assignment 1 pabrik

GROUP 26

Assignment 1 Presentation

CHEMICAL PLANT DESIGN

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{ }Amirah Amatullah (1206262071)

Farisa Imansari (1206212426)

Nurhayati (1206246616)

Osvaldo Sahat (1206247796)

Shella (1206238721)

CHAPTER I

Background Literature overview

Raw Material Analysis Market and Production

Capacity Analysis

Plant Location Analysis

CHAPTER III

Mass Balance

Energy Balance

CHAPTER IIProcess Selection

Process DescriptionBlock Flow Diagram

Process Flow Diagram

CHAPTER IV

Conclusion

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Indonesia is the largest producer and exporter of palm oil worldwide.Each processing of 1 ton fresh fruit bunch will be generated 22-23% oil palm empty fruit bunch

Oil palm empty fruit bunch usually used by the CPO industry as fuel for the boilers and burners, which generating oil palm empty fruit bunch ash.

Currently the oil palm empty fruit bunch ash just used as fertilizer. Other alternative use of oil palm empty fruit bunch ash need to be considered

Oil palm empty fruit bunch ash known to have high potassium levels. That could be used as a source of potassium chloride which has a variety of uses in industry

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Properties

Chemical formula KCl

Molar mass 74.5513 gmol1

Appearance white crystalline solid

Odor odorless

Density 1.984 g/cm3

Melting point 770 C (1,420 F; 1,040 K)

Boiling point 1,420 C (2,590 F; 1,690 K)

Solubility in water281 g/L (0C)

344 g/L (20C)

567 g/L (100C)

Solubility

soluble in glycerol, alkalies

slightly soluble in alcohol,

insoluble in ether

Acidity (pKa) ~7

Potassium chloride is a colorless or white, cubic, crystalline compound that closely resembles sodium chloride

Potassium chloride is typically extracted from the ground via traditional subsurface mining techniques and solution mining.

The largest use of potassium chloride is as a fertilizer. It is also used in chemical manufacture, pharmaceutical, food processing and also used in petroleum industry.

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Properties of potassium chloride

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The main raw material of potassium chloride plant is oil palm empty fruit bunch ash, which often used as fertilizer. Oil palm empty fruit bunch ash has high potassium levels. The chemical composition of oil palm empty fruit bunch ash is:

The ash composition of the oil palm empty fruit bunch

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Availability and potential of oil palm empty fruit bunch ash can be seen from the CPO plant production capacity data. Here is palm oil production data from 2007 until 2015:

2007 2008 2009 2010 2011 2012 2013 2014 2015

Production

(million metric tons) 16.8 19.2 19.4 21.8 23.5 26.5 27.0 31.0 31.5

Export

(million metric tons) n.a 14.2 15.5 15.6 16.5 18.1 21.2 20.0 19.5

Export

(in USD billion)n.a 15.6 10.0 16.4 20.2 21.6 19.0 18.4

The CPO industry will obtain oil palm fruit empty bunch waste around 1.2-1.4 tons for

each ton CPO production

Palm oil production and export

(Source : Food and Agriculture Organization of the United Nations, Indonesian Palm Oil Producers Association

(Gapki) and Indonesian Ministry of Agriculture, 2015)

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KCl is currently produced from threemajor production regions; Canada,Russia, and Belarus (togetheraccount 60% of global production)

Global potash consumption iscurrently 60 million tons, andexpected to grow to 70 million tonsby 2020 and 80 million tons by 2025according to Fertecon

According to CRU, 91 percent of allKCl used in fertilizers

Source: (CRU, 2012)

Together, the U.S., Brazil, China and India represent about two-thirds of world potashconsumption

Forecast of global KCl deliveries to 2017

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Parameter Quantity Unit Source

Global demand of potassium chloride in Southeast Asia, 2015 6 million Tons/year CRU

Global demand of potassium chloride for non-fertilizer 540000 Tons/year CRU

Global demand of potassium chloride for industrial 54000 Tons/year K+S Group

Market share 2% % Assumption

Production capacity for Southeast Asia 1080 Tons/year Calculation

Production capacity of our plant (Just to meet the demand of

4 countries)390 Tons/year Calculation

Production capacity / day1,2 Tons/day

Assumption: 330

work day

Market analysis of potassium chloride

In this analysis we will use the global demand of potassium chloride data as our reference to determine the capacity

These data show overall demand of potassium chloride,which include the KCl use for fertilizer (91%) and also for non-fertilizer (9%)

For market share we only take 2% from the demand (we consider the presence of raw material)

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Primary Factor

Plant location should be near from the source of raw material

Knowing the target market is one of important aspect in determining the location of the plant

Transportation facilities will influence the process of delivering the products and also transport of raw materials

The availability of utilities in the plant location is one of the important factors in considering the plant site selection

Secondary Factor

Soil and climate conditions is one of the main factors in choosing a plant location. We need to choose the area, which is not vulnerable to the danger like landslides, earthquakes, and floods, as a location for our plant.

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Place of Sambas, near Malaysia, Singapore, and Brunei Darussalam

We decided to built our plant beside PT Agronusa Investama in Sambas, West Kalimantan,

with the production capacity of up to 390 tons/year

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The advantages to build potassium chloride plant near PT. Agronusa Investama are:

It is not too far from the center of West Kalimantan (Pontianak)

Close from the source of raw material, which make it more efficient and make the transportation costs is low

It is near the harbor (Sintete) which made us easier to deliver potassium chloride to Singapore, Malaysia, and Brunei Darussalam. This advantages can reduce the cost of exported the product

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Process Selection

Neutralization Purification

Material Equipment

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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

Neutralization is used to separate Potassium from the other logam ,

such as calcium and magnessium to form potassium chloride (KCl)

2. HCl + K+ KCl + H+1 .NaCl + K + KCl + Na+

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Ksp

Lattice

enthalpy

Potassium is more reactive than the

sodium, the potassium is easier

ionizing and become soluble so that

it will not happen precipitation

reaction.

Lattice enthalpy NaCl > Lattice

enthalpy KCl, so K+ ion tends tobe more soluble in concentrated

Reactivity

HCl selected because Ksp values

of HCl is higher than NaCl, so

neutralization will work faster when

using HCl solution.

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HCl + K+ KCl + H+

Parameter PercentageNaCl HCl

Rating Scoring Rating Scoring

Time needed during the

process15% 2 0.3 5 0.75

CAPEX and OPEX 25% 5 1.25 3 0.75

Solubility 25% 3 0.75 5 1.25

Energy needed for

neutralization process10% 2 0.2 4 0.4

TOTAL65%

11 2.5 18 3.15

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There are two general purification process to separatepotassium and other ions.

Mixing boiling water EvaporationMixing boiling water Evaporation

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Mixing boiling water Evaporation

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

The energy of evaporator using steam. The purity of the evaporator has a higher

purity level than mixing boiling water up

to 96.5%,

Heat energy from the evaporator only from steam

Evaporator no need to use distilled water in the process.

Capital cost evaporator is smaller than the mixing boiling water from the energy,

utility, and equipment.

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Parameter PercentageEvaporator Mixing Boiling Water

Rating Scoring Rating Scoring

Purity 25% 5 1.25 3 0.75

Energy

requirement25% 5 1.25 3 0.75

Utility for water 25% 5 1.25 2 0.5

CAPEX and OPEX 25% 5 1.25 3 0.75

TOTAL 25% 11 2.5 18 1.5

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Main Raw Material: Ash from oil palm fruit empty fruitbunches

Silo Tank

Silo Tank: A vessel or a container which is specifically

functioned to safe raw materials in bulk.

It enables an easy and significant way of raw materials storing.

It might increase the production capacity. It can provide a higher quality of raw materials since it

is highly impenetrable by pollutants.

It provides a cleaner working environment because the raw materials used is measured and transferred to

the next equipment process automatically through a

safe and enclosed tube.

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Leaching: an operation where the twophases involved, solid and liquid, are inintimate contact. The solutes are able todiffuse from the solid to the liquid phase,causing a separation of the componentsoriginated in the solid.

Except KCl, there would still be some other

constituents dissolved. Counter-current leaching

is applied in this leaching process to increase

the potassium chloride concentration in the

leaching liquor.

Countercurrent Leaching. (A) Launder; (B) Rake; (C) Pump

Water leaching: construed as the removal

of water soluble and ion-exchangeable

inorganic constituents from solid substrate

with water. It is an inexpensive method to

decrease inorganic constituents in the

biomass content.

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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

PROCESS OPERATION CONDITIONS

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The liquid containing potassium that is generated from water leaching is transferred to a batch reactor vessel where it is subjected with hydrochloric acid to form a

neutralization reaction.

Objective: to precipitate potassium chloride by

reacting potassium ion from the leached ashes with

hydrochloric acid.

Since it has the lowest Ksp value, potassium chloride

is more likely to precipitate first before the otherprecipitation that can occur (calcium chloride or

magnesium chloride).

The reaction between potassium and hydrochloric

acid has the lowest Ksp value compared to the

other compounds if reacted with said acid.

Batch Reactor Illustration

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Temperature 27oC

Pressure 1 bar of

Time 1 hour

Inlet per day 70.7161 feed, 1.26817 HCl

Outlet 71.98427 tons/day


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Filtration: the process of separating suspended solid matter from a liquid, by causing thelatter to pass through the pores of some substance called a filter. The liquid that passesthrough the filter is called the filtrated.

Microfiltration: a common form of physicalfiltration process where a contaminated

fluid is flown through an exclusively

specific pore-sized membrane to

separate the solid and suspendedparticles from process liquid.

Doesnt need additional cleaning chemicals, generateshigh flow throughput and dry concentrate

Needs low operation costs Uses pressure less than 4 bar Fully automatic Constructed from stainless steel Provides a process as sterile as possible.

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 thepurity of potassium chloride needed.

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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

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Falling film evaporator is constructed

with vertical shell-and-tube heat

exchanger, with a laterally or

concentrically arranged centrifugal

separator.

Typical Falling Film Evaporator Configuration

Evaporation: the process by which water changes

from a liquid to a gas or vapor.

Provides a higher product quality due to the gentle evaporation and extremely short residence times in the

falling film evaporator.

Caters high energy efficiency, due to the multiple-effect arrangement or heating by thermal or

mechanical vapor recompressor.

Requires simple process control and automation. Reacts quickly to changes in energy supply, vacuum,

feed quantities, concentrations, etc. (Important for a

uniform final concentrate).

Objective: to produce a more moistureless final

product.

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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

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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.

Draft-Tube Crystallizer with Direct-

Contact Cooling

Draft-tube (DT) crystallizer uses direct-contact cooling,evaporation, or adiabatic evaporative cooling to

generate supersaturation.

It provides a mixed suspension as the active volumefor relieving the supersaturation.

This type of crystallizer employs internal magmarecirculation to control supersaturation generation.

It usually provides a mechanism for classified productremoval.

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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.

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Storage Leaching Neutralization

Microfiltration Evaporation Crystallization

Packaging

EPOFB Ashes

EPOFBAshes

Leached

Liquid

KCl Cake KCl (Dry)

KCl

Residue

Steam

Water

Leaching Residual

HCl

Mineral Residue

KCl (Wet)

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Component

Stream (Ton/day)

Input Output

Ash (Biomass) 7 7

Water - -

K+ - -

Ca2+ - -

Mg2+ - -

HCl - -

KCl - -

Total 7 7

EPOFB Ash Input

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Mass Balance of Acid Base

Neutralization Process

Component

Stream (Ton/day)

Solid

In

Liquid

In

Liquid

Out

Solid

Out

Ash

(Biomass)7 - 0 6.23

Water - 70 70 0

K+ - - 0.603 0

Ca2+ - - 0.100 0

Mg2+ - - 0.013 0

HCl - - - - --

KCl - - - -

Total 7 70 70.72 6.23

ComponentStream (Ton/day)

Input HCl 37% Output

Ash

(Biomass)- - -

Water 70 0.706 70.71

K+ 0.603 - 0

Ca2+ 0.100 - 0.100

Mg2+ 0.013 - 0.013

HCl - 0.563 0

KCl - - 1.16

Total 70.72 1.27 71.98

Mass Balance of Leaching Process

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Mass Balance of Evaporation ProcessMass Balance of Microfiltration Process


Feed Filtrate Concentrate

Ash

(Biomass)- - -

Water 70.71 63.63 7.070

K+ 0 0 0

Ca2+ 0.100 0.100 0

Mg2+ 0.013 0.013 0

HCl 0 0 0

KCl 1.165 0 1.165

Total 71.98 63.75 8.236


Feed Vapor Liquor

Ash

(Biomass)- - -

Water 7.070 7.070 0

K+ 0 0 0

Ca2+ 0 0 0

Mg2+ 0 0 0

HCl 0 0 0

KCl 1.165 1.165

Total 8.236 7.070 1.165


Feed Vapor Product

Ash

(Biomass)- - -

Water - 0 -

K+ - - -

Ca2+ - - -

Mg2+ - - -

HCl - - -

KCl 1.165 - 1.165

Total 1.165 0 1.165

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Mass Balance of Filling ProcessMass Balance of Crystallization Process


Input Output

Ash

(Biomass)- -

Water - -

K+ - -

Ca2+ - -

Mg2+ - -

HCl - -

KCl 1.165 1.165

Total 1.165 1.165

Input (kJ) Output (kJ) Heat Loss (kJ)

Ash 205800 Ash 184746.66

6966.33

Water 10265500 Water 10265500

K+ - K+ 11391.03

Ca2+ - Ca2+ 2207.205

Mg2+ - Mg2+ 488.775

Total 10471300 Total 10464333.67


Water 7998918.532 Water 7998918.532

34776.58

K+ 8787.366 K+ -

Ca2+ 1702.701 Ca2+ 1702.701

Mg2+ 377.055 Mg2+ 377.055

HCl 37% 47699.17794 HCl 37% -

KCl - KCl 21709.96749

Total 8057484.832 Total 8022708.256

Energy Balance of Water Leaching Process

Energy Balance of Neutralization Process

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Water 7998918.5 Water 7998918.53

0.00

Ca2+ 1702.701 Ca2+ 1702.701

Mg2+ 377.055 Mg2+ 377.055

KCl 21709.967 KCl 21709.967

Total 8022708.26 Total 8022708.26


Water 2814434 Water -

1548275Vapor - Vapor 1266160

KCl 76386.92 KCl 76386.92

Total 2890821 Total 1342547

Energy Balance of Filtration Process

Energy Balance of Evaporation Process

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KCl 14473.31 KCl 14473.31

0

Total 14473.31 Total 14473.31


Water 2814434 Water -

1548275Vapor - Vapor 1266160

KCl 76386.92 KCl 76386.92

Total 2890821 Total 1342547

Energy Balance of Evaporation Process

Energy Balance of Crystallization Process

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Raw Material Input (kJ) Product Output (kJ)

Material Energy Material Energy

Ashes 205800KCl 21709.967

Total 205800 Total 21709.967

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{ }Potassium Chloride is a useful material that can be used in many industriessuch as drilling industry.

Potassium chloride can be obtained from Oil Palm Empty Fruit Buncheswhich is usually useless and is considered as waste in CPO industry.

Our raw material is Oil Palm Fruit Empty Bunches (OPFEB) ashes.Theavailabilty of this material in is so high Indonesia because there are so manyCPO industries in Indonesia.

Our plant will be built in Sambas, West Kalimantan. The plant located inSambas, because of the source of material and targeted market is nearfrom our plant location with production capacity of KCl is around 390ton/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 ofashes because the content of K+ in ashes is small.

The energy efficiency is 10.549%

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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

PotashCorp (2014). Overview of PotashCorp and Its Industry. http://www.potashcorp.com/overview/nutrients [11 September 2015, 15.00]

Udoetok, I. (2012). Characterization of ash made from oil palm empty fruit bunches (oefb). International Journal of Environmental Sciences, 3(1), 518524. http://doi.org/10.6088/ijes.2012030131033

Yanni Sudiyani (2015). Info Maksi: Potensi Tinggi Bio Etanol Generasi Kedua. http://www.infosawit.com/mobile/index.php/news/detail/info-maksi---potensi-tinggi--bio-etanol-generasi-kedua [14 September 2015, 21.10]

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