean. The material for the STHE is carbon steel, because it has high thermal
conductivity and relatively cheap, but has long life span. These are the step to design
STHE
1. Determine the specification of fluid. The specifications are flow rate (kg/h) of
hot fluid and cold fluid, the temperature (C) inlet and outlet of the fluids, the
duty, and the location of fluids that pass the tube or shell, and the type of flow
in heat exchanger which are co-current or counter current. To determine the
duty, we use this equation
= mc Cc (t 2 t1 ) = mh Ch (T2 T1 )
If there is a phase change, we use
= . . ( ) + .
2. Determine physical properties of fluids, which are heat capacity (kJ/kg/K),
density (kg/m3), viscosity (Pa.s), thermal conductivity, and fouling factor
(W/m2/K). The fouling factor can be obtained from table below.
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6. Decide the type of shell and tube heat exchanger (fixed tubesheet, U-tube etc.),
outside diameter tube, inside diameter tube, tube thickness, length of tube,
number of pass, dan pitch type. Use the standard tube counts table for this
purpose.
1
1
= ( )
1
The value of K1 dan n1 are obtained from table 12.4 in Chemical
Engineering Design vol 6, 2005
- Diameter shell Ds
= +
The value of shell bundle clearance is obtained from figure 12.10 in
Chemical Engineering Design vol 6, 2005
9. Estimate tube side heat transfer coefficient
- Reynlods Number, Prandtl Number, and L/D
=
=
=
- Tube side heat transfer coefficient, hi
= . . (Pr)0.33 ( )
The value of jH is obtainable from figure 2.23 in Chemical Engineering
Design vol 6, 2005
10. Estimate shell side heat transfer coefficient
- Baffle spacing dan tube pitch
Baffle Spacing, lB = baffle spacing coefficient x inside diameter shell
Tube pitch, pt = tube pitch coefficient x outside diameter tube
The value of baffle spacing coefficient is 0.2 0.5 while tube pitch
coefficient is 1.25 1.35
- Shell Cross Flow Area
= . .
- Equivalent Diameter, de
1.10
For triangular pitch: = (2 0.9172 )
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1.27
For square pitch: = (2 0.7852 )
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2
= 8 . . .
2
Pressure drop must be below 0.5 bar. If the pressure drop above 0.5 bar, we must
change the value of Uc in step 3.
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log[ ( ) ( ) ]
=
log( )
To get the Nopt is by using graphically method using the figure below:
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6. Determining , and , that will be used for determining value of
by using Figure A.4 below
+ 1 =
Using the graph below, we can know the value of K which will be used
to calculate the velocity of vapor and liquid.
4
=
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4. Calculate the number of stage with equation +1
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Table lalayes.
Properties Value
Gas Flowrate (MMSCFD) 0.0464
Oil Flowrate (BOPD) 66.717
Water Flowrate (BWPD) 6.124
Total Liquid (BPD) 72.84
ATM Press. 14.7
Op Press (psig) 2529.46
Op Temp (F) 140
Gas Compressibility Z 0.95
Retention Time (min) t 10.00
Remove drops >__micron from gas 150
Remove H2O drops >__micron from oil 500
Remove oil drops >__micron from H2O 200
Vessel Liquid Level - beta 50%
Gas Molecular Weight 2.018
Oil Specific Gravity 0.84
Water Specific Gravity 1
Gas Viscosity m 0.009
Oil Viscosity ml 3.2
H2O Viscosity mw 0.69
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Trial No. 1 2 3 4 5 6
Assume CD 2.01 1.18 1.03 1.00 0.99 0.99
Vt = (4gDp(l-g)/3CDg)0.5 0.80 1.05 1.12 1.14 1.15 1.15
Re = 1488(DpVtg)/ 54.89 71.58 76.69 78.00 78.32 78.40
0.5
= 12 ( ) = 0.7
2.4( + )
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2 = 1.42[( ) + (( )]
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Diameter
15 16 17 18 19 20
(in)
Leff (gas) 0.00301 0.00282 0.00266 0.00251 0.00238 0.00226
Lss (gas) 1.25 1.34 1.42 1.50 1.59 1.67
Leff
4.62 4.06 3.60 3.21 2.88 2.60
(liquid)
Lss
6.17 5.42 4.80 4.28 3.84 3.47
(liquid)
Lss (ft) 7 6 5 5 4 4
L/D 5.20 4.13 3.53 3.00 2.53 2.10
Since L/D must be in the range of 3-5, the chosen length and diameter for the 3-
phase separator are 6 ft and 16 in.
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- Belt Conveyor 1
Belt conveyor is used to transfer Empty Fruit Bunch from Grinding process
to Hydrolysis Reactor.
Velocity of Conveyor
=( ) 100 /
So, the velocity of conveyor :
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250 /
= (238.5 /) 100 min=104.82 / = 174.70 ft/min
Power
= +
= (0.4 + )( )
300 100
L = Length of Conveyor
W = Capacity (ton/hr)
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= 0.9
= 1.218 + 0.9 = 2.128
- Belt Conveyor 2
Belt conveyor is used to transfer Empty Fruit Bunch from Warehouse to
Grinder.
Velocity of Conveyor
=( ) 100 /
So, the velocity of conveyor :
416.67 /
= ( 499.5 / ) 100 min=104.82 / min = 83.41 /
Power
= +
= (0.4 + )( )
300 100
L = Length of Conveyor
W = Capacity (ton/hr)
22.96 416.67
= (0.4 + )( ) = 1.985 hp
300 100
= 0.83
= 1.985 + 0.83 = 2.815
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Hammer Mills
We need the empty fruit bunch for hydrolysis is about 0.33 mm size in
particles. So we choose to use hammer mills according to tabel
The power requirement for hammer mills is based on the extent of size
reduction that expressed by the following equation
1 1
( ) = 10 ( )
Where d and di are the final and initial diameter (m), and Wi is work
index for the material. The work index for Empty fruit bunch is 13.81.
1 1
( ) = 10 (13.81 )( ) = 0.906857 /
300 20000
If the mass flow rate of empty fruit bunch is 416.67 ton/hour, the total power
requirement is
( ) = 0.906 416.67 = 377.503
To choose the dimension of hammer mills that we need, we look to the vendor
(SBM-Mining and Construction) PC4012-90 with the dimension 1800 mm x 1650
mm x 1800 mm.
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= 0.4529 (138)
Number of turns inside the cyclone is represented by the equation below.
= [0.1079 0.00077 + 1.924(106 ) 2 ] (139)
= [0.1079 0.00077 150 + 1.924(106 ) 1502 ]150 (140)
= 22.563 (141)
To obtain the particle diameter, we can use the equation:
0.5
9
= [4 ( )] (142)
4( )2
= (143)
9
4(21.05540.000324) 10 2
= (304800) (144)
91.285.105
= 0.002461 (145)
= 0.002461. (146)
= 8.3302 = 2.540 (147)
= = 0.635 (148)
4
0 = = 1.270 (149)
2
= = 1.270 (150)
2
= 2 = 5.079 (151)
= 2 + (8) = 5.397 (152)
= = 0.635 (153)
4
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There are some steps to sizing our compressor. We have five steps to calculate
operating data what we need to know. This is our step to size every compressor we
have.
A. Determine the type of compressor, (based on volume inlet and discharge
pressure)
B. Determine heat capacity each inlet flow to compressor
C. Calculate te compressor power
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Based on this graph, we know that our volume inlet flow and
discharge pressure are in centrifugal range are. This is our volume flow
inlet and discharge pressure table.
Compressor Specifications
Volume Discharge
Inlet Flow Pressure
Compressor (kg/hour) (kPa)
C-100 222789,365 800
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Z = compressibility factor
= universal gas constant
T
R1 = inlet temperature, K
= standard pressure
= standard temperature
E = overall efficiency
q = gas flow rate
W = work (kJ/mol)
P2 = pressure outlet
P1 = pressure inlet
Discharge Temperature
Compressor Head
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Compressor Sizing
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Types of Pump
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Pump is used in order to move liquid from one unit to another. For our plant,
the total pumps we need are around 6 pumps. Here is the brief description of each
pump usage.
We selected centrifugal pump as our type of pump in our plant because the
flow rate and viscosity is low, and there is no high temperature of mixture in our
plant. We used calculation based on handbook chemical engineering and
mechanical fluids course. The material that we are going to use is carbon steel.
First we input all of our data that needed such as mass flow, density,
pressure suction and discharge (or pressure at destination), vapor pressure,
temperature suction, and static head in the excel.
In sizing pump, we use that all the pump efficiency is 75%
= (173)
Then we can calculate head by using this equation
= (174)
Head Actual
= (175)
FHP
= (176)
BHP
= (177)
NPSHA
NPSH is calculated by many factor. The most important variable here is the
length t of pipe itself, equivalent length of valve and bending.
1() 2 2
= (2 1 ) 2 (178)
NPSHR
= (179)
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2
= = ( + + )+ (180)
2
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