PRELIMINARY DESIGN OF
POTASSIUM CHLORIDE
PRODUCTION FROM
OIL PALM EMPTY FRUIT
BUNCHES ASHES
GROUP 26
Amirah Amatullah
(1206262071)
Farisa Imansari
(1206212426)
Nurhayati
(1206246616)
Osvaldo Sahat
(1206247796)
Shella
(1206238721)
Outline
CHAPTER I
Background
Literature overview
Raw Material Analysis
Market and Production Capacity
Analysis
Plant Location Analysis
CHAPTER III
Mass Balance
Energy Balance
CHAPTER II
Process Selection
Process Description
Block Flow Diagram
Process Flow Diagram
CHAPTER IV
Conclusion
Chapter
{ Background }
Indonesia
Currently
Oil
palm empty
the
is the
oilfruit
largest
palmbunch
empty
producer
usually
ash
fruit
known
and
bunch
used
exporter
toby
ash
have
the
just
of
high
CPO
used
palm
potassium
oil worldwide.
levels.
{ Literature overview }
Properties of potassium chloride
Chemical formula
KCl
Molar mass
74.5513 gmol1
Appearance
Odor
odorless
Density
1.984 g/cm3
Melting point
Boiling point
Solubility in water
281g/L (0C)
344g/L (20C)
567g/L (100C)
Solubility
soluble inglycerol,alkalies
slightly soluble inalcohol,
insoluble inether
Acidity(pKa)
~7
(Source: various
Properties
Potassium chloride is a colorless or white, cubic, crystalline compound
that closely resembles sod
2007
2008
2009
2010
2011
2012
2013
2014
2015
Production
(million metric
tons)
Export
(million metric
tons)
Export
(in USD billion)
16.8
19.2
19.4
21.8
23.5
26.5
27.0
31.0
31.5
n.a
14.2
15.5
15.6
16.5
18.1
21.2
20.0
19.5
n.a
15.6
10.0
16.4
20.2
21.6
19.0
18.4
(Source : Food and Agriculture Organization of the United Nations, Indonesian Palm Oil Producers
Association (Gapki) and Indonesian Ministry of Agriculture, 2015)
The CPO industry will obtain oil palm fruit empty bunch waste around 1.2-1.4
tons for each ton CPO production
PRELIMINARY DESIGN OF POTASSIUM CHLORIDE PRODUCTION FROM OIL PALM
EMPTY FRUIT BUNCHES ASHES group 26
In this
For
The
market
analysis
share
wewe
will
only
usetake
the 2%
global demand of potassium chloride data as our reference to determine the capacit
Parameter
Global demand of potassium chloride in Southeast
Asia, 2015
Global demand of potassium chloride for nonfertilizer
Global demand of potassium chloride for industrial
Market share
Production capacity for Southeast Asia
Production capacity of our plant (Just to meet the
demand of 4 countries)
Production capacity / day
Quantity
Unit
Source
6 million
Tons/year
CRU
540000
Tons/year
CRU
54000
2%
1080
Tons/year
%
Tons/year
K+S Group
Assumption
Calculation
390
Tons/year
Calculation
1,2
Tons/day
Assumption: 330
work day
Chapter
II
Process Selection
Neutralization
Material
Purification
Equipment
{ Neutralization }
Neutralization is used to separate Potassium from the other logam ,
such as calcium and magnessium to form potassium chloride (KCl)
Neutralization reactions involve the reaction of an acid with a base (hydroxide).
This separation using precipitation method, where strong acids reacted with salts
of strong acids so the solution not dissolve
2. HCl + K+ KCl + H+
{ Material Selection }
Ksp
HCl + K+ KCl + H+
Reactivity
Lattice
enthalpy
Parameter
Percentage
NaCl
HCl
Rating
Scoring
Rating
Scoring
15%
0.3
0.75
25%
1.25
0.75
Solubility
25%
0.75
1.25
10%
0.2
0.4
11
2.5
18
3.15
TOTAL
65%
{ Purification }
There are two general purification process to separate
potassium and other ions.
Mixing
Mixing boiling
boiling water
water
Evaporation
Evaporation
{ Equipment Selection }
Mixing boiling water
The energy thermal of boiling water
came from boiler.
The type of boiler used is thermal liquid
heater
The most common heat sources are gas
and oil fuels, and electricity.
But, thermal fluids typically do not
transfer heat as well as water, serious
containment problems with thermal
fluids at high temperatures, including
corrosion, erosion, and freezing.
The cost production of this process is
expensive
Evaporation
Parameter
Percentag
e
Rating
Scoring
Rating
Scoring
Purity
25%
1.25
0.75
Energy
requirement
25%
1.25
0.75
25%
1.25
0.5
25%
1.25
0.75
TOTAL
25%
11
2.5
18
1.5
Silo Tank
{ Solid-Liquid Separation }
Leaching: an operation where the two
phases involved, solid and liquid, are in
intimate contact. The solutes are able to
diffuse from the solid to the liquid phase,
causing a separation of the components
originated in the solid.
Water leaching: construed as the
removal of water soluble and ionexchangeable inorganic constituents from
solid substrate with water. It is an
inexpensive
method
to
decrease
inorganic constituents in the biomass
content.
{ Solid-Liquid Separation }
PROCESS OPERATION CONDITIONS
Ratio of the liquid and solid fed to the unit 10:1
Stirring speed 550 rad/min
Time 30 minutes
Temperature 35oC
Pressure 1 bar
Inlet per day 7 tons of ashes, 70 tons of water
Liquid out 70.7161 tons/day
Solid out 6.2839 tons/day
{ Filtration }
Filtration: the process of separating suspended solid matter from a liquid, by
causing the latter to pass through the pores of some substance called a filter. The
liquid that passes through the filter is called the filtrated.
Objective: the removal of the residual liquid that wets the potassium chloride
produced after the neutralization process. The liquid from wet potassium chloride
formed from the neutralization process is full of Calcium and Magnesium ions which
could affect the purity of potassium chloride needed.
Microfiltration: a common form of
physical filtration process where a
contaminated fluid is flown through an
exclusively
specific
pore-sized
membrane to separate the solid and
suspended particles from process liquid.
{ Filtration }
PROCESS OPERATION CONDITIONS
Time 30 minutes
Temperature 27oC
Pressure 1 bar
Membrane size 0.1 m
Feed Inlet 71.98427 tons/day
Filtrate 63.75 tons/day
Concentrate 8.24 tons/day
{ Evaporation }
Falling
film
evaporator
is
constructed with vertical shell-andtube heat exchanger, with a laterally
or
concentrically
arranged
centrifugal separator.
water
{ Evaporation }
PROCESS OPERATION CONDITIONS
Temperature 95oC
Time 30 minutes
Pressure 1 bar
Feed is heated in advance with a heater until it reaches 95oC.
Requires a steam generator
Feed inlet 8.246 tons/day
Gas out 7.071 tons/day
Solid out 1.165 tons/day
{ Crystallization }
Crystallization: chemical solidliquid separation technique, where mass transfer of a solute
from the liquid solution to a pure solid crystalline phase occurs; the formation of solid crystal
precipitating from a solution, melt or more rarely deposited directly from a gas.
Objective: to form potassium chloride with more pure and more uniform-sized.
{ Crystallization }
PROCESS OPERATION CONDITIONS
Temperature 18oC
Pressure 1 bar
Time 30 minutes
Feed inlet 1.165 tons/day
Solid Outlet 1.165 tons/day
Requires a chiller for the cooled water as cooling agent
Feed is cooled in advance with a cooler until it reaches 18oC.
EPOFB
Ashes
Storage
EPOFB
Ashes
Leaching
Leached
Liquid
Leaching Residual
HCl
Neutralization
Mineral Residue
Steam
KCl (Wet)
Microfiltration
KCl Cake
Evaporation
KCl (Dry)
Crystallization
Residue
KCl
Packaging
Chapter
III
{ Mass balance }
EPOFB Ash Input
Stream
(Ton/day)
Component
Outpu
Input
t
Ash
7
7
(Biomass)
Water
-
K+
Ca2+
Mg2+
HCl
KCl
Total
7
7
PRELIMINARY DESIGN OF POTASSIUM CHLORIDE PRODUCTION FROM OIL PALM
35
EMPTY FRUIT BUNCHES ASHES group 26
{ Mass balance }
Mass Balance of Leaching Process
Componen
Solid
t
In
Ash
(Biomass)
Water
K+
Ca2+
Mg2+
HCl
KCl
Total
Stream (Ton/day)
Liquid Liquid
Solid
In
Out
Out
6.23
-
7
70
-
70
70
0.603
0.100
0.013
-70.72
0
0
0
0
--
6.23
Stream (Ton/day)
HCl
Input
Output
37%
-
70
0.603
0.100
0.013
70.72
0.706
0.563
-
1.27
70.71
0
0.100
0.013
0
1.16
71.98
{ Mass balance }
Mass Balance of Microfiltration Process Mass Balance of Evaporation
Process
Stream (Ton/day)
Stream (Ton/day)
Componen
t
Feed
Filtrate
Concentrat
e
Ash
(Biomass)
Water
70.71
63.63
7.070
K+
Ca2+
0.100
0.100
Mg2+
0.013
0.013
HCl
KCl
1.165
1.165
Total
71.98
63.75
8.236
Componen
t
Ash
(Biomass)
Water
K+
Ca2+
Mg2+
HCl
KCl
Total
Feed
Vapor
Liquor
7.070
0
0
0
0
1.165
8.236
7.070
0
0
0
0
7.070
0
0
0
0
0
1.165
1.165
{ Mass balance }
Mass Balance of Crystallization ProcessMass Balance of Filling Process
Componen
t
Ash
(Biomass)
Water
K+
Ca2+
Mg2+
HCl
KCl
Total
Stream (Ton/day)
Feed
Vapor Product
1.165
1.165
0
0
1.165
1.165
Componen
t
Ash
(Biomass)
Water
K+
Ca2+
Mg2+
HCl
KCl
Total
Stream (Ton/day)
Input
Output
1.165
1.165
1.165
1.165
{ Energy balance }
Energy Balance of Water Leaching Process
Input (kJ)
Ash
Water
K+
Ca2+
Mg2+
Total
205800
10265500
10471300
Output (kJ)
Ash
Water
K+
Ca2+
Mg2+
Total
184746.66
10265500
11391.03
2207.205
488.775
10464333.67
Heat Loss
(kJ)
6966.33
Output (kJ)
7998918.532
8787.366
1702.701
377.055
Water
K+
Ca2+
Mg2+
7998918.532
1702.701
377.055
47699.17794
HCl 37%
8057484.832
KCl
Total
21709.96749
8022708.256
Heat Loss
(kJ)
34776.58
{ Energy balance }
Energy Balance of Filtration Process
Input (kJ)
Water
Ca2+
Mg2+
KCl
Total
7998918.5
1702.701
377.055
21709.967
8022708.26
Output (kJ)
Water
Ca2+
Mg2+
KCl
Total
7998918.53
1702.701
377.055
21709.967
8022708.26
Heat Loss
(kJ)
0.00
2814434
76386.92
2890821
Output (kJ)
Water
Vapor
KCl
Total
1266160
76386.92
1342547
Heat Loss
(kJ)
1548275
{ Energy balance }
Energy Balance of Evaporation Process
Input (kJ)
Wate
r
Vapor
KCl
Total
Output (kJ)
2814434
Water
76386.92
2890821
Vapor
KCl
Total
1266160
76386.92
1342547
Heat Loss
(kJ)
1548275
14473.31
Output (kJ)
KCl
Heat Loss
(kJ)
14473.31
0
Total
14473.31
Total
14473.31
Energy
Ashes
205800
Total
205800
Energy
KCl
21709.967
Total
21709.967
Chapter
IV
{ conclusion }
Potassium Chloride is a useful material that can be used in many industries such as
drilling industry.
Potassium chloride can be obtained from Oil Palm Empty Fruit Bunches which is usually
useless and is considered as waste in CPO industry.
Our raw material is Oil Palm Fruit Empty Bunches (OPFEB) ashes.The availabilty of this
material in is so high Indonesia because there are so many CPO industries in Indonesia.
Our plant will be built in Sambas, West Kalimantan. The plant located in Sambas,
because of the source of material and targeted market is near from our plant location
with production capacity of KCl is around 390 ton/year
The process includes water leaching, neutralization using HCl, microfiltration,
evaporation, and crystallization.
The mass efficiency is 16.647% because to produce KCl, we need a lot of ashes
because the content of K+ in ashes is small.
The energy efficiency is 10.549%
THANK
YOU
{ References }
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September 2015, 18.22]
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September 2015, 20.09]
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{ References }
Mutu Certification International (2012). Assessment Report of PT. Agronusa Investama. Indonesia: Mutuagung Lestari
Nelson, B. P. N., Rhebergen, T., Berthelsen, S., Webb, M. J., Banabas, M., Oberthr, T., Lubis, A. (2002). Soil Acidification under Oil
Palm: Rates and Effects on Yield. Slides, 2225.
Nurhayati Abdullah and Fauziah Sulaiman (2013). The Properties of Washed Empty Friut Bunches of Oil Palm. Journal of Physical
Science, Vol. 24(2), 117-137, 2013
Peng, C., Zhang, F., & Guo, Z. (2009). Separation and Recovery of Potassium Chloride from Sintering Dust of Ironmaking Works. ISIJ
International, 49(5), 735742. http://doi.org/10.2355/isijinternational.49.735
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Sciences, 3(1), 518524. http://doi.org/10.6088/ijes.2012030131033
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(2015).
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Kedua.
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{ DISCUSSION }