Kapasitas Prosuksi pottassium pyrophosphate

no tahun kapasitas
1 2009 79897
2 2008 76083
Grafik Import Pottasium Pyrophosphate
3 2007 72929 85000
4 2006 69775 80000
5 2005 66621 f(x) = 3286.00000000037 x − 6521941.00000074
75000 R² = 0.998388937072018
Column C
import

n=2018 368852 ton/tahun 70000

Linear (Column C)
1418.662 ton/hari
65000

60000

55000
2004 2005 2006 2007 2008 2009 2010
Tahun
phosphate

1.00000074

Column C
Linear (Column C)
 KOH GAS BUANG
H20 H2O
A

TANGKI
PELARUT REAKTOR
KOH K2HPO4
H3PO4

TANGKI
PENAMPUNG
H3PO4
 EVAPORATOR KRISTALIZER TANGKI
K2HPO4 PRODUK,
H2O K2HPO4
KOH KOH terkristal=
2432,307837 kg
H3PO4 H3PO4
K2HPO4 K2HPO4
H2O H2O
 NERACA MASSA POTTASIUM PYRO
Kapasitas produksi = 368852 ton/tahun
Waktu operasi = 24 jam/hari ; 330 hari/tahun
Satuan massa = kilogram

Produksi Potassium Pyrophasphate = 368852

24
= 368852000
7920
= 46572.2222

Komposisi Bahan Baku :

Potassium Hydroxide ( KOH ) :
Komponen % Berat
KOH 85.00%
H₂O 15.00%
100.00%

Phosphoric acid ( H₃PO₄ ) :

Komponen % Berat
H₃PO₄ 75.00%
H₂O 25.00%
100.00%

Berat Molekul
KOH = 56.1 kg/kmol
H3PO4 = 98 kg/kmol
K2HPO4 = 174 kg/kmol
H2O = 18 kg/kmol
K4P2O7 = 330 kg/kmol

1. Tangki Pelarut
Fungsi :
Kondisi operasi :
Tekanan Operasi : 1 atm
Suhu Operasi 30°C

Bahan Masuk (KOH) darin gudang penampung =

Feed yang masuk
KOH = 85.00% x 2157.195715
H2O = 15.00% x 2157.195715

Kelarutan KOH dalam air (30 oC) = 98 gr /100gr H2O

Kebutuhan air untuk melarutkan KOH :
= (100/98)gr x 2157.20
= 1211.90770505618 kg

kebutuhan air yang di tambahkan di tangki pelarut :

= 1211.90770505618 - 323.6
= 888.33 kg

Neraca Massa Tangki Pelarut KOH

Masuk ( kg ) Keluar ( kg )
Feed gudang
KOH = 1833.62 KOH
H2O = 323.58 H2O

H2O proses
H2O = 888.33

Total = 3045.52 Total

2. REAKTOR
Fungsi : Meraeaksikan Potassium hydroxide dengan phosphoric acid membentuk dipotassium phosphate
Gas buang ( 60°C )

KOH ( 30°C )
H₃PO₄ ( 30°C ) REAKTOR

Kondisi Operasi :
Tekanan Operasi = 1 atm
Suhu operasi = 30°C

Feed masuk dari tangki pelarut :

KOH = 1833.61635775 kg
H2O = 1211.90770505618 kg

Perbandingan reaktan KOH dan H₃PO₄ berdasarkan keyes

Jadi H3PO4 yang dibutuhkan :

= 595 x 1833.61635775
680
= 1604.41431303125 kg
H3PO4 dengan kemurnian : 75 % berat maka,
= 1604.41431303125 = 2139.21908404167
75%
Komposisi larutan H3PO4 dari tangki :
H₃PO₄ = 75.00% x 2139.22 = 1604.41431303125
H₂O = 25.00% x 2139.22 = 534.805

2KOH + H3PO4 K2HPO4 + 2H2O

Konversi reaksi sebesar 81%
Reaktan :

KOH yang tersedia = 1833.61635775 kg

= 32.6847835606061 kmol

KOH yang bereksi = 32.6847835606061 x 81%

= 26.4746746840909 kmol
= 1485.2292497775 kg

H3PO4 yang bereaksi = 1 x 32.6847835606061

2
= 16.342 kmol
= 1601.55 kg

Produk :
K2HPO4 yang terbentuk = 1 x 32.6847835606061
2
= 16.342391780303 kmol
H2O yang terbentuk = 32.6847835606061 kmol
= 1x 32.6847835606061
1
 = 32.6847835606061 kmol
= 588.326104090909 kg

KOH yang tersisa = 1833.61635775 - 1485.2292497775

= 348.3871079725 kg

H3PO4 yang tersisa = 1604.41431303125 - 1601.554

= 2.860 kg
H2O total = 1211.90770505618 + 534.805
= 2335.039

Neraca Massa Reaktor

Masuk ( kg ) Keluar
dari tangki pelarut : KOH
KOH = 1833.61635775 H3PO4
H2O = 1211.90770505618 K2HPO4
H2O

H3PO4 Tangki :
H3PO4 = 1604.41431303125
H2O = 534.805

Total = 5529.862 Total

3.EVAPORATOR
Fungsi : Memekatkan Larutan sampai jenuh
H2O

51.42% K2HPO4

K2HPO4 64,03%
 Kondisi Operasi :
Tekanan Operasi : 1 atm
Suhu Operasi :

Komposisi bahan masuk evaporator :

KOH = 348.3871079725 0.063001
H3PO4 = 2.860 0.000517
K2HPO4 = 2843.57616977273 0.514222
H2O = 2335.039 0.42226
5529.86177646429
Konsentrasi solid dalam bahan = 2,843.576
5,529.86
= 51.42%
Data kelarutan K2HPO4 dalam air pada 60°C = 1.78

Sehingga titik jenuh Al2(SO4)3 berada pada = 1.7800

2.7800
= 64.03%
Neraca Massa Total
A = B + C
5529.86177646429 = B + C
C = 5529.86177646429 + B ......................................... ( 1 )

Neraca Massa K2HPO4 == x - =

A . XA = B . XB + C .XC
2843.57616977273 = 64% B + 0
B = 4441.09087189224 kg

Dengan persamaan ( 1 ) di dapatkan harga :

C = 5529.86177646429 - 4441.09087189224
= 1088.77090457205

Jadi H2O yang diuapkan sebesar = 1088.77090457205 kg

H2O yang tersisa = 2335.0385801575 - 1088.77090457205
= 1246.26767558546 kg
Neraca Massa Evaporator
Masauk ( kg ) Keluar ( kg )
feed masuk evaporator feed masuk ke kristalizer
KOH = 348.3871079725 KOH
H3PO4 = 2.85991856155329 H3PO4
K2HPO4 = 2843.57616977273 K2HPO4
H2O = 2335.0385801575 H2O
 H2O yang menguap

Total = 5529.862 Total

4.Crystalizer
Fungsi : Kristalisasi dipotassium phosphate dengan pendinginan.

Larutan K2HPO4 CRYSTALIZER

Kondisi operasi
Tekanan Operasi : 1 atm
Suhu operasi : 32°C
Komposisi feed masuk :
KOH = 348.3871079725 = 0.07844629124287
H3PO4 = 2.85991856155329 = 0.00064396758455
K2HPO4 = 2843.57616977273 = 0.64028776978417
H2O = 1246.26767558546 = 0.28062197138841
4441.09087189224

Komposisi feed masuk :

KOH = 348.3871079725
H3PO4 = 2.85991856155329
K2HPO4 = 2843.57616977273
H2O = 1246.26767558546

K2HPO4 Terlarut = 33 x 1246.26767558546

100
= 411.268332943201 kg

Sehingga K2HPO4 yang terkristal sebesar :

= 2843.576 - 411.268332943201
= 2432.30783682953 kg

Komposisi mother liquor

KOH = 348.3871
H3PO4 = 2.85991856155329
K2HPO4 = 411.268332943201
H2O = 1246.26767558546
Neraca massa kristalizer
Masuk ( kg ) Keluar ( kg )
KOH = 348.3871079725 KOH =
H3PO4 = 2.85991856155329 H3PO4 =
K2HPO4 = 2843.57616977273 K2HPO4(l) =
H2O = 1246.26767558546 H2O =

K2HPO4(s) =

Total = 4441.09087189224 Total =

5. CENTRIFUGE
Fungsi : Memisahkan cake dan filtrat

Campuran Bahan
CENTRIFUGE

Cake ( Solid )

Kondisi operasi
Tekanan Operasi : 1 atm
Suhu operasi : 32°C

Komposisi Feed masuk :

KOH = 348.3871079725
H3PO4 = 2.85991856155329
K2HPO4(l) = 411.268332943201
H2O = 1246.26767558546
K2HPO4(s) = 2432.30783682953
4441.09087189224

Bersifat solid
K2HPO4 kristal = 2432.308 kg

Bahan bersifat liquid

Komponen Berat (kg)
KOH 348.3871
H3PO4 2.8599
K2HPO4(l) 411.2683
H2O 1246.2677
Perhitungan Cake :
Asumsi cake terambil = 95% solid
Cake loss = 10%

terdiri dari :
K2HPO4(s) = 2432.30783682953 kg
Cake yang terambil = 95% x 2432.30783682953
= 2310.69244498805 kg
Cake loss = 5% x 2432.30783682953
= 121.615391841476 kg

Maka berat air pada cake keluar

Komponen solid (kg)
K2HPO4 2310.69244498805
H2O 121.6154
2432.30783682953

Berat air pada filtrat = air pada filtrat - air terikut cake
Berat air pada filtrat = 1246.2677 - 121.615391841476 =

Komposisi filtrat keluar:

Komponen Berat (kg)
KOH 348.3871
H3PO4 2.8599
K2HPO4(l) 411.2683
H2O 1124.6523

Neraca Massa Centrifuge

Masuk ( kg ) Keluar ( kg )
KOH = 348.3871079725 Crystal basah
H3PO4 = 2.85991856155329
K2HPO4(l) = 411.268332943201 K2HPO4 (s) = 2310.69244498805
H2O = 1246.26767558546 H2O = 121.6154

K2HPO4(s) = 2432.30783682953 Mother Liquor

KOH = 348.3871
K2HPO4(l) = 411.2683
 H2O = 1246.2677
H3PO4 = 2.8599
Total = 4441.09087189224 Total = 4441.091

6. ROTARY KILN
Fungsi : Mengeringkan Cake dengan udara panas

K2HPO4

Q ( Udara panas )

Kondisi operasi
Tekanan Operasi : 1 atm
Suhu operasi : 400°C

Feed Masuk :
K2HPO4 = 2310.69244498805 kg
H2O = 121.6154 kg

Reaksi yang terjadi :

2 K2HPO4 (s) K4P2O7(s) + H2O

Tinjauan reaksi :
Berat K2HPO4 (s) = 2310.69244498805 kg
Mol K2HPO4 = 13.2798416378624 kmol
produk K4P2O7 = (1/2) x 13.2798416378624 = 6.63992081893118
= 6.63992081893118 (kmol) x 330(kg/kmol)
= 2191.17387024729 kg
produk H2O = (1/2) x 13.2798416378624 = 6.63992081893118
= 6.63992081893118 (kmol) x 18(kg/kmol)
= 119.518574740761 kg

Produk K4P2O7 = 2191.17387024729

Total H2O = H2O pada feed + H2O produk reaksi
= 121.615391841476 + 119.518574740761
= 241.133966582238 kg
Asumsi kehilangan padatan = 0.1% (Petrochemical Handbook : 4.22)
maka produk solid = 99.9%
produk K4P2O7 = 2191.17387024729 x 99.9%
= 2188.98269637704 kg
kehilangan K4P2O7 = 2191.17387024729 - 2188.98269637704
= 2.19117387024744 kg
Kadar air pada produk = 0.08% (shanghai wanglong chemical)
maka produk solid = 99.92%
produk K4P2O7 = 2188.98269637704 kg
Produk K4P2O7 akhir = 2190.73528460473 kg
berat air pada K4P2O7 akhir = 2190.73528460473 - 2188.98269637704
= 1.75258822768365 kg
air pada feed = 241.133966582238 kg
penguapan air = 241.133966582238 - 1.75258822768365
= 239.381378354554 kg
Neraca massa Rotary Kiln
Masuk ( kg ) Keluar ( kg )
Cake Produk K4P2O7 Ke cooler

K4P2O7 = 2310.69244498805 K4P2O7 = 2188.98269637704

H2O = 121.6154 H2O = 1.75258822768365

Campuran ke cyclone

K4P2O7 = 2.19117387024744
H2O = 239.381378354554

Total = 2432.30783682953 Total = 2432.30783682953

7. CYCLONE
Fungsi : Memisahkan padatan dan udara panas

campuran bahan
panas + padatan CYCLONE

Feed masuk :
K4P2O7 = 2.19117387024744 kg
H2O (uap) = 239.381378354554 kg
Asumsi efisiensi cyclone = 99% ( Ludwig : 165 )
maka kehilangan solid = 1%
kehilangan solid = 2.19117387024744 x 1% =
produk solid = 2.19117387024744 - 0.02191173870247 =

Neraca Massa Cyclone

Masuk ( kg ) Keluar ( kg )
Campuran dr Kiln : Solid

K4P2O7 = 2.19117387024744 K4P2O7 = 2.16926213154496

H2O (gas) = 239.381378354554
Campuran ke udara bebas:

K4P2O7 = 0.02191173870247
H2O (gas) = 239.381378354554
Total = 241.572552224801 Total = 241.572552224801

8. ROTARY COOLER
Fungsi : Mendinginkan bahan dengan bantuan udara panas dan Mengeringkan Cake denganudara panas
Udara bebas + padatan

K4P2O7 Rotary Cooler

Kondisi operasi:
Tekanan Operasi: 1 atm
Suhu Operasi: 35°C
Feed masuk :
Komponen Dr kiln Dr cyclone Total
K2HPO4 = 2189.0 2.16926213154496 2191.15195850859
H2O = 1.752588 1.75258822768365
2190.7 2.16926213154496 2192.90454673627

asumsi kehilangan padatan = 0.1% ( Petrochemical Handbook : 4.22 )

Maka produk solid = 99.90%
Terdiri dari :
Komponen feed (kg) kehilangan solid (kg) Produk solid (kg)
K4P2O7 2191.15195850859 2.19115195850859 2188.96080655008
H2O 1.75258822768365 0.001752588227684 1.75083563945596
2192.90454673627 2.19290454673627 2190.71164218953

Neraca Masuk Rotary Cooler

 Masuk ( kg ) Keluar ( kg )
Produk dr Kiln : Produk K4P2O7 ;

K4P2O7 = 2188.98269637704 K4P2O7 = 2188.96080655008

H2O = 1.75258822768365 H2O = 1.75083563945596

Produk dr Cyclone : Campuran ke Cyclone :

K4P2O7 = 2.19115195850859
K4P2O7 = 2.16926213154496 H2O = 0.00175258822768

Total = 2192.90454673627 Total = 2192.90454673627

9. CYCLONE-2

campuran bahan
panas + padatan CYCLONE

Padatan

Feed masuk :
K4P2O7 = 2.19117387024744 kg
H2O (uap) = 0.00175258822768 kg

Asumsi efisiensi cyclone = 99% ( Ludwig : 165 )

maka kehilangan solid = 1%
kehilangan solid = 2.19117387024744 x 1% =
produk solid = 2.19117387024744 - 0.02191173870247 =

Neraca Massa Cyclone

Masuk ( kg ) Keluar ( kg )
Campuran dr Kiln : Solid

K4P2O7 = 2.19117387024744 K4P2O7 = 2.16926213154496

H2O (gas) = 0.00175258822768
Campuran ke udara bebas:

K4P2O7 = 0.02191173870247
 H2O (gas) = 0.00175258822768
Total = 2.19292645847512 Total : = 2.19292645847512

10. BALL MILL

Fungsi : Menghaluskan Bahan hingga 200 mesh

Kondisi Operasi :
Tekanan Operasi : 1 atm
Suhu Operasi : 32°C
Feed masuk :
K4P2O7 = 2188.96080655008 kg 2.16926213154496 kg
H2O = 1.75083563945596 kg 0.00175 kg
Total = 2191.13006868162 kg 1.75259 kg

Ukuran feed masuk = 10 mesh

ukuran feed keluar = 60 mesh

ukuran yang tidak sesuai ( reject ) = 5%

bahan dengan ukuran sesuai = 95%
Berat bahan masuk = 2191.13006868162 kg
Berat produk 60 mesh= 95% dari feed
Berat produk 60 mesh= 95% x 2191.130 = 2081.57356524754
Berat produk yang tidak sesuai = 2191.13006868162 - 2081.57356524754
= 109.556503434081

jadi :
K4P2O7 = 2191.1301 = 109.556503434081 = 2081.5736
H2O = 1.75084 = 0.0875417819728 = 1.66329

Neraca massa
Masuk ( kg ) Keluar ( kg )

fresh feed
K4P2O7 = 2081.5736 K4P2O7 = 2191.13006868162
H2O = 1.66329 H2O = 1.75084

recycle
K4P2O7 = 109.556503434081
H2O = 0.0875417819728
Total = 2192.8809 Total : = 2192.8809

11. SCREEN
Fungsi : Memisahkan ukuran 60 mesh

Kondisi Operasi :
Tekanan Operasi 1 atm
Suhu Operasi: 32°C

Feed masuk :
K4P2O7 = 2191.13006868162
H2O = 1.75084

Asumsi ukuran oversize 5% ( Perry 7ᵉᵈ : 21-14 )

Berat ukuran undersize = Feed - Berat oversize

Tersiri dari :
Komponen Feed (kg) Oversize (kg) Undersize(kg)
K4P2O7 2191.1301 109.5565 2081.5736
H2O 1.75084 0.08754 1.66329

Neraca massa:
Masuk ( kg ) Keluar ( kg )
Undersize
K4P2O7 = 2081.5736
K4P2O7 = 2191.1301 H2O = 1.75084
H2O = 1.75084 2083.32
Oversize :
K4P2O7 = 109.5565
H2O = 0.08754

Total = 2193 Total : = 2193

POTTASIUM PYROPHOSPHATE

368852 x 1000
x 330
368852000
7920
kg/jam
 2157.1957 kg

kg = 1833.62 kg
kg = 323.58 kg

gr /100gr H2O

Keluar ( kg )

= 1833.62
= 1211.90770505618

= 3045.52

uk dipotassium phosphate
Gas buang ( 60°C )

K₂HPO₄ (60°C )
 = 680 : 595

2139.21908404167 kg

1604.41431303125 kg
534.805 kg

kg

32.6847835606061

= 2843.57616977273 kg
1485.2292497775

+ 588.326104090909

Keluar ( kg )
= 348.3871079725
= 2.860
= 2843.57616977273
= 2335.039

= 5529.862

K2HPO4 64,03%
 100%
x

gr/cc (Perry 7th ed)

1.7800 100%
2.7800 x
64.03%

.......... ( 1 )

= 348.3871079725
= 2.85991856155329
= 2843.57616977273
= 1246.26767558546
 4441.09087189224
= 1088.77090457205

= 5529.862

kristal K2HPO4 + motherliquor

r ( kg )
348.3871079725
2.85991856155329
411.268332943201
1246.26767558546

2432.30783682953

4441.09087189224

Filtrat ( liquid )
 1124.6523 kg

g)

2310.69244498805
121.6154

348.3871
411.2683
 1246.2677
2.8599
4441.091

H2O uap

K4P2O7

6.63992081893118 kmol

6.63992081893118
emical Handbook : 4.22)

i wanglong chemical)

g)

2188.98269637704
1.75258822768365

2.19117387024744
239.381378354554

2432.30783682953

CYCLONE Udara panas

Padatan
 0.02191173870247 kg
2.16926213154496 kg

g)

2.16926213154496

0.02191173870247
239.381378354554
241.572552224801

anudara panas
bas + padatan Udara panas

Cooler K4P2O7
 Udara panas

0.02191173870247 kg
2.16926213154496 kg

g)

2.16926213154496

0.02191173870247
 0.00175258822768
2.19292645847512

2081.57356524754
2081.57356524754

2081.5736 kg
1.66329 kg

g)
 2191.13006868162
1.75084

2192.8809

g)

2081.5736
1.75084
2083.32

109.5565
0.08754

2193