Pra Rencana Pabrik Pembuatan Asam Asetat
Pra Rencana Pabrik Pembuatan Asam Asetat
ISKANDAR ZULKARNAIN
NIM 03121403046
DARMAWAN EDI PRAYOGA
NIM 03121403052
ISKANDAR ZULKARNAIN
NIM 03121403046
DARMAWAN EDI PRAYOGA
NIM 03121403052
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KATA PENGANTAR
Puji syukur kepada Tuhan Yang Maha Esa, berkat rahmat karunia, serta
bimbingan-Nya dapat diselesaikan Tugas Akhir yang berjudul “ Pra Rencana
Pabrik Pembuatan Asam Asetat Menggunakan Katalis Rhodium dengan
Kapasitas 95.000 Ton/Tahun”. Tugas Akhir ini dibuat untuk memenuhi
persyaratan untuk mengikuti ujian akhir tingkat sarjana pada Jurusan Teknik
Kimia Universitas Sriwijaya.
Penulis
vi
RINGKASAN
Iskandar Zulkarnain dan Darmawan Edi Prayoga; Dibimbing oleh Prof. Dr. Ir. H.
M. Said, M.Sc
RINGKASAN
vii
DAFTAR ISI
viii
BAB IV NERACA MASSA DAN NERACA PANAS................................. 24
4.1 Neraca Massa ........................................................................ 24
4.2 Neraca Panas ........................................................................ 30
BAB V UTILITAS ………………… .......................................................... 38
5.1 Unit Penyediaan Air……. ........................................................ 38
5.2 Unit Penyediaan Steam ............................................................ 39
5.3 Unit Penyediaan Tenaga Listrik ............................................... 40
5.4 Unit Penyediaan Bahan Bakar ................................................. 41
ix
DAFTAR TABEL
x
DAFTAR GAMBAR
xi
DAFTAR NOTASI
1. ACCUMULATOR
L,LT : Panjang Ellipsoidal, total, m
th, ts : Ketebalan Dinding Bagian Head, silinder, m
Ve,Vs : Volume elipsoidal, silinder, m3
Vt : Kapasitas,m3
V : Volumetrik flowrate,m3/jam
ID, OD : Diameter dalam, Diameter luar, m
P : Tekanan operasi, atm
S : Tekanan kerja yang diizinkan, atm
T : Temperatur operasi, K
ρ : Densitas, kg/m3
E : Efisiensi pengelasan
Cc : Korosi yang diizinkan, m
2. DECANTER
Wc :Laju alir light fase, kg/jam
ρc : Densitas, kg/m3
Wd : Laju alir heavy fase, kg/jam
ρd : Densitas, kg/m3
Ud : Velocity, m/sec
Lc : Volumetric flowrate continues phase, m3/det
ai : Interphase of area, m2
Ddec : Diameter decanter, m
H : Tinggi decanter, m
I : Dispersi Band, m
tr : Residence time of droplet, menit
Ap : Pipa area, m2
Dp : Pipe Diameter, m
xii
xiii
3. DISTILLATION COLUMN
α : Relatif volatilitas
Nm : Stage minimum
L/D : Refluks
N : Stage/tray
m : Rectifying section
p : Stripping section
FLV : Liquid-vapor flow factor
Uf : Kecepatan flooding, m/s
Uv : Volumetric flowrate, m3/s
An : Net area, m2
Ac : Cross section/luas area kolom, m2
Dc : Diameter kolom, m
Ad : Downcomer area, m2
Aa : Active area, m2
lw : Weir length, m
Ah : Hole area, m2
hw : Weir height, mm
dh : Hole diameter, mm
Lm : Liquid rate, kg/det
how : Weir liquid crest, mm liquid
Uh : Minimum design vapor velocity, m/s
xiv
Co : Orifice coefficient
hd : Dry plate drop, mm liquid
hr : Residual head, mm liquid
ht : Total pressure drop, mm liquid
hap : Downcomer pressure loss, mm
Aap : Area under apron, m2
Hdc : Head loss in the downcomer, mm
hb : Backup di downcomer, m
tr : Check resident time, s
θ : Sudut subintended antara pinggir plate dengan unperforated strip
Lm : Mean length, unperforated edge strips, m
Aup : Area of unperforated edge strip, m2
Lcz : Mean length of calming zone, m
Acz : Area of calming zone, m2
Ap : Total area perforated, Ap
Aoh : Area untuk 1 hole, m2
t : Tebal dinding, cm
r : Jari-jari tanki, m
S : Tekanan kerja yang diijinkan, atm
Cc : Korosi yang diijinkan, m
Ej : Efisiensi pengelasan
OD : Diameter luar, m
ID : Diameter dalam, m
EmV : Efisiensi tray, %
ρ : Densitas, kg/m3
μ : Viskositas, N.s/m2
FA : Fractional Area
He : Tinggi tutup elipsoidal, m
Ht : Tinggi tanki, m
Mcat : Massa katalis
xv
4. EXPANDER
T1 : Temperatur masuk, oC
P1 : Tekanan masuk, atm
P2 : Tekanan keluar, atm
f : Faktor keamanan
W : Laju alir masuk, kg/jam
K : Ratio spesifik heat
Q : Kapasitas laju alir volumetrik, ft3/min
ρ : Densitas, kg/m3
5. HEAT EXCHANGER(COOLER,CONDENSER,HEATER,REBOILER)
A : Area perpindahan panas, ft2
aα, ap : Area alir pada annulus, inner pipe, ft2
as, at : Area alir pada shell and tube, ft2
a” : External surface per 1 in, ft2/in ft
B : Baffle spacing, in
C” : Clearence antar tube, in
Cp : Spesific heat, Btu/lb oF
D : Diameter dalam tube, in
De : Diameter ekuivalen, in
DS : Diameter shell, in
f : Faktor friksi, ft2/in2
Gt,Gs : Laju alir pada tube, shell, lb/h.ft2
g : Percepatan gravitasi
h : Koefisien perpindahan panas, Btu/hr.ft2.oF
h1, ho : Koefisien perpindahan panas fluida bagian dalam, bagian luar
tube
jH : Faktor perpindahan panas
k : Konduktivitas termal, Btu/hr.ft2.oF
L : Panjang tube pipa, ft
LMTD : Logaritmic Mean Temperature Difference, oF
xvi
N : Jumlah baffle
Nt : Jumlah tube
PT : Tube pitch, in
∆PT : Return drop shell, psi
∆PS : Penurunan tekanan pada shell, psi
∆Pt : Penurunan tekanan pada tube, psi
ID : Inside diameter, ft
OD : Outside diameter, ft
Q : Beban panas heat exchanger, Btu/hr
Rd : Dirt factor, hr.ft2.oF/Btu
Re : Bilangan Reynold, dimensionless
s : Specific gravity
T1, T2 : Temperatur fluida panas inlet, outlet, oF
t1, t2 : Temperatur fluida dingin inlet, outlet, oF
Ta : Temperatur rata-rata fluida panas, oF
ta : Temperatur rata-rata fluida dingin, oF
tf : Temperatur film, oF
tw : Temperatur pipa bagian luar, oF
∆t : Beda temperatur yang sebenarnya, oF
U : Koefisien perpindahan panas
Uc, UD :Clean overall coefficient, Design overall coefficient, Btu.hr.ft2.oF
V : Kecepatan alir, ft/s
W : Kecepatan alir massa fluida panas, lb/hr
w : Kecepatan alir massa fluida dingin, lb/hr
μ : Viskositas, Cp
6. MIXING TANK
C : Corrosion maksimum, in
Dt : Diameter tangki, m
Di : Diameter impeller, m
E : Joint effisiensi
xvii
7. POMPA
A : Area alir pipa, in2
BHP : Brake Horse Power, HP
Dopt : Diameter optimum pipa, in
f : Faktor friksi
g : Percepatan gravitasi, ft/s2
gc : Konstanta percepatan gravitasi, ft/s2
Hf : Total friksi, ft
Hfs : Friksi pada dinding pipa, ft
Hfc : Friksi karena kontraksi tiba-tiba, ft
Hfe : Friksi karena ekspansi tiba-tiba, ft
Hff : Friksi karena fitting dan valve, ft
xviii
8. REAKTOR
BMav : BM rata – rata, kg/kmol
CAo : Konsentrasi Trigliserida mula – mula, kmol/m3
CBo : Konsentrasi Methanol mula – mula, kmol/m3
g : Percepatan Gravitasi, m/s2
HS : Tinggi Head Reaktor, m
HR : Tinggi reaktor total, m
k : Konstanta reaksi , m3/kmol.s, s-1
Mfr : Laju alir massa, kg/h
Qf : Volumetric Flowrate Umpan, m3/h
r1, r2 : Laju reaksi 1,2, kmol/m3.s
xix
9. TANKI
C : Allowable corrosion, m
D : Diameter tanki, m
E : Joint effisiensi
h : Tinggi head, m
He : Tinggi elipsoidal, m
Hs : Tinggi silinder tanki, m
Ht : Tinggi total tanki, m
P : Tekanan, atm
S : Allowable stress, psi
t : Tebal dinding tanki, m
Vh : Volume head, m3
Vs : Volume silinder, m3
Vt : Kapasitas tanki, m3
W : Laju alir massa, kg/h
ρ : Densitas, kg/m3
ρ : Densitas, kg/m3
Lampiran Halaman
1. Biodata
1.1 Biodata Iskandar Zulkarnain ............................................................. 99
1.2 Biodata Darmawan Edi Prayoga ...................................................... 100
2. Paten
2.1 Patent Utama US Patent No. 2016/9302974 B1 ............................ .. 101
2.2 Patent Pendukung US Patent No. 2015/0025270 A1 ........................ 102
3. Tugas Khusus
3.1 Reaktor ....... ...................................................................................... 103
3.2 Kolom Destilasi ................................................................................. 124
4. Perhitungan
4.1 Neraca Massa ........................................................................ 140
4.2 Neraca Panas ........................................................................ 194
4.3 Spesifikasi Peralatan ........................................................................ 246
4.4 Analisa Ekonomi ........................................................................ 516
5. Tugas Revisi ........................................................................ 524
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BAB I
PEMBAHASAN UMUM
1
2
Tahap kedua CH3Br dan CO direaksikan lagi dengan H2O dengan bantuan katalis
RhCl3 menghasilkan asam asetat dan asam bromide. Mekanisme reaksinya dapat
ditunjukkan :
Sifat Kimia
1. Bereaksi dengan karbon monoksida membentuk asam asetat
CH3OH + CO CH3COOH
2. Reaksi dehidrogenasi oksidatif dari methanol dengan katalis Ag
Molybdenum-Fe2O3 akan menghasilkan formaldehida.
MO-Fe2O3
CH3-OH CHO2 + H2
3. Dengan asam asetat menghasilkan proses esterifikasi.
CH3OH + CO CH3COOH
1.4.3. Asam Asetat
Sifat Fisika
Rumus Molekul : CH3COOH
Fase : Liquid
Berat Molekul : 60,052 gr/mol
Normal Boiling Point : 117,9 C
Freezing Point : 16,6 C
Temperatur Kritis : 594,4
Tekanan Kritis : 57,9 Bar
Densitas Liquid : 1049 Kg/m3
Heat Capacities : 4,840 + 25,485 x 10-2 T – 1,75 x10-4 T2 +
49,588 x10-9 T3 ( Cp dalam J/mol.K dan T
dalam K)
Panas Pembentukan : -435,13 KJ/mol
Energi Gibbs : -376,94 KJ/mol
(Coulson and Richardson edisi 4 volume 6)
Sifat Kimia
1. Reaksi dengan alkohol menghasilkan ester
CH3OH + CH3COOH CH3COOCH3 + H2O
2. Pembentukan garam keasaman
2CH3COOH + Zn (CH3COO)2Zn2+ + ½ H2
3. Konversi ke klorida-klorida asam
3CH3COOH + PCl3 3CH3COCl + H3PO3
4. Pembentukan ester
CH3COOH + CH3CH2OH CH3COOC2H5 + H2O
1.4.4. Metil Asetat
Rumus molekul : CH3COOCH3
Berat molekul : 74 kg/kmol
o
Fase (25 C) : liquid
Titik didih (Tbp) : 56,9 °C
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1.4.7. Rhodium
Rumus Molekul : Rh
Fase : Solid
Massa Jenis (suhu Kamar) : 12,41 gr/m3
Massa Jenis Pada titik lebur : 10,7 gr/cm3
Titik Lebur : 2237 K (1964 C)
Titik didih : 3968 K (3695 C)
Kalor Peleburan : 26,59 Kj/mol
Kalor Penguapan : 494 KJ/mol
Kapasitas Kalor (25 C) : 24,98 J/mol K
(http://id.wikipedia.org/wiki/Rodium
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bakteri
Fermentasi T= 45 - 65 Clostridium
6 Glokusa (gula) 97 % o
Anaerob C thermoaceticum
(Susan, 2011)
BAB II
PERENCANAAN PABRIK
13
14
Tabel 2.1. Data Impor Asam Asetat 2010 – 2015 (BPS, 2016)
112000
110000
108000
Kebutuhan
106000
104000
102000
100000
2011 2012 2013 2014 2015
Produk berupa uap keluar dari R-01 sebagai flue gas utilitas. Produk
berupa liquid dari R-01 akan diturunkan temperaturnya melalui C-01 dan masuk
ke FD-01 yang kondisi operasinya yaitu, T=130oC dan P=1,97 atm. Produk FD-01
yang berupa liquid akan direcycle ke R-01 dengan terlebih dahulu dinaikkan
temperatur dan tekanannya agar sesuai dengan kondisi operasi di R-01. Produk
berupa uap dari FD-01 akan masuk ke KD-01 dengan T=115oC dan P= 1,5 atm.
Asam asetat dan air akan keluar dari KD-01 melalui sidestream dan masuk ke
17
KD-02 yang kondisi operasinya T=115 oC dan P= 1,15 atm untuk dimurnikan.
Selanjutnya asam asetat dengan kemurnian tinggi akan didapat dari bottom
product KD-02. Sedangkan top product dari KD-02 sebagian besar berupa air.
Sebagian aliran akan direfluks kembali ke dalam kolom distilasi, dan sebagian
lagi menuju unit utilitas. Bottom produk KD-01 yang banyak mengandung asam
asetat kemudian ditampung di T-05. Top product dari KD-01 yang mengandung
asetaldehid dan metil iodida menuju ke D-01 (T=130oC dan P=1,5 atm) untuk
dipisahkan antara heavy phase dan light phase. Sebesar 27% dari total volume
feed D-01. Bottom product D-01 dialirkan menuju R-01 untuk di recycle..
BAB III
LOKASI DAN TATA LETAK PABRIK
19
20
19 18
21
22
15
16
20
17
9 13 14
7 8
12 6
10
4 3 5
11
2 9 1
KETERANGAN GAMBAR
1. Kantor Keamanan 7. Kantin 13. Pos Keamanan
2. Kantor Pusat 8. Perumahan 14. Ruang Kontrol
3. Kantor Diklat 9. Area Parkir 15. Area Proses
4. Kantor Pemasaran 10. Lapangan Hijau 16. Kantor Litbang
5. Kantor Produksi 11. Gedung Serbaguna 17. Lab
6. Poliklinik 12. Masjid 18. IPAL
19. Utilitas
20. Safety Fire
21. Storage
22. Area Perluasan
JURUSAN TEKNIK KIMIA
FAKULTAS TEKNIK
Gambar 3.2.
UNIVERSITAS SRIWIJAYA
LAYOUT PABRIK PEMBUATAN ASAM ASETAT MENGGUNAKAN KATALIS RHODIUM
DENGAN KAPASITAS 95.000 TON/TAHUN
DIGAMBAR OLEH : Iskandar Zulkarnain (03121403046)
Januari 2017
Darmawan Edi Prayoga (03121403052)
DIPERIKSA OLEH :
Prof. Dr. Ir. H. M. Said, M.Sc
DISETUJUI OLEH :
Prof. Dr. Ir. H. M. Said, M.Sc
Gambar 3.2. Layout Pabrik Pembuatan Asam Asetat Dengan Kapasitas 95.000
Ton per Tahun
BAB IV
NERACA MASSA DAN NERACA PANAS
Kapasitas Produksi : 95.000 ton/tahun
Waktu Produksi : 300 hari/tahun
Basis : 1 jam operasi
Satuan Massa : kg (kilogram)
Bahan Baku : Metanol (CH3OH) dan Karbon
Monoksida (CO)
Produk : Asam Asetat (CH3COOH)
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25
Q s in 356981,3486 -
Q s out - 118734,4631
Total 594244,2830 594244,2830
Q s in 655813,3173 -
Q s out 0,0000 218128,0406
Total 1135630,4327 1135630,4327
Q s in 714126,2309 -
Q s out - 237523,3186
Total 1081342,4888 1081342,4888
Qwout 685203,8381
Total 2592038,61 2592038,61
Qwout - 9240504,92
Total 9240504,92 9240504,92
4.2.15. COOLER – 01
4.2.15.1. COOLER – 01a (C- 01a)
Tabel Neraca Panas Cooler – 01a (C – 01a)
Panas masuk (kJ) Panas keluar (kJ)
Q10a 8991311,004 -
Q10b - 1558973,458
Qwin 110779,1821 -
Qwout - 443116,7282
Total 2002090,186 2002090,186
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4.2.16. COOLER – 02
Tabel Neraca Panas Cooler – 01 (C – 01)
Panas masuk (kJ) Panas keluar (kJ)
Q13 959472,0307 -
Q13 - 808815,8981
Qwin 75328,0663 -
Qwout - 225984,1989
Total 1034800,097 1034800,097
BAB V
UTILITAS
Make up = 5%
= 26127,6329 kg/jam
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39
1 kWatt
Daya untuk penerangan = 25.000.000 lumen x
54000 lumen
= 462,9630 kW
5.3.3 Penerangan Fasilitas Lainnya (Perumahan, Kantor Dan Fasilitas
Lainnya)
41
= 1868,1 kJ/kg
Kebutuhan steam, msteam = 21432,5782 kg/jam
Panas yang ditransfer boiler = msteam x λ
= 21432,5782 kg/jam x 1868,1 kJ/kg
= 40038199,34 kJ/jam
0,9478171 Btu
Panas yang ditransfer boiler = 40038199,34 kJ/jamx
1 kJ
= 37948889,98 Btu/jam
Efisiensi boiler = 80 %
Panas yang ditransfer boiler
Kebutuhan bahan bakar boiler =
Efisiensi boiler x Nilai kalor minyak diesel
37948889,98 Btu/jam
=
80% x 19800 Btu/lb
= 2395,7633 lb/jam
0,4535924 kg
= 2395,7633 lb/jam x
1 lb
= 1086,7 kg/jam
1. ACCUMULATOR (ACC-01)
IDENTIFIKASI
Nama Alat Accumulator
Kode Alat ACC-01
Jumlah 1 buah
Fungsi Tempat menampung sementara kondensat
produk dari CD -01.
DATA DESIGN
Tipe Silinder horizontal dengan tutup elipsoidal
Kapasitas 72.6142 m3 = 19182.4802 gallons
Temperatur 30 C
Tekanan 1 atm
Diameter dalam 1,4603 m = 57.4938 in
Panjang 5,0776 m = 199.9067 in
Tebal 0,0029 m
Waktu tinggal 30 menit
Bahan konstruksi Carbon Steel
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2. ACCUMULATOR (ACC-02)
IDENTIFIKASI
Nama Alat Accumulator
Kode Alat ACC-02
Jumlah 1 buah
Fungsi Tempat menampung sementara kondensat
produk dari CD -02.
DATA DESIGN
Tipe Silinder horizontal dengan tutup elipsoidal
Kapasitas 131,0961 m3 = 34631,6456 gallons
Temperatur 30 C
Tekanan 1 atm
Diameter dalam 1,8248 m = 71.843 in
Panjang 8,9874 m = 243,8105 in
Tebal 0,00578 m
Waktu tinggal 30 menit
Bahan konstruksi Carbon Steel
IDENTIFIKASI
Nama Alat Condensor
Kode Alat CD-02
Jumlah 1 buah
Operasi Kontinyu
Fungsi Mengkondensasikan top produk KD-02
DATA DESAIN
Tipe Shell and Tube Total Condensor
Bahan Konstruksi CarbonSteel
Rd Calculated 0,0008
UC 163,3324
UD 145,3861
Shell Side Tube Side
ID = 15,2500 in Number = 91
and Length dan 20 ft
B = 7,6250 in OD = 1-in
BWG 10
Pitch 1,25-in
triangular
Passes = 10 Passes = 10
∆Ps = 9,1911 psi ∆Pt = 0,0046 psi
47
SUMMARY
ho = 37,7625 h outside hio = 400,4187
Uc = 34,9016
UD = 35,2876
RD calculated = -0,0003
RD required = 0,0010
0,4309 ∆ P Calculated (psi) 0,1462
10 ∆ P Allowable (psi) 10
SUMMARY
ho = 38,9026 h outside hio = 360,3768
Uc = 35,5655
UD = 35,7045
RD calculated = -0,0001
RD required = 0,0010
0,4207 ∆ P Calculated (psi) 0,1609
10 ∆ P Allowable (psi) 10
SUMMARY
ho = 34,9365 h outside hio = 314,6147
Uc = 31,5869
UD = 34,4840
RD calculated = -0,0027
RD required = 0,0010
48
SUMMARY
ho = 151,577 h outside hio = 529,430
Uc = 118,650
UD = 87,740
RD calculated = 0,0030
RD required = 0,0010
3,0317 ∆ P Calculated (psi) 6,596
10 ∆ P Allowable (psi) 10
IDENTIFIKASI PERALATAN
Nama Alat: Decanter-01
Kode Alat : D-01
Tipe Alat : Vertikal Settler
Fungsi : Memisahkan heavy liquid dan light liquid
DATA DESIGN
Diameter 6,9268 m
Tinggi 3,4634 m
Waktu tinggal 1,9388 = 2,0 menit
Zt (light phase overflow) 3,1171 m
Zi (heavy phase overflow) 1,7317 m
Za (feed inlet) 2,8575 m
Bahan Konstruksi Stainless Steel
49
8. EXPANDER-01 (EXP-01)
IDENTIFIKASI PERALATAN
Nama Alat Expander-01
Kode Alat EXP-01
Jumlah 1 unit
Fungsi Untuk menurunkan tekanan output FD-01 menuju KD -01
Tipe Centrifugal expander
DATA DESIGN
Tekanan Masuk 1,81 atm
Tekanan Keluar 1,5 atm
o
Temperatur input 130 C
Power 28 Hp
Bahan Kontruksi Carbon Steel
SUMMARY
ho = 139,0035 h outside hio = 37,6889
Uc = 29,6497
UD = 27,4694
RD calculated = 0,0027
RD required = 0,001
0,2887 ∆ P Calculated (psi) 5,8152
10 ∆ P Allowable (psi) 10
SUMMARY
ho = 418,4951 h outside hio = 209,3825
Uc = 139,5584
UD = 98,4522
RD calculated = 0,003
RD required = 0,001
0,0413 ∆ P Calculated (psi) 3,8768
10 ∆ P Allowable (psi) 10
SUMMARY
ho = 1402,9844 h outside hio = 1397,3449
Uc = 700,0795
UD = 626,1284
RD calculated = 0,0169
RD required = 0,003
0,0503 ∆ P Calculated (psi) 9,8985
10 ∆ P Allowable (psi) 10
51
SUMMARY
ho = 20316,48 h outside hio = 74,3104
Uc = 74,0396
UD = 60,7426
RD calculated = 0,003
RD required = 0,001
0,3165 ∆ P Calculated (psi) 0,4005
10 ∆ P Allowable (psi) 10
SUMMARY
ho = 14928,58 h outside hio = 1370,274
Uc = 1255,0729
UD = 1059,873
RD calculated = 0,0017
RD required = 0,001
0,018 ∆ P Calculated (psi) 0,895
10 ∆ P Allowable (psi) 10
53
SUMMARY
ho = 74,865 h outside hio = 3,818
Uc = 3,6237
UD = 3,6081
RD calculated = 0,0028
RD required = 0,001
0,0001 ∆ P Calculated (psi) 0,006
10,000 ∆ P Allowable (psi) 10,000
54
IDENTIFIKASI
Nama / Kode Alat Kolom destilasi 1 / KD – 01
Jenis Tray Column
Jumlah 1 buah
Operasi Kontinyu
Fungsi Memisahkan Asam Asetat dari zat pengotor
DATA DESAIN
Top Bottom
Tekanan 1,4 Atm 1,55 atm
O O
Temperatur 94 C 125,4 C
KOLOM
Tinggi kolom 5,4055 m
Umpan Masuk stage ke - 7
Total Tray 18,018 tray
Top Bottom
Diameter 2,3656 M 2,4749 m
Tray spacing 0,3 M 0,3 m
Jumlah tray 11,4202 Buah 6,8133 buah
Tebal silinder 0,0097 m 0,0217 m
Tebal head 0,0097 m 0,0217 m
Material Stainless Steel
PELAT
Top Bottom
2
Downcomer area 0,5271 m 0,5770 m2
Active area 3,3385 m2 3,6542 m2
Hole Diameter 5 mm 5 mm
2
Hole area 0,3339 m 0,3654 m2
Tinggi weir 50 mm 50 mm
Panjang weir 1,8215 m 1,9057 m
Tebal pelat 5 mm 5 mm
mm
Pressure drop total 374,3014 mm liquid 306,2523
liquid
Tipe aliran cairan Single pass Single pass
Desain % flooding 85 % 85 %
Jumlah hole 17011,5047 Buah 18620,1788 buah
55
IDENTIFIKASI
Nama / Kode Alat Kolom destilasi 2 / KD – 02
Jenis Tray Column
Jumlah 1 buah
Operasi Kontinyu
Fungsi Memisahkan Asam Asetat dari air
DATA DESAIN
Top Bottom
Tekanan 1,1 Atm 1,3 atm
O
Temperatur 103,1 C 126,6 OC
KOLOM
Tinggi kolom 14,2128 m
Umpan Masuk stage ke - 21
Total Tray 46 tray
Top Bottom
Diameter 2,5697 m 2,6898 m
Tray spacing 0,3 m 0,3 m
Jumlah tray 20,9879 Buah 24,2345 buah
Tebal silinder 0,0210 m 0,0214 m
Tebal head 0,0210 m 0,0214 m
Material Stainless Steel
PELAT
Top Bottom
2
Downcomer area 0,622 m 0,6815 m2
Active area 3,9396 m2 4,3164 m2
Hole Diameter 5 mm 5 mm
2
Hole area 0,394 m 0,4316 m2
Tinggi weir 50 mm 50 mm
Panjang weir 1,9787 m 2,0711 m
Tebal pelat 5 mm 5 mm
mm
Pressure drop total 223,4443 mm liquid 477,6573
liquid
Tipe aliran cairan Single pass Single pass
Desain % flooding 85 % 85 %
Jumlah hole 20074,468 Buah 21994,1686 buah
56
IDENTIFIKASI
Nama Alat Mixing Tank
Kode Alat M T – 01
Jumlah 1 buah
Fungsi Tempat mencampurkan Rhadium, larutan
katalis metil iodida, metil asetat dan air
dengan cara pengadukan
DATA DESAIN
Tipe Silinder vertical dengan ellipsoidal head
Temperature design 30oC
Tekanan design 1atm
Kapasitas 3,8486 m3
DATA MEKANIK
Tipe pengaduk Disk flate blade turbine
Diameter vessel 1,3880 m
Tinggi silinder 2,0820 m
Tinggi tutup 0,3470 m
Tinggi total tangki 2,7761 m
Tinggi liquid 2,7761 m
Diameter impeller 0,4627 m
Tinggi impeller 0,44627 m
Lebar baffle 0,0139 m
Lebar blade pengaduk 0,0925 m
Panjang blade pengaduk 0,1157 m
Posisi baffle dari dinding Tanki 0,0289 m
Tebal tanki 0,0031 m
Kecepatan putaran pengaduk 1,2175 rps
Tenaga pengaduk 1 Hp
Bahan konstruksi Carbon steel
57
IDENTIFIKASI
Nama Alat Pompa – 01
Kode Alat P – 01
Jumlah 2 (1 buah cadangan)
Fungsi Memompakan metanol dan recycle menuju
reaktor.
Tipe Centrifugal pump
Temperatur, oC 30
Densitas, kg/m3 987,4529
Laju alir massa, kg/jam 8712,6913
Viskositas, cp 0,7856
Tekanan uap, mmHg 97,7452
Safety factor, % 10 %
Kapasitas pompa, gal/min 42,7331
Volumetric Flowrate, ft3/det 0,0952
Suction Discharge
NPS, in 6 4
SN 40 40
ID, in 6,065 4,026
OD, in 6,625 4,5
L, m 2 10
Velocity, ft/s 0,4744 1,0796
Total friction loss, ft. lbf/lb 0,0157 0,1046
Tekanan operasi, psi 14,7 220,5
NPSH, ft. lbf/lb 62,7280 513,9857
Required motor driver, Hp 33
Bahan Carbon Steel
58
SUMMARY
ho = 9516,341 h outside hio = 244,153
Uc = 238,046
UD = 175,589
RD calculated = 0,0010
RD required = 0,0010
9,1003 ∆ P Calculated (psi) 9,6680
10 ∆ P Allowable (psi) 10
IDENTIFIKASI
Nama Alat Reboiler
Kode Alat RB-02
Jumlah 1 buah
Operasi Kontinyu
Fungsi Memanaskan kembali reaktan masuk ke
KD-02
SUMMARY
ho = 1853,593 h outside hio = 238,104
Uc = 211
UD = 199,735
RD calculated = 0,0003
RD required = 0,003
2,87 ∆ P Calculated (psi) 0,973
10 ∆ P Allowable (psi) 10
65
IDENTIFIKASI
Nama Alat Tangki
Kode Alat T – 03
Jumlah 1 buah
Fungsi Tempat penyimpanan metil iodida
DATA DESIGN
Tipe Silinder vertikal dengan tutup elipsoidal
Kapasitas 189,3524 m3 = 50021,6131 gallons
Temperatur 30 C
Tekanan 1 atm
Diameter dalam 5,438 m
Tinggi 10,8759 m
Tebal 0,0064 m
Bahan Konstruksi Carbon Steel
Lama Penyimpanan 7 hari
68
IDENTIFIKASI
Nama Alat Tangki
Kode Alat T – 04
Jumlah 1 buah
Fungsi Tempat penyimpanan larutan promotor katalis
metil asetat
DATA DESIGN
Tipe Silinder vertikal dengan tutup elipsoidal
Kapasitas 46,5958 m3 = 12309,3066gallons
Temperatur 30 C
Tekanan 1 atm
Diameter dalam 3,4077 m
Tinggi 6,8154 m
Tebal 0,0052 m
Bahan Konstruksi Carbon Steel
Lama Penyimpanan 7 hari
69
IDENTIFIKASI
Nama Alat Tangki
Kode Alat T – 05
Jumlah 4 buah
Fungsi Tempat penyimpanan produk asam asetat
DATA DESIGN
Tipe Silinder vertikal dengan tutup elipsoidal
Kapasitas 24,5714 m3 = 6491,0892 gallons
Temperatur 30 C
Tekanan 1 atm
Diameter dalam 2,7531 m
Tinggi 2,7626 m
Tebal 0,0048 m
Bahan Konstruksi Carbon Steel
Lama Penyimpanan 7 hari
70
72
73
organisasi pada garis dan Staf (Line and Staff). Sistem organisasi semacam ini
mempunyai beberapa kelebihan, antara lain:
1. Bisa digunakan dalam organisasi skala besar dengan susunan organisasi yang
kompleks dan pembagian tugas yang beragam.
2. Bisa menghasilkan keputusan yang sehat dan logis melalui bantuan staf
(tenaga ahli).
3. Memiliki konsentrasi dan loyalitas tinggi terhadap pekerjaan.
4. Pelaksanaan pengawasan dan pertanggungjawaban lebih mudah dilakukan.
5. Cocok untuk perubahan yang cepat (rasionalisasi dan promosi).
Namun, modal untuk pengoperasian pabrik berasal dari kepemilikan
saham dan pinjaman yang berasal dari bank.
7.3.8. Operator/Karyawan
Operator/karyawan merupakan tenaga pelaksana yang secara langsung
bertugas melaksanakan pekerjaan di lapangan sesuai dengan bidang dan
keahliannya maing-masing. Semua pekerjaan operasional lapangan adalah tugas
dan tanggung jawab operator.
Pembagian jadwal shift untuk pekerja shift dapat dilihat tabel 7.1 dimana
pergantian antara shift dilakukan berdasarkan standar prosedur operasional yang
diberlakukan oleh pihak perusahaan.
7.4.2. Waktu Kerja Karyawan Non-Shift
Waktu kerja bagi karyawan non-shift perusahaan ini adalah 5 (lima) hari
kerja, yaitu :
1) Hari Senin s/d Kamis : Pukul 07.30 – 12.00 WIB
Pukul 13.00 – 16.30 WIB
2) Hari Jumat : Pukul 07.30 – 11.30 WIB
Pukul 13.00 – 17.00 WIB
Untuk Hari Sabtu, Minggu, dan hari libur Nasional, karyawan golongan
ini diliburkan.
ini dapat dikategorikan untuk buruh pada bidang teknik, produksi, dan
utilitas.
b. Indirect Operating Labor
Indirect Operating Labor adalah pekerja atau buruh yang tidak
berhubungan dengan jalannya operasi pabrik. Jenis pekerja ini dapat
dikategorikan untuk buruh pada bidang perbengkelan atau pemeliharaan,
bidang PUSLITBANG, bagian umum dan bagian pemasaran serta bagian
keuangan.
JUMLAH
BAGIAN
(ORANG)
Direktur Utama 1
Sekretaris Direktur Utama 1
A. Direktur Teknik dan Produksi 1
Sekretaris Direktur Teknik dan Produksi 1
1. Kepala Bagian Pengolahan dan Produksi 1
a. Kepala Seksi Proses 1
Operator Kontrol 12
Operator Lapangan 16
b. Kepala Seksi Utilitas 1
81
Operator Kontrol 10
Operator Lapangan 12
2. Kepala Bagian Teknik dan Pemeliharaan 1
a. Kepala Seksi Pemeliharaan dan Perbengkelan 1
Staff Bengkel 2
b. Kepala Seksi Instrumen 1
Operator Instrumentasi 6
3. Kepala Bagian Litbang 1
a. Kepala Seksi Perencanaan 1
Staff 3
b. Kepala Riset dan Pengembangan 1
Staff 2
c. Kepala Seksi Laboratorium 1
Staff 2
Analis 2
B. Direktur Pemasaran dan Keuangan 1
Sekretaris Direktur Pemasaran dan Keuangan 1
1. Kepala Bagian Keuangan 1
a. Kepala Seksi Keuangan dan Administrasi 1
Staff 4
2. Kepala Bagian Pemasaran 1
a. Kepala Seksi Penjualan dan Promosi 1
Staff 4
b. Kepala Seksi Pergudangan 1
Pekerja Gudang 2
C. Direktur Umum dan Kepegawaian 1
Sekretaris Direktur Umum dan Kepegawaian 1
1. Kepala Bagian Personalia 1
a. Kepala Seksi Humas dan Kepegawaian 1
Staff 4
b. Kepala Seksi Diklat 1
82
Staff 5
2. Kepala Bagian Pelayanan Umum 1
a. Kepala Seksi Kesehatan dan Admistrasi 1
Dokter 1
Perawat 2
b. Kepala Seksi Transportasi, Keamanan dan 1
Keselamatan Kerja
Pengemudi 5
Pemadam Kebakaran 6
Security 10
Jumlah Karyawan 147
Dewan Komisaris
Direktur Utama
Kabag
Kabag Teknik dan Kabag Penelitian
Pemeliharaan dan Kabag Keuangan Kabag Pemasaran Kabag Personalia Kabag Umum
Produksi dan Pengembangan
Perbengkelan
83
BAB VIII
ANALISA EKONOMI
84
85
Suatu pabrik dinyatakan layak berdiri jika pinjaman dari Bank sudah dapat
dilunasi sebelum mencapai setengah service life pabrik atau dengan kata lain, Pay
Out Time kurang dari setengah service life pabrik. (Peter, 1991)
FCI - TSV
Depresiasi =
Service life
Keterangan :
FCI = Fixed Capital Investment = US $ 14,138,711.9036
TSV = Salvage Value = 0
Salvage value = 0, nilai alat pada saat tahun ke 11. Salvage value di dapat
setelah mengalami pengurangan dari depresiasi 10 % per tahunnya. Sehingga,
pada saat tahun ke – 11 nilai alat pada pabrik bernilai 0.
US $ 14,138,711.9036
Sehingga, Depresiasi US $1,285,337,4458
11
US $ 14,138,711.9036
% Depresiasi 100% 9,09 %
US$ 1,285,337,4458
Atau:
100%
% Depresiasi 9,09 %
11tahun
8.2.1. Lama Pengangsuran Pinjaman
(Sumber:http://www.bankmandiri.co.id)
A
A = P ( , i, n)
P
i 1 i n
= P
1 i 1
n
Keterangan:
P : Pinjaman
i : Bunga Bank
n : Lama Waktu Angsuran
0,25 1 0,254
= US$ 12,475,334.0326
1 0,25 1
4
88
= US$ 5,282,577.0802
Tahun
Pinjaman Bunga Total Hutang Angsuran Sisa Hutang
Ke-
0 12,475,334.0326 0,0000 12,475,334.0326 0,0000 12,475,334.0326
1 12,475,334.0326 3,118,833,51 15,594,167.54 5,282,577.08 10,311,590.46
2 10,311,590.46 2,577,897.62 12,889,488.08 5,282,577.08 7,606,911.00
3 7,606,911.00 1,901,727.75 9,508,638.74 5,282,577.08 4,226,061.66
4 4,226,061.66 1,056,515.42 5,282,577.08 5,282,577.08 0,0000
Jumlah 8,654,974.29 55,750,205.47 21,130,308.32 34,619,897.15
Dari tabel diatas terlihat bahwa modal dapat dilunasi dalam jangka waktu
4 tahun dengan angsuran tetap pertahun sebesar US$ 5,282,577.08 Waktu
pengembalian modal yang kurang dari separuh umur pabrik (n<5,5 tahun),
menunjukkan bahwa pabrik Asam Asetat layak untuk didirikan.
Dengan :
Fixed capital Investment (FCI) = US $ 14,138,711.9036
Bunga Total Capital investment (TCI) = US $ 8,654,974.29
Annual Cash Flow (ACF) = US $ 922,972,130.6508
89
14,138,711.9036 8,654,974.29
POT = = 2 tahun 4 bulan
922,972,130.6508
Pay Out Time (POT) yang diperoleh adalah 2 tahun, yaitu kurang dari
setengah umur pabrik (5,5 tahun, Sumber : Peter hal. 309), dengan demikian
pabrik ini layak untuk didirikan.
Pabrik dinyatakan layak didirikan apabila hingga akhir service life pabrik,
nilai NPOLTP lebih besar dari pada nilai TCI ditambah dengan bunga Modal atau
pabrik juga layak didirikan jika TCS lebih besar dari TCI.
Net Profit Over Total Life of The Project adalah total keuntungan yang
diperoleh dalam bentuk uang tunai (termasuk angsuran untuk membayar bunga
modal) selama umur pabrik dan ditambah Capital Recovery. Ini dapat ditentukan
dengan persamaan berikut :
Keterangan :
CR = Capital Recovery
dalam bentuk uang tunai (termasuk uang tunai untuk membayar bunga modal)
selama service life.
Harga CCP ini ditentukan dengan persamaan :
Keterangan :
= US $ 10,136,059,658.4490
b. Capital Recovery
Capital Recovery (CR) adalah modal yang ada pada akhir umur pabrik.
Capital Recovery terdiri dari modal kerja Working Capital (WC), Salvage Value
(Vs) dan tanah (land). Harga CR dapat ditentukan dengan persamaan :
CR = WC + Vs + L (Peter, 1991)
Keterangan :
Vs (Salvage Value) = US $ 0
L (Land) = US $ 1,865,671.6418
CR = US $ 2,495,066.8065 + US $ 0 + US $ 1,865,671.6418
= US $ 4,360,738.4483
NPOTLP = CCP + CR
= US $ 10,140,420,396.8974
91
= US $ 10,131,563,128.8384
US $ 921,685,507.8676
ROR x 100 %
US $ 16,633,778.7102
ROR 55,4105 %
1 1 1 WC Vs
TCI = ACF ... n
…Peters hal 302
(1 i )1
(1 i ) 2
(1 i ) (1 i ) n
Keterangan :
TCI (Total Capital Investment) = US $ 16,633,778.7102
ACF (Annual Cash Flow) = US $ 922,972,130.6508
WC (Working Capital) = US $ 2,495,066.8065
Vs (Salvage Value) = US $ 0
93
1
(Discount Factor)
1 i n
Dari hasil trial and error, didapatkan nilai Discounted Cash Flow Rate of
Return (i) sebesar 1,1293.
Jadi, Discounted Cash Flow Rate of Return (DCF-ROR), i = 88,46 %.
Nilai Discounted Cash Flow Rate of Return ini lebih besar dari bunga bank yakni
25 % maka pabrik ini layak untuk didirikan.
Cara Matematis :
Nilai BEP secara matematis dapat dihitung dengan menggunakan persamaan :
Fixed Cost
BEP = 100 %
Selling Price Variable Cost
Keterangan :
Fixed Cost = Fixed Charge + Plant Overhead Cost + General Expenses
= US$ 3,780,484.0204
Variable Cost = Direct Production Cost
= US$ 3,431,315.8895
Selling Price = Total Income
= US$ 1,236,125,810.400
94
Sehingga:
Fixed Cost
BEP = 100 %
Selling Price Variable Cost
US $ 3,780,484.0204
= 100 %
US $ 1,236,125,810.400 US $ 3,431,315.8895
= 30,6685 %
Jadi Break Even Point (BEP) yang diperoleh = 30,6685 %. Dari grafik
BEP berdasarkan perhitungan yang telah dilakukan sebelumya, diperoleh data
bahwa selama produksi berjalan, fixed cost terlihat konstan untuk mengimbangi
ongkos produksi yang terus meningkat secara signifikan. Titik impas akan
tercapai bila pabrik beroperasi sebesar 30,6685 % dari kapasitas desain. Hal ini
memenuhi syarat, sehingga pabrik layak untuk didirikan. Untuk lebih jelasnya
dapat dilihat pada Gambar 8.1.
120,0000
100,0000
SP
80,0000
HARGA (JUTA US $)
60,0000 FC
40,0000
TPC
20,0000
0,0000
0 10 20 30 40 50 60 70 80 90 100 110
KAPASITAS PRODUKSI (%)
Discounted Cash
Lebih besar dari bunga Layak
6 Flowrate of Return 88,46 %
bank ( >25 %) didirikan
(DCF-ROR)
Dari hasil analisa dan perhitungan Pra Rencana Pabrik Pembuatan Asam
Asetat dapat disimpulkan :
1). Pra Rencana pabrik pembuatan Asam Asetat kapasitas 95.000 ton/tahun
direncanakan untuk memenuhi kebutuhan dalam negeri.
2). Dilihat dari faktor bahan baku, transportasi, pemasaran, penyerapan tenaga
kerja dan lingkungan, maka pabrik Asam Asetat didirikan di daerah
Kabupaten Bontang Selatan,Provinsi Kalimantan Timur.
3). Perusahaan berbentuk Perseroan Terbatas (PT) dengan struktur organisasi
line and staff, dimana pelaksana harian dipimpin oleh direktur utama
dengan karyawan pabrik sebanyak 147 orang.
4). Berdasarkan hasil analisa ekonomi, maka pabrik Asam Asetat dinyatakan
layak untuk didirikan. Dengan berdasarkan analisa ekonomi berikut :
a. Total Capital Investment (TCI) = US$ 16,633,778.7102
b. Total Production Cost (TPC) = US$ 7,211,799.9099
c. Selling Price = US$ 1,236,125,810.4
d. Rate of Return on Investemnt (ROR) = 55,4105 %
e. Break Even Point (BEP) = 30,6685 %
f. Annual Cash Flow (ACF) = US$ 922,972,130.6508
g. Pay Out time = 2 tahun 4 bulan
h. Service life = 11 tahun
96
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LAMPIRAN I
BIODATA PENULIS
99
BIODATA PESERTA SIDANG TUGAS AKHIR
JURUSAN TEKNIK KIMIA
100
US 20150025270A1
(19) United States
(12) Patent Application Publication (10) Pub. No.: US 2015/0025270 A1
Shimizu et al. (43) Pub. Date: Jan. 22, 2015
L
CD
JJ
(6
g
—Merthanol
Patent Application Publication Jan. 22, 2015 Sheet 2 0f2 US 2015/0025270 A1
F2IGURE
/14
34%
\
\
23\
2213
1
2
12CR?
Methanol CO
US 2015/0025270 A1 Jan. 22, 2015
PROCESS FOR PRODUCING ACETIC ACID methanol into the lower section of the second distillation
zone; removing an overhead stream containing methyl iodide
TECHNICAL FIELD and others from the second distillation zone; and withdrawing
a stream of a product acetic acid substantially free of hydro
[0001] The present invention relates to a process useful for gen iodide and methyl iodide from the bottom or a site near to
producing high-quality acetic acid while inhibiting corrosion the bottom of the second distillation zone.
of an apparatus (e.g., a distillation column).
[0006] Japanese Patent No. 4489487 (JP-4489487B, Patent
Document 3) discloses a process for separating hydrogen
BACKGROUND ART
iodide, which comprises distilling a mixture containing
[0002] In regard to a process for producing acetic acid, an hydrogen iodide, water, and a component having a boiling
industrially used production process comprises allowing point higher than that of water (e.g., acetic acid) to separate
methanol to continuously react with carbon monoxide in the hydrogen iodide, wherein an alcohol (e. g., methanol) is fed to
presence of a catalyst containing a group 8 metal of the a distillation column so that a zone having a water concentra
Periodic Table (such as a rhodium catalyst or an iridium tion of 5% by weight in the distillation column may be formed
catalyst), an ionic iodide (e.g., lithium iodide), and methyl between feed positions of the alcohol.
iodide and in the presence of water to give acetic acid. In this [0007] In the production of acetic acid, removal of hydro
process, usually, a reaction mixture obtained by carbonyla gen iodide by using the relationship between a water concen
tion of methanol is subjected to a ?ash distillation, the result tration and a hydrogen iodide concentration in a distillation
ing volatile component from the ?ash distillation is distilled column is also known. For example, Great Britain Patent No.
in a ?rst distillation column to form an overhead from a top of 1350726 (Patent Document 4) discloses that because of a
the column and a heavy component from a bottom thereof, peak concentration of hydrogen halides occurring in a middle
and an acetic acid stream is withdrawn as a side stream (side portion of a distillation column, if a side stream is withdrawn
cut stream) from the ?rst distillation column. Moreover, the from the middle portion of the distillation column then the
overhead from the ?rst distillation column is cooled and hydrogen halides will be removed therefrom, in a case where
condensed to form an aqueous phase and an organic phase, a liquid composition of carboxylic acid has a water concen
which are separated from each other; the aqueous phase tration ranging from 3 to 8% by weight. Further, this docu
mainly contains water and acetaldehyde, and the organic ment discloses that a reaction product of methanol and carbon
phase mainly contains methyl iodide. Further, the acetic acid monoxide is subjected to a ?ash distillation and then a frac
stream is subjected to a second distillation column to remove tion separated by the ?ash distillation is introduced into the
water and other impurities for obtaining or separating a fur distillation column to concentrate hydrogen iodide in a side
ther puri?ed acetic acid stream as a side stream (side cut stream from the middle portion of the distillation column,
stream) or bottom stream. The second distillation column is thereby removing the hydrogen iodide.
mainly used for dehydration in many cases. Since an over [0008] Japanese Patent Application Laid-Open Publication
head from the top of the second distillation column has a low No. 2006-160645 (JP-2006-160645A, Patent Document 5)
water content, the overhead is rarely separated into two discloses a process for producing acetic acid, which com
phases (an aqueous phase and an organic phase) even after prises: distilling a mixture containing hydrogen iodide, water,
cooling and condensation. In such a process, accumulation of methanol, methyl iodide, acetic acid and methyl acetate in a
hydrogen iodide in the ?rst and second distillation columns water content of not more than 5% by weight in a distillation
deteriorates the quality of product acetic acid due to contami column, withdrawing a fraction containing hydrogen iodide
nation with hydrogen iodide and causes corrosion of an appa from the top of the column, and withdrawing acetic acid as a
ratus (such as the ?rst and second distillation columns). side-cut stream by side-cut or a stream from the bottom of the
[0003] In order to remove hydrogen iodide, it has been column to reduce the concentration of hydrogen iodide to not
reported that hydrogen iodide is converted into methyl iodide, more than 50 ppm. According to this process, distillation at a
having a lower boiling point, by a reaction of hydrogen iodide water concentration of not more than 5% by weight in the
with methanol, and the resulting methyl iodide is separated as distillation system allows inhibition of concentration of
a lower boiling point stream. hydrogen iodide in the distillation system.
[0004] Japanese Patent Application Laid-Open Publication [0009] This document discloses that the mixture may be
No. 6-40999 (JP-6-40999A, Patent Document 1) discloses distilled by introducing at least one component selected from
that introduction of a small quantity of methanol below a feed the group consisting of methanol, methyl acetate and an alkali
point, at which a feeding composition is fed to a distillation metal hydroxide at an appropriate position of the distillation
zone, converts hydrogen iodide into methyl iodide which is column (for example, at the bottom, or between the bottom
removed as a light end stream of a distillation column. and the middle section) for maintaining or keeping the water
[0005] Japanese Patent Application Laid-Open Publication content of not more than 5% by weight in the distillation
No. 52-23016 (JP-52-23016A, Patent Document 2) discloses column and that such a process can remove hydrogen iodide.
a process for removing and collecting iodine-containing com Further, Patent document 5 discloses in Examples and Com
ponents and drying acetic acid, which comprises: introducing parative Examples that a liquid mixture containing 34% by
an acetic acid stream containing water, methyl iodide and weight of methyl iodide, 9.8% by weight of methyl acetate,
hydrogen iodide into a ?rst distillation zone intermediate; 1.2% by weight of water, 55% by weight of acetic acid, and
removing methyl iodide and others as an overhead fraction 190 ppm by weight of hydrogen iodide was distilled, and the
from the ?rst distillation zone; removing hydrogen iodide and resulting distillate from the top of the column was separated
others from the bottom of the ?rst distillation zone; withdraw into an upper layer and a lower layer.
ing a side stream (acetic acid stream) from the middle section [0010] Although these processes can inhibit the concentra
of the ?rst distillation zone for introducing the stream into the tion of hydrogen iodide in the distillation column, the hydro
upper section of a second distillation zone; introducing gen iodide removal ef?ciency is still insu?icient to produce a
US 2015/0025270 A1 Jan. 22, 2015
high-quality acetic acid. Moreover, even if the overhead from acetaldehyde) and an organic phase (a lower phase mainly
the distillation column is condensed, the overhead is not containing methyl iodide). Moreover, even if the condensate
e?iciently separated sometimes into an aqueous phase (upper is separated into the phases, these phases are mixed to form a
phase or light phase) and an organic phase (lower phase or mixed phase due to a small difference in speci?c gravity
heavy phase). In particular, when the liquid mixture is dis between the light phase and the heavy phase, so that the
tilled and the overhead (fraction) from the column top is distillation column cannot be operated stably. In particular, in
cooled and condensed according to Patent Document 5, the an industrial process, the boundary (interface) between the
condensate has an inef?cient separability into upper and aqueous phase and the organic phase varies depending on the
lower phases. Further, even if the condensate is separated into rapid expansion of carbon monoxide in the reaction system,
the lower phase and the upper phase, it is impossible to stably the ?ow rate and pressure ?uctuations in the ?ash distillation
perform or operate these processes due to an unsteady phase step and others. Therefore, the aqueous phase and the organic
boundary (liquid interface) between these phases. Thus the phase cannot be separated clearly, so that the process appa
continuous operation of the production apparatus sometimes ratus cannot be operated continuously. Further, feeding of
confronts obstruction or trouble. methanol or methyl acetate into the column from a position
[0011] Japanese Patent Application Laid-Open Publication lower than a plate for feeding the mixture meaninglessly
No. 2009-501129 (JP-2009-501129A, Patent Document 6) increases the diameter of the distillation column, resulting in
discloses a process for producing acetic acid, which com low economic ef?ciency.
prises: separating a reaction mixture obtained by carbonyla
tion of methanol into a catalyst stream and an acetic acid RELATED ART DOCUMENTS
stream in a catalyst-separating column; in a ?rst distillation
column, separating the acetic acid stream into a ?rst overhead Patent Documents
containing methyl iodide, methyl acetate and a portion of [0014] Patent Document 1: JP-6-40999A (Paragraph No.
water, and a ?rst higher boiling point stream containing por [0043])
tions of water and propionic acid, and withdrawing a ?rst side [0015] Patent Document 2: JP-52-23016A (Claims, page 5,
stream containing the acetic acid by side cut; feeding the ?rst the lower right column, page 7, the lower left column to the
side stream to a second distillation column; and withdrawing lower right column)
and collecting a second side stream containing the acetic acid [0016] Patent Document 3: JP-4489487B (Claims)
by side cut. This document discloses a process for reducing a [0017] Patent Document 4: GB Patent No. 1350726 speci
concentration of a hydrogen halide contained in a product ?cation (page 2, lines 66 to 76)
acetic acid, which comprises converting hydrogen iodide in [0018] Patent Document 5: JP-2006-l60645A (Claims,
the distillation column into methyl iodide and separating Paragraph No. [0036])
hydrogen iodide in the form of methyl iodide from the top of [0019] Patent Document 6: JP-2009-501129A (Claims,
the distillation column to inhibit condensation of the hydro Paragraph Nos. [0043] [0085], Examples 3 and 4, Compara
gen halide. The method for converting hydrogen iodide tive Example 2)
includes a method for feeding the ?rst distillation column
with water or water and a ?rst component (A) (wherein the SUMMARY OF THE INVENTION
?rst component (A) is at least one member selected from the
group consisting of methanol and methyl acetate) and a Problems to be Solved by the Invention
method for feeding the ?rst distillation column with the ?rst
component (A) from a lower position relative to a ?rst side [0020] It is therefore an object of the present invention to
stream port for side-cut of a ?rst side stream. Moreover, the provide a process for producing acetic acid, the process
document states that because supply of water to the ?rst improving liquid-liquid separation of a low-boiling stream
distillation column develops (forms) a zone having a high (overhead) from a distillation column while inhibiting con
water concentration in the distillation column and causes densation of hydro gen iodide, and a method for improving the
condensation of hydrogen halide in the zone, supply of water liquid-liquid separation of the low-boiling stream (overhead).
together with the ?rst component (A) allows e?icient conver [0021] Another object of the present invention is to provide
sion of hydrogen halide into a low-boiling component. a process for producing high-quality acetic acidby effectively
[0012] The patent document 6 discloses, in Examples, that inhibiting contamination with an impurity (e.g., hydrogen
methanol (4.9 mol/h), methyl acetate (7.4 mol/h) and water iodide), and a method for improving the quality of acetic acid.
(21.1 mol/h) were fed from the 27th plate from the top of the [0022] It is still another object of the present invention to
distillation column (having 30 plates) (Examples 3 and 4), provide a process for producing acetic acid, useful for ef?
and methanol was fed from the 43th from the top of the ciently separating a low-boiling stream (overhead) into an
distillation column (having 50 plates) (Comparative Example aqueous phase and an organic phase by cooling and condens
ing the stream from a distillation column, and operating a
2). production apparatus stably and continuously.
[0013] According to the process, unfortunately, a feeding
liquid has a high concentration of methyl acetate, and in Means to Solve the Problems
addition, the concentration of methyl acetate in an overhead
fraction or stream (vapor phase component) from the top of [0023] The inventors of the present invention made inten
the distillation column is further increased due to further sive studies to achieve the above objects and ?nally found that
condensation of methyl acetate in the distillation column and distillation of a mixture under feeding of a decreasing agent
by-product methyl acetate formed by feeding of methanol. (an agent for decreasing hydrogen iodide) to a distillation
Thus, if the fraction from the top of the distillation column is column achieves the followings (l) and (2), wherein the
cooled, the resulting condensate cannot be separated into an decreasing agent contains an effective amount of water in a
aqueous phase (an upper phase mainly containing water and concentration of not more than 5% by weight and an effective
US 2015/0025270 A1 Jan. 22, 2015
amount of methyl acetate in a concentration of not more than cut stream or bottom stream (or the side cut stream and the
9% by weight: (1) a zone having a high water concentration is bottom stream) containing acetic acid; and the overhead is
formed in the distillation column above a charging site (feed condensed to form an aqueous phase and an organic phase. In
site or part) of a volatile component to the distillation column, the process for producing acetic acid, the volatile phase com
and methyl acetate is allowed to effectively react with hydro ponent is distilled while being adjusted to a water concentra
gen iodide in the high-concentration zone to produce methyl tion of an effective amount and not more than 5% by weight
iodide (a lower boiling point component) and acetic acid, and a methyl acetate concentration of 0.5 to 9% by weight in
where methyl iodide has a high miscibility with an organic a distillation atmosphere of the volatile phase component in
phase, contrarily acetic acid has a high miscibility with an terms of a condensate or liquid form.
aqueous phase and is largely different in boiling point from [0028] At least one member selected from the group con
methyl iodide (largely different in boiling point from water sisting of methyl acetate, methanol and dimethyl ether, and if
formed by a reaction of methanol with hydrogen iodide); and necessary water, may be added (or supplied) to the mixture
(2) since a low-boiling stream (overhead) contains methyl (volatile phase component) or a distillation atmosphere of the
acetate in a predetermined proportion, the low-boiling stream mixture (volatile phase component) to adjust the concentra
(overhead) from the distillation column is cooled and con tions of water and methyl acetate, and the resulting volatile
densed to clearly and e?iciently separate the resulting con phase component may be distilled. Moreover, a distillation
densate into an organic phase containing methyl iodide and an atmosphere of a volatile phase component may be formed in
aqueous phase containing acetic acid, and thus the liquid the distillation column at a height equal to or upper than a feed
liquid separation of the low-boiling stream (overhead) from site of the volatile phase component.
the distillation column can signi?cantly be improved. The [0029] Further, the mixture may have a hydrogen iodide
present invention was accomplished based on the above ?nd concentration of about 100 to 10000 ppm. Such a mixture
ings. may be subjected to a distillation to form (or separate) a side
[0024] That is, a process for producing acetic acid accord cut stream containing acetic acid. The concentration of
ing to the present invention comprises: distilling a mixture hydrogen iodide in the side cut stream may be about 1 to 350
containing hydrogen iodide, water, methyl iodide, acetic acid, ppm
and methyl acetate to form an overhead containing a lower [0030] Furthermore, in order to e?iciently separate the
boiling point component; and condensing the overhead to overhead into an aqueous phase and an organic phase by
form separated liquid phases. In the process, acetic acid is condensation of the overhead, the separated lower phase (or
produced by distilling a mixture containing an effective ganic phase or heavy phase) may have a methyl acetate con
amount of water in a concentration of not more than 5% by centration of about 1 to 15% by weight, and the upper phase
weight and an effective amount of methyl acetate in a con (aqueous phase or light phase) may have a lower methyl
centration of not more than 9% by weight (methyl acetate in acetate concentration of about 0.4 to 8% by weight than the
a concentration of 0.5 to 9% by weight) to separate the mix lower phase has.
ture into an overhead (fraction) containing methyl iodide and [0031] The present invention also includes a method for
a side cut stream or bottom stream containing acetic acid. liquid-liquid separating a condensate, comprising: distilling a
[0025] The mixture may has a methyl acetate concentration mixture containing hydrogen iodide, water, methyl iodide,
of 0.07 to 1.2 mol/L and a water concentration of 0.28 to 2.8 acetic acid, and methyl acetate to form an overhead contain
mol/ L, and may be distilled continuously. The water content ing a lower boiling point component, and condensing the
ofthe mixture may be about 0.5 to 4.5% by weight (e.g., about overhead. In this method, the mixture containing an effective
1 to 4.3% by weight). The methyl acetate content of the amount of water in a concentration of not more than 5% by
mixture may be about 0.5 to 8% by weight (e.g., about 0.5 to weight and methyl acetate in a concentration of 0.5 to 9% by
7.5% by weight or about 0.8 to 7.5% by weight). The mixture weight is distilled to reduce a concentration of hydrogen
may further contain dimethyl ether. The concentration of iodide in the overhead and a side cut stream, and the conden
dimethyl ether may be about 0.15 to 3% by weight. sation of the overhead improves the liquid-liquid separation
[0026] The mixture may be fed to a distillation column of the condensate. In the method, the concentration of hydro
from an intermediate or lower position of the distillation gen iodide in the overhead and the side cut stream may be
column in height. Moreover, a zone having a high water reduced by adjusting a concentration of methyl acetate in the
concentration may be formed inside a distillation column at a mixture to 0.5 to 8% by weight (or by increasing a concen
position upper than a feed position at which the mixture is fed tration of methyl acetate in the mixture within the range of 0.4
to the distillation column; in the high water concentration to 8% by weight). Further, the liquid-liquid separation of the
zone, hydrogen iodide may be allowed to react with methyl condensate may be improved by adjusting (or controlling)
acetate to produce methyl iodide and acetic acid; and the concentrations of methyl iodide and methyl acetate in the
distillation may provide the overhead containing the resulting lower phase (organic phase or heavy phase) to 76 to 98% by
methyl iodide. weight and 1 to 15% by weight, respectively (with the proviso
[0027] The present invention includes the process for pro that the total of components in the lower phase (organic phase
ducing acetic acid, in which methanol is allowed to continu or heavy phase) is 100% by weight), and adjusting (or con
ously react with carbon monoxide by using a catalyst con trolling) concentrations of water and methyl acetate in the
taining a group 8 metal of the Periodic Table (such as a upper phase (aqueous phase or light phase) are adjusted to 50
rhodium catalyst or an iridium catalyst), an ionic iodide (e.g., to 90% by weight and 0.4 to 8% by weight, respectively (with
lithium iodide), and methyl iodide in the presence of water; the proviso that the total of components in the upper phase
the reaction product is separated into a low-volatile phase (aqueous phase or light phase) is 100% by weight).
component and a volatile phase component by a ?ash distil [0032] The present invention also includes an apparatus for
lation; the volatile phase component as the mixture is distilled producing acetic acid by distilling a mixture containing
to form the overhead containing methyl iodide and the side hydrogen iodide, water, methyl iodide, acetic acid, and
US 2015/0025270 A1 Jan. 22, 2015
methyl acetate. The apparatus comprises a controller for component to form (or provide) a ?rst overhead from a top of
adjusting (or setting to or controlling) a water concentration the column, a bottom stream from a bottom thereof, and a side
in the mixture to not less than an effective amount to not more cut stream (crude acetic acid stream); a decanter 4 for cooling
than 5% by weight and a methyl acetate concentration therein and condensing the ?rst overhead in a condenser C3 and for
to 0.5 to 9% by weight by feeding water and/or methyl separating the ?rst overhead into an aqueous phase (upper
acetate, and further comprises a distillation column for dis phase or light phase) and an organic phase (lower phase or
tilling the mixture having adjusted water concentration and heavy phase); a second distillation column (dehydration col
methyl acetate concentration to form (or provide) an over umn or puri?cation column) 5 for distilling the side cut stream
head containing methyl iodide and a side cut stream orbottom (crude acetic acid stream) from the ?rst distillation column 3
stream containing acetic acid, a cooling unit (a condenser) for to form a second overhead from a top of the second distillation
cooling the overhead from the distillation column, and a column, a bottom stream from a bottom thereof, and a side cut
liquid-liquid-separating unit (a decanter) for separating the stream (puri?ed acetic acid stream) from a side thereof; and
resulting condensate of the cooled overhead into two phases. an impurity-removing system [a third distillation column 6, a
[0033] As used herein, the term “mixture” is sometimes the water extraction column (water extractor) 7, and a fourth
same meaning as a volatile phase component obtained by distillation column 8] for removing an impurity from a con
?ash distillation. Moreover, an amount of a component in the densate (an aqueous phase and an organic phase) in a con
mixture means not an amount of the component in a vapor denser C4.
phase but an amount of the component in the form of the [0039] Methanol (a liquid reactant) and carbon monoxide
condensate or liquid. (a gaseous reactant) are continuously fed to the reactor 1 at
predetermined rates in the presence of a catalyst system (car
Effects of the Invention bonylation catalyst system) containing a metal catalyst (such
[0034] According to the present invention, since a mixture as a rhodium catalyst or an iridium catalyst) and a co-catalyst
containing a speci?c concentration of water and a speci?c [lithium iodide as an ionic iodide (or iodide salt) and methyl
concentration of methyl acetate is distilled to form separated iodide] and a de?nite amount of water, and the carbonylation
phases, the concentration of hydrogen iodide (or corrosion of reaction of methanol is continuously conducted. The reaction
an apparatus) can be inhibited and the liquid-liquid separation system usually contains acetic acid, which is a reaction prod
of a low-boiling stream (overhead) from a distillation column uct and also functions as a reaction solvent, and methyl
can be improved. Moreover, due to the conversion of hydro acetate, which is by-produced from a reaction of acetic acid
gen iodide into methyl iodide and the separation of the over with methanol. Inside the reactor 1, a liquid-phase reaction
head into an aqueous phase and an organic phase, the present system containing the metal catalyst component (such as a
invention effectively prevents contamination with an impu rhodium catalyst), the ionic iodide (such as lithium iodide),
rity (such as hydrogen iodide) to produce high-quality acetic methanol, acetic acid, and others is in equilibrium with a
acid. Further, cooling and condensing the low-boiling stream vapor-phase system containing unreacted carbon monoxide
(overhead) from the distillation column allows e?icient sepa and gaseous by-products derived from the reaction (hydro
ration of the stream into the aqueous phase and the organic gen, methane, carbon dioxide), a vaporized low-boiling com
phase, so that a production apparatus can be stably and con ponent (e.g., methyl iodide, acetic acid as a product, methyl
tinuously operated. Thus, the present invention is useful as a acetate, acetaldehyde, and hydrogen iodide), and others.
process for industrially producing acetic acid. [0040] In order to keep the inner pressure of the reactor 1
(e.g., reaction pressure, carbon monoxide partial pressure,
BRIEF DESCRIPTION OF DRAWINGS and hydrogen partial pressure) constant, a vapor stream is
withdrawn from the top through a discharge line 12 and
[0035] FIG. 1 is a diagram for explaining a production cooled in a condenser C1. A condensed liquid component
process of acetic acid in accordance with an embodiment of
(containing acetic acid, methyl acetate, methyl iodide, acetal
the present invention. dehyde, water, and others) in the condenser is recycled (or
[0036] FIG. 2 is a diagram for explaining a production re?uxed) to the reactor 1 through a recycle line (or re?ux line)
process of acetic acid in accordance with another embodi 13, and an uncondensed gaseous component (containing car
ment of the present invention. bon monoxide, hydrogen, and others) in the condenser is
discharged as offgas. In particular, the reaction system is an
DESCRIPTION OF EMBODIMENTS exothermic reaction system accompanying heat generation,
[0037] Hereinafter, the present invention will be explained and part of the quantity of heat generated in the reactor 1 is
in detail with reference to the drawings if necessary. FIG. 1 is removed by cooling the vapor component from the reactor 1
a diagram (a ?ow sheet, a schematic process drawing, or a in the condenser C1 and recycling the condensed component
schematic plant layout drawing) for explaining a production to the reactor 1.
process (or production apparatus) of acetic acid in accordance [0041] Components contained in the reaction mixture
with an embodiment of the present invention. (crude reaction liquid) may include acetic acid, a volatile
[0038] The process (or production apparatus) shown in component having a boiling point lower than that of acetic
FIG. 1 comprises a reactor (reaction system) 1 for allowing acid [e.g., a low-boiling component (e.g., methyl iodide as a
methanol to continuously react with carbon monoxide (car co-catalyst, methyl acetate as a reaction product of acetic acid
rying out the carbonylation reaction of methanol) in the pres with methanol, methanol, water, and dimethyl ether) or a
ence of a catalyst or a catalyst system and water; a ?asher or low-boiling impurity (hydrogen iodide, acetaldehyde, cro
evaporator (?ash evaporator) 2 for separating the reaction tonaldehyde)], and a low-volatile component having a boiling
mixture (liquid reaction medium) into a volatile phase com point higher than that of acetic acid [e.g., a metal catalyst
ponent and a low-volatile phase component; a ?rst distillation component (a rhodium catalyst, and lithium iodide as a co
column (splitter column) 3 for distilling the volatile phase catalyst) or a high-boiling impurity (for example, a by-prod
US 2015/0025270 A1 Jan. 22, 2015
uct, e.g., propionic acid, an aldehyde condensation product component (or volatile phase) fed through the feed line 22 is
such as 2-ethylcrotonaldehyde, and a C6_12alkyl iodide such distilled in the ?rst distillation column (splitter column) 3 and
as hexyl iodide or decyl iodide)]. separated into a ?rst overhead (a ?rst lower boiling point
[0042] Accordingly, the reaction mixture (a portion of the component containing methyl iodide, methyl acetate, acetal
reaction mixture) is continuously fed from the reactor 1 to the dehyde, water, and others) withdrawn from the column top or
?asher or evaporator (?ash evaporator, ?ash distillation col upper part (or site) of the column, a bottom stream [a stream
umn) 2 through a feed line 11 for a ?ash distillation, and mainly containing a higher boiling point component, e.g., a
separated into a volatile phase component from the column high-boiling impurity such as water, acetic acid, an entrained
top or upper part (or section) of the ?ash evaporator 2 (a lower catalyst (such as lithium iodide), propionic acid, a C6_l2alkyl
boiling point fraction mainly containing acetic acid as a prod iodide (such as hexyl iodide), or an aldehyde condensation
uct, methanol, methyl acetate, methyl iodide, water, propi product] withdrawn from the column bottom, and a side cut
onic acid, acetaldehyde, and hydrogen iodide as a by-prod stream [a ?rst liquid stream (crude acetic acid stream) mainly
uct) and a low-volatile phase component (a higher boiling containing acetic acid] from the side (a site upper than the
point fraction mainly containing a metal catalyst component feed site (or feed section) of the feed line 22). In this embodi
(high-boiling component) such as a rhodium catalyst and a ment, the side cut stream (crude acetic acid stream) is fed to
lithium iodide). the second distillation column 5 through a feed line 36, and
[0043] The low-volatile phase component (liquid catalyst the bottom stream from the column bottom is fed to the
mixture or bottom fraction) may be recycled to the reactor 1 reactor 1 through a recycle line 31. A portion or all of the
through a recycle line 21. In this embodiment, the low-vola bottom stream from the column bottom may be recycled to
tile phase component (liquid catalyst mixture or bottom frac the evaporator 2 through a line (not shown).
tion) is continuously withdrawn through a recycle line 21 [0046] The ?rst overhead is introduced into the condenser
from the bottom of the evaporator 2 and heat-removed and C3 through an introduction line 32 and cooled and condensed.
cooled in a heat exchanger (a condenser C6), and the cooled The resulting condensed component (a condensate contain
low-volatile phase component (liquid catalyst mixture) is ing methyl iodide, methyl acetate, acetic acid, acetaldehyde,
recycled to the reactor 1. Thus, the temperature of the reactor and others) is fed to the decanter 4 through an introduction
1 is easily controlled. The low-volatile phase component (liq line 33, and the resulting noncondensed component (a gas
uid catalyst mixture) usually contains the metal catalyst com component mainly containing carbon monoxide, hydrogen,
ponent, and in addition, components remaining without and others) is discharged as a vent gas.
evaporation (e.g., acetic acid, methyl iodide, water, and [0047] In order to inhibit the corrosion of the distillation
methyl acetate). column 3 and improve the liquid-liquid separation of the
[0044] A portion of the volatile phase component (or vola condensate in the decanter 4, the volatile component fed to the
tile phase) from the evaporator 2 is introduced into a con distillation column 3 through the feed line 22 contains not
denser (heat exchanger) C2 through a feed line 23, and cooled more than 5% by weight (e.g., l to 3% by weight) of water and
and separated into a condensed component containing acetic 0.5 to 9% by weight (e.g., 3 to 5% by weight) of methyl
acid (a liquid component containing acetic acid, methanol, acetate, in terms of condensate or liquid. In this embodiment,
methyl acetate, methyl iodide, water, propionic acid, acetal a water supply line 34a and a methyl acetate supply line 3511
dehyde, hydrogen iodide, and others) and a noncondensed are connected to the feed line 22 for adjusting (or controlling)
component (a gas component such as carbon monoxide or the water concentration of and methyl acetate concentration
hydrogen). A portion of the condensed component (liquid in the distillation column 3 (the concentrations in the volatile
component) is retained in a buffer tank 9 and recycled to the component).
reactor 1 through a recycle line 25, the other portion (remain [0048] More speci?cally, due to a low water concentration
der) of the condensed component (liquid component) is fed to in the volatile component, a zone having a high water con
the decanter 4 through a line 26, and the noncondensed com centration appears above the feed site of the volatile compo
ponent (gas component) is discharged as a vent gas. In this nent in the ?rst distillation column 3. In this zone, although
manner, since a portion of the volatile phase component from highly water-soluble hydrogen iodide is concentrated, feed
the ?ash evaporator 2 is cooled and e?iciently heat-removed ing of methyl acetate predominantly proceeds with a reaction
in the condenser (heat exchanger) C2 and then recycled to the of methyl acetate with hydrogen iodide to shift the following
reactor 1, the temperature of the reactor 1 is easily controlled. equilibrium reaction (1) rightward. Thus useful methyl iodide
Accordingly, since the succeeding distillation column(s) or and acetic acid can be obtained. Further, feeding of water
condenser(s) can be downsized (or miniaturized) even for a and/or methyl acetate can shift the following equilibrium
large-sized plant, acetic acid can be produced with a high reaction (2) rightward to form methanol and acetic acid. The
purity in a resource-saving and energy-saving equipment. In following reaction (3) of the resulting methanol with hydro
particular, according to the process shown in FIG. 1, the gen iodide can produce useful methyl iodide and water. That
low-volatile phase component (liquid catalyst mixture or bot is, ?nally, while production of hydrogen iodide as a by-prod
tom fraction) and a portion of the volatile phase component uct (shift reaction of the equilibrium reaction (3) leftward) is
(or volatile phase) are cooled and recycled to the reactor 1. inhibited, methyl iodide (which has a high a?inity with an
Thus even when the reactor is not necessarily equipped with organic phase and a low boiling point), acetic acid (which has
a heat-removable (or heat-removing) or cooling unit (e. g., an a high a?inity with water and has a high boiling point) and
external circulation cooling unit such as a jacket), the heat water are produced. Thus, methyl iodide, acetic acid and
removal can be achieved. water can be separated effectively by distillation. In addition,
[0045] The volatile phase component (or volatile phase) is as described below, in the decanter 4 these components can be
fed to a lower-middle part, in a height direction, of the ?rst separated e?iciently into an organic phase mainly containing
distillation column (splitter column) 3 (e.g., a plate column) methyl iodide and an aqueous phase mainly containing water
through a feed line 22. That is, a portion of the volatile phase and acetic acid.
US 2015/0025270 A1 Jan. 22, 2015
acetaldehyde and others) from the column top and a bottom condenser C2 to produce a condensate and a noncondensed
stream (a fraction mainly containing water) from the column component. The condensate is recycled to the reactor 1
bottom. Moreover, a portion of the organic phase (raf?nate) in through a recycle line 25, and the noncondensed component
the extractor 7 is fed to the third distillation column 6 through (gaseous component) is fed to the scrubber system 92 through
lines 71, 72, and another portion thereof is recycled to the a discharge line 27. In this embodiment, the position (feed
reactor 1 through recycle lines 73, 90. The bottom stream port) of a feed line 22 connected to the ?rst distillation column
from the fourth distillation column 8 is joined to (or combined 3 is located between the bottom and the intermediate of the
to) water of the water feed line 82 through a line 81, and used ?rst distillation column 3.
for water extraction in the extractor 7. The low-boiling stream [0062] Moreover, in the ?rst distillation column 3, the vola
(a fraction mainly containing acetaldehyde) from the column tile phase component from the ?ash evaporator 2 is distilled to
top of the fourth distillation column 8 is discharged as an give a ?rst overhead withdrawn from the column top, a bot
offgas. tom stream withdrawn from the column bottom, and a side cut
[0058] According to the process (or production apparatus), stream (crude acetic acid stream) from the side. The side cut
the water concentration and the methyl acetate concentration stream is withdrawn from a site above the position (feed port)
in the distillation system of the ?rst distillation column 3 are of the feed line 22 connected to the ?rst distillation column 3.
adjusted to not more than 5% by weight (for example, 1 to 3% The ?rst overhead is introduced into a condenser C3 through
by weight) and 0.5 to 9% by weight (for example, 3 to 5% by an introduction line 32 and is cooled and condensed to give a
weight), respectively, by feeding water and/or methyl acetate condensed component and a noncondensed component; the
through the water feed line 34a and the methyl acetate feed condensed component (a condensate containing methyl,
line 35a. Thus, the zone having a high hydrogen iodide con iodide, methyl acetate, acetic acid, acetaldehyde, and others)
centration can be formed in a predetermined zone in the ?rst is fed to a decanter 4 through an introduction line 33, and the
distillation column 3; and hydrogen iodide is allowed to con noncondensed component (a gas component mainly contain
tact with an ascending stream of methyl acetate (and metha ing carbon monoxide, hydrogen, and others) is fed to the
nol) having a low boiling point in the volatile phase compo scrubber system 92 through a discharge line 38. A portion of
nent, so that the reaction can convert hydrogen iodide into the bottom stream is returned to a ?ash evaporator 2 through
methyl iodide to produce acetic acid and water as by-prod a line 37, and another portion of the bottom stream is recycled
ucts. Further, in the decanter 4, since the methyl acetate to the reactor 1 through a recycle line 31. All of the bottom
content can be reduced, the aqueous phase (mainly containing stream may be returned to the ?ash evaporator 2 through the
acetic acid, methyl acetate and hydrogen iodide) and an line 37. A condensate in the decanter 4 (in this embodiment,
organic phase (mainly containing methyl iodide and methyl an aqueous phase) is returned to the ?rst distillation column 3
acetate) can be separated with a high liquid-liquid, separation through a re?ux line 42 for re?ux. A condensate in the
e?iciency. Thus, the side cut stream (crude acetic acid stream) decanter 4 (in this embodiment, an organic phase) is recycled
from the ?rst distillation column 3 can be prevented from to the reactor 1 through a recycle line 41.
contamination with hydrogen iodide, a load on the second [0063] Further, the side cut stream from the ?rst distillation
distillation column 5 can be decreased and the corrosion of column 3 is fed to a second distillation column (dehydration
the ?rst and second distillation columns 3, 5 can be inhibited. column or puri?cation column) 5 through a feed line 36 and is
[0059] FIG. 2 is a ?ow diagram for explaining a process (or separated, by distillation in the second distillation column 5,
apparatus) producing for acetic acid in accordance with into a second overhead withdrawn from the column top
another embodiment of the present invention. For explana through a line 52, a bottom stream withdrawn from the col
tion, the same reference numeral as that in FIG. 1 is given to umn bottom through a line 51, and a side cut stream (high
the substantially same element as that in FIG. 1. purity acetic acid stream) withdrawn from the side through a
[0060] In this embodiment, acetic acid is produced by basi line 55. The second overhead (lower boiling point fraction)
cally the same process as that shown in FIG. 1 except that (i) passes through a discharge line 52 and is cooled and con
a condensate obtained by condensing a volatile phase com densed in a condenser C4 to give a condensate and a noncon
ponent from a ?ash evaporator 2 is not fed to a decanter 4, (ii) densed component. A portion of the condensate (a condensate
separation processes (a third distillation column, a water mainly containing water) is returned to the second distillation
extractor, a fourth distillation column) for further separating column 5 through a re?ux line 53 for re?ux, and another
or removing an impurity from the condensate in the decanter portion of the condensate is recycled to the reactor 1 through
4 are not shown, (iii) an offgas from each condenser C1 to C4 a recycle line 91. Moreover, the noncondensed component
is treated by a scrubber system, and (iv) in a second distilla (gaseous component) is fed to the scrubber system 92 through
tion column 5, hydrogen iodide is further removed by addi a discharge line 56.
tion of an alkali component. [0064] In the scrubber system 92, a useful component (e. g.,
[0061] More speci?cally, a vapor phase is withdrawn from methyl iodide, acetic acid) is collected and recycled to the
a reactor 1 through a discharge line 12 and cooled in a con reactor 1, and carbon monoxide is puri?ed by PSA (pressure
denser C1; the resulting condensed liquid component is swing adsorption) or other methods and recycled to the reac
returned to the reactor 1 through a re?ux line 13 for re?ux, and tor 1.
the resulting noncondensed component (gaseous component) [0065] To the feed line 22 for feeding the volatile phase
is sent to a scrubber system 92 through a discharge line 14. component to the ?rst distillation column 3, a supply line 34b
Moreover, a reaction mixture in the reactor 1 is fed to a ?ash for feeding water and/or methyl acetate is connected. A high
evaporator 2 through a feed line 11 and subjected to a ?ash water concentration zone is formed by supplying water and/
distillation; a portion of the resulting volatile phase compo or methyl acetate through the supply line 34b and by main
nent is fed to a ?rst distillation column 3 through a feed line taining the water concentration and methyl acetate concen
22, and another portion of the volatile phase component tration of a feeding liquid to be fed into the ?rst distillation
passes through a feed line 23 and cooled and condensed in a column 3 to predetermined ranges (for example, 1 to 3% by
US 2015/0025270 A1 Jan. 22,2015
weight of water and 3 to 5% by weight of methyl acetate). In a complex (in particular, a form soluble in a liquid reaction
the zone, hydrogen iodide is concentrated and allowed to medium, e. g., a complex). As the rhodium catalyst, there may
react with methyl acetate to convert into methyl iodide. Thus be mentioned a rhodium iodide complex (for example, RhI3,
the ?rst distillation column 3 can be prevented from corro [RhI2(CO)4], and [Rh(CO)2I2]), a rhodium carbonyl com
sion. Since hydrogen iodide is concentrated aron a water plex; and others. These metal catalysts may be used singly or
concentration of 5% by weight, hydrogen iodide cannot be in combination. The concentration of the metal catalyst is, for
concentrated if a zone having such a water concentration is example, about 10 to 5000 ppm (on the basis of weight, the
not formed in the distillation column (for example, in the case same applies hereinafter) and particularly about 200 to 3000
where the water concentration at the top of the distillation ppm (e. g., about 500 to 1500 ppm) in the whole liquid phase
column is less than 5% by weight due to insuf?cient supply of in the reactor.
water). However, hydrogen iodide still existing in the distil [0073] As the co-catalyst or the accelerator, an ionic iodide
lation column depending on the equilibrium reaction can be or a metal iodide is employed which is useful for stabilization
converted into methyl iodide by methyl acetate. Thus, even if of the rhodium catalyst and inhibition of side reactions in a
a zone having a water concentration of about 5% by weight is low water content. It is suf?cient that the ionic iodide (or
not formed, the corrosion can be inhibited. Moreover, the metal iodide) can produce an iodide ion in the liquid reaction
reaction of hydrogen iodide with methyl acetate produces medium. The ionic iodide (or metal iodide) may include, for
methyl iodide, acetic acid and water to improve the liquid example, an alkali metal iodide (e.g., lithium iodide, sodium
liquid separation into an aqueous phase (light phase) and an iodide, and potassium iodide). The alkali metal iodide (e.g.,
organic phase (heavy phase) in the decanter 4. lithium iodide) also functions as a stabilizer for the carbony
[0066] As shown in FIG. 2, a supply line 35b, for feeding at lation catalyst (e.g., a rhodium catalyst). These co-catalysts
least one member selected from the group consisting of may be used alone or in combination. Among these co-cata
methyl acetate, methanol and dimethyl ether, and if necessary lysts, lithium iodide is preferred. In the liquid phase system
water, may be connected to the ?rst distillation column 3 (liquid reaction medium) in the reactor, the concentration of
instead of the feed line 22, and at least one member selected the co-catalyst (e.g., a metal iodide) is, for example, about 1
from the group consisting of methyl acetate, methanol and to 25% by weight, preferably about 2 to 22% by weight, and
dimethyl ether, and if necessary water may be supplied to the more preferably about 3 to 20% by weight in the whole liquid
column using the supply line 35b to maintain the water and phase.
methyl acetate concentrations in the ?rst distillation column 3 [0074] As the accelerator, methyl iodide is utilized. In the
to predetermined concentrations (concentrations correspond liquid phase system (liquid reaction medium) in the reactor,
ing to predetermined concentrations of water and methyl the concentration of methyl iodide is, for example, about 1 to
acetate in a mixture fed to the ?rst distillation column 3). In 20% by weight, preferably about 5 to 20% by weight, and
this embodiment, the supply line 35b connected to the ?rst more preferably about 6 to 16% by weight (e.g., about 8 to
distillation column 3 is located at substantially the same 14% by weight) in the whole liquid phase.
height as or above the feed site of the volatile phase compo
nent.
[0075] The reaction mixture usually contains methyl
acetate, which is produced by a reaction of acetic acid with
[0067] Further, an addition line 57a and/or 57b for adding
methanol. The proportion of methyl acetate may be about 0.1
an alkali component is connected to a feed line 36, connected
to 30% by weight, preferably about 0.3 to 20% by weight, and
to the second distillation column 5, and/or the second distil
more preferably about 0.5 to 10% by weight (e. g., about 0.5 to
lation column 5. The addition of the alkali component (an
6% by weight) in whole reaction mixture.
aqueous solution of an alkali such as sodium hydroxide,
potassium hydroxide, or lithium hydroxide) through the addi [0076] The reaction may be carried out, in the absence of a
tion line(s) converts hydrogen iodide into an alkali iodide, solvent or may usually be carried out in the presence of a
resulting in removal of hydrogen iodide. solvent. As the reaction solvent, acetic acid, which is a prod
[0068] According to such a process (or production appara uct, is usually employed.
tus), since not only hydrogen iodide can be converted into [0077] The water content of the reaction system may be a
methyl iodide and removed in the ?rst distillation column 3 low concentration. The water content of the reaction system
but also hydrogen iodide can also be removed by the alkali may for example be not more than 15% by weight (e.g., about
component in the second distillation column 5, acetic acid 0.1 to 12% by weight), preferably not more than 10% by
with a high purity can be produced. weight (e.g., about 0.1 to 8% by weight), more preferably
[0069] Hereinafter, steps and apparatus for producing ace about 0.1 to 5% by weight (e.g., about 0.5 to 3% by weight),
tic acid by carbonylation of methanol will be explained in and usually about 1 to 15% by weight (e.g., about 2 to 10% by
detail. weight) in the whole liquid phase in the reaction system.
[0070] [Carbonylation Reaction of Methanol] [0078] The carbon monoxide partial pressure in the reactor
[0071] In the reaction step (carbonylation reaction step), may for example be about 2 to 30 atmospheres and preferably
methanol is allowed to continuously react with carbon mon about 4 to 15 atmospheres. In the carbonylation reaction,
oxide using a catalyst system (a catalyst containing a group 8 hydrogen is formed (or generated) by a shift reaction between
metal of the Periodic Table, a co-catalyst, and an accelerator) carbon monoxide and water. In order to increase the catalyst
in the presence of water, thereby being carbonylated continu activity, hydrogen may be fed to the reactor 1, if necessary.
ously. The hydrogen partial pressure in the reaction system may for
[0072] The catalyst containing a group 8 metal of the Peri example be about 0.5 to 250 kPa, preferably about 1 to 200
odic Table may include, for example, a rhodium catalyst and kPa, and more preferably about 5 to 150 kPa (e.g., about 10 to
an iridium catalyst (in particular, a rhodium catalyst). The 100 kPa) in terms of absolute pressure.
catalyst may be used in the form of a halide (e.g., an iodide), [0079] The reaction temperature may be, for example,
a carboxylate (e.g., an acetate), a salt of an inorganic acid, or about 150 to 250° C., preferably about 160 to 230° C., and
US 2015/0025270 A1 Jan. 22, 2015
more preferably about 180 to 2200 C. Moreover, the reaction [0085] Moreover, a portion of the volatile phase component
pressure (total reactor pressure) may be, for example, about may be recycled to the reactor (for example, as described
15 to 40 atmospheres. above, a portion of the volatile phase component is heat
[0080] The space time yield of acetic acid in the reaction removed and condensed in a condenser or a heat exchanger
system may be, for example, about 5 mol/Lh to 50 mol/Lh, and then recycled to the reactor).
preferably about 8 mol/Lh to 40 mol/Lh, and more preferably [0086] The volatile phase component contains product ace
about 10 mol/Lh to 30 mol/Lh. tic acid, in addition, hydrogen iodide, a co-catalyst (such as
[0081] The catalyst mixture (liquid catalyst mixture) con methyl iodide), methyl acetate, water, by-product(s) (e.g., an
taining the catalyst system and water may be continuously fed aldehyde compound such as acetaldehyde or an aldehyde
to the reactor 1. Moreover, in order to adjust the pressure of condensation product, a C3_12alkanecarboxylic acid such as
the reactor, a vapor component (vent gas) may be withdrawn propionic acid, and a C6_12alkyl iodide such as hexyl iodide),
from the reactor. As described above, the vent gas may be fed and is fed to a distillation column (splitter column) for col
to the scrubber system, if necessary, and then a useful com lecting acetic acid. The separated higher boiling point catalyst
ponent (e.g., methyl iodide, acetic acid) may be collected and component (low-volatile phase component or metal catalyst
separated by adsorption treatment and recycled to the reactor component) is usually recycled to the reaction system.
1, and/or a useful gas component (e.g., carbon monoxide) [0087] [First Distillation]
may be separated and recycled to the reactor 1. Moreover, in [0088] The following embodiment explains distillation of
order to remove part of the reaction heat, the vapor compo the mixture and removal of hydrogen iodide in the ?rst dis
nent (vent gas) from the reactor may be condensation-treated tillation column (distillation in the ?rst distillation column).
by cooling with a condenser, a heat exchanger or other means. As far as the distillation is carried out by adjusting the water
The vapor component may be separated into a condensed concentration and methyl acetate concentration in the mix
component (a condensate containing acetic acid, methyl ture to predetermined concentrations, this embodiment is also
acetate, methyl iodide, acetaldehyde, water, and others) and a applicable to other distillations (the succeeding distillation in
noncondensed component (a gaseous component containing second or third distillation column).
carbon monoxide, hydrogen, and others), and the condensed [0089] The volatile phase component (mixture) contains
component may be recycled to the reactor to control the hydrogen iodide, water, methyl iodide, acetic acid, and
reaction temperature of the reaction system, which is an exo methyl acetate. The water content of the mixture may be not
thermic reaction system. Moreover, the reactor 1 may be less than an effective amount for forming a high water con
equipped with a heat-removable (or heat-removing) unit or a centration zone in the distillation column and not more than
cooling unit (e. g., a jacket) for controlling the temperature of 5% by weight. When the water content exceeds 5% by weight,
the reaction. The reactor is not necessarily equipped with a a condensed zone of hydrogen iodide is shifted downwardly
heat-removable or cooling apparatus. The noncondensed to a position for feeding the mixture (volatile phase compo
component may be recycled to the reactor 1, if necessary. nent) to the distillation column, and thus hydrogen iodide
[0082] [Flash Evaporation] cannot be removed effectively. The zone having a high water
[0083] In the ?ash evaporation step (?asher), the reaction concentration in the distillation column is shifted upwardly to
mixture continuously fed from the reactor to the ?asher the column top direction, and hydrogen iodide cannot be
(evaporator or ?ash distillation column) is separated into a removed effectively. According to the present invention, the
volatile phase component (lower boiling point component, condensed zone of hydrogen iodide can be formed above the
vapor component) and a low-volatile phase component feed position by adjusting the water concentration in the fed
(higher boiling point component, liquid component); wherein mixture to not more than 5% by weight, and hydrogen iodide
the volatile phase component contains acetic acid and methyl can be effectively removed due to methyl acetate (which is
iodide, and the low-volatile phase component contains a concentrated above the feed position) in the mixture, so that
higher boiling point catalyst component (a metal catalyst the corrosion can be inhibited. Moreover, even if the con
component, e.g., a metal catalyst and a metal iodide). The densed zone of hydrogen iodide is not formed in the distilla
volatile phase component (lower boiling point component, tion column, hydrogen iodide existing in the distillation col
vapor component) corresponds to the above-mentioned mix umn according to the equilibrium reaction is converted by
ture. methyl acetate, so that the corrosion can be inhibited.
[0084] The ?ash distillation may usually be carried out with [0090] The water content of the mixture may usually be
the use of a ?ash distillation column. The ?ash evaporation about 0.5 to 4.5% by weight (e.g., about 1 to 4.3% by weight)
step may be composed of a single step or may be composed of and preferably about 1.2 to 4% by weight (e.g., about 1.5 to
a plurality steps in combination. In the ?ash evaporation step, 3.5% by weight). According to the present invention, a high
the reaction mixture may be separated into a vapor compo water concentration zone inside the distillation column can be
nent and a liquid component with heating (thermostatic ?ash) formed above a position for feeding the mixture (volatile
or without heating (adiabatic ?ash), or the reaction mixture phase component) to the distillation column. Thus, hydrogen
may be separated by combination of these ?ash conditions. iodide is allowed to react with methyl acetate (and also
The ?ash distillation may be carried out, for example, at a methanol in the mixture and by-product methanol) at the high
temperature of the reaction mixture of about 80 to 2000 C. water concentration zone to produce methyl iodide and acetic
under a pressure (absolute pressure) of about 50 to 1,000 kPa acid.
(e.g., about 100 to 1,000 kPa), preferably about 100 to 500 [0091] The methyl acetate concentration in the mixture can
kPa, and more preferably about 100 to 300 kPa. The forma be selected within the range from not less than an effective
tion of by-product(s) or the decrease in the catalyst activity amount for converting hydrogen iodide into methyl iodide in
may further be inhibited by lowering the internal temperature the distillation column to not more than 9% by weight (0.5 to
and/ or pressure of the ?ash evaporator compared with those 9% by weight). When the methyl acetate concentration
of the reactor 1. exceeds 9% by weight, the condensate of the overhead shows
US 2015/0025270 A1 Jan. 22, 2015
a low liquid-liquid separation. The methyl acetate concentra [0097] The water concentration and the methyl acetate con
tion in the mixture may usually be about 0.5 to 8% by weight centration in the mixture may be adjusted by feeding (or
(e.g., about 0.5 to 7.5% by weight), preferably about 0.7 to supplying) water and/or methyl acetate. The mixture contain
6.5% by weight (e.g., about 1 to 5.5% by weight), and more ing a predetermined concentration, of water and that of
preferably 1.5 to 5% by weight (e.g., about 2 to 4.5% by methyl acetate may be directly distilled without adjusting the
weight), or may be about 0.5 to 7.2% by weight. The mixture water concentration and the methyl acetate concentration.
representatively contains about 1 to 4.3% by weight (e.g., Moreover, water and/or methyl acetate may be fed (or sup
about 1.3 to 3.7% by weight) ofwater; and about 0.5 to 7.5% plied or added) to the mixture (volatile phase component) or
by weight (e.g., about 0.8 to 7.5% by weight), preferably in the distillation atmosphere (the distillation atmosphere in
about 1.2 to 5% by weight (e.g., about 1.7 to 4.5% by weight) the distillation column) of the volatile phase component
of methyl acetate. (mixture) to adjust a water concentration to not more than 5%
[0092] The methyl iodide content of the mixture may for by weight and a methyl acetate concentration to 0.5 to 9% by
example be about 25 to 50% by weight (e.g., about 27 to 48% weight for distilling the volatile phase component. The water
by weight), preferably about 30 to 45% by weight (e.g., about and/or methyl acetate can be fed (or supplied) to the feed line
32 to 43% by weight), and more preferably about 35 to 40% 22 or the ?rst distillation column by using various lines con
by weight (e.g., about 36 to 39% by weight). nected to the ?rst distillation column or a new line.
[0093] When the distillation is carried out continuously, the [0098] The adjustment (or control) of the water concentra
methyl acetate concentration in the mixture may usually be tion and the methyl acetate concentration can be conducted by
analyZing or detecting water and methyl acetate concentra
about 0.07 to 1.2 mol/L (about 0.5 to 9% by weight), prefer
ably about 0.1 to 1.0 mol/ L, and more preferably about 0.3 to tions in the mixture (volatile phase component) introduced
0.8 mol/ L. Moreover, the water concentration in the mixture into the distillation column, and based on the results, and
adjusting the ratio of the components of the mixture in the
may be about 0.28 to 2.8 mol/L (about 0.5 to 5% by weight),
distillation column, or a unit or line (which is for supplying a
preferably about 0.56 to 2.5 mol/L (about 1 to 4.5% by
weight), and more preferably about 0.83 to 2.2 mol/L (about ?uid to the distillation column) by using a controller (control
1.5 to 4% by weight). unit); or can also be conducted by supplying or adding water
and/or methyl acetate. The unit for supplying the ?uid to the
[0094] According to the present invention, since hydrogen distillation column may include the reactor or ?asher which is
iodide can be removed e?iciently, the hydrogen iodide con located upstream of the distillation column, a decanter for
tent of the mixture is not particularly limited to a speci?c one. feeding a condensate to the distillation column, and others.
For example, the hydrogen iodide content may be about 10 to [0099] The distillation atmosphere (the distillation atmo
30000 ppm. The hydrogen iodide content of the mixture sphere in the distillation column) of the mixture (volatile
(volatile phase component) produced by the methanol carbo phase component) can be formed in an appropriate place
nylation reaction may be about 100 to 10000 ppm, preferably inside the distillation column. In order to convert hydrogen
about 200 to 7500 ppm, and more preferably about 300 to iodide effectively, it is preferred to form the distillation atmo
6000 ppm (e.g., about 500 to 5000 ppm) on the basis of sphere at the same height as or above the feed site of the
weight. Moreover, the acetic acid content of the mixture is not volatile phase component.
particularly limited to a speci?c one, and may for example be
about 30 to 70% by weight (e.g., about 35 to 75% by weight), [0100] Further, to the volatile phase component as the mix
preferably about 40 to 65% by weight (e.g., about 45 to 62% ture, or to the distillation atmosphere of the volatile phase
component as the mixture, at least one member selected from
by weight), and more preferably about 50 to 60% by weight
(e.g., about 54 to 58% by weight). the group consisting of methyl acetate, methanol and dim
ethyl ether (a methanol source) and if neces sary water may be
[0095] The mixture (volatile phase component) may fur added to form a volatile phase component (mixture) having
ther contain dimethyl ether. The concentration of dimethyl adjusted water and methyl acetate concentrations for distill
ether can for example be selected from the range of 0. 1 5 to 3% ing the volatile phase component (mixture). The amounts of
by weight, and may usually be about 0.15 to 2.5% by weight methyl acetate and water to be added are as described above.
(e.g., about 0.17 to 2.3% by weight), preferably about 0.2 to Moreover, the amount of methanol to be added may for
2% by weight (e.g., about 0.3 to 1.7% by weight), and more example be about 0.01 to 3.8 parts by weight (e.g., about 0.1
preferably about 0.5 to 1.5% by weight. Most of the remain to 3 parts by weight), preferably about 0.1 to 2.5 parts by
der (residual component) of the mixture is often methanol. As weight (e.g., about 0.2 to 2 parts by weight), and more pref
described above, the mixture (volatile phase component) pro erably about 0.2 to 1.5 parts by Weight (e.g., about 0.5 to 1.5
duced by the methanol carbonylation reaction practically parts by weight) relative to 100 parts by weight of the mixture
contains a trace of an impurity (e.g., acetaldehyde, an alde (volatile phase component). The amount of dimethyl ether to
hyde condensation product, a higher boiling point carboxylic be added is an amount to form the dimethyl ether concentra
acid such as propionic acid, and a C6_ 12alkyl iodide). tion in the mixture as described above. The amount of dim
[0096] The total amount of each component in the mixture ethyl ether to be added may for example be about 0.01 to 2.7
(volatile phase component) is 100% by weight. Moreover, parts by weight (e.g., about 0.03 to 2 parts by weight), pref
although the mixture (volatile phase component) may form a erably about 0.05 to 1.5 parts by weight (e.g., about 0.07 to 1.3
vapor phase (or distillation atmosphere), the amount and con parts by weight), and more preferably, about 0.1 to 1 parts by
centration of the above-mentioned each component indicate weight (e. g., about 0.2 to 0.8 parts by weight) relative to 100
those of the mixture (volatile phase component) in the form of parts by weight of the mixture (volatile phase component).
a liquid, for example, a condensate (for example, a lique?ed [0101] In the splitter column (?rst distillation column), the
condensate formed by cooling at 20 to 25° C.) obtained by mixture (volatile phase component) is distilled (in particular,
cooling and condensing a vapor phase mixture (a volatile continuously distilled) and separated into an overhead con
phase component forming a vapor phase). taining a lower boiling point component such as methyl
US 2015/0025270 A1 Jan. 22,2015
iodide (including methyl iodide produced by a reaction of stream may be recycled to the reaction system or others
methyl acetate with methanol), and a side cut stream or bot through a storage vessel having a buffering function. The
tom stream containing acetic acid, and acetic acid is col bottom stream may be fed to the second distillation column 5
lected. In the distillation column, usually, a volatile phase for removing a high boiling point impurity such as propionic
component is separated as a vapor overhead (usually contain acid.
ing methyl iodide, methyl acetate, acetaldehyde, water, and [0106] As the splitter column (distillation column), there
others); a side cut stream (side stream) containing acetic acid may be used a conventional distillation column, for example,
is separated as a liquid form by side-cut; and a bottom stream a plate column, a packed column, and a ?ash distillation
(bottom liquid stream or higher boiling point component, column. A distillation column such as a plate column or a
containing acetic acid, water, propionic acid, entrained metal packed column may be usually employed. The material of (or
catalyst component, a metal halide, and others) is separated as for forming) the distillation column is not limited to a speci?c
a liquid form. one, and a glass, a metal, a ceramic, or others can be used. In
[0102] This distillation can signi?cantly reduce the con usual, a distillation column made of a metal is used practi
centration of hydrogen iodide in the second overhead and the cally.
side cut stream. In particular, the side cut stream (crude acetic [0107] For the plate column, the theoretical number of
acid stream) having a signi?cantly decreased concentration plates is not particularly limited to a speci?c one, and,
of hydrogen iodide can be obtained. The hydrogen iodide depending on the species of the component to be separated, is
concentration in the side cut stream may for example be about about 5 to 50, preferably about 7 to 35, and more preferably
1 to 350 ppm, preferably about 2 to 300 ppm, and more about 8 to 30. Further, in order to separate acetaldehyde in the
preferably about 3 to 250 ppm. distillation column, the theoretical number of plates may be
[0103] The position of the feed line 22 connected (or about 10 to 80, preferably about 20 to 60, and more preferably
joined) to the ?rst distillation column 3 (the feed site of the about 25 to 50. Further, in the distillation column, the re?ux
volatile phase component) is not particularly limited to a ratio may be selected from, for example, about 0.5 to 3,000,
speci?c one. For example, the position of the feed line may be and preferably about 0.8 to 2,000 depending on the above
in an upper part, a middle part, or a lower part of the distilla mentioned theoretical number of plates, or may be reduced by
tion column. The mixture is practically fed to the distillation increasing the theoretical number of plates.
column from an intermediate or lower position of the distil [0108] The distillation temperature and pressure in the
lation column in height. Speci?cally, the connecting (or join splitter column (distillation column) may suitably be
ing) position of the feed line 22 (the feed site of the volatile selected. For example, in the distillation column, the inner
phase component) is practically located at an intermediate or temperature of the column (usually, the temperature of the
lower position of the ?rst distillation column 3. Since feeding column top) may be adjusted by adjusting the inner pressure
of the mixture in such a manner can form a high water con of the column, and may be, for example, about 20 to 180° C.,
centration zone between at or above an intermediate position preferably about 50 to 1 50° C., and more preferably about 100
of the distillation column and below thew re?ux line 42, thus to 140° C. The temperature of the column top can be set to a
the e?icient contact of hydrogen iodide with methyl acetate temperature lower than the boiling point of acetic acid
(and methanol) can be increased, which can improve the depending on the inner pressure of the column (for example,
hydrogen iodide removal ef?ciency. Moreover, the side cut lower than 1 18° C., preferably not higher than 117° C.). The
stream (crude acetic acid stream) from the ?rst distillation temperature of the column bottom can be set to a temperature
column 3 may be withdrawn from any of an upper part, a higher than the boiling point of acetic acid depending on the
middle part, and a lower part of the distillation column, for inner pressure of the column (for example, not lower than
example, the side cut stream may be withdrawn from the same 130° C., preferably not lower than 135° C.)
height as the position (feed site) of the feed line 22 joined to [0109] The overhead from the ?rst distillation column con
the ?rst distillation column 3 or from above or below the tains methyl iodide, acetaldehyde, and in addition, methyl
position (feed site) thereof. The side cut stream is usually acetate, water, methanol, acetic acid, an aldehyde or a carbo
withdrawn from a middle part or a lower part (lower part to nyl impurity (such as crotonaldehyde or butyraldehyde), a
middle part) of the distillation column, for example, a site C2_12alkyl iodide, a C3_12alkanecarboxylic acid, and others.
below the connecting position of the feed line 22 (the feed site [0110] [Condensation and Liquid-Liquid Separation]
of the volatile phase component) (e.g., a site between above [0111] The overhead from the ?rst distillation column is
the column bottom and below the connecting position (feed cooled and condensed in a cooling unit (condenser), and the
site) of the feed line 22). resulting condensate of the overhead can clearly be separated
[0104] Moreover, as shown in FIG. 2, the supply line 35b into an aqueous phase (light phase, upper phase) and an
connected to the ?rst distillation column 3 may be located at organic phase (heavy phase, lower phase) in a liquid-separat
the same height position as the feed site of the volatile phase ing unit (decanter). In this manner, the separability of the
component from the feed line 22, or may be located below or overhead into the aqueous phase (light phase) and the organic
above the feed site of the volatile phase component. The phase (heavy phase) can be improved.
supply line 35b is usually located at the same height position [0112] As described above, methyl acetate has a miscibility
as the feed site of the volatile phase component or above the with both aqueous phase (light phase) and organic phase
feed site of the volatile phase component. (heavy phase). The liquid-liquid separation decreases at a
[0105] The bottom stream may be removed (discharged) higher concentration of methyl acetate. Thus, the concentra
from the bottom or lower part of the distillation column. Since tion of methyl acetate in the separated organic phase (heavy
the bottom stream contains a useful component such as a phase, lower phase) may be about 0.5 to 15% by weight (e. g.,
metal catalyst component or acetic acid, the bottom stream about 1 to 15% by weight), preferably about 1.5 to 14% by
may be recycled to the reactor (or reaction step) or the ?ash weight (e. g., about 2 to 10% by weight), and more preferably
evaporation step, as described above. Moreover, the bottom about 2 to 8% by weight (e.g., about 2.5 to 7% by weight); and
US 2015/0025270 Al Jan. 22, 2015
the concentration of methyl acetate in the aqueous phase The distillation of the ?rst side cut stream (liquid crude acetic
(light phase, upper phase) may be about 0.2 to 8.5% by weight acid) condenses hydrogen iodide in the second distillation
(about 0.4 to 8% by weight), preferably about 0.5 to 7.5% by column. Moreover, hydrogen iodide is also produced by a
weight (e.g., about 0.6 to 6% by weight), and more preferably reaction of methyl iodide with water as shown in the above
about 0.7 to 5% by weight (e.g., about 0.8 to 4.5% by weight) mentioned equation (3). Thus, not only hydrogen iodide
or may be about 0.4 to 8% by weight (e.g., about 1 to 5% by together with water is concentrated in the upper part of the
weight). second distillation column, but also hydrogen iodide is liable
[0113] Moreover, the liquid-liquid separation into the to be produced by a reaction of methyl iodide with water in the
aqueous phase and the organic phase is sometimes in?uenced upperpart of the second distillation column. Accordingly, it is
by other components. In the separated organic phase (heavy preferable to add an alkali component for removing hydrogen
phase), the concentration of methyl iodide may for example iodide and for obtaining acetic acid with a further high purity.
be about 75 to 98% by weight (e.g., about 76 to 98% by Speci?cally, in the second distillation column, the ?rst side
weight) and preferably about 78 to 97% by weight (e. g., about cut stream may be distilled in the presence of an alkali com
80 to 96% by weight), and the concentration of acetic acid ponent (for example, an alkali metal hydroxide such as potas
may be about 1 to 10% by weight (e.g., about 2 to 8% by sium hydroxide), or a mixture containing the ?rst side cut
weight) and preferably about 2.5 to 7.5% by weight (e.g., stream and the alkali component may be distilled.
about 3 to 7.5% by weight). The concentration of water in the [0119] The alkali component (alkaline aqueous solution)
organic phase (heavy phase) is usually not more than 1% by can be added to the side cut stream or the distillation column
weight. Moreover, in the aqueous phase (light phase), the by using various routes connected to the distillation column
concentration of water may be about 50 to 90% by weight or a new route. In the example shown in the ?gure, the alkali
(e. g., about 55 to 90% by weight) and preferably about 60 to component may be added through at least one line of addition
85% by weight (e.g., about 65 to 80% by weight), and the lines 57a and 57b. Moreover, the position of the feed line 36
concentration of acetic acid may be about 10 to 40% by (or addition part) and that of an addition line 57b to the second
weight (e.g., 12 to 35% by weight) and preferably about 13 to distillation column 5 are not particularly limited. Each posi
30% by weight. The sum of the percentage of all components tion may be located at the middle part of the second distilla
in the organic phase (heavy phase) is 100% by weight, and tion column 5 or below or above the middle part thereof. In
that in the aqueous phase (light phase) is 100% by weight. usual, the position of addition by the feed line 36 is practically
[0114] The concentration of hydrogen iodide in the aque located at or below the middle part of the second distillation
ous phase (light phase) is higher than that in the organic phase column 5; the position of addition by the addition line 57b is
(heavy phase). For example, the concentration of hydrogen practically located at or above the middle part of the second
iodide in the organic phase (heavy phase) is about not more distillation column 5. The addition of the alkali component
than 70 ppm (for example, trace to 60 ppm), while the con according to such an embodiment allows hydrogen iodide to
centration of hydrogen iodide in the aqueous phase (light be ef?ciently neutralized prior to movement or migration of
phase) is about 10 to 1000 ppm (e.g., about 50 to 800 ppm). hydrogen iodide to the column top of the second distillation
For that reason, feeding of the aqueous phase (light phase) to column, even if the alkali component (non-volatile alkali
the third distillation column can improve the hydrogen iodide component) is easily moved to the lower part of the distilla
removal ef?ciency. Moreover, feeding of both of the aqueous tion column. Thus, the concentration of hydrogen iodide at all
phase (light phase) and the organic phase (heavy phase) to the over the distillation column including not only the lower part
third distillation column can further improve the hydrogen of the distillation column but also the upper part of the distil
iodide removal ef?ciency. lation column can be ef?ciently inhibited.
[0115] In an example shown in the ?gure, the organic phase [0120] In the second distillation column, the ?rst side cut
(heavy phase) is recycled to the reactor 1, and the aqueous stream may be distilled in the presence of a reactive compo
phase (light phase) is recycled to the ?rst distillation column nent having a boiling point lower than that of acetic acid and
3 for re?ux. The organic phase (heavy phase) and/or the converting hydrogen iodide into methyl iodide (at least one
aqueous phase (light phase) may be recycled to the reactor 1 methanol or a derivative thereof, selected from the group
or may be recycled to the ?rst distillation column 3. consisting of methanol, dimethyl ether and methyl acetate,
[0116] [Second Distillation] particularly, methyl acetate) in addition to the alkali compo
[0117] The ?rst side cut stream (liquid crude acetic acid) nent. The methanol or the derivative thereof (particularly,
usually contains acetic acid, and other components (e. g., methyl acetate) may be contained in the ?rst side cut stream,
methyl iodide, methyl acetate, water, and hydrogen iodide) and is preferably added via (through) the addition lines 57a,
which remain without separation in the ?rst distillation col 57b, and other routes. As described above, the reaction of
umn. The side cut stream (liquid crude acetic acid) from the methyl iodide with water easily occurs in the upper part of the
?rst distillation column is usually further distilled (or dehy distillation column, while the alkali component is easily
drated) in the second distillation column, and separated into moved to the lower part of the distillation column. Thus, the
an overhead (low-boiling content) from the column top, a amount of the alkali component existing in the upper part of
bottom stream (high-boiling component such as a C3_12alkan the distillation column sometimes decreases. The addition of
ecarboxylic acid including propionic acid) from the column the methanol or the derivative thereof, which has a low boil
bottom, and a side cut stream (puri?ed acetic acid) from the ing point, in combination of the alkali component can inhibit
side, and product acetic acid may be obtained as the side cut concentration of hydrogen iodide in the upper part of the
stream. distillation column with more certainty, and can remove
[0118] In the second distillation column, removal of hydro hydrogen iodide by converting hydrogen iodide into a metal
gen iodide by an alkali component is not necessarily needed. iodide or methyl iodide.
As described above, water and hydrogen iodide usually [0121] The water content of the ?rst side cut stream (liquid
remain in the ?rst side cut stream (liquid crude acetic acid). crude acetic acid) is usually about 0.3 to 5% by weight (e.g.,
US 2015/0025270 A1 Jan. 22, 2015
organic phase (heavy phase), a side cut stream and a bottom lows: 96% by weight ofMel, 0.7% by weight ofMA, 0.3% by
stream) indicates a ?ow rate per hour (the same applies here weight of H20, 90 ppm of H1, and 3.0% by weight of acetic
inafter). acid. From the ?rst distillation column, a side cut stream
[0132] In the continuous reaction process, the following containing acetic acid and a bottom stream were withdrawn in
test pieces were placed on 3nd plate from bottom (which was a proportion of 55.2 parts by weight and a proportion of 3
the ?rst plate above the charging plate of the ?rst distillation parts by weight, respectively. The composition of the side cut
column) undermost plate of the column (which was the ?rst stream was as follows: 2.6% by weight of Mel, 0.04% by
plate below the charging plate), and 19th plate from bottom weight of MA, 2.8% by weight of H20, 820 ppm of H1, and
(which was the column top).After leaving for 100 hours, each 93.6% by weight of acetic acid. The composition of the bot
test piece was examined for a corrosion test. The weight of tom stream was as follows: 0% by weight of Mel, 0.03% by
each test piece before and after the corrosion test was mea weight of MA, 2.6% by weight of H20, 800 ppm of H1, and
sured to determine a corrosion amount. Based on the mea 97.1% by weight of acetic acid. The column top temperature
sured corrosion amount (decrease in weight) and the area of of the ?rst distillation column was 115° C., and the column
the test piece, the corrosion rate (decrease in thickness) of the bottom temperature thereof was the same as that in Compara
test piece per year was converted into a thickness (mm) and tive Example 1.
shown in the unit “mm/Y”.
[0133] [Test Piece] Comparative Example 3
[0134] HB2: manufactured by Oda Kaki Co., Ltd, HAS
TELLOY B2 (nickel-based alloy) [0139] The corrosion test was carried out in the same man
[0135] HC: manufactured by Oda Koki Co., Ltd, HASTEL ner as in Comparative Example 1 except that the charging
LOY C (nickel-based alloy) mixture (volatile phase component) was adjusted to a methyl
[0136] SUS316L: manufactured by Umetoku lnc., SUS acetate concentration of 10% by weight and then fed to the
316 Low Carbon (stainless steel) ?rst distillation column and that the re?ux ratio in the ?rst
distillation column and the amounts of the light phase and the
Comparative Example 2 heavy phase recycled to the reaction system were changed
[0137] The corrosion test was carried out in the same man depending on the methyl acetate concentration. However, the
ner as in Comparative Example 1 except that the charging charging mixture (volatile phase component) had a poor liq
mixture (volatile phase component) was adjusted to a water uid-liquid separation into the light phase and the heavy phase.
concentration of 4% by weight and then fed to the ?rst dis These phases formed a mixed phase or one phase, and the
tillation column and that the re?ux ratio in the ?rst distillation results made the operation unstable after several hours. Thus
column and the amounts of the light phase and the heavy it was impossible to operate the process operation for a long
phase recycled to the reaction system were changed depend period of time.
ing on the water concentration.
[0138] The composition of the volatile phase component Examples 1 to 4
was as follows: 38.5% by weight of Mel, 0.3% by weight of
MA, 4.0% by weight ofHZO, 5000 ppm ole, and 56.7% by [0140] The corrosion test was carried out in the same man
weight of acetic acid. Moreover, the distillation was carried ner as in Comparative Example 1 except that the charging
out at a light phase re?ux ratio of 5, and the light phase (3.3 mixture (volatile phase component) having appropriate
parts by weight) and the heavy phase (38.5 parts by weight) methyl acetate and water concentrations in each Example is
were recycled to the reaction system. The composition of the fed to the ?rst distillation column and that the re?ux ratio in
column top of the ?rst distillation column (the composition of the ?rst distillation column and the amounts of the light phase
the overhead) was as follows: 64.3% by weight ofMel, 0.6% and the heavy phase recycled to the reaction system were
by weight of MA, 23.3% by weight of H20, 470 ppm of H1, changed depending on the methyl acetate and water concen
and 11.8% by weight of acetic acid. The composition of the trations.
aqueous phase (light phase) was as follows: 2.6% by weight [0141] Operation conditions in each of Examples and Com
of Mel, 0.3% by weight of MA, 68.0% by weight of H20, parative Examples are shown in Table 1. The results of the
1200 ppm of H1, and 29.0% by weight of acetic acid. The corrosion test are shown in Table 2. The unit of numerical
composition of the organic phase (heavy phase) was as fol values in Table 2 is the corrosion rate “mm/Y”.
TABLE 1
Parts by
weight Comparative Examples Examples
(ppm for H1) 1 2 3 1 2 3 4
Feed Flow rate 100 100 100 100 100 100 100
Mel 38.2 38.5 38 38 38.5 37 36
MA 0.3 0.3 10 0.5 1 4.2 7.2
Water 6.5 4 4 4 4 1.2 2
HI 5000 5000 200 4000 2000 600 300
AC 54.5 56.7 47.6 57.1 56.3 57.4 54.7
Side- Flow rate 54 55.2 43.5 55.2 55.2 54.2 51.6
cut Mel 2.9 2.6 2.3 1.7 4.0 3.1 2.3
MA 0.03 0.04 2.6 0.06 0.21 1.26 1.6
Water 5.3 2.8 2.8 2.8 2.7 0.7 1.2
US 2015/0025270 A1 Jan. 22, 2015
TABLE 1-continued
Parts by
weight Comparative Examples Examples
(ppm for HI) 1 2 3 1 2 4
DESCRIPTION OF REFERENCE NUMERALS and wherein the volatile phase component is distilled while
being adjusted to a water concentration of an effective
[0144] 1 . . . Reactor
amount and not more than 5% by weight and a methyl
[0145] 2 . . . Flash evaporator acetate concentration of 0.5 to 9% by weight in a distil
[0146] 3 . . . First distillation column (splitter column) lation atmosphere of the volatile phase component in
[0147] 4 . . . Decanter terms of a condensate or liquid form.
[0148] 5 . . . Second distillation column 8. The process according to claim 1, wherein at least one
[0149] 34a, 34b, 35a, 35b . . . Supply line member selected from the group consisting of methyl acetate,
1. A process for producing acetic acid, comprising: methanol and dimethyl ether, and if necessary water, is added
distilling a mixture containing hydrogen iodide, water, to the volatile phase component as the mixture or a distillation
methyl iodide, acetic acid, and methyl acetate to form an atmosphere thereof as the mixture to adjust the concentra
overhead containing a lower boiling point component, tions of water and methyl acetate, and the resulting volatile
and phase component is distilled.
condensing the overhead to form separated liquid phases, 9. The process according to claim 1, wherein a distillation
wherein the mixture contains an effective amount of water
atmosphere of a volatile phase component is formed in the
distillation column at a height equal to or upper than a feed
in a concentration of not more than 5% by weight and site of the volatile phase component.
methyl acetate in a concentration of 0.5 to 9% by weight, 10. The process according to claim 1, wherein the mixture
and is separated, in the distillation step, into the over contains 1 to 4.3% by weight of water and 0.8 to 7.5% by
head containing methyl iodide and a side cut stream or weight of methyl acetate, and is subjected to the distillation
bottom stream containing acetic acid. step.
2. The process according to claim 1, wherein the mixture 11. The process according to claim 1, wherein the mixture
has a methyl acetate concentration of 0.07 to 1.2 mol/L and a has a hydrogen iodide concentration of 100 to 10000 ppm,
water concentration of 0.28 to 2.8 mol/L, and is distilled and is subjected to a distillation to form the side cut stream
continuously. having a hydrogen iodide concentration of 1 to 350 ppm.
3. The process according to claim 1, wherein the mixture 12. The process according to claim 1, wherein the sepa
contains 0.5 to 4.5% by weight of water and 0.5 to 8% by rated liquid phases are a lower phase and an upper phase, the
weight of methyl acetate, and is subjected to the distillation lower phase has a methyl acetate concentration of 1 to 15% by
step. weight, and the upper phase has a methyl acetate concentra
4. The process according to claim 1, wherein the mixture tion of 0.4 to 8% by weight.
further contains dimethyl ether. 13. A method for improving a liquid-liquid separation of a
5. The process according to claim 1, wherein the mixture is condensate while reducing a concentration of hydrogen
fed to a distillation column from an intermediate or lower iodide in an overhead and a side cut stream, comprising:
position of the distillation column in height. distilling a mixture containing hydrogen iodide, water,
6. The process according to claim 1, wherein a zone having methyl iodide, acetic acid, and methyl acetate to form an
a high water concentration is formed inside a distillation overhead containing a lower boiling point component,
column at a position upper than a position at which the mix and
ture is fed to the distillation column, condensing the overhead to give a condensate containing
in the zone having the high water concentration, hydrogen separated liquid phases,
iodide is allowed to react with methyl acetate for pro wherein the mixture contains an effective amount of water
ducing methyl iodide and acetic acid, and in a concentration of not more than 5% by weight and
the distillation provides the overhead containing the result methyl acetate in a concentration of 0.5 to 9% by weight.
ing methyl iodide. 14. The method according to claim 13, wherein the con
7. The process for producing acetic acid according to claim centration of hydrogen iodide in the overhead and the side cut
1, wherein stream is reduced by adjusting a concentration of methyl
methanol is allowed to continuously react with carbon acetate in the mixture to 0.5 to 8% by weight.
monoxide by using a catalyst containing a group 8 metal 15. The method according to claim 13, wherein said
of the Periodic Table, an ionic iodide, and methyl iodide method improves the liquid-liquid separation of the conden
in the presence of water, sate, wherein concentrations of methyl iodide and methyl
the reaction product is separated into a low-volatile phase acetate in the lower phase are adjusted to 76 to 98% by weight
component and a volatile phase component by a ?ash and 1 to 15% by weight, respectively (with the proviso that
distillation, the total of components in the lower phase is 100% by
the volatile phase component as the mixture is distilled to weight), and concentrations of water and methyl acetate in the
form the overhead containing methyl iodide and the side upper phase are adjusted to 50 to 90% by weight and 0.4 to 8%
cut stream or bottom stream containing acetic acid, and by weight, respectively (with the proviso that the total of
the overhead is condensed to form an aqueous phase and an components in the upper phase is 100% by weight).
organic phase, * * * * *
LAMPIRAN III
TUGAS KHUSUS
3.1. REAKTOR
Reaktor merupakan sebuah alat industri kimia yang terjadi reaksi bahan
mentah menjadi hasil jadi yang lebih berharga. Tujuan pemilihan reaktor adalah
untuk mendapat keuntungan yang besar, biaya produksi rendah, modal kecil atau
volume reaktor minimum, operasinya sederhana dan murah, keselamatan kerja
terjamin dan polusi terhadap sekelilingnya (lingkungan) dijaga sekecil-kecilnya.
Pemilihan jenis reaktor dipengaruhi oleh fase zat pereaksi dan hasil reaksi, tipe
reaksi dan persamaan kecepatan reaksi, serta ada tidaknya reaksi samping,
kapasitas produksi, harga alat (reaktor) dan biaya instalasinya dan kemampuan
reaktor untuk menyediakan luas permukaan yang cukup untuk perpindahan panas.
1. Jenis-jenis reaktor
Berdasarkan bentuknya
a. Reaktor tangki, dikatakan reaktor tangki ideal bila pengadukannya
sempurna, sehingga komposisi dan suhu didalam reaktor setiap saat selalu
uniform. Dapat dipakai untuk proses batch, semi batch, dan proses alir.
b. Reaktor pipa, biasanya digunakan tanpa pengaduk sehingga disebut
reaktor alir pipa. Dikatakan ideal bila zat pereaksi yang berupa gas atau
cairan, mengalir didalam pipa dengan arah sejajar sumbu pipa.
Berdasarkan prosesnya
c. Reaktor Batch, biasanya untuk reaksi fase cair dan digunakan pada
kapasitas produksi yang kecil.
103
104
Dikatakan ideal jika zat pereaksi dan hasil reaksi mengalir dengan
kecepatan yang sama diseluruh penampang pipa. Keuntungan memberikan
volume yang lebih kecil daripada reaktor alir tangki berpengaduk, untuk konversi
yang sama. Kerugian harga alat dan biaya instalasi tinggi, memerlukan waktu
untuk mencapai kondisi steady state dan ntuk reaksi eksotermis kadang-kadang
105
terjadi bagian yang suhunya sangat tinggi pada tempat pemasukan. Dapat
menyebabkan kerusakan pada dinding reaktor.
3. Reaktor semi batch, biasanya berbentuk tangki berpengaduk
Product stream
Cooling/heating
medium in
Out
Feed
Gelembung gas
Partikel katalis
Feed
Gas
Liquid Liquid
Gas
Biasanya pada tipe ini, gas di butuhkan untuk jumlah yang cukup besar
atau cukup kecil (tergantung pada intensitas dari perpindahan massa dan reaksi
kimia). Selain itu, pada tipe ini, ketika off – gas mengandung reaktan dalam
konsentrasi yang tinggi, maka perlu dilakukan recycle kembali menuju reaktor.
Pada Simple Bubble Column, liquid akan dimasukan secara cocurrent atau
conter curent yang berlawanan dengan aliran gas dan mempunyai nilai residence
time yang lama. Hal ini dikarenakan, aliran liquid memiliki pengaruh pada nilai
residence time aliran gas yang secara relatif akan menurun. Jadi, dalam kolom
yang didesign sederhana ini, aliran gas akan selalu datang dari bawah menuju ke
atas dan dapat berupa fresh gas atau recycle gas.
10.1.2. Downflow Bubble Column
Downflow Bubble Column merupakan kolom yang digunakan untuk
mencapai nilai residence time yang lama dari aliran gas (Gambar 2). Pada tipe ini,
aliran liquid akan Dipompakan menuju kolom pada kecepatan yang dapat
mencapai lebih dari 20 cm/s, sehingga gas yang masuk pada bagian atas kolom
dapat diterima pada aliran dan bahkan dapat ditahan didalam suatu suspensi
hingga semuanya bereaksi secara sempurna. Selain itu pada tipe ini, gas – gas
yang tidak digunakan akan dihilangkan dari liquid dengan cara suatu proses
pemisahan.
Diperlukannya nilai residence time yang pendek dari aliran liquid. Kecepatan
yang Diperlukan dari aliran liquid tidak hanya Diperoleh dengan cara mengatur
masukan aliran liquid kedalam reaktor. Melainkan dapat dilakukan dengan
merecycle aliran liquid dari bottom kolom. Aplikasi – aplikasi dari Downflow
Bubble column biasanya dapat dilihat pada proses oxonation dalam pembuatan air
minum dan pada proses pengolahan air pada kolam berenang.
Downflow Bubble column sendiri dapat diklasifikasikan kembali menjadi
beberapa tipe yakni :
a. Simple Downflow Bubble column
b. Downflow Bubble column With Integrated Separator
c. Downflow – Upflow Bubble Column
d. Dip – Tube Sparging
a. Simple Downflow Bubble Column
Simple Downflow Bubble columnsecara spesifik cocok untuk gas – gas
yang bersifat soluble didalam fase liquid atau reaksi cepat. Gas – gas yang tidak
bereaksi tidak dapat Dipisahkan didalam kolom, sehingga dibutuhkan tambahan
alat separator. Simple Downflow Bubble column sering digunakan untuk tekanan
tinggi ( > 100 bar ). Bentuk kolom yang kecil memungkinkan Simple Downflow
Bubble column untuk mengurangi ketebalan dinding dari slinder reaktor. Untuk
meningkatkan perpindahan massa antara fase gas dan liquid, kolom dapat diisi
dengan partikel – partikel yang juga dapat mengurangi laju aliran liquid dan
menyebabkan pencampuran secara aksial antara gas dan liquid.
Aplikasi dari Simple Downflow Bubble column dapat ditemui pada proses
hidrogenasi dengan batas yang lebar dari substansi – substansi. Selain itu dengan
adanya penambahan aliran recycle liquid menciptakan pemilihan proses design
yang berbeda. Pencampuran kembali juga Diperlukan dalam tipe kolom ini,
dengan aliran recycle liquid maka Downflow Bubble columndapat dioperasikan
pada aliran Feed yang kecil. Selain itu,m recycleloop juga memberikan cara
sederhana dalam hal penambahan atau pengurangan panas sehingga perpindahan
panas didalam reaktor menjadi seragam.
110
Gambar 10.14.DipTubeSparging
112
Dalam Simple Bubble column dan Downflow Bubble column, energi harus
diberikan secara kontinu untuk kedua sistem fase dengan tujuan untuk menjaga
proses pencampuran antara gas dan liquid. Dengan kata lain, dalam Simple Bubble
column, energi yang diberikan secara kontinu adalah gas sedangkan dalam
Downflow Bubble column, energi yang diberikan secara kontinu adalah liquid.
Bentuk sederhana dari Bubble column (Gambar 8.A) terdiri atas pipa –
pipa vertikal dengan tidak adanya bagian internal. Gas dimasukan pada bagian
bawah sedangkan liquid dimasukan kedalam kolom secara cocurent atau counter
curent. Pencampuran kembali dari fase gas dan liquid didalam Simple Bubble
column dan pendistribusian yang tidak seragam dari gelembung – gelembung gas
kearah cross section dapat dikurangi dengan cara instalasi tray – tray, penggunaan
packing dan penggunaan shaft
c. Porous Plate
Peralatan ini dapat menghasilkan gelembung – gelembung yang sangat
baik akan tetapi sangat mudah untuk terjadi fouling dalam pori – pori sparger.
Peralatan sparger ini biasanya jarang digunakan dalam peralatan skala besar
(Gambar 11).
Selain dari ketiga tipe bentuk dasar dari “static” gas sparger, dynamic
sparger memberikan sebuah alternatif untuk tipe statik. Peralatan ini
menggunakan daya dari liquid jet untuk mendistribusikan gas dalam suatu zona
(Gambar 12).
c b
g f
Keterangan,
a. Tinggi Reaktor dengan Jaket Pendingin (TRJ)
b. CW (Cooling Water) In
c. Feed campuran katalis
d. Feed liquid Metanol
e. Feed Gas Karbon Monoksida
f. Output Produk
g. CW Out
2. Bagian - Bagian Bubble Column Reactor
119
4
2
Keterangan,
1. Reaktor Tampak dari Luar
2. Reaktor Setengah Bagian
3. Injector
4. Bagian Silinder Reaktor
5. Bagian Tutup Bawah Reaktor
3. Tutup Bagian Atas Bubble Column Reactor (Ellipsoidal Head)
120
Dinding Jaket
Dinding Reaktor
TTRJ
CW in TTR
IDR
TDR
ODR TJ
IDRJ
ODRJ
Keterangan
IDR : Inside Diameter Reaktor
ODR : Outside Diameter Reaktor
IDRJ : Inside Diamter Jaket Reaktor
ODRJ : Outside Diameter Jaket Reaktor
TJ : Tebal Jaket
TTR : Tinggi Tutup Reaktor
TTRJ : Tinggi Tutup Jaket Reaktor
TDR : Tebal Dinding Reaktor
121
IDR
ODR TS
IDRJ
ODRJ
TJ
Bagian CW
TDR
Bagian dalam reaktor
Keterangan,
IDR : Inside Diameter Reaktor
ODR : Outside Diameter Reaktor
IDRJ : Inside Diamter Jaket Reaktor
ODRJ : Outside Diameter Jaket Reaktor
TS : Tinggi Silinder
TJ : Tebal Jaket
TDR : Tebal Dinding Reaktor
122
ODRJ
IDRJ
ODR
IDR
TJ
TDR DIJ
TTR
TTRJ CW out
Nozzle Injector
Feed CO
Keterangan,
IDR : Inside Diameter Reaktor
DIJ : Diamter Injektor
ODR : Outside Diameter Reaktor
TDR :TebalDindingReaktor
IDRJ : Inside Diamter Jaket Reaktor
ODRJ : Outside Diameter Jaket Reaktor
TJ : Tebal Jaket
123
DIJ
DIJ
DOR
FT
FT
Feed EDK
Gambar di atas merupakan alat destilasi atau yang disebut destilator. Yang terdiri
dari thermometer, labu didih, steel head, pemanas, kondensor, dan labu
penampung destilat. Termometer biasanya digunakan untuk mengukur suhu uap
zat cair yang didestilasi selama proses destilasi berlangsung.
Single-stage distilation
Single-stage distilation biasa juga disebut dengan flash vaporization atau
equilibrium distilation, digunakan untuk menguapkan campuran secara
parsial. Pada keadaan setimbang, uap yang dihasilkan bercampur dengan
cairan yang tersisa, namun pada akhirnya uap tersebut akan dipisahkan dari
kolom seperti juga fase cair yang tersisa.
Multi stage distilation
adalah proses penyulingan air laut dengan mengubah sebagian air
menjadi uap dalam beberapa tahapan dasar penukar panas lawan yang
terjadi di dalam distilasi tersebut.
5) Distilasi berdasarkan jenisnya, yaitu:
Destilasi sederhana (biasa)
Destilasi sederhana atau destilasi biasa adalah teknik pemisahan kimia
untuk pemisahan dua atau lebih komponen yang memiliki perbedaan titik
didih yang jauh. Suatu campuran dapat dipisahkan dengan destilasi biasa ini
untuk memperoleh senyawa murninya. Senyawa yang terdapat dalam
campuran akan menguap pada saat mencapai titik didih masing-masing.
Destilasi bertingkat (fraksional)
Destilasi bertingkat adalah proses pemisahan destilasi ke dalam bagian-
bagian dengan titik didih makin lama makin tinggi yang selanjutnya
pemisahan bagian-bagian ini dimaksudkan untuk destilasi ulang. Destilasi
bertingkat merupakan proses pemurnian zat/ senyawa cair dimana zat
pencampurannya berupa senyawa cair yang titik didihnya rendah dan tidak
berbeda jauh dengan titik didih senyawa yang akan dimurnikan. Destilasi ini
bertujuan untuk memisahkan senyawa-senyawa dari suatu campuran yang
komponen-komponenya memiliki perbedaan titik didih relatif kecil.
Perbedaan distilasi fraksionasi dan distilasi sederhana adalah adanya
kolom fraksionasi. Di kolom ini terjadi pemanasan secara bertahap dengan
suhu yang berbeda-beda pada setiap platnya. Pemanasan yang berbeda-beda
ini bertujuan untuk pemurnian distilat yang lebih dari plat-plat di bawahnya.
Semakin suhunya ke atas, semakin tidak volatil cairannya.
128
Destilasi uap
Destilsi uap ini dibuat karena terdapatnya masalah dari beberapa senyawa
yang terkadang rusak atau molekul-molekulnya pecah saat pemanasan
dengan suhu tinggi. Distilasi uap digunakan pada campuran senyawa-
senyawa yang memiliki titik didih mencapai 200°C atau lebih. Distilasi uap
dapat menguapkan senyawa-senyawa ini dengan suhu mendekati 100 °C
dalam tekanan atmosfer dengan menggunakan uap atau air mendidih.
Distilasi Kering
Distilasi kering biasanya membutuhkan suhu yang lebih tinggi dibanding
distilasi biasa. Metode ini dapat digunakan untuk memperoleh bahan bakar
cair dari batu bara dan kayu. Selain itu, distilasi kering juga digunakan
untuk memecah garam-garam mineral. Bahan padat dipanaskan sehingga
menghasilkan produk-produk berupa cairan atau gas (yang dapat
berkondensasi menjadi padatan atau cairan). Produk-produk tersebut
disaring, dan pada saat yang bersamaan mereka berkondensasi dan
dikumpulkan.
Limbah ban / plastik / karet dibuang ke dalam tungku penyulingan tanpa
dipotong-potong atau penghapusan kabel. Oleh karena itu, hasil melalui
proses ini adalah minyak, gas mudah terbakar, kawat dan karbon.
Destilasi azeotrop
Destilasi Azeotrop digunakan dalam pemisahan campuran azeotrop yaitu
campuran dua atau lebih komponen yang sulit dipisahkan jika hanya
menggunakan destilasi biasa. Biasanya dalam prosesnya digunakan senyawa
lain yang dapat memecah ikatan azeotrop tersebut, atau dengan
menggunakan tekanan tinggi. Ketika campuran azeotrop dididihkan, fasa
uap yang dihasilkan memiliki komposisi yang sama dengan fasa cairnya.
Campuran azeotrop ini sering disebut juga constant boiling mixture karena
komposisinya yang senantiasa tetap jika campuran tersebut dididihkan.
Refluks / destruksi
Refluks/destruksi ini bisa dimasukkan dalam macam – macam destilasi
walaupun pada prinsipnya agak berkelainan. Refluks dilakukan untuk
129
Akhirnya keluar melewati slots dalam cap dan mem-bubble melalui liquid
pada tray.
2) Sieve Tray
Sieve tray adalah plate metal sederhana dengan lubang diantaranya.
Vapor lewat keatas melalui liquid pada plate. Jumlah dan ukuran lubang
menjadi parameter desain. Karena luasnya range operasi, kemudahan
perawatan, dan faktor biaya, kebanyakan aplikasinya sieve dan valve tray
diganti dengan bubble cap tray.
tergantung pada material konstruksi yang digunakan; untuk mild steel rasio
biaya bubble-cap : valve : sieve, mendekati 3,0 : 1,5 : 1,0.
b) Kapasitas
Perbedaan ketiganya tidak terlalu besar namun urutannya mulai dari
flowrate yang lebih besar adalah sieve, valve, bubble-cap.
c) Range Operasi
Ini merupakan faktor yang amat signifikan. Dengan range operasi yang
berarti range dari laju uap dan liquid melalui plates yang akan beroperasi
secara menguntungkan (operasi stabil). Fleksibelitas selalu diperlukan dalam
mengoperasikan pabrik untuk perubahan dalam laju produksi, dan untuk
menutupi kondisi start-up dan shut down. Perbandingan antara flowrate
tertinggi terhadap flowrate terendah disebut turn-down ratio.
- Bubble-cap plate mempunyai positive liquid seal sehingga dapat
beroperasi secara optimum pada laju uap yang rendah.
- Sieve plate tergantung pada laju uap sepanjang hole untuk menahan
liquid diatas plate dan tidak dapat beroperasi pada laju flowrate yang
rendah. Tetapi dengan desain yang baik, sieve plates dapat didesain
untuk operasi yang cukup memuaskan biasanya dari 50% hingga 120%
kapasitas desain.
- Valve plates fleksibilitasnya lebih tinggi dibandingkan sieve dan bubble cap.
d) Pressure drop
Pressure drop dari plate dapat menjadi pertimbangan utama
terutama dalam kolom vakum.Plate pressure drop tergantung dari desain detail
dari plate tetapi pada umumnnya sieve tray memberikan pressure terendah
lalu diikuti oleh valve, dengan bubble cap merupakan yang tertinggi.
Dari semua faktor dalam pemilihan tersebut dapat ditarik
kesimpulan, yakni Sieve plates merupakan plates termurah dan lebih
menguntungkan untuk berbagai aplikasi, Valve plates harus dipertimbangkan
jika turn over ratio tidak bisa dipenuhi oleh sieve plates, serta Bubble-cap
plates hanya digunakan jika laju uap yang akan ditangani sangat rendah.
135
Kebutuhan Katalis
Berdasarkan patent US 8,940,932 B2/2015, kebutuhan katalis yang
diperlukan untuk memproduksi asam asetat yaitu:
Metil Iodida (CH3I) = 13 %wt liquid reaction medium
140
141
1 3
2
1 atm
30 oC 5 P-3
4 MT-01
Keterangan :
Aliran 1 : Aliran keluar Silo tank (ST-01) masuk mixing tank 01 (MT-01)
Aliran 2 : Aliran keluar Silo tank (ST-02) masuk mixing tank 01 (MT-01)
Aliran 3 : Aliran keluar tanki (T-03) masuk mixing tank 01 (MT-01)
Aliran 4 : Aliran keluar tanki (T-04) masuk mixing tank 01 (MT-01)
Aliran 5 : Aliran H2O dari Utilitas
Aliran 6 : Aliran keluar mixing tank (MT-01) masuk Reaktor (R-01)
Kondisi Operasi:
T = 30 °C
P = 1 atm
Jumlah kebutuhan air yang disuplai dari utilitas yaitu jumlah total air – total air
yang terdapat pada setiap komponen.
0,2 % pada CH3I = 2320,899 kg/jam ×
0,2%
= 4,642 kg/jam
0,3 % pada CH3COOCH3 = 232,089 kg/jam ×
0,3%
= 0,696 kg/jam
Air yang ikut bersama dengan metanol (sebagai impuritis) = 75,1688 kg/jam
Maka, jumlah kebutuhan air yang disuplai dari unit utilitas ke dalam mixing tank
yaitu sebanyak 1828,243 kg/jam – (75,1688 kg/jam + 0,696 kg/jam + 4,642
kg/jam) = 1746,9845 kg/jam.
143
Neraca Massa MT – 01
Input (kg) Output (kg)
Komponen
Aliran 1 Aliran 2 Aliran 3 Aliran 4 Aliran 5 Aliran 6
CH3I - - - 2320,899 - 2320,899
CH3COOCH3 - - - - 232,089 232,089
H2O - 1733,9537 - 4,642 0,696 1739,2917
LiI 892,652 - - - - 892,652
Rhodium - - 14,242 - - 14,242
892,652 1733,9537 14,242 2325,541 232,785 5199,1737
Total
5199,1737 5199,1737
2. Reaktor (R-01)
Fungsi : Sebagai tempat bereaksi antara feed karbon monoksida dan methanol
Gambar :
Aliran 12
Komponen
Kmol Kg
CH3OH 0,00028 0,0090
CH3I 0,0163 2,3160
Rhodium 0,0347 14,2420
H2 O 0,1014 1,8244
CH3COOH 0,2321 13,9238
CH3CHO 0,0021 0,0908
LiI 6,6690 892,652
CH3COOCH3 0,0031 0,2316
Total 7,0588 925,299
145
Aliran 31
Komponen
Kmol Kg
CH3OH - -
CO - -
CH3I 7,1181 1010,339
[Rh(CO)2I2] - -
H2O 0,6643 11,9581
CH3COOH 1,4948 89,6857
CH3CHO 0,0027 0,1196
H2 - -
LiI - -
CH3COOCH3 1,1312 83,7066
Total 10,4111 1195,8090
Aliran 9
Komponen
Kmol Kg
CH3OH 232,5536 7441,7135
CO - -
CH3I 6,6859 1010,339
[Rh(CO)2I2] - -
H2O 4,8404 87,1269
CH3COOH 9,4478 89,6857
CH3CHO 0,0027 0,1196
H2 - -
LiI - -
CH3COOCH3 0,3556 83,7066
Total 253,886 8712,6913
146
Neraca overall:
F=W+D
Komposisi uap :
z j . F (W / D 1)
y * j.D (Treyball, 1980)
1 (W / Dm. j )
Komposisi liquid:
z j . F (W / D 1)
x j .W (Treyball, 1980)
m j (W / D)
Keterangan :
y*j.D = fraksi mol komponen j dalam fase uap
xj.W = fraksi mol komponen j dalam fase liquid xj.W
W = laju pembentukan liquid (kmol/jam)
D = laju pembentukan uap (kmol/jam)
m = koefisien kesetimbangan uap, m = Pi*/Pt
zj.F = fraksi mol komponen j dalam feed
F = mol feed (kmol/jam)
Pi* = Tekanan Uap Komponen i (atm)
Pt = Tekanan Operasi (atm)
vap
Komponen Kmol Pi* (atm) M zF y*D vap (kg)
(kmol)
CH3OH 0,282 52,6565 3,5104 0,0008 0,0024 0,0003 0,01
CO 0,282 749,2343 49,9489 0,0008 0,0363 0,2818 7,8927
CH3I 16,351 37,0789 2,4719 0,0447 0,1062 0,0181 2,5759
[Ru(CO)4I2] 0,034 - - 0,0001 - - -
H2O 101,569 20,8035 1,3869 0,2777 0,3820 0,1127 2,0291
CH3COOH 232,553 9,,856 0,657 0,6360 0,4109 0,2581 15,4863
CH3CHO 2,067 63,3728 4,2248 0,0057 0,0215 0,0022 0,1009
H2 2,726 42,0971 2,8064 0,0074 0,0205 2,7267 5,4535
150
1,0000
Total 365,6716 1,0000 362,2678 19320,8525
151
13
11
FD-01
12
Keterangan :
Aliran 11 : Aliran input produk liquid reaktor
Aliran 12 : Aliran produk liquid FD-01
Aliran 13 : Aliran produk uap FD-01
152
Kondisi operasi :
T = 1300C
P = 1,81 atm
Fraksi mol input FD-01 fase liquid
Komponen Kmol zf
CH3OH 0,2816 0,0008
CO - -
CH3I 16,3331 0,0451
[Ru(CO)4I2] 0,0347 0,0001
H2 O 101,4563 0,2801
CH3COOH 232,2954 0,6412
CH3CHO 2,0648 0,0057
H2 - -
LiI 6,669 0,0184
CH3COOCH3 3,1329 0,0086
Total 362,2679 1,0000
Untuk menentukan tekanan uap masing-masing zat digunakan rumus Antoine.
B
Rumus : Pi * Exp ( A )
C T (Smith & Van Ness, 2001)
Neraca overall:
F=W+D
Komposisi uap :
z j . F (W / D 1)
y * j.D
1 (W / Dm. j )
(Treyball, 1980)
∑ y*j.D = 1 (Treyball, 1980)
Komposisi liquid:
z j . F (W / D 1)
x j .W (Treyball, 1980)
m j (W / D)
Keterangan :
y*j.D = fraksi mol komponen j dalam fase uap
xj.W = fraksi mol komponen j dalam fase liquid
W = laju pembentukan liquid (kmol/jam)
D = laju pembentukan uap (kmol/jam)
m = koefisien kesetimbangan uap, m = Pi*/Pt
zj.F = fraksi mol komponen j dalam feed
F = mol feed (kmol/jam)
Pi* = Tekanan Uap Komponen i (atm)
Pt = Tekanan Operasi (atm)
CD-01
13 21
KD-01
17
20
RB-01
Keterangan :
Aliran 13 : Aliran input KD-01 dari E-01
Aliran 17 : Aliran sidestream product KD-01
(Treyball, 1980)
158
α = Relative Volatility
Penentuan komponen masing-masing di dalam bottom dan up produk, dengan
komponen referensi CH3COOH.
Komponen Ki Kref α = (Ki/Kref) log α
CH3OH 3,6706 0,6101 6,0164 0,7793
CO 370,9012 0,6101 607,9378 2,7839
CH3I 4,6914 0,6101 7,6895 0,8859
[Rh(CO)2I2] - 0,6101 - -66,9592
H2O 1,1109 0,6101 1,8209 0,2603
CH3COOH 0,6101 0,6101 1,0000 -
CH3CHO 8,9031 0,6101 14,5929 1,1641
H2 10,7020 0,6101 17,5414 1,2441
LiI - 0,6101 - -21,9523
CH3COOCH3 3,6265 0,6101 5,9442 0,7741
= 1,9956
= 229,2838 kg/jam
= -1,9956
= 4,5053
( ∑ )
B (intersept) = ∑Y −
( )
=0−
= -1,9956
m = 4,5053
b = -1,9956
Kondisi top KD – 01
Komponen kmol yi
CH3OH 0,2730 0,0074
CO - -
CH3I 16,1536 0,4356
[Rh(CO)2I2] - -
H2O 13,2459 0,3572
CH3COOH 2,3206 0,0626
CH3CHO 2,0616 0,0556
H2 - -
LiI - -
CH3COOCH3 3,0320 0,0812
Kondisi bottom KD – 01
Komponen kmol xi
CH3OH 0,0083 -
CO - -
CH3I 0,1632 0,0005
[Rh(CO)2I
2] - -
H2O 88,1091 0,2770
CH3COOH 229,7427 0,7222
CH3CHO 0,0012 -
H2 - -
LiI - -
CH3COOCH3 0,0977 0,0003
Sidestream KD-01
Komponen Kmol Fraksi Berat Kg
CH3OH 0,0083 - 0,2665
CO - - -
CH3I 0,1632 0,0016 23,1601
[Rh(CO)2I2] - - -
H2O 87,3119 0,1058 1571,6151
CH3COOH 220,8025 0,8922 13248,1501
CH3CHO 0,0012 - 0,0511
H2 - - -
LiI - - -
CH3COOCH3 0,0850 0,0004 6,2904
5. KONDENSOR (CD-01)
Fungsi : mengkondensasikan produk top kolom destilasi – 01
Gambar :
14a 14b
Keterangan :
Aliran 14a : Aliran Input CD-01
Aliran 14b : Aliran output CD-01
Kondisi operasi :
P = 1,4 atm
T = 50oC
166
Q = 1 (bubble)
n
xD
(L/D)m + 1 = /
1 (Treyball, 1980)
xf = Fraksi Mol Komponen Dalam Feed
Dengan trial and error, didapatkan Ꝋ = 1,4466
Komponen xf Α xf xD xD
/ /
6. ACCUMULATOR-01 (ACC-01)
Fungsi : Menampung sementara hasil kondensasi dari CD-01
Gambar :
14b 21
15
Keterangan:
Aliran 14b : Aliran kondensat dari CD-01
Aliran 15 : Aliran refluks ke KD-01
Aliran 21 : Aliran destilat KD-01
170
7. REBOILER (RB-01)
Fungsi : menguapkan sebagian produk bottom KD – 01
Gambar :
19
20
18
Keterangan :
aliran 18 : aliran input RB-01
aliran 19 : aliran reboiled RB - 01
aliran 20 : aliran bottom produk RB – 01
Kondisi Operasi:
P = 1,55 atm
T = 120oC
171
Dari Perhitungan :
F = 355,2089 kmol/jam
L = 60,8841 kmol/jam
V = 97,9709 kmol/jam
S = 308,3721 kmol/jam
CD-02
26
17
KD-02
30
RB-02
Keterangan :
Aliran 17 : Aliran input KD-02
Aliran 26 : Aliran top product KD-02
Aliran 30 : Aliran bottom product KD-02
Kondisi operasi :
T =115 ºC
P =1,15atm = 874 mmHg
Persamaan Antoine : ln Pi = A – (B/(T+C)) (Smith & Van Ness, 2001)
Komponen A B C
CH3OH 8,0724 1574,99 238,87
CO 6,2402 230,27 260,01
CH3I 6,988 1146,34 236,66
[Rh(CO)2I2] 9,68520 26833,7062 248,59
H2O 8,14019 1810,94 244,485
CH3COOH 7,2996 1479,02 216,82
CH3CHO 7,0565 1070,6 236,01
H2 6,14858 80,9480 277,53
LiI 8,49354 7459,8616 155,25
CH3COOCH3 7,28492 1277,2143 233,155
(Yaws C. L., 1996)
175
(Treyball, 1980)
0
= 1,9956
0 0
= -1,9956
CH3COOH - -1,9956 - -
Total 0,2603 - 0,5195 0,0678
= 15,3339
( ∑ )
B (intersept) = ∑Y −
( )
=0−
= -1,9956
maka Y = 15,3339X - 1,9956
Untuk mengetahui distribusi komponen lain digunakan Persamaan :
log (XD/XB) = m log α + b (Winkle, 1967)
Dimana :
( )
m = ( α α )
( ( ))
= ( )
m = 15,3339
b = -1,9956
Kondisi top KD – 02
Komponen Kmol yi
CH3OH 0,0083 -
CO - -
CH3I 0,1632 0,0018
[Rh(CO)2I2] - -
H2O 86,4388 0,9723
CH3COOH 2,2080 0,0248
CH3CHO 0,0012 -
H2 - -
LiI - -
CH3COOCH3 0,0850 0,0009
Kondisi bottom KD – 02
Komponen Kmol xi
CH3OH - -
CO - -
CH3I - -
[Rh(CO)2I2] - -
H2O 0,8731 0,0040
CH3COOH 218,5945 0,9960
CH3CHO - -
H2 - -
LiI - -
CH3COOCH3 - -
9. KONDENSOR (CD-02)
Fungsi : mengkondensasikan produk top kolom destilasi – 02
Gambar :
29a 29b
Keterangan :
Aliran 29a : Aliran Input CD-02
Aliran 29b : Aliran output CD-02
Kondisi operasi :
P = 1,1 atm
T = 80oC
Neraca bahan total, dimana :
V =L+D
R = Lo / D (Treyball, 1980)
V =RxD+D
= (R + 1) x D
Keterangan :
V = aliran vapor KD – 02
L = aliran refluks KD – 02
D = aliran distilat
Q = 1 (bubble)
n
xD
(L/D)m + 1 = /
1 (Treyball, 1980)
182
29b 26
25
Keterangan:
Aliran 29b : Aliran kondensat dari CD-02
Aliran 25 : Aliran refluks ke KD-02
Aliran 26 : Aliran destilat KD-02
27
30
28
Keterangan :
aliran 28 : aliran input RB-02
aliran 27 : aliran reboiled RB - 02
aliran 30 : aliran bottom produk RB – 02
Kondisi Operasi:
P = 1,3 atm
T = 132oC
L* =F+L
V* =V+(q–1)xF (Ludwig, 1997)
B* =L*-V
Dari Perhitungan :
F = 308,3721 kmol/jam
L = 557,6626 kmol/jam
V = 646,5671 kmol/jam
=866,0347 kmol/jam
Bahan pada vapor RB-02, V *
V* =V+(q–1)xF
= 646,5671 kmol/jam
Bahan pada bottom RB-02, B *
B* =L*-V*
= (866,0347 – 646,5671) kmol/jam
= 219,4676 kmol/jam
21
24
D-01
23
Keterangan :
21 : Aliran input (feed) dari KD-01
23 : Aliran heavy phase
24 : Aliran light phase
190
Kondisi operasi :
T = 30ºC (Nathan, 2008)
P = 1,5 atm
CH3OH - - -
CO - - -
CH3I 0,6170 6,8130 967,0362
[Rh(CO)2I2] - - -
H2O 0,1431 12,4580 224,2443
CH3COOH 0,0617 1,6116 96,6933
CH3CHO 0,0578 2,0579 90,5455
H2 - - -
LiI - - -
CH3COOCH3 0,1205 2,5529 188,9173
Total 1,0000 25,4934 1567,4366
CH3OH - - -
CO - - -
CH3I 2292,8470 1010,339 1192,3545
[Rh(CO)2I2] - - -
H2O 238,4259 11,9581 357,9569
CH3COOH 139,2380 89,6857 17,8978
CH3CHO 90,7115 0,1196 205,4673
H2 - - -
LiI - - -
CH3COOCH3 224,3712 83,7066 16,1081
1195,8090 1789,7846
Total
2985,5936 2985,5936
LAMPIRAN II
PERHITUNGAN NERACA PANAS
Temperatur referensi : 25 oC
Satuan : kiloJoule (kJ)
Kapasitas panas masing – masing senyawa dihitung menggunakan rumus berikut
Cp = A + B.T + CT2 + DT3
T
C p C p dt
To
T
A B.T CT 2 DT3 dt
To
A T To B T To 2 C T To 3 D T To 4
2 3 4
diketahui : T – To = ΔT, maka :
C p .T A T B T 2 C T 3 D T 4
2 3 4
Harga A, B, C, dan D untuk masing–masing senyawa dapat dilihat pada tabel
berikut :
Komponen A B C D
Methanol 21,152 0,070924 0,00002587 -0,00000002852
karbonmonoksida 30,869 -0,01285 0,000027892 -0,00000001272
asam asetat 19,795 0,073436 -0,00005602 0,00000001753
metil asetat 7,716 0,18225 -0,00001007 0,000000023802
Air 32,243 0,001924 0,000010555 -0,000000003596
Hidrogen 10,806 0,13892 -0,00001041 0,000000034855
Metil Iodida 4,84 0,25485 -0,0001753 0,000000049448
Rhodium 16,55 0,22454 -0,00004342 0,000000029144
LiI - - - -
194
195
Q = n . ΔHv ....... (Eq. 2.13. J.M Smith & H.C.Van Ness, 6thedition)
dengan : Q : Panas laten senyawa, kJ.
n : Mol senyawa, kmol.
ΔHv : Panas penguapan, kJ/kmol.
196
Panas reaksi, untuk menghitung panas yang dihasilkan dari reaksi kimia di
dalam reaktor.
1 atm
30 oC Q5 P-3
Q4 MT-01
Q6
Keterangan :
Q1 = aliran panas Litium Iodida
Q2 = aliran panas air dari utilitas
Q3 = aliran panas Rhodium
Q4 = aliran panas Metil Iodida dari Tank (T-03)
Q5 = aliran panas Metil Asetat dari Tank (T-04)
Q6 = aliran panas keluar dari Mixing Tank-01 (MT-01)
HEATER-01 (H-01)
HEATER-01a (H-01a)
Fungsi : Sebagai tempat menaikan temperatur katalis sebelum masuk reaktor
Gambar :
Qsi
Q6in
Q6out
Qso
199
Keterangan :
Q6a in : panas aliran masuk H – 01
Q6a out : panas aliran keluar H – 01
Qsi : panas steam masuk
Qso : panas steam keluar
HEATER-01b (H-01b)
Panas sensible yang masuk heater – 01b
Q6b = 237262,9343 kJ/jam
HEATER-01c (H-01c)
Panas sensible yang masuk heater – 01c
Q6c = 475509,8199 kJ/jam
HEATER-02 (H-02)
HEATER-02a (H-02a)
Fungsi : Sebagai tempat menaikan temperatur karbon monoksida dan hidrogen
sebelum masuk ke reaktor.
Gambar :
Qsi
Q8a in
Q8a out
Qso
Keterangan :
Q8a in : panas aliran masuk H – 02
Q8a out : panas aliran keluar H – 02
Qsi : panas steam masuk
Qso : panas steam keluar
HEATER-02b (H-02b)
Panas sensible yang masuk heater – 01b
Q8b = 479817,1154 kJ/jam
Panas sensible yang keluar Heater – 02b :
Tref = 25°C = 298,15 K
Toutput = 154°C = 427,15 K
Komponen Kmol ∫ Cp dT Q8b out
Karbon Monoksida 232,5535 3894,2604 905624,0843
Hidrogen 4,7939 2477,7808 11878,3079
Total 917502,3921
205
HEATER-02c (H-02c)
Panas sensible yang masuk heater – 02c
Q8c = 917502,3921 kJ/jam
HEATER-03 (H-03)
HEATER-03a (H-03a)
Fungsi : Sebagai tempat menaikan temperatur metanol umpan dari T-01 dan
recycle dari D-01 sebelum masuk reaktor.
Gambar : Qsi
Q9In
Q9out
Qso
Keterangan :
Q9a in : panas aliran masuk H – 03
Q9a out : panas aliran keluar H – 03
Qsi : panas steam masuk
Qso : panas steam keluar
HEATER-03b (H-03b)
Panas sensible yang masuk heater - 03
Q9b = 367216,2579 kJ/jam
HEATER-03c (H-03c)
Panas sensible yang masuk heater – 03c
Q9c = 776023,5465 kJ/jam
HEATER-04 (H-04)
Fungsi : Sebagai tempat menaikan temperatur recycle dari FD-01 sebelum
masuk reaktor.
Gambar :
Qsi
Q12in
Q12out
Qso
Keterangan :
Q12a in : panas aliran masuk H – 04
Q12a out : panas aliran keluar H – 04
Qsi : panas steam masuk
Qso : panas steam keluar
Q s out - 535,7053
Total 2672,0532 2672,0532
REAKTOR-01 (R-01)
Fungsi : Sebagai tempat bereaksi antara feed karbon monoksida dan methanol
Gambar :
Q6 Q10
Qwo
Q11
Q7
Qwi
Q9
Q8 Q12
Keterangan :
Q6 : panas masuk bersama aliran dari H – 01
Q7 : panas masuk bersama aliran dari T-01
Q9 : panas masuk bersama aliran dari H-03
Q8 : panas masuk bersama aliran dari H-02
Q12 : panas masuk bersama aliran dari H – 04
Q11 : panas keluar produk R -01
Q10 : panas keluar produk R -01
Qwi : panas bersama aliran air pendingin masuk
Qwo : panas bersama aliran air pendingin keluar
214
a. Input
Komponen Kmol ∫ Cp dT Qin (kJ)
Methanol 234,9025 5348,9137 1256473,6100
Karbonmonoksida 234,9025 5629,7937 1337251,88940
Metil Iodida 16,3512 5134,9585 82963,0841
Rhodium 0,0346 7107,6696 246,3826
Air 101,5691 6183,8552 628088,3377
Asam Asetat - - -
Asetaldehida - - -
Hidrogen 6,6690 4333,9945 11817,8818
Metil Asetat 3,1363 4533,1735 14217,5635
Total 3332058,7550
b. Output Top
c. Output Bottom
Komponen ΔĤof
Methanol -201300,0000
Karbonmonoksida -110620,0000
Hidrogen 0
Asetaldehida 170700
Air -242000
= 27408,1535 kg/jam
Qcw input = Kebutuhan Air Pendingin . Cp air (Twin-Tref)
= 137040,7676 kJ/jam
Qcw out = Kebutuhan Air Pendingin . Cp air (Twout-Tref)
= 685203,8381 kJ/jam
Qwin 137040,7676
Qwout 685203,8381
Total 2592038,61 2592038,61
FLASH DRUM
Fungsi : Mengubah cairan menjadi uap dari Reaktor – 01
Gamba r : Q13
Q11
FD-01
Q12
Keterangan :
Q11 : panas bersama aliran masuk dari R – 01
Q12 : panas bersama aliran keluar bottom FD – 12.
Q13 : panas bersama aliran keluar top FD – 01.
TOTAL 959472,0307
CONDENSOR – 01 (CD-01)
Fungsi : Mengkondensasikan produk Kolom Destilasi – CD 01
Gamba r :
Qwo
Q14 Q14
Keterangan :
Qwi CD-01
Q14a : panas
bersama aliran
masuk dari KD – 01
Q14b : panas bersama aliran keluar dari CD – 01
Qwi : panas bersama air pendingin masuk
Qwo : panas bersama air pendingin keluar
Kondisi Operasi :
T = 50 oC = 323,15 K
P = 1,4 atm
Output Refluks
Komponen Kmol ∫ Cp dT Q14out
Metanol 0,7211 551,0957 246,9514
Metil Iodida 26,5188 199,7324 5296,677
Metil Asetat 4,9776 249,3310 1241,07
Asetaldehid 3,3844 681,4019 2306,203
Air 21,7453 806,7308 17542,61
Asam Asetat 3,3844 517,5337 1971,65
Total 28605,16
Output Destilat
Komponen Kmol ∫ Cp dT Q15out
Metanol 0,272961 551,0957 150,4274
Metil Iodida 16,15364 199,7324 3226,405
Metil Asetat 3,0320 249,3310 755,9824
Asetaldehid 2,0616 681,4019 1404,795
Air 13,2459 806,7308 10685,86
Asam Asetat 2,3263 517,5337 1201,006
Total 17424,48
= 50982,0653 kg
Panas sensibel yang dibawa air pendingin masuk CD – 01 :
= 1066544,8056 kJ/jam
= 4266179,2225 kJ/jam
224
CONDENSOR – 02 (CD-02)
Fungsi : Mengkondensasikan produk Kolom Destilasi – CD 02
Gamba r :
Qwo
Q29a Q29b
Qwi CD-02
Keterangan :
Q29a : panas bersama aliran masuk dari KD – 02
Q29b : panas bersama aliran keluar dari CD – 02
Qwi : panas bersama air pendingin masuk
Qwo : panas bersama air pendingin keluar
Kondisi Operasi :
T = 80 oC = 353,15 K
P = 1,1 atm
Output Refluks
Komponen kmol ∫ Cp dT Q15out
Metanol 0,0522 1272,0020 66,4505
Metil Iodida 0,9736 17,2956 17,7018
Metil Asetat 0,5060 201,9124 107,6609
Asetaldehida 0,0070 572,0056 4,1673
Air 400,3568 677,5596 36370,3092
Asam Asetat 13,3334 431,7156 5979,2870
Total 373545,5769
Output Destilat
Komponen kmol ∫ Cp dT Q15out
Metanol 0,0083 1272,002 10,5938
Metil Iodida 0,1586 157,2957 2,8220
Metil Asetat 0,0824 201,9124 17,1637
Asetaldehid 0,0011 572,0056 0,6644
Air 65,2283 677,5596 58567,4591
Asam Asetat 2,1723 431,7156 953,2388
Total 59551,9418
Qtotal = Output refluks + Output Destilat
= 37545,5769+ 59551,9418
= 433097,5188 kJ/jam
Panas laten pengembunan CD-01, Qlc :
Lvc = - Lc [(Tc-T)/(Tc-Tb)]0,38
= 425784,2926 kg
= 8907407 kJ/jam
= 35629629,6034 kJ/jam
Qv* Qlv
Qsi
Ql*
Q20 Qco
Keterangan :
Ql* : panas bersama aliran masuk ke RB-01
Qv* : panas bersama aliran refluks Reboiler (RB-01)
Q20 : panas bersama aliran bottom Reboiler (RB-01)
Qlv : panas laten penguapan RB-01
Qsi : panas bersama aliran steam input.
Qco : panas bersama aliran condensate output.
Kondisi Operasi:
T = 120 oC = 393.15 K
Panas masuk ke reboiler (RB-01), Ql*
Komponen n (kmol) ∫ Cp dT (kJ/kmol) Ql* (kJ)
Metanol 0,7211 2336,2972 1684,347
Metil Iodida 42,6725 1560,7182 66599,7501
Metil Asetat 8,0223 1527,1285 12251,1184
Asetaldehid 5,4461 2616,6447 14250,5647
Air 35,7883 3074,7094 110038,707
Asam Asetat 15,0706 2196,2518 33098,7931
Total 237923,568
Qsi
Ql*
Q30 Qco
Keterangan :
Ql* : panas bersama aliran masuk ke
RB-02
Qv* : panas bersama aliran refluks Reboiler (RB-02)
Q30 : panas bersama aliran bottom Reboiler (RB-02)
Qlv : panas laten penguapan RB-02
Qsi : panas bersama aliran steam input.
Qco : panas bersama aliran condensate output.
Kondisi Operasi:
T = 132 oC = 405,15 K
DECANTER– 01 (D-01)
Fungsi : Mengubah cairan menjadi uap dari Reaktor – 01
Gamba r :
Q21
D-01 Q24
Q23
Keterangan :
Q21 : panas bersama aliran masuk dari KD – 01
Q24 : panas bersama aliran keluar top D– 01
Q23 : panas bersama aliran keluar bottom D – 01
Tref = 25 oC = 298,15 K
Temperatur masuk = 30 oC = 303,15 K
Temperatur keluar = 30 oC = 303,15 K
a. Panas masuk (Qin)
13 CD-01
KD-01 17
QL
Q20
Q V*
Q L* RB-01
Keterangan :
Q13 : panas bersama aliran masuk ke KD-01.
235
QV
CD-02
Q17
KD-02
QL
Q30
Q V*
Q L* RB-02
Keterangan :
Q17 : panas bersama aliran masuk ke KD-02.
Qv : panas bersama aliran top KD – 02.
Q30 : panas bersama aliran keluar bottom KD – 02.
Kondisi Operasi:
T ref = 25 oC = 298,15 K
T in = 115oC = 388,15 K
T bottom = 132oC = 405,15 K
COOLER – 01
COOLER – 01a (C- 01a)
Fungsi : Menurunkan suhu aliran keluaran top R-01 Menuju ke FD-01
Gambar :
Qw-in
Q11a in
Q11b out
Qwout
Keterangan :
Q11a : panas bersama aliran masuk top R-01
Q11b : panas bersama aliran keluar cooler – 01 (C – 01)
Qwin : panas air pendingin masuk C – 01
Qwout : panas air pendingin keluar C – 01
= 5275,1991 kg
= 5041,3527 kg
= 8378,3262 kJ/jam
= 105868,4075 kJ/jam
Panas sensibel air pendingin keluar dari C-01
Qwout m x Cpair x (T2 Tref )
= 423473,6302 kJ/jam
Qs = Q-wout - Q-win
= Q20 - Q33
Qs = 197976,7039 kJ/kmol
= 4474,5429 kg
COOLER – 02
Fungsi : Menurunkan suhu aliran keluaran top E-01 menuju ke KD-01
Gambar :
Qw-in
Q13a in
Q13b out
Qwout
Keterangan :
Q13a : panas bersama aliran masuk FD-01
Q13b : panas bersama aliran keluar cooler – 02 (C – 02)
Qwin : panas air pendingin masuk C – 02
Qwout : panas air pendingin keluar C – 02
= Q20 - Q33
Qs = 150656,1326 kJ/kmol
= 3587,0508 kg
Gambar :
input
ACC - 01
output
246
247
Perhitungan Desain:
1) Volume Accumulator, Vt
Volume liquid, Vt
Vt = Wl /ρl
7910,0137 kg / jam
=
120,0760kg / m3
= 72,6142 m3/jam
Faktor keamanan, 10 %
Vt = (1+0,10) x Vt
Vt = 79,8756 m3/jam
5) Panjang silinder
Hs = 3 . ID
= 4,3523 m
6) Panjang ellipsoidal
he = ¼ ID
248
= 0,3627 m
7) Panjang Accumulator
Ht = Hs + 2 he
= 4,8378 m + (2 x 0,4032 m)
= 5,0776 m
8) Tebal dinding accumulator (dipilihtebal head)
t = P.D (Peter & Timmerhaus, 1991)
C
2.S .E 0,2.P
Dimana :
t = Tebal dinding accumulator
P = Tekanan desain = 1 atm
S = Working stress = 932,23 atm
C = Korosi yang diizinkan = 0,00197
ID = Inside Diameter Accumulator = 1,4508 m
E = Welding joint efficiency = 0,85
(1atm. *1,4508m)
t = 0,00197
(2 * 932,23atm * 0,85) (0,2 *1atm)
t = 0,0029 m
= 0,29 cm
IDENTIFIKASI
Nama Alat Accumulator
Kode Alat ACC-01
Jumlah 1 buah
Fungsi Tempat menampung sementara kondensat
produk dari CD -01.
DATA DESIGN
Tipe Silinder horizontal dengan tutup elipsoidal
Kapasitas 72.6142 m3 = 19182.4802 gallons
Temperatur 30 C
Tekanan 1 atm
Diameter dalam 1,4603 m = 57.4938 in
Panjang 5,0776 m = 199.9067 in
Tebal 0,0029 m
Waktu tinggal 30 menit
Bahan konstruksi Carbon Steel
2. ACCUMULATOR (ACC-02)
Fungsi : Tempat menampung sementara kondensat dari CD-02.
Gambar :
input
ACC-02
ACC - 01
output
250
Perhitungan Desain:
1) Volume Accumulator, Vt
Volume liquid, Vt
Vt = Wl /ρl
15831,499 kg / jam
=
120,763kg / m3
= 131,0961 m3/jam
Faktor keamanan, 10 %
Vt = (1+0,10) x Vt
Vt = 144,2056 m3/jam
= 8,5573 m3
5) Panjang silinder
Hs = 3 . ID
= 5,4744 m
6) Panjang ellipsoidal
he = ¼ ID
= 0,4562 m
7) Panjang Accumulator
Ht = Hs + 2 he
= 7,7034 m + (2 x 0,6420 m)
= 6,3868 m
8) Tebal dinding accumulator (dipilihtebal head)
t = P.D (Peter & Timmerhaus, 1991)
C
2.S .E 0,2.P
Dimana :
t = Tebal dinding accumulator
P = Tekanan desain = 1 atm
S = Working stress = 932,23 atm
C = Korosi yang diizinkan = 0,00197
ID = Inside Diameter Accumulator = 5,987 m
E = Welding joint efficiency = 0,85
(1atm. * 5,987m)
t = 0,00197
(2 * 932,23atm * 0,85) (0,2 *1atm)
t = 0,00578 m
= 0,578 cm
IDENTIFIKASI
Nama Alat Accumulator
Kode Alat ACC-02
Jumlah 1 buah
Fungsi Tempat menampung sementara kondensat
produk dari CD -02.
DATA DESIGN
Tipe Silinder horizontal dengan tutup elipsoidal
Kapasitas 131,0961 m3 = 34631,6456 gallons
Temperatur 30 C
Tekanan 1 atm
Diameter dalam 1,8248 m = 71.843 in
Panjang 8,9874 m = 243,8105 in
Tebal 0,00578 m
Waktu tinggal 30 menit
Bahan konstruksi Carbon Steel
T2
T1
Tee
Return Head
t2
t 2 t1
LMTD
ln T1 / T2
LMTD =
∆t = 55,3177oF
c. Temperatur rata-rata
Tc = T avg = 0.5 (239+122) = 180,5 oF
tc = t avg = 0,5 (113 + 86) = 99,5000o F
Penentuan tipe Cooler :
Asumsi UD = 118 = Btu/hr.ft2.F
Q
A
U D t
A=
A = 124,3954 ft2
Karena A < 200 ft2 , maka dipilih jenis Double Pipe Heat Exchanger
Dari Tabel.10 Kern didapat spesifikasi data :
254
Rencana Klasifikasi
Data Pipa Annulus Inner Pipe
IPS (in) 4 2
SN 40 40
OD (in) 4,5 2,38
ID (in) 4,026 2,067
a” (ft2/ft) 2,814 2,258
De =
D 2
2
D1
2
D1
= 0,3692 ft
b. Kecepatan Massa, Ga
Ga = W/aa
= 114844,2430 lb/hr.ft2
Pada T = 180,5 oF
μ = 0,0120 lb/ft.hr
Rea = De.Ga/μ
= 1460061,6016
JH = 1000
k = 0,0680 Btu/hr.ft2(oF/ft)
c = 0,9730 Btu/lb.oF
255
c
1
3
=
k
= 0,7369
c. Koefisien perpindahan panas
0 ,14
c
1
k 3
ho = JH
De k w
= 1000 x x 0,7369 x 1
= 135,7312 Btu/hr.ft2.oF
b. Kecepatan Massa, Gp
Gp = w/ap
= 4825730,3370 lb/hr.ft2
Pada 99,5 oF
μ = 0,8011 lb/ft.hr
Rep = D.Gp/μ
= 763298,4854
JH = 910
k = 0,3630 Btu/hr.ft2(oF/ft)
c = 18,1600 Btu/lb.oF
256
c
1
18,1600 x0,8011
3 3
=
k 0,3630
= 3,7859
c. Koefisien Perpindahan Panas
0 ,14
k c
1
3
hi = JH
De k w
= 910 x x 3,7859 x 1
= 7260,3196 Btu/hr.ft2.oF
Dari tabel 11 Kern, untuk 2-in IPS standard pipe, external surface/foot length
= 2,2580 ft2.
Required length = 55,4259 ft
Diambil panjang 1 hairpin = 20 ft, maka jumlah hairpin yang dibutuhkan = 2
g. Dirt Factor, Rd
Actually Length = 20 x (2 x 2)
= 80 ft
Actually surface = 80 x 2,2580 ft
= 180,6400 ft2
UD = 81,2592 Btu/hr.ft2.oF
U C U D
Rd =
U C U D
= 0,0048 hr.ft2.oF/Btu
PRESSURE DROP
HOT FLUID: Annulus
a. De’ = (D2 – D1)
= 0,1372 ft
Rea = De’.Ga/μ
= 542451,8595
0,264
ƒ = 0,0035
(Re a' ) 0, 42
= 0,0045
ρ = 112,2998 lb/ft3
4 fGa 2 L
b. ΔFa =
2 g 2 De
= 0,0026 ft
Ga
c. Va =
3600
= 0,2641 fps
258
V 2
d. Fl = jumlah hairpin x
2g
= 0,0004
(Fa Fl )
e. Δpa =
144
= 0,0058 psi
COLD FLUID: Inner Pipe
a. Rep = 763298,4854
ƒ = 0 ,0035 0 , 264
(Re p ) 0 , 42
= 0,0044
ρ = 60,0871 lb/ft3
4 fGp 2 L
b. ΔFp =
2 g 2 D
= 12,5934 ft
c. ΔPp = Fp .
144
= 2,3164 Psi
SUMMARY
ho = 135,7312 h outside hio = 6305,4961
Uc = 132,8710
UD = 117,2870
RD calculated = 0,0048
RD required = 0,0010
0,0058 ∆ P Calculated (psi) 2,3164
10 ∆ P Allowable (psi) 10
259
4. CONDENSOR (CD-02)
Fungsi : Mengkondensasikan top produk KD-02
Tipe : Shell and Tube Total Condensor
Gambar :
Shell
Tube
Rear End
Head
b. LMTD
Fluida Panas Fluida Dingin Selisih
213,8 Suhu tinggi 113 113
213,8 Suhu rendah 86 86
0 Selisih 27 27
t 2 t1
LMTD =
ln (t 2 / t1 )
= 113,7665oF
260
a. Tc = T avg = 213,8 oF
tc = t avg = 99,5 oF
Q
A =
U D . t
A = 477,7449 ft2
Karena A > 200 ft2, maka dipilih HE jenis Shell and Tube.
(Hal.103, Kern, 1965)
Rencana Klasifikasi
a). Tube Side
Panjang tube (L) = 20 ft
(Hal.11-40,Heat Transfer Equipment Perry, 1997)
Outside Diameter (OD) = 1 inch
BWG =10
Pass =1
A
Jumlah tube (Nt) Nt =
L x a"
Nt = 91,2423
dari Tabel.9, Hal.842, Kern, 1965 didapat Nt yang mendekati adalah 91
Nt = 91
1
Nt
ni
UD = 145,3861 Btu/hr.ft2.oF
(koreksi memenuhi)
karena nilai Ud perhitungan mendekati dengan nilai Ud asumsi, maka data
untuk Shell.
b). Shell side
ID = 15,25 inci
Baffle Space = 7,6250 inci
(Hal.11-42 ,Heat Transfer Equipment Perry, 1997)
Pass (n) =1
Pt = 1,25
(Tabel.9, Hal.842, Kern, 1965)
262
Cp
Prandl Number ( Pr ) =
k
k = 0,3194 Btu/hr ftoF
263
Cp = 18,7200 Btu/lboF
Pr = 115,1708
0 ,14
k Cp
1
3
f. hi j H
D k
w
(Pers.6.15a, Kern, 1965)
dengan (μ/μw) = 1 untuk bahan kimia kecuai untuk hidrokarbon.
Koreksi viskositas diabaikan karena tidak significant, maka didapat :
hi = 228,9152 Btu/hr ft2oF
hio =
ID
hi x
OD
0 ,14
k Cp
1
3
f). ho jH
De k w
(Pers.6.15b, Kern, 1965)
Koreksi viskositas diabaikan karena tidak significant, maka didapat :
ho = 6464,8147 Btu/hr ft20F
= 0,0005 psi
s = 0,9548
f Gs Di ( N 1)
2
= 9,1911 psi
IDENTIFIKASI
Nama Alat Condensor
Kode Alat CD-02
Jumlah 1 buah
Operasi Kontinyu
Fungsi Mengkondensasikan top produk KD-02
DATA DESAIN
Tipe Shell and Tube Total Condensor
Bahan Konstruksi CarbonSteel
Rd Calculated 0,0008
UC 163,3324
UD 145,3861
Shell Side Tube Side
ID = 15,2500 in Number = 91
and Length dan 20 ft
B = 7,6250 in OD = 1-in
BWG 10
Pitch 1,25-in
triangular
Passes = 10 Passes = 10
∆Ps = 9,1911 psi ∆Pt = 0,0046 psi
267
T2
T1
Tee
Return Head
t2
b. LMTD
Fluida Panas Fluida Dingin Selisih
o o
( F) ( F)
419 (T1) Suhu Tinggi (th) 113 (t1) 306
366,8 (T2) Suhu Rendah (tc) 86 (t2) 280
Selisih 25,2
268
t 2 t1
LMTD
ln t 2 / t1 (Kern, 1965)
LMTD =
( )
∆t = 293,2195 oF
c. Temperatur rata-rata
Tc = T avg = 0,5 (419 + 366,8) = 392,9 oF
tc = t avg = 0,5 (113 + 86) = 99,5 oF
Penentuan tipe Cooler :
Asumsi UD = 34 = Btu/hr.ft2.F (Kern, 1965)
Q
A (Kern, 1965)
U D t
A=
A = 190,3455 ft2
Karena A < 200 ft2 , maka dipilih jenis Double Pipe Heat Exchanger
Dari Tabel.10 Kern didapat spesifikasi data :
Rencana Klasifikasi (Kern, 1965)
Data Pipa Annulus Inner Pipe
IPS (in) 6,0000 3,0000
SN 40,0000 40,0000
OD (in) 6,6250 3,5000
ID (in) 6,0650 3,068
a” (ft2/ft) 1,7340 0,9170
= (0,5054 2 –0,29172)
4
= 0,1337 ft2
Equivalent Diameter
De =
D 2
2
D1
2
D1 (Kern, 1965)
( )
=
= 0,5841 ft
d. Kecepatan Massa, Ga
Ga = W/aa
= 318478,7933 lb/hr.ft2
Pada T = 392,9 oF
μ = 7,6738 lb/ft.hr
Rea = De.Ga/μ
= 24243,3128
JH = 72 (Kern, 1965)
k = 0,0144 Btu/hr.ft2(oF/ft)
c = 18,19 Btu/lb.oF
c
1
3
=( )
k
= 21,3352
c. Koefisien perpindahan panas
0 ,14
k c
1
3
ho = JH
De k w (Kern, 1965)
270
= 72 x x 21,3352 x 1
= 37,7625 Btu/hr.ft2.oF
b. Kecepatan Massa, Gp
Gp = w/ap
= 226649,4801 lb/hr.ft2
Pada 99,5oF
μ = 1,9387 lb/ft.hr
Rep = D.Gp/μ
= 29890,0567
JH = 70 (Kern, 1965)
k = 0,3630 Btu/hr.ft2(oF/ft)
c = 18,18 Btu/lb.oF
1
c
1
18,1800 x 1,9378
3 3
=
k 0,3630
= 4,5962
271
hi = JH
De k w (Kern, 1965)
= 70 x x 4,5962 x 1
= 456,8010 Btu/hr.ft2.oF
UD = 33,7246 Btu/hr.ft2.oF
e. Required Surface
Q
A =
U D t (Kern, 1965)
= 191,9002 ft2
Dari tabel 11 Kern, untuk 3-in IPS standard pipe, external surface/foot length
= 0,9170 ft2. (Kern, 1965)
272
191,9002
Required length = = 209,2969 ft
0,9170
Diambil panjang 1 hairpin = 20 ft, maka jumlah hairpin yang dibutuhkan = 5
f. Dirt Factor, Rd
Actually Length = 5 x (20 x 2)
= 200 ft
Actually surface = 0,9170 x 200 ft
= 183,4000 ft2
UD =
= 35,2876 Btu/hr.ft2.oF
U C U D
Rd =
U C U D (Kern, 1965)
= -0,0003 hr.ft2.oF/Btu
PRESSURE DROP
HOT FLUID: Annulus
a. De’ = (D2 – D1)
= (0,5054-0,2917) ft
= 0,2138 ft
Rea = De’.Ga/μ
= 24243,3128
0,264
ƒ = 0,0035
(Re a' ) 0, 42
= 0,0035 +
= 0,0073
ρ = 63,2314 lb/ft3
273
4 fGa 2 L
d. ΔFa =
2 g 2 De (Felder &
Rosseau, 2005)
= 0,8294 ft
Ga
e. Va =
3600
= 1,3991 fps
V 2
d. Fl = jumlah hairpin x
2g (Kern, 1965)
=5x
= 0,1520 ft
(Fa Fl )
e. Δpa =
144
( )
=
= 0,4309 psi
ƒ = 0 ,0035 0 , 264
(Re p ) 0 , 42
= 0,0035 +
= 0,0070
ρ = 63,7797 lb/ft3
4 fGp 2 L
b. ΔFp =
2 g 2 D
274
= 0,33 ft
Fp .
c. ΔPp =
144
=
= 0,1462 Psi
SUMMARY
ho = 37,7625 h outside hio = 400,4187
Uc = 34,9016
UD = 35,2876
RD calculated = -0,0003
RD required = 0,0010
0,4309 ∆ P Calculated (psi) 0,1462
10 ∆ P Allowable (psi) 10
T2
T1
Tee
Return Head
t2
t1 = 30 oC = 86 oF
t2 = 45 oC = 113 oF
Perhitungan design sesuai dengan literatur pada Donald Q. Kern (1965).
b. LMTD
Fluida Panas Fluida Dingin Selisih
o o
( F) ( F)
366 (T1) Suhu Tinggi (th) 113 (t1) 253,8
314,6 (T2) Suhu Rendah (tc) 86 (t2) 228,6
Selisih 25,2
t 2 t1
LMTD
ln t 2 / t1 (Kern, 1965)
LMTD =
( )
∆t = 240,9804 oF
c. Temperatur rata-rata
Tc = T avg = 0,5 (366 + 314,6) = 340,7 oF
tc = t avg = 0,5 (113 + 86) = 99,5 oF
Penentuan tipe Cooler :
Asumsi UD = 34 = Btu/hr.ft2.F
Q
A (Kern, 1965)
U D t
A=
A = 192,5942 ft2
Karena A < 200 ft2 , maka dipilih jenis Double Pipe Heat Exchanger
Dari Tabel.10 Kern didapat spesifikasi data :
Rencana Klasifikasi (Kern, 1965)
276
De =
D 2
2
D1
2
D1 (Kern, 1965)
( )
=
= 0,5841 ft
f. Kecepatan Massa, Ga
Ga = W/aa
= 318478,7933 lb/hr.ft2
Pada T = 340,7 oF
μ = 8,3901 lb/ft.hr
Rea = De.Ga/μ
277
= 22173,5059
JH = 72 (Kern, 1965)
k = 0,0144 Btu/hr.ft2(oF/ft)
c = 18,1900 Btu/lb.oF
c
1
3
=( )
k
= 21,9794
c. Koefisien perpindahan panas
0 ,14
k c
1
3
ho = JH
De k
w (Kern, 1965)
= 72 x x 21,9794 x 1
= 38,9026 Btu/hr.ft2.oF
= 216602,2450 lb/hr.ft2
Pada 99,50 oF
μ = 1,939 lb/ft.hr
278
Rep = D.Gp/μ
= 28565,0485
JH = 63 (Kern, 1965)
k = 0,3630 Btu/hr.ft2(oF/ft)
c = 18,1800 Btu/lb.oF
1
c
1
18,1800 x1,939
3 3
=
k 0,3630
= 4,5962
hi = JH
De k w (Kern, 1965)
= 63 x x 4,5962 x 1
= 411,1209 Btu/hr.ft2.oF
UD = 34,3441 Btu/hr.ft2.oF
e. Required Surface
Q
A =
U D t (Kern, 1965)
= 190,6647 ft2
Dari tabel 11 Kern, untuk 3-in IPS standard pipe, external surface/foot length
= 0,9170 ft2.
190,6647
Required length = = 207,9222 ft
0,9170
Diambil panjang 1 hairpin = 20 ft, maka jumlah hairpin yang dibutuhkan = 5
f. Dirt Factor, Rd
Actually Length = 5 x (20 x 2)
= 200 ft
Actually surface = 0,9170 x 200 ft
= 183,4000 ft2
UD =
= 35,7045 Btu/hr.ft2.oF
U C U D
Rd =
U C U D (Kern, 1965)
= -0,0001 hr.ft2.oF/Btu
PRESSURE DROP
HOT FLUID: Annulus
a. De’ = (D2 – D1)
= (0,5054-0,2917) ft
= 0,2138 ft
280
Rea = De’.Ga/μ
= 22173,5059
0,264
ƒ = 0,0035
(Re a' ) 0, 42
= 0,0035 +
= 0,0074
ρ = 63,8531 lb/ft3
4 fGa 2 L
f. ΔFa =
2 g 2 De (Felder & Rosseau, 2005)
= 0,7799 ft
Ga
g. Va =
3600
= 1,3434 fps
V 2
d. Fl = jumlah hairpin x
2g (Kern, 1965)
= 5x
= 0,1401 ft
(Fa Fl )
e. Δpa =
144
( )
=
= 0,4207 psi
COLD FLUID: Inner Pipe
a. Rep = 28565,0485
ƒ = 0 ,0035 0 , 264
(Re p ) 0 , 42
281
= 0,0035 +
= 0,0070
ρ = 53,4408 lb/ft3
4 fGp 2 L
b. ΔFp =
2 g 2 D
= 0,4335 ft
Fp .
c. ΔPp =
144
=
= 0,1609 Psi
SUMMARY
ho = 38,9026 h outside hio = 360,3768
Uc = 35,5655
UD = 35,7045
RD calculated = -0,0001
RD required = 0,0010
0,4207 ∆ P Calculated (psi) 0,1609
10 ∆ P Allowable (psi) 10
T2
T1
Tee
t2
282
a. Beban Panas C - 01
Q = 1335333,6373 kJ/jam = 1265670,6168 Btu/hr
b. LMTD
t 2 t1
LMTD
ln t 2 / t1 (Kern, 1965)
LMTD =
( )
∆t = 190,5961 oF
c. Temperatur rata-rata
Tc = T avg = 0,5 (314,6 +266) = 290,3 oF
tc = t avg = 0,5 (113+86) = 99,5 oF
A=
283
A = 189,7312 ft2
Karena A < 200 ft2 , maka dipilih jenis Double Pipe Heat Exchanger
Dari Tabel.10 Kern didapat spesifikasi data :
Rencana Klasifikasi (Kern, 1965)
Data Pipa Annulus Inner Pipe
IPS (in) 6,0000 3,0000
SN 40,0000 40,0000
OD (in) 6,6250 3,5000
ID (in) 6,0650 3,0680
a” (ft2/ft) 1,7340 0,9170
De =
D 2
2
D1
2
D1 (Kern, 1965)
( )
=
= 0,5841 ft
h. Kecepatan Massa, Ga
Ga = W/aa
= 318478,7933 lb/hr.ft2
284
Pada T = 290,3oF
μ = 8,8741 lb/ft.hr
Rea = De.Ga/μ
= 20964,1518
JH = 70 (Kern, 1965)
k = 0,0126 Btu/hr.ft2(oF/ft)
c = 17,69 Btu/lb.oF
c
1
3
=( )
k
= 23,1937
c. Koefisien perpindahan panas
0 ,14
k c
1
3
ho = JH
De k w (Kern, 1965)
= 70 x x 23,1937 x 1
= 34,9365 Btu/hr.ft2.oF
b. Kecepatan Massa, Gp
Gp = w/ap
285
= 192249,2028 lb/hr.ft2
Pada 99,50 oF
μ = 1,939 lb/ft.hr
Rep = D.Gp/μ
= 25353,4205
JH = 55 (Kern, 1965)
k = 0,3630 Btu/hr.ft2(oF/ft)
c = 18,1800 Btu/lb.oF
1
c
1
18,1800 x 1,939
3 3
=
k 0,3630
= 4,5962
hi = JH
De k
w (Kern, 1965)
= 55 x x 4,5962 x 1
= 358,9150 Btu/hr.ft2.oF
1 1
Rd (Kern, 1965)
U D UC
Rd diasumsikan 0,001
1/UD = 0 00
UD = 30,6197 Btu/hr.ft2.oF
e. Required Surface
Q
A =
U D t (Kern, 1965)
= 216,8733 ft2
Dari tabel 11 Kern, untuk 3-in IPS standard pipe, external surface/foot length
= 0,9170 ft2. (Kern, 1965)
216,8733
Required length = = 236,5030 ft
0,9170
Diambil panjang 1 hairpin = 15 ft, maka jumlah hairpin yang dibutuhkan = 7
f. Dirt Factor, Rd
Actually Length = 7 x (15 x 2)
= 210 ft
Actually surface = 0,9170 x 210 ft
= 192,5700 ft2
UD =
= 34,4840 Btu/hr.ft2.oF
U C U D
Rd =
U C U D (Kern, 1965)
= -0,0027 hr.ft2.oF/Btu
PRESSURE DROP
287
0,264
ƒ = 0,0035
(Re a' ) 0, 42
= 0,0035 +
= 0,0075
ρ = 68,1969 lb/ft3
4 fGa 2 L
h. ΔFa =
2 g 2 De (Felder & Rosseau,
2005)
= 0,7732 ft
Ga
i. Va =
3600
= 1,2972 fps
V 2
d. Fl = jumlah hairpin x
2g (Kern, 1965)
=7x
= 0,1829 ft
(Fa Fl )
e. Δpa =
144
( )
=
288
= 0,4528 psi
COLD FLUID: Inner Pipe
a. Rep = 25353,4205
ƒ = 0 ,0035 0 , 264
(Re p ) 0 , 42
= 0,0035 +
= 0,0072
ρ = 54,9050 lb/ft3
4 fGp 2 L
b. ΔFp =
2 g 2 D
= 0,3485 ft
Fp .
c. ΔPp =
144
=
= 0,1329 Psi
SUMMARY
ho = 34,9365 h outside hio = 314,6147
Uc = 31,5869
UD = 34,4840
RD calculated = -0,0027
RD required = 0,0010
0,4528 ∆ P Calculated (psi) 0,1329
10 ∆ P Allowable (psi) 10
Gambar : t1
Gland
Return bend Gland
Gland
T2
T1
Tee
Return Head
t2
Fluida Panas : Keluaran FD-01
Flowrate, W1 = 18395,563 Kg/jam = 40555,226 lb/hr
o
T1 = 130 C = 266 oF
T2 = 115 oC = 239 oF
Fluida Dingin : Air Pendingin
Flowrate, W2 = 3587,051 Kg/jam = 7908,084 lb/hr
t1 = 30 oC = 86 oF
t2 = 50 oC = 122 oF
Perhitungan design sesuai dengan literatur pada Donald Q. Kern (1965).
a. Beban Panas C - 02
Q = 1034800,097 kJ/jam = 980815,611 Btu/hr
b. LMTD
Fluida Panas Fluida Dingin Selisih
(oF) (oF)
266 (T1) Suhu Tinggi (th) 122 (t1) 144
239 (T2) Suhu Rendah (tc) 86 (t2) 153
Selisih 9
t 2 t1
LMTD
ln t 2 / t1 (Kern, 1965)
LMTD =
( )
∆t = 148,4545 oF
c. Temperatur rata-rata
Tc = T avg = 0,5 (266 +239) = 252 oF
290
A=
A = 75,323 ft2
Karena A < 200 ft2 , maka dipilih jenis Double Pipe Heat Exchanger
Dari Tabel.10 Kern didapat spesifikasi data :
De =
D 2
2
D1
2
D1 (Kern, 1965)
291
( )
=
= 0,229 ft
j. Kecepatan Massa, Ga
Ga = W/aa
= 940001,332 lb/hr.ft2
Pada T = 252,5000 oF
μ = 0,2389 lb/ft.hr
Rea = De.Ga/μ
=
= 9997858,136
c
1
3
=( )
k
= 3,256
c. Koefisien perpindahan panas
0 ,14
k c
1
3
ho = JH
De k w (Kern, 1965)
= 1000 x x 3,256 x 1
= 151,577 Btu/hr.ft2.oF
292
b. Kecepatan Massa, Gp
Gp = w/ap
=
= 237969,842 lb/hr.ft2
Pada 104 oF
μ = 1,739 lb/ft.hr
Rep = D.Gp/μ
= 28159,156
JH = 80 (Kern, 1965)
k = 0,356 Btu/hr.ft2(oF/ft)
c = 18,170 Btu/lb.oF
1
c
1
18,170 x1,739
3 3
=
k 0,356
= 4,460
hi = JH
De k w (Kern, 1965)
= 80 x x 4,460 x 1
293
= 617,561 Btu/hr.ft2.oF
(hi o x ho )
Uc =
(hio ho )
= (529,430 x 151,577) / (529,430 + 151,577)
= 118,650 Btu/hr.ft2.oF
UD = 106,065 Btu/hr.ft2.oF
f. Required Surface
Q
A =
U D t (Kern, 1965)
= 62,290 ft2
Dari tabel 11 Kern, untuk 2,5-in IPS standard pipe, external surface/foot
length = 0,7530 ft (Kern, 1965)
62,290
Required length = = 82,723 ft
0,7530
294
UD =
= 87,740 Btu/hr.ft2.oF
U C U D
Rd =
U C U D (Kern, 1965)
= 0,003 hr.ft2.oF/Btu
PRESSURE DROP
HOT FLUID: Annulus
a. De’ = (D2 – D1)
= (0,3355 - 0,2400) ft
= 0,0955 ft
Rea = De’.Ga/μ
= 9997858,136
0,264
ƒ = 0,0035
(Re a' ) 0, 42
= 0,0035 +
= 0,004
ρ = 50,6900 lb/ft3
4 fGa 2 L
j. ΔFa =
2 g 2 De (Kern, 1965)
=
295
= 6,5525 ft
Ga
k. Va =
3600
= 5,151 fps
V 2
d. Fl = jumlah hairpin x
2g (Kern, 1965)
=5x
= 2,0601 ft
(Fa Fl )
e. Δpa =
144
( )
=
= 3,0317 psi
COLD FLUID: Inner Pipe
a. Rep = 28159,156
ƒ = 0 ,0035 0 , 264
(Re p ) 0 , 42
= 0,0035 +
= 0,007
ρ = 0,9804 lb/ft3
4 fGp 2 L
b. ΔFp =
2 g 2 D (Felder & Rosseau,
2005)
= 968,766 ft
Fp .
c. ΔPp =
144
=
= 6,596 Psi
296
SUMMARY
ho = 151,577 h outside hio = 529,430
Uc = 118,650
UD = 87,740
RD calculated = 0,0030
RD required = 0,0010
3,0317 ∆ P Calculated (psi) 6,596
10 ∆ P Allowable (psi) 10
Light liquid
DC-01
DC-01 h
Zt Za
Zi
1. Kondisi Operasi
P = 1,5 atm
T = 30 oC
297
2. Light liquid
Fraksi Densitas Viskositas
Komponen Flowrate (W)
Massa (kg/m3) (cP)
CH3OH 0,0000 782,8067 0,0000 0,8081
CH3I 0,6170 2265,1004 1192,3545 1,7728
H2O 0,1431 1023,0129 357,9569 0,9453
CH3COOH 0,0617 1037,9135 17,8978 0,9976
CH3CHO 0,0577 920,4705 205,4673 0,5347
CH3COOCH3 0,1205 932,0000 16,1081 0,6358
Campuran 1,000 1773,4165 1789,7846 1,3981
Wc = 1789,7846 kg/jam
ρc = 1773,4165 kg/m3
Qc = 1,0092 m3/jam = 0,0003 m3/s
μc = 1,3981 cP = 0,0140 kg/m
3. Heavy liquid
Fraksi Densitas Flowrate Viskositas
Komponen
Massa (kg/m3) (W) (cP)
CH3OH 0,0000 782,8067 0,0000 0,8081
CH3I 0,9349 2265,1004 1010,3390 1,7728
H2O 0,0100 1023,0129 11,9581 0,9453
CH3COOH 0,0300 1037,9135 89,6857 0,9976
CH3CHO 0,0001 920,4705 0,1196 0,5347
CH3COOCH3 0,0250 932,0000 83,7066 0,6358
Campuran 1,0000 2182,3791 1195,8090 1,7127
Wd = 1195,8090 kg/jam
ρd = 2182,3791 kg/m3
Qd = 0,5479 m3/jam = 0,0002 m3/s
μd = 1,7127 cP = 0,0171 kg/m.s
298
θ = 0,5454
1) Desain dekanter
d d2 .g .( d c )
Ud (Coulson & Richardson, 2003)
18. c
Lc = W c / ρc
1789,7846 kg / m 3
=
1773,4165 kg / m 3
= 1,0092 m3/jam
= 0,0280 m3/s
0,5
Ai
r =
0,5
9,4162
=
3,14
= 1,7317 m
Ddec =2xr
= 2 x 3,4634m
= 6,9268 m
h =2xr
= 2 x 1,7317 m
= 3,4634 m
I = 10 % x h
= 10 % x 3,4634 m
= 0,3463 m
g. Residence time of droplet ( tr)
I
tr =
Ud
0,3463 m
=
0,0030 m / s
= 116,3298 s
= 1,9388 menit= 2 menit (memenuhi syarat antara 2 – 10 menit)
h. Check dd
Wd 1 1
Ud = x x
d 3600 Ai
1195,8090 kg / jam 1 1
= x
3 x
2182,3791 kg / m 3600 9,4162m
2
300
= 0,000016 m/s
= 0,0162 mm/s
dd = Ud.18. c
0,5
g.( d c )
0,5
0,000016 m / s x 18 x 0,0014kg / m s
=
3
9,8 m / s (2182,3791 1773,4165) kg / m
2
= 0,00001007 m
= 10,0746 μm
dd(cek) = 10,0746 μm
dd (asumsi) = 136,7281 μm
2) Instalasi pipa
Kecepatan fluida dekanter (v) harus lebih kecil atau sama dengan 1 m / det
Maka diasumsikan bahwa kecepatan fluida dekanter (v) = 0,8 m/s.
(Coulson & Richardson, 2003)
a. Feed flow rate (Qr )
1 Wd Wc
Qr = x
3600 d c
= 0,0004 m3 /s
Qr
Ap =
v
0,0004 m 3 / s
=
0,8m / s
= 0,0005 m2
301
Maka digunakan pipa dengan ukuran mendekati nilai Dp, dapat ditentukan
dari Tabel 10-18 Properties of steel pipe, Perry's chemical Engineers'
Handbook, hal 10-72 – 10-74, yaitu sebagai berikut :
IPS = 3 in
SN = 10
ID = 3,26 in
OD = 3,5 in
Zt = 0,9 x h
= 0,9 x 3,4634 m
= 3,1171 m
Zi = 0,5 x h
= 0,5 x 3,4634 m
= 1,7317 m
Zt Zi
Za = x d Z i
c
= 2,8575 m
302
P.D
t= C (Peter & Timmerhaus, 1991)
(2.S .E ).(0,2.P)
Dengan :
Diperoleh :
OD = ID + ( 2 . t )
= 6,9268 + (2 x 0,0074) m
= 6,9417 m
303
8. EXPANDER-01 (EXP-01)
Kondisi Operasi
Temperatur : T in = 130oC = 726 R
Tekanan : P in = 1,81 atm
P out = 1,5 atm
304
k :
:1
Diameter Pipa, De
De : 0,363 x Q0,45 x 0,13
(Peter & Timmerhaus, 1991)
: 0,0450 m
NPS : 0,5 inch
SN : 10
ID : 0,674 inch
305
OD : 0,84 inch
a : 0,0025 ft2
Power Ekspander-01 (Pw)
P1 k 1/ k
Pw : kxP2 xQ 1 (McCabe, 1986)
P 2
k 1
Dimana:
k :1
Q : 0,1730 ft3/min
P1 : 1,81 atm
P2 : 1,5 atm
T : 726 R
Maka Pw : 27,3649 Hp
Rasio ekspansi
Rc = P
out
P
in
= 0,8287
Karena rasio ekspansi berada dibawah 5 maka digunakan single stage expander
Po = Rc x Pi
= 0,8287 x 1,81 atm
= 1,5 atm
Temperatur yang keluar dari expander 1
( K 1) / KN
P2
T2 = T1
p1
T2 = 129,9991 oC
Kapasitas Expander
Laju alir volumetric = 0,1573 ft3/min
306
Faktor Keamanan = 10 %
Kapasitas Expander = (100% + 10%) x 0,1573 ft3/min
= 0,1730 ft3/min
IDENTIFIKASI PERALATAN
Nama Alat Expander-01
Kode Alat EXP-01
Jumlah 1 unit
Fungsi Untuk menurunkan tekanan output FD-01 menuju KD -01
Tipe Centrifugal expander
DATA DESIGN
Tekanan Masuk 1,81 atm
Tekanan Keluar 1,5 atm
o
Temperatur input 130 C
Power 28 Hp
Bahan Kontruksi Carbon Steel
13
11
FD-01
12
307
1. Data Desain
Tekanan : 1,81 atm
Temperatur : 130 oC
Laju alir uap : 18395,563 kg/jam
Laju alir liquid : 925,29 kg/jam
Densitas uap : 0,174 kg/m3 (Hysys)
Densitas liquid : 1301,214 kg/m3 (Hysys)
925,29 0,174
=
18395,563 1301,214
= 0,001
= 13,229 m/s
4. Vessel area minimum, A
Qv
A =
Uv
29,401 m 3 / s
=
13,229 m / s
= 2,222 m2
5. Diameter vessel minimum, D
0,5
4A
D =
0,5
4(2,222) m 2
=
3,14
= 0,841 m
7. Tinggi Liquid, HL
Holding time, t = 10 menit ( 10-20 walas, 1990.. Hal 612)
= 0,167 jam
t
HL = QLx
A
0,167 jam
= 0,711 m 3 /jam x
2,222 m 2
309
= 0,053 m
8. Tinggi vessel, Ht
Jarak top ke nozzle inlet, Hv = 1,5 m (walas, 1990.. Hal
617)
Jarak nozzle inlet ke level liquid maksimum, HZ = 0,5 m (walas, 1990.. Hal
617)
Ht = HL + HZ + HV
= 0,053 m + 0,5 m + 1,5 m
= 2,053 m
Hhead = D/4 m
=0,841/4 (table 12, Peter edisi 5, hal 554)
= 0,210 m
Htotal = 2,264 m
9. Volume vessel, Vt
Digunakan vertikal FD dengan head tipe ellipsoidal.
Volume shell vessel, Vs = ¼ D2 Hs
Tinggi shell, Hs = 2,053 m
Maka :
Volume shell vessel , Vs = ¼ D2 Hs
= 1,141 m3
Volume head, Vh = 2 (1/24) D3
= 0,078 m3
Volume vessel, Vt = Vs + Vh
= 1,219 m3
Faktor keamanan = 10%
Maka Vt = 1,341
10. Tebal dinding vessel, t
310
PD
t = C (Table 4, hal 537, Peters and
(2SE 0,2P
Timmerhaus)
dimana :
P = Tekanan design = 1,81 atm = 192,568 kPa
D = Diameter vessel = 0,841 m = 33,122 in
S = Working stress allowable = 94500 kPa (table 4, Peter, hal
538)
E = Joint effisiensi = 0,85 (table 4, Peter, hal
538)
C = Korosi maksimum = 0,125 in (table 6, Peter, hal
538)
Maka :
192,568 33,122
t = 0,125
(2 x94500 x0,85 0,2 x192,568
= 0,165 in = 0,004 m
= 0,418 cm
IDENTIFIKASI
Nama Alat Flash Drum
Kode Alat FD-01
Jumlah 1 unit
Fungsi Untuk memisahkan antara produk dari R-
01 dengan katalis Rhodium
DATA DESAIN
Tipe Vertical Cylinder
Tekanan 1,81 atm
Temperatur 130 oC
Diameter 0,841 m
Tinggi 2,264 m
Tebal Dinding 0,04 m
Bahan Konstruksi Carbon steel
T2
T1
Tee
Return Head
t2
LMTD =
( )
∆t = 277,429 oF
c. Temperatur rata-rata
Tc = T avg = 0,5 (422,96+422,96) = 422,96 oF
tc = t avg = 0,5 (197+86) = 141,8o F
A=
A = 177,2954 ft2
Karena A < 200 ft2 , maka dipilih jenis Double Pipe Heat Exchanger
Dari Tabel.10 Kern didapat spesifikasi data :
313
Equivalent Diameter
De =
D 2
2
D1
2
D1
=
0,206 2
0,138 2
0,138
= 0,168 ft
b. Kecepatan Massa, Ga
Ga = W/aa
=
= 14277,8164 lb/hr.ft2
Pada T = 422,96 oF
μ = 0,038 lb/ft.hr
314
Rea = De.Ga/μ
=
= 63229,973
JH = 150 (Kern, 1965)
k = 0,1915 Btu/hr.ft2(oF/ft)
c = 0,7724 Btu/lb.oF
c
1
3
= ( )
k
= 0,535
c. Koefisien perpindahan panas
0 ,14
c
1
3
ho = JH k
De k w (Kern, 1965)
= 150 x 0,535 x 1,142 x 1
= 139,0035 Btu/hr.ft2.oF
a. Kecepatan Massa, Gp
Gp = w/ap
=
= 1104085,5668 lb/hr.ft2
Pada 141,8oF
μ = 0,064 lb/hr ft
315
Rep = D.Gp/μ
= 1979826,8105
JH = 180 (Kern, 1965)
k = 0,0194 Btu/hr.ft2(oF/ft)
c = 1,004 Btu/lb.oF
c
1
3
= ( )
k
= 1,4898
b. Koefisien Perpindahan Panas
0 ,14
c
1
3
hi = JH k
De k w
= 180 x 0,076 x 1,4898 x 1
= 45,3359 Btu/hr.ft2.oF
= 29,6497 Btu/hr.ft2.oF
d. Design Overall Coefficient, UD
1 1
Rd (Kern, 1965)
U D UC
Rd diasumsikan 0,001
= 0 00
316
UD = 27,2278 Btu/hr.ft2.oF
e. Required Surface
Q
A =
U D t (Kern, 1965)
=
= 182,3233 ft2
Dari tabel 11 Kern, untuk 1,5-in IPS standard pipe, external surface/foot length =
0,753 ft2.
Required length = = 242,1293 ft
f. Dirt Factor, Rd
Actually Length = 6 x 20 ft x 2
= 240 ft
Actually surface = 240 x 0,753 ft
= 180,72 ft2
UD =
= 27,4694 Btu/hr.ft2.oF
U C U D
Rd =
U C U D
= 0,002677 hr.ft2.oF/Btu
PRESSURE DROP
HOT FLUID: Annulus
a. De’ = (D2 – D1)
= 0,067 ft
Rea = De’.Ga/μ
317
= 25420,6237
0,264
ƒ = 0,0035
(Re a' ) 0, 42
= 0,0035 +
= 0,007
ρ = 0,49 lb/ft3
4 fGa 2 L
b. ΔFa =
2 g 2 De (Felder & Rosseau, 2005)
= 6,1066 ft
Ga
c. Va =
3600
= 8,0959 fps
V 2
d. Fl = jumlah hairpin x
2g (Kern, 1965)
= 1x
= 0,0001
(Fa Fl )
e. ΔPa =
144
( )
=
= 0,2887 Psi
318
0 , 264
ƒ = 0 ,0035 (Re p ) 0 , 42
= 0,0035 +
= 0,0041
ρ = 59,575 b/ft3
4 fGp 2 L
b. ΔFp =
2 g 2 D
= 14,0561 ft
Fp .
c. ΔPp =
144
= 5,8152 Psi
SUMMARY
ho = 139,0035 h outside hio = 37,6889
Uc = 29,6497
UD = 27,4694
RD calculated = 0,0027
RD required = 0,001
0,2887 ∆ P Calculated (psi) 5,8152
10 ∆ P Allowable (psi) 10
319
T2
T1
Tee
Return Head
t2
a. Beban Panas H - 01
Q = 400907,1801 kJ/jam = 2358152,0672 Btu/hr
b. LMTD
Fluida Panas Fluida Dingin Selisih
(oF) (oF)
422,96 (T1) Suhu Tinggi (th) 309,2 (t2) 113,76
422,96 (T2) Suhu Rendah (tc) 197,6 (t1) 255,96
Selisih -111,6
t 2 t1
LMTD
ln t 2 / t1 (Kern, 1965)
LMTD =
( )
320
∆t = 146,926 oF
c. Temperatur rata-rata
Tc = T avg = 0,5 (422,96+422,96) = 422,96 oF
tc = t avg = 0,5 (309,2+197,6) = 253,4o F
A=
A = 144,4491 ft2
Karena A < 200 ft2 , maka dipilih jenis Double Pipe Heat Exchanger
Dari Tabel.10 Kern didapat spesifikasi data :
Rencana Klasifikasi (Kern, 1965)
Data Pipa Annulus Inner Pipe
IPS (in) 3 1,25
SN 40 40
OD (in) 3,5 1,66
ID (in) 3,068 1,38
2
a” (ft /ft) 0,917 0,435
De =
D2
2
D1
2
D1
=
0,256 2
0,036 2
0,036
= 0,334 ft
3. Kecepatan Massa, Ga
Ga = W/aa
=
= 7747,7138 lb/hr.ft2
Pada T = 422,96 oF
μ = 0,038 lb/ft.hr
Rea = De.Ga/μ
=
= 68378,8024
JH = 900 (Kern, 1965)
2 o
k = 0,1915 Btu/hr.ft ( F/ft)
c = 0,7724 Btu/lb.oF
c
1
3
= ( )
k
= 0,535
c. Koefisien perpindahan panas
0 ,14
c
1
3
ho = JH k
De k w (Kern, 1965)
= 900 x 0,573 x 0,535 x 1
= 418,4951 Btu/hr.ft2.oF
ap = D2
4
= (0,115 ft )2
4
= 0,01 ft2
b. Kecepatan Massa, Gp
Gp = w/ap
=
= 1104085,5668 lb/hr.ft2
Pada 253,4oF
μ = 0,064 lb/hr ft
Rep = D.Gp/μ
= 1979826,8105
JH = 1000 (Kern, 1965)
k = 0,0194 Btu/hr.ft2(oF/ft)
c = 1,004 Btu/lb.oF
c
1
3
= ( )
k
= 1,4898
c. Koefisien Perpindahan Panas
0 ,14
c
1
3
hi = JH k
De k w (Kern, 1965)
= 1000 x 1,4898 x 0,076 x 1
= 251,866 Btu/hr.ft2.oF
Koreksi hi pada permukaan OD
hio = hi x ID/OD (Kern, 1965)
= 251,866 x (1,38/1,66) Btu/hr.ft2.oF
= 209,3825 Btu/jam ft2 oF
323
= 139,5584 Btu/hr.ft2.oF
UD = 98,3723 Btu/hr.ft2.oF
f. Required Surface
Q
A =
U D t (Kern, 1965)
= 146,8392 ft2
Dari tabel 11 Kern, untuk 1,0-in IPS standard pipe, external surface/foot length =
0,917 ft2.
Required length = = 160,13 ft
g. Dirt Factor, Rd
Actually Length = 4 x 20 ft x 2
= 160 ft
Actually surface = 160 x 0,917 ft
= 146,72 ft2
UD =
324
= 98,4522 Btu/hr.ft2.oF
U C U D
Rd =
U C U D (Kern, 1965)
= 0,002992 hr.ft2.oF/Btu
PRESSURE DROP
HOT FLUID: Annulus
a. De’ = (D2 – D1)
= 0,117 ft
Rea = De’.Ga/μ
=
= 24007,786
0,264
ƒ = 0,0035
(Re a' ) 0, 42
= 0,0035 +
= 0,007
ρ = 0,49 lb/ft3
4 fGa 2 L
l. ΔFa =
2 g 2 De (Felder & Rosseau, 2005)
= 10,9518 ft
Ga
m. Va =
3600
= 4,3932 fps
325
V 2
d. Fl = jumlah hairpin x
2g (Kern, 1965)
= 4x
= 1,1988
(Fa Fl )
e. Δpa =
144
( )
=
= 0,413 Psi
0 , 264
ƒ = 0 ,0035 (Re p ) 0 , 42
= 0,0035 +
= 0,0043
ρ = 59,575 b/ft3
4 fGp 2 L
b. ΔFp =
2 g 2 D
= 9,3707 ft
Fp .
c. ΔPp =
144
= 3,8768 Psi
326
SUMMARY
ho = 418,4951 h outside hio = 209,3825
Uc = 139,5584
UD = 98,4522
RD calculated = 0,003
RD required = 0,001
0,0413 ∆ P Calculated (psi) 3,8768
10 ∆ P Allowable (psi) 10
T2
T1
Tee
Return Head
t2
:
Fluida Panas : Saturated steam
Flowrate, W1 = 134,3641 kg/jam = 296,2218 lb/hr
T1 = 217,2 oC = 422,96 oF
T2 = 217,2 oC = 422,96 oF
Fluida Dingin : katalis untuk masuk reaktor
Flowrate, W2 = 5199,1737 kg/jam = 11462,2023 lb/hr
t1 = 120oC = 248oF
t2 = 165oC = 329oF
Perhitungan design sesuai dengan literatur pada Donald Q. Kern (1965).
a. Beban Panas H - 01
Q = 851608,333 kJ/jam = 3379455,2315 Btu/hr
327
b. LMTD
Fluida Panas Fluida Dingin Selisih
(oF) (oF)
422,96 (T1) Suhu Tinggi (th) 419 (t2) 3,96
422,96 (T2) Suhu Rendah (tc) 309,2 (t1) 113,76
Selisih -109,8
t 2 t1
LMTD
ln t 2 / t1 (Kern, 1965)
LMTD =
( )
∆t = 32,6995 oF
c. Temperatur rata-rata
Tc = T avg = 0,5 (422,96+422,96) = 422,96 oF
tc = t avg = 0,5 (419+309,2) = 364,1o F
A=
A = 172,2479 ft2
Karena A < 200 ft2 , maka dipilih jenis Double Pipe Heat Exchanger
Dari Tabel.10 Kern didapat spesifikasi data :
Rencana Klasifikasi
Data Pipa Annulus Inner Pipe
IPS (in) 3 1
SN 40 40
OD (in) 3,5 1,32
ID (in) 3,068 1,049
a” (ft2/ft) 0,917 0,344
328
De =
D2
2
D1
2
D1 (Kern, 1965)
=
0,256 2
0,112
0,11
= 0,484 ft
f. Kecepatan Massa, Ga
Ga = W/aa
=
= 7084,3781 lb/hr.ft2
Pada T = 422,96 oF
μ = 0,218 lb/ft.hr
Rea = De.Ga/μ
=
= 15750,5864
JH = 1000 (Kern, 1965)
k = 1,098 Btu/hr.ft2(oF/ft)
c = 0,067 Btu/lb.oF
c
1
3
= ( )
k
= 0,237
329
ho = JH k
De k w (Kern, 1965)
= 1000 x 2,268 x 0,237 x 1
= 1402,9844 Btu/hr.ft2.oF
COLD FLUID: Inner Pipe
a. Flow Area, ap
D = 1,049 inch = 0,087 ft
ap = D2
4
= (0,087 ft )2
4
= 0,006 ft2
b. Kecepatan Massa, Gp
Gp = w/ap
=
= 1910776,6654 lb/hr.ft2
Pada 364,1oF
μ = 0,064 lb/hr ft
Rep = D.Gp/μ
= 2604538,6068
JH = 900 (Kern, 1965)
k = 0,278 Btu/hr.ft2(oF/ft)
c = 1,004 Btu/lb.oF
c
1
3
= ( )
k
= 0,6143
330
= 700,0795 Btu/hr.ft2.oF
UD = 626,1284 Btu/hr.ft2.oF
f. Required Surface
Q
A =
U D t (Kern, 1965)
= 457,6706 ft2
Dari tabel 11 Kern, untuk 1,0-in IPS standard pipe, external surface/foot length =
0,917 ft2.
UD =
= 626,1284 Btu/hr.ft2.oF
331
U C U D
Rd =
U C U D (Kern, 1965)
=
= 0,0169 hr.ft2.oF/Btu
PRESSURE DROP
HOT FLUID: Annulus
b. De’ = (D2 – D1)
= 0,146 ft
Rea = De’.Ga/μ
=
= 4738,098
0,264
ƒ = 0,0035
(Re a' ) 0, 42
= 0,0035 +
= 0,011
ρ = 0,49 lb/ft3
4 fGa 2 L
n. ΔFa =
2 g 2 De (Kern, 1965)
= 12,5271 ft
Ga
o. Va =
3600
= 4,017 fps
332
V 2
d. Fl = jumlah hairpin x
2g (Kern, 1965)
= 9x
= 2,2551
(Fa Fl )
e. Δpa =
144
( )
=
= 0,0503 Psi
0 , 264
ƒ = 0 ,0035 (Re p ) 0 , 42
= 0,0035 +
= 0,004
ρ = 101,785 b/ft3
4 fGp 2 L
b. ΔFp =
2 g 2 D
= 14,0039 ft
Fp .
c. ΔPp =
144
= 9,8985 Psi
333
SUMMARY
ho = 1402,9844 h outside hio = 1397,3449
Uc = 700,0795
UD = 626,1284
RD calculated = 0,0169
RD required = 0,003
0,0503 ∆ P Calculated (psi) 9,8985
10 ∆ P Allowable (psi) 10
T2
T1
Tee
Return Head
t2
b. LMTD
Fluida Panas Fluida Dingin Selisih
(oF) (oF)
422,96 (T1) Suhu Tinggi (th) 197,6 (t2) 255,36
422,96 (T2) Suhu Rendah (tc) 86 (t1) 336,96
Selisih 90 -11,6
t 2 t1
LMTD
ln t 2 / t1 (Kern, 1965)
LMTD =
( )
∆t = 277,429 oF
c. Temperatur rata-rata
Tc = T avg = 0,5 (422,96+422,96) = 422,96 oF
tc = t avg = 0,5 (197+86) = 141,8o F
A=
A = 167,103 ft2
Karena A < 200 ft2 , maka dipilih jenis Double Pipe Heat Exchanger
Dari Tabel.10 Kern didapat spesifikasi data :
Rencana Klasifikasi (Kern, 1965)
Data Pipa Annulus Inner Pipe
IPS (in) 3 2,5
SN 40 40
OD (in) 3,5 2,88
ID (in) 3,068 2,469
a” (ft2/ft) 0,917 0,753
335
De =
D2
2
D1
2
D1 (Kern, 1965)
=
0,256 2
0,24 2
0,24
= 0,032 ft
l. Kecepatan Massa, Ga
Ga = W/aa
= 85897,5189 lb/hr.ft2
Pada T = 422,96 oF
μ = 0,038 lb/ft.hr
Rea = De.Ga/μ
= 73399,454
JH = 1000 (Kern, 1965)
k = 0,97 Btu/hr.ft2(oF/ft)
c = 0,7724 Btu/lb.oF
c
1
3
= ( )
k
= 0,311
336
ho = JH k
De k w (Kern, 1965)
= 1000 x 29,979 x 0,311 x 1
= 20316,48 Btu/hr.ft2.oF
Kecepatan Massa, Gp
Gp = w/ap
=
= 432611,466 lb/hr.ft2
Pada 141,8000oF
μ = 0,061 lb/hr ft
Rep = D.Gp/μ
=
= 1467212,797
JH = 1000 (Kern, 1965)
k = 0,0156 Btu/hr.ft2(oF/ft)
c = 0,384 Btu/lb.oF
c
1
3
= ( )
k
337
= 1,143
c. Koefisien Perpindahan Panas
0 ,14
c
1
3
hi = JH k
De k w (Kern, 1965)
= 1000 x 1,535 x 0,384 x 1
= 86,68 Btu/hr.ft2.oF
= 74,0396 Btu/hr.ft2.oF
Rd diasumsikan 0,001
= 0 00
UD = 60,583 Btu/hr.ft2.oF
f. Required Surface
Q
A =
U D t
= 165,495 ft2
338
Dari tabel 11 Kern, untuk 3-in IPS standard pipe, external surface/foot length =
0,917 ft2.
g. Dirt Factor, Rd
Actually Length = 9 x 10 ft x 4
= 180 ft
Actually surface = 180 x 0,917 ft
= 165,06 ft2
UD =
= 60,7426 Btu/hr.ft2.oF
U C U D
Rd =
U C U D (Kern, 1965)
=
= 0,002957 hr.ft2.oF/Btu
PRESSURE DROP
HOT FLUID: Annulus
c. De’ = (D2 – D1)
= 0,016 ft
Rea = De’.Ga/μ
= 35539,7491
0,264
ƒ = 0,0035
(Re a' ) 0, 42
= 0,0035 +
339
= 0,007
ρ = 56,73 lb/ft3
4 fGa 2 L
p. ΔFa =
2 g 2 De (Felder & Rosseau, 2005)
= 0,7788 ft
Ga
q. Va =
3600
= 13,7583 fps
V 2
d. Fl = jumlah hairpin x
2g (Kern, 1965)
=9x
= 0,0247
(Fa Fl )
e. Δpa =
144
( )
=
= 0,3165 Psi
0 , 264
ƒ = 0 ,0035 (Re p ) 0 , 42
= 0,0035 +
= 0,004
ρ = 56,76 b/ft3
340
4 fGp 2 L
b. ΔFp =
2 g 2 D
= 1,016 ft
Fp .
c. ΔPp =
144
= 0,4005 Psi
SUMMARY
ho = 20316,48 h outside hio = 74,3104
Uc = 74,0396
UD = 60,7426
RD calculated = 0,003
RD required = 0,001
0,3165 ∆ P Calculated (psi) 0,4005
10 ∆ P Allowable (psi) 10
T2
T1
Tee
Return Head
t2
a. Beban Panas H - 02
Q = 400907,1801 kJ/jam = 4506546,0943 Btu/hr
b. LMTD
Fluida Panas Fluida Dingin Selisih
(oF) (oF)
422,96 (T1) Suhu Tinggi (th) 309,2 (t2) 113,76
422,96 (T2) Suhu Rendah (tc) 197,6 (t1) 255,36
Selisih -111,6
t 2 t1
LMTD
ln t 2 / t1 (Kern, 1965)
LMTD =
( )
∆t = 163,251 oF
c. Temperatur rata-rata
Tc = T avg = 0,5 (422,96+422,96) = 422,96 oF
tc = t avg = 0,5 (309,2+197,6) = 253,4o F
Penentuan tipe Heater :
Asumsi UD = 150 Btu/hr.ft2.F
Q
A (Kern, 1965)
U D t
A=
A = 184,033 ft2
Karena A < 200 ft2 , maka dipilih jenis Double Pipe Heat Exchanger
342
De =
D 2
2
D1
2
D1 (Kern, 1965)
=
0,256 2
0,24 2
0,24
= 0,032 ft
n. Kecepatan Massa, Ga
Ga = W/aa
= 84734,3664 lb/hr.ft2
Pada T = 422,96 oF
μ = 0,038 lb/ft.hr
Rea = De.Ga/μ
343
= 72405,54
JH = 900 (Kern, 1965)
k = 0,0191 Btu/hr.ft2(oF/ft)
c = 0,7724 Btu/lb.oF
c
1
3
= ( )
k
= 1,152
c. Koefisien perpindahan panas
0 ,14
c
1
3
ho = JH k
De k w (Kern, 1965)
= 900 x 0,203 x 1,152 x 1
= 558,261 Btu/hr.ft2.oF
b. Kecepatan Massa, Gp
Gp = w/ap
=
= 432611,466 lb/hr.ft2
Pada 253,4oF
μ = 0,061 lb/hr ft
Rep = D.Gp/μ
344
= 1467212,797
JH = 1000 (Kern, 1965)
k = 0,0861 Btu/hr.ft2(oF/ft)
c = 0,384 Btu/lb.oF
c
1
3
= ( )
k
= 0,647
c. Koefisien Perpindahan Panas
0 ,14
c
1
3
hi = JH k
De k w (Kern, 1965)
= 1000 x 0,025 x 1,535 x 1
= 270,866 Btu/hr.ft2.oF
Koreksi hi pada permukaan OD
hio = hi x ID/OD (Kern, 1965)
= 270,866 x (2,469/2,88) Btu/hr.ft2.oF
= 232,211 Btu/jam ft2 oF
= 163,9961 Btu/hr.ft2.oF
UD = 150,5177 Btu/hr.ft2.oF
345
f. Required Surface
Q
A =
U D t (Kern, 1965)
= 251,142 ft2
Dari tabel 11 Kern, untuk 4-in IPS standard pipe, external surface/foot length =
0,917 ft2.
UD =
= 150,5177 Btu/hr.ft2.oF
U C U D
Rd =
U C U D (Kern, 1965)
= 0,00546 hr.ft2.oF/Btu
PRESSURE DROP
HOT FLUID: Annulus
d. De’ = (D2 – D1)
= 0,016 ft
Rea = De’.Ga/μ
=
= 35058,4995
346
0,264
ƒ = 0,0035
(Re a' ) 0, 42
= 0,0035 +
= 0,007
4 fGa 2 L
r. ΔFa =
2 g 2 De (Kern, 1965)
= 0,8428 ft
Ga
s. Va =
3600
= 0,4145 fps
V 2
d. Fl = jumlah hairpin x
2g (Kern, 1965)
= 5x
= 0,0133
(Fa Fl )
e. Δpa =
144
( )
=
= 0,3376 Psi
347
SUMMARY
ho = 558,2609 h outside hio = 232,2109
Uc = 163,9961
UD = 150,5177
RD calculated = 0,005
RD required = 0,001
0,3376 ∆ P Calculated (psi) 0,4449
10 ∆ P Allowable (psi) 10
T2
T1
Tee
Return Head
t2
a. Beban Panas H - 02
Q = 1557535,7637 kJ/jam = 6180801,8792 Btu/hr
348
b. LMTD
Fluida Panas Fluida Dingin Selisih
(oF) (oF)
422,96 (T1) Suhu Tinggi (th) 419 (t2) 3,96
422,96 (T2) Suhu Rendah (tc) 309,2 (t1) 113,76
Selisih -109,8
t 2 t1
LMTD
ln T1 / T2 (Kern, 1965)
LMTD =
( )
∆t = 32,7 oF
c. Temperatur rata-rata
Tc = T avg = 0.5 (422,96+422,96) = 422,96 oF
tc = t avg = 0.5 (329+248) = 364,1o F
A=
A = 189,0181 ft2
Karena A < 200 ft2 , maka dipilih jenis Double Pipe Heat Exchanger
Dari Tabel.10 Kern didapat spesifikasi data :
Rencana Klasifikasi (Kern, 1965)
Data Pipa Annulus Inner Pipe
IPS (in) 3 2,5
SN 40 40
OD (in) 3,5 2,88
ID (in) 3,068 2,469
2
a” (ft /ft) 0,917 0,753
349
De =
D2
2
D1
2
D1 (Kern, 1965)
=
0,256 2
0,24 2
0,24
= 0,032 ft
p. Kecepatan Massa, Ga
Ga = W/aa
= 82695,5183 lb/hr.ft2
Pada T = 422,96 oF
μ = 0,038 lb/ft.hr
Rea = De.Ga/μ
= 70663,344
JH = 1000 (Kern, 1965)
k = 0,98 Btu/hr.ft2(oF/ft)
c = 0,7724 Btu/lb.oF
c
1
3
= ( )
k
= 0,31
350
ho = JH k
De k w (Kern, 1965)
= 1000 x 0,31 x 30,288 x 1
= 20502,55 Btu/hr.ft2.oF
COLD FLUID: Inner Pipe
e. Flow Area, ap
D = 2,469 inch = 0,206 ft
ap = D2
4
= (0,206 ft )2
4
= 0,033 ft2
b. Kecepatan Massa, Gp
Gp = w/ap
=
= 432611,466lb/hr.ft2
Pada 364,1oF
μ = 0,061 lb/hr ft
Rep = D.Gp/μ
= 1467212,797
JH = 1000 (Kern, 1965)
2 o
k = 0,9876 Btu/hr.ft ( F/ft)
c = 0,384 Btu/lb.oF
c
1
3
= ( )
k
= 0,287
351
hi = JH k
De k w (Kern, 1965)
= 1000 x 0,287 x 1,535 x 1
= 1378,772 Btu/hr.ft2.oF
Koreksi hi pada permukaan OD
hio = hi x ID/OD (Kern, 1965)
= 1378,772 x (2,469/2,88) Btu/hr.ft2.oF
= 1182,01 Btu/jam ft2 oF
= 1117,5795 Btu/hr.ft2.oF
e. Design Overall Coefficient, UD
1 1
Rd (Kern, 1965)
U D UC
Rd diasumsikan 0,001
= 0 00
UD = 1030,633 Btu/hr.ft2.oF
f. Required Surface
Q
A =
U D t (Kern, 1965)
=
= 736,186 ft2
Dari tabel 11 Kern, untuk 4-in IPS standard pipe, external surface/foot length =
0,917 ft2.
352
g. Dirt Factor, Rd
Actually Length = 5 x 20 ft x 2
= 200 ft
Actually surface = 200 x 0,917 ft
= 183,4 ft2
UD =
= 1030,633 Btu/hr.ft2.oF
U C U D
Rd =
U C U D (Kern, 1965)
= 0,0075 hr.ft2.oF/Btu
PRESSURE DROP
HOT FLUID: Annulus
a. De’ = (D2 – D1) (Kern, 1965)
= 0,016 ft
Rea = De’.Ga/μ
= 34214,9344
0,264
ƒ = 0,0035
(Re a' ) 0, 42
= 0,0035 +
= 0,007
353
ρ = 55,78lb/ft3
4 fGa 2 L
b ΔFa =
2 g 2 De (Felder & Rosseau, 2005)
= 0,8359 ft
Ga
t. Va =
3600
= 0,4118 fps
V 2
d. Fl = jumlah hairpin x
2g (Kern, 1965)
= 4x
= 0,0132
(Fa Fl )
e. Δpa =
144
( )
=
= 0,3289 Psi
COLD FLUID: Inner Pipe
i. Rep = 1467212,797
0 , 264
0 , 0035
ƒ = (Re p ) 0 , 42
= 0,0035 +
= 0,004
ρ = 55,78 b/ft3
4 fGp 2 L
1. ΔFp =
2 g 2 D (Felder & Rosseau, 2005)
= 1,169 ft
354
Fp .
c. ΔPp =
144
= 0,4528 Psi
SUMMARY
ho = 20502,55 h outside hio = 1182,0101
Uc = 1117,5795
UD = 1030,633
RD calculated = 0,0075
RD required = 0,001
0,3289 ∆ P Calculated (psi) 0,4528
10 ∆ P Allowable (psi) 10
T2
T1
Tee
: Return Head
t2
Fluida Panas : Saturated steam
Flowrate, W1 = 199,7135 kg/jam = 440,2925 lb/hr
T1 = 217,2 oC = 422,96 oF
T2 = 217,2 oC = 422,96 oF
Fluida Dingin : Output MP-02 dan feed metanol untuk masuk reaktor
Flowrate, W2 = 7516,8824 kg/jam = 16571,8692 lb/hr
o
t1 = 3C = 100,4oF
t2 = 92oC = 177,8oF
355
a. Beban Panas H - 03
Q = 583819,5024 kJ/jam = 2316783,1916 Btu/hr
b. LMTD
Fluida Panas Fluida Dingin Selisih
(oF) (oF)
422,9600 (T1) Suhu Tinggi (th) 197,6 (t2) 222,36
422,9600 (T2) Suhu Rendah (tc) 86 (t1) 336,96
Selisih -111,6
t 2 t1
LMTD
ln t 2 / t1
LMTD =
( )
∆t = 249,686 oF
c. Temperatur rata-rata
Tc = T avg = 0,5 (422,96+422,96) = 422,96 oF
tc = t avg = 0,5 (197,6+86) = 141,8o F
A=
A = 167,018 ft2
Karena A < 200 ft2 , maka dipilih jenis Double Pipe Heat Exchanger
Dari Tabel.10 Kern didapat spesifikasi data :
356
Rencana Klasifikasi
Data Pipa Annulus Inner Pipe
IPS (in) 3 2,5
SN 40 40
OD (in) 3,5 2,88
ID (in) 3,068 2,469
a” (ft2/ft) 0,917 0,753
De =
D 2
2
D1
2
D1
=
0,256 2
0,24 2
0,24
= 0,032 ft
e. Kecepatan Massa, Ga
Ga = W/aa
=
= 72227,951 lb/hr.ft2
Pada T = 422,96 oF
μ = 0,038 lb/ft.hr
Rea = De.Ga/μ
357
= 50785,759
JH = 1000
k = 0,067 Btu/hr.ft2(oF/ft)
c = 0,7724 Btu/lb.oF
c
1
3
= ( )
k
= 0,759
c. Koefisien perpindahan panas
0 ,14
c
1
3
k
ho = JH
De k w
= 1000 x 2,071 x 0,759 x 1
= 1570,776 Btu/hr.ft2.oF
b. Kecepatan Massa, Gp
Gp = w/ap
= 498680,232 lb/hr.ft2
Pada 141,8 oF
μ = 0,039 lb/hr ft
Rep = D.Gp/μ
358
= 2649882,688
JH = 1000
k = 0,0167 Btu/hr.ft2(oF/ft)
c = 0,29 Btu/lb.oF
c
1
3
= ( )
k
= 0,876
c. Koefisien Perpindahan Panas
0 ,14
c
1
3
k
hi = JH
De k w
= 1000 x 0,876 x 1,023 x 1
= 71,117 Btu/hr.ft2.oF
Koreksi hi pada permukaan OD
hio = hi x ID/OD
= 71,117 x (2,469/2,88) Btu/hr.ft2.oF
= 60,968 Btu/jam ft2 oF
= 58,69 Btu/hr.ft2.oF
Rd diasumsikan 0,001
= 0 00
359
UD = 50,5931 Btu/hr.ft2.oF
f. Required Surface
Q
A =
U D t
= 167,3412 ft2
Dari tabel 11 Kern, untuk 3-in IPS standard pipe, external surface/foot length =
0,917 ft2.
Required length = = 182,488 ft
g. Dirt Factor, Rd
Actually Length = 9 x 10 ft x 2
= 180 ft
Actually surface = 180 x 0,917 ft
= 165,06 ft2
UD =
= 50,5931 Btu/hr.ft2.oF
U C U D
Rd =
U C U D
= 0,0027 hr.ft2.oF/Btu
PRESSURE DROP
HOT FLUID: Annulus
a. De’ = (D2 – D1)
= 0,0016 ft
Rea = De’.Ga/μ
=
360
= 29884,021
0,264
ƒ = 0,0035
(Re a' ) 0, 42
= 0,0035 +
= 0,007
ρ = 56,73 lb/ft3
4 fGa 2 L
g. ΔFa =
2 g 2 De
= 0,5706 ft
Ga
Va =
3600
= 0,3537 fps
V 2
d. Fl = jumlah hairpin x
2g
=9x
= 0,0155
(Fa Fl )
e. Δpa =
144
( )
=
= 0,2309 Psi
361
0 , 264
ƒ = 0 ,0035 (Re p ) 0 , 42
= 0,0035 +
= 0,004
ρ = 9,889 b/ft3
4 fGp 2 L
1. ΔFp =
2 g 2 D
= 42,8929 ft
Fp .
c. ΔPp =
144
= 2,9456 Psi
SUMMARY
ho = 1570,776 h outside hio = 60,968
Uc = 58,69
UD = 50,5931
RD calculated = 0,0027
RD required = 0,001
0,2309 ∆ P Calculated (psi) 2,946
10 ∆ P Allowable (psi) 10
362
Fungsi : Menaikkan suhu recycle dan feed metanol dari MP-02 ke reaktor
Tipe : Double Pipe Heat Exchanger
Gambar
t1
Gland
Return bend Gland
Gland
T2
: T1
Tee
Return Head
t2
LMTD =
( )
363
∆t = 163,251 oF
c. Temperatur rata-rata
Tc = T avg = 0,5 (422,96+422,96) = 422,96 oF
tc = t avg = 0,5 (255,36+113,76) = 253,4o F
A=
A = 175,235 ft2
Karena A < 200 ft2 , maka dipilih jenis Double Pipe Heat Exchanger
Dari Tabel.10 Kern didapat spesifikasi data :
Rencana Klasifikasi
Data Pipa Annulus Inner Pipe
IPS (in) 4 3
SN 40 40
OD (in) 4,5 3,5
ID (in) 4,062 3,068
2
a” (ft /ft) 1,178 0,917
Equivalent Diameter
De =
D2
2
D1
2
D1
=
0,3355 2
0,2917 2
0,2917
= 0,0943 ft
j. Kecepatan Massa, Ga
Ga = W/aa
= 26063,527 lb/hr.ft2
Pada T = 422,96 oF
μ = 0,038 lb/ft.hr
Rea = De.Ga/μ
= 64877,035
JH = 320
k = 0,203 Btu/hr.ft2(oF/ft)
c = 0,7724 Btu/lb.oF
c
1
3
= ( )
k
= 0,524
c. Koefisien perpindahan panas
0 ,14
k c
1
3
ho = JH
De k w
= 320 x 2,154 x 0,524 x 1
= 361,298 Btu/hr.ft2.oF
365
b. Kecepatan Massa, Gp
Gp = w/ap
=
= 322963,633 lb/hr.ft2
Pada 253,4oF
μ = 0,039 lb/hr ft
Rep = D.Gp/μ
= 2132516,413
JH = 1000
k = 0,6712 Btu/hr.ft2(oF/ft)
c = 0,29 Btu/lb.oF
c
1
3
= ( )
k
= 0,256
c. Koefisien Perpindahan Panas
0 ,14
k c
1
3
hi = JH
De k
w
= 1000 x 0,256 x 1,023 x 1
= 672,353 Btu/hr.ft2.oF
Koreksi hi pada permukaan OD
366
hio = hi x ID/OD
= 672,353x (3,0680/3,5000) Btu/hr.ft2.oF
= 589,365 Btu/jam ft2 oF
= 223,9874 Btu/hr.ft2.oF
UD = 139,4594 Btu/hr.ft2.oF
f. Required Surface
Q
A =
U D t
= 196,2077 ft2
Dari tabel 11 Kern, untuk 3-in IPS standard pipe, external surface/foot length =
1,178 ft2.
Required length = = 166,56 ft
g. Dirt Factor, Rd
Actually Length = 4 x 20 ft x 2
= 160 ft
Actually surface = 160 x 1,178 ft
367
= 188.48 ft2
UD =
= 139,4594 Btu/hr.ft2.oF
U C U D
Rd =
U C U D
= 0,0027 hr.ft2.oF/Btu
PRESSURE DROP
HOT FLUID: Annulus
a. De’ = (D2 – D1)
= 0,0438 ft
Rea = De’.Ga/μ
= 30171,356
0,264
ƒ = 0,0035
(Re a' ) 0, 42
= 0,0035 +
= 0,007
ρ = 56,73 lb/ft3
4 fGa 2 L
l. ΔFa =
2 g 2 De
= 0,0303 ft
Ga
Va =
3600
368
= 0,1276 fps
V 2
d. Fl = jumlah hairpin x
2g
=4x
= 0,001
(Fa Fl )
e. Δpa =
144
( )
=
= 0,0123 Psi
COLD FLUID: Inner Pipe
i. Rep = 2132516,413
0 , 264
ƒ = 0 ,0035
(Re p ) 0 , 42
= 0,0035 +
= 0,004
ρ = 9,889 b/ft3
4 fGp 2 L
1. ΔFp =
2 g 2 D
= 13,0310 ft
Fp .
c. ΔPp =
144
= 0,8949 Psi
369
SUMMARY
ho = 361,298 h outside hio = 589,356
Uc = 223,9874
UD = 139,4594
RD calculated = 0,0027
RD required = 0,001
0,0123 ∆ P Calculated (psi) 0,895
10 ∆ P Allowable (psi) 10
Fungsi : Menaikkan suhu recycle dan feed metanol dari MP-02 ke reaktor
Tipe : Double Pipe Heat Exchanger
Gambar :
t1
Gland
Return bend Gland
Gland
T2
: T1
Tee
Return Head
t2
a. Beban Panas H - 03
Q = 1646090 kJ/jam = 6532216,4068 Btu/hr
b. LMTD
Fluida Panas Fluida Dingin Selisih
(oF) (oF)
422,9600 (T1) Suhu Tinggi (th) 419 (t2) 3,96
422,9600 (T2) Suhu Rendah (tc) 309,2 (t1) 113,76
Selisih -109,8
t 2 t1
LMTD
ln t 2 / t1
LMTD =
( )
∆t = 32,7 oF
c. Temperatur rata-rata
Tc = T avg = 0,5 (422,96+422,96) = 422,96 oF
tc = t avg = 0,5 (255,2+332,6) = 293,9o F
A=
A = 199,765 ft2
Karena A < 200 ft2 , maka dipilih jenis Double Pipe Heat Exchanger
Dari Tabel.10 Kern didapat spesifikasi data :
371
Rencana Klasifikasi
Data Pipa Annulus Inner Pipe
IPS (in) 4 3
SN 40 40
OD (in) 4,5 3,5
ID (in) 4,062 3,068
a” (ft2/ft) 1,178 0,917
Equivalent Diameter
De =
D 2
2
D1
2
D1
=
0,3355 2
0,292 2
0,292
= 0,094 ft
o. Kecepatan Massa, Ga
Ga = W/aa
= 31754,918 lb/hr.ft2
Pada T = 422,96oF
μ = 0,038 lb/ft.hr
Rea = De.Ga/μ
372
= 79043,979
JH = 1000
k = 9,76 Btu/hr.ft2(oF/ft)
c = 0,7724 Btu/lb.oF
c
1
3
= ( )
k
= 1,152
c. Koefisien perpindahan panas
0 ,14
c
1
3
k
ho = JH
De k w
= 1000 x 0,203 x 1,152 x 1
= 14928,582 Btu/hr.ft2.oF
b. Kecepatan Massa, Gp
Gp = w/ap
= 322963,633 lb/hr.ft2
Pada 364,1oF
μ = 0,039 lb/hr ft
Rep = D.Gp/μ
373
= 213516,413
JH = 1000
k = 2,378 Btu/hr.ft2(oF/ft)
c = 0,29 Btu/lb.oF
c
1
3
= ( )
k
= 0,168
c. Koefisien Perpindahan Panas
0 ,14
c
1
3
k
hi = JH
De k w
= 1000 x 0,203 x 1,023 x 1
= 1563,22 Btu/hr.ft2.oF
Koreksi hi pada permukaan OD
hio = hi x ID/OD
= 1563,22 x (3,068/3,5) Btu/hr.ft2.oF
= 1370,274 Btu/jam ft2 oF
= 1255,0729 Btu/hr.ft2.oF
UD = 1059,873 Btu/hr.ft2.oF
374
f. Required Surface
Q
A =
U D t
= 758,4606 ft2
Dari tabel 11 Kern, untuk 2,5-in IPS standard pipe, external surface/foot length =
1,178 ft2.
g. Dirt Factor, Rd
Actually Length = 4 x 20 ft x 2
= 160 ft
Actually surface = 160 x 1,178 ft
= 188,48 ft2
UD =
= 1059,873 Btu/hr.ft2.oF
U C U D
Rd =
U C U D
= 0,0017 hr.ft2.oF/Btu
PRESSURE DROP
HOT FLUID: Annulus
a. De’ = (D2 – D1)
= 0,044 ft
Rea = De’.Ga/μ
= 36759,757
375
0,264
ƒ = 0,0035
(Re a' ) 0, 42
= 0,0035 +
= 0,007
ρ = 56,73 lb/ft3
4 fGa 2 L
q. ΔFa =
2 g 2 De
= 0,0431 ft
Ga
Va =
3600
= 0,1555 fps
V 2
d. Fl = jumlah hairpin x
2g
=4x
= 0,0026
(Fa Fl )
e. Δpa =
144
( )
=
= 0,018 Psi
COLD FLUID: Inner Pipe
i. Rep = 2132516,413
0 , 264
0 , 0035
ƒ = (Re p ) 0 , 42
376
= 0,0035 +
= 0,004
ρ = 9,889 b/ft3
4 fGp 2 L
1. ΔFp =
2 g 2 D
= 13,031 ft
Fp .
c. ΔPp =
144
= 0,8949 Psi
SUMMARY
ho = 14928,58 h outside hio = 1370,274
Uc = 1255,0729
UD = 1059,873
RD calculated = 0,0017
RD required = 0,001
0,018 ∆ P Calculated (psi) 0,895
10 ∆ P Allowable (psi) 10
T2
: T1
Tee
Return Head
t2
377
t 2 t1
LMTD
ln t 2 / t1 (Kern, 1965)
LMTD =
( )
∆t = 37,421 oF
c. Temperatur rata-rata
Tc = T avg = 0,5 (422,96+422,96) = 422,96 oF
tc = t avg = 0,5 (419+226) = 345,5o F
A=
A = 72,864 ft2
Karena A < 200 ft2 , maka dipilih jenis Double Pipe Heat Exchanger
Dari Tabel.10 Kern didapat spesifikasi data :
Rencana Klasifikasi
Data Pipa Annulus Inner Pipe
IPS (in) 4 3
SN 40 40
OD (in) 4,5 3,5
ID (in) 4,026 3,068
2
a” (ft /ft) 1,178 0,917
De =
D 2
2
D1
2
D1 (Kern, 1965)
=
0,336 2
0,292 2
0,292
= 0,094 ft
5. Kecepatan Massa, Ga
Ga = W/aa
379
= 58,783 lb/hr.ft2
Pada T = 422,96 oF
μ = 0,038 lb/ft.hr
Rea = De.Ga/μ
= 146,322
JH = 320 (Kern, 1965)
k = 0,0191 Btu/hr.ft2(oF/ft)
c = 0,7724 Btu/lb.oF
c
1
3
= ( )
k
= 1,152
c. Koefisien perpindahan panas
0 ,14
c
1
3
ho = JH k
De k w (Kern, 1965)
= 320 x 0,203 x 1,152 x 1
= 74,865 Btu/hr.ft2.oF
= 39755,164 lb/hr.ft2
Pada 302,0000oF
μ = 0,214 lb/hr ft
Rep = D.Gp/μ
= 47528,708
JH = 1000 (Kern, 1965)
2 o
k = 0,0001 Btu/hr.ft ( F/ft)
c = 0,309 Btu/lb.oF
c
1
3
= ( )
k
= 7,681
c. Koefisien Perpindahan Panas
0 ,14
c
1
3
hi = JH k
De k w (Kern, 1965)
= 1000 x 0,203 x 7,681 x 1
= 7,681 Btu/hr.ft2.oF
Koreksi hi pada permukaan OD
hio = hi x ID/OD
= 7,681 x (3,068/3,5) Btu/hr.ft2.oF
= 3,818 Btu/jam ft2 oF
= 3,6327 Btu/hr.ft2.oF
e. Design Overall Coefficient, UD
1 1
Rd (Kern, 1965)
U D UC
381
Rd diasumsikan 0,001
= 0 00
UD = 3,6081 Btu/hr.ft2.oF
f. Required Surface
Q
A =
U D t (Kern, 1965)
= 70,9662 ft2
Dari tabel 11 Kern, untuk 0,5-in IPS standard pipe, external surface/foot length =
1,178 ft2.
Required length = = 60,243 ft
g. Dirt Factor, Rd
Actually Length = 3 x 10 ft x 2
= 60 ft
Actually surface = 60 x 0,22 ft
= 70,68 ft2
UD =
= 3,6081 Btu/hr.ft2.oF
U C U D
Rd =
U C U D (Kern, 1965)
=
= 0,0019 hr.ft2.oF/Btu
PRESSURE DROP
HOT FLUID: Annulus
a. De’ = (D2 – D1)
= 0,044 ft
382
Rea = De’.Ga/μ
= 68,048
0,264
ƒ = 0,0035
(Re a' ) 0, 42
= 0,0035 +
= 0,048
ρ = 0,067 lb/ft3
4 fGa 2 L
u. ΔFa =
2 g 2 De (Felder & Rosseau, 2005)
= 0,2872 ft
Ga
v. Va =
3600
= 0,2437 fps
V 2
d. Fl = jumlah hairpin x
2g (Kern, 1965)
= 1x
= 5,2103 x 10-8
(Fa Fl )
e. Δpa =
144
( )
=
= 0,0001 Psi
COLD FLUID: Inner Pipe
a. Rep = 47528,708
383
0 , 264
ƒ = 0 ,0035 (Re p ) 0 , 42
= 0,0035 +
= 0,006
ρ = 12,808 b/ft3
4 fGp 2 L
b. ΔFp =
2 g 2 D
= 0,0689 ft
Fp .
c. ΔPp =
144
= 0,0061 Psi
SUMMARY
ho = 74,865 h outside hio = 3,818
Uc = 3,6237
UD = 3,6081
RD calculated = 0,0028
RD required = 0,001
0,0001 ∆ P Calculated (psi) 0,006
10,000 ∆ P Allowable (psi) 10,000
Gambar :
CD-01
14
15
ACC-01
KD-01
21
P = 1,5 atm
T = 115 C
13
19
18
20
RB-01
Steam
B. Perhitungan Disain
1) Menentukan kondisi operasi.
Dengan Trial and Error, didapatkan kondisi operasi :
a. Feed
P = 1,5 atm = 1140 mmHg
T = 115 oC = 388,15 oK
Komposisi :
Total 1 18395,5629
385
b. Top
P = 1,4 atm = 1064 mmHg
T = 94 oC = 367,15 oK
Komposisi :
c. Middle
P = 1,52 atm = 11552,2000 mmHg
T = 117 oC = 390,150 oK
Komposisi :
Total 14249,4437 1 1
386
d. Bottom
P = 1,55 atm = 1178 mmHg
T = 125,4 oC = 398,15 oK
Komposisi :
Total 528,7431 1 1
= √( ) = 6,9033
Menentukan Minimum Stage
Dengan menggunakan metode Fenske (Winkle, 1967)
Log x LK / x HK D x x HK / x LK B
NM
Log ( Avg )
Log 0,0018 x 1444400)
Log (6,9033)
= 4,0681
b) Pada Top – Middle - Feed
Menentukan Volatilitas Relatif, α
Light Key : Metil Iodida
Heavy Key : Asam Asetat
K LK
(Ludwig, 1997)
K HK
αD = KLK / KHK
= 3,1082/0,3255
= 9,549
αB = KLK / KHK
= 4,6914 / 0,6101
= 7,6896
= 8,569
Menentukan Minimum Stage
Dengan menggunakan metode Fenske (Winkle, 1967)
Log y LK / y HK D x x HK / x LK B
NM
Log ( Avg )
= 2,1393
388
Metanol 0 0 6,0164 0 0
Metil Iodida 0,0487 0,4763 7,6895 0,0605 0,5916
Air 0,2354 0,3039 1,8209 1,3275 1,7139
Asam Asetat 0,7003 0,0692 1 -1,4063 -0,1389
Asetaldehida 0,0062 0,0615 14,5929 0,0069 0,0685
Metil Asetat 0,0093 0,0891 5,9442 0,0124 0,1191
Hidrogen 0 0 17,5414 0 0
(L/D)m = 2,3541– 1
= 1,3541
(L/D) = 1,25 x (L/D)m
= 1,25 x 1,3541
= 1,6926
N Nm
0,1257 (dari grafik 5.18 Van Winkle)
N 1
N – 11,767 = 0,620 N + 0,620
N teori = 11,4202 stage
Menentukan lokasi feed di KD -01
Feed ditentukan dengan menggunakan metode Kirkbride.
m F X X LK F
2
Log = 0,206 Log
HK
p
LK
D X M X HK D
m
Log = -0,1699
p
m
= 0,6762
p
m = 0,6762 p
N Teoritical = m+p (Treyball, 1980)
11,4202 = 0,6762 p + p
p = 6,8133
m = 4,6069
Dari perhitungan diketahui :
m (Rectifying section ) = 4,6069 tray
p (Striping section) = 6,8133 tray
N Nm
0,5 (dari grafik 5.18 Van Winkle)
N 1
m
= 0,5028
p
m = 0,5028 p
N Teoritical = m+p (Ludwig, 1997)
6,5982 = 0,5082 p + p
p = 4,3907
m = 2,2075
maka, :
Total tray pada KD-01 = 11,2052 + 6,8133
= 18,0184tray
Feed masuk = pada tray 6,8133
≈ tray 7 dari bottom KD-01
Side Stream keluar = pada tray 2,2075
≈ tray 3 dari top KD-01
Bagian Top (Rectifying) = 2,2075 +4,6069 + 4,0464
= 11,4202 tray ≈ 12 tray
Bagian bottom (Stripping) = 6,8133 tray ≈ 7 tray
Jumlah tray antara side stream dengan feed plate
= 4,6069 – 2,2075 = 2,3994 tray ≈ 3 tray
b) Diameter kolom
0, 2
K1* = K1
20
0, 2
0,0300
= 0,0580
0.02
= 0,0319
Kecepatan Flooding (uf )
44,6180 15,9877
= 0,0319
15,9877
= 0,0426 m/s
Desain untuk 85 % flooding pada maksimum flow rate ( u )
u = 0,85 . uf (Coulson & Richardson, 2003)
= 0,85 . 0,0426 m/s = 0,0362 m/s
Maksimum laju alir volumetric (Uvmaks)
V
Uvmaks = (Coulson & Richardson, 2003)
V . 3600
393
= 8062,5235 kg/jam
15,230 kg / m 3 . 3600
= 0,1401 m3/s
Net area yang dibutuhkan (An)
An = U V maks
(Coulson & Richardson, 2003)
u
3
= 0,297 m / s
0,0401 m / s
= 3,8656 m2
Cross sectional area dengan 12 % downcomer area (Ac)
Asumsi diambil sebesar 12 % berdasarkan rekomendasi pada buku
Chemical Engineering, vol. 6, Coulson, p. 568
An
Ac = (Coulson & Richardson, 2003)
1 0,12
3,8656 m 2
=
1 0,12
= 4,3928 m2
Diameter kolom (Dc)
4 Ac
Dc = (Coulson & Richardson, 2003)
3,14
4 (4,3928m 2 )
=
3,14
= 2,3656 m
c) Desain plate
Diameter kolom (Dc) = 2,3656 m
Luas area kolom (Ac)
Dc 2 . 3,14
Ac = (Coulson & Richardson, 2003)
4
(2,3656) 2 . 3,14
=
4
394
= 4,3928 m2
Downcomer area (Ad)
Ad = persen downcomer x Ac (Coulson & Richardson, 2003)
= 0,12 (4,3928 m2)
= 0,5271 m2
Net area (An)
An = Ac – Ad
= 4,3928 m2 - 0,5271 m2 = 3,8656 m2
Active area (Aa)
Aa = Ac – 2 Ad (Coulson & Richardson, 2003)
= 4,3928 m2 – 2 (0,5271 m2)
= 3,3385 m2
Hole area (Ah)
Ditetapkan 10% dari Aa berdasarkan rekomendasi pada buku
Chemical Engineering, vol. 6, Coulson, p. 568
Ah = 10 % . Aa
= 0,1 (3,3385 m2)
= 0,3339 m2
Nilai weir length (Iw)
Ditentukandari figure 11.31, Coulson vol 6
Ad
Ordinat = x 100
Ac
2
= 0,5271 m2 100 = 12
4,3928 m
Iw
Absisnya = = 0,770
Dc
Sehingga :
Iw = Dc . 0,77
= 2,3656 m . 0,77
= 1,8215 m
395
Penentuan nilai weir height (hw), hole diameter (dh), dan plate
thickness, (nilai ini sama untuk kolom atas dan kolom bawah)
Weir height (hw) = 50 mm
Nilai weir height direkomendasikan pada buku Chemical
Engineering, vol. 6, Coulson, p. 571
Hole diameter (dh) = 5 mm
Ukuran tersebut merupakan preferred size sesuai rekomendasi
pada buku Chemical Engineering, vol. 6, Coulson, p. 573
Plate thickness = 5 mm (untuk carbon steel)
d) Pengecekan
a. Check weeping
Maximum liquid rate (Lmmax)
L
Lmmax =
3600
5068,1852 kg/jam
=
3600
= 1,4078 kg/det
Minimum liqiud rate (Lmmin)
Minimum liquid rate pada 70 % liquid turn down ratio
Lmmin = 0,7 Lmmax (Coulson & Richardson, 2003)
= 0,7 (1,4078 kg/det)
= 0,9855 kg/det
Weir liquid crest (how)
2
Lm 3
how = 750 (Coulson & Richardson, 2003)
l Iw
2
Lm, maks 3
howmaks = 750
l Iw
2
1,4078 kg / det 3
= 750 3
5068,1852 kg / m x 1,8215 m
= 50,2116 mm liquid
396
2
Lm, min 3
howmin = 750
l Iw
2
0,9855 kg / det 3
= 750 3
44,6180 kg / m x 1,8215 m
= 39,5855 mm liquid
Pada rate minimum
hw + how = 50 mm + 39,5855 mm
= 89,5855 mm
Dari figure 11.30 Coulson ed 6
K2 = 30,5
Minimum design vapour velocity (ŭh)
2003)
= 151,0183 m/s
Actual minimum vapour velocity (Uv,min actual)
min imum vapour rate
Uvmin actual = (Couldson..Eq.11.84)
Ah
0,7 x0,1401
= = 0,2937 m/s
0,3339
Ah Ah
= = 0,1
Ap Aa
Ah
x 100 = 10
Ap
Sehingga didapat nilai Orifice coeficient (Co) = 0,84
Dry plate drop (hd)
2
Uh
hd = 51 V
Co L
= 4,5598 mm liquid
Residual head (hr)
12,5 .10 3
hr = (Coulson & Richardson, 2003)
L
= 280,1561 mm liqiud
Karena nilai Aap lebih kecil dari nilai Ad, maka nilai Aap yang
digunakan pada perhitungan head loss di downcomer (hdc)
Head loss in the downcomer (hdc)
2
Lm, max
hdc = 166 (Coulson..Eq.11.92)
L Aap
= 31,1327 mm
Back up di downcomer (hb)
Hb = (hw + how) + ht + hdc (Coulson..p.474)
= 495,0197 mm = 0,4950 m
d. Check resident time (tr)
Ad hb L
tr =
Lm, maks
= 8,2699 s
Ketentuan bahwa nilai tr harus lebih besar dari 3 s, telah terpenuhi
e. Check Entrainment
Persen flooding actual.
Uv maks
uv = (Couldson..p.474)
An
= 0,0362 m/s
uv
% flooding = x100 (Coulson..p.474)
uf
= 85,000 %
Untuk nilai FLV = 0,03763 dari figure 11.29 Coulson p.475 didapat
nilai ψ = 0,0450. Ketentuan bahwa nilai ψ harus kecil dari 0,1
terpenuhi.
e) Trial plate layout
Digunakan plate type cartridge, dengan 50 mm unperforted strip
mengelilingi pinggir plate dan 50 mm wide calming zones.
399
Iw
Dari figure 11.32 Coulson ed 6 pada = 0,77
Dc
Di dapat nilai θC = 102o
Sudut subtended antarapinggir plate dengan unperforated strip (θ)
θ = 180 - θC (Coulson..p.475)
= 180 – 102
= 78o
Mean length, unperforated edge strips (Lm)
Lm = Dc hw x 3,14 (Coulson..p.475)
180
= 3,1507 m
Area of unperforated edge strip (Aup)
Aup = hw . Lm (Couldson..p.475)
-3
= 50 x 10 . 3,1507
= 0,1575 m2
Mean length of calming zone (Lcz)
= 1,8 m
Area of calming zone (Acz)
Acz = 2 (Lcz . hw) (Coulson..p.475)
= 0,18 m2
Total area perforated (Ap) (Coulson..p.475)
Ap = Aa – (Aup + Acz)
= 3,1507 – (0,1575 + 0,18)
= 3,001 m2
Dari figure 11.33 Coulson ed 6 di dapat nilai Ip/dh = 2,87 untuk nilai
Ah/Ap = 0,119. Nilai Ip/dh harus berada dalam range 2,5 – 4.0.
(Couldson hal 573)
Jumlah holes
Area untuk 1 hole (Aoh)
400
dh 2
Aoh = 3,14 (Couldson..p.475)
4
(5 x10 3 ) 2
= 3,14
4
= 0,000019625 m2
Ah
Jumlah holes = (Couldson..p.475)
Aoh
0,3339
Jumlah holes =
0,000019625
= 17011,5047
= 17012 holes
= 0,028 in
Maka :
P. R
ds
S . E 0, 6 P
C
0
00
( 00 0 ) − (0 0 )
= 0,3823 in
= 0,0097 m
g) Outside Diameter, OD
OD = IDtop + 2tsilinder
= 2,3656 + 2(0,0097) = 2,385 m
3) Desain kolom bagian bawah (Striping section)
a) Data fisik untuk rectifying section
q = 1
L ' L
q = (Treyball, Eq.9.126)
F
V’ = V ( q 1 ) F (Treyball, Eq.9.127)
L’ = F + L
= 8461,715 kg/jam
= 2,3505 kg/det
V’ = V
= 7910,0137 Kg/jam
= 2,1972 kg/det
b) Diameter kolom
Liquid –Vapour Flow Factor (FLV)
0, 2
K1* = K1
20
0, 2
0,0002
= 0,0560
20
= 0,0230
Kecepatan Flooding (uf )
uf = K1 * L V (Coulson. Eq.11.81)
V
= 0,0379 m/s
Desain untuk 85 % flooding pada maksimum flow rate ( u )
u = 0,85 . uf (Coulson. p.472)
= 0,85 . 0,0379 m/s
= 0,0322 m/s
Maksimum volumetric flow rate (Uvmaks)
V
Uvmaks = (Coulson. p.472)
V . 3600
= 0,1363 m3/s
Net area yang dibutuhkan (An)
403
An = U V maks
(Coulson. p.472)
u
0,1363 m 3 / s
=
0,0322 m / s
= 4,2312 m2
Cross section area dengan 12 % downcormer area (Ac)
Asumsi diambil sebesar 12 % berdasarkan rekomendasi pada buku
Chemical Engineering, vol. 6, Coulson, p. 568
An
Ac = (Coulson. p.472)
1 0,12
4,2312 m 2
=
1 0,12
= 4,8082 m2
Diameter kolom (Dc)
4 Ac
Dc = (Coulson & Richardson, 2003)
3,14
= 4 (4,8082 m 2 )
3,14
= 2,4749 m
c) Desain plate
Diameter kolom (Dc) = 2,4749 m
Luas area kolom (Ac)
2
Ac = Dc . 3,14
4
(2,4749 )2 . 3,14
=
4
= 4,8082 m2
Downcomer area (Ad)
Ad = persen downcomer x Ac (Coulson. p.473)
= 0,12 (4,8082 m2)
404
= 0,5770 m2
Net area (An)
An = Ac – Ad
= 4,8082 m2 - 0,5770 m2
= 4,2312 m2
Active area (Aa)
Aa = Ac – 2 Ad (Coulson. p.473)
2 2
= 4,8082 m – 2 (4,2312 m )
= 3,6542 m2
Hole area (Ah) ditetapkan 10% dari Aa berdasarkan rekomendasi pada
buku Chemical Engineering, vol. 6, Coulson, p. 568
Ah = 10 % . Aa
= 0,1 . 3,6542 m2 = 0,3654 m2
Nilai weir length (Iw) ditentukandari figure 11.31, Coulson ed 6
Ad
Ordinat = x 100 = 12
Ac
Iw
Absis = = 0,77
Dc
Sehingga :
Iw = Dc . 0,77
= 1,9057 m
Penentuan nilai weir height (hw) , hole diameter (dh), dan plate
thickness, (nilai ini sama untuk kolom atas dan kolom bawah)
Weir height (hw) = 50 mm (Coulson. p.571)
Hole diameter (dh) = 5 mm (Coulson. p.573)
Plate thickness = 5 mm (Coulson. p.573)
d) Pengecekan
a. Check weeping
Maximum liquid rate (Lmmax)
= 2,3505 kg/det
Minimum liqiud rate (Lmmin)
Minimum liquid rate pada 70 % liquid turn down ratio
Lmmin = 0,7 Lmmax (Coulson. p.473)
= 0,7 (2,3505 kg/det)
= 1,6453 kg/det
Weir liquid crest (how)
2
Lm 3
how = 750 (Coulson. Eq.11.85)
l Iw
2
= 56,4136 mm liquid
2
= 151,9072 m/s
Actual minimum vapour velocity (Uvmin actual)
Diperoleh nilai Uvmin actual lebih kecil dari Uh, maka weeping tidak
terjadi.
Ah Ah
= = 0,1
Ap Aa
Ah
x 100 = 10
Ap
Sehingga di dapat nilai Orifice coeficient (Co) = 0,8 4
Dry plate drop (hd)
2
Uh
hd = 51 V (Coulson..Eq.11.88)
Co L
= 2,7108 mm liquid
Residual head (hr)
hr = 12,5 .10 3 (Coulson..Eq.11.89)
L
3
= 12,5 .10
59,7896
= 209,0665 mm liquid
Total pressure drop (ht)
ht = hd + (hw + how) + hr (Coulson..p.474)
= 306,2523 mm liquid
Ketentuan bahwa nilai ht harus lebih besar dari 100 mm liquid
telah terpenuhi. (Coulson..p.474)
407
h. Check Entrainment
Persen flooding actual.
uv = Uv maks (Coulson..p.474)
An
= 0,0322 m/s
408
uv
% flooding = x 100 (Coulson..p.474)
uf
= 85
Untuk nilai FLV = 0,555 dari figure 11.29 Coulson ed 6 Didapat
nilaiψ = 0,041. Ketentuan bahwa nilai ψ harus lebih kecil dari 0,1
telah terpenuhi. (Coulson..p.475)
Lcz = ( Dc hw) sin C (Coulson..p.475)
2
00
( 00 0 ) − (0 )
= 0,0217 m
g) Outside Diameter, OD
OD = ID + 2tsilinder
= 2,4749 + 2(0,0217) = 2,5183 m
Total Pressure Drop = [N. Pressure drop] rectifying + [N. Pressure drop] Stripping
= [8 x 3649,5728] Pa + [9 x 2986,0698] Pa
= 56071,2104 Pa
= 0,5534 atm
2) Tinggi Kolom Destilasi-01
H = [N. Tray spacing] rectifying + [N. Tray spacing] Stripping
= [11,2052 x 0,3] m + [6,8133 x 0,3] m
411
= 5,4055 m
Ht = H + Heatas + Hebawah
= 5,4055 m + 0,5914 m + 0,6187 m
= 6,6156 m
412
IDENTIFIKASI
Nama / Kode Alat Kolom destilasi 1 / KD – 01
Jenis Tray Column
Jumlah 1 buah
Operasi Kontinyu
Fungsi Memisahkan Asam Asetat dari zat pengotor
DATA DESAIN
Top Bottom
Tekanan 1,4 Atm 1,55 atm
O O
Temperatur 94 C 125,4 C
KOLOM
Tinggi kolom 5,4055 m
Umpan Masuk stage ke - 7
Total Tray 18,018 tray
Top Bottom
Diameter 2,3656 M 2,4749 m
Tray spacing 0,3 M 0,3 m
Jumlah tray 11,4202 Buah 6,8133 buah
Tebal silinder 0,0097 m 0,0217 m
Tebal head 0,0097 m 0,0217 m
Material Stainless Steel
PELAT
Top Bottom
2
Downcomer area 0,5271 m 0,5770 m2
Active area 3,3385 m2 3,6542 m2
Hole Diameter 5 mm 5 mm
2
Hole area 0,3339 m 0,3654 m2
Tinggi weir 50 mm 50 mm
Panjang weir 1,8215 m 1,9057 m
Tebal pelat 5 mm 5 mm
Pressure drop total 374,3014 mm liquid 306,2523 mm liquid
Tipe aliran cairan Single pass Single pass
Desain % flooding 85 % 85 %
Jumlah hole 17011,5047 Buah 18620,1788 buah
413
CD-02
ACC-02
F KD-02
RB-02
Top
P = 1,1 atm = 836,0000 mmHg
o
T = 103,1 C = 376,25 K
Bottom
P = 1,3 atm = 988 mmHg
o
T = 126,6 C = 399,750 K
αD = KLK / KHK
= 1,7933
αB = KLK / KHK
= 1,8502
√( ) ( )
= 1,8215
n
xD
(L/D)m + 1 = ( ) /
1
(eq. 5.83 Van Winkle)
416
−( ) −
0
Dari grafik 5.18 hal hal.243 Van Winkle (Gilland Corelation) diperoleh :
− −
m
Log = -0,0625
p
m
= 0,8860
p
m = 0,8860 p
N teoritical = m+p (RE.Treyball, p.311)
45,2224 = 0,8860 p + p
p = 24,2345
m = 20,9879
b. Diameter kolom
Liquid –Vapour Flow Factor (FLV)
0, 2
K1*= K1
20
0, 2
0,005
= 0,0640
0.02
= 0,0485
Kecepatan Flooding (uf )
uf = K 1 * L V (Coulson. Eq.11.81)
V
107,2873 5,3727
= 0,0485
5,3727
= 0,2111 m/s
Desain untuk 85 % flooding pada maksimum flow rate ( u )
u = 0,85 . uf (Coulson. p.472)
= 0,85 . 0,211 m/s
= 0,1794 m/s
Maksimum laju alir volumetric (Uvmaks)
Uvmaks= V (Coulson. p.472)
V . 3600
419
= 15831,4498 kg/jam
3
5,3727 kg / m .3600
= 0,8185 m3/s
Net area yang dibutuhkan (An)
An = U V maks
(Coulson. p.472)
u
0,8185 m 3 / s
=
0,1794 m / s
= 4,5617 m2
Cross sectional area dengan 12 % downcomer area (Ac)
Asumsi diambil sebesar 12 % berdasarkan rekomendasi pada buku
Chemical Engineering, vol. 6, Coulson, p. 568
An
Ac = (Coulson. p.472)
1 0,12
2
= 4,5617 m
1 0,12
= 5,1837 m2
Diameter kolom (Dc)
4 Ac
Dc = (Coulson. p.472)
3,14
= 4 (5,1837 m 2 )
3,14
= 2,5697 m
c. Desain plate
Diameter kolom (Dc)
= 2,5697 m
Luas area kolom (Ac)
2
Ac = Dc .3,14 (Coulson. p.473)
4
420
2,5697 . 3,14
=
4
= 5,1837 m2
Downcomer area (Ad)
Ad = persen downcomer x Ac (Coulson. p.473)
= 0,12 (5,1837 m2)
= 0,622 m2
Net area (An)
An = Ac – Ad
= 5,1837 m2 - 0,622 m2
= 4,5617 m2
Active area (Aa)
Aa = Ac – 2 Ad
= 5,1837 m2 – 2 (0,622 m2)
= 3,9396 m2
Hole area (Ah)
Ditetapkan 10% dari Aa berdasarkan rekomendasi pada buku
Chemical Engineering, vol. 6, Coulson, p. 568
Ah = 10 % . Aa
= 0,1 (3,9396 m2)
= 0,3940 m2
Nilai weir length (Iw)
Ditentukandari figure 11.31, Coulson vol 6
Ad
Ordinat = x 100
Ac
2
= 0,622 m 2 100 %
5,1837 m
= 12 %
Iw
Absisnya =
Dc
= 0,770
421
Sehingga :
Iw = Dc . 0,77
= 2,5697 m . 0,77
= 1,9787 m
Penentuan nilai weir height (hw), hole diameter (dh), dan plate
thickness, (nilai ini sama untuk kolom atas dan kolom bawah)
Weir height (hw) = 50 mm
Nilai weir height direkomendasikan pada buku Chemical Engineering,
vol. 6, Coulson, p. 571
Hole diameter (dh) = 5 mm
Ukuran tersebut merupakan preferred size sesuai rekomendasi pada
buku Chemical Engineering, vol. 6, Coulson, p. 573
Plate thickness = 5 mm (untuk carbon steel)
d. Pengecekan
a. Check weeping
Maximum liquid rate (Lmmax)
L
Lmmax =
3600
= 14113,3013 kg/jam
3600
= 3,9204 kg/det
Minimum liqiud rate (Lmmin)
Minimum liquid rate pada 70 % liquid turn down ratio
Lmmin = 0,7 Lmmax (Coulson. p.473)
= 0,7 (3,9204 kg/det)
= 2,7443 kg/det
Weir liquid crest (how)
2
Lm 3
how = 750 (Coulson. Eq.11.85)
l Iw
422
2
Lm, maks 3
howmaks = 750
l Iw
2
3,9204kg / det 3
= 750 3
107,2873 kg / m x 1,9787m
= 52,3997 mm liquid
2
Lm, min 3
howmin = 750
l Iw
2
1,6057 kg / det 3
= 750 3
107,2873 kg / m x 1,5401 m
= 41,3106 mm liquid
Pada rate minimum
hw + how = 50 mm + 41,3106 mm
= 91,3106 mm
Dari figure 11.30 Coulson ed 6, diperoleh K2 = 30,700
Minimum design vapour velocity (ŭh)
= 262,2704 m/s
Actual minimum vapour velocity (Uvmin actual)
min imum vapour rate
Uvmin actual = (Couldson..Eq.11.84)
Ah
0,7 x 0,8185
= = 1,4543 m/s
0,3940
Karena nilai Uvmin actual lebih kecil dari Uh, maka weeping tidak
terjadi.
0,8185
= = 2,0776 m/s
0,3940
Dari figure 11.34 Coulsoned 6, untuk :
Plate thickness
= 1
hole diameter
Ah Ah
= = 0,1
Ap Aa
Ah
x 100 = 10
Ap
Sehingga didapat nilai Orifice coeficient (Co) = 0,84
Dry plate drop (hd)
2
Uh
hd = 51 V (Coulson..Eq.11.88)
Co L
= 15,6242 mm liquid
Residual head (hr)
12,5 .10 3
hr = (Coulson..Eq.11.89)
L
= 116,5095 mm liquid
Total pressure drop (ht)
ht = hd + (hw + how) + hr (J.M.Couldson..p.474)
= 15,6242 + 91,3106 + 116,5095
= 223,4443 mm liquid
Nilai ht lebih besar dari 100 mm liquid, terpenuhi (Coulson, p.474).
= 35,3827 mm
Back up di downcomer (hb)
hb = (hw + how) + ht + hdc (Coulson..p.474)
= 91,3106 mm + 223,4443 mm + 35,3827 mm
= 350,1376 mm
= 0,3501 m
d. Check resident time (tr)
Ad hb L
tr = (Couldson..Eq.11.95)
Lm, maks
= 5,9605 s
Ketentuan bahwa nilai tr lebih besar dari 3 s, telah terpenuhi.
e. Check Entrainment
Persen flooding actual.
Uv maks
uv = (Couldson..p.474)
An
= 0,1794 m/s
uv
% flooding = x100 (Couldson..p.474)
uf
= 85 %
425
Lm = Dc hw x 3,14 (Coulson..p.475)
180
= 3,4285 m
Area of unperforated edge strip (Aup)
Aup = hw . Lm (Couldson..p.475)
-3
= 50 x 10 m . 3,4285 m
= 0,1714 m2
Mean length of calming zone (Lcz)
Lcz = ( Dc hw) sin C (Couldson..p.475)
2
= 1,9582 m
Area of calming zone (Acz)
Acz = 2 (Lcz . hw) (Coulson..p.475)
= 0,1958 m2
Total area perforated (Ap) (Coulson..p.475)
426
Ap = Aa – (Aup + Acz)
= 3,9396 – (0,1714 + 0,1958)
= 2,83 m2
Dari figure 11.33 Coulson ed 6, didapat nilai Ip/dh = 2,83 untuk nilai
Ah/Ap = 0,1103. Nilai Ip/dh harus berada dalam range 2,5 – 4.0.
(Couldson hal 573).
Jumlah holes
Area untuk 1 hole (Aoh)
dh 2
Aoh = 3,14 (Couldson..p.475)
4
(0,0050) 2
= 3,14 = 0,000019625 m2
4
Ah
Jumlah holes = (Couldson..p.475)
Aoh
0,3940
=
0,000019625
= 20074,4680
= 20074 holes
= 0,2925 in = 0,0292 m
g. Outside Diameter (OD)
OD = IDtop + 2tsilinder
= 2,5697 m + 2 (0,0212 m)
= 2,6122 m
= 3,4709 kg/det
i. Diameter kolom
Liquid –Vapour Flow Factor (FLV)
0, 2
K1 * = K1
20
0, 2
0,1216
= 0,0450
20
= 0,0646
uf = K1 * L V (Coulson. Eq.11.81)
V
= 0,1978 m/s
Desain untuk 85 % flooding pada maksimum flow rate ( u )
u = 0,85 . uf (Coulson. p.472)
= 0,85 . 0,1978 m/s
429
= 0,1681 m/s
Maksimum volumetric flow rate (Uvmaks)
V
Uvmaks = (Coulson. p.472)
V . 3600
12495,4090
=
4,1309 x 3600
= 0,8402 m3/s
Net area yang dibutuhkan (An)
An = U V maks
(Coulson. p.472)
u
0,8402 m 3 / s
=
0,1681 m / s
= 4,9979 m2
Cross section area dengan 12 % downcormer area (Ac)
Asumsi diambil sebesar 12 % berdasarkan rekomendasi pada buku
Chemical Engineering, vol. 6, Coulson, p. 568
An
Ac = (Coulson. p.472)
1 0,12
2
= 4,9979 m
1 0,12
= 5,6794 m2
4 Ac
Dc = (J M.Couldson. p.472)
3,14
= 4 (5,6794 m 2 )
3,14
= 2,6898 m
430
j. Desain plate
Diameter kolom (Dc) = 2,6898 m
Luas area kolom (Ac)
Dc 2 . 3,14
Ac = (Coulson. p.473)
4
(2,6898 ) 2 . 3,14
=
4
= 5,6794 m2
Downcomer area (Ad)
Ad = persen downcomer x Ac (Coulson. p.473)
= 0,12 (5,6794 m2)
= 0,6815 m2
Net area (An)
An = Ac – Ad
= 5,6794 m2 - 0,6815 m2 = 3,8362 m2
Active area (Aa)
Aa = Ac – 2 Ad (Coulson. p.473)
= 5,6794 m2 – 2 (0,6815 m2)
= 4,3164 m2
Hole area (Ah)
Ditetapkan 10% dari Aa berdasarkan rekomendasi pada buku
Chemical Engineering, vol. 6, Coulson, p. 568.
Ah = 10 % . Aa
= 0,1 (4,3164 m2)
= 0,4316 m2
Nilai weir length (Iw)
Ditentukandari figure 11.31, Coulson vol 6
Ad m2
Ordinat = x 100 = 0,6815 100 = 12
Ac 5,6794 m2
Iw
Absisnya = = 0,770
Dc
431
Sehingga :
Iw = Dc . 0,77
= 2,6898 m . 0,77
= 2,0711 m
Penentuan nilai weir height (hw), hole diameter (dh), dan plate
thickness, (nilai ini sama untuk kolom atas dan kolom bawah)
Weir height (hw) = 50 mm
Nilai weir height direkomendasikan pada buku Chemical Engineering,
vol. 6, Coulson, p. 571
Hole diameter (dh) = 5 mm
Ukuran tersebut merupakan preferred size sesuai rekomendasi pada
buku Chemical Engineering, vol. 6, Coulson, p. 573
Plate thickness = 5 mm (untuk carbon steel)
k. Pengecekan
Check weeping
Maximum liquid rate (Lmmax)
L
Lmmax = (Coulson. p.473)
3600
= 7,1186 kg/det
Minimum liqiud rate (Lmmin)
Minimum liquid rate pada 70 % liquid turn down ratio
Lmmin = 0,7 Lmmax (Coulson. p.473)
= 0,7 (7,1186 kg/det)
= 4,9830 kg/det
Weir liquid crest (how)
2
Lm 3
how = 750 (Coulson. Eq.11.85)
l Iw
2
Lm, maks 3
howmaks = 750
l Iw
= 139,3890 mm liquid
432
2
Lm, min 3
howmin = 750
l Iw
= 109,8906 mm liquid
Pada rate minimum
hw + howmin= 50 mm + 109,8906 mm
= 159,8906 mm
Dari figure 11.30 Coulson ed 6
K2 = 37,21
Minimum design vapour velocity (ŭh)
= 364,4463 m/s
= 26,3751 mm liquid
Residual head (hr)
3
hr = 12,5 .10 (Coulson..Eq.11.89)
L
= 291,3916 mm liquid
Total pressure drop (ht)
ht = hd + (hw + how) + hr (Coulson..p.474)
= 477,6573 mm liquid
Ketentuan bahwa nilai ht harus lebih besar dari 100 mm liquid telah
terpenuhi (Coulson..p.474).
Downcomer liquid backup
Downcomer pressure loss (hap)
hap = hw – 10 mm (Coulson..p.477)
= 50 – 10
= 40 mm
Area under apron (Aap)
Aap = hap . Iw (Coulson..p.474)
= 40 x 10-3 . 2,0711
= 0,0828 m2
Karena nilai Aap lebih kecil dari nilai Ad, maka nilai Aap yang
digunakan pada perhitungan head loss di downcomer (hdc)
Head loss in the downcomer (hdc)
2
Lm, max
hdc = 166 (Coulson..Eq.11.92)
L Aap
2
Lm, max
= 166
L Aap
= 666,0246 mm
434
= 5,3538 s
Ketentuan bahwa nilai tr harus lebih besar dari 3 s , telah terpenuhi.
Check Entrainment
Persen flooding actual.
Uv maks
uv = (Coulson..p.474)
An
= 0,1681 m/s
= 85
Pada FLV = 0,6364 dan % flooding 85 %, pada figure 11.29 Coulson
p.475 diperoleh nilai ψ = 0,0450.
Ketentuan bahwa nilai ψ harus kecil dari 0,1 terpenuhi. Di bawah nilai
ini pengaruh entraiment terhadap efisiensi kecil.
Lm = Dc hw x 3,14 (Coulson..p.475)
180
= 3,5919 m
Area of unperforated edge strip (Aup)
Aup = hw . Lm (Coulson..p.475)
= 50 x 10-3 m x 3,5919 m
= 0,1796 m2
Mean length of calming zone (Lcz)
C
Lcz = ( Dc hw) sin (Coulson..p.475)
2
105
= (2,6898 0,050) sin
2
= 2,0515 m
Area of calming zone (Acz)
Acz = 2 (Lcz . hw) (Coulson..p.475)
= 2 x (2,0515 m x 0,05 m)
= 0,2051 m2
Total area perforated (Ap)
Ap = Aa – (Aup + Acz) (Coudson..p.475)
= 4,3164 – (0,1796 + 0,2051)
= 3,9316 m2
Dari figure 11.33 Coulson ed 6 didapat nilai Ip/dh = 2,830 untuk nilai
Ah/Ap = 0,114.
Nilai Ip/dh harus berada dalam range 2,5 – 4.0 (Coulson..p.465)
436
Jumlah holes
Area untuk 1 hole (Aoh)
dh 2
Aoh = 3,14 (Couldson..p.475)
4
(5 x10 3 ) 2
= 3,14
4
= 0,0000196 m2
Ah
Jumlah holes = (Couldson..p.475)
Aoh
0,4316
=
0,000019625
= 21994,1686
= 21994 holes
m. Ketebalan minimum kolom, ds
Karena tebal silinder tangki > tebal tutup tangki bagian bawah, maka
digunakan tebal silinder.
Ketebalan dinding bagian silinder, dsilinder
P. R
ds C (Peters and Timmerhaus, hal 537)
S . E 0, 6 P
ds = Tebal tanki bagian silinder (in)
P = Tekanan desain bottom = 1,3 atm
R = Jari-jari dalam tangki bottom= 1,3449 m
S = Working stress jenis bahan carbon steel (SA – 285, Cr. C)
= 13700 psia (table 4, Peter, hal.538)
E = Joint efficiency = 0,85 (table 4, Peter, hal.538)
Dari tabel, Handbook of Corrosion data 2nd Edition , ASM :
Rate of corrosion untuk carbon steel pada daerah Urban – Industrial
steady state sebesar 0,036 mm/tahun = 0,0014 in/tahun.
C = Tebal korosi yang diizinkan
= Rate of corrosion untuk carbon steel x usia alat
437
P. R
ds C
S . E 0, 6 P
00
( 0 0 ) − (0 )
= 0,868 in = 0,022 m
Total Pressure Drop = [N. Pressure drop] rectifying + [N. Pressure drop] Stripping
= [20,9879 x 2178,6620] Pa + [24,2345 x 4657,3302]
Pa
= 158593,6617 Pa
= 1,5652 atm
IDENTIFIKASI
Nama / Kode Alat Kolom destilasi 2 / KD – 02
Jenis Tray Column
Jumlah 1 buah
Operasi Kontinyu
Fungsi Memisahkan Asam Asetat dari air
DATA DESAIN
Top Bottom
Tekanan 1,1 Atm 1,3 atm
O
Temperatur 103,1 C 126,6 OC
KOLOM
Tinggi kolom 14,2128 m
Umpan Masuk stage ke - 21
Total Tray 46 tray
Top Bottom
Diameter 2,5697 m 2,6898 m
Tray spacing 0,3 m 0,3 m
Jumlah tray 20,9879 Buah 24,2345 buah
Tebal silinder 0,0210 m 0,0214 m
Tebal head 0,0210 m 0,0214 m
Material Stainless Steel
PELAT
Top Bottom
2
Downcomer area 0,622 m 0,6815 m2
Active area 3,9396 m2 4,3164 m2
Hole Diameter 5 mm 5 mm
2
Hole area 0,394 m 0,4316 m2
Tinggi weir 50 mm 50 mm
Panjang weir 1,9787 m 2,0711 m
Tebal pelat 5 mm 5 mm
Pressure drop total 223,4443 mm liquid 477,6573 mm liquid
Tipe aliran cairan Single pass Single pass
Desain % flooding 85 % 85 %
Jumlah hole 20074,468 Buah 21994,1686 buah
440
Data-data desain :
Tekanan (P) = 1 atm
Temperatur (T) = 30 o C
Densitas campuran () = 1486 kg/m3 = 92,7678 lb/ft3
Viskositas campuran () = 2,63 cP = 6,4087 lb/ft jam
Laju alir massa( W) = 5199,174 kg/jam
h = 0,25 . Dt
h = 0,25 . 1,3880 m
h = 0,3470 m
7. Lebar baffel, WB
WB / Dt = 0,01
WB = 0,01 x 1,3880 m
WB = 0,0139 m
Dimana,
P = Tekanan Design = 1 atm
R = Jari – Jari Tanki = 0,6500 m
S = Working Stress Allowable = 13700 atm (peters, tabel 4 hal
570)
Ej = Welding Joint Efficiency = 0,85 (peters, tabel 6 hal
571)
C = Tebal korosi yang diizinkan = 0,274 mm/th (peters, tabel 6 hal
571)
diasumsikan umur pabrik 11 tahun sehingga C = 0,000274 m/th
= 0,003014 m
444
1 x 0,6500
tT 0,003014
(13700 x 0,85) (0,6 x 1)
= 0,0031 m
Vessel
Volume (VT) = 3,8486 m3
Diameter (DT) = 1,3880 m
Tinggi Liquid (H) = 2 DT
= 2,7761 m
Impeler
Tipe impeler = 6 – vertical blade turbin
Diameter impeler (Di) = 0,4627 m
Tinggi impeler dari dasar tanki (E) = Di
= 0,4627 m
Lebar daun impeler (W) = 1/5 (Di)
= 0,0925 m
Di
Panjang daun impeler (L) =
4
= 0,1157 m
Dimana :
N = kecepatan putaran pengadukan, rps
Dt = Diameter tanki
Di = Diameter Impeller
g = gravitasi = 9,81 m/s2
gc = Faktor akselerasi =1
ρ = Densitas campuran = 1486 kg/m3
σ = Tegangan permukaan = 0,025N/m
μ = Viskositas campuran = 2,63 cP
Maka :
NRe =
1,2175 rps x 92,7678 lb / ft 3 x (1,5180) 2
=
0,00178 lb/ft. s
= 146192,1
1
P= Np. N3 Di5 ρ
gc
1
= x 6 x (1,2175 rps)3 x (1,5180 ft)5 x 92,7678 lb/ft3
32,177 ft/s2
= 251,6048 ft lbf/ s
= 0,4579 HP
IDENTIFIKASI
Nama Alat Mixing Tank
Kode Alat M T – 01
Jumlah 1 buah
Fungsi Tempat mencampurkan Rhadium, larutan
katalis metil iodida, metil asetat dan air
dengan cara pengadukan
DATA DESAIN
Tipe Silinder vertical dengan ellipsoidal head
Temperature design 30oC
Tekanan design 1atm
Kapasitas 3,8486 m3
DATA MEKANIK
Tipe pengaduk Disk flate blade turbine
Diameter vessel 1,3880 m
Tinggi silinder 2,0820 m
Tinggi tutup 0,3470 m
Tinggi total tangki 2,7761 m
Tinggi liquid 2,7761 m
Diameter impeller 0,4627 m
Tinggi impeller 0,44627 m
Lebar baffle 0,0139 m
Lebar blade pengaduk 0,0925 m
Panjang blade pengaduk 0,1157 m
Posisi baffle dari dinding Tanki 0,0289 m
Tebal tanki 0,0031 m
Kecepatan putaran pengaduk 1,2175 rps
Tenaga pengaduk 1 Hp
Bahan konstruksi Carbon steel
448
Suction
P-01
A) Kondisi Operasi
Temperatur (T) = 30o C = 86o F
Densitas (ρ) = 987,4529 kg/m3 = 61,6445 lb/ft3
Viskositas (μ) = 0,7856 cp = 1,9143 lb/ft jam
Laju alir (W) = 8712,6913 kg/jam = 320,1362 lb/menit
Tekanan uap (Pv) = 97,7452 mmHg = 272,0248 lbf/ft2
Safety Faktor (f) = 0,1
d) Ukuran Pipa
Suction Pipe Discharge Pipe
IPS = 6 in IPS = 4 in
SN = 40 SN = 40
L =2m = 6,5616 ft L = 10 m = 32,808 ft
ID = 6,065 in = 0,5054 ft ID = 4,026 in = 0,3355 ft
OD = 6,625 in = 0,5521 ft OD = 4,5 in = 0,3750 ft
a = 28,9000 in2 = 0,2007 ft2 a” = 12,7000 in2 = 0,0882 ft2
= 0,4744 ft/s
= 1707,8273 ft/jam
2 ( )
Velocity head =
gc
= 0,0070 ft lbf/lbm
b) Bilangan Reynold (Re)
ID
Re =
= 27795,2163
450
= 0 00
A
-
T-01
C
B
P-01
Za = 10 m = 32,8083 ft
Zb = 0m = 0 ft (reference)
Static suction head (SH) = 32,8083 ft
Pa = 1 atm = 14,7 psi = 2117,3762 lb/ft2
g/gc = 1 lbf/lb
Pa/ρ = 34,3482 lbf ft/lb
Pa Pb (Va 2 Vb 2 )
+
g
Za Zb + = Hf (Pers. III.3 Syarifuddin Ismail)
gc 2 g
452
Pb Pa g
= + ( Za Zb) - Hf
gc
Pb
= 34,3482 lbf ft/lb + 1 lbf/lb(32,8083 – 0)ft – 0,0157 ft lbf/lb
Pb/ρ = 67,1403 lbf ft/lb
Pb = 4138,8623 lbf/ft2
= 28,7421 psi
3) Suction Head (Hs)
Total suction pressure x 144 in 2 / ft 2
Hs =
= 62,7280 ft
= 1,0796 ft/s
= 3886,4577 ft/jam
2 ( )
Velocity head =
gc
453
= 0,0362 ft lbf/lbm
b) Bilangan Reynold (Re)
ID
Re =
= 41987,7913
Meterial yang digunakan adalah commercial steel pipe
Rough factor, έ = 0,00015 (Fig 14-1, Peters)
έ/D = 0,00045
Fanning friction factor (f) :
Pada Re = 41987,7913
didapat f = 0,005 (Fig.14-1, Peters)
2) Discharge Pressure
Zc = 0 m = 0.0000 ft
Zd = 1m = 3,2808 ft (reference)
Static discharge head (SH) = 3,2808 ft
Pd = 15 atm = 220,5 psi = 31760,64 lb/ft2
g/gc = 1 lbf/lb
Pd/ρ = 515,2223 lbf ft/lb
Pc Pd (Vc 2 Vd 2 )
+
g
Zc Zd + = Hf (Pers. III.3 Syarifuddin Ismail)
gc 2 g
455
Pc Pd g
= + ( Zd Zc) - Hf
gc
Pc
= 515,2223 lbf ft/lb + 1 lbf/lb (1,0000 – 0,0000) ft – 0,1046 ft lbf/lb
Pc/ρ = 518,3985 lbf ft/lb
Pc = 31956,4395 lbf/ft2
= 221,9197 psi
= 513,9857 ft
Ws x x q f ( gpm)
BHP
7,481gal / ft 3 x 550 ftlbf / sHp x (60s / min) x
= 28,2289 HP
IDENTIFIKASI
Nama Alat Pompa – 01
Kode Alat P – 01
Jumlah 2 (1 buah cadangan)
Fungsi Memompakan metanol dan recycle menuju
reaktor.
Tipe Centrifugal pump
Temperatur, oC 30
Densitas, kg/m3 987,4529
Laju alir massa, kg/jam 8712,6913
Viskositas, cp 0,7856
Tekanan uap, mmHg 97,7452
Safety factor, % 10 %
Kapasitas pompa, gal/min 42,7331
Volumetric Flowrate, ft3/det 0,0952
Suction Discharge
NPS, in 6 4
SN 40 40
ID, in 6,065 4,026
OD, in 6,625 4,5
L, m 2 10
Velocity, ft/s 0,4744 1,0796
Total friction loss, ft. lbf/lb 0,0157 0,1046
Tekanan operasi, psi 14,7 220,5
NPSH, ft. lbf/lb 62,7280 513,9857
Required motor driver, Hp 33
Bahan Carbon Steel
458
9
11
30 atm
215oc
8 12
Rh
Reaksi : CH3OH + CO CH3COOH
1. Data Kondisi Operasi :
Temperatur = 215oC
Tekanan = 15 atm
Konversi = 99 % terhadap metanol
Waktu Reaksi = 3,7790 menit = 0,0630 jam
Umpan Gas Total
Laju alir massa, WG = 6520,9914 kg/jam
Laju alir molar, Fao = 233,1243 kmol/jam
Densitas, G = 10,5857 kg/m3
Laju alir volumetrik umpan Reaktor, QG
WG
QG =
G
6520,9914 kg/jam
QG =
10,5857 kg/m 3
464
= 616,0200 m3/jam
Konsentrasi, CAO
FAO
CAO =
Q
233,1243 kmol/jam
=
616,0200 m 3 /jam
= 0,3784 kmol/m3
2. Umpan Liquid Total
Laju alir massa, WL = 12729,8385 kg/jam
Laju alir molar, FBO = 217,6908 kmol/jam
Densitas, L = 157,2266 kg/m3
Laju alir volumetrik, QL
WL
QL =
L
12729,8385 kg/jam
=
217,6908 kg/m 3
= 80,9649 m3/jam
Konsentrasi, CBO
FBO
CBO =
Q
217,6908 kmol/jam
=
80,9649 m 3 /jam
= 2,6887 kmol/m3
Q total =QG + QL
= 616,0200 m3/jam + 80,9649 m3/jam
= 696,9849 m3/jam
A. Menentukan Laju Reaksi
Menurut (Yuying, Chen.et, all.1989) dalam jurnalnya “Kinetic Study of
Carbonylation of Methanol to Acetic Acid and Acetic Anhydride over a Novel
Copolymerbound cis-Dicarbonylrhodium Complex” didapatkan data:
465
Pada T=488,15 K
Metanol
Laju alir massa, WL = 7451,4808 kg/jam
Laju alir molar, Fao = 233,5535 kmol/jam
Densitas, L = 12,12 kg/m3
Laju alir volumetrik umpan Reaktor, QL
WG
QL =
G
7451,4808 kg/jam
QL =
12,12 kg/m 3
= 614,8086 m3/jam
Konsentrasi, CAO
FAO
CAO =
Q
233,5535 kmol/jam
=
614,8086 m 3 /jam
= 0,3783 kmol/m3
Karbon Monoksida
Laju alir massa, WG = 6513,8249 kg/jam
Laju alir molar, FBO = 233,5535 kmol/jam
Densitas, G = 12,12 kg/m3
Laju alir volumetrik, QL
WL
QL =
L
6513,8249 kg/jam
=
12,12 kg/m 3
= 537,4443 m3/jam
466
Konsentrasi, CBO
FBO
CBO =
Q
233,5535 kmol/jam
=
537,4443 m 3 /jam
= 0,4327 kmol/m3
233,124 x 0,99
V =
0,639
= 360,905
Volume total, Vtotal = (100% + 10%) x 360,905 m3
= 396,995 m3
467
a. Diameter reaktor, DR
VR = Vsilinder + Vellipsoidal
3
DR H 2 DR
2
VR =
4 24
DR 6 DR
2 3
= DR
4 12
19
= DR 3
12
12VR
DR = 3
19
= √
= 4,887 m
= 488,7 cm
b. Tinggi silinder, H
H
3,5
DR
H = 3,5.DR
= 3,5 x (4,887m)
= 17,104 m
468
c. Tinggi ellipsoidal, h
DR
h
4
=
= 1,222 m
d. Tinggi reaktor, HR
HR = H + 2 h
= 17,104 m + 2 ( 1,222 m)
= 19,548 m
e. Menghitung ketebalan dinding reaktor, tw
P r
untuk silinder : t = C
S E - 0,6 P
P D
untuk ellipsoidal head : t = C
2S E - 0,2 P
(Peters, Tabel 4)
Keterangan :
t = tebal dinding, in
P = tekanan desain, kPa = 15 atm = 1595,869 kPa
D = diameter, cm = 4,887 m = 488,7 cm
r = jari-jari, cm = 2,443 m = 244,3 cm
S = tekanan kerja yang diizinkan, kPa = 94500 kPa (Tabel 4,
Peter)
E = efisiensi pengelasan = 0,85 (Tabel 4,
Peter)
C = korosi yang diizinkan, cm =0,125 in = 0,318 cm
(Tabel 6. Peter)
t = + 0,125
= 5,182 cm
= 51,817 mm
Tebal dinding ellipsoidal head :
P D
t = CC
2S E - 0,2 P
t = + 0,125
= 5,231 cm
= 52,31 mm
ID = 4,887 m
OD = ID + 2.t
= 4,887 m + 2 (0,052 m)
= 4,991 m
D. Menghitung Desain Perforated Plate
Berdasarkan literatur Treyball hal. 140, digunakan sparger yang
berbentuk lingkaran dengan diameter orifice yang memiliki range 1.5 mm – 5
mm.
a. Diameter bubble, dB
1
6.d O . .qc 3
dB = (Pers.6.1. Treyball)
g.
Dengan :
dO = 5 mm = 0.5 cm
= 14.68 dyne/cm
g = 980 cm/s2
gr . cm / s 2
qc = 1
dyne
= L G
maka :
1
6 (0.5 cm) (14.68 dyne / cm) (1 g.cm / s 2 .dyne 3
dB = 2 3
(980 cm / s ) ( 0.1466 g / cm )
= 0,6742 cm
= 6,742 mm
(Dari buku Peter Zenher & Matthias Kraume, hal 30, dB ≈ 3.5 mm)
b. Luas tiap lubang orifice, AO
dO
2
AO =
4
(0.5 cm) 2 (3.14)
=
4
= 0,1963 cm2
c. Volume tiap bubble, VB
d .
3
VB = B
6
(0,6742 cm) 3 (3.14)
VB =
6
= 0,1963 cm3
d. Jumlah gelembung
spesifik volume = RT/P. BM = 0,0956 L/gr
w = WG X Spesifik volume
= 6520,9914 L/gr x 0,0956 kg/jam
= 623,3185 m3/jam
w = 173144,0372 cm3/s
N BL = W / Vb
= 173144,0372 / 0,1963
= 1079600,7051 gelembung/s
e. Laju volumetrik gas pada tiap lubang,Q
6
5
3 6Q
dB = 1.378 3
(Pers. 18.31. Perry)
g 5
471
3
d B . .g 5
3
6
Q = 5
1.3786
7,2549 cm 3 / det
=
0,1963 cm 2
= 36,9582 cm/det
g. Kecepatan terminal bubble, Ut
2
Ut = (0.5. d B . g ) (Pers. 7.44. Deckwer)
d .
B g
2 14.68
= 0.50.6742980
0.674210,5857
= 18,2886 cm/det
h. Gas hold up, g
0.69
0.0661.U g
g (Pers. 7.25 b. Deckwer)
1 0.0661.U g
=
1 0.0661 (36,9582 cm / det)
= 0,2305
(Dari buku Peter Zenher & Mattihias Kraume, hal.30, gas hold up ≈ 6-30 % )
i. Kecepatan superfacial gas, Us
dengan :
n = fungsi Reynold Number di bubble = 2,39 (Hal 168. Deckwer)
472
maka,
Us = 18,2886 cm/det 1 0.23051,.39
= 12,7056 cm/det
= 14,7321 m2
0 , 29
g d O . DR 2
Nor0,29 =
0,0083 L p
Dengan :
Lp = jarak pitch = 0,5 in = 0,013 m
g = gas hold up = 0,2305
do = diameter orifice = 0,005 m
DR = diameter reaktor = 4,4845 m
maka,
Nor0,29 =
0,0083 0,013 m
Nor0,29 = 50,2668
Nor = 735339,5771 lubang
Keterangan :
OD = Outside diameter R-01 = 4,991 m
H = Tinggi silinder = 19,548 m
ID = Inside diameter R-01 = 4,887
Dari Tabel 12.1 Typical overall coefficients, Coulson hal 638 diperoleh nilai
overall heat transfer coefficient untuk cooling water :
Uc = 200 - 500 W/m2. oC
474
Dari Tabel 12.2 fouling factor coefficients, Coulson hal 640 diperoleh nilai
fouling factor untuk cooling water :
Rd = 3000 – 6000 W/m2. oC
Flowrate cooling water (m) = 27408,1535 kg/jam
Densitas air 30 oC () = 995,2 kg/m3
Residence time = 0,0828 jam
m
Volumetric flowrate air pendingin =
27408,1535 kg/jam
=
995,2 kg/m 3
= 27,5403 m3/jam
Volume jaket air pendingin = Volumetric flowrate x Residence time
= 27,5403 m3/jam x 0,0828 jam
= 2,2807 m3
V Jaket = (Volume Reaktor + Jaket) – (Volume Reaktor)
V Reaktor + Jaket = Volume Silinder + Volume head ellipsoidal (2:1)
1 1
= ( ID) 2 H ( ID) 3
4 24
V Reaktor = Volume Silinder + Volume head ellipsoidal (2:1)
1 1
= (OD) 2 H (OD) 3
4 24
Maka :
1 1 1 1
V Jaket = ( ID)2 H ( ID)3 (OD)2 H (OD)3
4 24 4 24
2,2807 m3 =
1
4
1
H ID 2 OD 2 ID 3 OD 3
24
2,2807 m3 = ( 12,3211 (ID2 – 4,991 m2) - (0,1308 (ID3 – 4,991 m2))
Dengan trial n error maka diperoleh nilai ID sebesar 5,143 meter, sehingga :
Tebal jaket pendingin = ID – OD
= 5,143 m –4,991 m = 0,1523 m
475
IDENTIFIKASI
Reaktor
Nama Alat
R – 01
Kode Alat
1 buah
Jumlah
Tempat terjadinya proses reaksi metanol
Fungsi
dengan karbon monoksida.
DATA DESIGN
Tipe Bubble Column Reaktor
Temperature design 215 oC
Tekanan design 15 atm
Kapasitas 26,4286 m3
DATA MEKANIK
Diameter vessel 4,887 m
Tinggi silinder 17,104 m
Tinggi tutup 1,222 m
Tinggi total tangki 19,548 m
Tebal tanki 0,0518 m
Tebal Jaket Pendingin 0,1523 m
Desain sparger :
Diameter bubble 0.0067 m
Interfacial Area 205,1497 m-1
Gelembung 1079601 buah
Jumlah orifice 735339,5771 buah
Luas Perforated Plate 14,7321 m2
Kecepatan gas masuk, Ug 36,9582 m3/jam
Debit per orifice, Q 7,2549 m3/detik
Bahan konstruksi Carbon steel
476
T2
:
T1
Tee
Return Head
t2
b. LMTD
Fluida Panas Fluida Dingin Selisih
(oF) (oF)
422,96 (T1) Suhu Tinggi (th) 284 (t2) 138,96
422,96 (T2) Suhu Rendah (tc) 266 (t1) 156,96
Selisih -18
477
t 2 t1
LMTD
ln t 2 / t1
156,9600 138,9600
LMTD
ln 156,9600 / 138,9600
∆t = 144,8218 oF
c. Temperatur rata-rata
Tc = T avg = 0,5 (422,96 + 422,96) = 422,96 oF
tc = t avg = 0,5 (284 + 266 ) = 275 o F
4809928,2958
A=
200 144,8218
A = 157,3980 ft2
Karena A < 200 ft2 , maka dipilih jenis Double Pipe Heat Exchanger
Dari Tabel.10 Kern didapat spesifikasi data :
Rencana Klasifikasi
Data Pipa Annulus Inner Pipe
IPS (in) 2 1,5
SN 40 40
OD (in) 2,38 1,9
ID (in) 2,067 1,61
a” (ft2/ft) 0,622 0,498
aa = (D22 – D12)
4
= (0,17232 –0,15832)
4
= 0,0036 ft2
Equivalent Diameter
De =
D2
2
D1
2
D1
=
0,1723 2
0,15832
0,1583
= 0,0291 ft
r. Kecepatan Massa, Ga
Ga = W/aa
= 3600,911 lb/hr / 0,0036 ft2
= 997094,110 lb/hr.ft2
Pada T = 422,9600 oF
μ = 0,2977 lb/ft.hr
Rea = De.Ga/μ
0,0291 x 997094,110
=
0,2977
= 97332,863
JH = 200
k = 0,0202 Btu/hr.ft2(oF/ft)
c = 8,5310 Btu/lb.oF
1
c 8,5310 x0,2977
1 3
3
=
k 0,0202
= 1,355
c. Koefisien perpindahan panas
k c
0 ,14
1
3
ho = JH
D k
w
= 200 x 0,6949 x 1,355 x 1
479
= 9516,341 Btu/hr.ft2.oF
COLD FLUID: Inner Pipe
f. Flow Area, ap
D = 1,61 inch = 0,1342 ft
ap = D2
4
= (0,1342 ft )2
4
= 0,0141 ft2
b. Kecepatan Massa, Gp
Gp = w/ap
= 18654,866 lb/hr / 0,0141 ft2
= 1280849,1363 lb/hr.ft2
Pada 275 oF
μ = 0,0250 lb/hr ft
Rep = D.Gp/μ
0,1342 x1280849,1363
=
0,0250
= 6970648,520
JH = 1000
k = 0,0149 Btu/hr.ft2(oF/ft)
c = 10,2700 Btu/lb.oF
1
c 10,2700 x0,0250
1 3
3
=
k 0,0149
= 2,5940
c. Koefisien Perpindahan Panas
0 ,14
c
1
k
3
hi = JH
D w k
= 1000 x 0,1112 x 2,5940 x 1
= 288,131 Btu/hr.ft2.oF
480
244,1530 9516,341
=
244,1530 9516,341
= 238,046 Btu/hr.ft2.oF
Rd diasumsikan 0,001
1 1
0,0010
U D 238,046
UD = 192,2750 Btu/hr.ft2.oF
f. Required Surface
Q
A =
U D t
4558932,194
=
192,2750 144,822
= 163,721 ft2
Dari tabel 11 Kern, untuk 1,5-in IPS standard pipe, external surface/foot length =
0,4980 ft2.
163,721
Required length = = 328,758 ft
0,4980
Diambil panjang 1 hairpin = 20 ft, maka jumlah hairpin yang dibutuhkan = 9
481
g. Dirt Factor, Rd
Actually Length = 9 x 20 ft x 2
= 360 ft
Actually surface = 360 x 0,4980 ft
= 179,280 ft2
4558932,194
UD =
179,2800 144,822
= 175,589 Btu/hr.ft2.oF
U C U D
Rd =
U C U D
238,046 175,589
=
238,046 175,589
= 0,0014 hr.ft2.oF/Btu
PRESSURE DROP
HOT FLUID: Annulus
b. De’ = (D2 – D1)
= 0,014 ft
Rea = De’.Ga/μ
= 97332,863
0,264
ƒ = 0,0035
(Re a' ) 0, 42
0,264
= 0,0035
(97332,863) 0, 42
= 0,006
ρ = 53,600 lb/ft3
4 fGa 2 L
w. ΔFa =
2 g 2 De
482
V 2
d. Fl = jumlah hairpin x
2g
5,167 2
= 9x
2 x 32, 2
= 3,732
(Fa Fl )
e. Δpa =
144
(240,755 5,167) x53,600
=
144
= 9,1003 Psi
COLD FLUID: Inner Pipe
a. Rep = 6970648,520
0 , 264
ƒ = 0 ,0035
(Re p ) 0 , 42
0,264
= 0,0035 (6970648,520) 0, 42
= 0,004
ρ = 61,920 b/ft3
4 fGp 2 L
b. ΔFp =
2 g 2 D
= 22,485 ft
Fp .
c. ΔPp =
144
483
622,485 x61,920
=
144
= 9,668 Psi
SUMMARY
ho = 9516,341 h outside hio = 244,153
Uc = 238,046
UD = 175,589
RD calculated = 0,0010
RD required = 0,0010
9,1003 ∆ P Calculated (psi) 9,6680
10 ∆ P Allowable (psi) 10
Rear End
Head
Perhitungan:
d. Beban Panas RB-02
Q = 47550590,904 kJ/jam = 45069263,174 Btu/jam
e. LMTD
Fluida Dingin Fluida Panas Selisih
422,96 Suhu tinggi 269,6 153,36
422,96 Suhu rendah 269,6 153,36
0 Selisih 0 0
t 2 t1
LMTD = = 153,36 oF
ln (t 2 / t1 )
t 2 t1
S = =0
(T1 t1 )
Q
A =
U D . t
45069263,174
A = 200.141,091
A = 1469,394 ft2
485
Karena A > 200 ft2, maka dipilih HE jenis Shell and Tube.
(Hal.103, Kern, 1965)
Rencana Klasifikasi
a). Tube Side
Panjang tube (L) = 20 ft
(Hal.11-40,Heat Transfer Equipment Perry, 1997)
Outside Diameter (OD) = 1 inch
BWG = 10
Pass =2 (Figure.18, Hal.828, Kern,1965)
a" = 0,2618 (Tabel.10, Hal.848, Kern,1965)
Jumlah tube (Nt) Nt = 280,633
dari Tabel.9, Hal.842, Kern, 1965 didapat Nt yang mendekati adalah 281
Nt = 281
1
Nt
ni
UD = Q
A.Δt
4506263,174
= 1471,316.153,36
486
UD = 199.736 Btu/hr.ft2.oF
(koreksi memenuhi)
karena nilai Ud perhitungan mendekati dengan nilai Ud asumsi, maka data
untuk Shell.
b). Shell side
ID = 25, inci
Baffle Space = 12,5 inci
(Hal.11-42 ,Heat Transfer Equipment Perry, 1997)
Pass (n) =4
Pt = 1,25
(Tabel.9, Hal.842, Kern, 1965)
Digunakan shell tipe K (kettle type reboiler)
d. L/D = 20 ft / 0,0610 ft
= 327,8689
jH =8 (Fig. 24,Hal 834,Kern,1965)
Cp
Prandl Number ( Pr ) =
k
k = 0,6088 Btu/hr ftoF (data hysis)
Cp = 21,0897 Btu/lboF (data hysis)
Pr = 67,904
0 ,14
k Cp
1
3
f. hi j H
D k
w
(Pers.6.15a, Kern, 1965)
dengan (μ/μw) = 1 untuk bahan kimia kecuali untuk hidrokarbon.
Koreksi viskositas diabaikan karena tidak significant, maka didapat :
hi = 325,279 Btu/hr ft2 oF
hio =
ID
hi x
OD
= 325,279 x (0,7320/1)
= 238,104 Btu/hr ft2 oF
(Pers.6.5, Kern, 1965)
ID x C' x B
a). Luas area laluan (as) =
144 Pt
= 0,043 ft2
k Cp
1 0 ,14
3
f). ho jH
D
e k w
(Pers.6.15b, Kern, 1965)
Koreksi viskositas diabaikan karena tidak significant, maka didapat :
ho = 1853,593 Btu/hr ft2 0F
489
= 0,0535 psi
= 0,973 psi
b). Shell Side
1. Faktor friksi
Res = 3227352,293
Faktor friksi ( f ) = 0,0018 (Figure. 29, Hal.839, Kern, 1965)
2. Number of cross, (N+1) (Pers.7.43, Kern, 1965)
N+1 = 12 L / B = 12 x (20 ft / 10,4167 ft)
= 230,4
Ds = ID/ 12 = 25 / 12
= 2,0833 ft
s = 1,6284
f Gs Di ( N 1)
2
3. Ps = (Pers.7.44, Kern, 1965)
5,22 x 1010 x De S fs
= 2,87 psi
IDENTIFIKASI
Nama Alat Reboiler
Kode Alat RB-02
Jumlah 1 buah
Operasi Kontinyu
Fungsi Memanaskan kembali reaktan masuk ke
KD-02
SUMMARY
ho = 1853,593 h outside hio = 238,104
Uc = 211
UD = 199,735
RD calculated = 0,0003
RD required = 0,003
2,87 ∆ P Calculated (psi) 0,973
10 ∆ P Allowable (psi) 10
491
Gambar :
3
Tinggi, H = D
2
Volume, Vt = D2H
4
3
Vt = D2 D
4 2
3
= D3
8
Vt 8
D3 =
3
Vt 8
D = 3
3
351,3584 m 3 8
= 3
3 3,14
= 6,6824 m
1 1
r = D = 6,6824 m = 3,3412 m
2 2
c. Volume Ellipsoidal Head , Ve
D 3
Ve =
24
3,14 (6,6824) 3
=
24
= 39,0398 m3
d. Volume Silinder, Vs
Vt = 2 Ve + Vs
Vs = Vt – 2 Ve
= 273,2788 m3
e. Tinggi Tangki, Ht
1) Tinggi Silinder, Hs
Hs = 3/2 . D = 3/2 x ( 6,6824 m) = 10,0235 m
493
2) Tinggi Ellipsoidal, h
h = ¼.D = ¼ x (6,6824 m) = 1,6706 m
3) Tinggi Tangki, Ht
Ht = Hs + 2h = 10,0235 2 x 1,6706 m = 13,3647 m
f. Tebal dinding, t
P r
Rumus:untuk silinder :t = C ... (Peters, Tabel 4)
S E - 0,6 P
Keterangan :
t = tebal dinding, in
P = tekanan desain, psi
=1 atm = 14,696 psi
r = jari-jari, in
= 3,344 m = 123131,6651 in
S = tekanan kerja yang diizinkan, psi
= 13700 psi (untuk material carbon steel suhu -20 hingga 650 oF)
E = efisiensi pengelasan
= 0,85 (spot examined)
Cc = korosi yang diizinkan, in
= 0,1187 mm/th,
diasumsian pabrik 11 tahun sehingga Cc = 0,0072 m = 0,2849 in
Tebal dinding silinder :
P r
t = CC
S E - 0,6 P
(14,696 psi 123,8424 in)
= 0,1187 in
(13700 psi 0,85) - (0,6 14,696 psi)
= 0,275 in
= 0,007 m
g. Outside diameter
OD = ID + 2t
= 6,6824 2 0,007 m
= 6,6968 m
494
IDENTIFIKASI
Nama Alat Tangki
Kode Alat T – 01
Jumlah 5 buah
Fungsi Tempat penyimpanan bahan baku metanol
DATA DESIGN
Tipe Silinder vertikal dengan tutup elipsoidal
Kapasitas 351,3584 m3 = 92819,0936 gallons
Temperatur 30 C
Tekanan 1 atm
Diameter dalam 6,6824 m
Tinggi 13,3647 m
Tebal 0,0072 m
Bahan Konstruksi Carbon Steel
Lama Penyimpanan 7 hari
a. Data
Temperatur, T : 30 oC
Tekanan, P : 25 atm
Laju alir massa, W : 6511,499 kg/jam
Densitas campuran , ρ : 91,39 kg/m3
Lama persediaan : 3 hari
495
b. Kapasitas Tanki, Vt
Lajualir x 24 jam
Vt = x Lama persediaan
Densitas
6511,499 kg / jam x 24 jam
Vt = x 1 hari
91,39 kg / m 3
Vt = 5129,97 m3
Tangki yang digunakan 6 buah, maka:
= 854,995 m3/ tangki
Safety factor = 10 %
Kapasitas tanki (Vt) = ( 1 + 0,1 ) x 854,995 m3
= 940,4945 m3
c. Diameter Tanki, Dt
Volume bola
4
V bola= D3
3
D3 = ( V x 3)/ (4 x 3,14)
D3 = 136,1457
D = (136,1457* 0,3)
D = 5,1444
r = 2,5722
Volume bagian head
h =¼D
= ¼ x 5,1444
= 1,2861
P. D
t C
2 S . E 0.2 P
= 0,019 m
= 1,9045 cm
e. Outside diameter, OD
OD = D + 2t
= 5,1444m + (2 x 0,019) m
= 5,1825 m
IDENTIFIKASI
Nama Alat Tangki
Kode Alat T – 02
Jumlah 6 buah
Fungsi Tempat penyimpanan bahan baku berupa karbon
monoksida
DATA DESIGN
Tipe Silinder vertikal dengan tutup elipsoidal
Kapasitas 943,1347 m3
Temperatur 30 C
Tekanan 25 atm
Diameter 5,1444 m
OD 5,1825 m
Tebal 0,019 m
Bahan Konstruksi Carbon Steel
Lama Penyimpanan 3 hari
497
Faktor keamanan = 10 %
Vt = 1,1 x 172,1385 m3
= 189,3524 m3
b. Diameter Tangki, D
Tipe tangki yang direncanakan adalah bejana silinder vertikal dengan tutup
ellipsoidal.
498
3
Tinggi, H = D
2
Volume, Vt = D2H
4
3
Vt = D2 D
4 2
3
= D3
8
Vt 8
D3 =
3
Vt 8
D = 3
3
189,3524 m 3 8
= 3
3 3,14
= 5,438 m
1 1
r = D = 5,438 m = 2,719 m
2 2
c. Volume Ellipsoidal Head , Ve
D 3
Ve =
24
3,14 (5,438 m) 3
=
24
= 21,0392 m3
d. Volume Silinder, Vs
Vt = 2 Ve + Vs
Vs = Vt – 2 Ve
= 147,2741 m3
e. Tinggi Tangki, Ht
a. Tinggi Silinder, Hs
Hs = 3/2 . D = 3/2 x (5,438 m) = 8,157 m
499
b. Tinggi Ellipsoidal, h
h = ¼.D = ¼ x (5,438 m) = 1,3595 m
c. Tinggi Tangki, Ht
Ht = Hs + 2h = 8,157 2 x 1,3595 m = 10,8759 m
f. Tebal dinding, t
P r
Rumus:untuk silinder : t = C ... (Peters, Tabel 4)
S E - 0,6 P
Keterangan :
t = tebal dinding, in
P = tekanan desain, psi
=1 atm = 14,6960 psi
r = jari-jari, in
= 2,719 m = 107,0463 in
S = tekanan kerja yang diizinkan, psi
= 13700 psi (untuk material carbon steel suhu -20 hingga 650 oF)
E = efisiensi pengelasan
= 0,85 (spot examined)
Cc = korosi yang diizinkan, in
= 0,274 mm/th
diasumsian pabrik 11 tahun sehingga Cc = 0,0064 m = 0,2529 in
= 0,2539 in
= 0,0064 m
g. Outside diameter
OD = ID + 2t
= 5,438 2 0,0064 m
= 5,4509 m
500
IDENTIFIKASI
Nama Alat Tangki
Kode Alat T – 03
Jumlah 1 buah
Fungsi Tempat penyimpanan metil iodida
DATA DESIGN
Tipe Silinder vertikal dengan tutup elipsoidal
Kapasitas 189,3524 m3 = 50021,6131 gallons
Temperatur 30 C
Tekanan 1 atm
Diameter dalam 5,438 m
Tinggi 10,8759 m
Tebal 0,0064 m
Bahan Konstruksi Carbon Steel
Lama Penyimpanan 7 hari
Perhitungan Desain :
a. Kapasitas Tangki, Vt
W.t
Volume liquid, Vt
232,089 kg/jam x 5 hari x 24 jam/hari
920,4705 kg/m 3
= 42,3598 m3
Digunakan 1 buah tangki dengan masing – masing tangki berkapasitas :
Vt = 42,3598 m3
Faktor keamanan = 10 %
Vt = 1,1 x 42,3598 m3
= 46,5958 m3
Diameter Tangki, D
Tipe tangki yang direncanakan adalah bejana silinder vertikal dengan tutup
ellipsoidal.
3
Tinggi, H = D
2
Volume, Vt = D2H
4
3
Vt = D2 D
4 2
3
= D3
8
Vt 8
D3 =
3
Vt 8
D = 3
3
46,5958 m 3 8
= 3
3 3,14
502
= 3,4077 m
1 1
r = D = 3,4077 m = 1,7039 m
2 2
b. Volume Ellipsoidal Head , Ve
D 3
Ve =
24
3,14 (3,7039 m) 3
=
24
= 5,1773 m3
c. Volume Silinder, Vs
Vt = 2 Ve + Vs
Vs = Vt – 2 Ve
= 36,2412 m3
d. Tinggi Tangki, Ht
a. Tinggi Silinder, Hs
Hs = 3/2 . D = 3/2 x (3,7039 m) = 5,1773 m
b. Tinggi Ellipsoidal, h
h = ¼.D = ¼ x (3,7039 m) = 0,8519 m
c. Tinggi Tangki, Ht
Ht = Hs + 2h = 5,1773 2 x 0,8519 m = 6,8154 m
e. Tebal dinding, t
P r
Rumus:untuk silinder : t = C (Peters, Tabel 4)
S E - 0,6 P
Keterangan :
t = tebal dinding, in
P = tekanan desain, psi
=1 atm = 14,696 psi
r = jari-jari, in
503
= 1,704 m = 67,0806 in
S = tekanan kerja yang diizinkan, psi
= 13700 psi (untuk material carbon steel suhu -20 hingga 650 oF)
E = efisiensi pengelasan
= 0,85 (spot examined)
Cc = korosi yang diizinkan, in
= 0,274 mm/th
Diasumsian pabrik 11 tahun sehingga Cc = 3,014 mm = 0,1187 in
= 0,2034 in
= 0,0052 m
g. Outside diameter
OD = ID + 2t
= 3,4077 2 0,0052 m
= 3,4180 m
504
IDENTIFIKASI
Nama Alat Tangki
Kode Alat T – 04
Jumlah 1 buah
Fungsi Tempat penyimpanan larutan promotor katalis
metil asetat
DATA DESIGN
Tipe Silinder vertikal dengan tutup elipsoidal
Kapasitas 46,5958 m3 = 12309,3066gallons
Temperatur 30 C
Tekanan 1 atm
Diameter dalam 3,4077 m
Tinggi 6,8154 m
Tebal 0,0052 m
Bahan Konstruksi Carbon Steel
Lama Penyimpanan 7 hari
Perhitungan Desain :
a. Kapasitas Tangki, Vt
W.t
Volume liquid, Vt
551,7013 kg/jam x 5 hari x 24 jam/hari
1037,326 kg/m 3
= 89,3507 m3
Digunakan 4 buah tangki dengan masing – masing tangki berkapasitas :
Vt = 22,3377 m3
Faktor keamanan = 10 %
Vt = 1,1 x 22,3377 m3
= 24,5714 m3
Diameter Tangki, D
Tipe tangki yang direncanakan adalah bejana silinder vertikal dengan tutup
ellipsoidal.
3
Tinggi, H = D
2
Volume, Vt = D2H
4
3
Vt = D2 D
4 2
3
= D3
8
Vt 8
D3 =
3
Vt 8
D = 3
3
24,5714 m 3 8
= 3
3 3,14
= 2,7531 m
506
1 1
r = D = 2,7531 m = 1,3766 m
2 2
b. Volume Ellipsoidal Head , Ve
D 3
Ve =
24
3,14 (2,7531 m) 3
=
24
= 2,7302 m3
c. Volume Silinder, Vs
Vt = 2 Ve + Vs
Vs = Vt – 2 Ve
= 22,3377 m3 – (2 x 2,7302 m3)
= 19,1111 m3-
d. Tinggi Tangki, Ht
a. Tinggi Silinder, Hs
Hs = 3/2 . D = 3/2 x (2,7302 m) = 4,1297 m
b. Tinggi Ellipsoidal, h
h = ¼.D = ¼ x (2,7302 m) = 0,6883 m
c. Tinggi Tangki, Ht
Ht = Hs + 2h = 4,1297 2 x 0,6883 m = 5,5062 m
e. Tebal dinding, t
P r
Rumus:untuk silinder : t = C ... (Peters, Tabel 4)
S E - 0,6 P
Keterangan :
t = tebal dinding, in
P = tekanan desain, psi
=1 atm = 14,696 psi
r = jari-jari, in
= 1,3766 m = 54,1949 in
S = tekanan kerja yang diizinkan, psi
= 13700 psi (untuk material carbon steel suhu -20 hingga 650 oF)
507
E = efisiensi pengelasan
= 0,85 (spot examined)
Cc = korosi yang diizinkan, in
= 0,274 mm/th
diasumsian pabrik 11 tahun sehingga Cc = 3,014 mm = 0,1187 in
= 0,1871in
= 0,0048 m
f. Outside diameter
OD = ID + 2t
ID= 2,7531 m
= 2,7531 2 0,0048 m
= 2,7626 m
IDENTIFIKASI
Nama Alat Tangki
Kode Alat T – 05
Jumlah 4 buah
Fungsi Tempat penyimpanan produk asam asetat
DATA DESIGN
Tipe Silinder vertikal dengan tutup elipsoidal
Kapasitas 24,5714 m3 = 6491,0892 gallons
Temperatur 30 C
Tekanan 1 atm
Diameter dalam 2,7531 m
Tinggi 2,7626 m
Tebal 0,0048 m
Bahan Konstruksi Carbon Steel
Lama Penyimpanan 7 hari
508
Perhitungan Desain :
g. Kapasitas Tangki, Vt
W.t
Volume liquid, Vt
1789,7846 kg/jam x 5 hari x 24 jam/hari
767,1795 kg/m 3
= 391,9341 m3
Digunakan 1 buah tangki dengan masing – masing tangki berkapasitas :
Vt = 97,9835 m3
Faktor keamanan = 10 %
Vt = 1,1 x 97,9835 m3
= 107.9835 m3
Diameter Tangki, D
Tipe tangki yang direncanakan adalah bejana silinder vertikal dengan tutup
ellipsoidal.
509
3
Tinggi, H = D
2
Volume, Vt = D2H
4
3
Vt = D2 D
4 2
3
= D3
8
Vt 8
D3 =
3
Vt 8
D = 3
3
107,7819 m 3 8
= 3
3 3,14
= 4,5067 m
1 1
r = D = 4,5067 m = 2,2534 m
2 2
h. Volume Ellipsoidal Head , Ve
D 3
Ve =
24
3,14 (4,5067 m) 3
=
24
= 11,9758 m3
i. Volume Silinder, Vs
Vt = 2 Ve + Vs
Vs = Vt – 2 Ve
= 107,7819 m3 – (2 x 11,9758 m3)
= 83,8303 m3
j. Tinggi Tangki, Ht
a. Tinggi Silinder, Hs
Hs = 3/2 . D = 3/2 x (4,5067 m) = 6,7601 m
b. Tinggi Ellipsoidal, h
510
= 0,2307 in
= 0,0059 m
l. Outside diameter
OD = ID + 2t
= 4,5067 2 0,0059 m
= 4,5185 m
511
IDENTIFIKASI
Nama Alat Tangki
Kode Alat T – 06
Jumlah 1 buah
Fungsi Tempat penyimpanan asetaldehid
DATA DESIGN
Tipe Silinder vertikal dengan tutup elipsoidal
Kapasitas 107,7819 m3 = 28472,9634 gallons
Temperatur 30 C
Tekanan 1 atm
Diameter dalam 4,5067 m
Tinggi 9,0135 m
Tebal 0,0059 m
Bahan Konstruksi Carbon Steel
Lama Penyimpanan 7 hari
Perhitungan Desain :
m. Kapasitas Tangki, Vt
W.t
Volume liquid, Vt
13131,3847 kg/jam x 5 hari x 24 jam/hari
1041,5000 kg/m 3
= 2118,1692 m3
Digunakan 5 buah tangki dengan masing – masing tangki berkapasitas :
Vt = 423,6338 m3
Faktor keamanan = 10 %
Vt = 1,1 x 423,6338 m3
= 465,9972 m3
Diameter Tangki, D
Tipe tangki yang direncanakan adalah bejana silinder vertikal dengan tutup
ellipsoidal.
3
Tinggi, H = D
2
Volume, Vt = D2H
4
3
Vt = D2 D
4 2
3
= D3
8
Vt 8
D3 =
3
Vt 8
D = 3
3
465,9972 m 3 8
= 3
3 3,14
= 7,3419 m
513
1 1
r = D = 7,3419 m = 3,6709 m
2 2
n. Volume Ellipsoidal Head , Ve
D 3
Ve =
24
3,14 (7,3419 m) 3
=
24
= 51,7775 m3
o. Volume Silinder, Vs
Vt = 2 Ve + Vs
Vs = Vt – 2 Ve
= 465,9972 m3 – (2 x 51,7775 m3)
= 362,4423 m3
p. Tinggi Tangki, Ht
a. Tinggi Silinder, Hs
Hs = 3/2 . D = 3/2 x (7,3419 m) = 11,0128 m
b. Tinggi Ellipsoidal, h
h = ¼.D = ¼ x (7,3419 m) = 1,8355 m
c. Tinggi Tangki, Ht
Ht = Hs + 2h = 11,0128 2 x 1,8355 m = 14,6838 m
q. Tebal dinding, t
P r
Rumus:untuk silinder : t = C ... (Peters, Tabel 4)
S E - 0,6 P
Keterangan :
t = tebal dinding, in
P = tekanan desain, psi
=1 atm = 14,696 psi
r = jari-jari, in
= 3,6709 m = 144,5248 in
S = tekanan kerja yang diizinkan, psi
= 13700 psi (untuk material carbon steel suhu -20 hingga 650 oF)
514
E = efisiensi pengelasan
= 0,85 (spot examined)
Cc = korosi yang diizinkan, in
= 0,274 mm/th
diasumsian pabrik 11 tahun sehingga Cc = 3,014 mm = 0,1187 in
= 0,3012 in
= 0,0077 m
r. Outside diameter
OD = ID + 2t
ID= 7,3014 m
= 7,3419 2 0,0077 m
= 7,3572 m
515
IDENTIFIKASI
Nama Alat Tangki
Kode Alat T – 07
Jumlah 5 buah
Fungsi Tempat penyimpanan produk asam asetat
DATA DESIGN
Tipe Silinder vertikal dengan tutup elipsoidal
Kapasitas 465,9972 m3 = 123103,4677 gallons
Temperatur 30 C
Tekanan 1 atm
Diameter dalam 7,3419 m
Tinggi 14,6838 m
Tebal 0,0077 m
Bahan Konstruksi Carbon Steel
Lama Penyimpanan 7 hari
LAMPIRAN IV
PERHITUNGAN EKONOMI
516
517
Apabila data harga untuk ukuran yang dibutuhkan tidak tersedia maka
dapat dipergunakan aturan yang disebut “Sixth – Tenth Factor Rule” dengan
faktor 0,6. Diperoleh harga korelasi sebagai berikut :
0,6
Kapasitas alat A
Harga alat A = Harga alat B x (Peter,Eq.6.1,pg.169)
Kapasitas alat B
Dengan menggunakan persamaan diatas, maka masing–masing harga
peralatan pada tahun 2021 dapat dihitung, dengan hasil perhitungan pada tabel
berikut :
Karbon Monoksida
Harga (US $/ kg) = 0,12 (PT. Pupuk Kaltim)
Kebutuhan /tahun (kg) = 6511,4994 kg/jam x 300 hari x 24 jam )
519
= 46.882.792,68 kg
Biaya / tahun (US$) = 46.882.792,68 kg x 0,12 US$/kg
= $ 5,625,935.48
Katalis Rodium
Harga (US $/ kg) = 17,00
Kebutuhan /tahun (kg) = (300 hari x 24 jam x 14,242 kg/jam)
= 102.542,4 kg
Biaya / tahun (US$) = 102.542,4 kg x 17,00 US$/kg
= $ 1,743,220.80
Metil Iodida
Harga (US $/ kg) = 1,00
Kebutuhan /tahun (kg) = 2320,899 kg/jam x 300 hari x 24jam
= 16.710.472,8 kg
Biaya / tahun (US$) = 16.710.472,8 kg x 1,00 US$/kg
= $ 16,71,.472.8
Metil asetat
Harga (US $/ kg) = 0,6
Kebutuhan /tahun (kg) = 232,089 kg/jam x 300 hari x 24 jam
= 1671040,8 kg
Biaya / tahun (US$) = 1671040,8 kg x 0,6 US$/kg
= $ 1,002,624.48
LiI
Harga (US $/ kg) = 20,0
Kebutuhan /tahun (kg) = 899,652 kg/jam x 300 hari x 24 jam
= 6.477.494,4 kg
Biaya / tahun (US$) = 6.477.494,4 kg x 20,0 US$/kg
520
= $ 129,549.888
Total Biaya Bahan Baku (US$) = 176,064,276.44
524
525
Oksidasi
10-10,5 T = 30 - Bakteri
4 Alkohol Q - Alkohol
% 35 oC (Nathan, 2008)
Vinegar
T = 250 RU/SiO2
o
Sintesis gas Gas Metana 80 – 85 C (Xuebing,
5
Metana dan Bromin % P = 40 – 2006)
80 atm
bakteri
Fermentasi Glokusa T= 45 - 65 Clostridium
6 97 % o
Anaerob (gula) C thermoaceticum
(Susan, 2011)