Kapasitas
: 50.000 ton/tahun
Waktu opersi
: 330 hari/tahun
: 24 jam/hari
tahun
ton
330 hari 24 jam
= 6.313,1313 kg/jam
: 10.731,7844 kg/jam
= 75 %
CaF2
= 6,5 %
CaCO3
=5%
SiO2
=5%
Al2O3
=2%
Fe2O3
=2%
Impurities
= 4,5 %
1.
Ball Mill
20 % dari H-115
C-114
H-115
F-111 A
Pada Ball Mill terjadi penambahan 20% bahan recycle dari screen.
Persamaannya :
Recycle (bahan masuk dari screen) =
2,5
x bahan masuk Ball Mill
7,5
Masuk
Keluar
Ke H-115 (Kg/jam)
Ca3(PO)4
8.048,8383
Ca3(PO)4
10.061,0479
CaCO3
536,5892
CaCO3
670,7365
CaF2
697,5660
CaF2
871,9575
SiO2
536,5892
SiO2
670,7365
Al2O3
214,6357
Al2O3
268,2946
Fe2O3
214,6357
Fe2O3
268,2946
Impurities
482,9303
Impurities
603,6629
Total
13.414,7305
Ca3(PO)4
2.012,2096
CaCO3
134,1473
CaF2
174,3915
SiO2
134,1473
Al2O3
53,6589
Fe2O3
53,6589
Impurities
120,7326
Total
13.414,7305
2.
Screen
Fungsi : Memisahkan atau mengayak batuan phosphate dengan ukuran 200 mesh.
Asumsi: 20% bahan masuk tidak lolos ayakan dan di recycle ke Ball Mill.
C-114
C-114
Screen
F-136
= 8.048,8383 + 2.012,2096
= 10.0061,0479 kg/jam
CaF2
= 697,5660
= 871,9575 kg/jam
+ 174,3915
CaCO3
= 536,5892
+ 134,1473
= 670,7365 kg/jam
SiO2
= 134,1473
+ 536,5892
= 670,7365 kg/jam
Al2O3
= 214,6357
+ 53,6589
= 268,2946 kg/jam
Fe2O3
= 214,6357
+ 53,6589
= 268,2946 kg/jam
Impurities
= 482,9303
+ 120,7326
= 603,6629 kg/jam
= 10.0061,0479
0,2
= 2.012,2096 kg/jam
CaCO3
= 670,7365
0,2
= 134,1473 kg/jam
CaF2
= 871,9575
0,2
= 174,3915 kg/jam
SiO2
= 670,7365
0,2
= 134,1473 kg/jam
Al2O3
= 286,2946
0,2
= 53,6589 kg/jam
Fe2O3
= 286,2946
0,2
= 53,6589 kg/jam
Impurities
= 603,6629
0,2
= 120,7326 kg/jam
= 10.0061,0479
0,8
= 8.048,8383 kg/jam
CaCO3
= 670,7365
0,8
= 536,5892 kg/jam
CaF2
= 871,9575
0,8
= 697,5660 kg/jam
SiO2
= 670,7365
0,8
= 536,5892 kg/jam
Al2O3
= 286,2946
0,8
= 214,6357 kg/jam
Fe2O3
= 286,2946
0,8
= 214,6357 kg/jam
Impurities
= 603,6629
0,8
= 482,9303 kg/jam
Masuk
Keluar
Ke F-116 (Kg/jam) :
Ca3(PO)4
10.0061,0479
Ca3(PO)4
8.048,8383
CaCO3
670,7365
CaCO3
536,5892
CaF2
871,9575
CaF2
697,5660
SiO2
670,7365
SiO2
536,5892
Al2O3
268,2946
Al2O3
214,6357
Fe2O3
268,2946
Fe2O3
214,6357
Impurities
603,6629
Impurities
482,9303
2.012,2096
Total
3.
13.414,7305
CaCO3
134,1473
CaF2
174,3915
SiO2
134,1473
Al2O3
53,6589
Fe2O3
53,6589
Impurities
120,7326
Total
13.141,7305
Mixer
Fungsi : tempat melarutkan batuan phosphat
WP
Mixer
F-116
R-110
1000 Kg
V2
60 Kg
M2
10.731,7844 Kg
M2 V2
1000 60
10.731,7844 V2
V2
634,9071 Kg
Keluar
Ke R-110 (Kg/jam) :
Ca3(PO)4
Ca3(PO)4
8.048,8383
CaCO3 =
536,5892
CaCO3
536,5892
CaF2
697,5660
CaF2
697,5660
SiO2
536,5892
SiO2
536,5892
Al2O3
214,6357
Al2O3
214,6357
8.048,8383
Fe2O3
214,6357
Fe2O3
214,6357
Impurities
482,9303
Impurities
482,9303
H2O
634,9071
Total
11.375,6915
4.
H2O
634,9071
Total
11.375,6915
Reaktor
Fungsi : tempat bereaksinya batuan phosphat dengan asam sulfat.
Penampung
Gas
M-117
R-110
H-123
F-111 B
3 CaSO4.2H2O + 2 H3PO4
95 %
CaSO4.2H2O + 2 HF
CaSO4.2H2O + CO2
d) 4HF + SiO2
SiF4
2H2O
= 310,1778
H2O
= 18,0152
CaF2
= 78,0725
H2SO4
= 98,0789
CaCO3
= 100,0873
CaSO4.2H2O = 172,1719
SiO2
= 60,0843
H3PO4
= 97,9950
CO2
= 44,0095
HF
= 20,0063
95 %
3CaSO4.2H2O + 2 H3PO4
73,9550
147,9099
73,9550
49,3033
S : 1,2975
73,9550
147,9099
73,9550
49,3033
= 24,6517
Kmol/jam
= 7.646,3964 Kg/jam
= 1,2975
Kmol/jam
= 402,4219 Kg/jam
H2SO4 yang dibutuhkan
= 73,9550
Kmol/jam
= 7.253,4219 Kg/jam
H2O yang dibutuhkan
= 147,9099 Kmol/jam
= 2.664,6271 Kg/jam
= 73,9550
Kmol/jam
= 12.732,9673 Kg/jam
H3PO4 yang terbentuk
= 49,3033
Kmol/jam
= 4.831,4780 Kg/jam
2.
CaF2
+ H2SO4 + 2 H2O
CaSO4.2H2O + 2 HF
M : 8,9345
B : 8,9345
8,9345
17,8691
8,9245
17,8691
S :0
8,9345
17,8691
8,9245
17,8691
= 8,9345
Kmol/jam
= 679,5660 Kg/jam
H2SO4 yang dibutuhkan
= 8,9345
Kmol/jam
= 876,2898 Kg/jam
H2O yang dibutuhkan
= 17,8691
Kmol/jam
= 321,9250 Kg/jam
CaSO4.2H2O yng terbentuk
= 8,9245
Kmol/jam
= 1.538,2767 Kg/jam
HF yang terbentuk
= 17,8692
Kmol/jam
= 357,4942 Kg/jam
3.
CaCO3
+ H2SO4 + H2O
CaSO4.2H2O +
CO2
M : 5,3612
B : 5,3612
5,3612
5,3612
5,3612
5,3612
S :
5,3612
5,3612
5,3612
5,3612
= 5,3612
Kmol/jam
= 536,5892 Kg/jam
H2SO4 yang dibutuhkan
= 5,3612
Kmol/jam
= 525,8218 Kg/jam
= 5,3612
Kmol/jam
= 9923,0500 Kg/jam
CO2 yang terbentuk
= 5,3612
Kmol/jam
= 235,9443 Kg/jam
4.
4HF
+ SiO2
SiF4
2H2O
M : 17,8691
8,9306
B : 17,8691
4,4673
4,4673
8,9345
S :
4,4633
4,4673
8,9345
HF yang bereaksi
= 17,8691 Kmol/jam
= 357,4942 Kg/jam
= 4,4673
Kmol/jam
= 268,4128 Kg/jam
SiO2 yang tersisa
= 4,4633
Kmol/jam
= 268,1764 Kg/jam
SiF4 yang terbentuk
= 4,4673
Kmol/jam
= 464,9494 Kg/jam
H2O yang terbentuk
= 8,9345
Kmol/jam
= 160,9575 Kg/jam
H2SO4 yang dibutuhkan untuk semua reaksi = 8.655,5335 Kg/jam
Asumsi : H2SO4 98% ke Reaktor berlebih 10 %
H2SO4 98% masuk Reaktor
= 9.503,7758 Kg/jam
Komposisi H2SO4 98 % :
H2SO4
= 9.330,6651 Kg/jam
H2O
= 173,1107
Kg/jam
= 3.083 Kg/jam
Masuk
Keluar
Ke H-123 (Kg/jam) :
Ca3(PO)4
8.048,8383
Ca3(PO)4 sisa =
402,4419
CaCO3
536,5892
H3PO4
4.831,4780
CaF2
697,5660
CaSO4.2H2O =
15.194,2940
SiO2
536,5892
SiO2 sisa
268,1764
Al2O3
214,6357
Al2O3
214,6357
Fe2O3
214,6357
Fe2O3
214,6357
Impurities
482,9303
Impurities
482,9303
H2O
634,9071
H2O
804,8646
H2SO4 sisa
848,2423
H2O
Ke Penampung (Kg/jam) :
3.083,1254
SiF4
464,9494
H2SO4
9.503,7758
CO2
235,9443
Total
23.962,5926
Total
23.962,5926
5.
Diketahui
Kg/jam
= 0,98 4.831,4780
= 4.734,8485 Kg/jam
H2SO4
= 0,98 848,2423
= 831,2774
Kg/jam
H2O
= 0,98 804,8646
= 788,7673
Kg/jam
Dari (Perry), kelarutan CaSO4.2H2O pada suhu 60oC adalah 0,2575/100 kg H2O
Jadi CaSO4.2H2O yang terikut filtrat
Masuk
Keluar
Ke V-120 (Kg/jam) :
Ca3(PO)4 sisa =
402,4419
H3PO4
H3PO4
4.831,4780
CaSO4.2H2O =
537,0637
CaSO4.2H2O =
15.194,2940
H2O
2.085,6843
SiO2 sisa
268,1764
H2SO4
831,2774
4.734,8485
Al2O3
214,6357
Ke F-124 (Kg/jam) :
Fe2O3
214,6357
Ca3(PO)4 sisa =
402,4419
Impurities
482,9303
H3PO4
96,6296
H2O
804,8646
CaSO4.2H2O =
14.657,2303
H2SO4
848,2423
SiO2 sisa
268,1764
Al2O3
214,6357
H2O
Fe2O3
214,6357
Impurities
482,9303
H2O
16,0973
H2SO4
16,9648
Total
24.558,6159
Total
6.
1.296,9170
24.558,6159
Evaporator
Komponen
H3PO4
Kg/jam
Fraksi
4.734,8485
0,5782
537,0637
0,1015
2.085,6843
0,2547
831,2774
0,0656
CaSO4.2H2O
H2O
H2SO4
Total
8.188,8739
Kadar pemekatan
: 75 %
Neraca Komponen
Feed
: 8.188,8739 Kg/jam
xf
: 0,5782
xL
: 0,75
Neraca Komponen
F xf = L xL
: L=
Neraca Massa Total
= L+V
= L+V
: 8.188,8739 = 6.313,1313 + V
= 8.188,8739 - 6.313,1313
= 1.875,7426 Kg/jam
: 1.875,7426 Kg/jam
Keluar
Ke F-130 (Kg/jam) :
H3PO4
4.734,8485
H3PO4
CaSO4.2H2O =
537,0637
CaSO4.2H2O =
537,0637
H2O
2.085,6843
H2O
209,9417
H2SO4
831,2774
H2SO4
831,2774
4.734,8485
Ke Ejector (Kg/jam) :
Total
Kemurnian Produk
8.188,8739
Uap H2O
1.875,7426
Total
8.188,8739
4.734,8485
100 % = 75 %
6.313,1313
= 4.734,8485 1,38
= 3.431,0496
=
3.431,0496
100 % = 0,5435 = 55 %
6.313,1313