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TUGAS PERANCANGAN PABRIK KIMIA
Preliminary Design of Palm Fruit Empty Bunch Into

Gasoline Plant with Capacity 100,000 Tons of Dry
Biomass/year
Nomor : 04
Disusun oleh:
Edi Sugiarto 13/348228/TK/40839
Lesna Christwinarso 13/346947/TK/40712
Pembimbing:
Muhammad Mufti Azis, S.T., M.Sc., Ph.D
DEPARTEMEN TEKNIK KIMIA

FAKULTAS TEKNIK
UNIVERSITAS GADJAH MADA
YOGYAKARTA
2017
i
PRAKATA
Puji syukur penyusun sampaikan ke hadirat Tuhan YME, karena atas

segala rahmat dan karunia-Nya, penyusun dapat meyelesaikan tugas perancangan
pabrik kimia dengan Judul Preliminary Design of Palm Fruit Empty Bunch Into
Gasoline Plant. Tugas Perancangan Pabrik Kimia ini merupakan tugas akhir yang
harus diselesaikan oleh setiap mahasiswa Departemen Teknik Kimia, Fakultas
Teknik, Universitas Gadjah Mada, Yogyakarta, sebagai prasyarat menyelesaikan
jenjang studi S-1.
Pada kesempatan kali ini, penyusun mengucapkan banyak terima kasih

kepada:
1. Pengurus Departemen Teknik Kimia Universitas Gadjah Mada.

2. Muhammad Mufti Azis, S.T., M.Sc., Ph.D. selaku pembimbing atas
segala bimbingan, dukungan dan arahan yang diberikan kepada penyusun
selama pengerjaan tugas ini.
3. Keluarga dan teman-teman yang selalu memberi dukungan baik moril
maupun material terutama di kala penyusun mengalami kesulitan.
4. Semua pihak yang telah membantu selama ini dan yang telah
memberikan perhatian yang tidak dapat penyusun sebutkan satu per satu.
Penyusun menyadari bahwa dalam pengerjaan dan penyusunan tugas

akhir ini terdapat banyak kekurangan dan jauh dari sempurna. Kritik dan saran
sangat penyusun harapkan untuk menyempurnakan tugas akhir ini. Akhir kata,
penulis berharap laporan ini bermanfaat dan dapat bernilai guna bagi semua pihak
yang membutuhkan.
iv
ABSTRACT
The preliminary design of gasoline plant from palm fruit empty bunch is
proposed to utilize 100,000 tons of dry palm fruit empty bunch/year to produce
11,957 tons gasoline/year as main product and 6,925 tons LPG/year as side
product. As raw materials, it is estimated that around 430,000 tons of wet palm
fruit empty bunch/year is required. Additionally, circa 35,000 tons of water/year
as well as 62,000 tons of air/year are required for the process.
The conversion of palm fruit empty bunch to gasoline consists of 3 main

steps namely biomass gasification to yield syngas, methanol synthesis from
syngas and gasoline synthesis from methanol. Biomass gasification is carried out
in a dual bed gasifiers. The first gasifier operates at 2.65 bara and 928ºC and the
second one operates at 2.35 bara and 1048ºC. The syngas from gasifier is reacted
over Cu/ZnO/Al2O3 catalyst and TEGDME to form methanol in a trickle bed reactor
which operates at 50 bar and 240ºC. TEGDME works as methanol absorbent as
well as to keep the reactor operates near isothermal condition. The methanol is
reacted over ZMS-5 catalyst to form hydrocarbon fraction at 2.75 bar and 512ºC
in a fludized bed reactor. Hydrocarbon fraction is separated into a number of
products such as: light gas which is utilised in utility to generate heat, LPG as side
product, and gasoline as main product.
The plant is going to be constructed in Pulau Muda, Teluk Meranti,

Palawan Regency, Riau on a 2 ha land with 287 employees for the plant
operation. The energy required to operate this plant in state of steam equals to
nearly 6 GJ/hr, electricity demand is 4.8 MW and the water demand for utility is
around 53 tons/hr. In addition, the air instrument required is 500 m3/hr.
The results from economic evaluation showed that the amount of fixed
capital for this plant is $ 27,482,667 + Rp 4,734,865,262 and the working capital
is $ 2,634,559 + Rp 13,555,029,424. This plant is classified as a high risk
chemical plant. Economic evaluations shows ROI before tax is 6.8 %, POT before
tax is 6.32 years, BEP is 74.73 %, SDP is 33.7 % and DCFRR is 18.65 %. To sum
up, it can be concluded that the preliminary design of palm fruit empty bunch
conversion into gasoline is attractive and deserves further follow-up.
v
TABLE OF CONTENT
COVER ............................................................................................................................ i
LEMBAR PENGESAHAN ............................................................................................ ii
PERNYATAAN ............................................................................................................... iii
PRAKATA ....................................................................................................................... iv
ABSTRACT ..................................................................................................................... v
TABLE OF CONTENT .................................................................................................. vi
CHAPTER 1 INTRODUCTION ................................................................................... 1
CHAPTER 2 COMPREHENSIVE PROCESS DESCRIPTION ............................... 20
CHAPTER 3 MATERIAL SPECIFICATIONS .......................................................... 21
CHAPTER 4 BLOCK FLOW DIAGRAM ................................................................... 24
CHAPTER 5 MATERIAL BALANCES ...................................................................... 30
CHAPTER 6 HEAT BALANCES ................................................................................. 42
CHAPTER 7 EQUIPMENT SPECIFICATION .......................................................... 48
CHAPTER 8 UTILITY .................................................................................................. 98
CHAPTER 9 PLANT LAYOUT ................................................................................... 161
CHAPTER 10 SHE MANAGEMENT .......................................................................... 168
CHAPTER 11 ORGANIZATORIAL STRUCTURES ............................................... 194
CHAPTER 12 ECONOMY ANALYSIS ....................................................................... 213
CHAPTER 13 CONCLUSIONS .................................................................................... 240
APPENDIX ...................................................................................................................... 241
BIBLIOGRAPHY ........................................................................................................... 287
vi
CHAPTER 1
INTRODUCTION
1.1 Background
Crude oil is an important lifeline for the national economic development. The
price of crude oil has always been fluctuating at best and unpredictable at worst
(Figure 1.1). Publications found before 2014 showed the constant rise in crude oil
price, ranging from 100-135 $/barrel (Isaak, 2014; Lichtblau, 2014). Since the mid of
2014 (Figure 1.1), however, the crude oil price dropped down to 43.41 $/barrel as of
nowadays due to excessive supply of crude oil in market (NASDAQ, 2016). Despite
of low crude oil price in these days, a recent publication predicts that the price of
crude oil will be creeping out to 82.6 $/barrel by the end of 2025 (World Bank,
2016).
Figure 1.1 Fluctuation of Crude Oil Price (EIA, 2016b)
It is generally accepted that relying solely on crude supply to meet the

national energy demand is an insecure practice. It is well known that most of the
crude oil come from regions with unstable politics such as Middle East and South
American countries. Several upheavals which happened in the past such as the Arab
embargo and Iran-Iraq War in the 1970s and 1980s respectively, caused the increase
Chemical Engineering Department, Universitas Gadjah Mada

Edi Sugiarto (13/348228/TK/40839) 1
Lesna Christwinarso (13/346947/TK/40712)
in crude oil price. This fact, of course, leads us to search for the possibility of making
gasoline from other resources beside crude oil, such as biomass.
Indonesia has a great biomass potential for renewable energy generation. Due
to the lack of knowhow and technology, utilization of biomass is still limited in
Indonesia and most of biomass is only used directly as cooking fuels in villages. As a
result, gasoline production from biomass was not feasible because of severe
limitation to apply an advanced technology such as Fischer-Tropsch (FT) process.
The FT process requires massive amount of biomass to gain a reasonable profit. In
addition, the cost for transportation of biomass on long distance is expensive which is
commonly required in Indonesia. Hence, numerous small-scale plants appears to be
more attractive rather than having a single mega plant.
Methanol to Gasoline (MTG) technology-based plant is proposed in this

project. The MTG plant is considered as an attractive option due to its capacity
flexibility which may operate as low as 500 kBD fuel with reasonable profit.
Furthermore, the proposed MTG can produce high octane gasoline with a RON rate
around 97.
Figure 1.2 Refined Petroleum Product Share 2012 (EIA, 2016a)
Figure 1.2 shows petroleum product share for various sectors in Indonesia. As
seen here, motor gasoline takes a significant portion gasoline of around 25% market
share, or owing to 22 MBPD in 2012 (EIA, 2016a). The proposed project is expected
to produce gasoline which may complement the current motor gasoline supply and

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thus stabilize its price. Additionally, the forecast also shows that the transportation
sector will be the main driving force of fuel consumption throughout 2035 (BP,
2016). Indonesia, as a growing country, will also be in constant need of gasoline with
the rise of gasoline consumption around 8% per year through 2020 (Yulianto, 2015).
To anticipate the increase of gasoline demand, the state-owned oil company
PERTAMINA, has initiated a number of projects to speed up the increase of gasoline
production by upgrading Refinery Unit V in Balikpapan and some other massive
projects (The Jakarta Post, 2016). However, even after the best scenario in which
their project works, there would still be a gap to meet the national gasoline demand
and it is predicted that about 175 KBD of petroleum product still needs to be
imported (Yulianto, 2015).
1.2 Raw Material Consideration

The basis of raw material consideration comes from the land coverage of
plantation based crops. From the data in figure 1.3, it can be shown that palm oil
owns almost half of the total plantation area in Indonesia. Hence, the residue from
palm oil production can be regarded as an attractive raw material in this project.
Figure 1.3 Agricultural Area in Indonesia by Commodity (Kementan RI,

2014)
The project is planned to use palm empty fruit bunch (EFB) due to its
abundant availability as shown in Table 1.1. Furthermore, the current practice shows

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that most of EFB has only been retained back to the plantation and left to decompose
naturally to utilize the nutrient. From this fact, it can be concluded that EFB has low
market competition, hence, it can be purchased at a low price (Awalludin et al.,
2015). It should be noted that EFB is uncommon to be processed as fuel due to its
high moisture content. However, the high moisture within the EFB can be utilized to
form steam during gasification, as demonstrated by TNEE gasifier (Corella et al.,
2007)
Table 1.1 Typical Palm Plantation Biomass Availability (Yusoff, 2006)
Biomass Availability ton/ha/year
Empty Fruit Bunches 4.42
Fibres 2.71
Shell 1.10
1.3 Gasoline Market Research
Figure 1.4 Domestic Gasoline Consumption and Production

(https://www.jodidata.org/oil/database/data-downloads.aspx)
Figure 1.4 shows the demand of motor gasoline in Indonesia from 1996 to
2012. It is clear from Figure 1.4 that there is strong trend on the increase of motor
gasoline consumption since 2000. It is also obvious that the gap between

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consumption and production capacity tend to be larger along with time which results
in increasing trend of annual gasoline import. To ensure product distribution, the
plant is going to make partnership with Pertamina to fulfil domestic need of gasoline
RON 95. The standard of gasoline quality specified by Pertamina is described in
Table 1.2.

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Table 1.2 Pertamina High-Octane Gasoline Specification
Limitation
Properties Unit ASTM/IP
Min Max
RON 95 - D-2699
Lead Content gr/liter - 0.013 D-3237
Density at 150C kg/m3 715 770 D-1298/D-4052
RVP at 37.8 0C kPa 45 60 D-323
Washed Gum mg/100ml - 5 D-381
Unwashed Gum mg/100ml - 70 D-381
Induction minute 480 - D-525
Period
Sulfur Content % m/m - 0.05 D-2622/4294
Appearance Clear and Bright Visual
Color Red Visual
Oxygen Content % m/m - 2.7 D-4815
Aromatic %v/v - 40 D-1319
Content
Benzene %v/v - 5 D-4420-94
Content
MMT mg/l Not Detected D-3831-94
Dye Content g/100 l - 0.13
Sediment mg/l - 1 D-5452-97
Sulphur % mass - 0.002 D-3227
Mercaptane
Mn mg/l Not Detected D-3831-94
Fe mg/l Not Detected D-5185

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1.4 LPG Market Research
LPG is a mixture of propane and butane which is the side product of this
proposed plant. LPG is the third highest imported commodity in domestic
marketplace after distillate fuel oil and gasoline. Due to national policy to convert
kerosene to LPG for residential purpose since 2006, the demand for LPG has been
reported to increase significantly. This trend is, unfortunately, followed by declining
domestic production capacity that finally results in increasing import for LPG. Hence,
it can be concluded that the demand for LPG to fulfil the national need is still large.
This decision will also be supported through partnership with Pertamina to fulfill
LPG domestic demand.
1.5 Preliminary Site Selection

Site selection can be driven based on feedstock orientation or market
orientation. Transportation of raw material in large amount is considered as an
expensive factor due to high water content of palm fruit empty bunch (up to 50%).
Hence, feedstock oriented site selection is more feasible and turns out to be the
decisive factor in this case. The primary factor taken into consideration in site
selection is EFB availability which is much related to palm fruit plantation. In
general, the amount of EFB can be estimated based on rule of thumb that 1 mass
palm fruit production produces 2 mass of EFB. Production of palm fruit by area is
described in table 1.3. Riau contributes as the largest palm fruit producer in
Indonesia. By contributing more than 10 million tons of EFB annually, the stability of
EFB supply in Riau is more likely to be reliable for large plant. As a result, we have
selected Riau as the location of this plant.

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Table 1.3 Raw Materials Availability
No Province Plantation Area (Ha) Annual EFB Production (ton)
1 Riau 2,381,895 10,527,975
2 North Sumatra 1,443,882 6,381,958
3 Central Borneo 1,182,737 5,227,697
4 South Sumatra 1,002,196 4,429,706
In order to minimize the cost of raw material transportation, the plant should
be built near to a plantation area. More detailed site selection is conducted to ensure
the availability of land, road, and other supporting facilities. It is conducted by
assistance of map generated by http://www.sustainablepalmoil.org/company/wilmar-
international-ltd/. In term of raw material supply, a flocked plantation area is more
favorable than the scattered one. Figure 1.5 shows the selected location for the plant.
Selected
Plantation Region
Proposed
Chemical Plant
Figure 1.5 Selected Plantation Region
Total plantation area in selected plantation region (Figure 1.5) is approximately

195,810 ha which produces 865482 ton of EFB/year. The proposed chemical plant
location is in Pulau Muda, Teluk Meranti, Palawan Regency, Riau. Since it is a new

Edi Sugiarto (13/348228/TK/40839) 8
plant to be built in Indonesia, we conclude that only half of the EFB produced can be
used as raw material with annual raw material demand is 432,741 ton of EFB/year
which consists of 235,294 ton of EFB/year as raw material and 197,447 ton of
EFB/year to generate heat for the process. Other factors that justify Riau as suitable
plant location are as follows:
 Access to raw material and utility
This plant is surrounded by palm producer regions with estimated annual EFB
availability surpasses 5 million tons per year that spreads within 125 km radius.
Location near river line will provide an advantage in term of water supply and
product shipping. Water for process and utility for plant will be supplied
directly from Kampar River which practically does not need long pipe line.
 Geographical consideration
Earthquake is main geographical-related aspect in determining plant location.

Indonesian Agency for Meteorology, Climatology, and Geophysics categorizes
Riau as a low risk area related to earthquake potential. Governmental records
show that smoke from fire spread as the only possible natural disaster
encountered, which practically does not affect industries in the region.
 Labor
This plant will utilize waste from palm industry that will directly give added
value to fruit plantation where major low-income community in Riau relies
their life on. With 110,000 people in Dumai search for job, this plant will open
new job opportunity for jobseeker in Dumai.
 Governmental Support
Riau is projected to be strategic industrial area to elevate national economic
growth, along with Sei Mangkei in North Sumatera, Bitung in North Sulawesi,
and Kulonprogo in Yogyakarta. Some governmental supports are given to boost
industrial growth in those areas such as incentive, income tax and value added
tax cut. This justifies Riau as suitable plant location.

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1.6 Plant Capacity Justification
Plant capacity is determined by some points of consideration such as gasoline
demand, raw material availability, and production capacity of existing plant. From
gasoline demand point of view Indonesia requires more than 300,000 barrel/day to
fulfill national demand. From raw material availability pont of view there is 432741
ton of EFB/year. From existing plant point of view proven existing production
capacity ranges from 2.5 to 16 thousand barrel/day. Existing production capacities
from various plants are listed in Table 1.4.
Table 1.4 Existing MTG Plant Capacity in the world
Established Plant Capacity

JAMG, Shanxi Province China, CTL, 2.5 KBD
S/U in 2009
JAMG, Shanxi Province China, S/U 25 KBD
2016
G2X Energy: Multi-License Gas to 12.5 KBD
Gasoline Agreement, Lake Charles, LA,
USA
Sundrop Fuel, Louisiana, USA 3.5 KBD
DKRW, Wyoming, USA, Coal to Liquids 15 KBD
ZeoGas LLC, Gulf Coast, USA, Gas to 16 KBD
Gasoline
Proposed plant capacity 0.4 KBD
1.7 Process Selection

There are several routes available to convert biomass to gasoline or other liquid
fuel products namely pyrolysis, hydrothermal treating, Fisher-Tropsch (FT), and
indirect liquefaction through methanol/DME intermediates (often referred as

Edi Sugiarto (13/348228/TK/40839) 10
methanol to gasoline or MTG). Brief description from each technology is discussed
here:
 Pyrolysis refers to thermochemical decomposition of organic material such as
biomass in absence of oxygen to produce wide range of fuel product.
Pyrolysis can be conducted at temperature around 600-1000 K (Dahlquist,
2013). Generally, the product is a mixture of char, bio-oil, and fuel gas. To
produce gasoline, the bio-oil from pyrolysis step has to be processed through
hydro-treatment and refining due to its complexity and composition which
contains oxygenates and probably also other valuable chemicals.
 Hydrothermal treatment converts biomass in water slurries at elevated
temperature and pressure to produce liquid fuel. The process may also involve
the use of catalysts to accelerate and control the product selectivity. Typically,
it is conducted within the temperature range of 523-647 K and pressure of 4-
22 MPa (Gupta and Demirbas, 2010). The liquid product is known as bio-
crude and it has similar specification to bio-oil produced from pyrolysis.
However, bio-crude has higher energy density as well as lower oxygenates
content than bio-oil from pyrolysis (Brown and Stevens, 2011). Similar to
pyrolysis, conversion of biomass to liquid fuels (gasoline standard) from
hydrothermal treatment is economically challenging due to the difficulty to
refine the intermediate products.
 Fischer-Tropsch (FT) as well as MTG synthesis require biomass gasification
step before it is converted to liquid fuels. Gasification is a thermochemical
reaction utilizing steam or oxygen at elevated temperature and pressure to
produce crude syngas. After purification, the syngas undergoes FT reaction
and refining, or methanol synthesis and MTG reaction. The simplified block
diagram of FT and MTG synthesis route can be seen in Figure 1.6.

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Figure 1.6 Simplified Block Diagram of FT and MTG Synthesis Route
For the FT synthesis, metals (usually iron or cobalt) catalysts are used to
convert syngas into linear organic alkanes and alkenes, as well as some
oxygenates. The product distribution typically follows Anderson-Schulz-Flory
distribution. It is known that the operating condition such as pressure,
temperature, space velocity and H2:CO ratio may influence the product
selectivity.
The commercial process of coal-based FT is usually conducted at low
temperature and low pressure (T=220-250oC, P=25-45 bar) or combination of
high temperature and low pressure (T=330-350oC, P=25 bar). The Low
Temperature FT (LTFT) produces large amount of paraffin while High
Temperature FT (HTFT) produces more olefins and oxygenated components
(Laurence, 2009). The mixture of FT products need to be refined by catalytic
cracking, hydrogenation, and/or isomerization to produce specific liquid fuel
products.
 For the MTG synthesis route, the overall conversion process uses methanol as
the intermediate. Methanol is then converted into gasoline with the aid of
ZSM-5 catalyst. Fixed bed and fluidized bed reactors have been used to
convert methanol to gasoline. ExxonMobil in 1980 used fixed-bed reactor
which operates in temperature range of 343-510oF (Tan et al., 2015). The
recent commercial plants use fluidized-bed reactor to produce higher octane
gasoline and operates at temperature range of 413oC (Keil, 1999).
A study by Amundson in 2016 conducted economic analysis by comparing
the cost of shorgum conversion to gasoline by FT and MTG technologies. The
Edi Sugiarto (13/348228/TK/40839) 12
result showed that MTG has better performance than the FT technology. MTG
showed lower capital investment, lower operating cost and hence lower fuel
production cost for gasoline production from shorgum. For this reason, we
have selected MTG technology to convert palm oil empty fruit bunch to
gasoline.
As stated in Figure 1.10, MTG technology consists of 3 main parts namely
gasification, methanol synthesis and methanol conversion to gasoline. Biomass
gasification converts biomass to syngas which is a mixture of H2, CO, CO2, CH4, tar,
NH3, H2S, and small particulates. For gasification step, there are several reactors
available in the market such as entrained flow, bubbling fluidized bed (BFB) and dual
fluidized bed (DFB) reactors. DFB reactor is selected in this work due to low
manufacturing cost for syngas production and good tolerance to feedstock variation.
This is essential because POEFB may contain different composition due to weather
changes. Furthermore, syngas produced from DFB has high H2 content which is
beneficial in subsequent reactor (i.e. methanol synthesis).
Conversion of syngas which consists of mostly CO, H2, and CO2 to methanol
undergoes exothermic equilibrium reaction. The reactions take place during methanol
formation are as follows.
CO2 + 3H2 CH3OH + H2O (2.1)
CO + 2H2 CH3OH (2.2)
CO + H2O CO2 + H2 (2.3)
Syngas to methanol conversion is strictly limited by chemical equilibrium
which is much related to temperature. Conversion of syngas into methanol can be
achieved by numerous technologies which generally can be classified into gas phase
and liquid phase methanol production. Gas phase reaction is a mature technology and
widely applied in several industries worldwide. Examples from the recent technology
for gas phase technologies are Haldor Topsoe A/S Low-Pressure Methanol Synthesis
Process and ICI synthetic low-pressure methanol (LPM) process. These processes are
suitable for large scale production such as 10,000 ton/day. The energy requirement

Edi Sugiarto (13/348228/TK/40839) 13
for Haldor Topsoe and ICI LPM processes are claimed around 7 Gcal/ton of product
methanol and 7.8 Gcal/ton of product methanol, respectively.
Liquid-Phase methanol process has received large attention due to its flexibility
to remove the product to shift the equilibrium as well as the use of lower pressure
than that for the gas phase process. Examples of liquid phase are liquid entrained
reactor (LER) and trickle bed reactor. The LER technology was developed by Air
Products and Chemicals Inc. and Eastman Chemical Co. in the 90s by using slurry
reactor with Cu/ZnO/Al2O3 catalyst. The reactor operates at 230 to 260°C and
pressure of 50 to 100 atm. The gas reactant is dissolved in an inert liquid oil slurried
with the catalyst. High resistance of gaseous mass transfer from gas phase into liquid
oil is the major challenge of this reactor.
Trickle bed reactor is also used for liquid phase methanol synthesis. Liquid
absorbent is used to absorb the methanol and thus it may shift the equilibrium to
produce more products. As reported by Liu et al (2015), tetra ethylene glycol
dimethyl ether (TEGDME) gave better methanol absorption performance compared
to paraffin oil in a trickle bed reactor. The optimum temperature was observed to be
240 °C. In addition, introduction of TEGDME to trickle bed reactor keeps
temperature profile along reactor nearly at isothermal and thus may eliminate
additional heat transfer. Based on industrial experience, randomly packed catalyst
trickle bed reactor is commonly used with the operating pressure around 70 atm.
Here, trickle bed reactor has been selected as the methanol synthesis reactor in this
project with TEGDME as liquid absorbent. In addition, Cu/ZnO/Al2O3 has been used
as the catalyst.
Gaseous products from trickle reactor is charged into distillation column to
separate the produced methanol from H2 and inerts (i.e. CH4). Clean methanol is then
pumped towards MTG reactor to convert methanol to gasoline with the aid of ZSM-5
catalyst. It has been noted in previous section that historically, MTG was operated in
a fixed bed reactor before migrating to fluidized bed reactor. In this work, fluidized

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bed reactor has been selected as the MTG reactor. Some advantages of fluidized bed
reactor over fixed bed reactor has been summarized in (Keil, 1999):
 Excellent heat transfer properties.
 Continuous regeneration of the catalyst (constant catalyst activity) and a
uniform bed temperature which result in a stable gasoline quality.
 Transient temperature profile during heat-up and cool-down are also
uniform and stable.
 The specific throughput in a fluid-bed system is higher.
 Higher octane numbers of product were obtianed.
 The yield of gasoline including alkylate is at least 7.5% higher.
 The durene content is lower (maximum 5 wt%.)
 Liquid injection, a unique feature in the fluid bed, provides the flexibility
to tailor the steam balance as per requirement.
 Specific investment cost is lower.

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CHAPTER 2
COMPREHENSIVE PROCESS DESCRIPTION
2.1 Plant Overview
The plant designed in this project produces gasoline as main product and LPG
as side product. The plant operates continuously in a year or equivalent to 330 days of
operation. The plant capacity is designed on the basis of 100,000 ton dry biomass per
annum. The result of plant raw material consumption and production capacity
calculation is summarized in table 2.1.
Table 2.1. Raw Materials and Product of Our Gasoline Plant
Raw Material Mass Flow, kg/hr Capacity, ton/annum

dry 12,626.26 100,000.00
Biomass
wet 29,708.85 235,294.09
Air 326,609.75 2,586,749.22
Steam 4,367.27 34,588.78
Biomass utility (wet) 24,930.16 197,446.87
Product Mass Flow, kg/hr Capacity, ton/annum
Gasoline 1,509.78 11,957.46
LPG 874.42 6,925.41
Mode of Operation
The plant operates continuously with exception of a pair sulfur guard bed in
area 300 which operates in batch mode alternately. The overview of plant operation is
given in block flow diagram of Figure 2.1. The PFD and stream balance of material
will be described in Chapter 4 and Chapter 5, respectively.

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Figure 2.1. Block Flow Diagram of Our Gasoline Plant
Biomass Handling (Area 100)

Fresh biomass with the average size of 400 mm is transported into an open
yard (Y-101) directly from palm oil mills around plantation area. The stored biomass
is conveyed into chipper (M-101) using belt conveyor (BC-101). The chipped
biomass is then classified using vibratory screen (SR-101). The screened biomass
with the size larger than 5 mm will be recycled into chipper (M-101) using another
belt conveyor (BC-102). The biomass which passes the SR-101 is conveyed into
hammer mill (M-102) to reduce the size further to obtain less than 0.5 mm by the
help of inclined belt conveyor (BC-103). The milled biomass is classified using
another vibratory screen (SR-102) where the oversize biomass is recycled into
hammer mill (M-101) using belt conveyor (BC-104) and elevator (L-101). The
product of SR-102 (undersize biomass) is transported with belt conveyor (BC-105) to
the biomass gasification plant (Area 200).
Biomass Gasification (Area 200)

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Biomass with diameter less than 0.5 mm is conveyed to dryer (D-201) to
reduce its moisture content into 16%. The dryer uses hot-flue gas from the outlet of
combustor (R-202) which is mixed with fresh air blown by compressor (C-202). Due
to the possibility of disturbance, the temperature of gas mixture is controlled using
temperature controller which regulates the flow of fresh-air.
Dried biomass is fed into a dual fluidized bed gasifiers (R-201) using screw
conveyor (SC-201). Steam is employed as gasifying agent. The gasifier employs
direct contact with olivine as hot-medium material to supply the heat required for the
gasification. The reactor operates at 928oC which is 12.5% below the softening
temperature of the ash. Steam and inherent moisture of biomass is used as
gasification medium which generates a crude syngas which contains H2, CO, CO2,
CH4, C2H2, C2H4, C2H6, NH3, H2S, HCl, tar, char, and unreacted H2O.
Table 2.2 Temperature deformation of ash derived from palm empty fruit bunch
(Hafiz et al., 2016)
Characteristics Temperature (oC)

Softening Temperature 1061
Hemispherical Temperature 1170
Fluid Temperature 1185
The outlet of gasifier (R-201) is then separated using cyclone (S-201) and
further filtered using bag-filter (F-201). The separated solids from cyclone (S-201)
which mostly contains olivine, char, and ash will then sent to the combustor (R-202).
The combustor is a transport type fluidized bed which has function to reheat olivine
from gasifier (R-201). The fresh olivine from silo storage (T-201) is also charged into
combustor to serve as make-up material due to possible separation loss. The outlet of
combustor (R-202) is separated in two stages by using cyclones in series (S-202 and
S-203) to separate flue-gas, olivine, and ash. The heated olivine is then charged into

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gasifier to provide heat for the endothermic gasification reactions. The heat from flue-
gas (outlet of R-202) is then utilized for drying biomass, while the ash residue
(possibly have high potassium content) is stored and distributed to the locals as
fertilizer. This is part of CSR from the company to create good partnership with the
locals to increase their plantation’s productivity as well as to maintain the stability of
raw material supply.
Syngas Cleanup (Area 300)
The raw syngas from the gasifiers is then transported to Syngas Cleanup
(Area 300). The gas is sent to the desulphurization vessel (A-301 A/B) to avoid H2S
poisoning to the Nickel catalyst (reformer catalyst). After desulphurization, the
syngas is then reformed using steam reformer (R-301) to convert methane and higher
hydrocarbons into syngas. The overall reaction is endothermic. Water content within
syngas is already around 40% and considering the endothermic equilibrium and high
temperature reaction, the reactor is designed with no additional of water. From the
outlet of reformer, the heat of the syngas is utilized through heat integration with a
number of heat-exchangers (E-301, E-302, E-303), and then eventually cooled in (E-
304). The water condensate in syngas is separated using flash separator (S-301).
Methanol Synthesis (Area 400)
The reformed syngas is then compressed in three-stage compressors to

increase its pressure to 50 bar before sent to methanol reactor (R-401). The reactor is
a trickle-bed reactor which uses TEGDME to absorb methanol into liquid phase. This
type of configuration will manipulate the nature of equilibrium; hence, the reaction
can further progress to methanol product. The unreacted gas from methanol synthesis
reactor is relatively low on CO and H2 concentration, hence, no reactant recycle is
necessary. However, the valuable pressure of unreacted gas will be used in two-stage
gas turbine (GT-401 and GT-402) to generate additional electricity for the plant. Due
to thermodynamics, the unreacted gas will be reduced to temperature of -98oC. The

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temperature is considerably low and will be used as refrigerant in condensers of
distillation columns in Area 500. On the other hand, the mixture of liquid product
from the reactor is then cooled and separated in (S-401) which separates methanol
and water from TEGDME. The TEGDME is then pumped and cooled in heat
exchanger (E-403) to enter trickle reactor (R-401) again. The separated methanol and
water will then be heated using integrated heat exchanger (E-303) and sent to Area
500. Due to possible variability from the heat integration system, bypass valve is
employed to control the stream temperature.
Methanol to Gasoline (Area 500)
The mixture of methanol and water enters fluidized bed methanol to gasoline
(MTG) reactor at 413˚C. The outlet from MTG reactor consists of hydrocarbon
product and water which is separated in a 3 phase separator (S-502). The output
generated from the 3 phase separator are light gas stream, water rich stream, and
hydrocarbon rich steam. The light gas stream is compressed to 12 bar through dual
stage compressor and separated in distillation column. The top product of the
distillation column is rich in C1-C2 hydrocarbon and the bottom product is rich in
C3+ hydrocarbon. The bottom product of (DC-501) is mixed with hydrocarbon rich
stream from 3 phase separator and then separated in (DC-502). The top product of
DC-502 is rich in C3-C4 is further compressed and stored in LPG vessel while the
bottom product which is rich in C5+ is pumped to a gasoline tank.

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Preliminary Design of Palm Fruit Empty Bunch Into Gasoline Plant
with Capacity 100,000 Tons of Dry Biomass/year
CHAPTER 3
MATERIAL SPECIFICATIONS
I. Raw Material
Raw materials in this plant are palm fruit empty bunch, steam, and
combustion air. Both steam and combustion air is used in biomass
gasification.
 Palm Fruit Empty Bunch
Table. 3.1. Proximate and Ultimate Analysis of PEFB (Omar et al., 2011)
Proximate Analysis (%wt)
Moisture Content 57.5
Ash Contenta 7.5
Volatile Mattera 71.2
Fixed Carbona 18.3
Ultimate Analysisb (%wt)
C 45.0
H 6.4
O 47.3
N 0.2
S 1.1
Phase Solid
Bulk density (kg/m3) 850
Diametre (cm) ± 50
Gate Price (Rp/ton) 100,000
a
Air Dry Basis b Ash Free Basis
 Steam
Steam is utilized in R-201 as reactant in biomass steam gasification. Steam
for gasification is described in following table.

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Table 3.2. Steam Specification

Chemical formula H2O
Molecular weight 18 gram/mol
Normal boiling point 100 ºC
Normal melting point 0 ºC
Phase Superheated steam
Pressure 1.62 bar
Temperature 500 ºC
 Combustion Air
Combustion air is utilized in R-202 to combust any remaining char on
olivine. Combustion air is described in following table.
Table 3.3. Combustion Air Specification
Composition N2 (79%) and O2 (21%)
Molecular weight 28.97 gram/mol
Heat capacity 1 kJ/kg/K
Phase Gas
Pressure 1.15 bar
Temperature 25 ºC
II. Product
There are 2 products from this plant which are gasoline as main product and
LPG as side product. Specification of products is described as follow.
Table 3.4. Specification of Gasoline Product
Composition >99.99% n-octane
RON 97
Phase Liquid
Sale Price (USD/barrel) 82.6

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Table 3.5. Specification of LPG Product

Composition Propane (17%), propene
(13.21%), isobutane
(41.74), n-butane
(4.9%), 1-butene (21%),
n-octane (0.2%)
Phase Liquid
Sale Price (USD/kg) 0.6

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CHAPTER 4
BLOCK FLOW DIAGRAM

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Edi Sugiarto (13/348228/TK/40839) 26

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Edi Sugiarto (13/348228/TK/40839) 28

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CHAPTER 5
MATERIAL BALANCE
Overall Mass Balance
Figure 5.1 Overall Process Diagram

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Reactors
Table 5.1 Material Balance of Steam Reformer
Stream Information
Inlet, kg/h Outlet, kg/h
Component
25 26
H2O 6,280.68 3,230.72
H2 281.29 818.89
CO 5,897.91 5,652.70
CO2 2,604.38 6,519.95
CH4 1,173.53 756.42
C2H2 57.70 -
C2H4 513.80 -
C2H6 19.88 -
Tar (C8H10) 149.53 -
NH3 76.58 76.58
HCl 25.94 25.94
Total 17,081.20 17,081.20
Table 5.2 Material Balance of Trickle Bed Reactor
Stream Information
Component
38 45 39 40
Water (H2O) 226.09 - - 223.18
H2 818.89 - 99.21 -
CO 5,641.28 - 596.74 -
CO2 6,372.58 - 6,379.70 -
CH4 745.17 - 745.17 -
CH3OH - - - 5,760.02
TEGDME - 18,986.96 - 18,986.96
13,804.02 18,986.96 7,820.82 24,970.15
Total
32,790.98 32,790.98

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Table 5.3 Material Balance of Gasifier
Stream Information
Component
5 6 16 7
Biomass 12,626.26 -
H 2O 2,405.00 4,367.27 6,273.58
H2 281.29
CO 5,897.91
CO2 2,604.38
CH4 1,173.53
C2H2 57.70
C2H4 513.80
C2H6 19.88
Tar (C8H10) 149.53
NH3 76.58
H 2S 13.40
HCl 25.94
Char 2,311.03
Olivine 340,909.09 340,909.09
15,031.27 4,367.27 340,909.09 360,307.62
Total
360,307.62 360,307.62

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Table 5.4 Material Balance of Combustor
Stream Information
Component
9 12 14&23 13
Biomass - - 10,595.32 -
Water (H2O) - 621.14 14,334.84 21,634.87
CO2 - 60.11 - 24,628.64
Char 2,287.92 - - -
Olivine 340,909.09 - 3.27 340,912.36
Ash - - - 761.35
O2 - 23,052.24 - 3,710.49
N2 - 75,167.74 - 75,167.74
Ar - 1,282.35 - 1,282.35
NO2 - - - 173.89
SO2 - - - 21.17
Cl2 - - - 21.17
343,197.01 100,183.58 24,933.43 468,314.02
Total
468,314.02 468,314.02

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Table 5.5 Material Balance of Methanol to Gasoline Reactor
Stream Information
Component
46 47
Water (H2O) 223.18 3,465.00
CH4 - 21.40
C2H4 - 115.21
C2H6 - 4.41
CH3OH 5,760.02 -
C3H8 - 148.57
C3H6 - 125.91
Iso-butane - 365.14
n-butane - 42.81
C4H8 - 183.83
Gasoline (C8H18) - 1,510.92
Total 5,983.20 5,983.20

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Table 5.6 Material Balance of Sulfur Guard Bed
Stream Information
Component
10 25
H2O 6,273.58 6,280.68
H2 281.29 281.29
CO 5,897.91 5,897.91
CO2 2,604.38 2,604.38
CH4 1,173.53 1,173.53
C2H2 57.70 57.70
C2H4 513.80 513.80
C2H6 19.88 19.88
Tar (C8H10) 149.53 149.53
NH3 76.58 76.58
H2S 13.40 -
HCl 25.94 25.94
Total 17,087.50 17,081.20
Screens
Table 5.7 Material Balance of SR-101
Stream Information
Outlet, kg/h
Component Inlet, kg/h
oversize undersize
Biomass, dry 29,026.98 5,805.40 23,221.58
H 2O 39,271.79 7,854.36 31,417.43
68,298.77 13,659.75 54,639.02
Total
68,298.77 68,298.77

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Table 5.8 Material Balance of SR-102
Stream Information
Outlet, kg/h
oversize undersize
Biomass, dry 29,026.98 5,805.40 23,221.58
H 2O 39,271.79 7,854.36 31,417.43
68,298.77 13,659.75 54,639.02
Total
68,298.77 68,298.77
Cyclones
Table 5.9 Material Balance of S-201
Stream Information
Component
7 8 9
H2O 6,273.58 6,273.58
H2 281.29 281.29
CO 5,897.91 5,897.91
CO2 2,604.38 2,604.38
CH4 1,173.53 1,173.53
C2H2 57.70 57.70
C2H4 513.80 513.80
C2H6 19.88 19.88
Tar (C8H10) 149.53 149.53
NH3 76.58 76.58
H 2S 13.40 13.40
HCl 25.94 25.94
Char 2,311.03 23.11 2,287.92
Olivine 340,909.09 340,909.09
360,307.62 17,110.61 343,197.01
Total
360,307.62 360,307.62

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Stream Information
Component
13 15 16
Water (H2O) 21,634.87 21,634.87 -
CO2 24,628.64 24,628.64 -
Olivine 340,912.36 3.27 340,909.09
Ash 761.35 761.35 -
O2 3,710.49 3,710.49 -
N2 75,167.74 75,167.74 -
Ar 1,282.35 1,282.35 -
NO2 173.89 173.89 -
SO2 21.17 21.17 -
Cl2 21.17 21.17 -
468,314.02 127,404.93 340,909.09
Total
468,314.02 468,314.02
Stream Information
Component
15 17 18
Water (H2O) 21,634.87 21,634.87 -
CO2 24,628.64 24,628.64 -
Olivine 3.27 - 3.27
Ash 761.35 152.27 609.08
O2 3,710.49 3,710.49 -
N2 75,167.74 75,167.74 -
Ar 1,282.35 1,282.35 -
NO2 173.89 173.89 -
SO2 21.17 21.17 -
Cl2 21.17 21.17 -
127,404.93 126,792.58 612.35
Total
127,404.93 127,404.93

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Stream Information
Component
48 49 50 51
Water (H2O) 3,465.00 3.47 4.34 3,457.19
CH4 21.40 21.13 0.27 0.00
C2H2 - - - -
C2H4 115.21 109.42 5.78 0.01
C2H6 4.41 4.11 0.29 0.00
C3H8 148.57 118.85 29.72 0.00
C3H6 125.91 103.57 22.34 0.00
I-butane 365.14 231.73 133.41 0.00
N-butane 42.81 23.77 19.04 0.00
1-butene 183.83 110.11 73.72 0.00
Gasoline 1,510.92 23.85 1,487.07 -
5,983.20 750.00 1,775.99 3,457.21
Total
5,983.20 5,983.20
Technical Data
Inner Diameter, m 1.5
Dimension
Shell Length, m 4.5

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Bag Filter
Table 5.13 Material Balance of F-201
Stream Information
Inlet, kg/hr Outlet, kg/hr
Component
8 10 11
H2O 6,273.58 6,273.58 -
H2 281.29 281.29 -
CO 5,897.91 5,897.91 -
CO2 2,604.38 2,604.38 -
CH4 1,173.53 1,173.53 -
C2H2 57.70 57.70 -
C2H4 513.80 513.80 -
C2H6 19.88 19.88 -
Tar (C8H10) 149.53 149.53 -
NH3 76.58 76.58 -
H 2S 13.40 13.40 -
HCl 25.94 25.94 -
Char 23.11 - 23.11
17,110.61 17,087.50 23.11
Total
17,110.61 17,110.61
Table 5.14 Material Balance of F-202

Component
17 19 20
Water (H2O) 21,634.87 21,634.87 -
CO2 24,628.64 24,628.64 -
Ash 152.27 - 152.27
O2 3,710.49 3,710.49 -
N2 75,167.74 75,167.74 -
Ar 1,282.35 1,282.35 -
NO2 173.89 173.89 -
SO2 21.17 21.17 -
Cl2 21.17 21.17 -
126,792.58 126,640.31 152.27
Total
126,792.58 126,792.58

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Distillation Columns
Table 5.15 Material Balance of Steam Reformer DC-401
Stream Information
Component
55 56 57
H2O 3.47 - 3.47
CH4 21.13 21.13 0.00
C2H4 109.42 106.60 2.81
C2H6 4.11 3.70 0.41
C3H8 118.85 - 118.85
C3H6 103.57 10.36 93.21
I-butane (C4H10) 231.73 - 231.73
N-butane (C4H10) 23.77 - 23.77
1-butene (C4H8) 110.11 - 110.11
Gasoline 23.85 - 23.85
750.00 141.79 608.21
Total
750.00 750.00
Table 5.16 Material Balance of Steam Reformer
Stream Information
Component
59 60 61
H2O 7.81 7.79 0.02
CH4 0.28 0.28 0.00
C2H4 8.59 8.59 0.00
C2H6 0.71 0.71 0.00
C3H8 148.57 148.57 0.00
C3H6 115.55 115.55 0.00
I-butane (C4H10) 365.14 364.97 0.17
N-butane (C4H10) 42.81 42.77 0.04
1-butene (C4H8) 183.83 183.69 0.13
Gasoline 1,510.92 1.51 1,509.41
2,384.20 874.42 1,509.78
Total
2,384.20 2,384.20

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Dryers
Table 5.17 Material Balance of D-201
Stream Information
Component
22 24 4 5
Dry Biomass - 12,626.26 - 12,626.26
Water (H2O) 23,038.71 17,082.59 37,716.30 2,405.00
CO2 24,764.49 - 24,764.49 -
O2 55,811.15 - 55,811.15 -
N2 245,055.30 - 245,055.30 -
Ar 4,180.60 - 4,180.60 -
NO2 173.89 - 173.89 -
SO2 21.17 - 21.17 -
Cl2 21.17 - 21.17 -
353,066.48 29,708.85 367,744.07 15,031.27
Total
377,996.64 377,996.64

Edi Sugiarto (13/348228/TK/40839) 41
CHAPTER 6
HEAT BALANCE
Dryer
Table 5.1 Heat Balance of D-201
Heat Balance
Inlet Heat Content + Heat of Outlet Heat Content + Heat of
Component Formation, MJ/h Formation, MJ/h
1 21 2 3&4
Biomass -813,975.85 -796,593.57
H2O -397,315.24 -1,966,307.41 -2,188,101.29 -153,339.51
CO2 -934,031.62 -942,776.86
O2 3,590.51 2,251.69
N2 79,303.33 50,111.64
Ar 671.45 425.90
NO2 439.75 402.74
SO2 -259.96 -263.37
Cl2 6.44 4.03
Total -4,027,878.60 -4,027,878.60

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Reactors
Table 5.2 Heat Balance of R-201
Heat Balance Total (Heat Content + Heat of Formation, MJ/h)

Inlet Outlet
Component
3 5 15 6
Biomass -647,740.26
H2O -124,686.14 -585,769.20 -569,896.62
H2 37,717.86
CO -172,860.85
CO2 -206,748.00
CH4 -15,357.05
C2H2 6,236.30
C2H4 22,578.55
C2H6 37.32
Tar (C8H10) 4,644.59
NH3 -66.16
H2S 66.65
HCl -460.35
Char -116,955.46
Olivine 5,698,869.73 5,351,737.36
Total 4,340,674.13 4,340,674.13

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Table 5.3 Material Balance of R-202
Heat Balance (Heat Content, MJ/h)

Inlet Outlet
Component
4 8 11 13 12
Biomass 3,248.09
H2O 684.68 0.00 139,505.98
CO2 0.00 115,613.74
Char 36,252.65
Olivine 5,351,737.36 0.00 5,698,924.44
Ash 4,594.64
O2 0.00 16,799.04
N2 0.00 356,495.36
Ar 0.00 2,870.13
NO2 498.90
SO2 44.21
Cl2 28.85
Heat of Reaction 943,452.49 6,335,375.28
Total 6,335,375.28 6,335,375.28

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Table 5.4 Heat Balance of R-301

Inlet Outlet
Component
23 24
H2O -569,896.62 -296,736.38
H2 37,717.86 104,280.34
CO -172,860.85 -168,583.92
CO2 -206,748.00 -520,965.95
CH4 -15,357.05 -11,523.92
C2H2 6,236.30
C2H4 22,578.55
C2H6 37.32
Tar (C8H10) 4,644.59
NH3 -66.16 -184.24
Total -893,714.07 -893,714.07

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Heat Exchangers
Table 5.5 Heat Balance of E-301
Heat Balance
Inlet Heat Content + Heat of Outlet Heat Content + Heat of
Component Formation, MJ/h Formation, MJ/h
24 29 5 25
H2O -296,736.38 -779,635.51 -585,769.20 -334,174.17
H2 104,280.34 40,332.40
CO -168,583.92 -202,773.11
CO2 -520,965.95 -561,269.40
CH4 -11,523.92 -28,248.45
NH3 -184.24 -1,447.65
Total -1,673,349.58 -1,673,349.58
Heat Balance (Total Enthalpies, MJ/kg)

Component
25 26
H2O -334,174.17 -354,450.24
H2 40,332.40 1,767.93
CO -202,773.11 -222,186.53
CO2 -561,269.40 -582,003.15
CH4 -28,248.45 -35,112.20
NH3 -1,447.65 -2,043.31
Heat Supplied -106,447.13
Total -1,194,027.51 -1,194,027.51

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Heat Balance (Total Enthalpies, MJ/kg)

Component
30 31
H2O -24,507.88 -23,940.16
H2 10,039.30 25,605.03
CO -217,630.76 -209,855.48
CO2 -564,813.22 -556,745.80
CH4 -33,342.80 -30,712.50
Total -795,648.90 -795,648.90

Inlet Outlet
Component
40 41
H2O -499,676.73 -535,356.01
CH4 -599.34 -781.65
C2H4 2,450.73 1,713.79
C2H6 -63.93 -96.88
C3H8 -1,639.55 -2,727.28
C3H6 1,320.14 504.73
I-butane (C4H10) -3,457.50 -6,170.44
N-butane (C4H10) -454.59 -771.85
1-butene (C4H8) 1,257.32 31.47
Gasoline -6,820.74 -17,794.92
Total -561,449.04 -561,449.04

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CHAPTER 7
EQUIPMENT SPECIFICATION
Material Selection
Material selection is crucial in the design of chemical plant. Negligence in

the selection may results in the high fabrication cost of the plant or even failure in
the plant’s operation. The selection of material should be based on the operating
condition of the process. As for that reason, we decide to code the operating
condition according to the table below.
Table 7.1. Operating Condition Codes*
Pressure Temperature Corrosivity

Atmospheric Ambient
A A 1 Non-Corrosive
(1-2 bar) (0-100 oC)
Mild-Pressure Hot Mild Corrosive, contains CO2
M H 2
(2-15 Bar) (100-800 oC) or trace of corrosive substances
Pressurized Red Corrosive, contains corrosive
P R o
3
(15-55 Bar) (800-1100 C) substances
Vacuum Subzero Corrosive, contains corrosive
V S 4
(<1 Bar) (<0 oC) and abrasive substances
*For example: AH3 denotes atmospheric pressure, hot temperature, and corrosive
condition in non-abrasive environment
In our plant, most of the equipment operates at pressure above atmospheric

condition. Examples of mild pressure condition in our plant are MTG reactor as
well as the distillation columns succeeding it. Meanwhile, the trickle bed reactor
and turbine condenser are an example of pressurized and vacuum condition
respectively.
High temperature covers a major portion of our plant’s process condition.
Examples for hot temperature condition are steam generating equipment, while
the examples for red temperature condition are gasifier and fluidized combustor.
As for subzero, the example is condenser used in de-ethanizer distillation column.

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To initiate the selection, we will benchmark several candidates of

materials in Table 2 which according to our personal judgment will be able to
satisfy our plant’s operating condition.
Table 7.2. Benchmarked Materials
Type Consideration
Material Category: Steel
Commonly used for briny, ambient environment. Lower
SS 202
corrosion resistance, but cheaper than stainless steel 300 series.
Most commonly used stainless steel in chemical industries, with
SS 304
coverage of around 60% according to various sources.
SS 316 Typically has higher corrosion resistance than SS 304.
Has similar corrosion resistance to SS 316, but also reinforced for
SS 330
high temperature application.
CS A53 Most commonly used carbon steel in chemical industries. Exhibit
Grade B great mechanical properties. Easy and low cost to fabricate.
Material Category: Special Alloys
Type of monel which is commonly used in chemical industries.
Monel 400
Has high resistance in reducing environment.
Typically used type for chemical industries. Specially designed to
Inconel 601
sustain high temperature and corrosion.
Material Category: Non-metals
Polyurethane Commonly used for belt conveyor material in biomass handling.
Polyester Typical material used in bag filter.
Highly resistant to alkaline corrosion and has extremely high
Graphite temperature service. However, has poor resistance to oxidation
and abrasion.
Asbestos Commonly used insulating material.
Refractory Alumina with service temperature up to 1800oC. Useful in high
Alumina temperature service, such as gasifier reactor.
Refractory Suitable material for hot gas filtering. Has refractoriness
Al2O3/SiO2 temperature of 1700oC.

Edi Sugiarto (13/348228/TK/40839) 49
The material of construction is selected in accordance to the best practice

or if not available, with consideration regarding materials’ temperature threshold
and corrosion resistance. The design temperature data are taken from American
Iron and Steel Institute’s Designer Handbook No. 9004, NORSOK Standard M-
001 published by Norwegian Petroleum Institute, and ANSI/ASME B31.3.
Table 2.3. Corrosion Resistance of Benchmarked Materials Outside of Best

Practice (Cheremisinoff, 1996)
Materials NH3 (g) CO2 (g) HCl (g) H2S (g) SO2 (g) Water*
SS 304 S S L L S S
SS 316 S S S S S S
SS 330 S S S S S S
Carbon Steel U S S M S S
Monel U S L L U S
Inconel U S L M U S
Graphite S S S U U S
Refractories S S S S S S
U = Unsatisfactory/Unreported, L = Limited service, M = Medium service,
S = Satisfactory
*Fresh water
From the data above, Monel, Inconel and graphite will be omitted for
further consideration due to its incompatibility for the gaseous processing in this
project.

Edi Sugiarto (13/348228/TK/40839) 50
Table 7.4. Threshold for Continuous Service of Carbon and Stainless Steel
Minimum Design Temperature*

Carbon Steel -15 Stainless Steel -101
Maximum Design Temperature
CS A53 450 SS 304 & 316 925
SS 202 845 SS 330 1150
*General alloys without impact testing
It is important to search for the best practice design wherever possible.

This is due to the vast variation of materials available. Besides that, selection
according to the best practice design will ensure the operational success of the
plant. Hence, we decide to list the best practice design used in our plant in the
following table.
Table 7.5. Specified Materials for Unit Operations
Unit Operation Material Consideration

Belt conveyor for biomass Typically used according to
Polyurethane
processing various manufacturer
The plant uses brackish/briny
Water processing
SS 202 water for the process. S 202
equipment around 0-60oC
should suffice the operation
Typical insulation Asbestos Typically used insulation
Insulation above 800oC Refractory Typically used for high
with temperature surges Alumina temperature insulation in reactor
Bag filter material below Typically used bag filter
Polyester
240oC (if any) material
Bag filter material above Refractory The only available high
240oC Al2O3/SiO2 temperature filter material
The material in our project will be selected according to the best practice
in Table 5. If not available, the material will be selected in accordance to the
corrosion resistance and temperature threshold data in Table 3 and 4 respectively.

Edi Sugiarto (13/348228/TK/40839) 51
The following figure is the logic sequence for selecting the material of
construction in our project.
Figure 7.1. Logic Sequence for Selecting Material of Construction

Edi Sugiarto (13/348228/TK/40839) 52
Reactors
 Packed Bed Reactor
Steam Reformer Sheet No. 3

Equipment No. R-301
Reforming tar and olefins
Description Capacity, m3 7.26
within crude syngas
Amount 1
Type Packed Column Reactor Adiabatic, non-isothermal
Operating Data
Pressure, bara 2.17 Quadrilobe
o
Geometry
Temperature, C 928 (in.) - 885 (out.) Cylinder
Catalyst
Type Ni/Al2O3 Loading
Catalyst 900
Eq. Dia, mm 11.65 density, kg/m3
Stream Information
Component
25 26
H 2O 6,280.68 3,230.72
H2 281.29 818.89
CO 5,897.91 5,652.70
CO2 2,604.38 6,519.95
CH4 1,173.53 756.42
C2H2 57.70 -
C2H4 513.80 -
C2H6 19.88 -
Tar (C8H10) 149.53 -
NH3 76.58 76.58
HCl 25.94 25.94
Total 17,081.20 17,081.20
Technical Data
Reaction Height, m 3.332
Description Inner Diameter, m 1.666
Catalyst Loading, kg 6534

Edi Sugiarto (13/348228/TK/40839) 53
 Trickle Bed Reactor

 Methanol Reactor
(R-401)
Trickle Bed Reactor Sheet No. 4

Equipment No. R-401
Producing Methanol from 3
Description Capacity, m 6.0496
Syngas
Amount 1
Cocurrent Trickle Bed
Type Adiabatic, isothermal
Reactor
Operating Data
Pressure, bara 50
o
Geometry Sphere
Temperature, C 240
Catalyst
Type Cu/ZnO/Al2O3 Bulk density,
Catalyst 1980
Size, m 1*10 -3
kg/m3
Stream Information
Component
38 45 39 gas 40 liq
Water (H2O) 226.09 - 121.73 104.37
H2 818.89 - 30.25 45.40
CO 5,641.28 - 370.77 67.88
CO2 6,372.58 - 4,323.96 2,048.63
CH4 745.17 - 745.18 -
CH3OH - - 386.62 5,559.23
TEGDME - 18,986.96 - 18,986.96
13,804.02 18,986.96 5,978.51 26,812.47
Total
32,791 32,791
Technical Data
Reaction Height, m 8.6
Catalyst Loading, kg 11,978.27

Edi Sugiarto (13/348228/TK/40839) 54
 Fluidized Bed Reactor
Gasifier Sheet No. 2

Equipment No. R-201
Produce Crude Syngas from 3
Description Capacity, m 7.82
Palm Empty Fruit Bunch
Amount 1
Type Circulating Fluidized Bed Adiabatic, non-isothermal
Operating Data
o
Temperature, C Pressure, bara 2.93
Olivine 1048 Type Olivine
Inlet Biomass 100 Circulating Size ≤0.5mm
Steam 500 Medium Density,
4,500
Outlet Syngas 928 kg/m3
Stream Information
Component
5 6 16 7
Biomass 12,626.26 -
H 2O 2,405.00 4,367.27 6,273.58
H2 281.29
CO 5,897.91
CO2 2,604.38
CH4 1,173.53
C2H2 57.70
C2H4 513.80
C2H6 19.88
Tar (C8H10) 149.53
NH3 76.58
H 2S 13.40
HCl 25.94
Char 2,311.03
Olivine 340,909.09 340,909.09
15,031.27 4,367.27 340,909.09 360,307.62
Total
360,307.62 360,307.62
Technical Data
Effective Height, m 18.068
Dimension

Edi Sugiarto (13/348228/TK/40839) 55
Combustor Sheet No. 2

Supply the heat required for Equipment No. R-202
Description gasification by combusting Capacity, m3 429.35
unreacted gas Amount 1
Type Circulating Fluidized Bed Adiabatic, non-isothermal
Operating Data
Temperature, oC Pressure, bara 2.64
Olivine 928 or 25 Type Olivine
Inlet Biomass 25 Circulating Size ≤0.5mm
Air 25 Medium Density,
4,500
Outlet Flue Gas 1048 kg/m3
Stream Information
Component
9 12 14&23 13
Biomass - - 10,595.32 -
Water (H2O) - 621.14 14,334.84 21,634.87
CO2 - 60.11 - 24,628.64
Char 2,287.92 - - -
Olivine 340,909.09 - 3.27 340,912.36
Ash - - - 761.35
O2 - 23,052.24 - 3,710.49
N2 - 75,167.74 - 75,167.74
Ar - 1,282.35 - 1,282.35
NO2 - - - 173.89
SO2 - - - 21.17
Cl2 - - - 21.17
343,197.01 100,183.58 24,933.43 468,314.02
Total
468,314.02 468,314.02
Technical Data
Dimension

Edi Sugiarto (13/348228/TK/40839) 56
Methanol-To-Gasoline Reactor Sheet No. 5

Equipment No. R-501
Converting methanol into
Description Capacity, m3 7.64
gasoline product
Amount 1
Type Bubbling Fluidized Bed Adiabatic, non-isothermal
Operating Data
Pressure, bara 2.79 Geometry Spherical
Temperature, C o
413 (in.) – 512 (out.) Catalyst Av. Dia, mm 0.05
3
Catalyst Type ZSM-5 Density, kg/m 1,580
Stream Information
Component
46 47
Water (H2O) 223.18 3,465.00
CH4 - 21.40
C2H4 - 115.21
C2H6 - 4.41
CH3OH 5,760.02 -
C3H8 - 148.57
C3H6 - 125.91
Iso-butane - 365.14
n-butane - 42.81
C4H8 - 183.83
Gasoline (C8H18) - 1,510.92
Total 5,983.20 5,983.20
Technical Data
Dimension

Edi Sugiarto (13/348228/TK/40839) 57
Adsorber
Sulfur Guard Bed Sheet No. 3

Chemically adsorb H2S in Equipment No. A-301A/B
Description syngas into concentration Capacity, m3 53,631.64
lower than 0.5 ppmv Amount 2 (1 on standby)
Type Packed Column Adsorber Adiabatic, isothermal, semi-batch
Operating Data
Pressure, bara 2.62
Geometry Spherical
Temperature, oC 928
Adsorbent
Type ZnO/TiO2 Saturation
Adsorbent 90
Av. Dia, mm 1.09 Time, days
Stream Information
Component
10 25
H 2O 6,273.58 6,280.68
H2 281.29 281.29
CO 5,897.91 5,897.91
CO2 2,604.38 2,604.38
CH4 1,173.53 1,173.53
C2H2 57.70 57.70
C2H4 513.80 513.80
C2H6 19.88 19.88
Tar (C8H10) 149.53 149.53
NH3 76.58 76.58
H 2S 13.40 -
HCl 25.94 25.94
Total 17,087.50 17,081.20
Technical Data
Shell Thickness, inch 0.25

Edi Sugiarto (13/348228/TK/40839) 58
Screens
Vibrating Screen Sheet No. 1

Equipment No. SR-101
Screening Biomass up to 5 2
Description Capacity, ton/h.m 10.315
mm
Amount 1
Type Vibrating Screen Adiabatic, isothermal
Stream Information
Outlet, kg/h
oversize undersize
Biomass, dry 29,026.98 5,805.40 23,221.58
H 2O 39,271.79 7,854.36 31,417.43
68,298.77 13,659.75 54,639.02
Total
68,298.77 68,298.77
Technical Data
Screen Area, m2 6.6213
Dimension Aperture Tyler mesh 4
size mm 4.699
Vibrating Screen Sheet No. 1

Equipment No. SR-102
Screening Biomass up to 2
0.5mm
Amount 1
Type Vibrating Screen Adiabatic, isothermal
Stream Information
Outlet, kg/h
oversize undersize
Biomass, dry 29,026.98 5,805.40 23,221.58
H 2O 39,271.79 7,854.36 31,417.43
68,298.77 13,659.75 54,639.02
Total
68,298.77 68,298.77
Technical Data
Screen Area, m2 32.6958
Dimension Aperture Tyler mesh 32
size mm 0.495

Edi Sugiarto (13/348228/TK/40839) 59
Compressors
 Single Stage
Compressor Sheet No. 2

Equipment No. C-201
Adjusting air pressure for the
Description Capacity, kg/kWh 358.26
combustor
Amount 1
Type Single-Stage Centrifugal Adiabatic, non-isothermal
Operating Data
Temp., oC 25 (in.) – 119 (out.) Pressure, bara 1.01 (in.) – 2.64 (out.)
Flowrate 3,472.88 kmol/hr 100,183.58 kg/hr
Technical Data
Power, HP 375
Specification Pressure Ratio 2.61
Efficiency, % 77.14
Compressor Sheet No. 2

Equipment No. C-202
Flowing air to be mixed with
hot flue gas for drying
Amount 1
Type Single-Stage Centrifugal Adiabatic, non-isothermal
Operating Data
Temp., C o
25 (in.) – 104 (out.) Pressure, bara 1.01 (in.) – 2.31 (out.)
Flowrate 7,849.09 kmol/hr 226,426.17 kg/hr
Technical Data
Power, HP 700
Efficiency, % 78.84

Edi Sugiarto (13/348228/TK/40839) 60
 Multi Stage Series 1
Compressor 1st Stage Sheet No. 4

Equipment No. C-401
Adjusting syngas pressure to
be used in methanol reactor
Amount 1
Type Three-stage Centrifugal Adiabatic, non-isothermal
Operating Data
Temp., Co
Flowrate 814.88 kmol/hr 13,804.02 kg/hr
Technical Data
Power, HP 105
Efficiency, % 78.43
Compressor 2nd Stage Sheet No. 4

Equipment No. C-402
Amount 1
Operating Data
Temp., Co
Technical Data
Power, HP 110
Efficiency, % 76.68
Compressor 3rd Stage Sheet No. 4

Equipment No. C-403
Amount 1
Operating Data
Temp., Co
Technical Data
Power, HP 120
Efficiency, % 77.96

Edi Sugiarto (13/348228/TK/40839) 61
 Multi Stage Series 2
Compressor 1st Stage Sheet No. 5

Equipment No. C-501
Adjusting gas pressure for
distillation requirement
Amount 1
Type Two-stage Centrifugal Adiabatic, non-isothermal
Operating Data
Temp., C o
Technical Data
Power, HP 1.5
Efficiency, % 78.96
Compressor 2nd Stage Sheet No. 5

Equipment No. C-502
Adjusting gas pressure for
distillation requirement
Amount 1
Type Two-stage Centrifugal Adiabatic, non-isothermal
Operating Data
Temp., oC 65 (in.) – 153 (out.) Pressure, bara 5.45 (in.) – 12.22 (out.)
Technical Data
Power, HP 2
Efficiency, % 67.15

Edi Sugiarto (13/348228/TK/40839) 62
Cyclones
Cyclone Sheet No. 2

Equipment No. S-201
Separating olivine and char
Description Capacity, m3/s 8.992
from process stream
Amount 1
Type High-Capacity Cyclone Adiabatic, isothermal
Operating Data
Temp., oC 928 Pressure, bara 2.65 (in.) – 2.64 (out.)
Stream Information
Component
7 8 9
H2O 6,273.58 6,273.58
H2 281.29 281.29
CO 5,897.91 5,897.91
CO2 2,604.38 2,604.38
CH4 1,173.53 1,173.53
C2H2 57.70 57.70
C2H4 513.80 513.80
C2H6 19.88 19.88
Tar (C8H10) 149.53 149.53
NH3 76.58 76.58
H 2S 13.40 13.40
HCl 25.94 25.94
Char 2,311.03 23.11 2,287.92
Olivine 340,909.09 340,909.09
360,307.62 17,110.61 343,197.01
Total
360,307.62 360,307.62
Technical Data
Dimension
Configuration See Cyclone Section

Edi Sugiarto (13/348228/TK/40839) 63
Classifier Cyclone Sheet No. 2

Equipment No. S-202
Separating olivine from ash
in the process stream
Amount 2 (parallel)
Type High-Capacity Cyclone Adiabatic, isothermal
Operating Data
Stream Information
Component
13 15 16
Water (H2O) 21,634.87 21,634.87 -
CO2 24,628.64 24,628.64 -
Olivine 340,912.36 3.27 340,909.09
Ash 761.35 761.35 -
O2 3,710.49 3,710.49 -
N2 75,167.74 75,167.74 -
Ar 1,282.35 1,282.35 -
NO2 173.89 173.89 -
SO2 21.17 21.17 -
Cl2 21.17 21.17 -
468,314.02 127,404.93 340,909.09
Total
468,314.02 468,314.02
Technical Data
Dimension

Edi Sugiarto (13/348228/TK/40839) 64
Cyclone Sheet No. 2

Equipment No. S-203
Separating ash from the
process stream
Amount 3 (parallel)
Type High-Efficiency Cyclone Adiabatic, isothermal
Operating Data
Stream Information
Component
15 17 18
Water (H2O) 21,634.87 21,634.87 -
CO2 24,628.64 24,628.64 -
Olivine 3.27 - 3.27
Ash 761.35 152.27 609.08
O2 3,710.49 3,710.49 -
N2 75,167.74 75,167.74 -
Ar 1,282.35 1,282.35 -
NO2 173.89 173.89 -
SO2 21.17 21.17 -
Cl2 21.17 21.17 -
127,404.93 126,792.58 612.35
Total
127,404.93 127,404.93
Technical Data
Inner Diameter, m 4.462 m
Dimension

Edi Sugiarto (13/348228/TK/40839) 65
Bag Filter
Bag Filter Sheet No. 2

Equipment No. F-201
Filtering entrained char in the
Description Capacity, kgd/cyc* 1477.19
syngas stream
Amount 1
Type Shaker Bag Filter Adiabatic, isothermal
Operating Data
Stream Information
Component
8 10 11
H2O 6,273.58 6,273.58 -
H2 281.29 281.29 -
CO 5,897.91 5,897.91 -
CO2 2,604.38 2,604.38 -
CH4 1,173.53 1,173.53 -
C2H2 57.70 57.70 -
C2H4 513.80 513.80 -
C2H6 19.88 19.88 -
Tar (C8H10) 149.53 149.53 -
NH3 76.58 76.58 -
H 2S 13.40 13.40 -
HCl 25.94 25.94 -
Char 23.11 - 23.11
17,110.61 17,087.50 23.11
Total
17,110.61 17,110.61
Technical Data
Cloth Area, m2 921.9207
Specification Filtration Time, min 383.51
ΔP max, bar 0.02
*kgd/cyc = kg dust/cycle

Edi Sugiarto (13/348228/TK/40839) 66
Bag Filter Sheet No. 2

Equipment No. F-202
Filtering entrained ash in the
Description Capacity, kgd/cyc* 1265.05
fluegas stream
Amount 1
Type Shaker Bag Filter Adiabatic, isothermal
Operating Data
Stream Information
Component
17 19 20
Water (H2O) 21,634.87 21,634.87 -
CO2 24,628.64 24,628.64 -
Ash 152.27 - 152.27
O2 3,710.49 3,710.49 -
N2 75,167.74 75,167.74 -
Ar 1,282.35 1,282.35 -
NO2 173.89 173.89 -
SO2 21.17 21.17 -
Cl2 21.17 21.17 -
126,792.58 126,640.31 152.27
Total
126,792.58 126,792.58
Technical Data
Cloth Area, m2 5435.7151
Specification Filtration Time, min 332.32
ΔP max, bar 0.02
*kgd/cyc = kg dust/cycle

Edi Sugiarto (13/348228/TK/40839) 67
Belt Conveyors
Belt Conveyor Sheet No. 1

Equipment No. BC-101
Transporting raw biomass
Description Capacity, ton/h.m2 2.39
into chipper
Amount 1
Type Troughed Belt Conveyor Adiabatic, isothermal
Operating Data
Temp., oC 25 Pressure, bara 1.01
Flowrate 54,639.02 kg/hr Belt Velocity, m/s 0.1948
Technical Data
Power, HP 1.5
Width, m 1.524
Specification
Length, m 15
Angle of Elevation 0o

Transporting oversize Equipment No. BC-102
2
Description chipped biomass into the Capacity, ton/h.m 0.50
chipper Amount 1
Operating Data
Technical Data
Power, HP 0.75
Width, m 0.9144
Specification
Length, m 30

Edi Sugiarto (13/348228/TK/40839) 68

Transporting undersize Equipment No. BC-103
Description chipped biomass into Capacity, ton/h.m2 8.96
hammer mill Amount 1
Operating Data
Technical Data
Power, HP 3.5
Width, m 0.6096
Specification
Length, m 10

Transporting oversize milled 2
biomass into hammer mill
Amount 1
Operating Data
o
Temp., C 25 Pressure, bara 1.01
Technical Data
Power, HP 1
Width, m 0.3556
Specification
Length, m 2.5

Transporting undersize 2
milled biomass into Area 200
Amount 1
Operating Data
o
Temp., C 25 Pressure, bara 1.01
Technical Data
Power, HP 5
Width, m 1.524
Specification
Length, m 60

Edi Sugiarto (13/348228/TK/40839) 69
Screw Conveyor
Screw Conveyor Sheet No. 2

Equipment No. SC-201
Transporting dried biomass
Description Capacity, ton/hr 30.03
into gasifier
Amount 1
Type Horizontal Screw Conveyor Adiabatic, isothermal
Operating Data
Flowrate 15,031.27 kg/hr Speed, rpm 136.61
Technical Data
Power, HP 0.75
Diameter, inch 9
Specification
Length, m 5
Screw Conveyor Sheet No. 2

Equipment No. SC-202
Transporting dried biomass
into combustor
Amount 1
Type Horizontal Screw Conveyor Adiabatic, isothermal
Operating Data
Flowrate 24,930.16 kg/hr Speed, rpm 94.16
Technical Data
Power, HP 2.5
Diameter, inch 12
Specification
Length, m 10

Edi Sugiarto (13/348228/TK/40839) 70
Bucket Elevator
Bucket Elevator Sheet No. 1

Vertically transport oversize Equipment No. L-101
Description milled biomass back into the Capacity, ton/h 13.66
hammer mill Amount 1
Type Centrifugal Discharge Adiabatic, isothermal
Operating Data
Flowrate 13,659.76 kg/hr Lift Velocity, ft/m 225
Technical Data
Power, HP
Bucket width, inch 10x6
Bucket depth, inch 6.25
Bucket spacing, inch 16
Head shaft speed, rpm 43
Specification
Head shaft size, inch 20
Tail shaft size, inch 16
Belt width, inch 11
Horizontal Transport, ft 0
Total elevation, ft 8.2021

Edi Sugiarto (13/348228/TK/40839) 71
Chipper and Mills
Chipper Sheet No. 1

Equipment No. M-101
Chipping raw biomass into
size less than 5mm
Amount 1
Type Horizontal Drum Chipper Adiabatic, isothermal
Operating Data
Flowrate 68,298.77 kg/hr
Technical Data
Power, HP 120
Size of input, mm 400
Specification
Size of output, mm 5
Feeder Elevation, m 0
Hammer Mill Sheet No. 1

Equipment No. M-102
Milling chipped biomass into
size less than 0.5mm
Amount 1
Type Hammer Mill Adiabatic, isothermal
Operating Data
Flowrate 68,298.77 kg/hr
Technical Data
Power, HP 300
Size of input, mm 5
Specification
Size of output, mm 0.5
Feeder Elevation, m 2.5

Edi Sugiarto (13/348228/TK/40839) 72
Tank and Bins
Olivine Bin Sheet No. 2

Storing Make-up Olivine for Equipment No. T-201
Description Dual-Fluidized Bed Gasifier Capacity, kg 2945.455
System Amount 1
Type Storage Bin Adiabatic, non-isothermal
Operating Data
Technical Data
Shell Diameter, m 0.6043
Discharge Diameter, m 0.0604
Specification Shell Height, m 3.0216
Total Height, m 3.3817
Elevation, m 21.25
LPG Tank Sheet No. 5

Equipment No. T-501
Final storage of Product
Description Capacity, month 1 (each)
LPG
Amount 2 (1 on standby)
Type Horizontal Hemispherical Adiabatic, non-isothermal
Operating Data
Temp., oC 40 Pressure, bara 12
Technical Data
Material CS SA 53 Grade B
Inner Diameter, ft 23.7962
Shell Thickness, inch 3
Specification
Shell Length, ft 118.9811
Head Type Hemispherical
Head Thickness, inch 1.5

Edi Sugiarto (13/348228/TK/40839) 73
Gasoline Tank Sheet No. 5

Equipment No. T-502
Final storage of Product
Description Capacity, month 0.75 (each)
Gasoline
Amount 2 (1 on standby)
Type Flat-Bottomed Conical Roof Adiabatic, non-isothermal
Operating Data
Technical Data
Material CS SA 53 Grade B
Inner Diameter, ft 60
0-6 ft 0.4375
Shell Thickness, inch
6-12 ft 0.3125
(from ground)
12-18 ft 0.25
Specification
Shell Height, ft 18
Head Type Conical Roof, Flat bottom
Bottom 0.3125
Head Thickness, inch
Roof 0.25
Head height, ft 5

Edi Sugiarto (13/348228/TK/40839) 74
Heat Exchangers
Shell and Tube Exchanger Sheet No. 3

Equipment No. E-301
Exchanging Heat Between
Type HE 1-1
Description syngas (hot) and steam
Amount 1
(cold)
Adiabatic, non-isothermal
Operating Data
Stream Hot Fluid; Shell Cold Fluid; Tube
Information inlet outlet inlet outlet
Temperature, oC 885 789 141 500
Vapor Fraction 1.00 1.00 1.00 1.00
Flowrate, kg/hr 17,081.20 4,367.27
Thermal Properties
A, ft 2
ΔTLMTD, Fo
UC, BTU/hr.ft2.oF* UD, BTU/hr.ft2.oF Rd, hr.ft2.oF/BTU
391.3569431 935.7149111 59.9920185 7.345474758 0.119469355
Shell Tube
ID, in 17.25 OD, in 1
Baffle Spacing, in 4.3125 BWG 14
Baffle cut, % 25 Length, ft 16
Pass 1 Nt 112
Pitch, in 1.25 Pass 1
Clearance, in 0.25 Geometric Design,
AES
Tube Layout Square Pitch TEMA Std.**
**TEMA design used in this project:
BEM = non-fouling material in tube (bundle is difficult to be removed)

AEM = fouling material in tube (removable tube bundle)
AES = high temperature difference between tube and shell
BKU = typical kettle reboiler with U-tube end

Edi Sugiarto (13/348228/TK/40839) 75

Equipment No. E-302
Boiling water using heat Type HE 1-1
Description
from syngas Amount 1
Operating Data
o
Temperature, C 798 500 35 141
Vapor Fraction 1.00 1.00 0.00 1.00
Flowrate, kg/hr 17,081.20 4,367.27
Thermal Properties
A, ft2 ΔTLMTD, oF UC, BTU/hr.ft2.oF* UD, BTU/hr.ft2.oF Rd, hr.ft2.oF/BTU
134.0416 897.135242 337.9530584 90.1537046 0.0081
Shell Tube
ID, in 25 OD, in 1
Baffle spacing, in 25 BWG 14
Pass 1 Nt 32
BKU
Tube Layout Square TEMA Std.**


Edi Sugiarto (13/348228/TK/40839) 76

Equipment No. E-303
Heating methanol using Type HE 1-1
Description
syngas Amount 2
Operating Data
o
Vapor Fraction 1.00 1.00 1.00 1.00
Flowrate, kg/hr 17,081.20 5,983.20
Thermal Properties
2785.552 139.7746954 8.275177025 8.177640585 0.01441324
Shell Tube
ID, in 39 OD, in 1
Pass 1 Nt 665
AEM


Edi Sugiarto (13/348228/TK/40839) 77

Equipment No. E-304
Partially condense water
Type HE 1-1
Description content in syngas using
Amount 1
cooling water
Operating Data
o
Vapor Fraction 1.00 0.82 0.00 0.00
Flowrate, 17,081.20 kg/hr 1,197,384 lb/hr
Thermal Properties
2155.93482 83.3084555 155.8820697 98.5996785 0.003726915
Shell Tube
ID, in 35 OD, in 1
Pass 1 Nt 522
AES


Edi Sugiarto (13/348228/TK/40839) 78

Equipment No. E-401
Interstage cooler of syngas Type HE 1-1
Description
using cooling water Amount 1
Operating Data
o
Vapor Fraction 1.00 1.00 0.00 0.00
Flowrate 13,804.02 kg/hr 74554.0775 lb/hr
Thermal Properties
703.5392 95.81239851 65.86701454 44.2406378 0.007421546
Shell Tube
ID, in 19.25 OD, in 3/4
Pass 1 Nt 224
Pitch, in 1 Pass 1
AES


Edi Sugiarto (13/348228/TK/40839) 79

Equipment No. E-402
Interstage cooler of syngas Type HE 1-1
Description
Operating Data
o
Vapor Fraction 1.00 1.00 0.00 0.00
Flowrate 13,804.02 kg/hr 45706.7275 lb/hr
Thermal Properties
254.4048 160.748649 104.8745967 44.7061722 0.012833078
Shell Tube
ID, in 12 OD, in 3/4
Baffle Spacing, in 3 BWG 14
Pass 1 Nt 81
Pitch, in 1 Pass 1
AEM


Edi Sugiarto (13/348228/TK/40839) 80

Equipment No. E-403
Cooling TEGDME using Type HE 1-1
Description
Cooling Water Amount 1
Operating Data
o
Vapor Fraction 0.00 0.00 0.00 0.00
Flowrate 18,986.96 kg/hr 50,246.25 lb/hr
Thermal Properties
130.2938544 314.9451352 220.4256 180.4392 0.001005355
Shell Tube
ID, in 8 OD, in 3/4
Pass 1 Nt 32
Pitch, in 1 Pass 1
BEM


Edi Sugiarto (13/348228/TK/40839) 81

Equipment No. E-501
Partially condense MTG
Type HE 1-1
Description reactor product using
Amount 1
cooling water
Operating Data
o
Vapor Fraction 1.00 0.08 0.00 0.00
Flowrate 5.983.20 kg/hr 307,302.93 lb/hr
Thermal Properties
469.1456 228.2041989 149.3503374 114.8141497 0.002014062
Shell Tube
ID, in 17.25 OD, in 1
Pass 1 Nt 112
BEM


Edi Sugiarto (13/348228/TK/40839) 82

Equipment No. E-502
Interstage cooler of light gas Type HE 1-1
Description
Operating Data
o
Vapor Fraction 1.00 1.00 0.00 0.00
Flowrate 750.00 kg/hr 8,832.014 kg/hr
Thermal Properties
130.2938544 54.22827681 41.98202965 39.88873926 0.001250016
Shell Tube
ID, in 10 OD, in ¾
Pass 1 Nt 52
Pitch, in 1 Pass 1
BEM


Edi Sugiarto (13/348228/TK/40839) 83

Equipment No. E-503
Interstage cooler of light gas Type HE 1-1
Description
Operating Data
o
Vapor Fraction 1.00 1.00 0.00 0.00
Flowrate 750.00 kg/hr 5813.42625 lb/hr
Thermal Properties
100.5056 56.04588663 56.46155592 41.28175519 0.00651261
Shell Tube
ID, in 8 OD, in 3/4
Pass 1 Nt 32
Pitch, in 1 Pass 1
BEM


Edi Sugiarto (13/348228/TK/40839) 84

Equipment No. E-504
Partially condense DC-501
Type HE 1-1
Description top product using unreacted
Amount 1
gas
Operating Data
o
Temperature, C 54 54 -98 -69
Vapor Fraction 1.00 0.64 1.00 1.00
Flowrate, kg/hr 11273 6,647.70
Thermal Properties
150.7584 295.1988542 47.2684161 25.02858376 0.018798543
Shell Tube
ID, in 12 OD, in 1
Pass 1 Nt 48
BEM


Edi Sugiarto (13/348228/TK/40839) 85

Equipment No. E-505
Reboiling bottom product of
Type HE 1-1
Description DC-501 using saturated
Amount 1
steam
Operating Data
Stream Hot Fluid; Tube Cold Fluid; Shell
o
Temperature, F 213 213 129 129
Vapor Fraction 1.00 0.00 0.00 0.75
Flowrate 3,022.382436 lb/hr 2,039.15 lb/hr
Thermal Properties
201.0624 83.606794 250 174.2211039 0.0017
Shell Tube
ID, in 25 OD, in 1
Pass 1 Nt 48
BKU


Edi Sugiarto (13/348228/TK/40839) 86

Equipment No. E-506
Condense Top product of Type HE 1-1
Description
DC-502 using unreacted gas Amount 1
Operating Data
o
Vapor Fraction 0.00 0.80 1.00 1.00
Flowrate, kg/hr 2659.189024 6,647.70
Thermal Properties
150.7584 295.1988542 47.2684161 25.02858376 0.018798543
Shell Tube
ID, in 12 OD, in 1
Pass 1 Nt 48
BEM


Edi Sugiarto (13/348228/TK/40839) 87

Equipment No. E-507
Reboiling bottom product of
Type HE 1-1
Description DC-502 using saturated
Amount 1
steam
Operating Data
Stream Hot Fluid; Tube Cold Fluid; Shell
Temperature, 511 F 511 F 245 C 245 C
Vapor Fraction 1.00 0.00 0.00 0.80
Flowrate 2,446.52 lb/hr 115.4939223 kmol gasoline/hr
Thermal Properties
255.5168 37.865756 250 200 0.0016
Shell Tube
ID, in 15.25 OD, in 0.25
Baffle spacing, in 15.25 BWG 14
Pass 1 Nt 61
BKU


Edi Sugiarto (13/348228/TK/40839) 88

Equipment No. E-508
Cooling LPG using Type HE 1-1
Description
unreacted gas Amount 1
Operating Data
o
Vapor Fraction 0.00 0.00 1.00 1.00
Flowrate, kg/hr 874.42 6,647.70
Thermal Properties
130.2938544 314.9451352 220.4256 180.4392 0.001005355
Shell Tube
ID, in 8 OD, in 3/4
Pass 1 Nt 32
Pitch, in 1 Pass 1
BEM


Edi Sugiarto (13/348228/TK/40839) 89

Equipment No. E-509
Cooling Gasoline Product Type HE 1-1
Description
using Cooling Water Amount 1
Operating Data
o
Vapor Fraction 0.00 0.00 0.00 0.00
Flowrate, kg/hr 1,509.78
Thermal Properties
142.6944129 115.8930636 151.2479981 131.055304 0.001018709
Shell Tube
ID, in 10 OD, in 3/4
Pass 1 Nt 52
Pitch, in 1 Pass 1
BEM


Edi Sugiarto (13/348228/TK/40839) 90
Distillation Columns
De-Ethanizer Sheet No. 4

Separating C1-C2 from light Equipment No. DC-401
Description
hydrocarbon stream Amount 1
Type Tray Column Non-adiabatic, non-isothermal
Operating Data
Feed Distillate Bottom
Pressure, bara 12 11.9 12.1
Temperature, oC 75 -43 54
Stream Information
Component
55 56 57
H2O 3.47 - 3.47
CH4 21.13 21.13 0.00
C2H4 109.42 106.60 2.81
C2H6 4.11 3.70 0.41
C3H8 118.85 - 118.85
C3H6 103.57 10.36 93.21
I-butane (C4H10) 231.73 - 231.73
N-butane (C4H10) 23.77 - 23.77
1-butene (C4H8) 110.11 - 110.11
Gasoline 23.85 - 23.85
750.00 141.79 608.21
Total
750.00 750.00
Technical Data
Height, m 9
Dimension Number of Tray 10
Feed Plate (from above) 6
Reflux ratio 2.985733977

Edi Sugiarto (13/348228/TK/40839) 91
De-Butanizer Sheet No. 4

Equipment No. DC-402
Description Separating LPG from gasoline
Amount 1
Type Tray Column Non-adiabatic, non- isothermal
Operating Data
Feed Distillate Bottom
Pressure, bara 12.1 12 12.2
o
Temperature, C 44 85 245
Stream Information
Component
59 60 61
H2O 7.81 7.79 0.02
CH4 0.28 0.28 0.00
C2H4 8.59 8.59 0.00
C2H6 0.71 0.71 0.00
C3H8 148.57 148.57 0.00
C3H6 115.55 115.55 0.00
I-butane (C4H10) 365.14 364.97 0.17
N-butane (C4H10) 42.81 42.77 0.04
1-butene (C4H8) 183.83 183.69 0.13
Gasoline 1,510.92 1.51 1,509.41
2,384.20 874.42 1,509.78
Total
2,384.20 2,384.20
Technical Data
Height, m 30
Dimension Number of Tray 52
Feed Plate (from above) 25
Reflux Ratio 0.420452675

Edi Sugiarto (13/348228/TK/40839) 92
Dryers
Biomass Dryer Sheet No. 2

Equipment No. D-201
Reducing moisture of the biomass
Description Capacity, m3
from 53% into 16%
Amount 1
Type Countercurrent Rotary Dryer Adiabatic, non-isothermal
Operating Data
Temperature, oC Pressure, bara 1.01
Gas 500(in.)-381(out.) Ret. Time, min
Solid 25(in.)-100(out) Speed, rpm
Stream Information
Component
22 24 4 5
Dry Biomass - 12,626.26 - 12,626.26
Water (H2O) 23,038.71 17,082.59 37,716.30 2,405.00
CO2 24,764.49 - 24,764.49 -
O2 55,811.15 - 55,811.15 -
N2 245,055.30 - 245,055.30 -
Ar 4,180.60 - 4,180.60 -
NO2 173.89 - 173.89 -
SO2 21.17 - 21.17 -
Cl2 21.17 - 21.17 -
353,066.48 29,708.85 367,744.07 15,031.27
Total
377,996.64 377,996.64
Technical Data
Length, m 14.25
Dimension Inner Diameter, m 1.4
Slope, cm/m 34.59

Edi Sugiarto (13/348228/TK/40839) 93
Flash and 3-Phase Separator
Flash Separator Sheet No. 3

Equipment No. S-301
Description Separating water from syngas
Amount 1
Type Vertical KO Drum Adiabatic, isothermal
Operating Data
Pressure, bara 1.27
Inlet Vapor
Temperature, oC 40 0.82
Fraction
Massflow, kg/hr 17,081.20
Technical Data
Dimension
Shell Height, m 3.29
Flash Separator Sheet No. 4

Separating TEGDME from Equipment No. S-401
Description
methanol product Amount 1
Type Horizontal KO Drum Adiabatic, isothermal
Operating Data
Pressure, bara 2.91
o
Inlet Vapor
Temperature, C 221 0.21
Fraction
Massflow, kg/hr 24,970.15
Technical Data
Dimension
Height, m 4.5

Edi Sugiarto (13/348228/TK/40839) 94
Three Phase Separator Sheet No. 5

Separating light gas, LPG, and Equipment No. S-501
Description
water in feed stream Amount 1
Type Horizontal 3-Phase KO Drum Adiabatic, isothermal
Operating Data
Pressure, bara 2.73
o
Inlet Vapor Fraction 0.05
Temperature, C 40
Stream Information
Component
48 49 50 51
Water (H2O) 3,465.00 3.47 4.34 3,457.19
CH4 21.40 21.13 0.27 0.00
C2H2 - - - -
C2H4 115.21 109.42 5.78 0.01
C2H6 4.41 4.11 0.29 0.00
C3H8 148.57 118.85 29.72 0.00
C3H6 125.91 103.57 22.34 0.00
I-butane 365.14 231.73 133.41 0.00
N-butane 42.81 23.77 19.04 0.00
1-butene 183.83 110.11 73.72 0.00
Gasoline 1,510.92 23.85 1,487.07 -
5,983.20 750.00 1,775.99 3,457.21
Total
5,983.20 5,983.20
Technical Data
Dimension
Shell Length, m 4.5

Edi Sugiarto (13/348228/TK/40839) 95
Pumps
Pump Sheet No. 4

Pumping TEGDME from Equipment No. P-401
Description
S-401 back into reactor Amount 2 (1 on standby)
Type Centrifugal, single stage Adiabatic, isothermal
Operating Data
Temp., oC 221 Pressure, bara 2.81  52.01
Flowrate 54,639.02 kg/hr Speed, rpm 3500
Technical Data
Head, m 510.6648185
Power, HP 69.66238552
Specification Efficiency, % 56.875
NPSHA 19.16402848
NPSHR 5
Pump Sheet No. 5

Pumping raw gasoline into Equipment No. P-501
Description
DC-501 Amount 2 (1 on standby)
Type Centrifugal, multistage Adiabatic, isothermal
Operating Data
Temp., oC 40 Pressure, bara 2.65  12.40
Flowrate 1,775.99 kg/hr Speed, rpm 3500
Technical Data
Head, m 176.3168012
Power, HP 7.343366589
NPSHA 21.49678411
NPSHR 5

Edi Sugiarto (13/348228/TK/40839) 96
Pump Sheet No. 5

Pumping back Top Product Equipment No. P-502
Description
of DC-501 Amount 2 (1 on standby)
Operating Data
Temp., oC -43 Pressure, bara 2.65  12.40
Flowrate kg/hr Speed, rpm 3500
Technical Data
Head, m 10
Power, HP 1.78
NPSHA 10.9675
NPSHR 5
Pump Sheet No. 5

Pumping back Top Product Equipment No. P-503
Description
of DC-502 Amount 2 (1 on standby)
Operating Data
Temp., C o
85 Pressure, bara 2.65  12.40
Flowrate kg/hr Speed, rpm 3500
Technical Data
Head, m 21
Power, HP 3.98
NPSHA 9.8654
NPSHR 5

Edi Sugiarto (13/348228/TK/40839) 97
CHAPTER 8
UTILITY
Utility unit is a part of the plant that provides supports to production process in
term of water supply, electricity, steam, and any other auxiliaries.
Utility is divided into some different sections, which are:
1. Water system
2. Steam generation
3. Instrument air system
4. Electric generation system
5. Waste treatment
1. Water system
Water demand
Water demand for plant is divided into some sections and calculated as follow.
Table 8.1. Water Demand Calculation
Consumstion Quantity
General Purpose Water
Domestic demand Assumption: 250 employees
Water demand= 100 kg/day/employee
=250 employees*100 kg/day/employee*1 day/24 hours
=1041.67 kg/hour
Laboratory Assumption: 750 kg/hr
Garden Assumption: 330 kg/hr
Sub-total 2121.67 kg/hr
Sub-total 2546 kg/hr
In addition of 20% overdesign
Hydrant Assumption: 25% from Domestic demand+ Laboratory+
Garden
=25%*(2121.67 kg/hr)
=530.42 kg/hr
Take 20% overdesign, hydrant water demand is
=1.2*530.42 kg/hr

Edi Sugiarto (13/348228/TK/40839) 98
=636.50 kg/hr
Cooling Water
Equipment Demand in kg/hr
E-304 203673.68
E-401 33817.51
E-402 20732.44
E-403 2636.95
E-501 139429.64
E-502 4006.18
E-503 2636.95
E-509 28129.75
Sub-Total 435063.10
10% overdesign 478569.40
Cooling water loss =7.5%*478569.40
(Calculated in cooling tower =35892.71
design as 7.5%)
Boiler Feed Water
Equipment Demand in kg/hr
E-505 1370.94
E-507 1109.73
Sub-Total 2480.68
Sub-total
In addition of 10% overdesign 2728.74
Steam loss (take 5%) =5%*2728.74
=136.44
Process Water
Process water for gasification 4367.27
Sub-Total 4367.27
10% overdesign 4803.99
Total water to produce is a sum of general purpose water, make up water for
cooling water loss, make up water for steam loss, and process water which is

Edi Sugiarto (13/348228/TK/40839) 99
44,016 kg/hr. Taking overdesign of 20% making water demand at 52,818

kg/hr.
Water Resource
Water is taken from Kampar River with average flow rate at 600 m3/second
which equals to 2,160,000,000 kg/hour. With water demand at 52,818 kg/hr,
percentage of water demand to river flow rate is 0.0025 % hence Kampar river
is sufficient to fulfill water demand.
Water Treatment
The water from Kampar River is firstly filtered with screen to filter out dirt
/floating garbage, like plastic, leaves, tree branches, and any possible dirt. It
aims to secure pump from failure by presence of dirt inside pump. Water is
pumped into sedimentation pond where mud(in form of sludge) naturally
settles due to gravitation. Water from sedimentation pond is pumped into
clarifier to chemically-aided settle colloidal particles. Chemicals used are
aluminum sulfate (alum) and sodium carbonate. Water discharged from the
clarifier is pumped to sand filters to filter out any solid particle using sand as
filter media. Water is pumped to carbon filter to undergo adsorption in order to
remove any remaining chemicals, solid particles, odour, or taste in water.
Water is stored in tank before distributed as general purpose water, cooling
water, boiler feed water, and process water. General purpose water requires
chlorine based chemical which is usually NaOCl as disinfectant. Cooling water
is circulated in a closed loop. Warm cooling water from process is cooled in
cooling tower to undergo evaporative cooling. Cooling water loss from
evaporation, windage loss, and blowdown is compensated with addition of
fresh cooling water. Process water does not require any addition of chemicals.
Water is pumped to cation exchanger and anion exchanger to remove content
of cation and anion to produce demineralized water. Demineralized water is
pumped to deaerator to remove content of oxygen which is high corrosive at
high temperature. Addition of oxygen scavanger is also carried out to reduce
content of oxygen. Steam loss is compensated with addition of fresh boiler feed
water. Water treatment processes are as follow.

Edi Sugiarto (13/348228/TK/40839) 100
 Sedimentation
Sedimentation is conducted to settle mud, sand, and other particulates
with gravitational aided process. Settling velocity depends on shape and
particle size, viscosity of fluid, density of both particle and fluid.
 Coagulation, floculation, and sedimentation (Clarification)
This process aims to reduce water turbidity by removing total dissolved
solid, total suspended solids, and other colloidal particles. This process
consists of 3 (three)
stages, which are:
 Coagulation
Coagulation stage is the process of destabilization of colloidal
particles
contained in the water with the addition of certain chemicals.
Rapid mixing is necessary to ensure maximum contact between
colloidal particles with added chemicals.
 Floculation
Flocculation stage is the process of combining unstable particles
into larger and heavier flocs to facilitate sedimentation. At this
stage, it takes a less turbulent area for particles to aggregate
properly. Therefore, mixing at this stage is set slower in order to
produces low movement of water.
 Sedimentation
Larger and heavier flocs are finally settled and removed from the
bottom of clarifier.
Chemicals used in clarifier are aluminum sulfate (alum) and sodium
carbonate. Alum is a widely used coagulant. This material is
economical, easily obtained and stored. Alum dosage depends on the
level of turbidity of water. Sodium carbonate is used to maintain the pH
of the water that becomes acidic due the formation of sulfuric acid
(H2SO4) in the reaction between water and alum. Addition of Sodium
carbonate is controlled in order to avoid high pH of water.

Edi Sugiarto (13/348228/TK/40839) 101
 Filtration
Two consecutive stages of filtration are used in this process which are
filtration with sand filter to remove any remaining solid particle and
filtration with carbon filter to remove any remaining chemicals, solid
particles, odour, or taste in water.
 Demineralization
Two consecutive stages of demineralization are used in this process
which are cation removal followed by anion removal. Cation
exchangers are used to remove cations contained in water, such as
sodium, calcium, magnesium, and others. Reaction that occurs in the
cation exchanger is:
Cation + Anion + H-Z(s) Cation-Z(s) + 2H+ + Anion
Within specified time cation resin will reach saturation, therefore

regeneration with sulfuric acid (H2SO4) is needed. Reaction during
regeneration is as follow.
Cation-Z(s) + H2SO4(aq) -Z(aq) + Cation-SO4(aq)
Anion exchangers are used to remove anions contained in water, such

as bicarbonate, chloride, alkaline carbonates, and more. Reaction that
occur anion exchanger is:
2H+ + Anion + R-OH(s) -anion(s) + H2O(l)
Within specified time anion resin will reach saturation, therefore

regeneration with NaOH is needed. Reaction during regeneration is as
follow.
R-anion(s) + NaOH(aq) -OH(s) + Na-anion(aq)
 Cooling water system

Warm cooling water must be cooled before it can be recirculated to
serve cooling duty in a closed loop cooling system. A cooling water
facilitates to decrease cooling water temperature. Warm cooling water
is contacted with flowing air. Water temperature decreases with 2
different phenomenons, which are sensible heat transfer from water to

Edi Sugiarto (13/348228/TK/40839) 102
flowing air (which is insignificant) and evaporation of some water that

reduce its temperature signficantly.
 Chlorination
Chlorination is needed as disinfectant in general purpose water to kill
any form of living organism in water. Chemical used is NaOCl which is
a widely used disinfectant in industry.
 Deaeration
Oxygen content in water will be highly corrosive at high temperature,
hence oxygen content must be reduced with 2 manners, whch are
stripping of oxygen in water with saturated steam followed by addition
of oxygen scavanger (hydrazine) that reacts with oxygen in following
reaction.
N2H4 + O2 N2 + 2H2O
2. Steam generation
Steam needed for this plant is 2,728.74 kg/hr at 40 psia. Condensate along with
boiler feed water make up are feed to boiler to produce 40 psia steam. There
are 2 stages in steam production which are:
 Deaeration
Oxygen content in water will be highly corrosive at high temperature,
hence oxygen content must be reduced with 2 manners, whch are
stripping of oxygen in water with saturated steam followed by addition
of oxygen scavanger (hydrazine) that reacts with oxygen in following
reaction.
N2H4 + O2 N2 + 2H2O
Side reaction also takes place.
N2H4 + 6Fe2O3 3O4 + 2H2O
 Steam Generation
Steam generation produces steam which is used in production process.
Water is pumped into the boiler from the deaerator. Boiler feed water at
a certain pressure and temperature will be heated using continuous fuel.
Fuel for this plant is a mixture of unreacted reactant gas and light gas

Edi Sugiarto (13/348228/TK/40839) 103
(top product of distillation column) which are produced in production

process. Fuel for boiler is listed below.
Unreacted Gas Light Gas
Mass Flowrate Mass Flowrate
Component Component
(kg/hr) (kg/hr)
H2 99.21 CH4 21.13
CO 596.74 C2H4 106.60
CO2 6,379.70 C2H6 3.70
CH4 745.17 C3H6 10.36
Calculation:
Steam condenses at 40 psia which is at 132ºC. Condensate which is
saturated water (with addition of make up water) is pumped back to
bolier. At 40 psia enthalpy of saturated vapor is 1169 Btu/lb water and
enthalpy of saturated water is 236 Btu/lb water, hence enthalpy of
vaporization is 933 Btu/lb(2,170.16 kJ/kg).
Qwater = mass of water*enthalpy of vaporization
= 2,728.74 kg/hr*2,170.16 kJ/kg
= 5,921,813 kJ/hr
Assuming boiler efficiency at 40%
Heat of combustion is calculated individually for each flammable

component.

Edi Sugiarto (13/348228/TK/40839) 104
Fuel Kg/hour H combustionUnit Mr H combustion Unit Q total, kJ/hr kmol/hr O2 demand, kmol/hr
H2 99.21 286 kJ/mol 2 143,000 kJ/kg 14,187,030 49.605 24.8025
CO 596.74 283 kJ/mol 28 10,107 kJ/kg 6,031,336 21.31214 10.65607143
CH4 745.17 889 kJ/mol 16 55,563 kJ/kg 41,403,508 46.57313 93.14625
CH4 21.13 889 kJ/mol 16 55,563 kJ/kg 1,174,036 1.320625 2.64125
C2H4 106.6 47.195 MJ/kg 28 47,195 kJ/kg 5,030,987 3.807143 11.42142857
C2H6 3.7 1,560 kJ/mol 30 52,000 kJ/kg 192,400 0.123333 0.493333333
C3H6 10.36 2,057 kJ/mol 42 48,976 kJ/kg 507,393 0.246667 1.11
Sum 68,526,691 144
With assumed perfect combustion 68,526,691 kJ/hr of heat is

generated, hence energy demand for steam generation is sufficient with
out any additional fuel with remaining heat 53,722,158.01 kJ/hour.
3. Instrument air system
Water Removal
Based on Coulson and Richardson, instrument air is nomally distributed at 6
bar (100 psig). Assuming 200 m3/hr of instrument air is needed for plant
control instrument,
Q air = 200 m3/hr. Water content in instrument air must be eliminated due to
corrosice characteristic of water.
Ambient air is taken as 28.5ºC (83.3 ºF) with relative humidity of 80%
(average ambient temperature in tropical countries).
Water content is read as = 0.0198 mass of water/mass of sry air
Density of air = 1 kg/m3

Edi Sugiarto (13/348228/TK/40839) 105
Water to remove = * Water content

Water to remove = *0.0198
Water to remove = 3.96 kg/hr
Silica water adsorption capacity = 0.5 kg water/kg silica

Silica needed = 3.96 kg water/hr / (0.5 kg water/kg silica)
Silica needed = 7.92 kg silica/hr
Silica needed = 17.424 lb silica/hr
Bulk density of silica = 48 lb/ft3
Volume Silica needed = Silica needed/ Bulk density of silica

Volume Silica needed = 17.424 lb silica/hr / 48 lb/ft3
Volume Silica needed = 0.363 ft3/hr
Take 24 hours of operation

Volume Silica needed = 0.363 ft3/hr*24 hours
Volume Silica needed = 8.712 ft3
Take 15% overdesign

Volume silica needed = 10.0188 ft3
Take H/D = 2,
D = 1.77 ft
H = 3.54 ft

Edi Sugiarto (13/348228/TK/40839) 106
Air Compression
It is assumed adiabatic reversible compression takes place. γ is assumed as 1.4.
4,189.34 J/mol
Power of compressor = 4,189.34 J/mol*
Power of compressor = 37,404,815.53 J/hr

Power of compressor = 37,404.82 kJ/hr
Power of compressor =13.93 Hp
4. Electric generation system

Plant site is located in a rural area, hence self electricity generation is a
necessity. Electricity consumption is listed as follow.
Production electricity requirement
Equipment Power in Hp
BC-101 17.97
M-101 58.75
SR-101 6.00

Edi Sugiarto (13/348228/TK/40839) 107
BC-102 7.00
BC-103 17.97
M-102 58.75
SR-102 6.00
BC-104 7.00
L-101 8.00
BC-105 17.97
SC-201 0.36
SC-202 0.59
D-201 2.00
C-201 375.00
C-202 700.00
C-401 105.00
C-402 110.00
C-403 120.00
P-401 70.00
C-501 1.50
C-502 2.00
P-501 7.34
Sub-Total 1699.20
Sub-Total + overdesign 10% 1869.12
Utility electricity requirement

Equipment Power in Hp
Pump 01 7.5
Pump 02 2
Pump 03 3
Pump 04 2

Edi Sugiarto (13/348228/TK/40839) 108
Pump 05 2
Pump 06 3
Pump 07 0.5
Pump 08 1
Pump 09 1
Pump 10 0.5
Pump 11 30
Pump 12 7.5
Pump 13 0.5
Pump 14 0.5
Pump 15 0.5
Pump 16 3
Pump 17 1
Instrument Air Compressor 34.83
Clarifier 18.6
Cooling T 1502.4
Sub-Total 1621.3
Sub-Total + overdesign 10% 1783.4
Electricity for production = 1869.12 Hp + 1783.4 Hp

= 3652.5 Hp
Electricity for instrumentation = 25%*Electricity for production

= 913.13 Hp
Electricity for instrumentation with 10% overdesign = 1.1*913.13 Hp
= 1004.45 Hp
Lighting in plant area = 750 kW = 1005.77 Hp
Domestic electricity = 300 kW * 1.34102209 Hp/kW

= 402.31 Hp

Edi Sugiarto (13/348228/TK/40839) 109
Lighting in plant area + Domestic electricity = 1005.77 Hp + 402.31 Hp

= 1408.07 Hp
with 20% overdesign = 1.2*1408.07 Hp = 1689.69 Hp
Total electricity generated = Electricity for production+ Electricity for

instrumentation+ Lighting in plant area +
Domestic electricity
= 3652.5 Hp + 1004.45 Hp + 1689.69 Hp
= 6346.7 Hp = 17,037,778 kJ/hour
Electricity is generated using electricity generation system with average overall

efficiency at 45%. Hence total heat that must be supplied = 17,037,778 kJ/hour
/ 45%
= 37,861,728 kJ/hour
Remaining heat from steam generation is 53,722,158.01 kJ/hour, hence it is

more than sufficient to generate electricity. There is remaining 15,860,429.61
kJ/hour which is generated into electricity for commercial sale to PLN.
Combustion air consumption for perfect combustion is calculated with

following table.
Fuel Kg/hour H combustionUnit Mr H combustion Unit Q total, kJ/hr kmol/hr O2 demand, kmol/hr
H2 99.21 286 kJ/mol 2 143,000 kJ/kg 14,187,030 49.605 24.8025
CO 596.74 283 kJ/mol 28 10,107 kJ/kg 6,031,336 21.31214 10.65607143
CH4 745.17 889 kJ/mol 16 55,563 kJ/kg 41,403,508 46.57313 93.14625
CH4 21.13 889 kJ/mol 16 55,563 kJ/kg 1,174,036 1.320625 2.64125
C2H4 106.6 47.195 MJ/kg 28 47,195 kJ/kg 5,030,987 3.807143 11.42142857
C2H6 3.7 1,560 kJ/mol 30 52,000 kJ/kg 192,400 0.123333 0.493333333
C3H6 10.36 2,057 kJ/mol 42 48,976 kJ/kg 507,393 0.246667 1.11
Sum 68,526,691 144
Oxygen needed = 144 kmol/hr
Assuming air consists of 21% of oxygen, air needed is = 144 kmol/hr / 0.21
= 687 kmol/hr

Edi Sugiarto (13/348228/TK/40839) 110
Give 10% excess air to ensure perfect combustion takes place.
Air needed = 1.1*687 kmol/hr
= 755.70 kmol/hr
At STP 22.4 L/mol
Air needed = 755.70 kmol/hr * 1000 mol/kmol / 22.4 L/mol
Air needed = 30,669.82 L/hr
Air needed = 30.67 m3/hr
5. Waste treatment
There are several waste which are generated from our plant. The amount
of waste and our procedures to handle it are listed below.
a. Gaseous Waste
Gaseous waste from our plant are mainly produced from
incineration of fuel as well as biomass to generate the required heat for the
process. From the list below, we know that the generated emission of SO 2
into the atmosphere is immense and will be a threat to the environmental
well-being.
SO2 = 21.17 kg/hr (57 ppmw)
CO2 = 24,764.49 kg/hr
From our point of view, the best way to handle this sulfur emission
is to scrub the sulfur using lime (calcium oxide) and then oxidize it to form
calcium sulphate (CaSO4). The CaSO4 then can be sold as marketable
gypsum. As for personal reason, we choose this technology due to its
technological maturity, in which it has been widely used in U.S. as well as
Europe.
The chemical reactions are as follows
CaO + SO2 → CaSO3
CaSO3 + 2H2O + ½O2 → CaSO4 · 2H2O

Edi Sugiarto (13/348228/TK/40839) 111
b. Liquid Waste (Waste Water)

The liquid waste in our plant is produced from separation of
syngas-water and also gasoline-water. The detail are as follows.
Table 1. Wastewater from syngas-water separation
Components Flowrate, kg/hr
Water (H2O) 3,004.63
CO 11.42
CO2 147.36
CH4 11.25
NH3 76.58
Table 2. Wastewater from gasoline-water separation

Components Flowrate, kg/hr
Water (H2O) 3,457.19
Oil (lumped) Trace
One thing to note from this pair of wastewater is that their water
contents are already quite high. For this case, we decide to build activated
sludge ponds to treat both of these wastewater. We choose this approach
due to the fact that NH3 can be eliminated using bacteria of genus
nitrosomonas and nitrobacter, while oily wastewater is also able to be
treated using Rhodobacterales bacteria. Hence, by using this approach,
we can simplify the operation of our wastewater treatment unit as well
as reducing the capital cost for building two specific wastewater
treatment facilities.
c. Solid Waste
Solid waste from our plant comes from the remains of incinerating
our raw material (biomass), with details as follows.
Ash Flowrate = 764.62 kg/hr (high-purity)

Edi Sugiarto (13/348228/TK/40839) 112
The ash itself, actually is rich in potassium and has a market

value due to its suitability for supplementing the growth of palm
plantations. Due to this fact, we can sell the ash into a fertilizer company.
However, we choose to give out the ash for free into the local
plantations. From one point of view, this may seem to be uneconomical,
but,on the greater picture, we believe that giving the ash for free will
enhance the stability of our raw material abundance, as well as
strenghten the relationship between our company and the locales,
which will benefit us in a long term.
Table 3. Specifications of Palm Empty Fruit Bunch Ash (Konsomboon,

Pipatmanomai, Madhiyanon, & Tia, 2011; Tay & Show, 1996)
Dry-Basis Composition, %wt
K2O 48.72 P2O5 3.61
CaO 13.51 Fe2O3 12.41
SiO2 12.14 Cr2O3 1.75
MgO 2.05 MnO2 0.59
Al2O3 0.22 Others 5.00
Bulk Density, kg/m3 755

Edi Sugiarto (13/348228/TK/40839) 113
UTILITY FLOW DIAGRAM

Edi Sugiarto (13/348228/TK/40839) 114
Equipment Calculation
Sedimentation Tank
Water flow rate = 52,819 kg/hr
Density of water = 1000 kg/m3
Volumetric flowrate = 52,819 kg/hr / 1000 kg/m3
= 52.82 m3/hr
Particle diametre = 0.000074 m

Density of particle = 2650 kg/m3 (assumed as silica)
Viscosity of water = 0.001 Pa second
Gravity = 10 m/s2
Assume laminer
Re = 0.371455333 , Re is less than 1.0, hence it is laminer.
Retention time of water in sedimentation tank usually ranges between 4 to 24

hours. Take 6 hours retention time.

Edi Sugiarto (13/348228/TK/40839) 115
Volume of sedimentation tank = 52.82 m3/hr * 6 hr

= 316.91 m3
Give 20% overdesign, volume of sedimentation tank = 1.2*316.91 m3

= 380.30 m3
Proportion in designing sedimentation tank is taken as height:length:width = 1:2:2,
hence:
Height = 4.56 m
Length = 9.13 m
Width = 9.13 m
Area of sedimentation tank = Length*width
= 9.13m*9.13m
= 83.32 m2
= 0.000176 m/sec
Settling velocity (0.005019667 m/sec) is higher than water superficial velocity
(0.000176 m/sec), hence it ensures proper particle settling.
Clarifier
= 52.82 m3/hr
Chemicals used are alum with 40 ppm dosage and Sodium carbonate with 9 ppm
dosage.
Chemicals demand:
Alum = 40/1000000 * 52,819 kg/hr
= 2.1128 kg/hr

Edi Sugiarto (13/348228/TK/40839) 116
= 50.71 kg/day
Sodium carbonate = 9/1000000*52,819 kg/hr
= 0.4754 kg/hr
= 11.41 kg/day
Retention time of fluid in coagulation zoneranges from 20-60 minutes, take 40
minutes.
Coagulation zone volume = 52.82 m3/hr*40 minutes * 1 hour/60 minutes
= 35.21 m3
Take D/H =1,
D = H = 3.55 m
Mixer with paddle with 4 blades is chosen for clarifier.

D impeler = 0.33*D coagulation zone
= 0.33*3.55 m
= 1.17 m
Blade width = 0.2*D impeler
= 0.2* 1.17 m
= 0.23 m
WELH = H clarifier
= 3.55 m
, take 61 rpm

Edi Sugiarto (13/348228/TK/40839) 117
Re = 4,318,246
With :
Rho = Fluid density, lb/ft3
N = mixing velocity, rps
Di = Impeler diameter, ft
Po = Mixing parametre
Gc = 32.2 ft/s2
Po is a parametre whose value is graphically read in following manner. Mixer with

paddle with 4 blades is represented with line number 15.
Po is taken as 0.8,
( ) ( )

Edi Sugiarto (13/348228/TK/40839) 118
Power = 2.58 Hp
Quantity of water = 52,819 kg/hr

= 52.82 ton/hr = 1,267.65 ton/day
Clarifier water flux ranges from 0.4 to 0.6 m2 day/ton, take at worst condition 0.4
m2 day/ton.
Area of clarifier = Quantity of water/ Clarifier water flux
= 1,267.65 ton/day / 0.4 m2 day/ton
= 507.06 m2
Diameter of clarifier = 25.4 meter
Clarifier height ranges between 3-5 meter, take 5 meter.
Scraper blade running at 0.02 rpm is employed to remove sludge from the bottom
of clarifier. Power of scraper blade is 16 Hp.
Carbon Filter
Retention time of water in carbon filter ranges from 6-30 minutes. Take 30
minutes retention time for design basis.
= 52.82 m3/hr
Volume of carbon filter = Volumetric flowrate*Retention time
= 52.82 m3/hr*30 minutes*1 hour/60 minutes
= 26.41 m3
A carbon filter L/D ranges between 5-10, take 5,
D = 1.9 m
L = 9.4 m

Edi Sugiarto (13/348228/TK/40839) 119
Superficial velocity of water in carbon filter ranges between 5 – 20 m/hr.

Calculated superficial velocity lies on that range hence it ensure appropriate
adsorption in carbon filter.
Sand filter
Dimension of sand filter is determined with following equation which is proposed
by Australian water engneer.
Q max = water volumetric flow rate

k = hydraulic conductivity of sand which is 0.001
hmax = depth of pondage above sand filter which is usually 0.2 meter
d = depth of sand filter which is usually limited to 0.6 meter to prevent excessive
pressure drop

Volumetric flow rate = 52,819 kg/hr / 1000 kg/m3
= 52.82 m3/hr = 0.01467 m3/sec
Take 20% overdesign for volumetric flow rate = 1.2*0.01467 m3/sec

= 0.0176 m3/sec
A = 13.20 m2
D = 4 meter

Edi Sugiarto (13/348228/TK/40839) 120
Cation exchanger
Cation content in water
Cation Content, mg/L Equivalent/L
Ca+2 55 0.00275
+2
Mg 18 0.0015
Na+ 98 0.00426
Total 0.00851
Polystyrene sulfonate homogeneoues (gel) resin is used in cation exchanger. Ion

exchange capacity lies between 1.2 to 1.6 equivalent/L, take 1.2 equivalent/L.
Water flow rate = 4,940.43 kg/hr

Volumetric flow rate = 4,940.43 kg/hr / 1000 kg/m3
= 4.94 m3/hr = 4,940.43 L/hr
Total of equivalent cation = Volumetric flow rate*Equivalent cation per liter

= 4,940.43 L/hr*0.00851 Equivalent/L
= 42.05 Equivalent/hr
Take 24 hours life time of cation exchanger

Equivalent cation trapeed = Total of equivalent cation*life time
= 42.05 Equivalent/hr*24 hours

Edi Sugiarto (13/348228/TK/40839) 121
= 1,009.14 Equivalent
Required volume of resin = 1,009.14 Equivalent / 1.2 equivalent/L / 80%

= 1,051.18 L
= 1.05 m3
Take L/D = 4, hence

D = 0.7 m
L = 2.8 m
Anion Exchanger
Anion exchanger is calculated with the exact same manner as cation exchanger
calculatio.
Anion Content, mg/L Equivalent/L
HCO3- 50 0.00082
SO42- 60 0.00125
Cl- 89 0.002507
Total 0.0045767
Resin used: Polystyrene sulfonate homogeneoues (gel) resin

Anion exchange capacity = 1.2 equivalent/L
Designed percent of saturation = 80%
Service time = 24 hours
H/D = 4
D = 0.56 m
H = 2.26 m

Edi Sugiarto (13/348228/TK/40839) 122
Cooling Tower
Water flow rate = 478,569 kg/hr = 1,052,853 lb/hr
Inlet air temperature = 28.5 ºC = 83.3 ºF (dry bulb)
RH = 80%
Water inlet temperature = 48.9 ºC = 120 ºF
Water outlet temperature = 26.7 ºC = 80 ºF
Water content in inlet air is determined n following manner.
Which is 0.0198 lb of water/lb of dry air.

5ºF increment of water temperature is used for calculation. Humidity of saturated
air is calculated with following equation.
M air pH O s
ws
M udara P pH O s
While saturated vapour pressure of water is calculated with following equation.
s
logpH O
ClogT DT ET
T
With:

Edi Sugiarto (13/348228/TK/40839) 123
pH2Os = Saturated vapour pressure, mmHg

T = Temperature, K
A, B, C, D, and E are constants with:
A = 29,8605
B = -3,15x103
C = -7,3037
D = 2,42x10-9
E = 1,81x10-6
Enthalphy of saturated air is calculated with following equation.

Hs 0, 4T ws 060,8 0,45T
With:
Hs = Enthalphy of saturated air, Btu/lb dry air
T = Temperature, oF
Calculation results are displayed in following table.
T water, F T water C T water, K PH2O (mmHg) PH2O (psia) ws Hs, Btu/lb dry air
120 48.9 321.889 88.414 1.710 0.085 123.118
115 46.1 319.111 76.843 1.486 0.072 108.024
110 43.3 316.333 66.598 1.288 0.062 94.933
105 40.6 313.556 57.551 1.113 0.053 83.543
100 37.8 310.778 49.585 0.959 0.045 73.602
95 35.0 308.000 42.590 0.824 0.038 64.903
90 32.2 305.222 36.465 0.705 0.032 57.271
85 29.4 302.444 31.120 0.602 0.027 50.557
80 26.7 299.667 26.469 0.512 0.023 44.635
Calculation of Gmin
W0 (Humidity of inlet air) = 0.0198 lb of water/lb of dry air.
H0 (Enthalpy of inlet air) = 0. 4T ws 060.8 0.45T

Edi Sugiarto (13/348228/TK/40839) 124
=
0. 4 8 . F 0.0 98 lb of water lb of dry air 060.8 0.45T
= 41.74 Btu/lb dry air.
Hs is plotted versus temperature and a straight Hs-coinciding line is plotted to
calculate minimum air flow needed.
With minimum air flow, H1 is 110 Btu/lb dry air

Tin Tout
Gmin LcpL
Hin Hout
80
Gmin
0 4 .74 tu lb dry air
Gmin = 616,948 lb dry air/hr
Take G = 1.5 Gmin

G = 1.5* 616,948 lb dry air/hr
G = 925,422.66 lb dry air/hr
From psychometric chart, wet bulb temperature is 78 F.

Edi Sugiarto (13/348228/TK/40839) 125
Water concentration is 1.25 gal/min/ft2 which equals to 1.02 kg/m2/sec.
Area for 1 cell is usually 26 m2

Number of cell =
=5
Kya is calculated with following equations.
0, 6
KySc ds G
, 95 * +
G G L0
With:
Ky = Mass transfer coefficient, kmol/m2s
Sc = Schmidt number, 0,6 for steam and air system
G = Molar gas flux velocity, kmol/m2s
G’ = Gas mass flux velocity, kg/m2s
ds = Packing diameter, m
G = Viscosity of air, kg/ms
L0 - ϕLt
= void space
ϕLt = liquid hold-up

Edi Sugiarto (13/348228/TK/40839) 126
,09 0 6 (7 7,5L )
Lt
ds
,508ds 0, 76
L’ = Liquid mass flux velocity, kg/m2s
For calculation take packing material as Raschig ring type of ceramic with
nominal size 2 in,
ds = 0,0725 m
= 0,74
From calculation step, Ky is 0.001923063 kmol/m2/sec or in term of mass

0.034615128 kg/m2/sec.
Value of a for Raschig ring packing is calculated with following equation.
( )
For L’ 0,68-2,00 kg/m2s for this design it is calculated that L’ is .0 9 75

kg/m2s) , value of each constant is:
m = 31,52
n =0
p = 0,481
a = 31.81228411 m2/m3.
Kya = 1.101186301 kg/m3 sec.
Slope = L/G
= 1,052,853 lb/hr / 925,422.66 lb/hr
= 1.137699283

Edi Sugiarto (13/348228/TK/40839) 127
Hout
dH
∫
Hs H
Hin
Integration is calculated numerically which is described in following tabel. H

is calculated as H0 + Slope*(T water – T outlet water )
H Btu/lb dry air Hs Btu/lb dry air 1/(Hs-H) 2*1/(Hs-H)
87.2460 123.1183 0.0279
81.5575 108.0242 0.0378 0.0756
75.8690 94.9332 0.0525 0.1049
70.1805 83.5426 0.0748 0.1497
64.4920 73.6021 0.1098 0.2195
58.8035 64.9033 0.1639 0.3279
53.1150 57.2711 0.2406 0.4812
47.4265 50.5571 0.3194 0.6389
41.7380 44.6352 0.3452
Total 1.9977
Hout dH
∫Hin Hs-H
= 6.24 meter
Distributor space = 0.5 m

Louver space = 1 m
Total height = 7.74 m
Q =245,005.65 ft3/min
Hi = 40 in of water
D = 62.5 lb/ft3
SAHP=1,546.75 Hp

Edi Sugiarto (13/348228/TK/40839) 128
Deaerator
Horizontal vessel with piggyback vertical
Type :
packing material
Packing material : Raschig ring ceramic
Packing size : 0.5 in
Packing factor, Fp : 2,100
Surface area, a : 368 m2/m3
Bulk density : 881 kg/m3 (Coulson)
Lw : 4,940.43 kg/hr
Vw : 1,500 kg/hr
ρ air : 1000 kg/m3
ρ steam : 0,6 kg/m3
FLV : 0.199589269
ΔP : 20 mm water/m of packed height
K4 : 0.38 (Fig. 11.44, Coulson)
Vw* : 1.444149566 kg/m2-s
Vertical vessel
Area packing : 0.950276601 m2
Diameter, D : 1.099968066 m
H/D : 1.2
height, H : 1.32 m
Horizontal vessel
Flowrate : 4.94 m3/hr
Retention time : 0.5 hr
Capacity : 0.741 m3
Overdesign 20% : 0.8892 m3
H/D : 2

Edi Sugiarto (13/348228/TK/40839) 129
Diameter, D : 0.8272 m
Height, H : 1.6544 m
Deaerator height : 2.1472 M

Edi Sugiarto (13/348228/TK/40839) 130
Pump Calculation
(UP-01)
Pump Sheet No. U

Pumping freshwater into Equipment No. UP-01
Description
equalization tank Amount 2 (1 on standby)
Type Centrifugal Adiabatic, isothermal
Operating Data
Temp., C o
25 Pressure, bara 1.01  1.01
Flowrate 52818.7622kg/hr
Technical Data
Head, m 14.499
Power, HP 7.5
NPSHA 7.3043
NPSHR 3.5
Data for Pump Calculation
Parameter Point A Point B Origin of data

Temperature, ˚C 25 25 Design
Pressure, bara 1.01 1.01 Design
Relative elevation, m 0 3 Design
Elbow 3 1 See Pumping Layout
Tee 1 1 See Pumping Layout
Gate Valve 1 1 See Pumping Layout
Globe Valve 0 1 See Pumping Layout

Edi Sugiarto (13/348228/TK/40839) 131
Physical Properties Data
We obtain the physical properties data using interpolation on the available

data obtained from the following table (Holman, 2009).
The interpolation equation is as follows
With T = Temperature of the target

Ti = Temperature of the reference
X = Properties of the target
Xi = Properties of the reference
Hence, for T = 25oC, we obtain

ρ = 996.2806 kg/m3
= 0.000896 N.s/m2
The volumetric flowrate is then obtained as follows

Q = 53.0160 m3/hr
= 63.6191 m3/hr (20% overdesign)

Edi Sugiarto (13/348228/TK/40839) 132
Calculating Optimum Pipe Diameter

The optimum pipe diameter is determined by the following equation (Sinnott,
2005).
With Dopt = Optimum pipe diameter, mm

Ge = Fluid mass flowrate, kg/s
ρ = Fluid density, kg/m3
From our design, we know that we design mass flowrate as follows
G = 52818.7622 kg/hr
= 14.6719 kg/s
Taking 20% overdesign, then

Ge = 17.6063 kg/s
Hence, we obtain
104.1525 mm
= 4.1005 inch
We prefer to take standard pipe size for our plant. The selection is based on
the following data (Kern, 1950).

Edi Sugiarto (13/348228/TK/40839) 133
Hence, we take pipe with NPS of 4 inch, Sch No. 40.

Piping Layout
Piping layout is described in following figure.

Edi Sugiarto (13/348228/TK/40839) 134
Velocity Calculation
Value of velocity has lied in appropriate value for liquid velocity between 1-3
m/sec, hence the value is satisfactory.
Reynolds Number Calculation

Edi Sugiarto (13/348228/TK/40839) 135
Reynolds number has exceeded 4000, hence it is categorized as turbulent flow

which is desired in fluid flow to prevent formation of fouling.
Friction Factor and Relative Roughness Calculation

Friction factor is determined through graphical analysis (G. G. Brown, 1950).
Parameter of relative roughness is needed in friction factor determination. Relative
roughness is determined through following figure.
Ɛ/D is taken at 0.00045. Friction factor is determined through following figure.

Edi Sugiarto (13/348228/TK/40839) 136
f = 0.0185
Equivalent Pipe Length Calculation (G. G. Brown, 1950)
Suction Discharge
Type
Number Le (ft) Number Le (ft)
3 11 Elbow 1 11
1 25 Standar tee 1 25
1 2.25 Gate valve 1 2.25
0 120 Globe valve 1 120
60.25 ft 158.25 ft
Total
18.3642 m 48.2346 m
+ pipe
68.3642 m 201.2346 m
length
(the determination of equivalent pipe length is depicted in the next page figure)

Edi Sugiarto (13/348228/TK/40839) 137
Head Calculation
Head is calculated from Bernoulli equation as follows.

Edi Sugiarto (13/348228/TK/40839) 138
Following considerations are taken:

 vA = vB.
 PA = PB.
Hence,
Power Calculation
The following equation is used for calculating theoretical power.
P=
 Ws  Q  ρ
550
With: P = Theoretical Power, Hp
-Ws = total head, ft
Q = Flow rate, ft3/s
ρ = Density, lb/ft3
Q = 63.6191 m3/hr
= 0.6242 ft3/s
ρ = 996.2806 kg/m3
= 62.1866 lb/ft3

Edi Sugiarto (13/348228/TK/40839) 139
We then estimate the pump efficiency from literature (Sinnott, 2005).
We obtain, pump efficiency of 0.7.
We then estimate the motor efficiency using the following data.
Hence, we assume that the motor will have efficiency of 80%.

Edi Sugiarto (13/348228/TK/40839) 140
Total efficiency is a product of pump and motor efficiency.
Actual Power
Take standard power of 7.5 HP.
Risk of Cavitation
Cavitation occurs when suction pressure is lower than fluid vapor pressure. In
this case fluid phase changes from liquid into vapor resulting sudden volume change
that may rupture pump material. Cavitation is a serious problem in pump operation,
hence it must be avoided. Setting NPSHA at least 2 feet higher than NPSHR will avoid
cavitation.
NPSHA
For safety, take liquid vapor pressure at 30oC, which is 3739.6924 Pa.
NPSHR
NPSHR is graphically estimated with following figure.

Edi Sugiarto (13/348228/TK/40839) 141
NSPHR is taken as 3.5 metre. To ensure cavitation does not take place,
difference between NPSHA and NPSHR must be greater than 2 feet.
Hence pump is determined to be safe from cavitation.
Pump List
1. Utility Pump 01 (UP-01)

Description : Pumping fresh river water into equalization tank with flow of
52818.7622 kg/hr.
Type : Centrifugal pump, mixed flow impeller
Number : 2 (1 on standby)
Total Head : 14.4999 m
NPSHA : 7.3043 m
NPSHR : 3.5000 m
Efficiency : 0.56
Power (calc.) : 3.3573 HP
Power (true) : 5.9952 HP
Power (Std.)* : 7.5 HP

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*According to NEMA electrical motor power standard.

Description : Pumping water from equalization tank into sedimentation
tank with flow of 52818.7622 kg/hr.
Total Head : 4.1205m
NPSHA : 9.0106 m
NPSHR : 3.5000 m
Efficiency : 0.56
Power (Std.)* : 2 HP

Description : Pumping water from sedimentation tank into clarifier with
flow of 52818.7622 kg/hr.
NPSHA : 9.0106 m
NPSHR : 3.5000 m
Efficiency : 0.56

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Description : Pumping water from clarifier into sand filter with flow of
52818.7622 kg/hr.
NPSHA : 9.0106 m
NPSHR : 3.5000 m
Efficiency : 0.56

Description : Pumping water from sand filter into carbon filter with flow of
52818.7622 kg/hr.
NPSHA : 9.1172 m
NPSHR : 3.5000 m
Efficiency : 0.56

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Description : Pumping water from carbon filter into clear well with flow of
52818.7622 kg/hr.
NPSHA : 9.2238 m
NPSHR : 3.5000 m
Efficiency : 0.56

Description : Pumping water from clear well into disinfectant mixer with
NPSHA : 6.6372 m
NPSHR : 4.5000 m
Efficiency : 0.464

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Description : Pumping water from clear well into cold basin with flow of
35892.7056 kg/hr.
NPSHA : 9.6209 m
NPSHR : 3.0000 m
Efficiency : 0.552

Description : Pumping water from clear well into cation exchanger with
NPSHA : 9.1236 m
NPSHR : 4.0000 m

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Efficiency : 0.400
Description : Pumping water from disinfectant mixer into potable water
tank with flow of 3182.5000 kg/hr.
NPSHA : 8.4495 m
NPSHR : 4.5000 m
Efficiency : 0.464

Description : Pumping water from hot basin into cooling tower with flow
of 478569.4083kg/hr.
NPSHA : 9.7137 m
NPSHR : 3.2500 m

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Efficiency : 0.697
Description : Pumping water from cooling tower into cold basin with flow
of 445069.5497kg/hr.
NPSHA : 9.7137 m
NPSHR : 3.2500 m
Efficiency : 0.697

Description : Pumping water from cation exchanger into anion exchanger
with flow of 4940.4295 kg/hr.
NPSHA : 8.6120 m

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NPSHR : 4.0000 m
Efficiency : 0.400
Description : Pumping water from anion exchanger into demineralized
water tank with flow of 4940.4295 kg/hr.
NPSHA : 8.6120 m
NPSHR : 4.0000 m
Efficiency : 0.400

Description : Pumping water from demineralized water tank into deaerator
with flow of 136.4372 kg/hr.

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NPSHA : 8.9811 m
NPSHR : 5.0000 m
Efficiency : 0.280
Description : Pumping water from demineralized water tank into E-302 as
process water with flow of 4803.9923 kg/hr.
NPSHA : 8.6867 m
NPSHR : 4.5000 m
Efficiency : 0.420

Description : Pumping water from deaerator into boiler with flow of
2728.7449 kg/hr.

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NPSHA : 8.2916 m
NPSHR : 4.5000 m
Efficiency : 0.420
Closed Tank/Drop-off Area List
1. Equalization Tank (UT-01)

Description : Temporarily store freshwater to stabilize the subsequent
process.
Type : Concrete Basin, cuboid
Number :1
Retention : 1.5 hours
Calculations
Water massflow : 52818.7622 kg/hrs
Taking rough density of water as 1000 kg/m3 then,

Debit : 52.8188 m3/hrs
Hence, the required tank volume is

Volume : Debit * Retention time
: 79.2281 m3
Take overdesign 20%,
Volume Dsg : 95.0738 m3

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Take L = W = 2 H, hence
√
L = 5.7504 m
W = 5.7504 m
H = 2.8752 m (height of basin)
2. Coagullant Drop-off area (UT-03)

Description : Dropping area for alum and soda ash for clarifier
Type : squre-marked, drop-off area*
Number :1
*Alum and soda ash is stored in main warehouse and delivered into UT-03 using
conventional transportation equipment
**For quantity of alum and soda ash, see UC-01 (clarifier).
3. Clear Well (UT-04)

Description : Temporarily store clear water for the subsequent process.
Number :1
Calculations


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: 184.8657 m3
√
L = 7.6270 m
W = 7.6270 m
4. Desinfectant Tank (UT-05)

Description : Storing NaOCl 5% for disinfectant mixer UM-01 for one
week operation
Type : Vertical Cylindrical Tank, with stirrer
Number :1
Calculations
Potable water : 3182.5 kg/hr
≈ 8 500 m3/hr
NaOCl Dose : 0.5 ppm
Hence,
NaOCl Req. : 1.5913 kg/hr
For 1 week : 378.7175 kg

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Volume of 5% NaOCl
Solution Density : 1008 kg/m3
Solution Volume :
: 7.5142 m3
Take overdesign 10%, then

Volume : 8.2657 m = 504402 inch
Take H/D as 1.2, hence
We found,
D = 81.18 inch
H = 97.41 inch
Impeller diameter is calculated as one-third of vessel diameter, hence

Di = 27.06 inch
Specific gravity of NaOCl 5% is 1.008, hence we can calculate the number of

impeller as follows
Impeller No. =
= 1.2096
Hence, we take number of impeller as 2.

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We can calculate rotational speed of impeller using the following equation
( )
with, H and Di in dimension of feet.
Hence,
N = 114.0387 rpm
We can estimate the power requirements using the following equation
( ) ( )
From figure 8.8 Rasse and Barrow, we have the data as follows
Np= 6
Hence,
P = 8.5224 HP
Take motor efficiency of 70%, hence

Preq = 12.1749 HP
Using standard NEMA motor, we got

Pdsg = 15 HP
5. Potable Water Tank (UT-06)

Description : Temporarily store potable water for consumption.
Number :1
Retention : 8 hours
Calculations

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: 25.4600 m3
√
L = 3.9387 m
W = 3.9387 m
6. Cold Basin (UT-07)

Description : Temporarily store cold water for further process.
Number :1
Calculations

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Debit : 514.4621 m3/hrs

: 1286.1553 m3
√
L = 14.5602 m
W = 14.5602 m
7. Hot Basin (UT-08)
Description : Temporarily store hot water for further cooling.
Number :1
Calculations

Debit : 478.5694 m3/hrs


Edi Sugiarto (13/348228/TK/40839) 157
: 1196.4235 m3
√
L = 14.2134 m
W = 14.2134 m
8. Demineralized Water Tank (UT-09)

Description : Temporarily store demin. water for further process.
Number :1
Calculations


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: 12.3511 m3
√
L = 3.0948 m
W = 3.0948 m
9. Hydrazine Tank (UT-10)

Description : Temporarily store hydrazine for dearator.
Type : vertical cylinder
Number :1
Retention : 24 hours
Calculations
Hydrazine req. : 136.4372 kg/hrs
Taking rough density of hydrazine as 1020 kg/m3 then,


: 3.2103 m3

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Take H/D as 1.2, hence
We found,
D = 1.5989 meter
H = 1.9187 meter

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CHAPTER 9
PLANT LAYOUT

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CHAPTER 10
SHE MANAGEMENT
SHE management is a specific set of system to identify, control, and prevent

hazard so that its impact to humans and its surrounding can be minimized. In a
chemical process plant, SHE management is absolutely needed to ensure the
continuation of the process as well as minimizing environmental damage.
There are 12 known elements of SHE management, in which for our chemical
plant, will be applied as follows.
1. Process safety information

Process safety information in our plant will involves every written
documentation to be preserved and handled in an orderly manner. The
documentation itself compromises of, but not limited to, MSDS (Material
Safety Data Sheet) of every chemicals, PFD (Process Flow Diagram), P&ID
(Piping and Instrumentation Diagram), list of all equipment, and working
schedule of every employees in the plant.
2. Process hazard analysis
Process hazard analysis involves routinity to find clues about the possibility
for hazard to cause consequence as well as its severity when it happens. For
the analysis several methods may be applied, in which for our plants, we will
use what-if analysis.
3. Operating procedures
Operating procedures involves the necessity for each activity to has its own
standard procedures. The standard itself will be compromised of, but not
limited to: list of activity, notable operating condition, list of safety
equipment for the activity, and a set of emergency procedures.
4. Employee training
Employee training involves the routine and non-routine training of the
employees. The routine training will be conducted every 6 month to ensure

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the best performance of our employee to handle hazardous situation.

Meanwhile, non-routine training will be conducted out of necessity, such as
when there is a modification to our plant.
5. Contractors
Contractors involves a system to pre-selecting, qualifying, monitoring, and
evaluating the safety performance of the contractors. This is a very
important element of SHE management to prevent sabotage within our
plant.
6. Pre-startup safety review
Pre-startup safety review involves a set of review to ensure the standard of our
facility before startup of our plant can be conducted.
7. Mechanical integrity of equipment
Mechanical integrity of equipment involves the checking and managing of
equipment within our chemical plant whether it has been erected or it is stored
in the warehouse.
8. Non-routine work authorization
Non-routine work authorization involves a review to control the consistency
and safety in a non-routine work within our plant. Every non-routine work
should be authorized before being conducted, no matter the urgency of the
work. The very best example of this authorization will be the permit to check
hot-spot in our gasifier reactor.
9. Management of change
Management of change involves of a set of procedures which ensures that
every change made to our original plant design will be recorded and handled
in an orderly manner. The change itself is managed to ensure the acceptance
of managerial section in our plant.
10. Incident investigation
Incident investigation involves a set of system to ensure that every incident,
accident, and near-miss which had occurred by the very beginning of plant
operation and changes made to the plant is recorded. The record is then will
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be used to serve as a evidence to make the changes out of necessity in our

plant.
11. Emergency preparedness
Emergency preparedness involves a system to ensure the capability of our
process equipment, facilities, and employees to handle emergency situation
12. Compliance audits
Compliance audits involves a system to ensure the procedural and standard of
audited subject to comply with the rules.
Whereas, to manage the roots of accident, we choose to conduct 3E:
1. Engineering control
Engineering control involves a set of control devices to manipulate and
stabilize the process in our plant. The details on this system will be thoroughly
explained in the subsequent section.
2. Education and training
Education and training involves a set of procedure to ensure the knowledge
and capability of our employees will can meet with our 12 elements of SHE.
The training compromises of, but not limited to:
a. Chemical spill handling
b. Operating procedure to use fire-fighting equipment
c. Operating procedure for each levels of emergency
d. Operating procedure to use first-aid kit
3. Enforcement
Enforcement involves a set of rules to ensure that every procedure will be conducted
without excuses. The failure to abide by the rules will be met with a proper
punishment. The punishment may be compromised of, but not limited to: verbal
warning, written warning, salary cut, suspension, or firing the subject

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Table 10.1. Hazard Identification of Chemicals

A. Hazard Identification of Chemicals Involved in Process
Hazardous Properties
radioactive
Component Annotation Management
flammable
explosive
oxidizing
corrosive
irritant
toxic
Raw Materal
1. Palm fruit empty bunch as raw material is
1. Palm fruit stored in open yard Y-101 because it does
- - - - - - - None
empty bunch not require any kind of protection from
atmospheric condition or weather.
2. Atmospheric
- - - - - - - None None
air
3. Water in state
- - - - - - - None None
of steam
Product
1. Exposure and inhalation to gasoline 1. Workers must wear full face protection and
may lead to eye, respiratory, and skin respiratory kit.
irritation. 2. Avoiding contact between gasoline and air
4. Gasoline - √ - √ - - - 2. Flammable in contact with open fire, that may produce flammable mixture.
spark, static electric. 3. Eliminate any kind of ignition source such
3. Boiling point range 30ºC -200ºC, flash as naked flame, short circuit, and static
point at -43ºC, and autoingnition electric charge.
temperature at 280 ºC.
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4. LFL at 1.4% and UFL at 7.6%.

5. ACGIH TLV-TWA: 300 ppm, ACGIH
TLV-STEL: 500 ppm.
6. LD50 rat = >5000 ppm weight.
1. Exposure and inhalation vapour may 1. Workers must wear full face protection and
lead to eye, respiratory, and skin respiratory kit.
irritation. 2. Avoiding contact between LPG and air that
2. Liquid contact may result in cold burn. may produce explosive mixture.
3. Extremely flammable in contact with 3. Eliminate any kind of ignition source such
naked flame, spark, static electric. as naked flame, short circuit, and static
√ √ - - - - - 4. Mixture with air produces explosive electric charge.
5. LPG
mixture.
5. Boiling point at -40 ºC, flash point at
-104ºC, and autoingnition temperature
at 405-466ºC.
6. LEL at 1.9% and UEL at 10%.
7. TLV-TWA: 600 ppm, TLV-STEL: 750
ppm. LC50 rat = 658 g/m3.
Intermediate Product
1. Extremely flammable gas. 1. Workers must wear full face protection and
2. Mixture with air produces explosive respiratory kit.
mixture. 2. Avoiding contact between hydrogen and air
3. Boiling point at -252.9 ºC, flash that may produce explosive mixture.
point at -104ºC, and autoingnition 3. Eliminate any kind of ignition source such
temperature at 566ºC. as naked flame, short circuit, and static
6. Hydrogen (H2) 4. LEL at 4% and UEL at 77%. electric charge.
TLV-TWA: not classified, TLV-
√ √ - - - - -
STEL: not classified. LC50 rat >15000

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ppm at 1 hour test.

1. Extremely flammable gas. 1. Workers must wear full face protection and
2. Toxic gas if inhaled. respiratory kit.
3. Mixture with air produces explosive 2. Avoiding contact between carbon
mixture. monoxide and air that may produce
7. Carbon 4. Boiling point at -191.5ºC, flash point explosive mixture.
Monoxide √ √ - - √ - - not available, and autoingnition 3. Eliminate any kind of ignition source such
(CO) temperature at 605ºC. as naked flame, short circuit, and static
5. LFL at 12.5% and UFL at 74%.
electric charge.
TLV-TWA: 25 ppm, TLV-STEL: 200
ppm. LC50 rat 1880 ppm for 4 hours
test.
1. May cause asphyxiant 1. Workers must wear full face protection and
2. Concentration above 1% is dangerous. respiratory kit.
8. Carbon 3. Stable and nonreactive gas.
- - - - - - -
Dioxide (CO2) 4. Boiling point at -78.5ºC.
5. TLV-TWA: 5000 ppm, TLV-STEL:
3000 ppm. LC50: Not available.
1. Nontoxic and extremely flammable 1. Workers must wear full face protection and
gas. respiratory kit.
2. Working in methane contaning 2. Avoiding contact between methane and air
environment with oxygen content less that may produce explosive mixture.
9. Methane
√ √ - - - - - than 19.5% is classified dangerous. 3. Eliminate any kind of ignition source such
(CH4)
3. Mixture with air produces explosive as naked flame, short circuit, and static
mixture. electric charge.
4. Boiling point at -161.4ºC, flash point
at -188°C, and autoingnition
temperature at 580ºC.

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5. LFL at 12.5% and UFL at 74%.

TLV-TWA: 1000 ppm, LC50 rat
13023 ppm.
2. Mixture with air produces explosive 2. Avoiding contact between acetylene and air
mixture. that may produce explosive mixture.
10. Acetylene √ √ - - - - - 3. Boiling point at -83.3ºC, flash point 3. Eliminate any kind of ignition source such
(C2H2) at -18.15°C, and autoingnition as naked flame, short circuit, and static
temperature at 305ºC. electric charge.
4. LEL at 2.3% and UEL at 99.99%.
TLV-STEL: 2500 ppm. LC50 fish 545
mg/l for 96 hours test.
2. Mixture with air produces explosive 2. Avoiding contact between ethylene and air
11. Ethylene √ √ - - - - - 3. Boiling point at -102.4ºC, flash point 3. Eliminate any kind of ignition source such
(C2H4)
at -136.1°C, and autoingnition as naked flame, short circuit, and static
temperature at 450ºC. electric charge.
4. LEL at 2.7% and UEL at 36%. TLV-
STEL: 200 ppm. LC50: 960000 ppm.
1. Irritant in contact with skin, eye, 1. Workers must wear full face protection and
- - - √ - - - inhalation, or ingestion. respiratory kit.
12. Tar
2. Combustible at high temperature.
3. Boiling point at 66°C.
13. Ammonia - √ √ √ √ - - 1. Cause severe skin burn, blindness, and 1. Workers must wear full face protection and
(NH3) respiratory damage. respiratory kit.

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2. LD50 rat = 350 mg/kg. 2. Adequate ammonia detector in plant must

3. Corrosive to metal. be employed to detect any leakage.
4. OSHA (final) TWA: 50 ppm; STEL:35
mg/m3.
5. Slightly flammable gas.
6. LFL =15% UFL=28%.
1. Toxic and extremely flammable gas. 1. Workers must wear full face protection and
mixture. 2. Avoiding contact between ethylene and air
14. Hydrogen 3. Boiling point at -60.3ºC, and that may produce explosive mixture.
Sulfide (H2S) √ √ √ √ √ - - autoingnition temperature at 270ºC. 3. Eliminate any kind of ignition source such
4. LEL at 4.3% and UEL at 45%. TLV- as naked flame, short circuit, and static
TWA= 10 ppm and TLV-STEL: 15 electric charge.
ppm. LC50: 356 ppm.
4. Adequate hydrogen sulfide detector in plant
must be employed to detect any leakage.
1. Corrosive to metal. 1. Workers must wear full face protection and
2. Hygroscopic. respiratory kit.
3. Extremely dangerous in case of 2. Adequate hydrogen sulfide detector in plant
15. Hydrochloric - √ √ - - - - inhalation and skin contact. must be employed to detect any leakage.
Acid (HCl)
4. TLV-TWA= 10 ppm and TLV-STEL: 5
ppm. LC50: 1562 ppm.
1. Side product of biomass gasification. It 1. Stored in closed bin and sold to palm
- - - √ - - - is fine particle that may cause irritation plantation as fertilizer.
16. Ash
in eye, skin, and respiratory system. 2. Workers must wear full face protection and
respiratory kit.
17. Methanol √ √ - √ - - - 1. Irritant and extremely flammable 1. Workers must wear full face protection and
(CH3OH) volatile liquid. respiratory kit.

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2. Mixture with air produces explosive 2. Avoiding contact between methanol and air
3. Boiling point at 64.5ºC, flash point at 3. Eliminate any kind of ignition source such
12°C, and autoingnition temperature at as naked flame, short circuit, and static
464ºC. electric charge.
4. LFL at 6% and UFL at 36.5%. TLV- 4. Adequate methanol detector in plant must be
TWA: 200 ppm, TLV-STEL = 250 employed to detect any leakage.
ppm, LD50:5628 ppm, LC50:64000
ppm.
1. Nontoxic and extremely flammable gas. 1. Workers must wear full face protection and
mixture. 2. Avoiding contact between propane and air
18. Propane √ √ - - - - - 3. Boiling point at -42.1ºC, flash point that may produce explosive mixture.
(C3H8) at -104.4°C, and autoingnition 3. Eliminate any kind of ignition source such
4. LFL at 2.1% and UFL at 9.5%. TLV- electric charge.
TWA: 1000 ppm, LC50 rat 658 mg/l.
mixture. 2. Avoiding contact between propane and air
19. Propene √ √ - - - - - 3. Boiling point at -47.7ºC, flash point that may produce explosive mixture.
(C3H6) at -107.8°C, and autoingnition 3. Eliminate any kind of ignition source such
LFL at 2% and UFL at 11.1%. TLV- electric charge.
TWA:500 ppm, LC50 rat 658 mg/l.
20. Iso-butane √ √ - - - - - 2. Mixture with air produces explosive respiratory kit.
(C4H10) mixture. 2. Avoiding contact between isobutane and air

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3. Boiling point at -12ºC, flash point at that may produce explosive mixture.
-83.15°C, and autoingnition temperature 3. Eliminate any kind of ignition source such
at 460ºC. as naked flame, short circuit, and static
LFL at 1.8% and UFL at 8.4%. TLV- electric charge.
TWA: 800 ppm, TLV-STEL: 1000
ppm, LC50 rat 658000 mg/m³.
mixture. 2. Avoiding contact between N-butane and air
3. Boiling point at -0.5ºC, flash point at that may produce explosive mixture.
21. N-butane √ √ - - - - - -60°C, and autoingnition temperature at 3. Eliminate any kind of ignition source such
(C4H10) 365ºC. as naked flame, short circuit, and static
TWA: 800 ppm, LC50 rat 658000
mg/m³.
mixture. 2. Avoiding contact between N-butane and air
22. 1-butene 3. Boiling point at -0.5ºC, flash point at that may produce explosive mixture.
(CH₃CH₂CH= √ √ - - - - - -60°C, and autoingnition temperature at 3. Eliminate any kind of ignition source such
CH₂) 365ºC. as naked flame, short circuit, and static
TWA: 800 ppm, LC50 rat 658000
mg/m³.
1. Exposure and inhalation may lead to 1. Workers must wear full face protection and
23. N-octane - √ - √ - - - eye, respiratory, and skin irritation. respiratory kit.
(C8H18) 2. Flammable in contact with open fire, 2. Avoiding contact between N-octane and air
spark, static electric. that may produce flammable mixture.

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3. Boiling point: 125.6ºC, flash point: 3. Eliminate any kind of ignition source such
13.33ºC, and autoingnition temperature as naked flame, short circuit, and static
at 206ºC. electric charge.
4. LFL at 1% and UFL at 6.5%.
5. TLV-TWA: 300 ppm. TLV-STEL: 375
ppm.
Supporting Material
1. Dust in high concentration may irritate 1. Workers must wear full face protection and
24. Olivine - - - √ - - - respiratory system. respiratory kit.
(Mg2SO4)
2. TLV-TWA= 4 mg/m3.
- - - √ - - - 1. LD50: 5140 ppm 1. Workers must wear full face protection and
25. TEGDME
2. Boiling point: 276ºC. respiratory kit.
Utility
26. Sodium 1. Corrosive to metals, such as aluminum 1. NaOH solution should be stored in dry and
Hydroxide and carbon steel. closed storage tank made from stainless
(NaOH) 5% 2. Corrosive to skin and eyes. stell.
3. Irritant to skin, eye, and respiratory 2. Workers must wear full face protection and
- - √ √ - - - system. respiratory kit.
4. Highly reactive. Solid NaOH can react
violently with water (exothermic),
acetic acid, hydrofluoric acid,
peroxide, aluminum.
5. STEL: 2 mg / m3
1. Reactive with moisture. 1. Alum should be stored in dry and closed
27. Alum 2. May corrode metal in presence of storage tank made from stainless stell.
- - - √ - - - moisture.
(Al2(SO4)3) 2. Workers must wear full face protection and
3. Irtitant to skin, eye, and respiratory respiratory kit.
system.

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4. LD50 :> 9000 ppm.

1. Irritant and corrosice to skin, eye, and 1. Sodium hypochlorit should be stored in dry
28. Sodium respiratory system. and closed storage tank made from copper.
Hypochlorit - - √ √ - √ - 2. Corrosive to alumunium and stainless 2. Workers must wear full face protection and
(NaOCl) stell. Noncorrosive to copper. respiratory kit.
3. TWA and STEL: 1 ppm as Cl2.
4. LD50: 5800 ppm.
29. Libricating Oli pelumas harus disimpan di tempat yang
oil - √ - √ - - - - tertutup, sejuk, terhindar dari sumber panas,
dan terhindar dari sumber nyala api.
30. Sulfuric Acid 1. Corrosive and irritant to skin, eye, and 1. Sulfuric acid solution should be stored in
(H2SO4) 5% respiratory system. dry and closed storage tank coated with
- - √ √ √ - - 2. LC50 :255 ppm polyethylene.
3. Hygroscopic. 2. Workers must wear full face protection and
4. Corrosive to metalic surface. respiratory kit.
5. STEL: 3 mg/m3.
31. Activated 1. Combustible material. 1. Eliminate any kind of ignition source such
Carbon 2. Irritant in case of skin and eye contact, as naked flame, short circuit, and static
- - - √ - - - inhalation, and ingestion. electric charge.
3. TWA: 15 mg/m3. 2. Workers must wear full face protection and
4. LD50: > 10000 ppm. respiratory kit.
32. Hydrazine 1. Corrrosive and irritant case of skin and 1. Hydrazine is stored in closed tank to
eye contact, inhalation, and ingestion. prevent mixture with air.
2. Toxic material with LD50: 129 ppm. 2. Workers must wear full face protection and
- √ √ √ √ - - respiratory kit.
3. Flammable, LFL= 2,9%, UFL= 98 %
flash point: 72°C. 3. Keep away from heat and any kind of
ignition source such as naked flame, short
circuit, and static electric charge.

Edi Sugiarto (13/348228/TK/40839) 179
Table 10.2. Hazard Identification of Equipment

B. Hazard Identification in Equipment
Hazard
Rotating Eqp.
Temperature
Composition
Equipment Annotation Management
Elevation
Quantity
Pressure
Process
1. Belt conveyor (BC-101, 1. Operating condition at 25°C and 1. Workers must wear full face protection,
BC-102, BC-103, BC- - - √ - - √ 1 atm. respiratory kit such as mask, and ear
104, and BC-105) 2. May produce fine dust. muff.
1. Operating condition at 25°C and 1. Workers must wear full face protection,
2. Mill (M-101 and M-102) - - √ - - √ 1 atm. respiratory kit such as mask, and ear
2. May produce fine dust. muff.
1. Insulation in outer surface.
1. Operating condition at 250°C
- √ √ - - √ 2. Workers must wear full face protection,
3. Rotary dryer (D-201) and 1 atm.
respiratory kit such as mask, and ear
2. May produce fine dust.
muff.
1. Insulation on the outer surface of
reactor to prevent excessive heat loss
1. Fluidized bed gasifier
- √ - - √ √ and ensure safe temperature.
4. Biomass gasifier (R-201) 2. P = 1.58 bar T = 928°C
2. Pressure and temperature controller are
3. Produces syngas (CO, CO2, H2).
employed to maintain operating
temperature.

Edi Sugiarto (13/348228/TK/40839) 180

1. Fluidized bed reactor
reactor to prevent excessive heat loss
- √ - - - √ 2. P = 1.1 bar T = 1048°C
5. Char combustor (R-202) and ensure safe temperature.
3. Produces flue gas as combustion
2. Temperature controller is employed to
product.
maintain operating temperature.
1. S-201, T = 928°C 1. Insulation on the outer surface of
S-202, T = 987°C cyclone to prevent excessive heat loss
6. Cyclone (S-201, S-202, S- - √ - - - - S-203, T = 921°C and ensure safe temperature.
203) 2. S-201, P = 1.58 bar
S-202, P = 1.1 bar
S-203, P = 1.1 bar
adsorber to prevent excessive heat loss
1. Adsorber that adsorbs reactively and ensure safe temperature.
7. Sulfur adsorber (A-301 - √ - - √ - sulfur. 2. H2S detector around adsorber is needed
A/B)
2. P= 1.52 bar; T = 928°C. to detect any leakage since H2S is toxic.
3. Water sprinkler is needed to absorb
leaked H2S in case of leakage.
8. Tar reformer (R-301) - √ - - √ √ 1. P= 1.39 bar; T = 928°C. and ensure safe temperature.
2. Employ pressure controller to prevent
overpressure.

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1. Flash drum is equipped with pressure

controller to prevent overpressure.
Pressure controller regulates outlet gas
- - - - √ √ flow rate.
9. Flash drum (S-301) 1. P= 1.29 bar; T = 40°C.
2. Flash drum is equipped with level
controller to maintain liquid level
inside flash drum. Level controller
regulates outlet liquid flow rate
and ensure safe temperature.
2. Pressure controller that regulates outlet
gas flow rate to prevent overpressure or
even explosion.
3. Employ check valve at reactor inlet to
prevent back flow.
1. P= 1.29 bar; T = 40°C. 4. Disc typed relief valve to release gas in
10. Trickle bed reactor (R- √ √ - - √ √ 2. Produce methanol and water order to decrease reactor pressure in
401) from syngas (CO, CO2, and H2) case of pressure controller failure. It is
over Cu/ZnO/Al2O3 catalyst. followed by scrubber to absorb
methanol and flare to combust syngas
before safely released to the
environment.
5. Employ H2, CO, CO2, and methanol
detector around reactor to detect any
leakage.
6. Employ water sprinkler to absorb
released methanol in case of leakage.

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1. Flash drum is equipped with level

regulates outlet liquid flow rate.
2. Spring typed relief valve to release gas
11. Flash drum (S-301) - √ - - √ √ 1. P= 2.81 bar; T = 221°C. in order to decrease reactor pressure in
case of pressure controller failure. It is
followed by scrubber to absorb
methanol and flare to combust any
remaining methanol before safely
released to the environment.
1. Reactor is equipped with pressure
controller to maintain pressure inside
flash drum. Level controller regulates
outlet gas flow rate.
in order to decrease reactor pressure in
case of pressure controller failure. It is
12. Gasoline synthesis √ √ - - √ √ followed flare to combust hydrocarbon
1. P= 2.75 bar; T = 512°C.
reactor (R-501) before safely released to the
environment.
and ensure safe temperature.
4. Employ hydrocarbon detector around
reactor to detect any leakage.
5. Employ water sprinkler in case of fire.

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1. Separator is equipped with level

regulates outlet liquid flow rate.
13. Three phase separator √ - - - √ √ in order to decrease separator pressure
1. P= 2.73 bar; T = 40°C.
(S-501) in case of overpressure. It is followed
flare to combust hydrocarbon before
safely released to the environment.
separator to detect any leakage.
1. Distillation column is equipped with
level controller at the bottom to
maintain bottom liquid level. Level
controller regulates bottom flow rate.
in order to decrease distillation column
1. Separates hydrocarbon product
14. Distillation column (DC- √ √ - - √ √ pressure in case of overpressure. It is
into light gas, LPG, and
501 and DC-502) followed flare to combust hydrocarbon
gasoline at 12 bar.
before safely released to the
environment.
distillation column to detect any
leakage.

Edi Sugiarto (13/348228/TK/40839) 184

in order to decrease tank pressure in
case of overpressure. It is followed
flare to combust LPG before safely
√ - - - √ √ 1. Storing LPG product at 12 bar
15. LPG tank (T-501 A/B) released to the environment.
and ambient temperature.
2. Employ LPG detector around
distillation column to detect any
leakage.
1. Use floating roof tank.
16. Gasoline tank (T-501 - - - - √ √ 1. Storing gasoline product at 12
2. Build dyke around tank in case of spill.
A/B) bar and ambient temperature.
Utility
1. Employ pressure differential sensor to
17. Sand filter - - - - - - - measure pressure drop. It is needed to
detect requirement of back wash.
1. Gradual water quality inspection to
18. Carbon filter - - - - - - - detect requirement of activated carbon
replacement.
19. Cation and anion - - - - - - 1. Gradual water quality inspection to
-
exchanger detect requirement of regeneration.

Edi Sugiarto (13/348228/TK/40839) 185
1. To assure maximum deaeration feed

water temperature must be maintained
above 225ºF. This is accomplished by
- √ - - - - 1. P = 2.75 bar controlling the temperature of the low
20. Deaerator
T = 110ºC pressure steam supplied to the
deaerator.
2. At bottom part a level controller must
be employed to maintain liquid level.
1. Employ pressure controller that
regulates outlet steam flow rate to
maintain steam pressure.
2. Employ disc typed relief valve to
√ √ - - - - 1. P = 2.75 bar release steam in order to decrease
21. Boiler
T = 110ºC reactor pressure in case of pressure
controller failure that leads to
overpressure.
3. Level controller must be employed to
maintain liquid level in boiler.
1. Employ temperature controler that
22. Cooling tower - - - - - - - regulates air flow to maintain outlet
water temperature.

Edi Sugiarto (13/348228/TK/40839) 186
Table 10.3. Hazard Identification of Plant Layout

C. Plant layout and process location hazard identification
Hazard
Operability and
maintainability
Hazardous
Equipment Annotation Management
Explosion
material
release
Fire
Plant layout
1. Biomass yard is placed outside process area to

1. Biomass yard - - - √ facilitate raw material delivery without
compromising safety.
√ √ - √ 2. LPG tank is placed outside process area to facilitate
2. LPG tank
product shipping without compromising safety.
1. Gasoline tank is placed outside process area to
facilitate product shipping without compromising
3. Gasoline tank - √ - √ safety.
2. Dyke around tank is build in case of spill or
leakage.
Process location
Adequate distance between plant site and office must be

4. Distance between designed to provide sufficient time in case of
plant site and √ √ √ - emergency evacuation. A temporary assembly point at
office. safe location must be provided to accomodate workers
in case of emergency.

Edi Sugiarto (13/348228/TK/40839) 187
5. Distance between - - - - At least 1000 m distance must be provided.

plant site and road.
6. Distance between At least 10 km distance between plant site and city
plant site and √ √ √ - centre must be provied to ensure safety during
residential area. emergency condition.
Table 10.4 Hazard Identification of Chemical Exposure

D. Chemical exposure identification
Hazard
any other body

Kidney failure
Respiratory
Damage on
Type of exposure Annotation Management
Irritation
mutation
damage
Genetic
Cancer
part
Process
1. Carbon Monoxide (CO) - √ - - - -
2. Ammonia (NH3) - √ - √ - √
3. Tar - - - - - √
4. Hydrogen Sulfide (H2S) - √ - - - √
Workers must wear full face protection, glove, and
5. Hydrochloric Acid (HCl) - √ - √ - √ respiratory kit.
6. Methanol (CH3OH) - √ √ √ √ √
7. N-octane (C8H18) - - - - - √
8. Gasoline - √ √ √ - √

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9. Olivine (Mg2SO4) - - - - - √
10. TEGDME - - - - - √
Utility
11. Sodium Hydroxide
- √ - √ - √
(NaOH) 5%
12. Hydrazine √ √ - √ - √
13. Sodium Hypochlorit Workers must wear full face protection, glove, and
- √ - √ - √
(NaOCl) respiratory kit.
14. Sulfuric Acid (H2SO4) - √ - √ - √
5%
15. Alum (Al2(SO4)3) - - - - - √
Table 10.5. Hazard Identification of Chemical Exposure
E. Physical exposure identification
Hazard
Skin tissue
Deafness
Type of Annotation Management

damage
Cancer
exposure
URI
1. Noise √ - - - Generated by compressors, pumps, and Workers must wear era plug.
grinder.
2. Heat - - √ - Generated by boiler, heat exchanger, and Adequate insulation in heat generating equipment and
reactor. safe radius around those equipment to prevent injury.
3. Dust - - - √ Produced in char combustion. Workers must wear full face protection and respiratory
kit.
Table 10.6. Hazard Identification of Waste

Edi Sugiarto (13/348228/TK/40839) 189
A. Hazard Identification of Gaseous Waste

Hazard
Ozone Depletion
Global Warming
Emission Source Annotation Management
Ecological
Formation
Acid Rain
Damage
SMOG
Toxic
R-202 and CO2 is produced directly from CO2 is disposed to atmospheric air through
1. CO2 - √ √ √ -
boiler. combustion in R-202 and boiler. stack.
R-202 and - - - - - -
H2O is produced directly from H2O is disposed to atmospheric air through
2. H2O
boiler. combustion in R-202 and boiler. stack.

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B. Hazard Identification of Liquid Waste

Hazard
Contamination
Water Quality
Degradation
Ecological
Poisoning
Poisoning
Liquid Waste Source
Damage
Resource
Aquatic
Human
Annotation Management
Biota
Water
Process condensate is produced from Neutralization of process
1. Process condensation of process stream which is condensate with NaOH solution.
S-301 √ √ √ √ √
condensate separated in S-301. It contains dissolved Biodegradation in pond is taken
HCl, NH3, and H2S.
as final treatment before
Process water is produced from Biodegradation in pond is taken
released to environment.
√ √ √ condensation of process stream which is as final treatment before
2. Process water S-501 - √
separated in S-501. It contains hydrocarbon released to environment.
fraction.
3. Lubricating Lubrication Lubricating oil is used in all rotating Used lubricating oil is stored and
- √ √ √ - equipment. Lubricating oil is classified as
Oil sent to waste treatment company
B3 waste. for further treatment.
4. Cation Cation Regeneration of saturated cation exchanger Waste is neutralized with NaOH
exchanger exchanger - √ √ √ √ with sulfuric acid solution results in waste before released to the
regeneration that contains cation-SO4 ions. Acidic waste environment.
is very likely to be found.

Edi Sugiarto (13/348228/TK/40839) 191
4. Anion Anion Regeneration of saturated anion exchanger Waste is neutralized with H2SO4
exchanger exchanger - √ √ √ √ with caustic solution results in waste that before released to the
regeneration contains Na-anion ions. Waste with basic environment.
pH is very likely to be found.
5. Domestic Office and Treated with active sludge and
- - √ √ - -
waste housing aeration to reduce BOD of waste
water before released to the
environment.
C. Hazard Identification of Solid Waste
Hazard
Contamination
Radioactive
Source Annotation Management
Ecological
Resource
Damage
Solid Waste
Others
Water
Toxic
1. Sludge Sedimentation Stored in open land field.

- √ - - - -
tank and clarifier
in water treatment.
2. Char R-201 Produced in biomass Char is stored in closed storage and
- √ - - -
gasification. sold to the third part.
3. Ash R-202 - Produced in char Stored in silo and sold to plantation
- √ - -
combustion. company as fertilizer.

Edi Sugiarto (13/348228/TK/40839) 192
4. Sulfur A-301 A/B Sulfur in process stream Used adsorbent is stored properly in
√ √ is adsorbed chemically closed storgae and sent to waste

√ - -
using adsorbent in A- treatment company for further
301 A/B. treatment.

Edi Sugiarto (13/348228/TK/40839) 193
CHAPTER 11
ORGANIZATORIAL STRUCTURES
To ensure a proper working environment, an adequate organizational structure

should be provided in our project. In our case, the organizational hierarchy can be
generalized as follows.
1. President Director
2. Division Director
3. General Manager
4. Section Manager
5. Foreman/Shift Head
6. General Employees or Operator
The main responsibility lies in the president director, assisted by several division
director. Where as, nnual udit will have highest authority regarding overall plant’s
decision.

Edi Sugiarto (13/348228/TK/40839) 194
Organizatiorial Tree Diagram
President Director
Production Accounting and General Affairs Human Resource and

Director Marketing Director Director Administration Director
General Manager General Manager General Manager General Manager General Manager
General Manager General Manager General Manager General Manager General Manager
of Research and of Health, Safety, of Regulation and of Administration of Human
of Process System of Facilities of Accounting of Marketing of External Affairs
Development and Environment Security and Personalia Resource
Section Manager Section Manager of Section Manager

Section Manager Section Manager Section Manager Section Manager Section Manager Section Manager Section Manager
of Workshop and Laboratory and of Health and
of Process of Audit of Inquiry of Regulation of Logistic of Administration of Recruitment
Maintenance Quality Testing Safety
Section Manager Section Manager Section Manager

Section Manager Section Manager of Section Manager Section Manager of Section Manager Section Manager Section Manager
of Electricity and of Product of Human
of Utility Development of Ecology Corporate Planning of Security of Collaboration of Personalia
Instrumentation Marketing Development
Section Manager of
Information and
Technology
Figure 11.1. Organizatorial Structure of Palm Empty Fruit Bunch to Gasoline Plant

Edi Sugiarto (13/348228/TK/40839) 195
Details and List of Employees

In this section, we give a comprehensive list of employees as well as their minimum
qualifications according to our initial plans. This list in future, however, can be
changed according to the company necessities.
1) President Director
Responsibility : Making decision regarding overall plant operation to ensure best
performance in overall company performance.
Qualifications : Bachelor Degree with minimum 5 years of experience in both
Production and Economy Management. Chemical Engineering
degree is preferred
No. of Seat : 1 person
President director are assisted by 4 Division Directors, as follows
1.1) Production Director
Responsibility : Ensuring best performance related to company’s
production.
Qualifications : Bachelor degree of chemical engineering with
minimum 4 years of experience in Production Division
or related fields.
Production director are assisted by several Departement Manager as
follows:
a. General Manager of Process System
Responsibility : Coordinating activities within process and
system department.
Qualitications : Bachelor degree of chemical engineering
with minimum 3 years of experience in
Process System Department or related fields.
General manager of process system are assisted by several Section
Manager as follows:

Edi Sugiarto (13/348228/TK/40839) 196
 Section Manager of Process

Responsibility : Coordinating activities within process section.
Qualifications : Bachelor degree of chemical engineering or
Associate degree with minimum 3 years of
experience in related fields
Staffs : 44 employees, consist of:
a) 4 seat of Shift Coordinator (Associate
degree)
b) 40 seat of Operator (High School Degree)
 Section Manager of Utility
Responsibility : Coordinating activities within utility section.
a) 4 seat of Shift Coordinator (Associate
degree)
b) 36 seat of Operator (High School Degree)
b. General Manager of Facilities
Responsibility : Coordinating activities within facilities
department.
Qualitications : Bachelor degree of chemical engineering,
mechanical engineering, or electrical
engineering with minimum 3 years of
experience in Facilities Department or related
fields.

Edi Sugiarto (13/348228/TK/40839) 197
General manager of facilities are assisted by several Section Manager

as follows
 Section Manager of Workshop and Maintenance
Responsibility : Coordinating activities within workshop and
maintenance section.
Qualifications : Bachelor degree of mechanical engineering or
a) 2 seat of Head Coordinator (Associate
degree)
b) 6 seat of Technician (High School Degree)
 Section Manager of Electricity and Instrumentation
Responsibility : Coordinating activities within electricity and
instrumentation section.
Qualifications : Bachelor degree of electrical engineering or
degree)
 Section Manager of Information and Technology
Responsibility : Coordinating activities within information and
technology section.
Qualifications : Bachelor degree of information and
technology or Associate degree with minimum
3 years of experience in related fields

Edi Sugiarto (13/348228/TK/40839) 198

degree)
c. General Manager of Research and Development
Responsibility : Coordinating activities within research and
development department.
minimum 3 years of experience in Research
and Development Department or related
fields.
General manager of research and development are assisted by several
Section Manager as follows
 Section Manager of Laboratory and Quality Testing
Responsibility : Coordinating activities within laboratory and
quality testing section.
a) 2 seat of Staff I (Associate degree)
b) 2 seat of Staff II (Associate degree)
c) 4 seat of Analyst (High schol degree)
 Section Manager of Development
Responsibility : Coordinating activities within development
section.

Edi Sugiarto (13/348228/TK/40839) 199

d. General Manager of Health, Safety, and Environment
Responsibility : Coordinating activities within health, safety,
and environment department.
minimum 3 years of experience in health,
safety, and environment or related fields.
General manager of health, safety, and environment are assisted by
several Section Manager as follows
 Section Manager of Health and Safety
Responsibility : Coordinating activities within health and
safety section.
a) 1 seat of Safety Officer (Associate degree)
b) 2 seat of Staff I (Associate degree)
c) 1 seat of Health Officer (Associate degree)
d) 5 seat of Medical Personeel (High school
degree)
 Section Manager of Ecology

Edi Sugiarto (13/348228/TK/40839) 200
Responsibility : Coordinating activities within ecology section.

1.2) Accounting and Marketing Director
Responsibility : Ensuring best performance related to company’s
accounting and marketing.
Qualifications : Bachelor degree of economy with minimum 4 years of
experience in Accounting and Marketing Division or
related fields.
Accounting and marketing director are assisted by several Departement
Manager as follows:
a. General Manager of Accounting
Responsibility : Coordinating activities within accounting
department.
Qualitications : Bachelor degree of economy or accounting
with minimum 3 years of experience in
accounting or related fields.
General manager of accounting are assisted by several Section
Manager as follows
 Section Manager of Audit
Responsibility : Coordinating activities within audit section.
Qualifications : Bachelor degree of accounting with minimum
2 years of experience in related fields

Edi Sugiarto (13/348228/TK/40839) 201

a) 2 seat of Head Coordinator (Bachelor
Degree)
b) 2 seat of Secretary (Bachelor Degree)
c) 2 seat of Staff III (High School Degree)
 Section Manager of Corporate Planning
Responsibility : Coordinating activities within corporate
planning section.
Qualifications : Bachelor degree of economy or accounting
with minimum 2 years of experience in related
fields
Degree)
b. General Manager of Marketing
Responsibility : Coordinating activities within marketing
department.
Qualitications : Bachelor degree of economy with minimum 3
years of experience in marketing or related
fields.
General manager of marketing are assisted by several Section
Manager as follows
 Section Manager of Logistic
Responsibility : Coordinating activities within logistic section.
Qualifications : Bachelor degree of economy with minimum 2
years of experience in related fields

Edi Sugiarto (13/348228/TK/40839) 202

a) 1 seat of Staff I (Bachelor degree)
c) 2 seat of Staff III (High school degree)
 Section Manager of Collaboration
Responsibility : Coordinating activities within collaboration
section.
Qualifications : Bachelor degree of economy with minimum 2
years of experience in related fields
1.3) General Affairs Director
Responsibility : Managing general affairs in the operation of the
company
Qualifications : Bachelor degree of Laws or Psychology with minimum
3 years of experience in General Affairs Division or
related fields.
General affairs director are assisted by several Departement Manager as
follows:
a. General Manager of Regulation and Security
Responsibility : Coordinating activities within regulation and
security department.
Qualitications : Bachelor degree of Law or person with
similar qualities

Edi Sugiarto (13/348228/TK/40839) 203
General manager of Regulation and Security are assisted by several

Section Manager as follows
 Section Manager of Regulation
Responsibility : Coordinating activities within regulation
section.
Qualifications : Bachelor degree of Laws or similar qualities
 Section Manager of Security
Responsibility : Coordinating activities within security section.
Qualifications : High School Degree with at least 3 years of
a) 4 seat of Shift Coordinator (Highschool
degree)
b) 30 seat of security officer (Highschool
degree)
b. General Manager of External Affairs
Responsibility : Coordinating activities within external affairs
department.
Qualitications : Bachelor degree of International Relationship
or similar qualities
General manager of External Affairs are assisted by several Section
Manager as follows
 Section Manager of Logistic

Edi Sugiarto (13/348228/TK/40839) 204
Responsibility : Coordinating activities within logistic section.

Qualifications : Bachelor degree of International Relationship
degree)
b) 1 seat of secretary (Associate degree)
c) 1 seat of staff III (High school degree)
 Section Manager of Collaboration
Responsibility : Coordinating activities within collaboration
section.
degree)
b) 1 seat of secretary (Associate degree)
1.4) Human Resource and Administration Director
Responsibility : Managing human resource and administration in the
company
Qualifications : Bachelor degree of Laws with minimum 3 years of
experience in Human Resource and Administration
Division or related fields.
Human Resource and Administration Director are assisted by several
Departement Manager as follows:
a. General Manager of Administration and Personalia

Edi Sugiarto (13/348228/TK/40839) 205
Responsibility : Coordinating activities within administration

and personalia department.
Qualitications : Bachelor degree of Laws or International
Relationship or similar qualities
General manager of administration and personalia are assisted by
several Section Manager as follows
 Section Manager of Administration
section.
Qualifications : Bachelor degree of Laws or International
a) 2 seat of staff II (Associate degree)
b) 3 seat of staff III (High school degree)
 Section Manager of Personalia
section.
Qualifications : Bachelor degree of Laws or International
a) 1 seat of staff I (Bachelor degree)
b) 2 seat of staff II (Associate degree)
b. General Manager of Human Resource
Responsibility : Coordinating activities within human resource
department.

Edi Sugiarto (13/348228/TK/40839) 206
Qualitications : Bachelor degree of International Relationship

General manager of human resource are assisted by several Section
Manager as follows
 Section Manager of Recruitment
Responsibility : Coordinating activities within recruitment
section.
or Psychology or similar qualities
d) 1 seat of staff I (Bachelor degree)
e) 2 seat of staff II (Associate degree)
f) 1 seat of staff III (High school degree)
 Section Manager of Human Development
Responsibility : Coordinating activities within human
development section.
or Psychology or similar qualities
g) 1 seat of staff I (Bachelor degree)
h) 2 seat of staff II (Associate degree)
i) 1 seat of staff III (High school degree)
We also decide to outsource cleaning service for the company which amounted
to 10 employees. Regarding day off, we decide to give our employees two weeks in a
year. If the day off is not taken, then the working hours will be taken as overtime. As
for national holiday, non-shift employee will be permitted to not work, while shift
employee, their work will be counted as overtime.

Edi Sugiarto (13/348228/TK/40839) 207

Edi Sugiarto (13/348228/TK/40839) 208
Working Schedules
The schedules in our plant can be classified as shift and non-shift
schedule. Generally, shift working schedule are applied to employee which works
in production or security department.
a. Non-shift
Employees which are not directly involved in production or security
activities will be classified as non-shift employees. They will work 5 days in a
week with schedule as follows:
Monday-Thursday
 Work Time : 07.00 - 16.00
 Break : 12.00 - 13.00
Friday
 Work Time : 07.00 - 17.00
 Break : 11.30 - 13.30
Saturday-Sunday
 Day off
b. Shift
Employees which are directly involved in production or security activities
will be classified as shift employees. They will work with schedule as follows
 Morning Shift : 08.00 - 16.00
 Evening Shift : 16.00 - 24.00
 Night Shift : 24.00 - 08.00
The work shift schedule is given in the next page

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Table 11.1 Shift Work Time Table
Schedule
Shift
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Morning A A A D D C C B B B A A D D
Evening B B B A A D D C C C B B A A
Night C C C B B A A D D D C C B B
Day off D D D C C B B A A A D D C C
Days Sat Su Mo Tu We Th Fri Sat Su Mo Tu We Th Fri
Schedule
Shift
15 16 17 18 19 20 21 22 23 24 25 26 27 28
Morning C C C B B A A D D D C C B B
Evening D D D C C B B A A A D D C C
Night A A A D D C C B B B A A D D
Day off B B B A A D D C C C B B A A
Days Sat Su Mo Tu We Th Fri Sat Su Mo Tu We Th Fri

Edi Sugiarto (13/348228/TK/40839) 210
Operator Requirement
Number of operators in chemical plant is estimated with following equation.
Where,
NOL = number of operator per shift
P = number of processing steps involving the handling of particulate solid. In general
the value of P is zero
Nnp = number of nonparticulate steps (compressors, towers, reactors, heaters, and
exchangers)
There are 5 steps involving the handling of particulate solid which are solid transport,
solid size reduction, solid size classification, solid drying, and solid particulate
removal. There are 82 nonparticulate equipments involved.
It is rounded to 30 operators/shift. There are 4 shifts that requires total of 120

operators.
Employees Salary
Salary for each employee in managerial position is described as follow.
Table 11.2. Managerial Employees Salary
Level Number of employee Salary / person / month Total
President Director 1 Rp100,000,000.00 Rp100,000,000.00
director 4 Rp68,750,000.00 Rp275,000,000.00
Head of Division 10 Rp25,000,000.00 Rp250,000,000.00
Section Chief 21 Rp15,500,000.00 Rp325,500,000.00
Engineer 8 Rp9,500,000.00 Rp76,000,000.00
Total 44 Rp1,026,500,000

Edi Sugiarto (13/348228/TK/40839) 211
Salary for each employee in nonmanagerial position is described as follows.

Table 11.3. Non-Managerial Employees Salary
Level Number of employee Salary / person / month Total
Operator 120 Rp6,750,000.00 Rp810,000,000.00
Staff I 24 Rp9,000,000.00 Rp216,000,000.00
Staff II 12 Rp7,500,000.00 Rp90,000,000.00
Staff III 23 Rp6,000,000.00 Rp138,000,000.00
Technician 16 Rp6,000,000.00 Rp96,000,000.00
Analyst 5 Rp6,000,000.00 Rp30,000,000.00
Head of security 3 Rp4,500,000.00 Rp13,500,000.00
Security 30 Rp3,750,000.00 Rp112,500,000.00
Cleaning Service 10 Rp3,300,000.00 Rp33,000,000.00
Total 243 Rp1,539,000,000
Hence total annual salary that must be paid is Rp 30,786,000,000.

Edi Sugiarto (13/348228/TK/40839) 212
CHAPTER 12
ECONOMY EVALUATION
Economy evaluation is an important aspect in plant desgin. Items in economy

evaluation are as follows:
1. Fixed capital investment

2. Manufacturing cost
3. Working capital
4. General expense
5. Profit analysis
6. Feasibility analysis
Economy evaluation is conducted in base of the year of plant construction which

is 2020 for thi plant. Equipment cost is taken from www.matche.com and
http://www.mhhe.com/engcs/chemical/peters/data/ce.html. All equipment costs
from those sources are based on price in 2014. Equipment cost in 2020 is
estimated with following equation.
CEP cost index in 2020 is estimated with linear regression from CEP cost
indexes in previous years. CEP cost indexes in previous years are listed and
plotted below.

Edi Sugiarto (13/348228/TK/40839) 213
Year CEP index Year CEP index Year CEP index Year CEP index
1963 102.4 1973 144.1 1983 317.0 1993 359.2
1964 103.3 1974 165.4 1984 322.7 1994 368.1
1965 104.2 1975 182.4 1985 325.3 1995 381.1
1966 107.2 1976 192.1 1986 318.4 1996 381.7
1967 109.7 1977 204.1 1987 323.8 1997 386.5
1968 113.7 1978 218.8 1988 342.5 1998 389.5
1969 119.0 1979 238.7 1989 355.4 1999 390.6
1970 125.7 1980 261.2 1990 357.6 2000 394.1
1971 132.3 1981 297.0 1991 361.3
1972 137.2 1982 314.0 1992 358.2
CEP Cost Index

500
450 y = 9.5215x - 18609
400 R² = 0.9505
350
300
250
200
150
100
50
00
1960 1970 1980 1990 2000 2010
CEP cost index in 2004 can be calculated with following manner:
CEP cost index in 2020 can be calculated with following manner:

Edi Sugiarto (13/348228/TK/40839) 214
2.1 Fixed Capital Investment

Purchased Equipment Cost (PEC)
Area 100
Equipment No Price/item, Price/item, $ Total price Total price
$ (2014) (2020) (2020), $ (2020), Rp
Belt conveyor 1 30,765 33,863 33,863 -
Chipper 1 49,341 54,310 54,310 -
Screen 1 36,147 39,787 39,787 -
Belt conveyor 1 55,759 61,374 61,374 -
Belt conveyor 1 20,228 22,265 22,265 -
Hammer mill 1 24,409 26,867 26,867 -
Screen 1 36,596 40,281 40,281 -
Belt conveyor 1 8,255 9,086 9,086 -
Bucket Elevator 1 9,000 9,906 9,906 -
Bucket Elevator 1 9,000 9,906 9,906 -
Belt conveyor 1 108,464 119,387 119,387 -
Subtotal 427,033 -

Edi Sugiarto (13/348228/TK/40839) 215
Area 200
Equipment No Price/item, $ Price/item, Total price Total price
(2014) $ (2020) (2020), $ (2020), Rp
Silo 1 3,200 3,522 3,522 -
Rot. Dryer 1 179,143 197,183 197,183 -
Gasifier 1 712,329 784,062 784,062 -
Combuster 1 712,329 784,062 784,062 -
Cyclone 1 31,600 34,782 34,782 -
Cyclone 2 93,000 102,365 204,731 -
Cyclone 3 64,800 71,326 213,977 -
Belt conveyor 1 5,634 6,201 6,201 -
Screw 1
conveyor 10,852 11,945 11,945 -
Cloth Filter 1 8,700 9,576 9,576 -
Cloth Filter 1 9,300 10,237 10,237 -
Blower 2 178,064 195,996 391,991 -
Blower 2 320,985 353,309 706,618 -
Subtotal 3,358,889 -

Edi Sugiarto (13/348228/TK/40839) 216
Area 300
Equipment No Price/item, Price/item, Total price Total price
$ (2014) $ (2020) (2020), $ (2020), Rp
Adsorber 1 29,180 32,119 32,119 -
Reformer 1 24,984 27,500 27,500 -
S & T heat 1
exchanger 6,431 7,079 7,079 -
S & T heat 1
exchanger 3,866 4,255 4,255 -
S & T heat 2
exchanger 22,087 24,311 48,622 -
S & T heat 1
exchanger 18,587 20,459 20,459 -
Flash drum 1 27,100 29,829 29,829 -
Subtotal 169,863 -

Edi Sugiarto (13/348228/TK/40839) 217
Area 400
Equipment No Price/item, Price/item, Total price Total
$ (2014) $ (2020) (2020), $ price
(2020),
Rp
Compressor 1 53,498 58,885 58,885 -
Compressor 1 56,083 61,731 61,731 -
Compressor 1 60,911 67,045 67,045 -
Turbine 1 63,406 69,791 69,791 -
Turbine 1 63,406 69,791 69,791 -
S & T HE 1 9,047 9,958 9,958 -
S & T HE 1 5,220 5,746 5,746 -
S & T HE 1 3,866 4,255 4,255 -
S & T HE 1 3,866 4,255 4,255 -
Pump 2 5,327 5,863 11,727 -
Methanol syn 1
718,250
Reactor 652,538 718,250 -
Methanol 1
TEGDME sep 28,500 31,370.04 31,370 -

Edi Sugiarto (13/348228/TK/40839) 218
Area 500
Equipment No Price/item, Price/item, Total price Total
$ (2014) $ (2020) (2020), $ price
(2020),
Rp
MTG reactor 1 1,191,400 1,311,378 1,311,378 -
3-phase separator 1 28,000 30,820 30,820 -
Distillation column 1 5,780 6,362 6,362 -
Distillation column 1 51,312 56,479 56,479 -
Compressor 1 2,700 2,972 2,972 -
Compressor 1 3,400 3,742 3,742 -
Cen. Pump 2 1,884 2,074 4,147 -
Cen. Pump 2 3,662 4,031 8,062 -
Cen. Pump 2 3,662 4,031 8,062 -
S & T HE 1 7,184 7,907 7,907 -
S & T HE 1 3,866 4,255 4,255 -
S & T HE 1 3,522 3,877 3,877 -
Condensor 1 4,105 4,518 4,518 -
Reboiler 1 4,678 5,149 5,149 -
Condensor 1 4,105 4,518 4,518 -

Edi Sugiarto (13/348228/TK/40839) 219
Reboiler 1 5,220 5,746 5,746 -

S & T HE 1 3,866 4,255 4,255 -
S & T HE 1 4,105 4,518 4,518 -
LPG vessel 2 147,800 162,684 325,368 -
Gasoline tank 2 121,642 133,891.73 267,783 -
Total purchased equipment cost (PEC) is $ 7,138,509.
Utility Equipment Cost (UEC)

Equipment No Price/item, Price/item, $ Total price Total price
$ (2014) (2020) (2020),$ (2020), Rp
Equalization tank 1 - - - 151,380,000

Sedimentation tank 1 - - - 375,375,000
Coagulant tank 1 5,800 6,384.08 6,384.08 -
Clarifier 1 41,000 45,128.83 45,128.83 -
Sand filter 1 20,300 22,344.27 22,344.27 -
Carbon filter 1 50,700 55,805.65 55,805.65 -
Chlorination tank 1 5,800 6,384.08 6,384.08 -
Clear well 1 - - - 246,375,000
Disenfectant tank 1 5,900 6,494.15 6,494.15 -
Disenfectant mixing 1
tank 5,900 6,494.15 6,494.15 -
Potable water tank 1 - - - 72,000,000
Hot Basin 1 - - - 907,380,000
Cold Basin 1 - - - 959,220,000
Cooling Tower 1 973,600 1,071,644.59 1,071,644.59 -

Edi Sugiarto (13/348228/TK/40839) 220
Anion Exchanger 2 12,000 13,208.44 26,416.88 -

Cation Exchanger 2 14,700 16,180.34 32,360.67 -
Demin water tank 1 - - - 44,175,000
Deaerator 1 25,600 28,178.00 28,178.00 -
Boiler 1 280,000 308,196.88 308,196.88 -
Hydrazine tank 1 19,800 21,793.92 21,793.92 -
NaOH tank 1 5,800 6,384.08 6,384.08 -
H2SO4 tank 1 5,800 6,384.08 6,384.08 -
Centrifugal pump 34 3,662 4,030.77 137,046.35 -
Total 1,758,051.88 2,755,905,000
Total Utility Equipment Cost (UEC) is $ 1,758,051.88 and Rp 2,755,905,000.
Taking currency $1 = Rp 13,362 total UEC in USD is $ 1,993,690.10.
Labor cost
Labor consists of 95% domestic labor and 5% foreign labor. Installation labour
cost is 11% PEC.
Labour = 11%*PEC
= 11%*$ 7,138,509
= $ 785,236

Edi Sugiarto (13/348228/TK/40839) 221
Labour = $ 39,262 + Rp 2,237,922,679
Items in fixed capital investment are calculated in following manner.

A. Purchased Equipment Cost (PEC)
PEC = $ 7,138,509
B. Delivery Equipment Cost
 Delivery cost
 Tax
C. Installation Cost
 Material
 Labor
D. Pipping Cost
 Material

Edi Sugiarto (13/348228/TK/40839) 222
 Labor
E. Instrumentation Cost
 Material
 Labor
F. Insulation Cost
 Material
 Labor
G. Electrical Cost
 Material

Edi Sugiarto (13/348228/TK/40839) 223
 Labor
H. Building Cost & Services
I. Land & Yard Inprovement Cost

= 10%*PEC
= $713,851
J. Utilities Cost
 Utility Equipment Cost (UEC)
UEC = $ 1,758,051.88 + Rp 2,755,905,000
 Installation
o Material
o Labour
Physical Plant Cost (PPC) = $ 20,794,996 + Rp 3,582,676,500

K. Engineering & Construction

Edi Sugiarto (13/348228/TK/40839) 224
L. Contractor's Fee
M. Contingency
2.2 Manufacturing Cost

Plant is designed to run continuously 24 hours/day and 330 days/year. Raw
material price is calculated as follow.
1. Raw material
Price of palm fruit empty bunch: Rp50,000/ton
Annual demand: 432,741 ton/year
Total price: Rp 21,637,051,900
Utility supporting material prices are calculated as follow.
1. Anion resin
Price : Rp 69,000 /L

Edi Sugiarto (13/348228/TK/40839) 225
Annual demand : 556 L / year

Total price : Rp 38,364,000
Service time : 1 year
Total price : Rp 38,364,000 (2013)
Rp 41,255,025 (2020)
2. Cation resin
Price : Rp 34,000 /L
Annual demand : 1077 L / year
Total price : Rp 36,618,000
Service time : 1 year
Total price : Rp 36,618,000 (2013)
Rp 39,377,450 (2020)
3. NaOCl
Price : Rp 17,333,333/ton
Annual demand : 12.7 ton/year
Total price : Rp 220,133,333 (2013)
Rp 236,722,085 (2020)
4. Al2(SO4)3
Price : Rp 1,600.00 /kg
Annual demand : 401,544 kg/year
Total price : Rp 642,470,400 (2013)
Rp 690,885,521 (2020)
5. H2SO4
Price : Rp 2,700.00/kg
Annual demand : 28,294 kg / year
Total price : Rp 76,393,800 (2013)
Rp 82,150,665 (2020)
6. NaOH
Price : Rp3,200.00 /kg
Annual demand : 22600 kg / year

Edi Sugiarto (13/348228/TK/40839) 226
Total price : Rp72,320,000 (2013)

Rp77,769,872 (2020)
7. N2H4
Price : Rp9,571.97 /kg
Annual demand : 1,077,120 kg / year
Total price : Rp10,310,158,172 (2013)
Rp11,087,108,448 (2020)
Total utility supporting material price is Rp 12,255,269,065 / year
Sales are calculated as follow.

 Gasoline
International gasoline price = $ 100.17 / barrel
Gasoline product = 1,510 kg/hr
36,235 kg/day
11,957,458 kg/year
15,330 m3/year
132,579 barel/year
Gasoline sale = $ 100.17 / barrel*132,579 barel/year
= $ 13,280,407/ year
 LPG
International LPG price = $ 0.756/ kg
LPG product = 874 kg/hr
20,986 kg/day
6,925,406 kg/year
LPG sale = 6,925,406 kg/year * $ 0.756/ kg
= $ 5,235,607
Total sale is = Gasoline sale + LPG sale
= $ 13,280,407/ year + $ 5,235,607/ year
= $ 18,516,014.55/ year

Edi Sugiarto (13/348228/TK/40839) 227
Employee salary
Managerial labour salary detail is as follow
Level No. of employee Salary/employee/month Total
President Director 1 Rp100,000,000.00 Rp100,000,000.00
director 4 Rp68,750,000.00 Rp275,000,000.00
Head of Division 10 Rp25,000,000.00 Rp250,000,000.00
Section Chief 21 Rp15,500,000.00 Rp325,500,000.00
Engineer 8 Rp9,500,000.00 Rp76,000,000.00
Total 44 Rp1,026,500,000
Non-managerial labour salary detail is as follow

Level No. of employee Salary/employee/month Total
Operator 120 Rp6,750,000.00 Rp810,000,000.00
Staff I 24 Rp9,000,000.00 Rp216,000,000.00
Staff II 12 Rp7,500,000.00 Rp90,000,000.00
Staff III 23 Rp6,000,000.00 Rp138,000,000.00
Technician 16 Rp6,000,000.00 Rp96,000,000.00
Analyst 5 Rp6,000,000.00 Rp30,000,000.00
Head of security 3 Rp4,500,000.00 Rp13,500,000.00
Security 30 Rp3,750,000.00 Rp112,500,000.00
Cleaning Service 10 Rp3,300,000.00 Rp33,000,000.00
Total 243 Rp1,539,000,000
Annual employee salary is Rp30,786,000,000 / year
Direct manufacturing cost

 Raw materials = $ 0 +Rp 21,637,051,900
 Operating Labour = Rp1,539,000,000/month * 12 months/year
= $ 0 + Rp18,468,000,000

Edi Sugiarto (13/348228/TK/40839) 228
 Operating Supervision = 15%*Operating Labour

= 15%*($ 0 + Rp18,468,000,000)
= $ 0 + Rp 2,770,200,000
 Maintenance = 6%*FC
= 6%*($ 27,482,667+ Rp 4,734,865,262)
= $ 1,648,960 + Rp 284,091,915
 Plant Supplies = 15%*Maintenance
= 15%*($ 1,648,960 + Rp 284,091,915)
= $ 247,344 + Rp 42,613,787
 Royalties & Patents = 5%*Sales
= 5%*($ 18,516,014)
= $ 925,801
 Utilities = Rp 12,255,269,065
 Direct manufacturing cost = $ 2,822,105 + Rp 55,457,226,668
Indirect manufacturing cost
 Payroll overhead = 15%*labour
= 15*( Rp18,468,000,000)
= Rp 2,770,200,000
 Laboratory = 10%*labour
= 10*( Rp18,468,000,000)
= Rp 1,846,800,000
 General Plant Overhead = 50%*labour
= 50%*( Rp18,468,000,000)
= Rp 9,234,000,000
 Packaging and shipping = 2%*sales
= 2%*($ 18,516,014)
= $ 370,320
 Indirect manufacturing cost = $ 370,320 + Rp 13,851,000,000
Fixed manufacturing cost

Edi Sugiarto (13/348228/TK/40839) 229
 Depreciation
Some assumptions are taken to calculate annual depreciation, which are:
Straight line depreciation is used to calculate annual depreciation
Salvage value for chemical plant is usually taken as 10% of fixed capital
Plant life time is usually taken as 10 years
Depreciation = (Fixed capital – Salvage value)/plan life time
= (Fixed capital – 10%* Fixed capital) / 10 years
= (90%*Fixed capital)/10 years
= 9%*Fixed capital
= 9%*($ 27,482,667 + Rp4,734,865,262)
= $ 2,473,440 + Rp 426,137,874
 Property Taxes = 2%*FC

= 2%*($ 27,482,667 + Rp4,734,865,262)
= $ 549,653 + Rp 94,697,305.25
 Insurances = 1%*FC
= 1%*($ 27,482,667 + Rp4,734,865,262)
= $ 274,827 + Rp 47,348,652
 Fixed manufacturing cost = $ 3,297,920 + Rp 568,183,831
Manufacturing cost = Direct manufacturing cost + Indirect manufacturing cost +

Fixed manufacturing cost
= $ 2,822,105 + Rp 55,457,226,668) + ($ 370,320 + Rp
13,851,000,000) + ($ 3,297,920 + Rp 568,183,831)
= $ 6,490,345 + Rp 69,876,410,499
2.3 Working Capital
 Raw Material Inventory
Raw material inventory is taken as 1 month raw material inventory

Edi Sugiarto (13/348228/TK/40839) 230
 In Process Inventory
In process inventory is taken as 12 hours of manufacturing cost
 Product Inventory
Product Inventory is taken as 1 month of manufacturing cost
 Extended Credit
Extended credit is taken as 1 month of sale
 Available Cash
Available Cash is taken as 1 month of manufacturing cost
Working capital = $ 2,634,559 + Rp 13,555,029,424

2.4 General Expense

Edi Sugiarto (13/348228/TK/40839) 231
 Administration = 2%*sales
= 2%*
= $ 370,320 / year
 Sales Promotion = 3%*sales
= 3%*$ 18,516,014 / year
= $ 555,480 / year
 Research = 4%*sales
= 4%*$ 18,516,014/ year
= $ 740,641 / year
 Finance = 10.07% FC + 11.72% WC
= 10.07%*($27,482,667+Rp4,734,865,262) + 11.72%*($ 2,634,559
+ Rp 13,555,029,424)
= $ 3,076,275 + Rp 2,065,450,380
 General expense = $ 4,742,716 + Rp 2,065,450,380

Edi Sugiarto (13/348228/TK/40839) 232
Calculations are summarised as follow.

Item Value
$ 27,482,667 + Rp 4,734,865,262
Fixed capital
$ 27,837,020
$ 6,490,345 + Rp 69,876,410,499
Manufacturing cost
$ 11,719,832
$ 2,634,559 + Rp 13,555,029,424
Working capital
$ 3,649,005
$ 4,742,716 + Rp 2,065,450,380
General expense
$ 4,897,293
= Fixed capital + working capital
= ($ 27,482,667 + Rp 4,734,865,262) +
Total capital
$ 2,634,559 + Rp 13,555,029,424)
investment
= $ 30,117,226 + Rp 18,289,894,687
= $ 31,486,025
Total production = Manufacturing cost + General expense
cost = ($ 6,490,345 + Rp 69,876,410,499) +
($ 4,742,716 + Rp 2,065,450,380)
= $ 11,233,061 + Rp 71,941,860,880
= $ 16,617,125
2.5 Feasibility analysis
Sales = $ 18,516,015/year
Total production cost = $ 16,617,125/year
Profit before tax = ($ 18,516,015 - $ 16,617,125)/year
= $ 1,898,890 /year
Income tax = 25%* Profit before tax
= 25%*$ 1,898,890/year
= $ 474,722.38/year
Profit after tax = Profit before tax - Income tax

Edi Sugiarto (13/348228/TK/40839) 233
= $ 1,898,890 /year - $ 474,722.38/year

= $ 1,424,167
Return of an investment before tax
Return of an investment after tax
Pay Out Time before tax
Pay Out Time after tax

Edi Sugiarto (13/348228/TK/40839) 234
Break even point and Shutdown point

Break even point or abbreviated as BEP represents percentage of full production
capacity that is required to cover total costs, consisting of both fixed and variable
costs to the company. At BEP a plant does not gain profit nor loss. BEP is
calculated as follow.
Fa  0,3  Ra
BEP= x 100%
S a  Va  0,7  Ra
With: Fa : annual fixed cost
Ra : annual regulated cost
Va : annual variable cost
Sa : annual sales cost
Fixed Cost (Fa) Value in $
Depreciation 2,505,331
Taxes 556,740
Insurance 278,370
Total 3,340,442
Variable Cost (Va) Value in $

Raw material 1,619,297
Packaging, shipping 370,320
Utilities 917,173
Royalties 925,801
Total 3,832,592

Edi Sugiarto (13/348228/TK/40839) 235
Regulated Cost (Ra) Value in $

Labor 1,382,128
Overhead 691,064
Supervision 207,319
Laboratory 138,213
General expense 4,897,292
Maintenance 1,670,221
Plant supplies 250,533
Total 9,236,772
0,3  R a
SDP= x 100%
S a  Va  0,7  R a
= 33.7 %

Edi Sugiarto (13/348228/TK/40839) 236
20000000
18000000
16000000
BEP
14000000 Sa
12000000 Ra
SDP
10000000
8000000
6000000
Va
4000000
2000000
Fa
0
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Lang factor
Lang factor is a ratio of the total cost of installing a process in a plant to the cost
of its major technical components.
Based on reference Lang factor for solid-fluid process plant is 3.63
FC/TCI

Edi Sugiarto (13/348228/TK/40839) 237
Discounted Cash Flow Rate of Return (DCFRR)

Some assupmtions taken for DCFRR calculation are as follow.
1. Plant life time is 10 years
2. Annual profit and taxes are constant
3. Constant straight line depreciation
4. Salvage value of fixed capital is 10%
DCFRR is calculated through trial and error with following equation.
 1 1 1 1  WC  SV
FC  WC  C      
(1  i)10  (1  i)10
....
 (1  i) (1  i) (1  i)
2 3
FC = Fixed Capital
= $ 27,837,020
WC = Working Capital
= $ 3,649,005
C = Annual Cash Flow
= Profit after Tax + Finance + Depreciation
= ($ 1,424,167) + ($ 3,076,275 + Rp 2,065,450,380/(Rp13,362/$1)) + ($
2,473,440 + (Rp 426,137,874)/(Rp13,362/$1))
= $ 7,160,350.23
SV = Salvage Value
= 10%*Fixed Capital
= 10%*$ 27,837,020
= $ 2,783,702

Edi Sugiarto (13/348228/TK/40839) 238
Year Cash Flow Annual cash flow ($)

0 Fxed Capital +Working Capital -31,486,025
1 Annual Cash Flow 7,160,350
10 Annual Cash Flow + Working Capital + Salvage Value 13,593,057
20000000
15000000
10000000
5000000
0
-5000000 1 2 3 4 5 6 7 8 9 10 11
-10000000
-15000000
-20000000
-25000000
-30000000
-35000000
With trial and error, i = 19.62 %

Edi Sugiarto (13/348228/TK/40839) 239
Sensitivity
Raw material price and product price are varied to observe sensitivity of this
plant.
Parameter Factor DCFRR
Product price 0.8 0.1056
1 0.1962
1.2 0.2779
Raw material price 0.8 0.2058
1 0.1962
1.2 0.1865
0.29
0.24
Product Price
0.19
Raw Material
0.14
0.09
0.75 0.95 1.15
It is concluded that product price is the most important factor in DCFRR.

Edi Sugiarto (13/348228/TK/40839) 240
CHAPTER 13
CONCLUSIONS
This plant is calssified as high risk petroleum industry. It is high risk due to high
temperature and pressure involed in process. Feasibility parameters are
summarised as follow.
Table 13.1. Profitability Analysis
Parametre Calculated Reference Is it economically
attractive?
ROIb 6.8 % Minimum 39 % No
POTb 6.32 years Maximum 2 years No
BEP 74.73 % Between 40% and 60% No
SDP 33.7 % - -
DCFRR 18.65 % At least 1.5 interest rate Yes
Interest rate based on BCA Bank interest rate for 2017 is 6.75 %, hence this plant
is economically attractive in term of DCFRR. It is also economically attractive in
term of SDP. All parametres other than DCFRR indicate this plant as
economically non attractive, but DCFRR indicates that this plant is economically
attractive. We conclude that this plant is economically attractive.

Edi Sugiarto (13/348228/TK/40839) 241
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Sulfur Guard Bed
(A-301)
Sulfur Guard Bed Sheet No. 3

Chemically adsorb H2S in Equipment No. A-301A/B
Description syngas into concentration Capacity, m3 53,631.64
lower than 0.5 ppmv Amount 2 (1 on standby)
Type Packed Column Adsorber Adiabatic, isothermal, semi-batch
Operating Data
Pressure, bara 2.62
Geometry Spherical
Temperature, oC 928
Adsorbent
Type ZnO/TiO2 Saturation
Adsorbent 90
Av. Dia, mm 1.09 Time, days
Stream Information
Component
10 25
H 2O 6,273.58 6,280.68
H2 281.29 281.29
CO 5,897.91 5,897.91
CO2 2,604.38 2,604.38
CH4 1,173.53 1,173.53
C2H2 57.70 57.70
C2H4 513.80 513.80
C2H6 19.88 19.88
Tar (C8H10) 149.53 149.53
NH3 76.58 76.58
H 2S 13.40 -
HCl 25.94 25.94
Total 17,087.50 17,081.20
Technical Data
Shell Thickness, inch 0.25
Edi Sugiarto (13/348228/TK/40839)

Lesna Christwinarso (13/346947/TK/40712) 1
Adsorption Model in Sulfur Guard Bed
Haimour, et.all (2005) provides regression data for several adsorption model. In
which they conclude that Redlich-Peterson isotherm model has the best precision
for H2S adsorption in ZnO. The sumary of their experiment are tabulated below.
Table 1. Adsorption Constant
Langmuir Freundlich Redlich-Peterson

Q0 KL R2 KF n R2 a b x R2
125 84.6 0.91 3.01 0.685 0.89 1.45 1.8E-5 2.09 0.98
With, Q0 = Langmuir constant, kg adsorbate/kg solid

KL = Langmuir constant, kg/m3
KF = Freundlich constant,
n = Freundlich constant
a,b,x = Redlich-Peterson constant
R2 = sum of square root
The equation for Redlich-Peterson model is described as follows
With, Cs = Equilibrium H2S concentration on adsorbent,
C = Equilibrium H2S concentration in solution,
Edi Sugiarto (13/348228/TK/40839)

Adsorbent
The adsorbent used in this project has the spec as follows

Table 2. Adsorbent Data (Lew et al., 1989; Sofekun, 1996)
ZnO/TiO2 Physical Properties
Type ZnO/TiO2 Porosity 0.87
MW 81.41 g/mol Particle Density 5,606 kg/m3
Geometry Spherical Surface Area 2.4 m2/g
Size 1090 μm Max. Operation 1050oC
Adsorber Model
Adsorber is modelled as continous packed column reactor. The adsorption

is assumed as equilibrium adsorption due to the low concentration of adsorbate in
the inlet of adsorber. The saturation time of adsorber will be defined using
breakthrough curve obtained from solving the model with maximum H2S outlet
concentration of 5 ppm.
Figure 1. Adsorber Model (Richardson et.all., 2002)
Material Balance
Material balance of adsorbate in the fluid is governed by the following equation
Edi Sugiarto (13/348228/TK/40839)

( ) [( ) ] [ ]
* +
( ) [ ] [ ]
( )
( ) [ ] [ ]
( )
Simplify ( )=
( ) [ ] [ ]
Substitute Cs = f(C) =
( ) [ ] [ ( )]
( ) [ ] [ ( )] [ ]
( ) [ ] [ ]
( )
( ) [ ]
[ ( )]
[ ] [ ]
* ( )+
With, u = superficial velocity, m/s
= superficial area, m2
= active time, s
= porosity
z = bed length, m
Edi Sugiarto (13/348228/TK/40839)

Adsorber Sizing
The size of adsorber is found using trial-error method using L/D = 5.

Try L = 10 m and D = 2m
Results from solving our model are depicted in Figure 1 and Figure 2.
Figure 1. Gas Concentration in Guard Bed as Function of Inlet Distance and

Adsorption Time
Figure 1 shows that the saturation of Guard Bed begins from the inlet into
the outlet of the vessel. This phenomenon happened due to the adsorption starts at
the inlet of Guard Bed and slowly shift into further part of Guard Bed due to the
bed saturation.
Edi Sugiarto (13/348228/TK/40839)

Figure 2. Breakthrough Curve of Sulfur Guard Bed
Using Figure 2 as our basis, we can determine our bed active time. According to
our maximum outlet concentration of 5 ppm, the bed saturates at around 120 days.
Hence, take 25% safety design, we get bed active time as 90 days. The active
time and size of adsorber is deemed acceptable. However, due to the active time is
found to be less than 360 days, we will need 2 adsorbers which operate
alternately.
Pressure Drop
Due to the negligible change of component and temperature within adsorber, the
pressure drop of reactor can be simply calculated using Ergun Equation outside of
the Matlab Program.
( ) ( )
( )( ) ( )( )
Edi Sugiarto (13/348228/TK/40839)

Calculate:
( )
( )( )
( )
( )
( )( )
Mechanical Design
1. Shell Thickness
Standard operating condition
P = 2.62 bara
= 1.61 barg
= 0.161 N/mm2
T = 928 oC
The operation for this reactor is categorized as

 Above 800oC
 No expected temperature surge
 Corrosive
Hence, we choose SS 330 as for our design (See our Material
Selection Logic Sequence Section). As for the vendor, we trust VDM
Metals GmbH which has been leading metal industries since 1930 to
provide their Nicrofer 3718 (SS 330) alloys for our design.
According to their Datasheet at temperature of up to 1000oC, we
can design the thickness as follows.
S = 80 N/mm2 (tensile strength)
E = 0.85 (joint efficiency)
C = 0.125 in (corrosion allowance)
Edi Sugiarto (13/348228/TK/40839)

R = 1 meter (shell inner diameter)
= 39.3701 in
The equation for shell thickness calculation is as follows
Take standard thickness of 0.25 inch.

2. Vessel Head
There are three viable head which may be chosen for the design.
Figure 3. Vessel Head

a. Hemispherical head
b. Ellipsoidal head
c. Torispherical head
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According to Sinnott (2005), hemispherical head has the best
pressure design, however, has higher manufacturing cost. Hence, he says
that for pressure below 10 barg, torispherical head is the best choice.
Meanwhile, hemispherical head should be chosen if the pressure exceed
15 barg
Following the reference, we used torispherical head for this vessel
design.
Figure 4. Design of Torispherical Head
The data for design is referenced from Brownell et al. (1959).

OD = 79.2402 inch
= 80 inch (table reference for data determination)
ID = OD – 2t
= 80 – 2 x 0.25
= 79.5 inch
a = ID/2
= 39.75 inch
icr = 4.375 inch
r = 80 inch
AB = a – icr
= 35.375
BC = r – icr
= 75.625
b = √
= 13.1588 inch
Edi Sugiarto (13/348228/TK/40839)

The equation for shell thickness calculation is as follows
Take standard thickness of 0.3125 inch
According to the same reference (Brownell et al., 1959), for head

thickness of 5/16 inch, straight flange height (sf) should be in range of 1.5-
3.0 inch If we choose 2 inch, then the height of our head is as follows.
Hh = 13.1588 + sf + ht
= 13.1588 + 2 + 0.3125
= 15.4713 inch
= 0.3930 m
3. Grid Support
Grid support is important for design to ensure that the adsorbent
will rest well in the vessel. According to the standard, the grid support will
usually be designed with thickness of 4-6 inch. In this design, we choose
perforated alumina ceramic grid support with thickness of 4 inch.
4. Vessel True Volume

Shell height is the sum of catalyst loading height and grid support
thickness.
Catalyst height = 10 m
Grid support thck. = 4 inch
= 0.102 m
Shell height = 10.102 m
Then, the height of vessel is calculated as follows

Vessel height = shell height + 2 x head height
= 10.102 + 2 x 0.3930
= 10.888 m
Edi Sugiarto (13/348228/TK/40839)

Vessel true volume is calculated as follows
Vessel volume = Shell Vol. + 2(Head Vol.)+2(Flange Vol.)
= ¼.π.ID2.h + 2(0,000049.ID3)+2(¼.π.ID2.sf)
= 53,631.64 m3
5. Inlet-Outlet Feed Hole
We assume that the change of flowrate due to the adsorption within
the vessel is negligible (adsorbed H2S component within the system is in
order of ppm). The feed hole is designed using basis of inlet feed.
Feed inlet moleflowrate = 860.36 kmol/hr
= 0.23898 kmol/s
At high temperature and low pressure, the ideal gas law can
satisfyingly estimate the gas density.
Hence, the volumetric flowrate is as follows

Q = F/
= 0.23898 / 0.0263
= 0.11 m3/s
According to the reference (Sinnott, 2005), optimum velocity for
gas phase transport is around 15-30 m/s. Taking 20 m/s for the design,
then
A = Q/v
= 0.11 / 20
= 0.0055 m2
Hence, the superficial hole diameter is
D =√
= 0.191 m
= 7.52 inch
Take standard diameter of 8 inch (Brownell et al., 1959).
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6. Man Hole
Man hole functions for cleaning and load-unloading of the vessel. We take
standard man hole diameter of 20 inch with thickness of 0.3125 inch.
7. Isolation Thickness
Assumption in designing thickness isolation
 Steady state; q1 = q2 = q3 = q4
 Inner wall temperature of vessel is equal to the bulk fluid temperature
Figure 5. Isolation in Sulfur Guard Bed

With
R1 = inner radius of vessel (ID)
R2 = outer radius of vessel (OD)
R3 = outer radius of isolated vessel
Xs = wall thickness
Xis = isolation thickness
Ta = outer ambient temperature (average according to BPS is 25oC)
T1 = inner wall temperature
T2 = outer wall temperature
T3 = outer isolation temperature (designed to be 55oC)
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We choose calcium silicate as isolation material with the properties as
follows (Holman, 2009).
Max. operation = 1000oC

Density (ρis) = 140 kg/m3
Conductivity (Kis) = 0.0645 W/mK
Emissivity (εis) = 0.93
The properties of vessel wall (SS 330) from our vendor (VDM Metals) are
as follows.
Density (ρs) = 8000 kg/m3

Conductivity (Ks) = 25.6 W/mK @900oC
= 27.0 W/mK @1000oC
Take interpolation to calculate conductivity at inner wall temperature of

928oC
Physical properties of air is determined by using average temperature

between outer isolator temperature and ambient air temperature.
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The physical properties of air at 40oC is as follows (Holman, 2009).
Natural air velocity (v) = 1.7 10-5 m2/s

Thermal expansion coeff (β) = 0.0032 K-1
Thermal conductivity (k) = 0.0272 W/mK
Gas density (ρ) = 1.1302 kg/m3
Prandtl Number (Pr) = 0.7051
The Grashoff and Rayleigh number are calculated as follows

( )
With g = gravitational acceleration

L = vessel length
( )
( )
The Rayleigh number is greater than 109, hence we have

turbulence flow of air. The calculation of convection heat transfer
coefficient for turbulent flow is as follows (Holman, 2009)
( )
( )
From the same literature, the radiation heat transfer coefficient is

calculated as follows.
( ) ( )
with = Boltzman constants, 5,669.10-8 W/m2K4
hr = radiation heat transfer coefficient
Edi Sugiarto (13/348228/TK/40839)

Hence,
( )
( )
Calculating heat transfer per length as follows.

From outside isolator into environment
q4 = (hc + hr). 2.π.R3.(T3-Ta)
= (3.6144 + 6.4154) 2.π.R3.(328 – 298)
= 1890.5746 R3
From outside wall into outside isolator

( )
( )
( )
( )
( )
( )
From inside wall into outside wall

( )
( )
( )
( )
( )
Edi Sugiarto (13/348228/TK/40839)

Use q4 = q2
( )
( )
Use q3 = q4
( )
( )
( )
( ( ))
( )
( )
The result of trial value is

T2 = 1201 (same as wall inside temperature)
Hence, we use q3 = q4 for calculation
( )
( )
Isolation thickness = R3 – R2 = 1.1858 – 1.0127 = 0.1731 m

The heat loss during the operation then,
( )
( )
( )
Edi Sugiarto (13/348228/TK/40839)

Matlab SourceCode
function sulfurguard4
clc;
clear;
%% Data-data awal
dp0 = 1.09E-3; %diameter partikel ZnO, m
rp0 = dp0/2;
rhos = 5606; %particle density, kg/m3
W = 1/81.41; %oxygen content, kmol/kg
Vp0 = 4/3*pi()*rp0^3;
epsilon = 0.87; % void fraction pada bed

m = epsilon/(1-epsilon);
T = 928+273.15; % Temperatur operasi, Kelvin

P = 2.62E5; %N/m2
Fh2o_0 = 5808.870424/1000/60; %kmol/s

Fh2s_0 = 6.569608842/1000/60;
Finert = 8523.903787/1000/60;
Ftot = Fh2o_0 + Fh2s_0 + Finert; %kmol/s
Mtot = 17087.50/3600; %kg/s
V = Ftot*8314*T/P; %m3/s
Ch2s0 = Fh2s_0 / V; %kmol/m3
%% Initial Conditions
% Shooting konfigurasi reaktor
Zr = 10; %m
Dr = 2; %m
S = pi()/4*Dr^2; %m2
v = V/S; %m/s
Zspan = linspace(0,Zr,30);
% Shooting waktu operasi

t = 300; %days
% matrices
n = 30;
tspan = linspace(0,t,n);
dt = tspan(2) - tspan(1);
Edi Sugiarto (13/348228/TK/40839)

IC = zeros(1,n) + Ch2s0;
IC(1) = 0;
%% Parameter
a = 1.45;
b = 0.00018;
beta = 2.09;
MWh2s = 34; %g/mol
%% Begin ODE
[z,Y]=ode15s(@f,Zspan,IC,[]);
%% Display
display(Y(:,1:n))
figure(1)
surf(tspan,z,Y)
xlabel('Waktu')
ylabel('Jarak')
zlabel('Konsentrasi')
colorbar
endrect = Y(end,:);
figure(2)
plot(tspan,endrect)
%% Function
function dYdz=f(z,Y)
for i = 1:n
Q(i) = -a*((b*beta-b)*Y(i)*beta-
1)/(b*Y(i)*beta+1)^2/MWh2s*5606;
end
dYdz(1)= 0;
for i=2:(n)
dYdz(i)= -(1+1/m*Q(i))*(Y(i)-Y(i-1))/dt/v;
dYdz;
end
dYdz=dYdz';
end
end
Edi Sugiarto (13/348228/TK/40839)

Sulfur Guard Bed Schematics
Legend:
1. Outlet Pipe
2. Grid Support
3. Man-hole
4. Inlet Pipe
Figure 6. Sulfur Guard Bed Schematics
Edi Sugiarto (13/348228/TK/40839)

Methanol Reactor
(R-401)
Duty : Producing 5,760.02 kg/hr of methanol from syngas which

consits of 818.89 kg/hr of H2, 5,641.28 kg/hr of CO, 6,372.58 kg/hr
of CO2 in 18,986.96 kg/hr TEGDME absorbent.
Equipment : Cocurrent trickle bed reactor.
Operating condition : 240ºC and 50 atm
Number of equimpment : 1
Choosing Flow Regime
The flow regime for gas-liquid methanol synthesis is given in figure below (Sie
and Krishna, 1998).
Figure 1. Flow Regime for Gas-Liquid Methanol Synthesis
Hence, for our equipment operation, we choose:

VG = 0.25 m/s
VL = 7.5 kg/m2s
Edi Sugiarto (13/348228/TK/40839)

Catalyst
The catalyst used in our project has the spec as follows
Name : MK-121
Supplier : Haldor Topsøe A/S
Type : CuO/ZnO/Al2O3
Geometry : Speher
Diametre : 1 mm
Loading Density : 1980 kg/m3
Operating Temp. : 200-310oC
Operating Pres. : 40-125 barg
(Haldor Topsøe A/S, 2008, 2016)
Reactor Diameter Sizing

In section “choosing flow regime”, we already chose that the gas velocity is 0.25 m/s.
VG = 0.25 m/s
Hence, we can calculate the superficial area of the reactor as follows
F = 13,804.02 kg/hr (gas massflow at inlet)
ρgas = 21.8108 kg/m3 (gas density, data)
Hence,
A = 0.7032 m2
L =
= 30.4267 m
D =√
= 0.9462 m
Edi Sugiarto (13/348228/TK/40839)

Kinetics in Methanol Reactor
Since there are 3 different phases (gas, liquid absorbent and solid catalyst) mass transfer
along with chemical reaction take place simultaneously. Resistances involved in this
system are described as follow.
Figure 2. Mass Transfer Involved in Trickle Bed Reactor
Firstly gaseous reactants dissolve from gas bulk into liquid bulk. Mass flux at steady
state is mathematically formulated as:
( ) ( )
Second step is mass transfer from liquid bulk into solid catalyst surface. In trickle bed
reactor porous catalyst is not prefered due to high mass tranfer resistance in presence of
liquid absorbent. Mass flux at steady state is mathematically formulated as:
( )
Every mass transfer resistance and chemical reaction kinetic must be observed
individually, hence controlling rate can be determined.
For trickle bed reactor kLa is determined by following equation:
( )
With: kLa = volumetric liquid film mass transfer coefficient, 1/sec
Edi Sugiarto (13/348228/TK/40839)

vl = Liquid superficial velocity, m/s
δgl = pressure gradient when both liquid and gas phase are flowing through
trickle-bed reactor, Pa/m
Di = diffusion of i component coefficient, m2/s
(Kodra and Levec, 1990)
Diffusion of each component in TEGDME is calculated with equation developed by
Wilkie and Chang (1955).
With: DL = Liquid diffusivity, m2/s

= An association factor for the solvent
2.6 for water (some workers recommend 2.26)
1.9 for methanol
1.5 for ethanol
1.0 for unassociated solvents
M = moleecular mass of solvent
iscosity of sol ent, cP
T = temperature, K
Vm = molear volume of the solute at its boiling point, m3/kmole. This can be
estimated from the group contributions given in Table 8.6 of Coulson
and Richardson Volume 6 6th edition.
Vm calculation
Vm of H2 = 0.0143
Vm of CO = 0.0307
Edi Sugiarto (13/348228/TK/40839)

Vm of CO2 = 0.0340
Vm of H2O =0.0189
Vm of CH3OH = 1* 0.0148+4* 0.0037+1* 0.0074 = 0.037
Diffusivity calculation
Diffusivity of H2
cP
sec
Diffusivity of other components is calculated with the same manner of calculation.
Diffusivities of other components are listed below.
Component Diffusivity ( sec)
H2 4.4547E-08
CO 2.8167E-08
CO2 2.6493E-08
H2O 3.7683E-08
CH3OH 2.5183E-08
kLa calculation
kLa calculation for H2
so ent ss flo te
l
g h
,
h sec
g
Edi Sugiarto (13/348228/TK/40839)

P , value of δgl is pressumed to be 1 bar for every 30
meter of reactor length

DH2 = 4.4547E-08 m2/s
( )
kLa of other components are calculated with the same manner of calculation. kLa of
other components are listed below.
Component kLa ( sec)
H2 8.8956
CO 7.0735
CO2 6.8601
H2O 8.1816
CH3OH 6.6883
ksa calculation
For trickle bed reactor ks is determined by following equation:
With: ks,i = liquid-solid mass transfer coefficient of component i, m/s

dp = Solid particle diameter, m
vl = Liquid superficial velocity, m/s
ρl = Liquid density, kg/m3
μl = Liquid viscosity, kg/m/s
Di = diffusion of i component coefficient, m2/s
(Kodra and Levec, 1990)
ks calculation for H2.

dp = 1E-03 m
Edi Sugiarto (13/348228/TK/40839)

so ent ss flo te
l
g h
,
h sec
g
s
3
ρl = 128 kg/m
μl = 0.000257539 kg/m/s
Di = 4.4547E-08 m2/s
,
s
Volumetric liquid solid interfacial are for trickle bed reactor is calculated as follow.
With als = volumetric liquid solid interfacial area, m2/m3

εb = bed porosity
dp = particle diameter, m
For this reactor
εb = 0.35
dp = 1E-03 m
ksa is calculated as follow.
Edi Sugiarto (13/348228/TK/40839)

, s
ksa of other components are calculated with the same manner of calculation. Ksa of
other components are listed below.
Component ksa ( sec)

H2 104,988.24
CO 166,043.56
CO2 176,533.19
H2O 124,112.66
CH3OH 185,720.59
From previous calculation it is concluded that gas-liquid mass transfer is far slower than
liquid-solid mass transfer. In trickle bed reactor In trickle bed reactor porous catalyst is
not preferred due to high mass transfer resistance in presence of liquid absorbent.
Component mass balance in gas bulk at steady state
Figure 3. Volume element in Trickle Bed Modeling
Edi Sugiarto (13/348228/TK/40839)

H2
| |
| |
| |
li
Analogous for other components
Component mass balance in liquid bulk at steady state

H2
| |
| |
| |
li
Analogous for other components
Edi Sugiarto (13/348228/TK/40839)

Component concentration in gaseous phase is calculated as follows.
n
P
Component concentration in liquid phase is calculated as follows.

n
Henry constant for each component in TEGDME is not provided specifically for
TEGDME and approached by squalane system. Henry constant for squalane system is
provided as follows.
Reaction in liquid phase methanol synthesis is given by Graaf, 1988 as follows.
e e
Heat balance is given as follows.
∑ | ∑ |
∑ | ∑ |
∑ | ∑ |
li
∑ p ∑
∑
(∑ , )
Edi Sugiarto (13/348228/TK/40839)

(∑ , )
(∑ , )
(∑ , )
(∑ , )
(∑ , )
Initial conditions for these equations are as follows.
Gas phase at inlet in mole/second:
CO2 = 40.23
CO = 55.96
H2 = 113.73
MEOH = 0
H2O = 3.48
CH4 = 12.93
Liquid phase at inlet in mole/second:
CO2 = 0
CO = 0
H2 = 0
MEOH = 0
H2O = 0
CH4 = 0
TEGDME = 23
Temperature at inlet:
T = 240ºC
Those differential equations are solved simultaneously using ODE15s function in

Matlab R2010a.
Edi Sugiarto (13/348228/TK/40839)

Equilibrium Determination
Equilibrium determination is performed to determine maximum achievable product.
This is performed by setting the length of reactor at infinity. Length of reactor is set to
100 m in equilibrium determination.
At infinity maximum achievable methanol product in liquid phase is 52.63 mole/second.
Take 90% from equilibrium as product target to determine reactor length.
Product target = 0.9* 52.63 mole/second
= 47.37 mole/second
From graphical reading reactor height should be 8.586 meter which is rounded as 8.6
meter. Profile of molar flow both in gas and liquid phase and also temperature profile is
provided below.
Figure 4. Reactant and Product Molar Flow Rate in Gaseous Phase
Reactant (H2 and CO) molar flow rates in gaseous phase are observed to decrease along
reactor length. This trend is caused by absorption of reactant in TEGDME followed by
reaction of H2 and CO in liquid phase. Methanol is observed to increase along reactor
length. This trend is caused by increased methanol content in TEGDME that leads to
mass transfer from TEGDME into gaseous pahse.
Edi Sugiarto (13/348228/TK/40839)

Figure 5. Reactant and Product Molar Flow Rate in Liquid Phase
Reactant flow rate is observed to have sharp increase at the beginning of reactor length.
This is caused by contact of fresh TEGDME with gas stream that leads to high reactant
mass transfer from gas pahse into TEGDME. Reactant molar flow rates along reactor
length are observed to decrease which is caused by reaction that consumes both
reactant. Methanol molar flow rate is observed to increase along reactor because
methanol is formed in reaction.
Edi Sugiarto (13/348228/TK/40839)

Figure 6. Temperature Profile in Reactor
Figure 6 shows presence of TEGDME keeps reactor near isothermal with temperature
increase below 0.2ºC within 10 meter reactor length.
Mechanical Design of Trickle Bed Reactor
 Standard shell diameter calculation
Previously calculated, shell diameter is taken at 0.9462 m.
 Material selection
Corrosion due to presence of corrosive substance (mixture of water and carbon
dioxide) must be prevented by choosing appropriate material. Based on
industrial experience, stainless steel SA-301 is employed as material in methanol
synthesis reactor.
 Head type
Design pressure is taken as a basis for head type selection. With design pressure
at 792 psig, hemispherical head will be chosen.
 Shell thickness calculation based on internal pressure
Shell thickness is calculated based on 4 different aspects, which are internal
pressure, windward side, leeward side, and buckling.
Based on API-ASME, shell thickness based on internal pressure is as follow.
Edi Sugiarto (13/348228/TK/40839)

With : P = Design pressure, which is taken as 1.1 of operating pressure, psig
Di = Inside diameter, in
S = Allowable working stress, which is 15,000 psi for stainless steel SA-
301 at 240 °C
E = Joint efficiency, whch is taken as 0.80 for double welded butt joint
C = Corrosion allowance, which is taken at 4 mm (0.1575 in) for
corrosive substance
,
Take 1.50 in which is the nearest practical thickness and constructed from 6
metal plates with ¼ in in thickness.
 Head thickness
Head thickness is calculated based on API-ASME standard which is stated in
Rase and Barrow, 1957. Head thickness is calculated as follow.
With : P = Design pressure, psig

Dm = mean diameter, in
S = allowable working stress, psi
E = Joint efficiency, dimensionless
C = Corrosion allowance, in
While Dm is calculated as follow.
Edi Sugiarto (13/348228/TK/40839)

Take 0.8125 which is the nearest practical thickness and constructed from 13
metal plates with 1/16 in thickness.
 Reactor auxiliaries
Liquid Distributor
To avoid channelling liquid distributor must be provided at top of the reactor.
For high liquid load with reactor diameter that lies between 0.25 m and 2 m
channel type distributor with bottom holes VKG will be appropriate liquid
distributor.
Figure 7. Channel type distributor with bottom holes VKG

Weight of liquid distributor is determined by reactor diameter which is described
as follows.
Edi Sugiarto (13/348228/TK/40839)

Reactor diamter is 0.96 m (37.8 in), hence liquid distributor weight for stainless
steel is 65 lb.
Liquid Redistributor
Liquid redistributor is employed to avoid chanelling along reactor. Liquid
redistributor collects liquid and redistributes it with the same manner as liquid
distributor. Liquid redistributor has the same type as liquid distributor and based
on Wallas, 1990 liquid distributor is employed every 3-10 time of tower inside
diameter or every 10-15 feet at maximum. Take 10 feet interval between liquid
redistributor, hence for 8.6 m reactor height 2 liquid redistributors are sufficient.
Catalyst Support
Catalyst support supports wet catalyst bed. Stainless steel grid plate catalyst
support is employed. Based on wallas, 1990 catalyst support is employed every
10-15 feet. Take 10 feet interval between catalyst support, hence for 8.6 m
reactor height 3 catalyst supports are sufficient. Weight of catalyst support is
determined by reactor diameter which is described as follows.
Edi Sugiarto (13/348228/TK/40839)

Reactor diamter is 0.96 m (37.8 in), hence catalyst support weight for stainless
steel is 660 lb/sq ft and 2 in (0.17 ft) high. Reactor cross sectional area is 0.7032
m2 (7.5692 ft2), hence single catalyst support weighs 4995.67 lb.
Man hole
Man hole is provided to give access for people to enter reactor. Man hole is
necessary for reactor/vessel with diameter more than 40 in. Since this reactor
diameter is 37.8 in man hole is not provided.
Hand hole
Hand hole is needed to give access for catalyst loading and unloading. Hand
holes are provided at every empty space between liquid distributor and packing
support. Based on Brownell 1959 hand hole specifications are described as
follow.
Nominal pipe size = 8 in
Diameter luar flange = 13,5 in
Tebal flange minimum = 1,125 in
Diameter luar raised face = 10,625 in
 Shell thickness calculation based on windward, leeward, and buckling
Dm is calculated as follow.
Edi Sugiarto (13/348228/TK/40839)

Material specific gravity = 7.8
Material density = 7.8 * 62.5 lb/ft3
Material density = 487,5 lb/ft3
L shell = 8.6 m
L shell = 338.5827 in
H head without thckness = 0.5*Di

H head without thckness = 0.5*37.251 in
H head without thckness = 18.6259 in
H head with thckness = H head without thckness + t head
H head with thckness = 18.6259 in + 0.8125 in
H head with thckness = 19.4385 in
te i l of shell i t
te i l of shell in in
te i l of shell
te i l of shell
M material of shell = V material of shell*Material density

l
te i l of shell ft
ft
te i l of shell l
te i l of he s i t
te i l of he s in
te i l of he s ,
te i l of he s
Edi Sugiarto (13/348228/TK/40839)

M material of 2 heads = V material of 2 shells*Material density
l
te i l of he s
ft
te i l of he s l
Assuming there is 3 in plastic insulation
Edi Sugiarto (13/348228/TK/40839)

Edi Sugiarto (13/348228/TK/40839)
For safety factor use 0.8 correction factor for Sb
Basis Thickness
Internal Pressure 1.5 in
Windward 0.0375 in
Leeward 0.0428 in
Buckling 0.0147 in
Thickness calculation based on internal pressure gives the thickest material,

hence it will be used.
Edi Sugiarto (13/348228/TK/40839)

PROCESS ENGINEERING FLOW DIAGRAM
221
Flue G as 2.81
Clean Syngas
(To Stack) 42
PIC (To Area 400)
3 81 302 40
2.29 1.21
4 30
Process Water
AREA 100 T -201
928
2 .64 C rude Syngas
(From Utility) 35
3.67
1.21
40
25
8 9 28 (To A rea 300) 32
TIC 29 S-301
AREA 200
2.62 302
1.01 141
10
1 3.23 FIC
401
33
Water Condensate
Y-101 BC-101 C har 40 (To Treatment)
798
F-201 928 (To D isposal) PIC 885
T-301
500 432 1.21
2 .62 1.84 1.73 1.63 1.42
301
31
11 26 27 28 77
9 28
2 .65
S-201 E-301 E-303 E-304
E-302
M-101
25
2.9 3
14
7
104 8
2.3 4 S-203
1 048
2 .33
17
AREA 300 TIC
301
413
Methanol
(To Area 500)
15 2.79
46
104 8
PIC 2.35 S-202 R-301
BC-102 202
F-202
SR-101 13
G rinded B iom ass 928
Superheated Steam
(From A rea 100) 9
2.64
500 (To Area 200)
25 2.93
1.01 3 24 R-202 6
2 25 25
1.0 1 1.01 FIC
20 1 928
L-101 D -201 2.17
BC-103 FIC
104 8
R -201 20 1
A sh EQUIPMENTS CODE
14o 2.9 3
16 (To D isposal)
25
CONTROL CODE
M-102 100
10 48
2.31
FIC
2.93
20 1 20
Superheated Steam 5 A Adsorber FC Flow Controller
(From A rea 300) A sh
50 0 SC -201
2.9 3
104 8 (To D isposal)
2.33
SR-102 6
A-301A A-301B AC Accumulator
25
2.93
18
FI Flow Indicator
BC-104 25 Grinded Biomass 23
1.01
(To Area 200) 22
500
SC -202
3
25
2 .31
BC Belt Conveyor LC Level Controller
1.0 1
BC-105 69
WIC
A ir
119
C Compressor/Blower
101
(From A tm osphere)
2.64
12
PC Pressure Controller
C-201
D Rotary Dryer
25
1 .01
70
928
RC Ratio Controller
TIC
202
2.62
10 4 921
2.31
M P-201 2.31 10 DC Distillation Column
C-202
21 19
TC Temperature Controller
E Heat Exchanger
EV Valve/Expansion Valve
Pressure, Bara
F Bag Filter
FIC o
-98
503
-98 GT Gas Turbine
Temperature, C
1.31 1.31
SP-501
65 71
-98
L Bucket Elevator Stream Number
AREA 500 C-501
72
1.31
PIC
502
M Mill/Chipper
Clean Syngas
AREA 400 Unreacted Gas 117
52
TIC
502
E-504
-43
Light Gas
(To Utility)
Control Valve
(From Area 300)
5.74 E-502 11.8
MP Mixing Point
(From Area 400)
56
240
FIC
501 LI
502
73
-69
1.27
Pipeline
FIC
401
50
65 M P-502 P Pump
39 53
5.45 AC-501
40
1.21
30
GT-401 P-502
66
-73
1.27 R Reactor Pneumatic Signal
75
55
DC-501 TIC
12.0 504
C-502
C-401 FIC SP-502 S Separator/Cyclone Electrical Signal
TIC 504
153 -73
54 503 -73
FIC
12.22 E-505 75
1.27
74
1.27 40
LIC
163
4.68
34 401 GT-402
TIC
503
TI
12.0
62
LI SC Screw Conveyor
209
512
501 E-503 505
T-501A/B
506
Mechanical Signal
50.32
Unreacted Gas 2.75 PI
45
-98
(To Area 500) 47
503 SP Splitting Point
FIC
1.31
E-401 401 E-501 FIC
506
65
54 -60 -62 SR Screen

12.4
57
E-506 1.20 1.20
50
35
4.46 76 67
R-401 49
40
2.65
AC-502 M P-503 T Storage Tank/Silo
40 LIC 60
48
2.73 504
85
E-508
C-402 12.2
Unreacted Gas
Y Open Yard
Methanol 40 44 P-503
12.4 12.3 -15 (To Utility)
221
(To Area 300) 1.18
58 59
176 2.81 PIC 68
36
15.29
42 501
M P-501 FIC
TIC 505
LIC 506
TIC PIC
501
E-402 402 402 DC-502
240 221
DEPARTEMEN TEKNIK KIMIA
98 50 2.91
S-501
15.03
37
40 41 S-401 E-507
LIC
TIC
40
1.01
LI
FAKULTAS TEKNIK
505 64
EV-401
TIC
FIC
401 R-501
40
2.65
507 40
12.0
PIC
504
T-502 A/B
507
UNIVERSITAS GADJAH MADA 2017
C-403 403
50 61 63
245
E-509
221
M ethanol
P-501
FIC
12.2 EV-501
Disusun Oleh :
52.01 502
44
221 (From Area 400) 413
2.81 46 W ater
240
50.32 E-403 43
2.79
40 (To Treatm ent) Edi Sugiarto (13/348228/TK/40839)
38 2.65
P-401 51

Dosen Pembimbing
Muhammad Mufti Azis, S.T., M.Sc., Ph.D.
S tream 1 9 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77
Biomass 23,221.58 23,221.58 23,221.58 - 12,626.26 - - - - - - - - - - - - - - - - - 10,595.32 12,626.26 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Water 31,417.43 31,417.43 31,417.43 37,716.30 2,405.00 4,367.27 6,273.58 6,273.58 - 6,273.58 - 621.14 21,634.87 - 21,634.87 - 21,634.87 - 21,634.87 - 1,403.84 23,038.71 14,334.84 17,082.59 6,280.68 3,230.72 3,230.72 3,230.72 3,230.72 226.09 3,004.63 4,367.27 4,367.27 226.09 226.09 226.09 226.09 226.09 - 223.18 223.18 223.18 - - - 223.18 3,465.00 3,465.00 3.47 4.34 3,457.19 3.47 3.47 3.47 3.47 - 3.47 4.34 7.81 7.79 0.02 7.79 0.02 0.02 - - - - 621.14 1,403.84 - - - - - - 3,230.72
H2 - - - - - - 281.29 281.29 - 281.29 - - - - - - - - - - - - - - 281.29 818.89 818.89 818.89 818.89 818.89 0.00 - - 818.89 818.89 818.89 818.89 818.89 99.21 - - - - - - - - - - - - - - - - - - - - - - - - - 99.21 99.21 99.21 99.21 - - 14.88 84.33 84.33 14.88 84.33 84.33 818.89
CO - - - - - - 5,897.91 5,897.91 - 5,897.91 - - - - - - - - - - - - - - 5,897.91 5,652.70 5,652.70 5,652.70 5,652.70 5,641.28 11.42 - - 5,641.28 5,641.28 5,641.28 5,641.28 5,641.28 596.74 - - - - - - - - - - - - - - - - - - - - - - - - - 596.74 596.74 596.74 596.74 - - 89.51 507.23 507.23 89.51 507.23 507.23 5,652.70
CO 2 - - - 24,764.49 - - 2,604.38 2,604.38 - 2,604.38 - 60.11 24,628.64 - 24,628.64 - 24,628.64 - 24,628.64 - 135.86 24,764.49 - - 2,604.38 6,519.95 6,519.95 6,519.95 6,519.95 6,372.58 147.36 - - 6,372.58 6,372.58 6,372.58 6,372.58 6,372.58 6,379.70 - - - - - - - - - - - - - - - - - - - - - - - - - 6,379.70 6,379.70 6,379.70 6,379.70 60.11 135.86 956.96 5,422.75 5,422.75 956.96 5,422.75 5,422.75 6,519.95
CH 4 - - - - - - 1,173.53 1,173.53 - 1,173.53 - - - - - - - - - - - - - - 1,173.53 756.42 756.42 756.42 756.42 745.17 11.25 - - 745.17 745.17 745.17 745.17 745.17 745.17 - - - - - - - 21.40 21.40 21.13 0.27 0.00 21.13 21.13 21.13 21.13 21.13 0.00 0.27 0.28 0.28 0.00 0.28 0.00 0.00 745.17 745.17 745.17 745.17 - - 111.78 633.40 633.40 111.78 633.40 633.40 756.42
C 2H 2 - - - - - - 57.70 57.70 - 57.70 - - - - - - - - - - - - - - 57.70 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
C 2H 4 - - - - - - 513.80 513.80 - 513.80 - - - - - - - - - - - - - - 513.80 - - - - - - - - - - - - - - - - - - - - - 115.21 115.21 109.42 5.78 0.01 109.42 109.42 109.42 109.42 106.60 2.81 5.78 8.59 8.59 0.00 8.59 0.00 0.00 - - - - - - - - - - - - -
C 2H 6 - - - - - - 19.88 19.88 - 19.88 - - - - - - - - - - - - - - 19.88 - - - - - - - - - - - - - - - - - - - - - 4.41 4.41 4.11 0.29 0.00 4.11 4.11 4.11 4.11 3.70 0.41 0.29 0.71 0.71 0.00 0.71 0.00 0.00 - - - - - - - - - - - - -
Tar - - - - - - 149.53 149.53 - 149.53 - - - - - - - - - - - - - - 149.53 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
NH 3 - - - - - - 76.58 76.58 - 76.58 - - - - - - - - - - - - - - 76.58 76.58 76.58 76.58 76.58 - 76.58 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 76.58
H 2S - - - - - - 13.40 13.40 - 13.40 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
HCl - - - - - - 25.94 25.94 - 25.94 - - - - - - - - - - - - - - 25.94 25.94 25.94 25.94 25.94 - 25.94 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25.94
Char - - - - - - 2,311.03 23.11 2,287.92 - 23.11 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Olivine - - - - - - 340,909.09 - 340,909.09 - - - 340,912.36 3.27 3.27 340,909.09 - 3.27 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Ash - - - - - - - - - - - - 761.35 - 761.35 - 152.27 609.08 - 152.27 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
O2 - - - 55,811.15 - - - - - - - 23,052.24 3,710.49 - 3,710.49 - 3,710.49 - 3,710.49 - 52,100.66 55,811.15 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23,052.24 52,100.66 - - - - - - -
N2 - - - 245,055.30 - - - - - - - 75,167.74 75,167.74 - 75,167.74 - 75,167.74 - 75,167.74 - 169,887.55 245,055.30 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 75,167.74 169,887.55 - - - - - - -
Ar - - - 4,180.60 - - - - - - - 1,282.35 1,282.35 - 1,282.35 - 1,282.35 - 1,282.35 - 2,898.25 4,180.60 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1,282.35 2,898.25 - - - - - - -
NO2 - - - 173.89 - - - - - - - - 173.89 - 173.89 - 173.89 - 173.89 - - 173.89 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
SO2 - - - 21.17 - - - - - - - - 21.17 - 21.17 - 21.17 - 21.17 - - 21.17 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Cl2 - - - 21.17 - - - - - - - - 21.17 - 21.17 - 21.17 - 21.17 - - 21.17 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
CH3OH - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5,760.02 5,760.02 5,760.02 - - - 5,760.02 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
C3H8 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 148.57 148.57 118.85 29.72 0.00 118.85 118.85 118.85 118.85 - 118.85 29.72 148.57 148.57 0.00 148.57 0.00 0.00 - - - - - - - - - - - - -
C3H6 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 125.91 125.91 103.57 22.34 0.00 103.57 103.57 103.57 103.57 10.36 93.21 22.34 115.55 115.55 0.00 115.55 0.00 0.00 - - - - - - - - - - - - -
I-butane - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 365.14 365.14 231.73 133.41 0.00 231.73 231.73 231.73 231.73 - 231.73 133.41 365.14 364.97 0.17 364.97 0.17 0.17 - - - - - - - - - - - - -
N-butane - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42.81 42.81 23.77 19.04 0.00 23.77 23.77 23.77 23.77 - 23.77 19.04 42.81 42.77 0.04 42.77 0.04 0.04 - - - - - - - - - - - - -
1-butene - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 183.83 183.83 110.11 73.72 0.00 110.11 110.11 110.11 110.11 - 110.11 73.72 183.83 183.69 0.13 183.69 0.13 0.13 - - - - - - - - - - - - -
c8h18 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1,510.92 1,510.92 23.85 1,487.07 - 23.85 23.85 23.85 23.85 - 23.85 1,487.07 1,510.92 1.51 1,509.41 1.51 1,509.41 1,509.41 - - - - - - - - - - - - -
TEGDM E - - - - - - - - - - 18,986.96 18,986.96 - 18,986.96 18,986.96 18,986.96 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Total M assflow,
54,639.02
kg/hr 54,639.02 54,639.02 367,744.07 15,031.27 4,367.27 360,307.62 17,110.61 343,197.01 17,087.50 23.11 100,183.58 468,314.02 3.27 127,404.93 340,909.09 126,792.58 612.35 126,640.31 152.27 226,426.17 353,066.48 24,930.16 29,708.85 17,081.20 17,081.20 17,081.20 17,081.20 17,081.20 13,804.02 3,277.18 4,367.27 4,367.27 13,804.02 13,804.02 13,804.02 13,804.02 13,804.02 7,820.82 24,970.15 24,970.15 5,983.20 18,986.96 18,986.96 18,986.96 5,983.20 5,983.20 5,983.20 750.00 1,775.99 3,457.21 750.00 750.00 750.00 750.00 141.79 608.21 1,775.99 2,384.20 874.42 1,509.78 874.42 1,509.78 1,509.78 7,820.82 7,820.82 7,820.82 7,820.82 100,183.58 226,426.17 1,173.12 6,647.70 6,647.70 1,173.12 6,647.70 6,647.70 17,081.20

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TUGAS PERANCANGAN PABRIK KIMIA

Preliminary Design of Palm Fruit Empty Bunch Into

DEPARTEMEN TEKNIK KIMIA

Puji syukur penyusun sampaikan ke hadirat Tuhan YME, karena atas

Pada kesempatan kali ini, penyusun mengucapkan banyak terima kasih

1. Pengurus Departemen Teknik Kimia Universitas Gadjah Mada.

Penyusun menyadari bahwa dalam pengerjaan dan penyusunan tugas

The conversion of palm fruit empty bunch to gasoline consists of 3 main

The plant is going to be constructed in Pulau Muda, Teluk Meranti,

Figure 1.1 Fluctuation of Crude Oil Price (EIA, 2016b)

It is generally accepted that relying solely on crude supply to meet the

Chemical Engineering Department, Universitas Gadjah Mada

Methanol to Gasoline (MTG) technology-based plant is proposed in this

Figure 1.2 Refined Petroleum Product Share 2012 (EIA, 2016a)

Chemical Engineering Department, Universitas Gadjah Mada

1.2 Raw Material Consideration

Figure 1.3 Agricultural Area in Indonesia by Commodity (Kementan RI,

Chemical Engineering Department, Universitas Gadjah Mada

1.3 Gasoline Market Research

Figure 1.4 Domestic Gasoline Consumption and Production

Chemical Engineering Department, Universitas Gadjah Mada

Chemical Engineering Department, Universitas Gadjah Mada

Chemical Engineering Department, Universitas Gadjah Mada

1.5 Preliminary Site Selection

Chemical Engineering Department, Universitas Gadjah Mada

Figure 1.5 Selected Plantation Region

Total plantation area in selected plantation region (Figure 1.5) is approximately

Chemical Engineering Department, Universitas Gadjah Mada

Earthquake is main geographical-related aspect in determining plant location.

Chemical Engineering Department, Universitas Gadjah Mada

Established Plant Capacity

1.7 Process Selection

Chemical Engineering Department, Universitas Gadjah Mada

Chemical Engineering Department, Universitas Gadjah Mada

Chemical Engineering Department, Universitas Gadjah Mada

Chemical Engineering Department, Universitas Gadjah Mada

Chemical Engineering Department, Universitas Gadjah Mada

2.1 Plant Overview

Table 2.1. Raw Materials and Product of Our Gasoline Plant

Raw Material Mass Flow, kg/hr Capacity, ton/annum

Chemical Engineering Department, Universitas Gadjah Mada

Biomass Handling (Area 100)

Biomass Gasification (Area 200)

Chemical Engineering Department, Universitas Gadjah Mada

Characteristics Temperature (oC)

Chemical Engineering Department, Universitas Gadjah Mada

Syngas Cleanup (Area 300)

Methanol Synthesis (Area 400)

The reformed syngas is then compressed in three-stage compressors to

Chemical Engineering Department, Universitas Gadjah Mada

Methanol to Gasoline (Area 500)

Chemical Engineering Department, Universitas Gadjah Mada

Chemical Engineering Department, Universitas Gadjah Mada

Table 3.2. Steam Specification

Chemical Engineering Department, Universitas Gadjah Mada

Table 3.5. Specification of LPG Product

Chemical Engineering Department, Universitas Gadjah Mada

Chemical Engineering Department, Universitas Gadjah Mada

Chemical Engineering Department, Universitas Gadjah Mada

Chemical Engineering Department, Universitas Gadjah Mada

Chemical Engineering Department, Universitas Gadjah Mada

Chemical Engineering Department, Universitas Gadjah Mada

Chemical Engineering Department, Universitas Gadjah Mada