Beruflich Dokumente
Kultur Dokumente
Report Assignment 3
GROUP 23
GROUP PERSONNEL:
ANDERSEN (1406604626)
ARIF HENDRAWAN (1406531763)
DIMAS NURWANSYAH (1406531624)
EDWARD GUSTAF (1406531920)
MAULINA CAHYA INDAH S. (1406531845)
2 Universitas Indonesia
flash separator, 1 PF Filter, 1 boiler, 9 condenser, 3 reboiler, pumps, 1 turbine, 4
heat exchangers, 3 distillation column, 1 clarifier, 1 centrifuge, 2 reverse osmosis
train, cartridge filter, ion exchangers, deaerators and photovoltaic. All the process
equipment mentioned above should be designed and calculated to continue to the
next step of preliminary design which is instrument analysis and economic
analysis. In terms of the processes that occur in the chemical industry in general,
consists of two kinds of processes; the chemical process / chemical reaction (to
form new substances) and physical processes (physical changes). All the
equipment is sized manually, beside that there are several equipment that we sized
with software as comparison. Also, some equipment is designed using vendor data
and information, such as Babcock & Wilcox for boiler and DOW for reverse
osmosis.
In order to make easier, efficient and safe plant, piping and
instrumentation diagram is also play an important role needed to put controls of
some variable in plant production such as temperature, pressure, flow rate, pH and
level. on the other hand, this instrumentation also makes this plant safely to work
with high pressure operating condition. The instrumentation in this plant divided
into controller, transmitter and analyser which works together in controlling plant.
This piping and instrumentation diagrams are divided into five areas based on
process flow diagram in previous assignment, which are pre-treatment, ethanol
production, ethanol fermentation, condensate treatment and electricity production.
The consideration when determining control for process are including
safety factor, environmental protection factor, equipment protection factor,
smooth operation and production rate factor, product quality factor, profit and
monitoring diagnosis. First thing to consider is safety factor such as pressure in
vessels which is controlled using pressure safety valve. Environmental factor is
also considered in controlling temperature and quality of waste water from the
plant. Equipment protection is also important for example protection for pumps
using level controller to ensure that only liquid which entering the pumps. Flow
controller is also used to ensure smooth operation and production rate. Product
quality is controlled using analyszer in ethanol product.
3 Universitas Indonesia
LIST OF CONTENTS
EXECUTIVE SUMMARY..................................................................................... 2
LIST OF CONTENTS ............................................................................................ 4
LIST OF FIGURES ................................................................................................ 5
LIST OF TABLES .................................................................................................. 6
CHAPTER 1 EQUIPMENT SIZING ..................................................................... 8
1.1. Main Process Unit Sizing ............................................................................. 8
1.1.1. Biomass Storage (Warehouse) .............................................................. 8
1.1.2. Storage Tank ......................................................................................... 8
1.1.3. Pipe ..................................................................................................... 11
1.1.4. Reactor ................................................................................................ 12
1.1.5. Flash Separator ................................................................................... 15
1.1.6. Turbine ................................................................................................ 16
1.1.9. Heat Exchanger ................................................................................... 21
1.1.10. Distillation Column............................................................................. 30
1.1.11. Pump ................................................................................................... 32
1.1.12. Belt Conveyor ..................................................................................... 34
1.1.13. Clarifier ............................................................................................... 35
1.1.14. Reverse Osmosis ................................................................................. 35
1.1.15. Absorption Chiller .............................................................................. 36
1.2. Water Utility Sizing .................................................................................. 37
CHAPTER 2 PIPING AND INSTRUMENTATION DIAGRAM (P&ID) ......... 45
2.1. Piping and Instrumentation Design ............................................................ 45
2.2. Plant Control Tabulation ............................................................................ 52
CHAPTER 3 CONCLUSION ............................................................................... 59
REFERENCE ........................................................................................................ 60
APPENDICES ...................................................................................................... 62
4 Universitas Indonesia
LIST OF FIGURES
5 Universitas Indonesia
LIST OF TABLES
6 Universitas Indonesia
Table 1.39. Clarifier Specification ........................................................................ 35
Table 1.40. Reverse Osmosis Specification .......................................................... 35
Table 1.41. Absorption Chiller Specification ....................................................... 36
Table 1.42. Mass Balance Water Utility per Equipment ...................................... 37
Table 1 43. Vessel Specification (V-106) ............................................................. 38
Table 1.44. Vessel Specification (V-ST) .............................................................. 38
Table 1.45. Cation Exchanger Specification ......................................................... 39
Table 1.46. Anion Exchanger Specification ......................................................... 39
Table 1.47. Deaerator Specification ...................................................................... 39
Table 1.48. Strainer Pump Specification (P-501) ................................................. 40
Table 1.49. SW RO Booster Pump Specification (P-502) .................................... 41
Table 1.50. Polishing Pump Specification (P-503) ............................................... 41
Table 1.51. High Pressure Pump Specification (P-504) ....................................... 42
Table 1.52. Ion Exchange Pump Specification (P-505) ........................................ 42
Table 1.53. Deaerator Pump Specification (P-506) .............................................. 43
Table 1.54. Boiler Feed Water Pump Specification (P-507) ................................ 43
Table 1.55. Water Utility Pipe Specification ........................................................ 44
Table 2.1. Plant Control Tabulation ...................................................................... 52
Table B.1. Storage Tank Capacity ........................................................................ 62
Table E.1. Flash Separator Calculation ................................................................. 74
Table I.1. Typical Overall Coefficicents ............................................................... 80
Table I.2. Typical Tube Properties ........................................................................ 81
Table I.3. Typical Shell Properties ........................................................................ 81
Table I 4. Typical Fouling Factor ......................................................................... 84
Table I.5. PFHE Parameter Range ........................................................................ 84
Table I.6. Approximate Values of Overall Heat Transfer Coefficient .................. 85
Table I.7. Fouling Factor Coefficient for PFHE ................................................... 85
Table J.1. Mass and Mole Balance........................................................................ 86
Table J.2. Properties of Column............................................................................ 86
Table J.3. Properties of Reboiler and Condenser .................................................. 87
Table J.4. Volumetric Flow Rate of Vapor ........................................................... 88
Table J.5. Velocity of Vapor ................................................................................. 88
Table J.6. Minimum cross-sectional area and diameter needed............................ 89
Table L.1. Belt Conveyor Data for Capacity ........................................................ 92
Table N.1. Initial Data for Reverse Osmosis ........................................................ 95
Table N.2. Membrane Element Type .................................................................... 95
Table N.3. Active Membrane Area ....................................................................... 96
Table N.4. Average Membrane Flux..................................................................... 96
Table N.5. Correlation Between System Recovery and Number of Stages .......... 97
7 Universitas Indonesia
CHAPTER 1
EQUIPMENT SIZING
Equipment Specification
Equipment Name Empty Fruit Bunches Warehouse
Equipment Code W-1
Functiom Storage for Empty Fruit Bunches
(Raw Material)
Number of Unit 1
Material Concrete
Type Rectangle building with a triangular
prism roofs
Operation Data
Temperature 30
Pressure 1 atm
Bulk Density 1,150 kg/m3
Dimension
Capacity 589 tons
Length 14.64 m
Width 10.98 m
Height 3.66M
Universitas Indonesia
10
Universitas Indonesia
11
1.1.3. Pipe
Pipe is an important element in a plant because it is connecting one
equipment with another. Plant layout is needed to sizing the whole pipe, this pipe
sizing is just preferred to the pipeline through the pump.
Universitas Indonesia
12
V 1 m/s
A 0.031794289 m2
ID 0.201 m
ID 201.252 mm
Nominal 8
Schedule 40
Length 5 m
1.1.4. Reactor
1.1.4.1. Hydrolisis Reactor
Hydrolysis reactor acts like a continuous stirred tank reactor. In this
polygeneration plant the reactor is used to hydrolyze cellulose, and hemicellulose
to be smaller molecule, monomer, known as glucose and xylose. The specification
of hydrolysis reactor is shown from table 1.10.
Hydrolysis Reactor
Flow Reactor
Fao 2490.00 mol/s
X 0.95 %
K 964.00 1/min
Ca 50.48 mol/m3
V 0.05 m3/s
Volume of Fluid 2.92 m3/min
Universitas Indonesia
13
Volume of
3.21 m3
Reactor
Diameter of
1.24 m
Reactor
Height of Fluid 2.54 m
Height of
2.8 m
Reactor
Shell Thickness 1.17 cm
Diameter of
0.434 m
Impeller
Length of Baffle 0.124 m
Position of
Impeller from 0.41 m
Bottom
Specific Power
2 kW/m3
for Agitation
Residence Time 1 min
Neutralization Reactor
Flow Reactor
Fao 104.02 mol/s
X 0.94 %
K 728.00 1/min
Ca 44.99 mol/m3
V 0.003 m3/s
Volume of Fluid 0.18 m3/min
Volume of
0.20 m3
Reactor
Diameter of
0.5 m
Reactor
Height of Fluid 1.005 m
Height of Reactor 1.16 m
Shell Thickness 1.09 cm
Diameter of
0.175 m
Impeller
Universitas Indonesia
14
Seed Fermenter
Batch Reactor
Glucose &
Component Unit
Xylose
X 0.93 %
0.04 1/h
t 72.00 H
Volume of Fluid 27.26 m3
Volume of
29.99 m3
Reactor
Simplified Michaelis
Kinetics Model
Menten (First Order)
Diameter of
2.62 m
Reactor
Height of Fluid 5.36 m
Height of Reactor 5.9 m
Shell Thickness 1.306 cm
Diameter of
0.917 m
Impeller
Length of Baffle 0.262 m
Position of
Impeller from 0.87 m
Bottom
Specific Power
3 kW/m3
for Agitation
Total Needed
2 Unit
Seed Fermenter
Universitas Indonesia
15
1.1.4.5.Main Fermenter
Main fermenter also categorized as bioreactor that acts like batch reactor.
It is using bacteria from seed fermenter to produce bioethanol from glucose and
xylose fermentation. The specification of main fermenter is shown from Table
1.13.
Main Fermenter
Batch Reactor
Glucose
Component & Unit
Xylose
X 0.93 %
0.13 1/h
T 20.00 H
Volume of Fluid 151.03 m3
Volume of Reactor 166.13 m3
Simplified
Kinetics Model Michaelis Menten
(First Order)
Diameter of Reactor 4.63 m
Height of Fluid 9.48 m
Height of Reactor 10.42 m
Shell Thickness 1.62 cm
Diameter of Impeller 1.6205 m
Length of Baffle 0.463 m
Position of Impeller
1.54 m
from Bottom
Specific Power for
3 kW/m3
Agitation
Total Needed Main
1 Unit
Fermenter
Universitas Indonesia
16
Separator
P 14.69 Psi
S 80 Psi
R 0.14 m
E 0.85 Efficiency
A min 0.06 m2
D min 0.28 m
L 0.56 m
L/D 2.00 Dimensionless
Separator
1.44 cm
thickness
Head & bottom
0.86 cm & tori spherical
thickness & type
1.1.6. Turbine
Turbine is used to generate electricity and to lower steam pressure in outlet
stream. The turbine in this polygeneration is using 3 turbines and each of turbines
have several stages. The specification of turbine is shown from Table 1.15 until
1.17.
1.1.6.1.High PressureTurbiner
Table 1.15. High Pressure Turbine Specification
Universitas Indonesia
17
Design Specification
Mode of Operation Back Pressure Turbine
Number of Stages 5
Rotating Speed
(rpm) 4800
Power (kW) 11124.76
Generator
Efficiency (%) 0.85
Diameter (m) 0.945
Casing turbine: Carbon steel
Rotor of turbine:
Stainless steel type 12% Cr, 6% Ni,
1.5% Mo
Material Stator: Carbon steel
Blade: AISI 403
Diaphragm: Carbon steel
Universitas Indonesia
18
Design Specification
Mode of Operation Back Pressure Turbine
Number of Stages 3
Rotating Speed (rpm) 3800
Power (kW) 1279
Generator Efficiency
(%) 0.85
Diameter (m) 0.682
Casing turbine: Carbon steel
Rotor of turbine:
Stainless steel type 12% Cr, 6%
Ni, 1.5% Mo
Material Stator: Carbon steel
Blade: AISI 403
Diaphragm: Carbon steel
Universitas Indonesia
19
Design Specification
Mode of Operation Back Pressure Turbine
Number of Stages
Rotating Speed (rpm)
Power (kW) 12660
Generator Efficiency (%) 0.85
Diameter (m) 0.682
Casing turbine: Carbon steel
Rotor of turbine:
Stainless steel type 12% Cr, 6% Ni,
1.5% Mo
Material Stator: Carbon steel
Blade: AISI 403
Diaphragm: Carbon steel
Design Specification
Area Filter (m2) 151.4
Cake Thickness (cm) 1.96
1.1.8. Boiler
Sizing of boiler to generate steam for electricity and steam utility is done using
benchmarking and vendor data collecting method. The data of similar plant using
lignin as fuel for the boiler to generate steam in a power plant have been collected.
The only designed data are furnace width and depth. The specification is shown in
Table 1.19.
Universitas Indonesia
20
Equipment Specification
Vendor Babcock & Wilcox
Boiler System TowerPak Stirling Power
Fuel Type Biomass (Lignin)
Steam Produced 114969 kg/h
Steam Pressure 900 psig
Steam Temperature 454 C
Efficiency 50%
Boiler
Type Two Drum S. P. B.
No. of Boilers 1
Design Pressure 1050 Psi
Heating Surface 42.32 m2
Furnace Width 6.823 m
Furnace Depth 6.203 m
Steam Drum I.D. 1.8 m
Mud Drum I.D. 1.2 m
Superheater
Type Parallel Flow
Gas Passes 1
Steam Passes 12
Heating Surface 37 m2
Economizer
Type Fin Tube
Design Pressure 1075 Psi
Heating Surface 78 m2
Universitas Indonesia
21
Equipment Specification
Equipment Name Heat Exchanger
Equipment Code E-302
Type Shell and Tube
Operating Condition
Shell Tube
Data
Side Side
Fluid Flow (kg/h) 114968 38143
o
Temperature in ( C) 50 255
Temperature out (oC) 176 193
Operating pressure
6302 1317
(kPa)
Operating Conditions
No. of passes 1 2
2
Fouling factor (m
o 0.0002 0.00009
C/W)
Heat Duty (MW) 17.821
T LMTD ( C)o
92.577
Overall U (W/m2 oC) 1032.160
Design Specification
Type of unit Fixed tube
Material SS-316 or SA-240
Heat Transfer Area
186.496
(m2)
Tube OD (mm) 19.050
Tube Length (m) 4.880
Shell ID (m) 0.540
Tube Pitch (mm) 24
Tube Thickness (mm) 0.710
Number of tubes 319
Tube arrangement Triangular
Universitas Indonesia
22
Equipment Specification
Equipment Name Heat Exchanger
Equipment Code E401
Type Shell and Tube
Operating Condition
Shell Tube
Data
Side Side
Fluid Flow (kg/h) 2154 38143
o
Temperature in ( C) 162 194
Temperature out (oC) 190 193
Operating pressure
101 1317.225
(kPa)
No. of passes 1 2
Fouling factor (m2
o 0.0002 0.00009
C/W)
Heat Duty (MW) 0.441
T LMTD (oC) 11.980
Overall U (W/m2 oC) 574.163
Design Specification
Type of unit Fixed tube
Material SS-316 or SA-240
Heat Transfer Area
64.078
(m2)
Tube OD (mm) 19.050
Tube Length (m) 4.880
Shell ID (m) 0.540
Tube Pitch (mm) 24
Tube Thickness (mm) 0.710
Number of tubes 110
Tube arrangement Triangular
1.1.9.2. Condenser
Condenser in this polygeneration plant including condensate condensers
and distillation columns condensers. The specification is shown from Table 1.22
until Table 1.23.
Universitas Indonesia
23
Equipment Specification
Equipment Name Condenser
Equipment Code E-403
Type Plate and Frame
Operation Data
LMTD (oC) 53.046
Heat Duty (MW) 0.045
Fouling Factor (m2 oC/W) 0.000081
Overall U (W/m2 oC) 642.3004664
Design Specification
Plate Area (m2) 0.03
Plate Length (m) 0.110
Plate Width (m) 0.274
Plate Spacing (m) 0.005
Plate Thickness (m) 0.003
Amount of Plate 45
Equipment Specification
Equipment Name Condenser
Equipment Code E404
Type Shell and Tube
Operating Condition
Shell Tube
Data
Side Side
Fluid Flow (kg/h) 462440 38143
Temperature in (oC) 25 193
Operating Condition
Temperature out (oC) 45 49
Operating pressure (kPa) 101 1317.225
No. of passes 1 2
Fouling factor (m2 oC/W) 0.00009 0.00009
Heat Duty (MW) 8.247
Universitas Indonesia
24
Design Specification
Type of unit Fixed tube
Material SS-316 or SA-240
2
Heat Transfer Area (m ) 41.811
Tube OD (mm) 19.050
Tube Length (m) 4.880
Shell ID (m) 0.540
Tube Pitch (mm) 24
Tube Thickness (mm) 0.710
Number of tubes 72
Tube arrangement Triangular
Equipment Specification
Equipment Name Condenser
Equipment Code E402
Type Shell and Tube
Operating Condition
Shell Tube
Data
Side Side
Fluid Flow (kg/h) 1851692 75782
Temperature in (oC) 25 49
Temperature out (oC) 45 49
Operating pressure (kPa) 101 11.69351
No. of passes 1 2
Fouling factor (m2 oC/W) 0.002 0.00009
Heat Duty (MW) 44.387
T LMTD (oC) 11.118
Overall U (W/m2 oC) 347.912
Design Specification
Type of unit Fixed tube
Material SS-316 or SA-240
2
Heat Transfer Area (m ) 11475.241
Tube OD (mm) 19.050
Tube Length (m) 4.880
Shell ID (m) 0.540
Tube Pitch (mm) 24
Universitas Indonesia
25
Equipment Specification
Equipment Name Condenser
Equipment Code E502
Type Shell and Tube
Operating Condition
Shell Tube
Data
Side Side
Fluid Flow (kg/h) 44066 823
o
Temperature in ( C) 25 78
o
Temperature out ( C) 70 77
Operating pressure
101 101.325
(kPa)
No. of passes 1 2
2
Fouling factor (m
o 0.00009 0.00009
C/W)
Heat Duty (MW) 2.324
T LMTD ( C)o
23.230
2o
Overall U (W/m C) 710.204
Design Specification
Type of unit Fixed tube
Material SS-316 or SA-240
Heat Transfer Area
140.882
(m2)
Tube OD (mm) 19.050
Tube Length (m) 4.880
Shell ID (m) 0.540
Tube Pitch (mm) 24
Tube Thickness (mm) 0.710
Number of tubes 241
Tube arrangement Triangular
Universitas Indonesia
26
Equipment Specification
Equipment Name Condenser
Equipment Code E504
Type Shell and Tube
Operating Condition
Shell Tube
Data
Side Side
Fluid Flow (kg/h) 7052 776
o
Temperature in ( C) 25 78
Temperature out (oC) 70 77
Operating pressure
101 101.325
(kPa)
No. of passes 1 2
Fouling factor (m2
o 0.00009 0.00009
C/W)
Heat Duty (MW) 0.372
T LMTD (oC) 23.324
Overall U (W/m2 oC) 756.239
Design Specification
Type of unit Fixed tube
Material SS-316 or SA-240
Heat Transfer Area
21.089
(m2)
Tube OD (mm) 19.050
Tube Length (m) 4.880
Shell ID (m) 0.540
Tube Pitch (mm) 24
Tube Thickness (mm) 0.710
Number of tubes 36
Tube arrangement Triangular
Equipment Specification
Equipment Name Condenser
Equipment Code E506
Type Shell and Tube
Universitas Indonesia
27
Operating Condition
Shell Tube
Data
Side Side
Fluid Flow (kg/h) 2057 125
o
Temperature in ( C) 25 87
Temperature out (oC) 70 86
Operating pressure
101 42.05803
(kPa)
No. of passes 1 2
Fouling factor (m2
o 0.00009 0.00009
C/W)
Heat Duty (MW) 0.108
T LMTD (oC) 34.453
Overall U (W/m2 oC) 759.695
Design Specification
Type of unit Fixed tube
Material SS-316 or SA-240
Heat Transfer Area
15.743
(m2)
Tube OD (mm) 19.050
Tube Length (m) 4.880
Shell ID (m) 0.540
Tube Pitch (mm) 24
Tube Thickness (mm) 0.710
Number of tubes 27
Tube arrangement Triangular
1.1.9.3. Reboiler
Reboiler is designed using the same steps as designing shell and tube heat
exchanger. The type used for reboiler is kettle heat exchanger. The specification
of three reboiler for three distillation columns is shown from Table 1.28 through
Table 1.30.
Universitas Indonesia
28
Equipment Specification
Equipment Name Reboiler
Equipment Code E503
Type Kettle
Operating Condition
Shell Tube
Data
Side Side
Fluid Flow (kg/h) 10244 38143
o
Temperature in ( C) 100 190
o
Temperature out ( C) 101 135
Operating pressure
101 1317.225
(kPa)
No. of passes 1 2
2
Fouling factor (m
o 0.00009 0.00009
C/W)
Heat Duty (MW) 2.727
T LMTD ( C)o
57.682
Overall U (W/m2 oC) 1458.705
Design Specification
Type of unit Fixed tube
Material SS-316 or SA-240
Heat Transfer Area
32.405
(m2)
Tube OD (mm) 19.050
Tube Length (m) 4.880
Shell ID (m) 0.540
Tube Pitch (mm) 24
Tube Thickness (mm) 0.710
Number of tubes 56
Tube arrangement Triangular
Equipment Specification
Equipment Name Reboiler
Equipment Code E505
Type Kettle
Universitas Indonesia
29
Operating Condition
Shell Tube
Data
Side Side
Fluid Flow (kg/h) 1607 1044
o
Temperature in ( C) 113 221
o
Temperature out ( C) 149 178
Operating pressure
101 962.5875
(kPa)
No. of passes 1 2
2
Fouling factor (m
o 0.00009 0.00009
C/W)
Heat Duty (MW) 0.418
T LMTD ( C)o
64.610
Overall U (W/m2 oC) 763.117
Design Specification
Type of unit Fixed tube
Material SS-316 or SA-240
Heat Transfer Area
8.488
(m2)
Tube OD (mm) 19.050
Tube Length (m) 4.880
Shell ID (m) 0.540
Tube Pitch (mm) 24
Tube Thickness (mm) 0.710
Number of tubes 15
Tube arrangement Triangular
Equipment Specification
Equipment Name Reboiler
Equipment Code E507
Type Kettle
Operating Condition
Shell Tube
Data
Side Side
Fluid Flow (kg/h) 1038 38143
o
Temperature in ( C) 143 192
o
Temperature out ( C) 165 190
Universitas Indonesia
30
Operating Conditions
Operating pressure
42 1317.225
(kPa)
No. of passes 1 2
2
Fouling factor (m
o 0.0002 0.00009
C/W)
Heat Duty (MW) 0.111
T LMTD ( C)o
36.430
2o
Overall U (W/m C) 738.534
Design Specification
Type of unit Fixed tube
Material SS-316 or SA-240
Heat Transfer Area
4.132
(m2)
Tube OD (mm) 19.050
Tube Length (m) 4.880
Shell ID (m) 0.540
Tube Pitch (mm) 24
Tube Thickness (mm) 0.710
Number of tubes 7
Tube arrangement Triangular
Equipment Specification
Equipment Name Distillation Column
Equipment Code T-501
To separate ethanol from
Function
sulphuric acid, water, and waste
Operating Data
Feed Flow Rate (kgmole/hr) 339.95620
Reflux Ratio 4.834
Column Pressure (kPa) 101.325
Number of Actual Tray 18
o
Condenser Temperature ( C) 78.1
o
Boiler Temperature ( C) 100.1
Stage Efficiency (%) 71.746
Universitas Indonesia
31
Construction Data
Material Stainless Steel
Column Height (m) 10.289
Column Diameter (m) 0.762
Plate Type SS Sieve Tray
Material SS-316
Shell Thickness (in) 1.265
Head Type Torispherical
Head Thickness (in) 0.185
Equipment Specification
Equipment Name Extractive Distillation Column
Equipment Code T-502
To separate ethanol from water
Function
and EG
Operating Data
Feed Flow Rate (kgmole/hr) 31.992
Reflux Ratio 1.874
Column Pressure (kPa) 101.325
Number of Actual Tray 10
o
Condenser Temperature ( C) 78.14
o
Boiler Temperature ( C) 149.379
Stage Efficiency (%) 55.813
Construction Data
Material Stainless Steel
Column Height (m) 5.8019
Column Diameter (m) 0.559
Plate Type SS Sieve Tray
Material SS-316
Shell Thickness (in) 1.261
Head Type Torispherical
Head Thickness (in) 0.1046
Universitas Indonesia
32
Equipment Specification
Equipment Name Recovery Distillation Column
Equipment Code T-503
Function To recover EG from water
Operating Data
Feed Flow Rate 15.152 kgmole/hr
Reflux Ratio 1.935
Column Pressure 101.325 kPa
Number of Actual Tray 9
Condenser Temperature 87.218oC
Boiler Temperature 165.239oC
Stage Efficiency 55.41%
Construction Data
Material Stainless Steel
Column Height 5.331 m
Column Diameter 0.219 m
Plate Type SS Sieve Tray
Material SS-316
Shell Thickness 1.259 in
Head Type Torispherical
Head Thickness 0.1397
1.1.11. Pump
Pump is an equipment to circulate the liquid phase fluid through pipe.
Pumps specification in our plant is shown in Table 1.34 until 1.37.
Ethanol Dehydration
Equipment Specification
Equipment Name Pump
Equipment Code P-501
Type Centrifugal pump
Operation Data
Temperature (K) 438.251
Density (3 ) 998
Pressure inlet (Pa) 42,060
Pressure outlet (Pa) 101,300
Universitas Indonesia
33
Operation Data
3
Flow rate( ) 1.942 x 104
2
Friction Loss ( 2 ) 4.534
Efficiency (%) 75
Fluid Ethanol
Design Specification
Power (W) 16.51
Head (m) 6.52
NPSHa (m) 9.889
Electricity
Equipment Specification
Equipment Name Pump
Equipment Code P-100
Type Centrifugal pump
Operation Data
Temperature (K) 322.734
Density (3 ) 866
Pressure inlet (Pa) 11,690
Pressure outlet (Pa) 6,302,000
Vapor pressure (Pa) 6,467.220
3
Flow rate( ) 4.251 x 104
Efficiency (%) 75
Fluid Water
Design Specification
Power (W) 3,567.85
Head (m) 742.13
NPSHa (m) 10.649
New Condensate
Equipment Specification
Equipment Name Pump
Equipment Code P-401
Type Centrifugal pump
Operation Data
Temperature (K) 313
Density (3 ) 1022
Pressure inlet (Pa) 1,066,000
Pressure outlet (Pa) 3,500,000
Universitas Indonesia
34
Operation Data
Vapor pressure (Pa) 33350
3
Flow rate( ) 4.142 x 106
Efficiency (%) 75
Mixture acetic acid,
Fluid
methanol and water
Design Specification
Power (W) 1.35
Head (m) 243.47
NPSHa (m) 6.33
New Condensate
Equipment Specification
Equipment Name Pump
Equipment Code P-402
Type Centrifugal pump
Operation Data
Temperature (K) 303
1004
Density (3 )
Pressure inlet (Pa) 100,000
Pressure outlet (Pa) 200,000
Vapor pressure (Pa) 6564
3
Flow rate( ) 3.456 x 104
Efficiency (%) 75
Fluid Water
Design Specification
Power (W) 48.17
Head (m) 10.62
NPSHa (m) 9.16
Design Specification
Type Flat & Roll
Inclination degree 30o
Width (inches) 16
Length (ft) 100
Universitas Indonesia
35
Design Specification
Power (hp) 1.9
Maximum velocity (ft/min) 85.73
Maximum capacity (ton/hr) 29.16
Material of Belt Polymer or Plastic
1.1.13. Clarifier
Clarifier is used to separate solid product because of previous process
produces CaCO3. It must be separated because it is the reason of plugging and
fouling in a pipeline. The specification of clarifier that we use is shown in Table
1.39.
Equipment Specification
Equipment Name Reverse Osmosis
Equipment Code RO501
Membrane Type (DOW) SW30HR-400
Feed Source Sea Water, Open Intake
Table 1.40. Reverse Osmosis Specification (continued)
Universitas Indonesia
36
Equipment Specification
SDI <5
Permeate Flow (gpm) 27
Recovery (%) 75
Design Specification
Flow Configuration Plug Flow
2
Active Membrane Area (ft ) 370
Average Flux (gfd) 19
Number of Element (Ne) 6
Number of Pressure Vessels 1
Number of Stages 2
Staging Ratio 2:1
Equipment Design
Refrigerant Ammonia-Water
Heat Input LP Steam
Cooler Cooling water
Universitas Indonesia
37
The water requirement for the plant is derived from Wain 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 sea 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. We need
water for utility and raw material for steam reformer. There is a specialization of water
treatment for raw material, because we need to demineralize the water first. Here the
steps for water treatment that we design regarding the process flow diagram:
1. Screening
2. Stainer
3. Catride Filter
4. RO Unit 1
5. RO Unit 2
6. Ion Exchanger
7. Dearator
The overall mass balance of water treatment unit is shown in table below.
Table 1.42. Mass Balance Water Utility per Equipment
1.2.3.1. Vesssel
Universitas Indonesia
39
Code DA-100
Remove gases soluble in water, such as O2 and
Function
CO2 to preventive corrosion and deposite
Material Stainless Steel 316
Universitas Indonesia
40
1.2.3.2. Pump
Strainer Pump
Equipment Specification
Equipment Name Pump
Equipment Code P-501
Type Centrifugal pump
Operation Data
Temperature (K) 303
Density (3 ) 1004
Pressure inlet (Pa) 101,325
Pressure outlet (Pa) 202,650
Vapor pressure (Pa) 6564
3
Flow rate( ) 0.3049
Efficiency (%) 75
Fluid Water
Design Specification
Power (W) 43,042.5
Head (m) 10.75
NPSHa (m) 9.167
Universitas Indonesia
41
SW RO Booster Pump
Equipment Specification
Equipment Name Pump
Equipment Code P-502
Type Centrifugal pump
Operation Data
Temperature (K) 303
Density (3 ) 1004
Operation Data
Pressure inlet (Pa) 151,988
Pressure outlet (Pa) 303,975
Vapor pressure (Pa) 6564
3
Flow rate( ) 0.3033
Efficiency (%) 75
Fluid Water
Design Specification
Power (W) 62,838.17
Head (m) 15.79
NPSHa (m) 9.28
Polishing Pump
Equipment Specification
Equipment Name Pump
Equipment Code P-105
Type Centrifugal pump
Operation Data
Temperature (K) 303
Density (3 ) 1004
Pressure inlet (Pa) 151,988
Pressure outlet (Pa) 303,975
Vapor pressure (Pa) 6564
3
Flow rate( ) 1.660 x 103
Efficiency (%) 75
Fluid Water
Design Specification
Power (W) 339.64
Head (m) 15.58
NPSHa (m) 9.48
Universitas Indonesia
42
Universitas Indonesia
43
Deaerator Pump
Equipment Specification
Equipment Name Pump
Equipment Code P-506
Type Centrifugal pump
Operation Data
Temperature (K) 303
Density (3 ) 1004
Pressure inlet (Pa) 101,325
Pressure outlet (Pa) 202,650
Vapor pressure (Pa) 6564
3
Flow rate( ) 1.650 x 103
Efficiency (%) 75
Fluid Water
Design Specification
Power (W) 226.29
Head (m) 10.43
NPSHa (m) 9.48
Universitas Indonesia
44
1.2.3.3. Pipe
Internal Nominal
Stream Schedule Length
Diameter (mm) (inch)
100 360.776 16 40 7.5
102 358.879 16 40 7.5
103 26.723 1.25 40 3
104 26.723 1.25 40 3
105 26.656 1.25 40 2.5
106 26.656 1.25 40 2.5
107 26.656 1.25 40 2.5
108 26.656 1.25 40 2.5
109 26.656 1.25 40 2.5
110 26.656 1.25 40 2.5
111 25.982 1 40 3
Universitas Indonesia
CHAPTER 2
PIPING AND INSTRUMENTATION DIAGRAM (P&ID)
45 Universitas Indonesia
Figure 2.1. P&ID of Electricity Production
46 Universitas Indonesia
Figure 2.2. P&ID of Pretreatment
47 Universitas Indonesia
Figure 2.3. P&ID of Ethanol Fermentation
48 Universitas Indonesia
Figure 2.4. P&ID of Ethanol Production
49 Universitas Indonesia
Figure 2.5. P&ID of Condensate Treatment
50 Universitas Indonesia
Figure 2.6. Water Treatment Utility
51 Universitas Indonesia
2.2. Plant Control Tabulation
52 Universitas Indonesia
Table 2.2. Plant Control Tabulation (continued)
53 Universitas Indonesia
Table 2.3. Plant Control Tabulation (continued)
54 Universitas Indonesia
Table 2.4. Plant Control Tabulation (continued)
55 Universitas Indonesia
Table 2.5. Plant Control Tabulation (continued)
56 Universitas Indonesia
Table 2.6. Plant Control Tabulation (continued)
58 Universitas Indonesia
CHAPTER 3
CONCLUSION
Li, C., Knierim, B., Manisseri, C., Arora, R., Scheller, H., Auer, M.,
Vogel, K., Simmons, B., & Singh, S. (2010). Comparison of dilute acid and ionic
liquid pretreatment of switchgrass: Biomass recalcitrance, delignification and
enzymatic saccharification. Bioresource Technology, 101, 4900-4906.
Mood, S.H., Golfeshan, A.H., Tabatabaei, M., Jouzani, G.S., Najafi, G.H.,
Gholami, M., & Ardjmand, M. (2013). Lignocellulosic biomass to bioethanol, a
comprehensive review with a focus on pretreatment. Renewable and Sustainable
Energy Reviews, 27, 77-93.
Wooley, R.J. & Putsche, V. (1996). Development of an ASPEN PLUS
physical property database for biofuels components. NREL: Colorado.
Kim, J.S., Choi, W.I., Kang, M., Park, J.Y., Lee, J.S., (2012) Kinetic Study
of Empty Fruit Bunch Using Hot Liquid Water and Dilute Acid. Appl. Biochem
Biotechnol 167:1527-1539
Harris, J. F. & Smuk, J. M. (1961). Forest Prod. J., 11, 303.
Liu S. & Qureshi, N. (2009). How microbes tolerate ethanol and butanol.
New Biotechnology, 26, 117-121.
Huang, H.-J., Ramaswamy, S., Tschirner, U.W., & Ramarao, B.V. (2008).
A review of separation technologies in current and future biorefineries. Separation
and Purification Technology, 62, 1-21.
Ahmad, F., Jameel, A.T., Kamarudin, M.H., & Mel, M. (2011). Study of
growth kinetic and modeling of ethanol production by Saccharomyces cerevisae.
African Journal of Biotechnology, 16(81), 18842-18846.
Cho, H., Smith, A. D., & Mago, P. (2014). Combined Cooling, Heating
and Power : A Review of Performance Improvement and Optimization. Applied
Energy 136, 168-185.
Deng, J., Wang, R., & Han, G. (2011). A Review of Thermally Activated
Cooling Technologies for Combined Cooling, Heating and Power Systems.
Progress in Energy and Combustion Science 37, 172-203.
Erlangga, A. (2008). Analisis Sistem Combined Cooling Heating and
Power Generation (CCHP) pada Aplikasi Perhotelan . Depok.
Hanafizadeh, P., Eshraghi, J., Ahmadi, P., & Satari, A. m. (2016).
Evaluation and Sizing of a CCHP System for a Commercial and Office Buildings.
Journal of Building Engineering 5, 67 -78.
Herold, K., Radermacher, R., & Klein, S. (1996). Absorption Chillers and
Heat Pumps. Boca Raton: CRC Press Inc.
Herrmann, F. (2008). The Absorption Refrigerator as a Thermal
Transformer. Germany: Universitt Karlsruhe.
Petchers, N. (2002). Combined Heating, Cooling & Power Handbook:
Technologies & Applications. Fairmont Press.
Bandyopadhyay S and Sahu GC. (2010). Modified Problem Table Algorithm for
Energy Targeting, Ind Eng Chem Res, 49: 11557.
Hohman EC. (1971). Optimum Networks of HeatExchange, PhD Thesis,
University of Southern California.
Linnhoff B and de Leur J. (1988). Appropriate Placement of Furnaces in the
Integrated Process, IChemE SympSer, 109: 259.
Linnhoff B and Flower JR. (1978). Synthesis of Heat Exchanger Networks,
AIChEJ, 24: 633.
Linnhoff B,Mason DR and Wardle I. (1979). Understanding Heat Exchanger
Networks, Comp Chem Eng, 3: 295.
Seider, W.D., Seader, J.D., Lewin, D.R., 1996. Product and Process Design
Principles. New York: John Wiley & Sons, Inc.
Smith, Robin. 2005. Chemical Process Design and Integration, 2nd edition. Centre
of Process Integration, University of Manchester, UK.
APPENDICES
Appendix A. Warehouse
The warehouse is used to stocking the raw materials (Empty Fruit
Bunches). The raw materials are stocked every day from the supplier. The
warehouse is a rectangle building with a triangular prism roofs. Some
specifications that should be known are
Bulk density for nickel ore is 1150 kg/m3
The processs will be done with feed flow rate is 600 tons/day or 25 tons/h
Basic Planning
Construction materials : Concrete
Materials Store = 1150 kg/m3
Raw Material Volume
Volume = 600,000 kg /1150 kg/m3 = 530 m3
To ensure that the warehouse is safe and not overloaded, we decided to make the
ware house is 90% full. So the ware house volume is
Volume warehouse = 530 m3 : 0.9 = 588.88 m3
Volume of warehouse = length x width x height = 4 : 3: 1
Length = 4 x 3.66 = 14.64 m
Width = 3 x 3.66 = 10.98 m
Height = 1 x 3.66 = 3.66 m
62 Universitas Indonesia
V-Ca(OH)2 21.550
63 Universitas Indonesia
64
Capacity for ethanol and Ethylen Glycol , and H2SO4 > 38 m3 , so it used
Vertical Concrete Foundation type.
3. Choose Storage Tank Type: Slim or Fat
In this part, off-grid plant determine length and diameter ratio of storage
based on vessel function.
Because storage tank in off-grid plant is for storing liquid and using concrete
plant so it choose L/D ratio around 0.8-1 for Ethanol, EG, H2SO4, and water
tank in utility . In this case, off-grid plant choose 0.8 ratio. Because the taller
tank, will be more troubled by wind.
4. Calculate Internal Diameter and Length
Universitas Indonesia
65
Previously, off-grid plant have chosen 0.8 L/D ratio. So diameter calculation
equation is:
2
(3 ) = ( )
2
2 4
(3 ) = ( )
2 5
1/3
() = ( )
1
5
() = 0.8
5. Determine Material of Storage Tank Basic
Consideration of determining material is corrosion resistance. There are some
liquid in off-grid plant corrosif such as H2SO4, so it will choose to use
stainless steel 316 as the material. While for Ethanol and EG, because they
are not corrosif so it chooce stainless stell. For vessel in utility is used HDPE
material.
6. Calculate Vessel Thickness
To calculate vessel thickness :
PR
ts = +
SE 0.6 P
7. Determine Open or Closed Head
Head or roof would be chosen if liquid is not volatile and closed head would
be chosen if liquid is volatile. Because material in off-grid plant is volatile,
acid, flammable so off-grid plant choose closed head.
Ion exchanger
Here is the step for determining cation and anion exchanger column size.
1. Calculate Tank Dimension
Mineral Removed =
Cation Losses x Water Flow Rate x Total Cation Inlet x Regeneration Cycle
Amount of Mineral Removed
Resin Volume =
Resin Capacity
Water Flow Rate
Resin Surface Area =
Maximum Flow Rate
Universitas Indonesia
66
Resin Volume
Resin Bed Height =
Resin Surface Area
ID
b = rc (rc icr)2 ( icr)
2
OA = t h + b + sf
Deaerator
Here is the step for determining Deaerator column size.
1. Calculate Tank Capacity
water for aeration = 5,748.41 kg/h = 0.5748 m/h
Resisdance Time = 15 second = 0.25 h
Safety factor = 20% (Peter and Timmerhouse, 1991, hal. 37)
Volume of Water = 0.5748 m/h x 0.25 h = 0.1437 m
Universitas Indonesia
67
Universitas Indonesia
68
E = Efficiency
C = Corrosion factor, in
Material is recommeded Stainless Steel 316
f = 15,600 psi (Peters & Timmerhause, 1991, Table 4, page 538)
E = 80% (Brownell and Young, 1959, table 13.2)
C = 0.125 in
ri = 18 in
38.964 psi x 18 in
ts = + 0.125 in
2(15,600 psi 0.8 0.638.964 psi)
ts = 0.1531 in = 3.886 mm
Use ts standart = 0.1874 in = 3/16 in = 5 mm
OD = ID + (2ts)
OD = 36 in + (2 x 0.1875 in)
OD = 36.375 in
Use OD standart is 38 in
6. Determine Head Thickness
OD = 38 in
Rc = 36 in
0.885
= +
0.1
0.885 38.964 36
= + 0.125
15,600 0.85 0.138.964
= 0.218
Use th standart 1/4 in = 6.35 mm
Appendix C. Pipe
To calculate the size of the pipe, we need to volumetric rate of fluid which
goes through it and also the velocity of the fluid. We assume that the velocity of
water is 3 m/s and non-water is 1 m/s.
=
=
Universitas Indonesia
69
4
=
After getting know the minimum internal diameter, we look at the tables
below to find the appropriate pipe size from vendor. We use Pipe Schedule 40.
Appendix D. Reactor
1. Hydrolysis Reactor
Hydrolysis reactor acts like CSTR. The reaction is assumed as first order. So,
CSTR design equation for calculating volume, is,
- Volume of Fluid
= . /
= (2490 0.95)60/(96450.48)
V = 2.92 m3
- Volume of Reactor = 1.1 x 2.92 = 3.21 m3
- Diameter of hydrolysis reactor
= 1.24
- Height of Reactor
Hr=Hs+Hc = 2D+d = 2.48 + 0.466 = 2.8 m
- Height of Fluid in Reactor
Hf= (volume of liquid in reactor x high of reactor)/reactor volume
Hf= (2.92 x 2.8)/3.21 = 2.54 m
- Diameter of impeller
Di = 0.35 x D = 0.35 x 1.24 = 0.434 meter
- Length of baffle = 0.12 x D = 0.12 x 1.24 = 0.124 meter
- Shell Thickness
= [()/(. 0.6)] + ()
ds = [(17.57x17.9)/(15250.0.85-0.6x17.57)] + (0.042x10)
ds = 0.44 inch = 1.15 cm
- Position of impeller from bottom
h=0.33xD = 0.414 meter
- Specific power for agitation
Power= 2 kW/m3
Universitas Indonesia
71
2. Neutralization Reactor
Neutralization reactor acts like CSTR. So, CSTR design equation for
calculating volume, is,
- Volume of Fluid
= . /
= (104.2 0.94)60/(72844.99)
V = 0.20 m3
- Volume of Reactor = 1.1 x 0.20 = 0.22 m3
- Diameter of neutralization reactor
= 0.5089
- Height of Reactor
Hr=Hs+Hc = 2D+d = 1.01 + 0.13 = 1.14 m
- Height of Fluid in Reactor
Hf= (volume of liquid in reactor x height of reactor)/reactor volume
Hf= (0.20 x 1.14)/0.22 = 1.04 m
- Diameter of impeller
Di = 0.35 x D = 0.35 x 0.5089 = 0.178 meter
- Length of baffle = 0.12 x D = 0.1 x 1.24 = 0.051 meter
- Shell thickness
= [()/(. 0.6)] + ()
ds = 1.09 cm
- Position of impeller from bottom
h=0.33xD = 0.17 meter
- Specific power for agitation = 1 kW/m3
3. Seed Fermenter
Seed fermenter is a batch bioreactor. The volume of seed fermenter is obtained
by production capacity. The design equation of batch reactor and first order
reaction, is,
Universitas Indonesia
72
= (/ )/
= (1/1 0.93)/0.04
= 72
- Volume of Fluid
Volume of fluid in batch reactor is obtained by production capacity, which
in this seed fermenter, V, is 27.26 m3
- Volume of Reactor = 1.1 x 27.26 = 30 m3
- Diameter of neutralization reactor
= 2.62
- Height of Reactor
Hr=Hs+Hc = 2D+d = 5.24 + 0.66 = 5.9 m
- Height of Fluid in Reactor
Hf= (volume of liquid in reactor x height of reactor)/reactor volume
Hf= (27.26 x 5.9)/30= 5.35 m
- Diameter of impeller
Di = 0.35 x D = 0.35 x 2.62 = 0.92 meter
- Length of baffle = 0.1 x D = 0.1 x 2.62 = 0.26 meter
- Shell thickness
= [()/(. 0.6)] + ()
ds = 1.09 cm
- Position of impeller from bottom
h=0.33xD = 0.87 meter
- Specific power for agitation = 3 kW/m3
4. Main Fermenter
Main fermenter is also a batch bioreactor. The volume of main fermenter is
obtained by production capacity. The design equation of batch reactor and first
order reaction, is,
= (/ )/
= (1/1 0.93)/0.13
Universitas Indonesia
73
= 20
- Volume of Fluid
Volume of fluid in batch reactor is obtained by production capacity, which
in this seed fermenter, V, is 151.03 m3
- Volume of Reactor = 1.1 x 151.03 = 166.13 m3
- Diameter of neutralization reactor
= 4.63
- Height of Reactor
Hr=Hs+Hc = 2D+d = 9.26 + 1.16= 10.42 m
- Height of Fluid in Reactor
Hf= (volume of liquid in reactor x height of reactor)/reactor volume
Hf= (151.03 x 10.42)/166.13= 9.48 m
- Diameter of impeller
Di = 0.35 x D = 0.35 x 4.63 = 1.62 meter
- Length of baffle = 0.1 x D = 0.1 x 4.63 = 0.46 meter
- Shell thickness
= [()/(. 0.6)] + ()
ds = 1.62 cm
- Position of impeller from bottom
h=0.33xD = 0.87 meter
- Specific power for agitation = 3 kW/m3
= . ( )^0.5
Universitas Indonesia
74
+
=
+
4
= ( )^0.5
= ( ).
=
(2 ) + 0.4
Flash
Name Unit
Conditions
W Liquid 0.52 kg/s
W vapor 0.08 kg/s
Liquid 681.10 kg/m3
Vapor 1.79 kg/m3
Kv 0.28 Constant
v vapor max 5.495045512 m/s
A min 0.060688882 m2
D min 0.278047978 m
L/D 2 m/m
L 0.556095956 m
P 14.69232286 Psia
R 5.473385396 Inch
S 80 Psi
E 85 %
T 0.566806357 Inch
T 1.439688147 cm
Appendix G. Turbine
1. Determination type of steam turbine.
In determining the type of turbine there are several factors that must be
considered, namely the electrical energy is generated, and the condition of the
fluid feed and products (output), the ambient temperature and the system adopted
in the power plant.
In determining the number of stages, there are some diagrams that commonly
used:
Universitas Indonesia
75
1) Curtis Turbine.
Curtis turbine is used to power generated up to 4000 kW.
2) Reaction Turbine.
Same with Curtis turbine, reaction turbine is used for low output power and
there are chemical reaction in the process.
3) Rateau Turbine.
Rateau turbine is used to power generated from 4000 kW up to above 30000
kW
Universitas Indonesia
76
120
= = 5
25
Based on international design standard, the turbine with output power 1279
kW, can be operated with speeds 3500 4000 rpm, and usually used 3800 rpm.
Based on Curtis turbine, can be known the enthalpy change per stage is 25 kJ/kg.
So the number of stage which needed for this turbine is
Universitas Indonesia
77
75
= = = 3
25
60 (1000 / )0,5
=
3.147
60 (1000 75 /6.5)0,5
= = 682.66
3.147 3
4. Vacuum Turbine
Because output power of the turbine is 12660 kW, so use Rateau turbine
typical III.
Based on international design standard, the turbine with output power 12660
kW, can be operated with speeds 5000 6000 rpm, and usually used 5500 rpm.
Based on Rateau turbine, can be known the enthalpy change per stage is 25 kJ/kg.
So the number of stage which needed for this turbine is
100
= = = 4
25
Universitas Indonesia
78
60 (1000 / )0,5
=
3.147
60 (1000 100 /2)0,5
= = 753.64
3.147 4
Appendix H. Boiler
Sizing of boiler to generate steam for electricity and steam utility is done
using benchmarking and vendor data collecting method. The data of similar plant
using lignin as fuel for the boiler to generate steam in a power plant have been
collected. The only designed data are furnace width and depth. The steps of
determining furnace width and depth are shown below.
Universitas Indonesia
79
Universitas Indonesia
80
Universitas Indonesia
81
Universitas Indonesia
82
K1 249.000
n1 2.207
Tube bundle diameter, Db 5.2 mm
Num of tubes in center, Nr 0 tubes
Shell diameter 539.75 mm
Trial baffle spacing 107.95 mm
cross flow area, As 11653.20 mm2
equivalent diameter, de 13.53 mm
volumetric flow rate 0.01 m3/s
shell side velocity 1.05 m/s
Universitas Indonesia
83
1/3
=
1/3
=
= ( )
Universitas Indonesia
84
Universitas Indonesia
85
4) Calculate the plate length and width using chosen plate area and L/P
ratio.
5) Assume the value of overall heat transfer coefficient for the first guess.
The first assumption can be made by using the table below:
Universitas Indonesia
86
Universitas Indonesia
87
Reboiler
Pressure 1 Bar
100.100 o
Temperature C
Density of Vapor 0.5882 kg/m3
Density of Liquid 947.6180 kg/m3
Surface Tension 372.2000 N/m
Molecular Weight 18.3963 kg/kgmole
Viscosity of Vapor 0.0120 Ns/m2
Viscosity of Liquid 0.5357 Ns/m2
Condenser
Pressure 1 Bar
78.1000 o
Temperature C
Density of Vapor 1.4625 kg/m3
Density of Liquid 758.4786 kg/m3
Surface Tension 0.0238 N/m
Molecular Weight 42.1330 kg/kgmole
Viscosity of Vapor 0.0074 Ns/m2
Viscosity of Liquid 0.4358 Ns/m2
Universitas Indonesia
88
Using the graph below, we can know the value of K which will be used to
calculate the velocity of vapor and liquid.
Universitas Indonesia
89
Third, we calculate the area needed for the column. We also consider the
downcomer area (10% of cross-sectional area). From that, we can also get the
diameter.
1
=
1 0.1
4
=
A (bottom) 0.032 m2
A (top) 0.4243 m2
Diameter (bottom) 0.203 m
Diameter (top) 0.735 m
We choose the wider area as the minimum cross-sectional area for the
distillation column, which is 0.4243 m2. Therefore, the diameter is 0.735 meters.
6.842 4.561
= = 0.403
+ 1 7.841
Universitas Indonesia
90
Figure J.2. Gilliand equation and graph
(Source : J.P. Holman, 1959)
= 0.267
+1
12.656
= 0.267
+1
= 17.64 18
Material
SS316 Stainless steel is used for the material of distillation column. It is the
standard molybdenum-bearing grade, second in importance to 304 amongst the
austenitic stainless steels. The molybdenum gives 316 better overall corrosion
resistant properties than Grade 304, particularly higher resistance to pitting and
crevice corrosion in chloride environments with the allowable stress of SS316
given 16.700 psi.
Shell Thickness
Total shell thickness, considering the corrosion for 10 (commonly) years is
Universitas Indonesia
91
= + ( ) =
0.6
14.7 15
+ 0.125 10 = 1.265 = 3.20
16700 0.85 0.6 14.7
Head Thickness
The type of head selected for distillation column is tori-spherical. It is
selected because the range of pressure is suitable with the operating pressure of
the vessel through HYSYS. The ratio of L/D is 13.5.
= 15
= 13.5 15 = 202.5
0.885
=
0.1
0.885 14.7 202.5
= = 0.185 = 0.46
16700 0.85 0.1 14.7
The same calculation and method is also use for Extractive Distillation Column
(T-502) and Recovery Distillation Column (T-503).
Appendix K. Pump
There are several steps to sizing pump.
Find out physical properties of the stream which will go into the pump and other
information needed in the calculation (mass flow, pressure inlet, pressure output,
vapor pressure, temperature, density, static head, pipe length after pump). By
using these formula below, we get the information of Power, Head, and NPSHa of
each pump:
dWao dWpompa P V2
( gz ) F
dm dm 2
P1( Atm) V2 2 F PVapor
NPSHa = ( z2 z1 )
g 2g g g
Assumptions :
Pump efficiency 75%
Universitas Indonesia
92
Universitas Indonesia
93
c. Conveyor length
The length of the conveyor is adjusted to the distance of the warehouse
and the shredder which is 8 m or 26.24 ft.The required power is:
Where :
= (0,4 + ) (100) with L = conveyor length (ft)and W = capacity
300
(MT/h)
= (0.001) (H) (W) with H = lift (m)
is gotten from the figure below
Universitas Indonesia
94
Appendix M. Clarifier
Mass flowrate= 9.26 ton/h
Water flowrate= 9.18 m3/h
Clarifier volume= 10.1 m3
Assume that clarifier height is 5 meter and D2/D1=0.4
D2/D1=y/(y+h)
0.4 = y/(y+5)
Y= 3.33 meter
h= 5 meter
Universitas Indonesia
95
Seawater, Open
Feed Source:
Intake, SDI < 5
Required Permeate Flow: 26.3 ppm
Six-element pressure vessels to be used
Universitas Indonesia
96
Universitas Indonesia
97
The number of stages defines how many pressure vessels in series the
feed will pass through until it exits the system and is discharged as
concentrate. Every stage consists of a certain number of pressure
vessels in parallel. The number of stages is a function of the planned
system recovery, the number of elements per vessel, and the feed water
quality. The higher the system recovery and the lower the feed water
quality, the longer the system will be with more elements in series. The
selected stages for 6 element vessels is 2 stage basen on Table N.5.
Universitas Indonesia