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BAB V

NERACA MASSA DAN NERACA PANAS

5.1 Neraca Massa


Basis 1 hari operasi dalam satuan Kg
5.1.1 Neraca massa pada Dryer Tower
Komponen Input (Kg) Output (Kg)
Feed
O2 (g) 883.621,614 883.621,614
N2 (g) 2.916.515,481 2.916.515,481
H2O (g) 84.872,144 -
Sirkulasi
H2SO4 (l) 35.034.480 35.034.480
H2O (l) 533.520 618.392,144
Jumlah 39.453.009,238 39.453.009,238
Tabel 16. Neraca Massa pada Dryer Tower

5.1.2 Neraca Massa pada Sulphur Burner


Tabel 17. Neraca Massa pada Sulphur Burner
Komponen Input (Kg) Output (Kg)
Feed
S(l) 618.237,731 -
N2 (g) 2.916.515,481 2.916.515,481
O2 (g) 883.621,614 265.383,883
SO2 (g) - 1.236.475,463
Jumlah 4.418.374,826 4.418.374,826

5.1.3 Neraca Massa pada Konverter Unggun I, II, III


Tabel 18. Neraca Massa pada Konverter Unggun I, II, III
Komponen Input (Kg) Output (Kg)
Feed
N2 (g) 2.916.515,481 2.916.515,481
O2 (g) 265.383,883 32.305,695

64
65

SO2 (g) 1.236.475,463 304.162,711


SO3 (g) - 1.165.390,940
Jumlah 4.418.374,826 4.418.374,826

5.1.4 Neraca Massa pada Absorber Tower I


Tabel 19. Neraca Massa pada Absorber Tower I
Komponen Input (Kg) Output (Kg)
Feed
N2 (g) 2.916.515,481 2.916.515,481
O2 (g) 32.305,695 32.305,695
SO2 (g) 304.162,711 304.162,711
SO3 (g) 1.165.390,940 -
Sirkulasi
H2SO4 (l) 37.043.880 35.616.276,099
H2O (l) 564.120 564.120
H2S2O7 (l) - 2.592.994,841
Jumlah 42.026.374,826 42.026.374,826

5.1.5 Neraca Massa pada Konverter Unggun IV


Tabel 20. Neraca Massa pada Konverter Unggun IV
Komponen Input (Kg) Output (Kg)
Feed
N2 (g) 2.916.515,481 2.916.515,481
O2 (g) 32.305,695 28.815,428
SO2 (g) 304.162,711 290.201,643
SO3 (g) - 17.451,336
Jumlah 3.252.983,886 3.252.983,886

5.1.6 Neraca Massa pada Absorber Tower II


Tabel 21. Neraca Massa pada Absorber Tower II
Komponen Input (Kg) Output (Kg)
Feed
N2 (g) 2.916.515,481 -
66

O2 (g) 28.815,428 -
SO2 (g) 290.201,643 -
SO3 (g) 17.451,336 -
Sirkulasi
H2SO4 (l) 1.427.603,900 1.406.226,014
H2O (l) 21.740,161 21.740,161
H2S2O7 (l) 38.829,222
Sisa gas yang dibuang
SO2 (g) 290.201,643
N2 (g) 2.916.515,481
O2 (g) 28.815,428
Jumlah 4.702.327,948 4.702.327,948

5.1.7 Neraca Massa Tangki Sirkulasi I


Tabel 22. Neraca Massa pada Tangki Sirkulasi I
Komponen Input (Kg) Output (Kg)
Feed
Injeksi H2O 199.080,979 -
H2SO4 70.650.756,099 73.505.963,901
H2O 1.182.512,144 1.119.380,161
H2S2O7 2.592.994,841 -
Jumlah 74.625.344,062 74.625.344,062

5.1.8 Neraca Massa Tangki Sirkulasi II


Tabel 23. Neraca Massa Tangki Sirukulasi II
Komponen Input (Kg) Output (Kg)
Feed
Injeksi H2O 4.252,102 -
H2SO4 1.406.226,014
H2O 21.740,161
H2S2O7 38.829,222 -
Produk
H2SO4 1.448.981,786
H2O 22.065,712
Jumlah 1.471.047,499 1.471.047,499
67

5.1.9 Neraca Massa Overall


Tabel 24. Neraca Massa Overall
Satuan (kg)
No. Komponen
Input Output
1. Dryer Tower
O2 (g) 883.621,614
N2 (g) 2.916.515,481
H2O (g) 84.872,144
2. Sulphur Burner
S (l) 618.237,731 -
3. Absorber Tower 2
SO2 (g) 290.201,643
O2 (g) 28.815,428
N2 (g) 2.916.515,481
4. Tangki Sirkulasi I
H2O 199.080,979
5. Tangki Sirkulasi II
H2O 4.252,102 -
(Produk ) : H2SO4 (l) 1.448.981,786
H2O (l) 22.065,712
Jumlah 4.706.580,050 4.706.580,050

Efisiensi = Produk X 100%


Bahan Baku

= x 100%

% Yield = 1.471.047,499 kg X 100 %


68

1.790.064,570 kg

= 82 %

Diagram Alir Neraca Massa


69

5.2 Neraca Panas


Basis 1 hari operasi dalam satuan kkal
5.2.1 Neraca Panas Dryer Tower
Tabel 25. Neraca Panas Dryer Tower
Panas Bahan Masuk Panas Bahan Keluar
Komponen
(kkal) (kkal)
Q O2 (g) 1.555.174,040 4.665.522,121
Q N2 (g) 5.833.030,962 17.499.092,885
Q H2O (g) 305.539,717 -
Q H2SO4 (l) 421.990.311,600 447.565.482,000
Q H2O (l) 17.606.160,000 21.643.725,027
Q Kondensasi 50.720.639,502 -
Q Sensibel 3.359.269,448 -
Q Loss - 9.996.303,237
Jumlah 501.370.125,270 501.370.125,270

5.2.2 Neraca Panas pada Blower


Tabel 26. Neraca Panas pada Blower
Panas Bahan Masuk Panas Bahan Keluar
Komponen
(kkal) (kkal)
Q O2 (g) 4.665.522,121 12.922.966,103
Q N2 (g) 17.499.092,885 47.393.376,564
Q dari Blower 38.151.727,661 -
Jumlah 60.316.342,667 60.316.342,667

5.2.3 Neraca Panas pada Sulphur Burner


Tabel 27. Neraca Panas pada Sulphur Burner
Panas Bahan Masuk Panas Bahan Keluar
Komponen
(kkal) (kkal)
Q O2 (g) 12.922.966,103 80.623.623,522
70

Q N2 (g) 47.393.376,564 949.325.789,018


Q S (l) 11.765.064,027 -
Q SO2 (g) - 281.730.934,168
Q Reaksi 1.370.555.770,646 -
Q Loss - 130.956.830,632
Jumlah 1.442.637.177,340 1.442.637.177,340

5.2.4 Neraca Panas pada Waste Heat Boiler


Tabel 28. Neraca Panas pada Waste Heat Boiler
Panas Bahan Masuk Panas Bahan Keluar
Komponen
(kkal) (kkal)
Q SO2(g) 281.730.943,168 92.828.395,359
Q O2(g) 80.623.623,522 25.543.198,696
Q N2(g) 949.325.789,018 291.943.199,634
Q H2O (l) 2.059.200.000,000 2.587.200.000,000
Q Loss - 373.365.553,018
Jumlah 3.370.880.346,708 3.370.880.346,708

5.2.5 Neraca Panas pada Converter Bed I


Tabel 29. Neraca Panas pada Converter Bed I
Panas Bahan Masuk Panas Bahan Keluar
Komponen
(kkal) (kkal)
Q SO2(g) 92.828.395,359 58.356.695,936
Q O2(g) 25.543.198,696 10.041.354,370
Q N2(g) 291.943.199,634 507.473.693,669
Q SO3(g) - 135.464.542,263
Q Reaksi 298.108.438,069 -
Q Pendingin 2.913.054,479 -
Jumlah 711.336.286,238 711.336.286,238
71

5.2.6 Neraca Panas pada Steam Superheater


Tabel 30. Neraca Panas pada Steam Superheater
Panas Bahan Masuk Panas Bahan Keluar
Komponen
(kkal) (kkal)
Q SO2(g) 58.356.695,936 34.221.127,671
Q O2(g) 10.041.354,370 6.559.421,767
Q N2(g) 507.473.693,669 320.743.790,007
Q H2O(g) 2.587.200.000,000 2.840.640.000,000
Q SO3(g) 135.464.542,263 92.008.086,626
Q Loss - 4.363.860,167
Jumlah 3.298.536.286,238 3.298.536.286,238

5.2.7 Neraca Panas pada Converter Bed II


Tabel 31. Neraca Panas pada Converter Bed II
Panas Bahan Masuk Panas Bahan Keluar
Komponen
(kkal) (kkal)
Q SO2(g) 34.221.127,671 30.571.753,632
Q O2(g) 6.559.421,767 4.686.974,270
Q N2(g) 320.743.790,007 388.188.210,502
Q SO3(g) 92.008.086,626 119.252.493,047
Q Reaksi 36.256.872,465 -
Q Pendingin 52.910.132,916 -
Jumlah 542.699.431,451 542.699.431,451

5.2.8 Neraca Panas pada 2nd Heat Exchanger


Tabel 32. Neraca Panas pada 2nd Heat Exchanger
Panas Bahan Masuk Panas Bahan Keluar
Komponen
(kkal) (kkal)
Q SO2(g) 47.735.655,412 49.048.399,321
Q O2(g) 7.085.672,097 7.050.928,609
Q N2(g) 613.401.535,933 612.686.989,640
Q SO3(g) 119.252.493,047 103.198.395,374
Q Loss - 15.490.643,544
Jumlah 787.475.356,489 787.475.356,489

5.2.9 Neraca Panas pada Converter Bed III


Tabel 33. Neraca Panas pada Converter Bed III
Panas Bahan Masuk Panas Bahan Keluar
Komponen
(kkal) (kkal)
Q SO2(g) 26.213.383,796 26.401.323,311
72

Q O2(g) 3.941.505,500 3.505.167,868


Q N2(g) 320.743.790,007 341.757.284,047
Q SO3(g) 103.198.395,374 111.271.526,916
Q Reaksi 7.239.908,644 -
Q Pendingin 21.598.318,820 -
Jumlah 482.935.302,141 482.935.302,141

5.2.10 Neraca Panas pada 1st Heat Exchanger


Tabel 34. Neraca Panas pada 1st Heat Exchanger
Panas Bahan Masuk Panas Bahan Keluar
Komponen
(kkal) (kkal)
Q SO2(g) 30.416.271,908 31.062.616,857
Q O2(g) 3.896.066,773 4.313.779,405
Q N2(g) 381.859.371,908 412.511.949,612
Q SO3(g) 111.271.526,916 55.555.351,483
Q Loss - 23.999.539,336
Jumlah 527.443.236,693 527.443.236,693

5.2.11 Neraca Panas 1st Economizer


Tabel 35. Neraca Panas 1st Economizer
Panas Bahan Masuk Panas Bahan Keluar
Komponen
(kkal) (kkal)
Q SO2(g) 13.898.715,077 6.980.534,217
Q O2(g) 1.915.081,578 1.003.091,818
Q N2(g) 187.298.624,180 100.401.045,428
Q H2O(g) 1.235.520.000,000 1.573.440.000,000
Q SO3(g) 55.555.351,483 27.847.016,502
Q Pendingin 215.483.915,647 -
Jumlah 1.709.671.687,966 1.709.671.687,966

5.2.12 Neraca Panas pada 2nd Economizer B


Tabel 36. Neraca Panas pada 2nd Economizer B
Panas Bahan Masuk Panas Bahan Keluar
Komponen
(kkal) (kkal)
Q SO2(g) 19.443.510.049 11.013.152,334
Q O2(g) 2.509.823,738 1.093.545,475
Q N2(g) 263.798.825,243 122.712.388,857
Q H2O(g) 834.240.000,000 1.235.520.000,000
Q SO3(g) 1.286.163,429 495.268,903
Q Pendingin 249.556.033,109 -
Jumlah 1.370.834.355,568 1.370.834.355,568
73

5.2.13 Neraca Panas pada 2nd Economizer A


Tabel 37. Neraca Panas pada 2nd Economizer A
Panas Bahan Masuk Panas Bahan Keluar
Komponen
(kkal) (kkal)
Q SO2(g) 22.220.739,768 19.443.510.049
Q O2(g) 2.903.154,32 2.509.823,738
Q N2(g) 311.469.270,778 263.798.825,243
Q H2O(g) 1.573.440.000,000 2.059.200.000,000
Q SO3(g) 1.526.136,744 1.286.163,429
Q Pendingin 434.679.020,846 -
Jumlah 2.346.238.322,460 2.346.238.322,460

5.2.14 Neraca Panas Absorption Tower I


Tabel 38. Neraca Panas Absorption Tower I
Panas Bahan Masuk Panas Bahan Keluar
Komponen
(kkal) (kkal)
Q SO2(g) 6.980.534,217 4.014.947,785
Q SO3(g) 27.847.016,502 -
Q O2(g) 1.003.091,818 390.898,905
Q N2(g) 100.401.045,428 40.102.087,862
Q H2SO4(l) 1.027.597.231,200 1.264.021.638,752
Q H2O(l) 43.239.798,000 56.468.412,000
Q H2S2O7 (l) - 35.778.264,522
Q Reaksi 231.535.996,156 -
Q Loss - 37.828.463,496
Jumlah 1.438.604.713,322 1.438.604.713,322

5.2.15 Neraca Panas pada Converter Bed IV


Tabel 39. Neraca Panas pada Converter Bed IV
Panas Bahan Masuk Panas Bahan Keluar
Komponen
(kkal) (kkal)
Q SO2(g) 22.835.015,525 22.220.739,768
Q O2(g) 3.109.423,109 2.903.154,323
Q N2(g) 291.943.199,634 311.469.270,778
Q SO3(g) - 1.526.136,744
Q Reaksi 5.115.422,731 -
Q Pendingin 15.116.240,616 -
Jumlah 338.119.301,614 338.119.301,614
74

5.2.16 Neraca Panas pada Absorption Tower II


Tabel 40. Neraca Panas pada Absorption Tower II
Panas Bahan Masuk Panas Bahan Keluar
Komponen
(kkal) (kkal)
Q SO2(g) 11.013.152,334 9.678.224,778
Q SO3(g) 495.268,903 -
Q O2(g) 1.093.545,475 960.994,508
Q N2(g) 122.712.388,857 107.838.159,905
Q H2SO4(l) 39.601.732,197 41.132.110,920
Q H2O(l) 1.666.383,334 1.793.563,276
Q H2S2O7 (l) - 441.566,557
Q Reaksi 3.467.173,308 -
Q Loss - 18.205.024,464
Jumlah 180.049.644,407 180.049.644,407

5.2.17 Neraca Panas pada 1st Absorption Tower Pump Tank


Tabel 41. Neraca Panas pada 1st Absorption Tower Pump Tank
Panas Bahan Masuk Panas Bahan Keluar
Komponen
(kkal) (kkal)
Q H2S2O7 (l) 35.778.264,522 -
Q H2SO4 (l) 1.711.587.120,752 2.039.055.438.615
Q H2O (l) 79.107.541,920 85.800.489,335
Q Reaksi 223.004.345,505 -
Q Pendingin 75.378.655,251 -
Jumlah 2.124.855.927,950 2.124.855.927,950

5.2.18 Neraca Panas pada 2nd Absorption Tower Pump Tank


Tabel 42. Neraca Panas pada 2nd Absorption Tower Pump Tank
Panas Bahan Masuk Panas Bahan Keluar
Komponen
(kkal) (kkal)
Q H2S2O7 (l) 441.566,557 -
Q H2SO4 (l) 41.132.110,920 40.194.754,755
75

Q H2O (l) 1.814.823,786 1.691.336,862


Q Reaksi 3.339.414,722 -
Q Loss - 4.841.824,367
Jumlah 46.727.915,984 46.727.915,984

5.2.19 Neraca Panas Overall


Tabel 43. Neraca Panas Overall
Komponen Panas Masuk (kkal) Panas Keluar (kkal)
1. Drying Tower
Q O2 (g) 1.555.174,040 -
Q N2 (g) 5.833.030,962 -
Q H2O (g) 305.539,717 -
Q Kondensasi 50.720.639,502 -
Q Sensibel 3.359.269,448 -
Q Loss - 9.996.303,237
2. Blower
Q dari Blower 38.151.727,661 -
3. Sulphur Burner
-
Q S(l) 11.765.065,027
-
Q Reaksi 1.370.555.770,646
130.956.830,632
Q Loss -
4. Waste Heat Boiler
373.365.553,018
Q Loss -
5. Converter Bed I
-
Q Reaksi 298.108.438,069
-
Q Pendingin 2.913.054,479
Komponen Panas Masuk (kkal) Panas Keluar (kkal)
6. Steam Superheated
Q H2O (g) - 2.840.640.000,000
Q Loss - 4.363.860,167
7. Converter Bed II
Q Reaksi 36.256.872,465 -
Q Pendingin 52.910.132,916 -
8. 2nd Heat Exchanger
Q Loss - 15.490.643,544
9. Converter Bed III
Q Reaksi 7.239.908,644 -
Q Pendingin 21.598.318,820 -
10. 1st Heat Exchanger
Q Loss - 23.999.539,336
11. 1st Economizer
Q Pendingin 215.483.915,647 -
76

12. 2nd Economizer B


Q H2O (l) 834.240.000,000 -
Q Pendingin 249.556.033,109 -
13. 2nd Economizer A
Q Pendingin 434.679.020,846 -
14. Absorption Tower I
Q Reaksi 231.535.996,156 -
Q Loss - 37.828.463,496
15. 1st Absorption Tower
Pump Tank
Q H2O (l) 995.404,894 24.954.531,335
Q H2SO4 (l) - 589.467.895,815
Q Reaksi 223.004.345,505 -
Q Pendingin 75.378.655,251 -
16. Converter Bed IV
Q Reaksi 5.115.422,731 -
Q Pendingin 15.116.240,616 -
Komponen Panas Masuk (kkal) Panas Keluar (kkal)
17. Absorption Tower II
Q SO2 (g) - 9.678.224,778
Q O2 (g) - 960.994,508
Q N2 (g) - 107.838.159,905
Q Reaksi 3.467.173,308 -
Q Loss - 18.205.024,464
18. 2nd Absorption Tower
Pump Tank
Q H2O (l) 21.260,510 24.953,527
Q H2SO4 (l) - 593.022,559
Q Reaksi 3.339.414,722 -
Q Loss - 4.841.824,367
Jumlah 4.193.205.824,689 4.193.205.824,689

Efisiensi = Panas Total – Total Panas Yang Hilang X 100 %


Panas Total

Total Panas yang hilang =


1. Q loss Drying Tower = 9.996.303,237 kkal
2. Q loss Sulphur Burner = 130.956.830,632 kkal
3. Q loss Waste Heat Boiler = 373.365.553,018 kkal
4. Q loss Steam superheaeted = 4.363.860,167 kkal
5. Q loss 2nd Heat Exchanger = 15.490.643,544 kkal
6. Q loss 1st Heat Exchanger = 23.999.539,336 kkal
7. Q loss Absorption Tower I = 37.828.463,496 kkal
8. Q loss Absorption Tower II = 18.205.024,464 kkal
9. Q loss 2nd AT pump tank = 4.841.824,367 kkal +
Total panas yang hilang = 619,048,042.262 kkal
77

= 4.193.205.824,689 – 619.048.042,262 X 100 %


4.193.205.824,689

= 85 %
78

Diagram alir neraca panas