Tk23 Report Assignment3

UNIVERSITAS INDONESIA
POLYGENERATION OF OFF-GRID SOLAR POWER,

BIOMASS, ETHANOL, AND COOLING
Report Assignment 3
GROUP 23
GROUP PERSONNEL:
ANDERSEN (1406604626)
ARIF HENDRAWAN (1406531763)
DIMAS NURWANSYAH (1406531624)
EDWARD GUSTAF (1406531920)
MAULINA CAHYA INDAH S. (1406531845)
CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
DEPOK
OCTOBER 2017
1 Universitas Indonesia
EXECUTIVE SUMMARY
Polygeneration plant of off-grid solar power, biomass, ethanol and cooling

produces ethanol for industries, electricity for local society in Indragiri Hilir, Riau
and cooling for local public school. This plant uses empty fruit bunch (EFB) as
raw material along with solar power from photovoltaic method. In order to
produce this product, this plant need some equipment to use such as elevator,
conveyor, shredder, reactor, distillation column, pump, heat exchanger, deaerator,
boiler, condenser, separator, centrifuge, clarifier, filter, absorption chiller, and
pipe. based on the energy balance calculated, the process of manufacturing need
much energy, therefore to build power generation from turbine in this plant.
Through power generation to produce electricity, the plant adapted the combined
cooling and power (CCP). Process manufacturing and power generation in this
plant also produces some waste especially during separation in distillation
column, clarifier, centrifuge and flash separator. This waste mostly contains solid
waste and liquid waste. Through this plant, ethanol produced per hour is 768 kg,
electricity generated is about 27.5 MW and 280 PK cooling capacity.
Water utility mass balance is also determined in this assignment on order
to calculate the size of all equipment in water utility. The water that should be
obtained from the sea for water utility is about 1,100,000 kg/h. This amount will
be divided to fulfil cooling water and boiler feed water (BFW) of this
polygeneration plant. Intake basin from the sea about 200 m from the plant will be
built with travelling screen to separate big impurities like fish or seaweed. After
that, seawater will be pumped with cooling water pump. NaOCl will be added to
kill microorganism that harmfull to the process system. An additional strainer also
installed in order to ensure large particle dont pass to the process. Reverse
osmosis is used to reduce the amount of mineral from seawater. Ion exchange
resin is also installed to reduce significantly the amount of ions both cation and
anion. Boiler feed waters CO2 and O2 concentration has to be low to reduce
corrosion. Therefore, the deaerator also installed to treat boiler feed water.
The process in polygeneration plant, both in main process and utilities,
using a bucket elevator, a shredder, conveyor, 4 mixer, 2 deaerator, 4 reactor, 1
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.
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
LIST OF FIGURES
Figure 1.1. Boiler Model ....................................................................................... 20

Figure 1.2. Kawamura Design Parameters ............. Error! Bookmark not defined.
Figure 2.1. P&ID of Electricity Production .......................................................... 46
Figure 2.2. P&ID of Pretreatment ......................................................................... 47
Figure 2.3. P&ID of Ethanol Fermentation ........................................................... 48
Figure 2.4. P&ID of Ethanol Production .............................................................. 49
Figure 2.5. P&ID of Condensate Treatment ......................................................... 50
Figure 2.6. Water Treatment Utility...................................................................... 51
Figure B.1. Algorithm to Choose Storage Tank Type Horizontal/Vertical .......... 64
Figure B.2. Algorithm to Choose Storage Tank Type Slim/Fat ........................... 64
Figure C.1. Nominal Size of Pipe, Schedule 40 (in mm)...................................... 69
Figure C.2. Nominal Size of Pipe, many schedule (in inch) ................................. 69
Figure G.1. Rateau Turbine Typical III ................................................................ 75
Figure G.2. Curtis Turbine Typical III .................................................................. 76
Figure H.1. Boiler Design ..................................................................................... 78
Figure I.1. Correction Factor Correlation ............................................................. 81
Figure I 2. Tube-side Heat Transfer Factor ........................................................... 82
Figure I.3. Shell-side Heat Transfer Factor ........................................................... 83
Figure J.1. Correlation of FLV and K ................................................................... 88
Figure J.2. Gilliand equation and graph ................................................................ 90
Figure L.1. Power required for Empty Conveyor ................................................. 94
LIST OF TABLES
Table 1.1. Warehouse Specification........................................................................ 8

Table 1.2. Vessel Specification (V-100) ................................................................. 8
Table 1.3. Vessel Specification (V-EG).................................................................. 9
Table 1.4. Vessel Specification (V-106) ............................................................... 10
Table 1.5. Vessel Specification (V-107) ............................................................... 10
Table 1.6. Ethanol Pipe Specification ................................................................... 11
Table 1.7. Electricity Pipe Specification ............................................................... 11
Table 1.8. Mixing Tank Pipe Specification .......................................................... 11
Table 1.9. Deaerator Pipe Specification ................................................................ 12
Table 1.10. Hydrolysis Reactor Specification....................................................... 12
Table 1.11. Neutralization Reactor Specification ................................................. 13
Table 1.12. Seed fermenter Specification ............................................................. 14
Table 1.13. Main Fermenter Specification ............................................................ 15
Table 1.14. Separator Specification ...................................................................... 16
Table 1.15. High Pressure Turbine Specification ................................................. 16
Table 1.16. Medium Pressure Turbine Specification ............................................ 17
Table 1.17. Vacuum Pressure Turbine Specification ............................................ 18
Table 1.18. P&F Filter .......................................................................................... 19
Table 1.19. Boiler Specification............................................................................ 20
Table 1.20. BFW Preheater Specification ............................................................. 21
Table 1.21. Filtrate Preheater Specification .......................................................... 22
Table 1.22. CCP Condensate Condenser Specification ........................................ 23
Table 1.23. HP Condensate Condenser Specification........................................... 23
Table 1.24. Turbine Condensate Condenser Specification ................................... 24
Table 1.25. T501 Condenser Specification ........................................................... 25
Table 1.28. T501 Reboiler Specification .............................................................. 28
Table 1.31. Distillation Column Specification ...................................................... 30
Table 1.32. Extractive Column Specification ....................................................... 31
Table 1.33. Recovery Column Specification ........................................................ 32
Table 1.34. Ethanol Dehydration Pump Specification (P-501)............................. 32
Table 1.35. Electricity Pump Specification (P-100) ............................................. 33
Table 1.36. New Condensate Pump Specification (P-401) ................................... 33
Table 1.37. New Condensate Pump Specification (P-402) ................................... 34
Table 1.38. Belt Conveyor .................................................................................... 34
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
CHAPTER 1
EQUIPMENT SIZING
1.1. Main Process Unit Sizing

1.1.1. Biomass Storage (Warehouse)
Warehouse used to place raw material that is EFB. Where the EFB is
obtained from oil palm plantations around the plant and filled every day.The detail
specification of EFB warehouse can be shown from Table 1.1.
Table 1.1. Warehouse Specification
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
1.1.2. Storage Tank

Every vessel has the different specification and design. The detail
specification of each vessel can be shown from Table 1.2 to 1.5.
1.1.2.1. Storage Tank Main Process Unit
Table 1.2. Vessel Specification (V-100)
Equipment Name V-100

Type of fluid Ethanol
Mass flow (kg/h) 776.354
9
Table 1.2. Vessel Specification (V-100) (continued)
Density (kg/ m3) 737.2

Flow rate (m3/h) 1.053
Volume (m3/week) 176.923
Volume tank (m3) 194.615
Temperature (C) 78.146
Pressure (kPa) 101.30
vertical with concrete
Horizontal/vertical
foundation
L/D 0.8
D (m) 6.639
L (m) 5.311
Thickness (mm) >12
Open/close vessel Close
Vessel head type Dished head
Material type Carbon Steel SA283
Table 1.3. Vessel Specification (V-EG)
Equipment Name V-105

Type of fluide Ethylene Glycol
Density (kg/m3) 1107.147
Temperature (C) 30
Horizontal with concrete
Horizontal/vertical
supports
L/D 0.8
D (m) 2.723
L (m) 2.178
Thickness (mm) 10
Material type Carbon Steel SA283
Universitas Indonesia
10
Equipment Name V-H2SO4 (Make-UP)

Type of fluide Sulphate Acid
Mass flow (kg/h) 64,636.91
Density (kg/m3) 1,840
Volume (m3/week) 5,901.631
Volume tank (m3) 6,491.794
Temperature (C) 25
Horizontal/vertical Concrete Foundation
L/D 0.8
D (m) 21.123
L (m) 16.898
Thickness (mm) >12
Material type Stainless Steel 316
Equipment Name V-Ca(OH)2

Type of fluide Kalsium Hidroksida
Temperature (C) 25
Horizontal/vertical Vertical with legs
L/D 3
D (m) 0.915
L (m) 2.746
Thickness (mm) 5
Vessel head type Torispherical Dished head
Material type Carbon Stell SA283
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.
Table 1.6. Ethanol Pipe Specification
Name Ethanol Unit

0.1938 kg/s
789.3 kg/m3
Flow 0.000245524 m3/s
Fluid Non Water
V 1 m/s
A 0.000245524 m2
ID 0.018 m
ID 17.685 mm
Nominal 1 "
Schedule 40
Length 3 m
Table 1.7. Electricity Pipe Specification
Name Electricity Unit

0.3679 kg/s
1004.443148 kg/m3
Flow 0.000366301 m3/s
Fluid Non Water
V 1 m/s
A 0.000366301 m2
ID 0.022 m
ID 21.602 mm
Nominal 1 "
Schedule 40
Length 3 m
Table 1.8. Mixing Tank Pipe Specification
Name Mixing Tank Unit

31.9356 kg/s
1004.443148 kg/m3
Flow 0.031794289 m3/s
Fluid Non Water
12
Table 1.8. Mixing Tank Pipe Specification (continued)
V 1 m/s
A 0.031794289 m2
ID 0.201 m
ID 201.252 mm
Nominal 8
Schedule 40
Length 5 m
Table 1.9. Deaerator Pipe Specification
Name Deaerator Unit

0.3679 kg/s
1004.443148 kg/m3
Flow 0.000366301 m3/s
Fluid Non Water
v 1 m/s
A 0.000366301 m2
ID 0.022 m
ID 21.602 mm
Nominal 1 "
Schedule 40
Length 3 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.
Table 1.10. Hydrolysis Reactor Specification
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
13
Table 1.10. Hydrolysis Reactor Specification (continued)
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
1.1.4.2. Neutralization Reactor

Neutralization reactor acts like a continuous stirred tank reactor. In this
polygeneration plant, the reactor is used to neutralize acid which involved in flow
stream. Very diluted acid, H2SO4, is neutralized by calcium hydroxide, Ca(OH)2.
The specification of neutralization reactor is shown from table 1.11.
Table 1.11. Neutralization Reactor Specification
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 Reactor 1.16 m
Diameter of
0.175 m
Impeller
14
Table 1.11. Neutralization Reactor Specification (continued)

Position of
Bottom
Specific Power
1 kw/m3
for Agitation
Residence Time 1.43 min
1.1.4.3. Seed Fermenter

Seed fermenter is categorized as bioreactor that acts like batch reactor. It is
used to cultivate biomass (bacteria). The specification of seed fermenter is shown
from table 1.12.
Table 1.12. Seed fermenter Specification
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
Diameter of
0.917 m
Impeller
Position of
Bottom
Specific Power
3 kW/m3
for Agitation
Total Needed
2 Unit
Seed Fermenter
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.
Table 1.13. Main Fermenter Specification
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
Diameter of Impeller 1.6205 m
Position of Impeller
1.54 m
from Bottom
Specific Power for
3 kW/m3
Agitation
Total Needed Main
1 Unit
Fermenter
1.1.5. Flash Separator

Flash separator is used to separate component from feed stream based on
boiling point and relative volatility difference of each component. The flash
separator in this polygeneration is used to separate between glucose-xylose, and
diluted acid. The specification of flash separator is shown from Table 1.14.
16
Table 1.14. Separator Specification
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
High Pressure Turbine

K-100
Identification
Steam Turbine Generator
Decreasing the gas pressure and
Function:
produce electricity
Operation: Continuous
Working Fluid Specification
Type of Fluid Steam
Inlet Outlet
Flow rate (kg/s) 31.94 31.94
Pressure (kPa) 6299 1317
Temperature (oC) 454 254.9
17
Table 1.15. High Pressure Turbine Specification (continued)
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
1.1.6.2. Medium Pressure Turbine

Table 1.16. Medium Pressure Turbine Specification
Medium Pressure Turbine

K-101
Identification
Function:
produce electricity
Type of Fluid Steam
Inlet Outlet
Flow rate (kg/s) 21.34 21.34
Pressure (kPa) 1317 962.6
o
Temperature ( C) 254.9 221.3
18
Table 1.16. Medium Presure Turbine Specification (continued)
Number of Stages 3
Rotating Speed (rpm) 3800
Power (kW) 1279
Generator Efficiency
(%) 0.85
Diameter (m) 0.682
Rotor of turbine:
Stainless steel type 12% Cr, 6%
Ni, 1.5% Mo
Blade: AISI 403
1.1.6.3. Vacuum Pressure Turbine

Table 1.17. Vacuum Pressure Turbine Specification
Vacuum Pressure Turbine

Identification: K-102
Function:
produce electricity
Type of Fluid Steam
Inlet Outlet
Flow rate (kg/s) 21.05 21.05
Pressure (kPa) 962.6 11.69
Temperature (oC) 221.3 49.09
19
Table 1.17. Vacuum Pressure Turbine Specification (continued)
Number of Stages
Rotating Speed (rpm)
Power (kW) 12660
Generator Efficiency (%) 0.85
Diameter (m) 0.682
Rotor of turbine:
Stainless steel type 12% Cr, 6% Ni,
1.5% Mo
Blade: AISI 403
1.1.7. P&F Filter

P&F filter is aim to separate between hydrolyzed and un-hydrolyzed
product. The specification of P&F filter is shown from Table 1.18.
Table 1.18. P&F Filter
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.
20
Figure 1.1. Boiler Model
(Source: ThermCraft, Inc.)
Table 1.19. Boiler 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
21
1.1.9. Heat Exchanger

1.1.9.1. Heat Exchanger
Two heat exchangers is used in this polygeneration plant to preheat the
boiler feed water and filtrate to flash tank. The specification is shown in Table
1.20 and 1.21.
Table 1.20. BFW Preheater 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
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
22
Table 1.21. Filtrate Preheater Specification
Equipment Name Heat Exchanger
Equipment Code E401
Type Shell and Tube
Operating Condition
Shell Tube
Data
Side Side
o
Operating pressure
101 1317.225
(kPa)
No. of passes 1 2
Fouling factor (m2
o 0.0002 0.00009
C/W)
T LMTD (oC) 11.980
Heat Transfer Area
64.078
(m2)
Tube OD (mm) 19.050
Shell ID (m) 0.540
Tube Pitch (mm) 24
Number of tubes 110
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.
23
Table 1.22. CCP Condensate Condenser Specification
Equipment Name Condenser
Equipment Code E-403
Type Plate and Frame
Operation Data
LMTD (oC) 53.046
Fouling Factor (m2 oC/W) 0.000081
Overall U (W/m2 oC) 642.3004664
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
Table 1.23. HP Condensate Condenser Specification
Equipment Code E404
Type Shell and Tube
Operating Condition
Shell Tube
Data
Side Side
Temperature in (oC) 25 193
Operating Condition
Operating pressure (kPa) 101 1317.225
No. of passes 1 2
Fouling factor (m2 oC/W) 0.00009 0.00009
T LMTD (oC) 58.322

2o
Overall U (W/m C) 3382.092
24
Table 1.23. HP Condensate Condenser Specification (continued)
2
Heat Transfer Area (m ) 41.811
Tube OD (mm) 19.050
Shell ID (m) 0.540
Tube Pitch (mm) 24
Number of tubes 72
Table 1.24. Turbine Condensate Condenser Specification
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
Operating pressure (kPa) 101 11.69351
No. of passes 1 2
Fouling factor (m2 oC/W) 0.002 0.00009
T LMTD (oC) 11.118
2
Heat Transfer Area (m ) 11475.241
Tube OD (mm) 19.050
Shell ID (m) 0.540
Tube Pitch (mm) 24
25
Table 1.24. Turbine Condensate Condenser Specification (continued)

Number of tubes 19656
Table 1.25. T501 Condenser Specification
Equipment Code E502
Type Shell and Tube
Operating Condition
Shell Tube
Data
Side Side
o
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)
T LMTD ( C)o
23.230
2o
Heat Transfer Area
140.882
(m2)
Tube OD (mm) 19.050
Shell ID (m) 0.540
Tube Pitch (mm) 24
Number of tubes 241
26
Equipment Code E504
Type Shell and Tube
Operating Condition
Shell Tube
Data
Side Side
o
Operating pressure
101 101.325
(kPa)
No. of passes 1 2
Fouling factor (m2
o 0.00009 0.00009
C/W)
T LMTD (oC) 23.324
Heat Transfer Area
21.089
(m2)
Tube OD (mm) 19.050
Shell ID (m) 0.540
Tube Pitch (mm) 24
Number of tubes 36
Equipment Code E506
Type Shell and Tube
27
Table 1.27. T503 Condenser Specification (continued)
Operating Condition
Shell Tube
Data
Side Side
o
Operating pressure
101 42.05803
(kPa)
No. of passes 1 2
Fouling factor (m2
o 0.00009 0.00009
C/W)
T LMTD (oC) 34.453
Heat Transfer Area
15.743
(m2)
Tube OD (mm) 19.050
Shell ID (m) 0.540
Tube Pitch (mm) 24
Number of tubes 27
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.
28
Table 1.28. T501 Reboiler Specification
Equipment Name Reboiler
Equipment Code E503
Type Kettle
Operating Condition
Shell Tube
Data
Side Side
o
o
Operating pressure
101 1317.225
(kPa)
No. of passes 1 2
2
Fouling factor (m
o 0.00009 0.00009
C/W)
T LMTD ( C)o
57.682
Heat Transfer Area
32.405
(m2)
Tube OD (mm) 19.050
Shell ID (m) 0.540
Tube Pitch (mm) 24
Number of tubes 56
Equipment Code E505
Type Kettle
29
Table 1.29. T502 Reboiler Specification (continued)
Operating Condition
Shell Tube
Data
Side Side
o
o
Operating pressure
101 962.5875
(kPa)
No. of passes 1 2
2
Fouling factor (m
o 0.00009 0.00009
C/W)
T LMTD ( C)o
64.610
Heat Transfer Area
8.488
(m2)
Tube OD (mm) 19.050
Shell ID (m) 0.540
Tube Pitch (mm) 24
Number of tubes 15
Equipment Code E507
Type Kettle
Operating Condition
Shell Tube
Data
Side Side
o
o
30
Table 1.30. T503 Reboiler Specification (continued)
Operating Conditions
Operating pressure
42 1317.225
(kPa)
No. of passes 1 2
2
Fouling factor (m
o 0.0002 0.00009
C/W)
T LMTD ( C)o
36.430
2o
Heat Transfer Area
4.132
(m2)
Tube OD (mm) 19.050
Shell ID (m) 0.540
Tube Pitch (mm) 24
Number of tubes 7
1.1.10. Distillation Column

1.1.10.1. Distillation Column
Table 1.31. Distillation Column 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
31
Table 1.31. Distillation Column Specification (continued)
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
1.1.10.2. Extractive Column

Table 1.32. Extractive Column Specification
Equipment Name Extractive Distillation Column
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
o
Condenser Temperature ( C) 78.14
o
Boiler Temperature ( C) 149.379
Stage Efficiency (%) 55.813
Construction Data
Column Height (m) 5.8019
Column Diameter (m) 0.559
Material SS-316
Shell Thickness (in) 1.261
Head Thickness (in) 0.1046
32
1.1.10.3. Recovery Column

Table 1.33. Recovery Column Specification
Equipment Name Recovery Distillation Column
Function To recover EG from water
Operating Data
Feed Flow Rate 15.152 kgmole/hr
Reflux Ratio 1.935
Column Pressure 101.325 kPa
Condenser Temperature 87.218oC
Boiler Temperature 165.239oC
Stage Efficiency 55.41%
Construction Data
Column Height 5.331 m
Column Diameter 0.219 m
Material SS-316
Shell Thickness 1.259 in
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.
Table 1.34. Ethanol Dehydration Pump Specification (P-501)
Ethanol Dehydration
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
33
Table 1.34. Ethanol Dehydration Pump Specification (P-501) (continued)
Operation Data
3
Flow rate( ) 1.942 x 104

2
Friction Loss ( 2 ) 4.534
Efficiency (%) 75
Fluid Ethanol
Power (W) 16.51
Head (m) 6.52
NPSHa (m) 9.889
Table 1.35. Electricity Pump Specification (P-100)
Electricity
Equipment Name Pump
Operation Data
Temperature (K) 322.734

Density (3 ) 866
Pressure outlet (Pa) 6,302,000
Vapor pressure (Pa) 6,467.220
3
Flow rate( ) 4.251 x 104
Efficiency (%) 75
Fluid Water
Power (W) 3,567.85
Head (m) 742.13
NPSHa (m) 10.649
Table 1.36. New Condensate Pump Specification (P-401)
New Condensate
Equipment Name Pump
Operation Data
Temperature (K) 313

Density (3 ) 1022
Pressure inlet (Pa) 1,066,000
34
Table 1.36. New Condensate Pump Specification (P-401) (continued)
Operation Data
Vapor pressure (Pa) 33350
3
Flow rate( ) 4.142 x 106
Efficiency (%) 75
Mixture acetic acid,
Fluid
methanol and water
Power (W) 1.35
Head (m) 243.47
NPSHa (m) 6.33
Table 1.37. New Condensate Pump Specification (P-402)
New Condensate
Equipment Name Pump
Operation Data
Temperature (K) 303
1004
Density (3 )
3
Flow rate( ) 3.456 x 104
Efficiency (%) 75
Fluid Water
Power (W) 48.17
Head (m) 10.62
NPSHa (m) 9.16
1.1.12. Belt Conveyor

Conveyor is aim to load solid that has been crushed through a belt. The
specification of turbine is shown from table 1.37.
Table 1.38. Belt Conveyor
Type Flat & Roll
Inclination degree 30o
Width (inches) 16
Length (ft) 100
35
Table 1.38. Belt Conveyor (continued)
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.
Table 1.39. Clarifier Specification
Clarifier Mass Flow

9.26 Ton/h
Rate
Volumetric Flow Rate 9.186 m3/h
Clarifier Volume 10.104 m3
Clarifier Height 5 m
D2/D1 0.4 m
Y 3.333 m
y/(y+h) 0.4 m/m
D1 2.348 m
D2 0.939 m
Amount of Unit 1
1.1.14. Reverse Osmosis

Reverse osmosis is used to treat seawater before being used as boiler feed
water (BFW). The sizing steps are based on vendor product (DOW), feed water
source and specified product quality. The specification for RO membrane are
shown in Table 1.40.
Table 1.40. Reverse Osmosis 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)
36
SDI <5
Permeate Flow (gpm) 27
Recovery (%) 75
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
1.1.15. Absorption Chiller

Absorption chiller sizing, operating conditions and parameters are
obtained using standard for this unit from ASHRAE/IESNA Standard 90.1-1999
and ARI Standard 560. The data is shown in Table 1.41.
Table 1.41. Absorption Chiller Specification
Equipment Design
Refrigerant Ammonia-Water
Heat Input LP Steam
Cooler Cooling water
Temperature of Cooling Water

22.2
Entering Absorber (C)
Leaving Chilled Water

6.7
Temperature (C)
Chilled Water Temperature
5.6
Rise (C)
Entering Cooling Water
29.4
Tempertature (C)
Fouling Factor (m2. C/W) 0.000044
Efficiency 0.7 COP
37
1.2. Water Utility Sizing
1.2.1. Utility Process Description and Equipment
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
1.2.2. Utility Mass Balance
The overall mass balance of water treatment unit is shown in table below.
Table 1.42. Mass Balance Water Utility per Equipment
In (kg/h) Out (kg/h)

Equipment
Stream Mass Flow Stream Mass Flow
100 1,110,430.33 103 8,108.493
Stainer Filter 101 1.11 102 1,096,770.79
Deposite 5,552.157
T-501 103 8,108.493 104 8,108.493
104 8,108.493 105 8,067.951
F-503
Deposite 40.542
RO Unit 1 105 8,067.951 106 8,067.951
106 8,067.951 107 6,050.963
RO Unit 2
Precipitation 2,016.988
T-502 107 6,050.963 108 6,050.963
T-503 (CE-100) 108 6,050.963 109 6,050.963
T-503 (AE-
109 6,050.963 110 6,050.963
100)
Deaerator 110 6,050.963 111 5,748.415
Precipitation 302.548
38
1.2.3. Utility Sizing
1.2.3.1. Vesssel
Table 1 43. Vessel Specification (V-106)
Equipment Name V-Backwash Tank

Type of fluide Water
Temperature (C) 25
L/D 0.8
D (m) 13.021
L (m) 10.417
Thickness (mm) >12
Vessel head type Flat head
Material type HDPE
Table 1.44. Vessel Specification (V-ST)
Equipment Name V-Suckback Tank

Type of fluide Water
Temperature (C) 25
L/D 0.8
D (m) 11.822
L (m) 9.458
Thickness (mm) >12
Vessel head type Flat Head
Material type HDPE
39
Table 1.45. Cation Exchanger Specification
Name Cation Exchanger

Code CE-100
Function Remove soluble positive ions and water hardness
Operation Semi-continuous
Material Carbon Steel SA-283 Grade C
Type Vertical with Head Torispherical
Pressure Design (psi) 17.197
Amount (column) 2
3
Resin Volume (m ) 2.836
3
Flowrate (m /h) 6.051
Tank diameter (m) 0.628
Tank height (m) 0.889
shell thickness (mm) 5
head thickness (mm) 5
Table 1.46. Anion Exchanger Specification
Name Anion Exchanger

Code AE-100
Function Remove soluble negative ions and water hardness
Operation Semi-continuous
Material Carbon Steel SA-283 Grade C
Type Vertical with Head Torispherical
Amount (column) 2
3
Resin Volume (m ) 1.751
3
Flowrate (m /h) 5.977
Tank diameter (m) 0.667
Shell thickness (mm) 5
Head thickness (mm) 5
Table 1.47. Deaerator Specification
Code DA-100
Remove gases soluble in water, such as O2 and
Function
CO2 to preventive corrosion and deposite
Material Stainless Steel 316
40
Table 1. 47. Deaerator Specification (continued)
Type Vertical with Head Torisperical

Amount (column) 1
Volume /capacity
(m3) 1.815
Tank Diameter (m) 0.914
Shell thickness (mm) 5
Head thickness (mm) 6.35
1.2.3.2. Pump
Pump is an equipment to circulate the liquid phase fluid through pipe.

There are seven pumps in our water utility to process water to become cooling
water and boiler feed water. Pumps specification in this plant is shown in Table
1.48 to 1.54.
Table 1.48. Strainer Pump Specification (P-501)
Strainer Pump
Equipment Name Pump
Operation Data
Temperature (K) 303

Density (3 ) 1004
3
Flow rate( ) 0.3049
Efficiency (%) 75
Fluid Water
Power (W) 43,042.5
Head (m) 10.75
NPSHa (m) 9.167
41
Table 1.49. SW RO Booster Pump Specification (P-502)
SW RO Booster Pump
Equipment Name Pump
Operation Data
Temperature (K) 303

Density (3 ) 1004
Operation Data
3
Flow rate( ) 0.3033
Efficiency (%) 75
Fluid Water
Power (W) 62,838.17
Head (m) 15.79
NPSHa (m) 9.28
Table 1.50. Polishing Pump Specification (P-503)
Polishing Pump
Equipment Name Pump
Operation Data
Temperature (K) 303

Density (3 ) 1004
3
Flow rate( ) 1.660 x 103
Efficiency (%) 75
Fluid Water
Power (W) 339.64
Head (m) 15.58
NPSHa (m) 9.48
42
Table 1.51. High Pressure Pump Specification (P-504)
High Pressure Pump

Equipment Name Pump
Operation Data
Temperature (K) 303

Density (3 ) 1004
Pressure outlet (Pa) 1,185,502.5
3
Flow rate( ) 1.650 x 103
Efficiency (%) 75
Fluid Water
Power (W) 2391.92
Head (m) 10.62
NPSHa (m) 9.53
Table 1.52. Ion Exchange Pump Specification (P-505)
Ion Exchange Pump

Equipment Name Pump
Operation Data
Temperature (K) 303

Density (3 ) 1004
3
Flow rate( ) 1.650 x 103
Efficiency (%) 75
Fluid Water
Power (W) 671.90
Head (m) 30.97
NPSHa (m) 9.53
43
Table 1.53. Deaerator Pump Specification (P-506)
Deaerator Pump
Equipment Name Pump
Operation Data
Temperature (K) 303

Density (3 ) 1004
3
Flow rate( ) 1.650 x 103
Efficiency (%) 75
Fluid Water
Power (W) 226.29
Head (m) 10.43
NPSHa (m) 9.48
Table 1.54. Boiler Feed Water Pump Specification (P-507)
Boiler Feed Water Pump

Equipment Name Pump
Operation Data
Temperature (K) 303

Density (3 ) 1004
3
Flow rate( ) 1.589 x 103
Efficiency (%) 75
Fluid Water
Power (W) 12,936.48
Head (m) 620.02
NPSHa (m) 9.17
44
1.2.3.3. Pipe
Pipe is an important element in a plant because it is connecting one

equipment with another. Not only in main process unit, sizing pipe in water
process utility is an important thing to do. Plant layout is needed to sizing the
whole pipe, this pipe sizing is just preferred to the pipeline through the pump.
Table 1.55. Water Utility Pipe Specification
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
CHAPTER 2
PIPING AND INSTRUMENTATION DIAGRAM (P&ID)
2.1. Piping and Instrumentation Design

P&ID stands for Piping and Instrumentation Diagram or Drawing.
Alternatively, it could also be called Process and Instrumentation Diagram or
simply P&I diagram or drawing. A P&ID is a working document that is used by
every discipline involved in the design, engineering and construction of process
plants. It is used as a Process Plant Layout and Piping Design reference for
checking engineering and design documents and drawings associated with a
project.
Figure 2.1. P&ID of Electricity Production
Figure 2.2. P&ID of Pretreatment
Figure 2.3. P&ID of Ethanol Fermentation
Figure 2.4. P&ID of Ethanol Production
Figure 2.5. P&ID of Condensate Treatment
Figure 2.6. Water Treatment Utility
2.2. Plant Control Tabulation
Table 2.1. Plant Control Tabulation
Operation Controlled Controlling

Controller Function Control Procedures
Equipment Parameter Parameter
When the level transmitter give
an electric signal to the level
Controlling the level in indicator control, the LIC will
Mixer (MX- Level Control Level Indicator
Flow Rate hydrolisis reactor to be not give high alarm to control
101) Valve Control
higher than 80% room and operator should open
the outlet valve manually to
prevent flooding
The reaction within the reactor
in hydrolisis is endothermic.
Thus, wee need to keep the
reaction inside to the desired
Control the temperature of condition. The temperature
Hydrolisis reactor to keep the transmitter will give an electic
Temperature Temperature Indicator
Reactor (R- Temperature conversion of signal to TIC and the the signal
Transmitter Control
101) hemicellulose and will turn into pneumatic signal
cellulose high to flow into valve. If the
temperature is too high, the
reactor will increase the flow
of cooling water and vicce
versa.
Table 2.2. Plant Control Tabulation (continued)

When the pressure exceed 1.2
atm, the pressure transmitter
Control the pressure of
Pressure Relief Pressure Indicator will give an electic signal to
Pressure reactor by reducing exceed
Valve Control PIC and open the pressure
pressure
relief valve to reduce the
pressure inside reactor
When the flow transmitter of
Control the flow of mixer and solid EFB meet, the
Flow Indicator
Flow Rate Flow Control H2SO4 and recovery to flow will give pneumatic
Control
1:7 signal to control the ratio of
1:7 feed and H2SO4
Pressure in to the plate &
frame filter should not less
than.. Atm. Therefore,
Plate & Control the pressure of
Pressure Indicator should the pressure less than
Frame Filter Pressure Pressure Valve reactor by reducing exceed
Control atm, the pressure transmitter
(PFF-101) pressure
will give electric signal to PIC
and close the pressure valve to
reduce flow of output reactor
Motor analyzer is placed on
top of the reactor agitator to
Neutralizing Control the RPM of
give analyzer to DCS to keep
Reactor (R- Motor RPM Motor Analyzer agitator needed in the
the RPM at steady state to
401) reactor
reach optimum condition for
neutralization

Flow rate of Ca(OH)2 will be
Control the flow rate in to controlled though flow valve
Flow Indicator
Flow Rate Flow Control the reactor keep the pH and pH analyzer through
Control
inside reactor stay neutral product of neutralization
reactor
Flow rate of cold water in will
depend on the temperature
Temperature Temperature Indicator Control the cold water into
Temperature inside the reactor to keep the
Transmitter Control reactor
reaction not too hot since the
reaction will be exothermic
Reaction inside the is
exothermic, therefore the
Seed
temperature is controlled by
Fermentor &
cooling water. The temperature
Main Temperature Temperature Indicator Control the flow rate of
Temperature transmitter will emil pneumatic
Fermentor Transmitter Control water into the reactor
signal to release the colling
(R-403, R-
water inside the reactor should
402)
the temperature rise above
40oC
Flow transmitter will emit
pneumatic signal should the
Flow Indicator Control the flow inside the flowrate of seed fermenter
Flow Rate Flow Control
Control reactor higher than those of nitrogen
flowrate for saccharomyces
feed

Motor analyzer is placed on
top of the reactor agitator to
Control the RPM of
give analyzer to DCS to keep
Motor RPM Motor Analyzer agitator needed in the
the RPM at steady state to
reactor
reach optimum condition for
neutralization
Control the pressure of will give an electic signal to
Pressure Relief Pressure Indicator
Pressure reactor by reducing exceed PIC and open the pressure
Valve Control
pressure relief valve to reduce the
pressure inside distillation
column
Distillation
Column,
Control the pressure of will give an electic signal to
Extractive Pressure Relief Pressure Indicator
Pressure reactor by reducing exceed PIC and open the pressure
and Recovery Valve Control
pressure relief valve to reduce the
(T-501, T-
pressure inside distillation
502, T-503)
column
Flow transmitter will emit
Control the flow inside the pneumatic signal should the
Temperature Flow Indicator
Temperature reactor with cooling water temperature inside the column
Transmitter Control
and To condensate flow reach higher than 150oC and
emits cooling water

When the level of column
Control Flow of product reach higher than 80% of
Level Control Level Indicator out from distillationbottom space in column, the
Level
Valve Control column to prevent valve will open to emit the
flooding inside column flowrate to prevent the
flooding in bottom plate tray
Control the pressure of
Boiler (B- Pressure Relief Pressure Indicator will give an electic signal to
Pressure reactor by reducing exceed
301) Valve Control PIC and open the pressure
pressure
relief valve to reduce the
pressure inside steam drum
Flow transmitter of lignin will
be send through pneumatic
signal and Flow indication
Control the flowrate of
Flow Indicator control of Air will receive it
Flow Rate Flow Control lignin and air based on
Control and control the ratio of lignin
their ratio
and air to achieve complete
combustion within the process
needed
Flow of boiler feed water
Control temperature of
Temperature Temperature Indicator though heat exchanger will
Temperature boiler feed water inside the
Transmitter Control increase should the
boiler based on flowrate
temperature not achieve 167oC

Level transmitter in steam
drum will emit pneumatic
Control flowrate of boiler signal to prevent flooding
Level Control Level Indicator feed water to boiler to should it reach more than 80&
Level
Valve Control prevent flooding in steam of volume capacity of steam
drum drum and control valve will
lower or shut the flowrate into
boiler
Within the range of pH 6.9-8.3,
should the pH exceed or lower
within the range, the analyzer
Control the pH of CO2
Deaerator (T- transmitter will emit pneumatic
pH Flow Control Analyzer and amine based on the
402) signal to control flowrate of
flowrate to deaerator
amine and CO2 to keep pH
within the range given
conditions
Level transmitter in deaerator
Control flowrate of boiler
will emit pneumatic signal to
Level Control Level Indicator feed water to boiler to
Level prevent flooding should it
Valve Control prevent flooding to steam
reach more than 80& of
drum
volume capacity of deaerator
Pressure in to the pump will
emit pneumatic signal though
Pump (P-501, Control flow in to the
Pressure Relief Pressure Indicator pressure transmitter to PIC to
P-510, P-503, Pressure pump based on their
Valve Control reduce flowrate whether the
P-506) pressure in
pressure increase to reduce the
pressure inside and vice versa

Analyze concentration of
Control the flowrate of Natrium in Cation and
Ion Exchange Natrium in Anion concentration of SiO2 in
Analyzer Indicator
(T-503, T- Concentration Analyzer exchanger and SiO2 in Anion. If both of them already
Controller
504) Cation exchanger through exceed the concentration of
flowrate of control valve required, the flow rate of valve
will close
Analyzer Indicator Controller
Deaerator (T- Analyzer Indicator Control the concentration
Concentration Analyzer Analyzer to control the
403) Controller CO2 and O2 to deaerator
concentration of CO2 and O2
emit though deaerator
Level transmitter in deaerator
Level Control Level Indicator Control flowrate of boiler
Level prevent flooding should it
Valve Control feed water to boiler
reach more than 80& of
volume capacity of deaerator
CHAPTER 3
CONCLUSION
Based on this assignment, we can conclude several important things:

The piping instrument diagram includes a diagram representation of the
equipment, piping, and instrumentation.
The controlled parameter for off-grid plant is temperature, flow rate,
pressure and level.
The types of main equipment are steam generator reactor, distillation
column, separator, pump, heat exchanger, and storage tank.
Utilitys equipment in our plant are pump, strainer, filter RO, storage tank,
RO Unit 1, RO unit 2, ion exchanger, and deaerator.
REFERENCE
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
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Seider, W.D., Seader, J.D., Lewin, D.R., 1996. Product and Process Design
Principles. New York: John Wiley & Sons, Inc.
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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
Appendix B. Storage tank

In this off-grid plant is used vessel in process and utility. Vessel is used for
tank in proses or ulitity for pressure fluida.
1. Determine Storage Capacity In this case, we choose storage capacity is about
for storing 7-days of production.
Table B.1. Storage Tank Capacity
Storage Name Storage Capacity (m3)

V-Ethanol 776.354
V-EG 78.280
V-H2SO4 64636.910
V-Ca(OH)2 21.550
64
2. Choose Storage Tank Type: Vertical or Horizontal In this part, we determine

which type of storage tank that we should choose based on our storage
capacity.
Figure B.1. Algorithm to Choose Storage Tank Type Horizontal/Vertical
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.
Figure B.2. Algorithm to Choose Storage Tank Type Slim/Fat
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
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
66
Resin Volume
Resin Bed Height =
Resin Surface Area
4xResin Surface Area

Tank Diameter =
3.14
Tank Empty Space = 75%xResin Bed Height

Sand Layer = 50%xResin Bed Height
Total Bed Height = Resin Bed Height + Sand Layer + Graver Height
Total Tank Height = Empty Space + Total Bed Height
2. Calculate Design Pressure
g
RB (g ) 2KZT
[1 e(
c )
PB = R ]
2K
PL = KxPB
Ptotal = PB + PL
Pdesign = 1.1(Poperation + Ptotal )
3. Calculate Vessel Thickness
P. ri
ts = +C
f. E 0.6P
4. Determine Head
1 rc
W = (3 + )
4 icr
P. rc. W
th = +C
2f. e 0.2P
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
67
Volume of Tanki = 1.2 x 0.1437 m = 0.17244 m

2. Determine Tank Dimension
Top volume is Torispherical Flanged and Dished Head
Vd = 0.1039
1
Vtangki = DH + 0.1039D + 0.1039D = 4.1348D
4
H/D = 5
Vtangki = 4.1348D
0.17244 m = 4.1348 x D
D = 0.762 m
H/D = 5
H/0.762 m = 5
H = 3.811 m
Because D < D standart so it use standart diameter = 0.9144 m = 3 ft = 36 in
H < H standart so it use satndart height = 4.5721 m = 15 ft = 180 in
3. Calculate Tank Capacity
Pabs = Poperation + Phidrostatis
(h 1)
Pabs = 29.4 psi +
144
61.9399 lb/ft x(15 1)
Pabs = 29.4 psi +
144
Pabs = 35.421 psi
Design pressure 5-10% above absolute pressure (Coulson, 1988 hal.637).
Design pressure that choose is 10% above.
Pdesign = 1.1 xPabs = 1.1 x 35.421 psi = 38.964 psi
4. Determine Shell Thickness

=
2( 0.6)
+ ( & 1959 . 256)
Where : ts = Shell thickness, in
P = Pressure design, psi
f = Allowable Stress, psi
d = Shell Diameter, in
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.

=

=

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.
Figure C.1. Nominal Size of Pipe, Schedule 40 (in mm)
Figure C.2. Nominal Size of Pipe, many schedule (in inch)
(Source : Brownell & Young, 1959)

70
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
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
- Diameter of neutralization reactor
= 0.5089
- Height of Reactor
Hr=Hs+Hc = 2D+d = 1.01 + 0.13 = 1.14 m
Hf= (volume of liquid in reactor x height of reactor)/reactor volume
Hf= (0.20 x 1.14)/0.22 = 1.04 m
Di = 0.35 x D = 0.35 x 0.5089 = 0.178 meter
- Shell thickness
= [()/(. 0.6)] + ()
ds = 1.09 cm
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,
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
= 2.62
- Height of Reactor
Hr=Hs+Hc = 2D+d = 5.24 + 0.66 = 5.9 m
Hf= (27.26 x 5.9)/30= 5.35 m
Di = 0.35 x D = 0.35 x 2.62 = 0.92 meter
- Shell thickness
= [()/(. 0.6)] + ()
ds = 1.09 cm
h=0.33xD = 0.87 meter
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
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
= 4.63
- Height of Reactor
Hr=Hs+Hc = 2D+d = 9.26 + 1.16= 10.42 m
Hf= (151.03 x 10.42)/166.13= 9.48 m
Di = 0.35 x D = 0.35 x 4.63 = 1.62 meter
- Shell thickness
= [()/(. 0.6)] + ()
ds = 1.62 cm
h=0.33xD = 0.87 meter
Appendix E. Flash Separator

Flash separator is a tool used to separate chemicals by boiling point
difference of each component in the separator. In other words, it is used when the
difference of relative volatility is high enough. These are conditions that obtained
from simulation.

= . ( )^0.5

74
+
=
+
4
= ( )^0.5

= ( ).

=
(2 ) + 0.4
Table E.1. Flash Separator Calculation
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:
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
2. High Pressure Turbine

Because output power of the first turbine is 11124.76 kW, so use Rateau
turbine typical III.
Figure G.1. Rateau Turbine Typical III
Based on international design standard, the turbine with output power

11124.76 kW, can be operated with speeds 4000 6000 rpm, and usually used
4800 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
76

120
= = 5
25
From equation of Rateau turbine, diameter of turbine is

60 (1000 / )0.5
=
3.147
60 (1000 123 /2)0,5

= = 945.63
3.147 5
3. Medium Pressure Turbine

Because output power of the turbine is 1279 kW, so use Curtis turbine typical
III.
Figure G.2. Curtis Turbine Typical III
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
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
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.
Figure H.1. Boiler Design

1) Determine the volume of the furnace. This is done using equation

below with qv value determined from lignin data obtained from
HYSYS simulation.
2) Determining Hfu + Hb and heat transfer area in boiler (Fgrate).
79
3) Determining a and b which is furnace width and depth, but first

determine the value of qb for lignin.
Appendix I. Heat Exchanger

Shell and Tube Heat Exchanger
This type of heat exchanger is covering almost all heat exchanger in this
polygeneration plant due to its capacity and ability in handling large pressure and
temperature different. The exchangers which fall into this category in
polygeneration plant are majority of heat exchangers, condensers and reboilers.
Reboiler use a little bit different type of shell and tube heat exchanger which is
kettle shell and tube that has an extra room for vapor to go back to distillation
column.
The steps in designing this type of heat exchanger is listed below:
1) Determine heat flow which is exchanged, the mass flow and physical
properties of each fluid passing the heat exchanger. Physical properties
needed are pressure, temperature, heat capacity (Cp), conductivity (k), density
() and viscosity ().
2) Assume the value of overall heat transfer coefficient for the first guess. The
first assumption can be made by using the Table I.1.
80
Table I.1. Typical Overall Coefficicents
3) Calculate the Log Mean Temperature Different (LMTD)

1 = (2 1 )
2 = (1 2 )
1 2
=

ln (1 )
2
After, that determine the correction factor FT to calculate corrected LMTD

using the value of R and P, then determine the FT using the Figure I.1:
1 2
=
2 1
2 1
=
2 1
81
Figure I.1. Correction Factor Correlation

(Source : J. P. Holman, 1959)
4) Determine the tube and shell properties. The properties used in this plant is
almost the same for each exchanger, the typical value from heuristic is used.
The value is shown in Table I.2 and I.3. The difference is located at the
number of tube passes in shell which can be manipulated between 1 until 8.
Table I.2. Typical Tube Properties
Use 3/4 intube, 1.6 mm thickness, 4.88 m long

Outer Diameter 19.05 mm
Thickness 1.6 mm
Inner Diameter 15.85 mm
Tube length 4.88 m
Area per tube 0.292 m2
Number of tubes 14 Tubes
Tube cross sectional area 0.00020 m2
Area per pass 0.00279 m2
Volumetric flow 0.00033 m3/s
Tube side velocity, ut 0.11987 m/s
Table I.3. Typical Shell Properties
Tube pitch, Pt 23.8125 Mm

ID shell 21.25 In
Pitch Type Triangle
Number of Tube Passes in Shell 2
82
Table I.3. Typical Shell Properties
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
5) Calculate Heat Transfer Coefficient in Tube and Shell

=

Determine jh using Re data and L/D, baffle cut using Figure I.2 and I.3:
Figure I 2. Tube-side Heat Transfer Factor

(Source : J.P. Holman, 1959)
83
Figure I.3. Shell-side Heat Transfer Factor

1/3
=

1/3
=

= ( )

6) Calculate Overall Heat Transfer Coefficient

Fouling factor of the both fluid is determined using Table I.4 for known
fluids:
84
Table I 4. Typical Fouling Factor

=
+
Using newton-raphson method, change assumed U until U = Uc.

Plate and Frame Heat Exchanger
Plate and frame heat exchanger is used for some exchangers with low
pressure and temperature different. The steps for designing this type of heat
exchangers is shown below:
1) Determine heat flow which is exchanged, the mass flow and physical
properties of each fluid passing the heat exchanger. Physical
properties needed are pressure, temperature, heat capacity (Cp),
conductivity (k), density () and viscosity ().
2) Calculate Log Mean Temperature Different (LMTD)
(1 2 ) (2 1 )
=
1
ln 2
2 1
3) Determine some parameters listed in range at Table I.5.
Table I.5. PFHE Parameter Range
Plate Dimension Range

Length (m) Ratio of L/P: 2-3
Wide (m) Ratio of L/P: 2-3
Effective Area (m2) 0.03-1.5
Plate Spacing (m) 0.0015 0.005
Plate Thickness (m) 0.0005 -0.003
Hydraulic Mean Diameter (m) 2 x plate spacing
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:
Table I.6. Approximate Values of Overall Heat Transfer Coefficient

6) Calculate heat transfer area using LMTD, overall heat transfer
coefficient and plate area.
7) Calculate all coefficient needed, such as NOCP, CCSA and HMD.
8) Determine fouling factor of the cold and hot fluid using data from
Table I.7.
Table I.7. Fouling Factor Coefficient for PFHE
86
9) Calculate overall heat transfer coefficient by considering fouling factor

coefficient.
1 1 1 tp 1 1
= + + + +
U hf cold hf hot k SS204 foulinf factor cold foulinf factor hot
10) Using newton-raphson method, change assumed U until U = Uc.
Appendix J. Distillation Column

The mass and mole balance of the distillation column is shown in tables below
Table J.1. Mass and Mole Balance
Component Feed Distillate Bottom

Mole
Mole
Mole Rate Mol Rate Mol Mol
Name MW Rate
(kgmol/h) Fraction (kgmol/ Fraction Fraction
(kgmol/h)
h)
Glucose 180.15 9.26E-02 0.000272 0 1.73E-74 0.0926 2.89E-04
Xylose 150.13 6.24E-01 0.00183 0 1.00E-30 0.6241 1.95E-03
Cellulose 162.14 0 0 0 0 0 0
Hemicell
582 0 0 0 0 0 0
ulose
Lignin 1513.5 0 0 0 0 0 0
5-HMF 126.11 0 0 0 0 0 0
H2SO4 98.079 3.08E-01 0.000906 0 1.00E-30 0.308 9.61E-04
H2O 18 322.14649 0.94761 2.7399 0.14033 319.4066 0.9968
Ethanol 46 16.784962 0.04937 16.7849 0.859665 0 3.76E-08
Eglycol 62.07 0 0 0 0 0 0
Glycerol 92.09 0 0 0 0 0 0
339.95620 1 19.5248 1 320.4313 1
The properties of column is shown in the table below
Table J.2. Properties of Column
Properties Value Unit

F 339.956 kgmol/h
D 19.525 kgmol/h
B 320.431 kgmol/h
External Reflux Ratio 10.000
Reflux Ratio 4.823
87
Table J.2. Properties of Column
Vm top 214.775 kgmol/h

Lm top 195.250 kgmol/h
V'm bottom 214.775 kgmol/h
L'm bottom 535.206 kgmol/h
Minimum Tray 12.656 13
Actual Tray 17.640 18
Optimal Feed Stage 0.112 1
Column Efficiency 71.746 %
The properties of Reboiler and Condenser is shown in the table below
Table J.3. Properties of Reboiler and Condenser
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
Calculation of Column Diameter

First, we calculate the volumetric vapor flowrate at the stripping and
rectifying section.
88
Table J.4. Volumetric Flow Rate of Vapor
Vm (bottom) 214.775 m3/s

Vm (top) 210.775 m3/s
Second, we calculate the velocity of vapor at the stripping and rectifying

section.

=

Using the graph below, we can know the value of K which will be used to
calculate the velocity of vapor and liquid.
Figure J.1. Correlation of FLV and K

Table J.5. Velocity of Vapor
uf (bottom) 77.396 m/s

uf (top) 5.416 m/s
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
=

Table J.6. Minimum cross-sectional area and diameter needed
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.
Calculation of Column Height

First, we have to calculate the number of stage. We know from the
simulation that the minimum reflux ratio (RDm) is 4.834. Assume that the external
reflux ratio (RD) is 1.5 times RDm, so RDis 7.252. We use Gilliand equation and
graph to get the number of stage. We know that the minimum tray is 12.656.
6.842 4.561
= = 0.403
+ 1 7.841
90

Figure J.2. Gilliand equation and graph

= 0.267
+1
12.656
= 0.267
+1
= 17.64 18
Second, we assume that a plate spacing is 0.5 m. Therefore, the height is

18 stages x 0.5 meter/stage = 9 meters. The top and bottom space height is
assumed to be 0.25 m while bottom space height is also assumed to be 0.25 m.
Therefore, we can conclude that column height is 10.28 meters.
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
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%
92
The terms of velocity difference neglected due to its small number

No fitting
The pump power requirementcan be calculated by equation:

=
Where is mass flow, g is gravity acceleration, and H is head. The Wact or
BHP (brake horse power) is calculated by multiply FHP and efficiency.
Appendix L. Belt Conveyor

Belt Conveyor (1-CO-1) is used to transport Empty Fruit Bunches. The
capacity of the conveyor is 25 tons/h. Belt conveyor will be installed with the total
length of 8 m with elevation of 30. Another design parameter for the belt
conveyor:
a. Belt speed
Belt speed is the speed in order to fulfill our production capacity, which is 25
tons/hour.
b. Belt width
Belt width needs to be adjusted so that it can fulfill the nickel ore capacity.
From Tabel A.1, because the capacity of conveyor should be 25 tons/h, the belt
width should be above 16 inches. To ensure that the conveyor don't use too
much spaces, we decided to use 16 inches belt width with 300 elevation, thus
giving maximum capacity 29.16 tons/h.
Table L.1. Belt Conveyor Data for Capacity
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
94
Figure L.1. Power required for Empty Conveyor
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
95
Appendix N. Reverse Osmosis

Reverse osmosis is used to treat seawater before being used as boiler feed
water (BFW). The sizing steps are based on vendor product (DOW), feed water
source and specified product quality. The steps used are:
1) Consider feed source, feed quality, feed/product flow, and required

product quality.
Table N.1. Initial Data for Reverse Osmosis
Seawater, Open
Feed Source:
Intake, SDI < 5
Required Permeate Flow: 26.3 ppm
Six-element pressure vessels to be used
2) Select the flow configuration and number of passes.

The selected configuration is plug flow and number of passes is 1.
3) Select membrane element type.
The membrane type is chosen using DOW seawater reverse osmosis
product which is recommended based on the permeate flow and feed
water source. Table N.2 show the DOW reverse osmosis product.
Based on Table N.2, SW30HR is chosen.
Table N.2. Membrane Element Type
The effective membrane area is chosen for SW element based on

DOW. Based on Table I.3, 370 ft2 membrane area is chosen.
96
Table N.3. Active Membrane Area
4) Select average membrane flux.

Average membrane flux is determined using typical data for seawater
open intake source based on Table N.4 is 19 gfd.
Table N.4. Average Membrane Flux
5) Calculate the number of elements needed.

Divide the design permeate flowrate QP by the design flux f and by the
membrane surface area of the selected element SE (ft2 or m2) to obtain
the number of elements NE.
6) Calculate number of pressure vessels needed.

Divide the number of elements NE by the number of elements per
pressure vessel, NEpV, to obtain the number of pressure vessels, NV
round up to the nearest integer. For large systems, 6-element vessels
are standard, but vessels with up to 8 elements are available. For
smaller and/or compact systems, shorter vessels may be selected.
7) Select number of stages.
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.
Table N.5. Correlation Between System Recovery and Number of Stages
8) Select the staging ratio.

Selected staging ratio is 2:1..

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UNIVERSITAS INDONESIA

POLYGENERATION OF OFF-GRID SOLAR POWER,

CHEMICAL ENGINEERING DEPARTMENT

Polygeneration plant of off-grid solar power, biomass, ethanol and cooling

Figure 1.1. Boiler Model ....................................................................................... 20

Table 1.1. Warehouse Specification........................................................................ 8

1.1. Main Process Unit Sizing

Table 1.1. Warehouse Specification

1.1.2. Storage Tank

Equipment Name V-100

Table 1.2. Vessel Specification (V-100) (continued)

Density (kg/ m3) 737.2

Table 1.3. Vessel Specification (V-EG)

Equipment Name V-105

Table 1.4. Vessel Specification (V-106)

Equipment Name V-H2SO4 (Make-UP)

Table 1.5. Vessel Specification (V-107)

Equipment Name V-Ca(OH)2

Table 1.6. Ethanol Pipe Specification

Name Ethanol Unit

Table 1.7. Electricity Pipe Specification

Name Electricity Unit

Table 1.8. Mixing Tank Pipe Specification

Name Mixing Tank Unit

Table 1.8. Mixing Tank Pipe Specification (continued)

Table 1.9. Deaerator Pipe Specification

Name Deaerator Unit

Table 1.10. Hydrolysis Reactor Specification

Table 1.10. Hydrolysis Reactor Specification (continued)

1.1.4.2. Neutralization Reactor

Table 1.11. Neutralization Reactor Specification

Table 1.11. Neutralization Reactor Specification (continued)

Length of Baffle 0.05 m

1.1.4.3. Seed Fermenter

Table 1.12. Seed fermenter Specification

Table 1.13. Main Fermenter Specification

1.1.5. Flash Separator

Table 1.14. Separator Specification

High Pressure Turbine

Table 1.15. High Pressure Turbine Specification (continued)

1.1.6.2. Medium Pressure Turbine

Medium Pressure Turbine

Table 1.16. Medium Presure Turbine Specification (continued)

1.1.6.3. Vacuum Pressure Turbine

Vacuum Pressure Turbine

Table 1.17. Vacuum Pressure Turbine Specification (continued)

1.1.7. P&F Filter

Table 1.18. P&F Filter

Figure 1.1. Boiler Model

(Source: ThermCraft, Inc.)

Table 1.19. Boiler Specification

1.1.9. Heat Exchanger

Table 1.20. BFW Preheater Specification

Table 1.21. Filtrate Preheater Specification

Table 1.22. CCP Condensate Condenser Specification

Table 1.23. HP Condensate Condenser Specification

T LMTD (oC) 58.322

Table 1.23. HP Condensate Condenser Specification (continued)

Table 1.24. Turbine Condensate Condenser Specification

Table 1.24. Turbine Condensate Condenser Specification (continued)

Tube Thickness (mm) 0.710

Table 1.25. T501 Condenser Specification

Table 1.26. T502 Condenser Specification

Table 1.27. T503 Condenser Specification