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Assignment 1 Presentation

CHEMICAL PLANT DESIGN

}
GROUP 26
Amirah Amatullah
(1206262071)
Farisa Imansari

(1206212426)

Nurhayati

(1206246616)

Osvaldo Sahat

(1206247796)

Shella

(1206238721)

CHAPTER I
Background
Literature overview
Raw Material Analysis
Market and Production
Capacity Analysis
Plant Location Analysis
CHAPTER III
Mass Balance
Energy Balance

CHAPTER II
Process Selection
Process Description
Block Flow Diagram
Process Flow Diagram

CHAPTER IV
Conclusion

{
Indonesia is the largest producer
and exporter of palm oil worldwide.
Each processing of 1 ton fresh fruit
bunch will be generated 22-23% oil
palm empty fruit bunch

Currently the oil palm empty fruit


bunch ash just used as fertilizer.
Other alternative use of oil palm
empty fruit bunch ash need to be
considered

}
Oil palm empty fruit bunch usually
used by the CPO industry as fuel for
the boilers and burners, which
generating oil palm empty fruit
bunch ash.

Oil palm empty fruit bunch ash


known to have high potassium
levels. That could be used as a
source of potassium chloride which
has a variety of uses in industry

}
Properties of potassium chloride

Potassium chloride is typically


extracted from the ground via
traditional subsurface mining
techniques and solution mining.
The largest use of potassium
chloride is as a fertilizer. It is also
used in chemical manufacture,
pharmaceutical, food processing
and also used in petroleum industry.

Chemical formula

KCl

Molar mass

74.5513 gmol1

Appearance

white crystalline solid

Odor

odorless

Density

1.984 g/cm3

Melting point

770 C (1,420 F; 1,040 K)

Boiling point

1,420 C (2,590 F; 1,690 K)

Solubility in water

(Source: various

Potassium chloride is a colorless or


white, cubic, crystalline compound
that closely resembles sodium
chloride

Properties

281 g/L (0C)


344 g/L (20C)
567 g/L (100C)

Solubility

soluble in glycerol, alkalies


slightly soluble in alcohol,
insoluble in ether

Acidity (pKa)

~7

The main raw material of potassium chloride plant is oil palm empty fruit bunch ash,
which often used as fertilizer. Oil palm empty fruit bunch ash has high potassium
levels. The chemical composition of oil palm empty fruit bunch ash is:

(Source: Nurhayati Abdullah and Fauziah Sulaiman, 2013)

The ash composition of the oil palm empty fruit bunch

Availability and potential of oil palm empty fruit bunch ash can be seen from the
CPO plant production capacity data. Here is palm oil production data from 2007
until 2015:
Palm oil production and export

2007

2008

2009

2010

2011

2012

2013

2014

2015

Production
(million metric tons)

16.8

19.2

19.4

21.8

23.5

26.5

27.0

31.0

31.5

Export
(million metric tons)

n.a

14.2

15.5

15.6

16.5

18.1

21.2

20.0

19.5

n.a

15.6

10.0

16.4

20.2

21.6

19.0

18.4

Export
(in USD billion)

(Source : Food and Agriculture Organization of the United Nations, Indonesian Palm Oil Producers Association
(Gapki) and Indonesian Ministry of Agriculture, 2015)

The CPO industry will obtain oil palm fruit empty bunch waste around 1.2-1.4 tons for
each ton CPO production
7

KCl is currently produced from three


major production regions; Canada,
Russia,
and Belarus (together
account 60% of global production)
Global potash consumption is
currently 60 million tons, and
expected to grow to 70 million tons
by 2020 and 80 million tons by 2025
according to Fertecon
According to CRU, 91 percent of all
KCl used in fertilizers
Forecast of global KCl deliveries to 2017
Source: (CRU, 2012)

Together, the U.S., Brazil, China and India represent about two-thirds of world potash
consumption
8

}
In this analysis we will
use the global
demand of
potassium chloride
data as our
reference to
determine the
capacity

These data show


overall demand of
potassium chloride,
which include the
KCl use for fertilizer
(91%) and also for
non-fertilizer (9%)

For market share we


only take 2% from
the demand (we
consider the
presence of raw
material)

Market analysis of potassium chloride

Parameter
Global demand of potassium chloride in Southeast Asia, 2015
Global demand of potassium chloride for non-fertilizer
Global demand of potassium chloride for industrial
Market share
Production capacity for Southeast Asia
Production capacity of our plant (Just to meet the demand of
4 countries)
Production capacity / day

Quantity
6 million
540000
54000
2%
1080

Unit
Tons/year
Tons/year
Tons/year
%
Tons/year

Source
CRU
CRU
K+S Group
Assumption
Calculation

390

Tons/year

Calculation

1,2

Tons/day

Assumption: 330
work day

{
Primary
Factor

Plant location should be near from the source of raw material


Knowing the target market is one of important aspect in determining the
location of the plant
Transportation facilities will influence the process of delivering the
products and also transport of raw materials

The availability of utilities in the plant location is one of the important


factors in considering the plant site selection

Secondary
Factor

Soil and climate conditions is one of the main factors in choosing a plant
location. We need to choose the area, which is not vulnerable to the
danger like landslides, earthquakes, and floods, as a location for our
plant.

10

}
(Source: Googlemaps.com, 2015)

We decided to built our plant beside PT Agronusa Investama in Sambas, West Kalimantan,
with the production capacity of up to 390 tons/year

Place of Sambas, near Malaysia, Singapore, and Brunei Darussalam


11

The advantages to build potassium chloride plant near PT.


Agronusa Investama are:
It is not too far from the center of West Kalimantan (Pontianak)

Close from the source of raw material, which make it more efficient
and make the transportation costs is low
It is near the harbor (Sintete) which made us easier to deliver
potassium chloride to Singapore, Malaysia, and Brunei Darussalam.
This advantages can reduce the cost of exported the product

12

Process Selection

Neutralization

Material

Purification

Equipment

14

Neutralization is used to separate Potassium from the other logam ,


such as calcium and magnessium to form potassium chloride (KCl)
Neutralization reactions involve the reaction of an acid with a base (hydroxide).
This separation using precipitation method, where strong acids reacted with salts
of strong acids so the solution not dissolve

1 .NaCl + K + KCl + Na+

2. HCl + K+ KCl + H+

15

}
Ksp

HCl + K+ KCl + H+

Reactivity

Lattice
enthalpy

HCl selected because Ksp values


of HCl is higher than NaCl, so
neutralization will work faster when
using HCl solution.

Potassium is more reactive than the


sodium, the potassium is easier
ionizing and become soluble so that
it will not happen precipitation
reaction.

Lattice enthalpy NaCl > Lattice


enthalpy KCl, so K+ ion tends to
be more soluble in concentrated

16

}
Parameter

Percentage

Time needed during the


process

NaCl

HCl

Rating

Scoring

Rating

Scoring

15%

0.3

0.75

CAPEX and OPEX

25%

1.25

0.75

Solubility

25%

0.75

1.25

Energy needed for


neutralization process

10%

0.2

0.4

11

2.5

18

3.15

TOTAL

65%

17

There are two general purification process to separate


potassium and other ions.

Mixing boiling
boiling water
Mixing
water

Evaporation
Evaporation

18

Mixing boiling water

Evaporation

The energy thermal of boiling water


came from boiler.
The type of boiler used is thermal liquid
heater
The most common heat sources are gas
and oil fuels, and electricity.
But, thermal fluids typically do not
transfer heat as well as water, serious
containment problems with thermal fluids
at high temperatures, including corrosion,
erosion, and freezing.
The cost production of this process is
expensive

The energy of evaporator using steam.


The purity of the evaporator has a higher
purity level than mixing boiling water up
to 96.5%,
Heat energy from the evaporator only
from steam
Evaporator no need to use distilled water
in the process.
Capital cost evaporator is smaller than
the mixing boiling water from the energy,
utility, and equipment.

19

}
Parameter

Percentage

Purity

Evaporator

Mixing Boiling Water

Rating

Scoring

Rating

Scoring

25%

1.25

0.75

Energy
requirement

25%

1.25

0.75

Utility for water

25%

1.25

0.5

CAPEX and OPEX

25%

1.25

0.75

TOTAL

25%

11

2.5

18

1.5
20

}
Main Raw Material: Ash from oil palm fruit empty fruit
bunches
Silo Tank: A vessel or a container which is specifically
functioned to safe raw materials in bulk.

Silo Tank

It enables an easy and significant way of raw materials


storing.
It might increase the production capacity.
It can provide a higher quality of raw materials since it
is highly impenetrable by pollutants.
It provides a cleaner working environment because
the raw materials used is measured and transferred to
the next equipment process automatically through a
safe and enclosed tube.
21

{
Leaching: an operation where the two
phases involved, solid and liquid, are in
intimate contact. The solutes are able to
diffuse from the solid to the liquid phase,
causing a separation of the components
originated in the solid.
Water leaching: construed as the removal
of water soluble and ion-exchangeable
inorganic constituents from solid substrate
with water. It is an inexpensive method to
decrease inorganic constituents in the
biomass content.

}
Except KCl, there would still be some other
constituents dissolved. Counter-current leaching
is applied in this leaching process to increase
the potassium chloride concentration in the
leaching liquor.

Countercurrent Leaching. (A) Launder; (B) Rake; (C) Pump

22

PROCESS OPERATION CONDITIONS


Ratio of the liquid and solid fed to the unit 10:1
Stirring speed 550 rad/min
Time 30 minutes
Temperature 35oC
Pressure 1 bar
Inlet per day 7 tons of ashes, 70 tons of water
Liquid out 70.7161 tons/day
Solid out 6.2839 tons/day

23

The liquid containing potassium that is generated from water leaching is transferred to
a batch reactor vessel where it is subjected with hydrochloric acid to form a
neutralization reaction.
Objective: to precipitate potassium chloride by
reacting potassium ion from the leached ashes with
hydrochloric acid.
The reaction between potassium and hydrochloric
acid has the lowest Ksp value compared to the
other compounds if reacted with said acid.
Since it has the lowest Ksp value, potassium chloride
is more likely to precipitate first before the other
precipitation that can occur (calcium chloride or
magnesium chloride).

Batch Reactor Illustration


24

PROCESS OPERATION CONDITIONS


Temperature 27oC
Pressure 1 bar of
Time 1 hour
Inlet per day 70.7161 feed, 1.26817 HCl
Outlet 71.98427 tons/day

25

Filtration: the process of separating suspended solid matter from a liquid, by causing the
latter to pass through the pores of some substance called a filter. The liquid that passes
through the filter is called the filtrated.
Objective: the removal of the residual liquid that wets the potassium chloride produced
after the neutralization process. The liquid from wet potassium chloride formed from the
neutralization process is full of Calcium and Magnesium ions which could affect the
purity of potassium chloride needed.

Microfiltration: a common form of physical


filtration process where a contaminated
fluid is flown through an exclusively
specific
pore-sized
membrane
to
separate the solid and suspended
particles from process liquid.

Doesnt need additional cleaning chemicals, generates


high flow throughput and dry concentrate
Needs low operation costs
Uses pressure less than 4 bar
Fully automatic
Constructed from stainless steel
Provides a process as sterile as possible.

26

PROCESS OPERATION CONDITIONS

Time 30 minutes
Temperature 27oC
Pressure 1 bar
Membrane size 0.1 m
Feed Inlet 71.98427 tons/day
Filtrate 63.75 tons/day
Concentrate 8.24 tons/day

27

{
Falling film evaporator is constructed
with vertical shell-and-tube heat
exchanger, with a laterally or
concentrically arranged centrifugal
separator.

Typical Falling Film Evaporator Configuration

}
Objective: to produce a more moistureless final
product.
Evaporation: the process by which water changes
from a liquid to a gas or vapor.
Provides a higher product quality due to the gentle
evaporation and extremely short residence times in the
falling film evaporator.
Caters high energy efficiency, due to the multipleeffect arrangement or heating by thermal or
mechanical vapor recompressor.
Requires simple process control and automation.
Reacts quickly to changes in energy supply, vacuum,
feed quantities, concentrations, etc. (Important for a
uniform final concentrate).
28

PROCESS OPERATION CONDITIONS

Temperature 95oC
Time 30 minutes
Pressure 1 bar
Feed is heated in advance with a heater until it reaches 95oC.
Requires a steam generator
Feed inlet 8.246 tons/day
Gas out 7.071 tons/day
Solid out 1.165 tons/day

29

Crystallization: chemical solidliquid separation technique, where mass transfer of a solute


from the liquid solution to a pure solid crystalline phase occurs; the formation of solid
crystal precipitating from a solution, melt or more rarely deposited directly from a gas.
Objective: to form potassium chloride with more pure and more uniform-sized.

Draft-Tube Crystallizer with DirectContact Cooling

Draft-tube (DT) crystallizer uses direct-contact cooling,


evaporation, or adiabatic evaporative cooling to
generate supersaturation.
It provides a mixed suspension as the active volume
for relieving the supersaturation.
This type of crystallizer employs internal magma
recirculation to control supersaturation generation.
It usually provides a mechanism for classified product
removal.
30

PROCESS OPERATION CONDITIONS

Temperature 18oC
Pressure 1 bar
Time 30 minutes
Feed inlet 1.165 tons/day
Solid Outlet 1.165 tons/day
Requires a chiller for the cooled water as cooling agent
Feed is cooled in advance with a cooler until it reaches 18oC.

31

{
EPOFB
Ashes

Storage

EPOFB
Ashes

Water

Leaching

}
Leached
Liquid

Leaching Residual

HCl

Neutralization
Mineral Residue

Steam
KCl (Wet)

Microfiltration

KCl Cake

Evaporation

KCl (Dry)

Crystallization

Residue
KCl

Packaging
32

33

EPOFB Ash Input


Stream
(Ton/day)
Component
Input Output
Ash (Biomass)
7
7
Water
K+
Ca2+
Mg2+
HCl
KCl
Total
7
7

35

Mass Balance of Leaching Process


Component
Ash
(Biomass)
Water
K+
Ca2+
Mg2+
HCl
KCl
Total

Solid
In

Stream (Ton/day)
Liquid
Liquid
In
Out

Solid
Out

6.23

70
70

70
0.603
0.100
0.013
-70.72

0
0
0
0
-6.23

Mass Balance of Acid Base


Neutralization Process
Component
Ash
(Biomass)
Water
K+
Ca2+
Mg2+
HCl
KCl
Total

Stream (Ton/day)
Input
HCl 37%
Output

70
0.603
0.100
0.013
70.72

0.706
0.563
1.27

70.71
0
0.100
0.013
0
1.16
71.98

36

Mass Balance of Microfiltration Process


Component

Stream (Ton/day)
Feed

Filtrate

Concentrate

Ash
(Biomass)

Water

70.71

63.63

7.070

K+

Ca2+

0.100

0.100

Mg2+

0.013

0.013

HCl

KCl

1.165

1.165

Total

71.98

63.75

8.236

Mass Balance of Evaporation Process


Component

Ash
(Biomass)
Water
K+
Ca2+
Mg2+
HCl
KCl
Total

Stream (Ton/day)
Feed
Vapor
Liquor

7.070
0
0
0
0
1.165
8.236

7.070
0
0
0
0

0
0
0
0
0
1.165
1.165

7.070

37

Mass Balance of Crystallization Process


Component

Ash
(Biomass)
Water
K+
Ca2+
Mg2+
HCl
KCl
Total

Stream (Ton/day)
Feed
Vapor Product
-

1.165
1.165

0
0

1.165
1.165

Mass Balance of Filling Process


Component

Ash
(Biomass)
Water
K+
Ca2+
Mg2+
HCl
KCl
Total

Stream (Ton/day)
Input
Output
-

1.165
1.165

1.165
1.165

38

Energy Balance of Water Leaching Process


Input (kJ)
Ash
Water
K+
Ca2+
Mg2+
Total

205800
10265500
10471300

Output (kJ)
Ash
Water
K+
Ca2+
Mg2+
Total

Heat Loss (kJ)

184746.66
10265500
11391.03
2207.205
488.775
10464333.67

6966.33

Energy Balance of Neutralization Process


Input (kJ)
Water
K+
Ca2+
Mg2+
HCl 37%
KCl
Total

7998918.532
8787.366
1702.701
377.055
47699.17794
8057484.832

Output (kJ)
Water
K+
Ca2+
Mg2+
HCl 37%
KCl
Total

7998918.532
1702.701
377.055
21709.96749
8022708.256

Heat Loss (kJ)

34776.58

39

Energy Balance of Filtration Process


Input (kJ)
Water
7998918.5
Ca2+
1702.701
Mg2+
377.055
KCl
21709.967

Output (kJ)
Water
7998918.53
Ca2+
1702.701
Mg2+
377.055
KCl
21709.967

Total

Total

8022708.26

Heat Loss (kJ)

0.00

8022708.26

Energy Balance of Evaporation Process


Input (kJ)
Water
Vapor
KCl
Total

2814434
76386.92
2890821

Output (kJ)
Water
Vapor
KCl
Total

1266160
76386.92
1342547

Heat Loss (kJ)

1548275

40

Energy Balance of Evaporation Process


Input (kJ)
Water
Vapor
KCl
Total

2814434
76386.92
2890821

Output (kJ)
Water
Vapor
KCl
Total

1266160
76386.92
1342547

Heat Loss (kJ)

1548275

Energy Balance of Crystallization Process


Input (kJ)
KCl

14473.31

Output (kJ)
KCl

Heat Loss (kJ)

14473.31
0

Total

14473.31

Total

14473.31

41

}
Raw Material Input (kJ)
Material

Energy

Ashes

205800

Total

205800

Product Output (kJ)


Material

Energy

KCl

21709.967

Total

21709.967

42

Potassium Chloride is a useful material that can be used in many industries


such as drilling industry.
Potassium chloride can be obtained from Oil Palm Empty Fruit Bunches
which is usually useless and is considered as waste in CPO industry.
Our raw material is Oil Palm Fruit Empty Bunches (OPFEB) ashes.The
availabilty of this material in is so high Indonesia because there are so many
CPO industries in Indonesia.
Our plant will be built in Sambas, West Kalimantan. The plant located in
Sambas, because of the source of material and targeted market is near
from our plant location with production capacity of KCl is around 390
ton/year
The process includes water leaching, neutralization using HCl, microfiltration,
evaporation, and crystallization.
The mass efficiency is 16.647% because to produce KCl, we need a lot of
ashes because the content of K+ in ashes is small.
The energy efficiency is 10.549%
44

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124.
Berge, M. (2012). Global Fertilizer Supply / Demand Five-Year Market Outlook ( 2012-2017 ).
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Effects on Yield. Slides, 2225.
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