D.1 Continous Stirred Tank Reaktor : Muh. Nur Ichsan Tamiogy (180140142)
Kode : CSTR-100
Fungsi : Tempat terjadinya reaksi PF resin dari
Phenol dan Formaldehida
Tipe Perancangan : Silinder tegak dengan Torispherical flange dan dishedhead
sebagai tutup atas dan bawah
Kondisi Operasi,
Temperatur : 95oC = 368,15 oK
Tekanan : 1 atm
Laju alir massa : 4.419,188.kg/jam
Katalisator : Asam Sulfat
Jenis Reaksi : Eksotermis
Konversi : 98%
= 8,0718 m3/jam
laju alir mol
Konsentrasi awal (CA0) = laju alir volumetrik
161,2642 kmol/jam
= 8,0718 m3 /jam
= 19,9786 kmol/m3
Faktor keamanan 20% maka volume yang akan mengisi reaktor adalah 80%
Vr = 0,8 x 8,0718 m3/jam
= 6,4574 m3/jam
K = Aе-Ea/RT
K = (28,99) е-(135,88)/(8,314)(368,15)
K = (28,99) е-0,04524
K = 27,7077/jam
Keterangan :
CAO = konsentrasi formaldehida mula - mula
CPO = konsentrasi fenol mula – mula
τ = waktu tinggal
V = volume reaktor
Fv = laju alir
XA = konversi formaldehida
Jika,
CA = CAO – (1 – XA)
Cp = CPO – CAO XA
CAO = 35,5990
CPO = 36,3255
M = CPO / CAO
= 1,0204
Maka,
-rA = k [ CA0 (1-XA)] [CPO - CAO XA]
= k CA02 (1-XA) (CPO / CAO - XA)
= k CA02 (1-XA) (1,0204 - XA)
= 22,7077 . 35,59902 (1- 0,98) (1,0204 – 0,98)
= 28.777,2139 x (0,02)(0,0404)
= 23,2519
Steady state,
FA0 = V0 . CAO
τ = V/V0
FA0 . XA = (-rA) V
𝑉 𝑋𝐴
=
𝐹𝐴0 −𝑟𝐴
𝑉 𝑋𝐴
=
𝑉0 𝐶𝐴0 −𝑟𝐴
τ 𝑋𝐴
=
𝐶𝐴0 −𝑟𝐴
𝐶𝐴0 𝑋𝐴
τ=
𝐾𝐶2𝐴0 (1−𝑋𝐴 )(𝑀−𝑋𝐴 )
35,5990 . 98%
τ=
27,7077 .35,5990 2 (1−98%)(1,0204−98%)
= 49,0014 m3
= 504,1070 ft3
Ruang bebas reaktor direncanakan 20% dari volume minimum reaktor, maka :
Volume reaktor, V = 0,2 x 49,0014 m3
= 9,8003 m3
3 8 x 49,0014
Dt =√ 3 x 3,14
3 392,0112
=√ 9,42
= 3√41,6148
= 3,4654 m
= 136,4331 in
Tinggi tangki H
3
Hs = 2 Dt
3
= 2 x 3,4654 m
= 5,1981 m
= 222.8897 in
= 0,8664 m
= 22,6102 in
= 21,7790 m3
5,4434 m3
=1
4
3,14 x (3,4654 m)2
= 2,0010 m
D.1.7 Menghitung Tekanan desain
Keterangan :
ρ = total densitas (kg/m3)
g = percepatan gravitasi = 32,174 ft/det2
gc = Faktor konversi percepatan gravitasi = 32,174 ft/det2
P = tekanan hidrostatik (Psi)
Phidrostatik = ρh g
= 1030,9729 x 2,0010 x 9,8
= 20.217,1724 Pa
= 2,9322 psi
Poperasi = 1 atm
= 14,6959 Psi
Pdesain = Phidrostatik + Poperasi
= 2,9322 psi + 14,6959 Psi
= 17,6281 psi
= 2,5106 in
= 0,0638 m
ID shell =D
= 136,4331 in
OD shell = ID + 2t
= 136,4331 in + (2 × 2,5106) in
= 141,4543 in
Tutup reaktor terbuat dari bahan yang sama dengan shell, maka:
Diameter tutup = 3,4654 m = 136,4332 in
Tebal tutup tangki = 2,5106 in = 0,0638 m
Dari tabel 5.7 Brownell and Young, 1959 diperoleh:
r = 132in = 3,3528 m
Radius sudut dalam, icr = 8 3/8 in = 0,2127 m
Straight flange, sf = 1 1/2 in = 0,0381 m
Dimensi keseluruhan (OA) = t + b + sf (Brownell dan Young, 1959)
Dimana :
OA = tinggi keseluruhan tutup tangki
a = radius dalam
b = pinggang bagian dalam
r = radius pinggang
ID
a = 2
3,4654 m
= 2
= 1,7327 m
AB = a – icr
= 1,7327 m – 0,2127 m
= 1,5198 m
BC = r – icr
= 3,302 m – 0,2127 m 2,3098
= 3,0893 m 9,5438
AC = √BC2 -AB2
= 2,6896 m
b = r – AC
= 3,302 m – 2,6896 m
= 0,6124 m
OA = t + b + sf
= 0,0638 m + 0,6124 m + 0,0381 m
= 0,7143 m
= 28,1220 in
Tinggi keseluruhan reaktor
H = Hs + (2 × OA)
= 5,1981 m + (2 × 0,7143 m)
= 6,6267 m
= 21.7411 ft
= 260.8937 in
Perhitungan dimensi pengaduk dilakukan berdasarkan rumus pada Tabel 3.4-1
dan Gambar 3.4-4 Geankoplis 1993.
Da H C 1
= 0,3 s/d 0,5 =1 =
Dt Dt Dt 3
W 1 L 1 J 1
= = =
Da 5 Da 4 Dt 12
Dimana:
C = Jarak pengaduk dari dasar tangki (m)
Da = Diameter pengaduk (m)
Dt = Diameter tangki (m)
H = Panjang efektif tiang pengaduk (m)
J = Lebar baffle (m)
L = Panjang daun pengaduk (m)
W = Lebar pengaduk (m)
▪ Diameter pengaduk (Da)
Da = 0,3 (Dt) = 0,3(3,4654 m)
Da = 1,0396 m
▪ Tinggi efektif tiang pengaduk (H)
H = Dt
H = 3,4654 m
▪ Jarak pengaduk dari dasar tangki (C)
1 3,4654 m
C = Dt =
3 3
C = 1,1551 m
▪ Lebar pengaduk (W)
1 1,0396 m
W = Da =
5 5
W = 0,2079 m
▪ Panjang daun pengaduk (L)
1 1,0396 m
L = Da =
4 4
L = 0,2599 m
▪ Lebar baffle (J), dimana jumlah baffle yang digunakan yaitu 4 unit
1 3,4654 m
J = Dt =
12 12
J = 0,2888 m
Dengan :
Dt = diameter reaktor
N = kecepatan putaran pengaduk (rpm)
WELH = water equivalent liquid high (in)
WELH = ZI x Sg
ZI = Hc + OA + Sf
Sg = specific gravity
Dari perhitungan yang diperoleh :
Da = 1,0396 m
= 40,9291 in
Hc = 2,0010 m
= 78,7795 in
OA = 0,7143 m
= 28,1220 in
Sf = 1 ½ in
ρair = 952,2 kg/m3
ρcampuran = 1.030,9729 kg/m3
Sehingga diperoleh,
ρcampuran
Sg = ρair
1.030,9729 kg/m3
= 952,1 kg/m3
= 1,0828
ZI = Hc + OA + Sf
= 78,7795 in + 28,1220 in + 1 ½ in
= 108,4015 in
WELH = Hc x Sg
= 78,7795 in x 1,0828
= 83,3024 in
Maka,
600 WELH
N = π Da(in) √2Da(in)
600 85,3024
= 3,14 x 40,9291 √2 x 40,9291
= (4,6686) (1,0421)
= 4,8651 rpm
= 0,5088 rps
Untuk menentukan aliran menggunakan rumus:
Da2 x N x ρ
NRe = μ
Dimana,
Da = Diameter reaktor (ft) = 3,4108 ft
N = Jumlah putaran (rps) = 0,5088 rps
ρ = densitas campuran (lb/ft3 ) = 64,3615 lb/ft3
µ = viskositas campuran (lb/ft.s) = 0,0005 lb/ft.h
= 736.023,1948
Dimana,
S = maksimum design, bearing stress yang diizinkan (lb/in2)
T = momen putar (lb/in) = 63,025 lb/in
D = diameter poros (in)
Dimana,
H = daya motor pada poros = 1,0785 hp
N = putaran pengaduk = 4,8651 rpm
Sehingga,
lb
63,025in x 1,0785
τ = 4,8651
= 13,9714 lb/in2
Bila menggunakan Hot Roller Steel SAE 1020 (mengandung 20% carbon), dengan
batas = 36.000 lb/in2, maka:
S = 20% x 36.000 lb/in2
= 7.200 lb/in2
Jadi,
16 x τ
D = (πxS)
16 x 13,9714 lb/in2
=( )
3,14 x 7.200 lb/in2
= 0,0099 in
Maka,
L = (232,5236 in + 10,2322 in) – 108,4015 in
= 134,3543 in
= 3,4126 m
= 0,0608 ft3/s
Asumsi aliran
Dari Peters dan Timmerhause 3th, persamaan 45 hal 381, didapat :
Di optimal = 3,9 x Q0,45 x ρ0,13
= 3,9 x (0,0608)0,45 x (56,2476)0,13
= 1,8675 in
1,6755 lb/jam
=
112,6200 lb/ft3
= 0,0149 ft3/s
Dari Peters & Timmerhause, persamaaan 45 hal 381, didapat:
Di Optimal = 3,9 × QL0,45 × ρ0,13
= 3,9 × (0,0149 ft3/det)0,45 × ( 112,6200 lb/ft3)0,13
= 1,0854
Digunakan pipa standar 1 1/4 in, (Geankolpis, 1993) Apendix A.5, dimana:
OD = 1,660 in = 0,045 ft
ID = 1,380 in = 0,030 ft
Luas (A) = 0,01040 ft2
3. Nozzle Produk
Laju alir = 8.321,8026 kg/jam = 5,0962 lb/s
Dimana,
P = tekanan desain (psi)
Do = diameter luar gasket (in)
Di = diameter dalam gasket (in)
y = yield stress (lb/in2)
m = faktor gasket
Dari Gambar 12.11 Brownell and Young, untuk material gasket stainless steel
diperoleh:
y = 9.000 lb/in2
m = 3,75
sehingga,
do 9.000−(15,57090693 x 3,75)
=√
di 9.000−15,57090693 (3,75+1)
do
= √1,00198
di
do
= 1,00099
di
do = 1,00099 x 136,4331 in
do = 136,5682 in
Nilai bo = b
Sehingga b = 0, 03375 in
Dengan menggunakan persamaan 12.88 hal 54 (Brownell young, 1959) adalah:
Wm2 = Hy = π x b x G x y
Dimana,
Hy = berat beban bolt maksimum (lb)
Bo = effective gasket (in)
G = diameter gasket rata-rata (in)
Sehingga,
Wm2 = Hy = 3,14 x 0,03375 in x 136,5006 in x 9.000 lb/in2
= 130.190,8598 lb
= 12,9874 in2
= 23,5707 buah
Jadi digunakan baut dengan ukuran 1 in sebanyak 24 buah.
Boltingarea diameter (C) = ID shell + 2 (1,45 × Ho ) + R
Dimana,
ID shell = 136,4331 in
Ho shell = tebal shell = 3 in
Sehingga,
C = 136,4331 in + 2 (1,45 × 3 in) + 1,375 in
= 144,1581 in
Perhitungan diameter Flange luar :
Flange OD (A) = C + 2E
= 144,1581 in + (2 × 1,0625 in)
= 146,2831 in
Koreksi lebar gasket
Ab actual = jumlah bolting × root area
= 23,5707× 0,551 in2
= 12,9875 in2
Lebar gasket minimum
Ab actual ×fallaw
Nmin =
2yaπG
Hubungan lever arm diberikan pada persamaan 12.101 hal 242 (Brownell young,
1959)
hG = ½ (BC-G)
= ½ (144,1581 in – 136,5006 in)
= 3,8287 in
Moment flange,
Ma = W x hg
= 1.686.738,575 lb x 3,8287 in
= 6.458.015,982 lb.in
Perbedaan antara beban baut flange dengan gaya hidrostatik total (HG) adalah:
HG = Wm1 – H
= 259.748,9462 lb – 257.836,4316 lb
= 1.912,5146 lb
Perbedaan antara gaya hidrostatik total dengan gaya hidrostatik dalam area flange
adalah:
HT = H - HD
= 257.836,4316 lb – 257.581,4936 lb
= 254,9380 lb
Hubungan lever arm
hT = ½ (hD + hG)
= ½ (3,8625 in + 3,8287 in)
= 3,8456 in
Moment diberikan:
MT = HT x hT
= 254,9380 lb x 3,8456 in
= 980,3896 lb.in
Dimana,
A
K =B
146,1581 in
= 136,4331 in
= 1,07128
= 2,2653 in
Gambar D.4 Detail untuk flange and bolt pada head reaktor
D.1.18 Menentukan Tebal Jacket
Perencanaan jacket berdasarkan (Brownell young, 1959)
Ditetapkan jarak jacket = 5/8 in
Diameter luar reaktor (OD) = 3,5929 m
Diameter dalam jacket (IDj) = Diameter luar reaktor + jarak jacket
= 141,4543 in + 5/8 in
= 142,0793in
= 3,6088 m
Dimana,
Umur Alat = 20 tahun
P = tekanan desain (psi) = 17,6281 psi
D = Diameter dalam jacket = 142,0793 in
S = Working stress yang diizinkan (psi) = 18.750 psi
E = Effisiensi pengelasan = 0,8
CA = Korosi yang diizinkan (in) = 0,125
PxD
t = + CA x Umur alat
2SE−0,2P
17,6281 psi x 142,0793 in
= + 0,125 in/tahun x 20 tahun
2 x 18.750 psi x 0,8−0,2 x 17,6281 psi
= 2,5669 in
= 0.0653 m
6,2648 lb/s
=
62,8649 lb/ft3
= 0,0996 ft3/s
Dari Peters & Timmerhause, persamaaan 45 hal 381, didapat:
Di Optimal = 3,9 × QL0,45 × ρ0,13
= 3,9 × (0,0996 ft3/det)0,45 × ( 62,8649 lb/ft3)0,13
= 2,3664 in
Digunakan pipa standar 2 1/2 in, (Geankolpis, 1993) Apendix A.5, dimana:
OD = 2,875 in = 0.2396 ft
ID = 2,649 in = 0,2208 ft
Luas (A) = 0,03322 ft
Maka,
1
Ws = 4 x 3,14 ((141,4543 in)2 – (136,4331 in)2) x 222.8897 in x 1,134 lb/in3
= 276.852,9060 lb
A = 6,28 × Rc × h
= 6,28 × 63 in × 119,6947 in
= 47.356,0432 in2
Wd =Axtxρ
= 47.356,0432 in2 x 2,413 in × 1,134 lb/in3
= 129.582,3299 lb
Wc =m×t
= 8.321,8388 kg/jam × 1,5003 jam
= 12.385 kg
= 27.525,2751 lb
V = ¼ x π x D2 x L
= ¼ x 3,14 x (0,0099 in)2 x 10,2323 in
= 0,00079 in3
Maka,
Wp =V×ρ
= 0,00079 in3 × 1,134 lb/in3
= 0,00089 lb
Maka,
Wi = 5.713,5691 in3x 1,134 lb/in3
= 6.499,5994 lb
Berat total,
WT = Ws + 2Wd + Wc + Wp + Wi + Wa
= 276.852,9060 lb + 2(129.582,3299 lb) + 27.525,2751 lb + 0,00089 lb
+ 6.499,5994 lb + 49.833,5231 lb
= 619.875,9643 lb
= 281.171,008 kg
Dengan faktor keamanan adalah 10%, maka berat total reaktor adalah:
= 1,1 × 281.117,008 lb
= 309.228,7088 lb
18.000
= 140,3222
1+
18000 (2,28)2
= 14.870,7384 lb/in2
fc < 15.000 psi, sehingga memenuhi ( B & Y, 1959).
Jarak antara center line kolom penyangga dengan center line line shell (a):
a = ½ × lebar flange + 1,5
= ½ × 3,565 + 1,5
= 3,2825 in
y = ½ × lebar flange
= ½ × 3,565 in
= 1,7825 in
Z = I/y
= 26 in4 /1,7825 in
= 14,5862 in3
Beban kompresi total maksimum tiap lug (P) :
= 84.335,1024 lb
Keterangan :
Pw = beban angin total pada permukaan yang terbuka, lbm
H = tinggi reaktor di atas pondasi, ft
L = jarak dari fondasi ke bagian bawah reaktor, ft
Dbc = diameter anchor-bolt circle, ft
n = jumlah penyangga, n
ΣW = berat reaktor lb
Menghitung beban ekstentrik :
Pa
fac = Z
84.335,1024 lb × 3,2825 in
= 14,5862 in3
= 13.913,1649 lb/in2
f = fc – fac
= 14.620,886 lb/in2– 13.913,1649 lb/in2
= 1.707,7218 lb/in2
Luas penampang lintang :
P
A = f
84.335,1024 lb
= 5.777,0986 lb/in2
= 24.257,2524 lb
Luas lubang baut :
P bolt
Abolt = f bolt
24.257,2524
= 12.000
= 2,0214 in2
Keterangan :
F bolt = stress maksimum yang dapat ditahan oleh setiap baut
= 12.000 psi
Digunakan baut standar dengan diameter = 2 ¼ in (Tabel 10.4 B&Y, 1959).
Ketebalan plat horizontal :
6 My
thp = √fallow
Pbolt 2l
My = 4π
[(1+µ) ln πe + (1-γ1)]
Dengan :
thp = tebal horizontal plat, in
My = bending momen maksimum sepanjang sumbu radial, in-lb
P = beban baut maksimum, lb
A = panjang kompresi plate digunakan
h = tinggi gusset
= 20 in (Brownell & Young 1959)
b = lebar gusset, in
l = jarak radial dari luar horizontal plate luar ke shell, in
µ = passion ratio (untuk steel, µ= 0,3)
f allow = stress yang diizinkan = 12,000 psi
γ1 = konstanta dari tabel 10.6 Brownell and Young,1959)
e = jarak konentrasi beban
= setengah dari dimensi, in
=½x
Ketebalan plat kompresi :
b
I
= 10 ¼ in / 6 in
= 1,70833 in
Dari tabel 10.6 Brownell and Young, 1959 diperoleh γl
γl = 0,009683
24.257,2524 2×6
My = 4π
[(1+0,3) ln π × 0,8125 + (1-0,0968)]
= 6.155,0463 lb-in
6 × 6.155,0463
thp =√ 12.000
= 189,1111 in2
Dengan :
Pb = base plate loading
F = kapasitas bearing (untuk cor, f = 300 psi)
(Ie-0,8 fw)
n baru = 2
9,9932 -(0,8 × 4,944)
= 2
= 3,0190 in
15,4940 - (0,95 hb)
m baru = 2
15,4950 - (0,95 × 10)
= 2
= 2,9975 in
Tekanan aktual, Pa :
Pb
Pa = Abp baru
56.733,3333
= 154,8750
= 366,3168 psi
Tebal base plate
Tbp = (0,00015 × Pa × n2)1/2
= (0,00015 × 366,3168 × 3,01902)1/2
= 0,7077 in (digunakan plat standar 1 in)
Tinggi pondasi = 30 in
Volume pondasi = 1/3 × tinggi pondasi × ((a + b) + (a × b)1/2)
= 163.987,07205 in3
= 94,89993 ft3
Berat pondasi (W) = V × densitas beton
= 94,89993 ft3 × 140 lb/ft
= 13.285,98963 lb
= 11.296,4843 lb/ft2
= 5,5363 ton/ft2< 10 ton/ft2