PT.

IPDS RAILROAD INDONESIA

GROUP 5

AIRLANGGA EKA S. (2714100058)

ARIFA NURIYANI (2714100080)

HALIDA AZMI FALAH (2714100090)

ICHSAN SALMAN (2714100129)

JOURDY PRADITYA (2714100133)

 UTILITIES
1. AIR NEEDED

AIR IS ONE OF THE IMPORTANT THINGS IN FACTORY PROCESS OR INDUSTRY. AIR CAN USUALLY
BE USED FOR CHEMICAL REACTION PROCESS. IN THIS FACTORY, AIR NEEDED FOR THE
CHEMICAL REACTION PROCESS IS:

No. Area/Equipment Quantity Unit Other Requirement

1 Ore Preparation 18 m3/min 0.6 Mpa

2 Electric Smelting

a. High Pressure 2 m3/min 1.2 Mpa

b. Low Pressure 9.5 m3/min 0.6 Mpa

c. Refining 3.5 m3/min 0.3 Mpa

TOTAL 33 m3/min 2.7 Mpa

2. WATER NEEDED

THIS UNIT OVERSEES SUPPLYING AND TREATING WATER TO MEET WATER REQUIREMENTS
AS FOLLOWS:

a. WATER FOR PUBLIC SUPPLY AND SANITATION

WATER FOR PUBLIC USE IS THE WATER NEEDED FOR FACILITIES IN FULFILLING THE NEEDS OF
EMPLOYEES LIKE TO TAKE A SHOWER, SINK, TOILET (MCK) AND FOR OTHER OFFICE NEEDS, AND
THE NEEDS OF HOME STAIRS. SANITARY WATER IS REQUIRED FOR WASHING OR CLEANING
EQUIPMENT MANUFACTURERS, UTILITIES, LABORATORIES AND OTHERS.
SOME OF THE REQUIREMENTS FOR SANITARY WATER IS AS FOLLOWS:

1. THE PHYSICAL REQUIREMENTS; BELOW ROOM TEMPERATURE, A COLORLESS, TASTELESS,

AND ODORLESS, TURBIDITY LEVELS <1 MG SIO2 / LITER.

2. TERMS OF CHEMISTRY; DOES NOT CONTAIN ORGANIC AND INORGANIC SUBSTANCES THAT
DISSOLVED IN WATER, OTHER HEAVY METALS THAT ARE TOXIC.

3. CONDITIONS FOR BIOLOGICAL (BACTERIOLOGICAL); DOES NOT CONTAIN GERMS/BACTERIA,

ESPECIALLY PATHOGENS.
Water needed for this general purpose is:

No. Needs Amount Unit

Water for employees (15 L/Men/Day)
1. 1.5 m3/day
Total employees are 100 Men
Water for employees housing
2. 1.56 m3/day
There are 13 houses (120L/House)
3. Water for cleanliness and landscaping 23 m3/day
Total amount needed 26.06 m3/day

b. Air Conditioning
The water required for the processes exchange/heat transfer in a heat exchanger with a purpose to transfer heat of a
substance in a stream into the water. Things that should be considered in the provision of cooling water are:
Water hardness that can cause scale (crust) in piping systems.
Microorganisms, such as bacteria, plankton lives in water rivers, develop and grow, causing fouling means of heat
exchangers.
Iron, which can corrode.
Oil, which is the cause of the disruption of the film corrosion.
Inhibitor, lowers the heat transfer coefficient, can be food microbes causing sediment.
 STANDARD QUALITY OF COOLING TOWER IS :
O CA HARDNESS AS CACO3 : < 150 PPM
O MG HARDNESS AS MGCO3 : < 100 PPM
O SILICA AS SIO2 : < 200 PPM
O TURBIDITY : < 10
O CL- AND SO42- : < 1000 PPM
O PH :68
O CA2+ : MAX 300 PPM
O SILICA : MAX 150 PPM
O TDS : MAX 2500 PPM
EQUIPMENT WHICH USES COOLING WATER CAN BE SEEN ON THE FOLLOWING TABLE

No Equipment Amount of needs Unit

1. Cooling Tower 1 1013.9 m3/hour
2. Cooling Tower 2 763.7 m3/hour
3. Cooling Bath 294.6 m3/hour
Total amount 2072.2 m3/hour
Recovery 90% 1864.98 m3/hour
Make up 10% 207.22 m3/hour
 COOLING WATER IS PRODUCED BY THE COOLING TOWER. UNIT OF THE COOLING WATER PROCESS
WATER WITH COOLING OF THE TEMPERATURE 50C BECOME 30C, TO BE USED MORE AS WATER FOR
THE COOLING PROCESS IN THE HEAT EXCHANGE APPARATUS OF A TOOL REQUIRE REFRIGERATION.
TOTAL OF COOLING WATER REQUIRED IS ABOUT 2072.2 M3/HOUR.

THE COOLING WATER COMING OUT OF THE HEAT TRANSFER MEDIA IN THE AREA THE PROCESS WILL BE
CIRCULATED AND COOLED AGAIN ENTIRELY IN IN THE COOLING TOWER. EVAPORATION AND WATER
LEAKAGE WILL OCCUR IN IN THIS COOLING TOWER. THEREFORE, TO KEEP THE AMOUNT OF WATER
COOLING WATER MUST BE ADDED THAT THE AMOUNT OF MAKEUP IN ACCORDANCE WITH THE AMOUNT
OF WATER LOST. THEN THE MAKEUP WATER FOR COOLING TOWERS AMOUNTING TO 207.22 M3/HOUR.

3. COMPRESSED AIR NEEDED

COMPRESSED AIR WILL BE NEEDED FOR THE PROCESS AND FOR GENERAL USE. COMPRESSED AIR IS
USED IN THE ELECTRIC ARC FURNACE. ELECTRICAL ARC FURNACE HAS HIGH PRESSURE ABOUT 1.4 MPA
IN 0.021 M3/MIN.

4. ELECTRICAL NEEDED
COMPLIANCE OF ELECTRICAL NEEDED IN PT. IPDS RAILROAD ARE HELPED BY OUR POWER PLANT THAT
IS BUILT, AND PLN AS A BACKUP DEVICE FOR AVOIDING DISTRACTIONS THAT MAY OCCUR IN OUR POWER
PLANT.
4.1 PROCESSING UNIT

TABLE 1. ELECTRICAL NEEDED FOR PROCESSING UNIT

Electrical Power Amount Total Electrical

No. Device Name
(kW) (pcs) Power (kW)
1. Screw Conveyor 5 1 5
2. Electric Arc Furnace 1130 1 1130
3. Extruder 57.25 1 57.25
4. Roller Conveyor 0.2 2 0.4
5. Re-Heating Furnace 1130 1 1130
6. Pump 0.7 6 4.2
7. Hot Rolled 3300 1 3300
TOTAL 5623.13
4.2 LIGHTING IN THE BUILDINGS

CHEMICAL ENGINEERS HANDBOOK. 3RD ED, IS RECOMMENDED FOR LIGHTING CALCULATION WITH LUMEN UNIT.
BY DETERMINING THE LAMP TYPE WILL BE USED, WE CAN CALCULATE TOTAL ELECTRICAL BEING PREPARED
FOR LIGHTING. THE FORMULA IS:
 L : LUMEN PER OUTLET

A : AREA, FT2

F : FOOD CANDLE (IN TABLE 13, PERRY 3TH)

U : UTILITIES COEFFICIENT (IN TABLE 16, PERRY 3TH)

D : LAMP EFFICIENCY (TABLE 16, PERRY 3TH)

TABLE 2. ELECTRICAL NEEDED FOR LIGHTING IN THE BUILDINGS

No. Buildings Name Area (m2) Area (ft2) F U Lumen

1. Security Post 70 753.46 20 0.50 37672.77

2. Mosque 100 1076.36 20 0.55 48925.68
3. Canteen 75 807.27 10 0.51 19786.12
4. Office 500 5381.82 20 0.58 231975.19
5. Health Clinic 100 1076.36 20 0,55 48925.68
6. Control Room 150 1614.55 35 0.60 117727.41
7. Laboratory 100 1076.36 35 0.60 78484.94
8. Storage 100 1076.36 5 0.52 12937.08
TOTAL 1195 12862.56 5636.85 4.41 596434.85
FOR ALL AREA IN THE BUILDINGS WILL BE PLANNED USING FLUORESCENT LAMP (40 WATT = 1.960
LUMEN/PCS). SO WE NEED :

596434.85
= 305
1960
= 40 305 = 12200 = .

4.3 LIGHTING ON THE NON-BUILDINGS

TABLE 3. ELECTRICAL NEEDED FOR LIGHTING ON THE NON-BUILDINGS

Area Non-
No. Area (m2) Area (ft2) F U Lumen
Buildings

1. Park Area 200 2152.73 10 0.49 54916.57

2. Process 3000 32290.95 10 0.59 684130.21

3. Utilities 1500 16145.47 10 0.59 342065.11

4. Road and Park 3500 37672.77 5 0.53 444254.37

TOTAL 8.200 88.261,92 35 2,2 1525366.27
FOR ALL AREA ON THE NON-BUILDINGS WILL BE PLANNED USING MERCURY LAMP (250 WATT = 10.000
LUMEN/PCS). SO WE NEED:
1.525.366,27
= 153
10.000
= 250 153 = 38.250 = ,

4.4 OTHER ELECTRICAL NEEDED

OTHER ELECTRICAL NEEDED IN OUR COMPANY CAN BE ESTIMATED ABOUT 20000 WATT FOR AIR CONDITIONER,
COMPUTER, ETC.

4.5 TOTAL ELECTRICAL NEEDED

TABLE 4. TOTAL ELECTRICAL NEEDED FOR THE COMPANY

No. Needed Power (kW)

1. Processing Unit 5623.13
2. Building Lighting 12.2
3. Non-Building Lighting 38.25
4. Other Needed 20
TOTAL 5693.58

TOTAL ELECTRICAL NEEDED AT ALL IS 5.693,58 KW = 5,69358 MW.

 SUPPORTING EQUIPMENT
1. 0O SCREW CONVEYOR

GIVEN: L = 250 M

W = 30 TONS/HOUR

BELT WIDTH = 20

ASKED : POWER = ... ?

ASSUMPTION: SCREW CONVEYOR THAT WE USED IS ASSUMED AS BELT CONVEYOR SO THAT THE
POWER CAN BE CALCULATED.

ANSWER:

30
= 100
65

= 46,15 /
 = + +

= 0,4 +
300 100

750 30
= 0,4 +
300 100

= 0,87

= 0

1,83
= 46,15
100
= 0,84

= 0,87 + 0 + 0,84
= , = ,
PROCESS FLOW DIAGRAM
COST OF PRODUCTION
MASS BALANCE