UNIVERSITAS INDONESIA

PRELIMINARY DESIGN OF CASEIN PLANT FROM SKIM MILK

PLANT DESIGN REPORT ASSIGNMENT 3

GROUP 10 ADI KHAFIDH PERSADA FITRI ANISA LATIFANI AYU CHAERUNNISA MUHAMMAD IKHLAS PIJAR RELIGIA

0906640702 0906557871 0906640822 0906489896 0906557953

ENGINEERING FACULTY BIOPROCESS ENGINEERING STUDY PROGRAM DEPOK SEPTEMBER 2012

CHAPTER 5 HEAT EXCHANGER NETWORK AND UTILITY UNIT ANALYSIS

We need a heat to make a casein in a casein plant which the heat needs the big energy, so we must make a plant to optimize the energy so that energy in our plant can be efficiently. To save energy optimally, we can calculate Heat Exchanger Network (HEN). The purpose of HEN calculating is to know the minimum of heat exchanger that is needed. The amount of heat exchanger is affecting the minimum utility for temperature differences that is predicted. Besides that, the calculating of HEN is also needed to know the cold utility is needed. To calculate of Heat Exchanger Network (HEN), we must follow this procedure: Determining the cold and hot stream Calculating the stream spesification and determining of T min Making of population streams Making of cascade diagram To know about the calculating of HEN, we can calculate one by one of the procedure above: 1.1 Heat Exchanger Network a. Determining The Cold and Hot streams In the first step, we can determine the cold and hot stream from the super pro data. The cold and hot stream data from super pro data can be looked in table below: Table 1.1. Hot Streams Data of Casein Plant
Number 1 R2 Stream Ts Tt Condition

78 35 Hot Table 1.2. Cold Streams Data of Casein Plant

Stream Ts Tt Condition Cold Cold Cold Cold

Number 1 2 3 4

R1 R2 W1 W2

25 35 25 25

40 78 65 45

b. Calculating The Stream Spesification and Determining of Tmin To calculate the stream spesification in our casein plant, we can use this formula below: Assumption: T min : 10 C

The Cp data is getting from process simulation in Hysys dan Super Pro software program. To find the target and supply temperature for our heat utility in cold and hot streams can be found with this formula: For Hot Stream = =
1 2 1 2

(3.1) (3.2)

For Cold Stream = + = +

1 2 1 2

(3.3) (3.4)

where Ts is supply temperature (C) and Tt is target temperature (C). For each hot and cold stream in our plant can be looked in the table below: Table 1.3. Streams Spesification Nama R1 R2 R2 W1 W2 Condition kg/h Cp (KJ/kgC) cold 11200 4,2 hot 12440 1,52 Cold 12440 1,52 cold 4309 4,2 Cold 4088 4,2 Tabel 1.4. Supply and Target Temperature Condition Cp 47040,00 18908,80 18908,80 18097,80 17169,60 Q (kJ/h) 7,06E+05 8,13E+05 8,13E+05 7,24E+05 3,43E+05

Nama

Cp Ts (C) Tt (C) Ts* Tt* Tm (C) (KJ/kgC) R1 cold 4,2 25 40 30 45 10 R2 hot 1,52 78 35 73 30 10 R2 Cold 1,52 35 78 40 83 10 W1 cold 4,2 25 65 30 70 10 W2 Cold 4,2 25 45 30 50 10 After making the stream spesification, we can make a stream population to know the

hot and cold stream distribution at the temperature something. c. Making Of Stream Population The temperature difference (H) is getting from this formula: = H interval has a negative value, it is called a surplus. (3.5) From the formula above, if H interval has a positive value, it is called a deficit. But, if

Interval Temp (C)

83 78
73

Stream Population
78

T (C) CpC-CpH H interval (MW) Surplus/defisit

10 3 0,0
0,0

0 0 0 6 27 126

defisit defisit defisit defisit defisit defisit

70 65
cp 1,52 cp 1,52

20 5

0,0 1,2 5,4 12,6

50 45

cp 4,2

cp 4,2

cp 4,2

5 35 35 25 25 10

40 30 25

Figure 5.1. Stream Population Graphic Stream population graphic is shown the hot and cold stream phenomenans in the temperature range something. This graphic is using to calculate the value of Q (calor) which is transmitted in the range of temperature where the value of Q will be used in cascade diagram. d. Making Of Cascade Diagram Cascade diagram shows the clear energy in temperature interval. Cascade process can be done during the energy can be transferred with the temperature gradient differences into the temperature level below. From the cascade diagram, the needing of hot and cold utility can be calculated based on energy distribution in each temperature interval. To know furtherly about the cascade diagram in our casein plant, we can look in the figure below:

hot utility

hot utility 0 MW

83
H = 0 73 H = 0

83
H = 0 73 H = 0

126 MW 126 MW 126 MW H = 0 126 MW H = 6 120 MW H = 27 93 MW H = 126 -33 MW cold utility

0 MW 0 MW H = 0 0 MW H = 6 -6 MW H = 27 -27 MW H = 126 -126 MW cold utility

70 50 45 40 30

70 50 45 40 30

Figure 1.4. Cascade Diagram From the cascade diagram above for heat exchanger network in our casein plant, we conclude that we need a hot and cold utility. It can look from the hot utility line where the hot utility in our plant is 126 MW atau sekitar 8,13 x 10 5 kJ/h. Besides that, the cold utility in our plant is 33 MW atau sekitar 3,15 x 105 kJ/h. From the curve above, the pinch node in our casein plant is 500C and 700C . So, our group decide the pinch node in our casein plant is 500C. After make the scheme, the grand composite curve can be made. This curve is to determine utility type that will be used. The curve is:

Grand Composite Curve

90 80 70 60 50 40 30 20 10 0 0 50 H (MW) 100 150 Temperature (oC)

Grand Composite

-50

Figure 1.5. Grand Composite Curve From figure above it can be seen that hot utility is needed to increase temperature of cold stream process. In this case, we need utility to fulfill the hot stream.

1.2 Utility 1.2.1 Water Utility Water supply system is needed to support the sustainability of the production plant. Utility water is required as process water, cooling water in heat exchanger systems, boiler feed water, equipment wash water and domestic water needs. The design of the water supply system based on the ease of water collection, treatment system efficiency and economic factors. In the casein plant used several types of water, namely, process water, cooling water, boiler feed water, equipment wash water, domestic water and fire water. Can be explained as follows: 1.2.1.1Water Utility Classification a. Process Water Most of the water used in the dissolution and dilution systems. In unit steam explosion, water is required to dissolve sulfuric acid for coagulation process. Besides that, process water is used in the last step of washing tank. Capacity of water needed in the process in an casein plant is at 30255,22 kg/day. b. Cooling Water Cooling water system is used to maintain the temperature in the washing reactor. All water used in the cooling system using water at ambient temperature is assumed to be 25oC. Ice water is the most common form of cooling water used in dairies. Water is cooled in an ice water tank where ice is formed on in chiller. The source of cooling water is come from the PT. KIJA. The need for cooling water at the plant reached 156,97 kg/day. The cooling water is needed in our plant can look in the table below: Tabel 2.1.1.2. Cooling Water In Our Plant Unit Acidification unit Plate Heat Exchanger Total Cooling water needs (kg/h) 117,28 39,69 156,97

c. Domestic Water This water is used to meet the water needs of the staff and factory workers. Domestic water includes water MCK (bathing, washing, toilet), drinking water, water for watering plants and other water needs. Assumed domestic needs for each person is 100 liters/day. Thus, the total water needed for domestic water is 10,000 liters/day.

d. Water Fire Extinguisher Firefighting water used to extinguish the fire in case of fire. Water is one of the water reserves that can be used at any time. Firefighting water used was water with the low specs, but has undergone treatment first. The amount of water required for fire is assumed to 10,000 kg /day. e. Water Resources Water supply to the plant will be taken from Jababeka industrial area manager, PT. KIJA. PT. KIJA independently manage all water providers to the needs of industries that exist within the industry. Water supplied by PT. KIJA is considered clean enough and qualify for use as water for industrial plants. So in the factory there is no clean water management facilities further. So, the total amount of water utility in our plant is 50412,196 kg/h or 50412,196 L/day. 1.2.2 Gas Utility Gas Utility is need to make an air for spray drying. It comes from compressor. In compresor, the refrigerant vapour is compressed to a high pressure in the compressor. This increases the temperature of the vapour. The work carried out by the compressor is transferred to the gas in the form of heat. This means that the gas leaving the Compressor contains a greater quantity of heat than was absorbed in the evaporator. All this heat must therefore be removed by cooling in the condenser. The most commonly used refrigerating compressor is the piston compressor. The gas is drawn into cylinders and compressed by pistons in the cylinders. The machines can be equipped with a varying number of cylinders. They are available for refrigerating capacities between 0,1 and 400 kW. The screw compressor (Figure 2.4), is also very common nowadays, especially for higher capacities. The principal components are two helical rotors installed in a common housing. As the rotors turn, gas is drawn into the gaps between the teeth and is trapped in the clearances. The volume between the teeth is progressively reduced as the captive gas is conveyed along the length of the rotors, so the gas is gradually compressed and the pressure increases. The compressed vapour continues to the condenser. Oil is sprayed on the meshing faces in most screw compressors in order to reduce leakage between the gaps in the rotors. In this way it is possible to obtain high efficiency even at low speeds. The oil is removed from the vapour in an oil trap before the condenser. Screw compressors are used in large installations. One of the greatest advantages of the screw compressor is that the capacity can be varied down to 10 % of full power without excessive electric power losses.

Figure 2.4. Screw Conveyor Source: Dairy Proceesing Handbook Generally, diesel is used as fuel material in screw compressor. We can assumed that efficient in screw conveyor as 40%. So, the fuel utility in the screw compressor is : 0,4 m = needing calor/heating value of fuel 0,4 m = 33875 J/0,00334 J/l m = 25355538 ,92 l 1.2.3 Steam Utility Generation of the heating medium takes place in steam boilers which are sometimes located in the heating plant. The boiler is usually fuelled with oil, coal or gas. Thermal energy is released by the burning fuel and absorbed by the heating medium. The efficiency of the boiler is in the range of 80 92 %, and heat losses in the piping system often amount to about 15 %. Consequently, only between 65 and 77 % of the total thermal energy of the fuel can be utilised in production. From the point of view of operating costs, it is most important that the efficiency of the boiler does not drop below the minimum level, and for this reason, boiler efficiency is very closely checked in the dairy. The steam temperature in the steam system described below must be between 140 and 150 C. In the case of saturated steam, this is equivalent to a gauge pressure of 270 385 kPa (2,7 3,8 bar). The boilers operate at a considerably higher pressure, as a rule 900 1 100 kPa (9 11 bar), so that smaller piping dimensions can be used to compensate for heat and pressure losses in the system. Figure 2.1 is a simplified diagram of the steam system and the distribution network. The water used for generation of steam is referred to as feed water. Makeup water often contains calcium salts, which make the water hard. Treatment of feed water is often

necessary, as it contains oxygen and carbon dioxide. If this is not done, the salts will be deposited in the system and form scale in the boiler, resulting in drastically reduced efficiency. Oxygen can cause severe corrosion in the water and steam parts. Water-softening filters (10) are therefore included in the system. They remove the calcium and magnesium salts, and a de-gassing apparatus (11) removes the gases in the feed water. Impurities in the form of sludge are removed by blowing down the boiler. Chemical conditioning of boiler water and treatment of boiler feed water are necessary to keep the steam system in good operating condition.

Figure 2.1. Steam Production and Distribution Steam Source: Dairy Processing Handbook
Notes:

A feed water pump keeps the water in the boiler at a constant level. The water in the boiler is heated by the burning fuel and converted to steam. It takes a great deal of heat, about 2 260 kJ (540 kcal) at atmospheric pressure, to convert one kilogram of water to steam. This heat, which is referred to as vaporisation heat, will subsequently be released as the steam

condenses on the heat transfer surfaces at the points of consumption (5). The condensed steam, condensate, is collected in steam traps (6) and a condensate tank (7) and pumped back to the boiler by a condensate pump. Two main types of boilers are used for the generation of steam: the fire tube boiler (which is the most common type in dairies) and the water tube boiler. The choice is influenced by the required steam pressure and steam power, i.e. the quantity of steam utilised at a given time. Boilers for low pressures and small power outputs are often tubular boilers in which the flue gases pass inside the tubes. Boilers for high pressures and large steam power outputs are mostly water-tube boilers, in which the water is circulated inside the tubes. Figure 2.2 shows the principle of the fire tube boiler. The hot flue gases are blown by a fan through the tubes. Heat from the flue gases is conducted through the walls of the tubes to the water surrounding the outside of the tubes. The water is heated to boiling point and the steam is collected in the steam dome for distribution to the system.

Figure 2.2. Fire Tube Boiler Source: Dairy Processing Handbook

When the pressure inside the steam dome reaches the required (pre-set) level, the steam valve can be opened and the steam flows to the points of consumption. The burner is started and stopped automatically, keeping the steam pressure at the required level. Feed water is added so that the correct water level is maintained in the boiler. The safety valve opens if the highest permitted pressure in the steam dome is exceeded. Water-tube boilers (Figure 2.3) are available in a wide range of models. The principle is that the feed water passes through tubes which are externally heated by the flue gases. Steam generation takes place in the tubes, which are inclined so that the steam can rise to the steam dome. The steam passes into the two upper domes via the superheater before being fed into the distribution system. The steam is heated by the flue gases for a second time in the

superheater i.e. the steam is superheated, and becomes dryer as a result. The lower dome also collects sediment sludge, the impurities which were present in the feed water. The sludge is removed from this dome by bottom-blowing the boiler. In other types of boilers, the sludge collects in the bottom of the boiler.

Figure 2.3. Water-Tube Boiler Source: Dairy Processing Handbook

The steam which passes through the piping system is cooled by the surrounding air and consequently starts to condense. It is possible to reduce this condensation by insulating the pipes, but condensation can never be completely avoided. The pipes must therefore be installed with a slight slope towards the condensate collection points, which are located in various parts of the piping system. Steam traps are installed at these points. They permit the condensate to pass (and preferably also air), but not steam. The condensate is collected in the same way at the various steam consumption points and is returned to a collecting tank in the heating plant by condensate pumps and a piping system. Condensate can be returned to the feed water tank by steam pressure without using a condensate tank or condensate pump. This system is very often used.

Figure 2.4. Stream Distribution Source: Dairy Processing Handbook

Generally, the fuel which is used in boiler is diesel. It is assumed that the steam required in the plant is entirely derived from fossil material. It is assumed that the boiler used to use diesel as fuel. It is assumed that the efficiency of the boiler which is owned by the boiler plant is 40%. Thus, the diesel fuel used to generate steam in the plant is equal to: 0,4 m = needing calor/heating value of fuel 0,4 m = 33875J/0,00334 J/l m = 25355538 ,92 l 1.2.4 Electricity Utility As the plant in general, to run the equipment contained in the bioethanol plant required no small amount of energy. Equipment that requires a supply of energy, among others: Pump Plate Heat Exchanger Washing Tank Centrifugal Decanter Spray Drying Conveyor

Electric needs at the casein plant can be seen in the following table: Table 2.1. Needing Energy In Casein Plant
Demand Of Energy
Pump For Mixing Tank P-101 Pump For Dilution Of HCl P-102 Pump For Washing Tank P-103 Pump For Washing Tank P-104 Pump For Milk P-105 Pump For Curd Casein P-106 Plate Heat Exchanger Heat Exchanger 1 Heat Exchanger 2 Heat Exchanger 3 Washing Tank 1 Washing Tank 2 Mixing Tank Decanter 1 Decanter 2 Decanter 3 Fan Spray Drying Spray Drying Pneumatic Conveyor 1 Pneumatic Conveyor 2 Pneumatic Conveyor 3 HCl Storage Tank Water Storage Tank Total kebutuhan listrik untuk proses 0,01 0,01 1,34 170,89 170,89 170,89 4,80 8,74 2,68 2,68 2,68 1,34 1,34

Hp
1 0,5 0,5 0,5 2 2 35444,11

kw
0,74 0,37 0,37 0,37 1,49 1,49 26430,68 2,3 2,3 2,3 0,01 0,01 1 127434 127,434 127,434 3,58 5 2 2 2 1 1

kwh
17,89 8,94 8,94 8,94 35,79 35,79 634336,32 55,2 55,2 55,2 0,24 0,24 24 2986,42 2986,42 2986,42 143,2 120 48 48 48 24 24 644057,15

Electricity is needed on the basis of casein plant from skim milk is a power type AC (accuired current). The power requirement of the plant's total amounted to 644057,15 kWh / day. While supporting the need for lighting and other assumed 5% of the total energy that is 32202,85 kwh / day. So the total electricity needs of the bioethanol plant 676260,01 kWh for each day. Electrical power is largely used for two main purposes. The first necessity that requires electrical power is the need of the production process. The second purpose is to use the power of production support facilities. Power to support facilities used for lighting and air-conditioning (AC) in the office, laboratory, workshop and control room, air supply (tap

and clean), water supply (and the net), and the sewage treatment plant. Electricity in casein plant is supplying from PT. Cikarang Listrisindo. To know about the all of utility in our plant can be showed in table below: Table 2.2. The Utility Of Casein Plant
Utility Water Electricity Diesel Source PT. KIJA PT. Cikarang Listrisindo Pertamina Demand per year

50412,196 kg/h 676260,01 kWh

50711,07 Kl

References:
Albert, Johan. 1991. Centrifugal Decanter Handbook. Newyork: McGraw Hill Book Co. Paundhitro, Slamet. 2008. Spray Drying Handbook. Newyork: McGraw Hill Book Co. Robert, Kevin. 2008. Unit Operation Of Chemical Engineering. Newyork: McGraw Hill Book Co. Smith, Julian 2008. Dairy Processing Handbook.. Newyork: McGraw Hill Book Co.