COATER
Mencari massa ZA
H2SO4 = 5,555.56
SO4 = BM SO4
BM H2SO4
= 5,442.18
Massa ZA = BM ZA
BM SO4
= 7,482.99
2. POLISHING SCREEN
DAP
KCl
POLISHING
SCREEN ZA
Urea
H2 O
Filler
Asumsi
Over size particle = 0.10
Under size particle = 0.08
On size particle = 0.82
Total = 1.00
2.00
Inlet
Komponen <12>
Xmass Mass (kg/jam)
DAP 0.28 18,893.85
KCl 0.24 16,108.80
ZA 0.14 9,125.60
Urea 0.13 9,040.89
H2O 0.02 1,016.26
Filler 0.20 13,158.77
1.00 67,344.17
Total
67,344.17
3. COOLER
asumsi suhu
<7> dan <12>
DAP
KCl
ZA
Urea
COOLER H2O
Filler
Asumsi
Debu ke Cyclone = 0.001
Aliran 12
Komponen Mass (kg/jam) Cp (kJ/kg°C)
DAP 18,893.85 1.38
KCl 16,108.80 0.80
ZA 9,125.60 1.67
Urea 9,040.89 1.34
H2 O 1,016.26 4.19
Filler 13,158.77 1.34
Total
ASUS:
Tebakan awal
Objective minimum
Aliran 8
Komponen Mass (kg/jam) Cp (kJ/kg°C)
Udara Kering 82,720 1.01
H2 O - 4.19
Total
Aliran 9
Komponen Mass (kg/jam) Cp (kJ/kg°C)
DAP 18.89 1.38
KCl 16.11 0.80
ZA 9.13 1.67
Urea 9.04 1.34
Filler 13.16 1.34
Udara Kering 82,720 1.01
H2 O 1,654 4.19
Total
Qinlet Qoutlet ∆Q
10,261,612.08 10,261,612.08 -
Perhitungan T9 73.40 C
ASUS:
constraint
ASUS:
Cek laju alir volumetrik udara kering constraint
Udara kering 82,720 kg/jam
ρ 1.17 kg/m3
Udara kering 70,520.03 m3/jam
1,175.33 m3/menit
41,136.69 ft3/menit
19,588.90 liter/detik
Cek apakah ada kompresor dengan laju alir sebesar ini? Jika tidak ada lakukan solver ulang, ubah T outlet udara k
Mencari Heat Capasity dan Mass Density Udara Kering dari HYSYS
ρ = 1.17
Cp UK = 1.01
T udara = 26
Humidity = 70%
= 0.014
Massa UK + air = Massa H2O
Neraca Massa Over All
IN
Komponen <7>
Xmass Mass Rate (kg/jam)
DAP 0.27 18,912.74
KCl 0.23 16,124.91
ZA 0.13 9,134.73
Urea 0.13 9,049.93
H2O 0.04 2,670.66
Filler 0.19 13,171.93
Udara Kering - -
1.00 69,064.90
Total
4. PROCESS SCREEN
DAP
KCl
ZA
Urea
H2 O
PROCESS SCREEN
Filler
Asumsi
On size particle = 0.820
Over size particle = 0.10
Under size particle = 0.050
Debu = 0.030
Total = 1.00
F6 = F3 + F4 + F5 + F7
F6 = 0.03 F6 + 0.1 F6 + 0.05 F6 + F7
0.82 F6 = F7
F6 = F7 / 0.82
5. ROTARY DRYER
DAP
KCl
ZA
Urea
H2 O
Filler
ROTARY DRYER
Asumsi
Debu Ke Cyclone = 0.001
Aliran 6
Komponen Mass (kg/jam) Cp (kJ/kg°C)
DAP 23,064.32 1.38
KCl 19,664.53 0.80
ZA 11,139.91 1.67
Urea 11,036.50 1.34
H2 O 3,256.90 4.19
Filler 16,063.32 1.34
Total
Aliran 2
Komponen Mass (kg/jam) Cp (kJ/kg°C)
Udara Kering 57,420 1.01
H2 O - 4.19
Total
Aliran 3
Komponen Mass (kg/jam) Cp (kJ/kg°C)
DAP 23.06 1.38
KCl 19.66 0.80
ZA 11.14 1.67
Urea 11.04 1.34
H2 O 1,148 4.19
Filler 16.06 1.34
Udara Kering 57,420 1.01
Total
Aliran 1
Komponen Mass (kg/jam) Cp (kJ/kg°C)
DAP 23,087.39 1.38
KCl 19,684.19 0.80
ZA 11,151.05 1.67
Urea 11,047.54 1.34
H2 O 4,405.30 4.19
Filler 16,079.39 1.34
Total
Qinlet Qoutlet ∆Q
15,427,245.06 15,427,245.06 -
Perhitungan T3 88.42 C
6. BELT CONVEYOR
Urea KCl
<19> <18>
7. GRANULATOR
MAP <16>
ZA
H2O
GRANULATOR
GRANULATOR
Reaksi ZA
Mula-mula
Massa ZA <20> = 6,151.05
Mol ZA <20> = 46.60
Outlet ZA
Massa ZA <1> = 11,151.05
Mol ZA <1> = 84.48
2 NH3
m 75.76
r 75.76
s -
diasumsikan sisa = 0
sementara diasumsikan ZA inlet tidak dihitung
Reaksi DAP
Mula-mula
Massa DAP <20> = 6,860.54
Mol DAP <20> = 51.97
Sisa
Massa DAP <1> = 23,087.39
Mol DAP <1> = 174.90
1 NH3
m 122.93
r 122.93
s -
8. PN-TANK
2.00 NH3
m 56.24
r 56.24
s -
INLET
Komponen <24> NH3
Xmass Mass Rate (kg/jam)
DAP - -
KCl - -
ZA - -
Urea - -
H2O - -
Filler - -
Udara Kering - -
NH3 1.00 3,045.97
H2SO4 - -
MAP - -
H3PO4 - -
1.00 3,045.97
Total
9. DRYER CYCLONE
Partikel kecil <1>
<6>
DAP
KCl
ZA
Urea
H2O
Filler
Partikel besar <2>
Inlet
Komponen <6>
Xmass Mass (kg/jam)
DAP 0.27 23,064.32
KCl 0.23 19,664.53
ZA 0.13 11,139.91
Urea 0.13 11,036.50
H2O 0.04 3,256.90
Filler 0.19 16,063.32
1.00 84,225.49
Total
84,225.49
DAP <14>
KCl
ZA
Urea <13>
Air
Filler Coating Oil
Coating Powder
Komposisi
0.15
0.15
0.15 literatur pupuk petro
0.10
0.02
0.43
0.002
0.004
kg/jam
kg/jam
x massa P2O5
kg/jam
kg/jam
kg/jam
x massa K2O
kg/jam
x massa K
kg/jam
kg/jam
x massa H2SO4
kg/jam
x massa SO4
kg/jam
kg/jam =
kg/jam
x massa ZA
kg/jam
kg/jam
kg/jam
kg/jam
kg/jam
kg/jam
kg/jam
kg/jam
kg/jam
kg/jam +
kg/jam
kg/jam
Inlet Outlet
<14> <15>
Xmass Mass (kg/jam) Xmass
0.28 15,492.96 0.28
0.24 13,209.22 0.24
0.14 7,482.99 0.13
0.13 7,413.53 0.13
0.02 833.33 0.02
0.20 10,790.19 0.19
- - 0.002
- - 0.004
1.00 55,222.22 1.00
55,555.56 55,555.56
<12>
<10> <11>
<9>
85 °C
<7>
<8>
Udara Kering
Cp (kJ/kg°C)
1.38
0.80
1.67
1.34
4.19
1.34
Q (kJ/jam)
2,218,465
1,089,641
1,299,780
1,030,787
950,429
1,500,282
8,089,385
Q (kJ/jam)
1,069,014
525,066
626,327
496,706
174,450
722,943
3,614,506
T udara kering 26
Q (kJ/jam) Humidity 70%
2,172,227 H 0.014
- Asumsi udara sudah mengalami pemisahan uap air
2,172,227
Solver
ASUS:
constraint
ASUS:
constraint
ada lakukan solver ulang, ubah T outlet udara kering jadi lebih tinggi
vol
vol
vol
vol
kg/m3
kJ/kg°C
°C
Debu
<3>
<6>
<5> <4>
F7
F4
F5
F3
Outlet
<3> Debu <4> Oversize
Xmass Mass Rate (kg/jam) Xmass
0.27 691.93 0.27
0.23 589.94 0.23
0.13 334.20 0.13
0.13 331.09 0.13
0.04 97.71 0.04
0.19 481.90 0.19
1.00 2,526.76 1.00
<3>
<1>
70 °C
Udara Kering
Air
Q (kJ/jam)
2,705,445
1,328,831
1,585,098
1,257,057
1,159,060
1,829,613
9,865,104
Q (kJ/jam)
6,959,304
-
6,959,304
Q (kJ/jam)
2,230,242
1,095,425
1,306,680
1,036,259
1,291,088
1,508,247
8,467,941
Solver
Inlet Outlet
<2> udara <3> udara + uap air + debu
Xmass Mass Rate (kg/jam) Xmass
- - 0.000393
- - 0.000335
- - 0.000190
- - 0.000188
- - 0.019581
- - 0.000274
1.00 57,420 0.979039
1.00 57,420 1.000000
142,874.86
ZA Filler
<17> <16>
<20>
On Size Particle
<4> <5>
NH3
<21>
<20>
+ 1 H2SO4
37.88
37.88
-
kmol/jam
kg/jam
kmol/jam
kg/jam
kg/jam
kmol
kg/jam
kmol
+ 1 (NH4)H2PO4
122.93
122.93
-
Massa MAP
kmol Mol MAP
kg/jam Massa MAP
kg/jam
INLET
<20> <21> NH3
Xmass Mass Rate (kg/jam) Xmass
0.11 6,860.54
0.33 19,684.19
0.10 6,151.05
0.18 11,047.54
0.01 671.46
0.27 16,079.39
- -
- -
- -
- -
1.00 60,494.17
85,454.858044
liran <16>
kg/jam
kg/jam
kg/jam
+ H3PO4
122.93
122.93
-
PN-Tank
kg/jam
kmol/jam
kmol/jam
kg/jam
kmol/jam
kg/jam
+ H2SO4
28.12
28.12
-
kg/jam
kmol/jam
kmol/jam
kg/jam
kmol/jam
kg/jam
kg/jam
Outlet
< 3 > (partikel kecil) < 4 > (partikel besar)
Xmass Mass (kg/jam) Xmass
0.27 18.91 0.27
0.23 16.12 0.23
0.13 9.13 0.13
0.13 9.05 0.13
0.04 2.67 0.04
0.19 13.17 0.19
1.00 69.06 1.00
69,064.90
DAP
KCl
<15> ZA
Urea
Air
Filler
Coating Oil
Coating Powder
3,459.65 kg/jam
BM Urea x massa N dalam Urea
2 x BM N
7,413.53 kg/jam
Outlet
<15>
Mass (kg/jam)
15,492.96
13,209.22
7,482.99
7,413.53
833.33
10,790.19
111.11
222.22
55,555.56
55,555.56
DAP
<14> KCl
ZA
Urea
H2 O
Filler
3.00 4.00
Outlet
<10> Undersize <11> Oversize
Mass (kg/jam) Xmass Mass (kg/jam)
1,511.51 0.28 1,889.39
1,288.70 0.24 1,610.88
730.05 0.14 912.56
723.27 0.13 904.09
81.30 0.02 101.63
1,052.70 0.20 1,315.88
5,387.53 1.00 6,734.42
67,344.17
73.40 °C
DAP
KCl 41
<12> ZA
Urea
H2 O
Filler
26 °C
8,800,000.00
17,600,000,000.00
°C
DAP
KCl
<7> ZA
Urea
H2 O
Filler
Outlet
<4> Oversize <5> Undersize <7> Onsize
Mass Rate (kg/jam) Xmass Mass Rate (kg/jam) Xmass
2,306.43 0.27 1,153.22 0.27
1,966.45 0.23 983.23 0.23
1,113.99 0.13 557.00 0.13
1,103.65 0.13 551.82 0.13
325.69 0.04 162.85 0.04
1,606.33 0.19 803.17 0.19
8,422.55 1.00 4,211.27 1.00
84,225.49
Uap Air
Udara Kering + Debu
88.42 °C
1.40 bar
<6>
85 °C
<2>
120 °C
-
memiliki kandungan air jenuh
26 °C --> Humidity 100%
0.02 kg air/kg udara kering
Outlet
> udara + uap air + debu <6>
Mass Rate (kg/jam) Xmass Mass Rate (kg/jam)
23.06 0.27 23,064.32
19.66 0.23 19,664.53
11.14 0.13 11,139.91
11.04 0.13 11,036.50
1,148 0.04 3,256.90
16.06 0.19 16,063.32
57,420 - -
58,649.37 1.00 84,225.49
142,874.86
INLET
Undersize Polishing Screen <11> Oversize Polishing Screen <16> Filler
Mass Rate (kg/jam) Xmass Mass Rate (kg/jam) Xmass
1,511.51 0.28 1,889.39 -
1,288.70 0.24 1,610.88 -
730.05 0.14 912.56 -
723.27 0.13 904.09 -
81.30 0.02 101.63 -
1,052.70 0.20 1,315.88 1.00
- - - -
5,387.53 1.00 6,734.42 1.00
DAP
KCl
<1> ZA
Urea
H2O
Filler
1 (NH4)2SO4
46.60
37.88 -
84.48
1 (NH4)2HPO4
51.97
122.93 -
174.90
= 122.93 kmol
= 14,137.02 kg/jam
OUTLET
<21> NH3 <1>
Mass Rate (kg/jam) Xmass Mass Rate (kg/jam)
- 0.27 23,087.39
- 0.23 19,684.19
- 0.13 11,151.05
- 0.13 11,047.54
- 0.05 4,405.30
- 0.19 16,079.39
- - -
3,377.70 - -
- - -
- - -
3,377.70 1.00 85,454.86
85,454.858044 85,454.858044
MAP <16>
ZA
H2O
(NH4)H2PO4
122.93
122.93
(NH4)2SO4
-
28.12 -
28.12
OUTLET
<26> H2SO4 <16>
Mass Rate (kg/jam) Xmass Mass Rate (kg/jam)
- -
- -
- 3,712.12
- -
1,866.92 3,733.84
- -
- -
- -
2,755.97 -
- 14,137.02
-
4,622.89 21,582.99
21,582.99 21,582.99
< 2 > (partikel besar)
Mass (kg/jam)
23,041.26
19,644.86
11,128.77
11,025.46
3,253.65
16,047.26
84,141.26
84,225.49
DAP
KCl
ZA
Urea
H2 O
Filler
<16> Filler <17> ZA <18> KCl
Mass Rate (kg/jam) Xmass Mass Rate (kg/jam) Xmass
- - - -
- - - 1.00
- 1.00 2,837.46 -
- - - -
- - - -
11,301.31 - - -
- - - -
11,301.31 1.00 2,837.46 1.00
5,000.00
POLISHING SCREEN
Over size particle = 0.10000
Under size particle = 0.08000
On size particle = 0.82000
Total = 1.00000
16,226.85
OUTLET
Komponen Massa yang bereaksi <1>
Xmass
DAP 16,226.85 0.08
KCl - 0.23
ZA 1,287.88 0.12
Urea - 0.13
H2O - 0.05
Filler - 0.19
Udara Kering - -
NH3positif (3,377.70) 0.04
H2SO4 - -
MAP (14,137.02) 0.17
1.00
Total
85,454.86
NH3
<21> DAP
KCl
<1> ZA
Urea
H2O
Filler
<20>
Data CP
KCl 0.19 kcal/kg C
CO(NH2)2 0.32 kcal/kg C
H2SO4 0.38 kcal/kg C
NH3 (l) 1.1 kcal/kg C
H3PO4 0.43 kcal/kg C
H2 O 1 kcal/kg C
(NH4)2SO4 0.4 kcal/kg C
NH4H2PO4 0.33 kcal/kg C
(NH4)2HPO4 0.33 kcal/kg C
NH3 (g) 0.4 kcal/kg C
H2O (g) 0.5 kcal/kg C
NH4OH 90 J/g C
1 PN-TANK
Qloss
NH3 <1> (5)oC
Reaksi 1
NH3 + H3PO4 (NH4)H2PO4
m 123 123
r 123 123 122.93 -
s 0 0 122.93
Reaksi 2
2 NH3 + H2SO4 (NH4)2SO4
m 56.2 28.1 0
r 56.2 28.1 28.122 -
s 0 0 28.122
Senyawa Δ Hf (kkal/mol)
NH3 -16.06
H2SO4 -193.91
(NH4)2.SO4 -281.86
H3PO4 -306.2
NH4.H2PO4 -338.64
(NH4)2HPO4 -370.38
(Referensi : Hougen, tabel 29)
T PN TANK = 120 C
T reff = 25 C
1 kKal = 4.2 kJ
Reaksi 1
Delta H saat suhu 25 C = ∆Hproduk-∆reaktan
= -2013.6040230078 kKal
= -8457.1368966326 kJ
Reaksi 2
Delta H saat suhu 25 C = ∆Hproduk-∆reaktan
= -1570.0585399449 kKal
= -6594.2458677686 kJ
Delta H Produk = m.Cp.∆T
= 1068.6409550046 kKal
= 4488.2920110193 kJ
Delta H Reaktan = m.CpNH3.DT+m.CpH3PO4.DT
= 6892.7341597796 kKal
28949.4834710744 kJ
Delta H Rx2 = ∆H25+∆Hproduk-∆Hreaktan
= -31055.4373278237 kJ
Delta H Total = -98371.7687431449 kJ Reaksi Eksothermis
Neraca Massa
INLET OUTLET
Komponen <24> <25> <26> <16>
X kg/h X kg/h X kg/h X
DAP 0 0 0 0 0 0
KCl 0 0 0 0 0 0
ZA 0 0 0 0 0 0
Urea 0 0 0 0 0 0
H2O 0 0 0.1342 1866 0.4038 1867
Filler 0 0 0 0 0 0
Udara Kering 0 0 0 0 0 0
NH3 1 3046 0 0 0 0
H2SO4 0 0 0 0 0.5962 2756
MAP 0 0 0 0 0 0
H3PO4 0 0 0.8658 12047 0 0
1 3046 1 13914 1 4623
Total
21582.9862061305 21582.98621
T NH3 = 5 C
H = -67011.4160875455 kkal
= -281447.947567691 kJ
T H3PO4 = 33 C
H = 56369.68 kkal
= 236752.656 kJ
T H2SO4 = 33 C
H = 23313.5067370476 kkal
= 97916.7282956 kJ
T outlet = 120 C
H = 914285.559814818 kkal
= 3839999.35122224 kJ
Neraca Energi
H24+H25+H26+Hs = H16+HR+Qloss+Qwc
4217238.09207346 = 3943693.26363817 + Qwc
273544.828435292 = Qwc (kJ)
2. GRANULATOR
Qloss
Qloss
<16> (120)oC
Rotary Dryer <1>
<21> (5)oC (65)oC
C-120
<20> (30)oC
Reaksi 1
2 NH3 + 1 H2SO4 1 (NH4)2SO4
m 75.8 37.8788 46.599
r 75.8 37.8788 37.879 -
s 0 0 84.478
Reaksi 2
1 NH3 + 1 (NH4)H2PO4 1 (NH4)2HPO4
m 123 122.93 52
r 123 122.93 123 -
s 0 0 175
Senyawa Δ Hf (kkal/mol)
NH3 -16.06
H2SO4 -193.91
(NH4)2.SO4 -281.86
H3PO4 -306.2
NH4.H2PO4 -338.64
(NH4)2HPO4 -370.38
(Referensi : Hougen, tabel 29)
T granulator = 120 C
T reff = 25 C
1 kkal = 4.2 kJ
Reaksi 1
Delta H saat suhu 25 C = ∆Hproduk-∆reaktan
= -8947185.35353536 kkal
= -37578178.4848485 kJ
Delta H Produk = m.Cp.∆T
= 1439.3939393939 kkal
= 6045.4545454546 kJ
Delta H Reaktan = mNH3.Cp.DT + mH2SO4.Cp.DT
= 9284.0909090909 kkal
= 38993.1818181818 kJ
Delta H Rx1 = -37611126.2121212 kJ
Reaksi 2
Delta H saat suhu 25 C = ∆Hproduk-∆reaktan
= -1927.5525690331 kkal
= -8095.720789939 kJ
Delta H Produk = 3853.8758315808 kkal
= 16186.2784926394 kJ
Delta H Reaktan = 16700.1286035168 kkal
= 70140.5401347705 kJ
Delta H Rx2 = -62049.9824320701 kJ
T <20> = 30 C
H = 61202.4801178883 kkal
= 257050.416495131 kJ
T <21> = 5 C
H = -74309.3958855253 kkal
= -312099.462719206 kJ
T <1> = 120 C
H = 2183023.57119157 kkal
= 9168698.99900459 kJ
Neraca Energi
H20+H21+H16+HR = H1+Qloss
41458126.4995514 = 9168698.999 + Qloss
32289427.5005469 = Qloss (kJ)
3. ROTARY DRYER
Qloss Dryer Cyclone <21> (88)oC
Granulator
<11> (65)oC Screen <12> (85)oC
B-130
(3)
343 K
Ts1 70 C
Granul basah 1 (6)
(1) 2
Granul kering
(2) Ts2 85
Udara Kering
Tg2 120
Tg1-Tw = 10.4 C
Tg1 = 53.4 C
Fraksi komponen antara solid dan H2O yang diinginkan setelah pengeringan
Dry Solid = 0.99 kg dry solid/kg total
H2O = 0.01 kg H2O/kg total
Moisture Content X = 0.0101 kg H2O/kg dry solid
Heat Balance
G.ĤGin + Ls.Ĥs11 = G.ĤGout + Ls.Ĥs12
dimana,
CG= ( 1.005 + 1.88 H' ) ( T - Tref ) + l.H'
pada suhu 393 K (udara masuk),2202.59 kJ/kg
pada suhu 326 K (udara masuk),2370.67 kJ/kg
Ĥs = Cps (T - Tref) + X.CpA(T -Tref)
dimana Cps = 1.2 kJ/kg.K
Cpa = 4.19 kJ/kg.K
Neraca Massa
Aliran 6
Komponen Mass (kg/jam) Cp (kJ/kg°C) Q (kJ/jam)
DAP 23064.3228796 1.38 2705445.074
KCl 19664.5286705 0.795 1328830.525
ZA 11139.9110507 1.674 1585097.943
Urea 11036.4995845 1.34 1257057.303
H2O 3256.90263732 4.1868 1159059.997
Filler 16063.3246348 1.34 1829612.676
Total 9865103.517
Aliran 2
Komponen Mass (kg/jam)Cp (kJ/kg°C) Q (kJ/jam)
Udara Kering 57420 1.01 6959304
H2O 0 4.1868 0
Total 6959304
Aliran 3
Cp
Komponen Mass (kg/jam) (kJ/kg° Q (kJ/jam) m.Cp
C)
DAP 23.0643228796 1.38 2814.3520609 31.8287656
KCl 19.6645286705 0.795 1382.3222517 15.6333003
ZA 11.1399110507 1.674 1648.9056484 18.6482111
Urea 11.0364995845 1.34 1307.6598171 14.7889094
H2O 1148.4 4.1868 425142.01663 4808.12112
Filler 16.0633246348 1.34 1903.2632578 21.524855
Udara Kering 57420 1.01 5127943.0209 57994.2
Total 5562141.5406 62904.7452
Aliran 1
Komponen Mass (kg/jam) Cp (kJ/kg°C) Q (kJ/jam)
DAP 23087.3872025 1.38 2230241.604
KCl 19684.1931991 0.795 1095425.352
ZA 11151.0509617 1.674 1306680.152
Urea 11047.536084 1.34 1036258.885
H2O 4405.30263732 4.1868 1291088.476
Filler 16079.3879595 1.34 1508246.591
Total 8467941.058
Neraca Energi
H1+H2 = H3+H6+Qloss
15427245.0580014 = 9928008.263 + Qloss
5499236.79541608 = Qloss
4. COOLER
Qloss Cooler Cyclone <9> (73)oC
Coater <12>
Screen <7> (85)oC (60)oC
B-140
Neraca Massa
Aliran 7
Komponen Mass (kg/jam) Cp (kJ/kg°C) Q (kJ/jam)
DAP 18912.7447613 1.38 2218464.9605
KCl 16124.9135098 0.795 1089641.0304
ZA 9134.72706156 1.674 1299780.3136
Urea 9049.92965926 1.34 1030786.9882
H2O 2670.6601626 4.1868 950429.19735
Filler 13171.9262006 1.34 1500282.3942
Total 8089384.8843
Aliran 12
Komponen Mass (kg/jam) Cp (kJ/kg°C) Q (kJ/jam)
DAP 18893.8509103 1.38 1069014.08450704
KCl 16108.8047051 0.795 525066.489361702
ZA 9125.6014601 1.674 626326.530612245
Urea 9040.88877049 1.34 496706.429050493
H2O 1016.2601626 4.1868 174450
Filler 13158.7674331 1.34 722942.682776836
Total 3614506.21630832
Aliran 8
Komponen Mass (kg/jam) Cp (kJ/kg°C) Q (kJ/jam)
Udara Kering 82720 1.01 2172227.2
H2O 0 4.1868 0
Total 2172227.2
Aliran 9
Komponen Mass (kg/jam) Cp (kJ/k Q (kJ/jam) m.Cp
DAP 18.8938509103 1.38 1913.8441247 26.0735143
KCl 16.1088047051 0.795 940.02074463 12.8064997
ZA 9.1256014601 1.674 1121.3054796 15.2762568
Urea 9.0408887705 1.34 889.24804146 12.114791
Filler 13.1587674331 1.34 1294.2763112 17.6327484
Udara Kering 82720 1.01 6132518.8574 83547.2
H2O 1654.4 4.1868 508428.31588 6926.64192
Total 6647105.868 90557.7457
Neraca Energi
<7> +<8> = <12> + <9> +Qloss
10261612.0843 = 3705064 + Qloss
6556548.12225 = Qloss (kJ)
5. FURNACE
Granulator
<9> (120)oC
Reaksi Eksothermis
kkal/kgmol
kkal/kgmol
kkal/kgmol
kkal/kgmol
kkal/kgmol
kkal/kgmol
kkal/kgmol
kkal/kgmol
kkal/kgmol
OUTLET
<16>
kg/h
0
0
3712.12
0
3733.84
0
0
0
0
14137.0
21583
21582.98621
Rotary Dryer <1>
(65)oC
(NH4)2HPO4
Reaksi Eksotermis
OUTLET
kg/h
23087
19684
11151
11048
4405.3
16079
0
0
0
0
85455
85454.85804
een <12> (85)oC
Outlet
<12>
kg/h
23064.3
19664.52867
11139.91105
11036.49958
3256.902637
16063.32463
0
84225.48946
142874.858044154
kg H2O/kg Udara kering
% KCl = 99%
ρ KCl = ### kg/m3= ### lb/cuft
Volume gra= 10.6 m3/jam
= 372 cuft/ = ### cuft/hari
Asumsi :
Tangki terisi 80% fee = ### cuft
Tinggi silinder bejana 1,5 kali diameter silinder
α = 120o
Menghitung diameter =d (π/4 x Di2 x 1,5 x Di) + (π/24 x Di3 / tg (0,5 x α))
Volume tan11174.37 = (3,14/4 x Di2 x 1,5 x Di) + (3,14/24 x Di3 / tg (0,5 x 120))
11174.37 = (1,1775 x Di3) + (0,0756 x Di3)
11174.37 = 1.93 Di3
Di3 = ###
Di = ### ft = 215 in
Hsili = ### ft = 323 in
Menghitung tinggi gra= (π/4 x Di2 x Hgranul) + (3,14/24 x Di3 / tg (0,5 x 120))
Volume gra 8939.49 = (3,14/4 x 21,472 x Hgranul)
8502.94 = 253 x Hgr+ 437
= ### inch
Standa
= 0.31 inch ~ 5/16 inch
= 0.1 inch
Standa
= 0.19 inch ~ 3/16 inch
% urea = ###
ρ urea = 800 kg/m3= ### lb/cuft
Volume gra= 9.71 m3/jam
= 340 cuft/ = ### cuft/hari
Asumsi :
Tangki terisi 80% fee = ### cuft
Tinggi silinder bejana 1,5 kali diameter silinder
α = 120o
Menghitung diameter =d (π/4 x Di2 x 1,5 x Di) + (π/24 x Di3 / tg (0,5 x α))
Volume tan10191.17 = (3,14/4 x Di2 x 1,5 x Di) + (3,14/24 x Di3 / tg (0,5 x 120))
10191.17 = (1,1775 x Di3) + (0,0756 x Di3)
10191.17 = 1.25 Di3
Di3 = ###
Di = ### ft = 241 in
Hsili = ### ft = 362 in
Menghitung tinggi gra= (π/4 x Di2 x Hgranul) + (3,14/24 x Di3 / tg (0,5 x 120))
Volume gra 8152.94 = (3,14/4 x 21,472 x Hgranul)
7538.61 = 317 x Hgr+ 614
Tinggi gran= ### ft = 285 in
= ### inch
Standa
= 0.19 inch ~ 3/16 inch
= 0.12 inch
Standa
= 0.19 inch ~ 3/16 inch
Menghitung tinggi tutup bawah
Hb = Do/2
tan (α/2)
= 120
0.58
= ### inch
SPESIFIKASI
Nama Alat= Urea Storage Tank
Fungsi = Menampung bahan baku padat yang berupa Urea
Kapasitas = ### m3
Diameter = 6.14 m
Tinggi tota= ### m
Tebal Tang= 0m
Tebal Tutu = 0m
Bahan Kons = High Alloy Steel SA 240 Grade M
Jumlah = 1 buah
% ZA = 99%
ρ ZA = 1769 kg/m3= ### lb/cuft
Volume gra= 1.6 m /jam
3
= 56.1 cuft/ = ### cuft/hari
Asumsi :
Tangki terisi 80% fee = ### cuft
Tinggi silinder bejana 1,5 kali diameter silinder
α = 120o
Menghitung diameter =d (π/4 x Di2 x 1,5 x Di) + (π/24 x Di3 / tg (0,5 x α))
Volume tan 1684.19 = (3,14/4 x Di2 x 1,5 x Di) + (3,14/24 x Di3 / tg (0,5 x 120))
1684.19 = (1,1775 x Di3) + (0,0756 x Di3)
1684.19 = 1.25 Di3
Di3 = ###
Di = ### ft = 132 in
Hsili = ### ft = 199 in
Menghitung tinggi gra= (π/4 x Di2 x Hgranul) + (3,14/24 x Di3 / tg (0,5 x 120))
Volume gra 1347.35 = (3,14/4 x 21,472 x Hgranul)
1245.83 = 95.6 x Hgr+ 102
= ### inch
Standa
= 0.19 inch ~ 3/16 inch
= 0.07 inch
Standa
= 0.19 inch ~ 3/16 inch
SPESIFIKASI
Nama Alat= ZA Storage Tank
Fungsi = Menampung bahan baku padat yang berupa KCl 99%
Kapasitas = ### m3
Diameter = 3.36 m
Tinggi tota= 7.16 m
Tebal Tang= 0m
Tebal Tutu = 0m
Bahan Kons = High Alloy Steel SA 240 Grade M
Jumlah = 1 buah
Menentukan tebal silinder, digunakan High alloy SA 240 grade M tipe 316
ts = 0.17 inch
(standarisasi berdasarkan Brownel &Young tabel 5.7)
ts = 0.19 inch ~ 3/16 inch 0.19
Menghitung Do
Do = 2 x ts + Di
Do = ### inch ≈ 132 inch
Do ≈ 11 ft
sf = 3.5 inch
icr = 8 inch
r = 130 inch
BC = =r ### inch
b= r- (BC2-AB
= 2)0,5### inch
(Appendiks F)
Manhole = 20 inch
Cover plate thic = 0.38 inch
Bolthing flange = 0.13 inch
SPESIFIKASI
Nama = Tangki penampung H2SO4 98%
Fungsi = Tangki penampung H2SO4 98%
Kapasitas = ### ft3
Bentuk = Silinder dengan tutup atas dan bawah benbertuk standard dishead
Diameter l = 3.35 m
Tebal tangk= ### m
Tebal tutup= ### m
Tebal tutu = ### m
Tinggi tutu= 0.67 m
Tinggi tut = 0.67 m
Tinggi tang= 6.37 m
Bahan kons= High alloy steel SA 240 grade M Tipe 316
ρ H3PO4 98%
= 115 lb/ft3
Menentukan tebal silinder, digunakan High alloy SA 240 grade M tipe 316
ts = 0.29 inch
(standarisasi berdasarkan Brownel &Young tabel 5.7)
ts = 0.31 inch ~ 5/16 inch
Menghitung Do
Do = 2 x ts + Di
Do = ### inch ≈ 210 inch
Do ≈ 17.5 ft
sf = 6 inch
icr = 0.88 inch cek lagi
r = 180 inch
BC = =r ### inch
(Appendiks F)
Manhole = 20 inch
Cover plate thic = 0.38 inch
Bolthing flange = 0.13 inch
SPESIFIKASI
Nama = Tangki penampung H2SO4 98%
Fungsi = Tangki penampung H2SO4 98%
Kapasitas = ### ft3
Bentuk = Silinder dengan tutup atas dan bawah benbertuk standard dishead
Diameter l = 5.33 m
Tebal tangk= ### m
Tebal tutup= ### m
Tebal tutu = ### m
Tinggi tutu= 1.03 m
Tinggi tut = 1.03 m
Tinggi tang= ### m
Bahan kons= High alloy steel SA 240 grade M Tipe 316
ρ H2SO4 98%
= 115 lb/ft3
Menentukan tebal silinder, digunakan High alloy SA 240 grade M tipe 316
ts = 0.18 inch
(standarisasi berdasarkan Brownel &Young tabel 5.7)
ts = 0.25 inch ~ 4/16 inch
Menghitung Do
Do = 2 x ts + Di
Do = ### inch ≈ 132 inch
Do ≈ 11 ft
sf = 3.5 inch
icr = 8 inch
r = 130 inch
BC = =r ### inch
b= r- (BC2-AB
= 2)0,5### inch
(Appendiks F)
Manhole = 20 inch
Cover plate thic = 0.38 inch
Bolthing flange = 0.13 inch
SPESIFIKASI
Nama = Tangki penampung H2SO4 98%
Fungsi = Tangki penampung H2SO4 98%
Kapasitas = ### ft3
Bentuk = Silinder dengan tutup atas dan bawah benbertuk standard dishead
Diameter l = 3.35 m
Tebal tangk= ### m
Tebal tutup= ### m
Tebal tutu = ### m
Tinggi tutu= 0.67 m
Tinggi tut = 0.67 m
Tinggi tang= 6.37 m
Bahan kons= High alloy steel SA 240 grade M Tipe 316
volume coat
= laju alir bahan / ρ coating oil
volume coat
= ### ft3
H liquid si = 5.39 ft
H liquid = H liq silinder + H tutup bawah
H liquid = 6.84 ft
ts = 0.09 inch
(standarisasi berdasarkan Brownel &Young tabel 5.7)
ts = 0.19 inch ~ 3/16
Menghitung Do
Do = 2 x ts + Di
Do = ### inch ≈ 60 inch
Do ≈ 5 ft
(standarisasi berdasarkan brownel & young tabel 5.7)
Di = ### inch
H sili= 90 inch
sf = 2 inch
icr = 0.56 inch
r = 54 inch
BC = =r ### inch
b= r- (BC2-AB
= 2)0,59.40 inch
tinggi tutup atas = ### inch
hb = ((60/2))/(𝑡𝑔 (120/2))
SPESIFIKASI
Nama = Tangki penampung Coating oil
Fungsi = Tangki penampung Coating oil
Kapasitas = ### ft3
Bentuk = Silinder dengan tutup atas benbertuk standard dishead dan tutup
bawah berbentuk conical
Diameter l = 1.52 m
Tebal tangk= ### m
Tebal tutup= ### m
Tebal tutu = ### m
Tinggi tutu= 0.29 m
Tinggi tut = 0.44 m
Tinggi tang= 3.02 m
Bahan kons= High alloy steel SA 240 grade M Tipe 316
Asumsi :
Tangki terisi 80% fee = ### cuft
Tinggi silinder bejana 1,5 kali diameter silinder
α = 120o
= 0.07 inch
Standa
= 0.19 inch ~ 3/16 inch
Standa
= 60 inch
sehingga,
Di = 59.6 inch
H = 89.4 inch
= 0.08 inch
Standa
= 0.19 inch ~ 3/16 inch
SPESIFIKASI
Nama Alat= Coating Powder Bin
Fungsi = Menampung Coating Agent untuk proses coating
Kapasitas = 3.84 m3
Diameter = 1.51 m
Tinggi tota= 2.71 m
Tebal Tang= 0.48 cm
Tebal Tutu = 0.48 cm
Bahan Kons = High Alloy Steel SA 240 Grade M
Jumlah = 1 buah
Diharapkan volume dari produk akan mengisi 70% dari volume gudang, pada bagian persegi
panjang & = 3s
tinggi = 2s
volume gud= 3s x 3s x 2s
1845.70 = 18s
s = 103 m
SPESIFIKASI
panjang gu= 308 m
lebar guda = 308 m
tinggi gud = 205 m
volume gud= ### m3
konstruksi = Pondasi dasar beton
lb/cuft