Tk21 Report Assignment2

UNIVERSITAS INDONESIA
RENEWABLE BIODIESEL FROM

CRUDE PALM OIL, JATROPHA OIL, NYAMPLUNG OIL
REPORT ASSIGNMENT 2
GROUP 21
GROUP PERSONNEL:
DANAR ADITYA S.
(1206263401)
DENNY SETYADARMA
(1206263351)
HASANNUDIN
(1206230725)
MUHAMMAD HAFIZ AL RASYID
(1206219161)
TITEN PINASTI
(1306482054)
CHEMICAL ENGINEERING DEPARTMENT

FACULTY OF ENGINEERING
DEPOK
2015
EXECUTIVE SUMMARY
In order to design renewable diesel plant, we have to make Piping and

Instrumentation Diagram and Equipment Sizing. Piping and Instrumentation
Diagram known as P&ID is one of some objectives in this assignment. It is the
completion of Process Flow Diagram made in first assignment. It makes P&ID is
more detail than PFD. P&ID is used in manufacturing the renewable biodiesel
plant. Valves and some controllers also connected to the P&ID. P&ID is a used by
process engineer in communicating with other engineer from another discipline.
With this P&ID, we expect the other engineer can understand the whole plant
system easily. In this P&ID we separate it to some pages based on process to
make easy in attaching the valves and controller. There are 4 pages containing of
Degumming, Bleaching, Steam Methane Reforming, Hydrothreating.
After designing P&ID, We need to calculate the specification of the
process equipment being used in a plant known as equipment sizing. This is
another objective of this assignment There are equipment specifications,
equipment sizing, equipment calculations used in making renewable biodiesel
plant in this second assignment. Equipment needed in this plant are 5 tanks, 4
pumps, heat exchanger, reactor, three phase separator. These data is used for
manufacturing in plant design. Sizing of equipment based on rule of thumbs of the
equipment and industrial calculation method by using manual calculation and
software.
ii
Universitas Indonesia
TABLE OF CONTENTS
EXECUTIVE SUMMARY .................................................................................... ii

TABLE OF CONTENTS ....................................................................................... iii
LIST OF FIGURES ................................................................................................ v
LIST OF TABLES ................................................................................................. vi
CHAPTER 1 ........................................................................................................... 1
CONTROL AND INSTRUMENT DESIGN .......................................................... 1
1.1.
Plant Control Tabulation .......................................................................... 1
1.2.
Piping and Instrument Diagram .............. Error! Bookmark not defined.
1.3.
Start up, Normal and Shutdown Procedure ............................................ 12
1.3.1.
Start Up Procedure .......................................................................... 12
1.3.1.1.
1.3.2.
Start Up Procedures for Each Section ..................................... 13
Shut Down Procedure ..................................................................... 14
CHAPTER 2 ......................................................................................................... 15
EQUIPMENT SIZING ......................................................................................... 15
2.1.
Main Equiment ....................................................................................... 15
2.1.1.
Storage Tank ................................................................................... 15
Crude Palm Oil Storage Tank T-101 ................................................................ 15

Jatropha Oil Storage Tank T-101 ...................................................................... 16
Nyamplung Oil Storage Tank T-101 ................................................................ 17
Renewable Biodiesel Storage Tank T-102........................................................ 18
Degumming Tank V-101 .................................................................................. 19
Shift Converter Reactor R-102 ......................................................................... 20
Absorber Column V-103................................................................................... 21
2.2.
Supporting Equipment............................................................................ 24
Heat Exchanger E-101 ...................................................................................... 24

Heat Exchanger E-102 ...................................................................................... 25
Heat Exchanger E-103 ...................................................................................... 26
Cooler E-104 ..................................................................................................... 29
CONCLUSION ..................................................................................................... 38
iii
REFERENCES ..................................................................................................... 39
APPENDIX ........................................................................................................... 40
Storage Tank ..................................................................................................... 40
Crude Palm Oil Storage Tank ........................................................................... 41
Jatropha Oil Storage Tank ................................................................................ 41
Nyamplung Oil Storage Tank ........................................................................... 42
Renewable Biodiesel Storage Tank .................................................................. 42
Degumming Tank ............................................................................................. 48
Hydrotreating Reactor Sizing ........................................................................... 52
Shift Converter Reactor R-102 ......................................................................... 60
Absorber Calculation ........................................................................................ 62
Heat Exchanger Design Procedure ................................................................... 70
Heat Exchanger E-101 ...................................................................................... 75
iv
LIST OF FIGURES
Figure A.1. Types of head of storage tank ............................................................ 44
Figure A.1. Power Number ................................................................................... 51
Figure B.1. Fixed Bed Reactor ............................................................................. 53
Figure B.2. Polymath Programming ..................................................................... 55
Figure B.3. Polymath Programming Result .......................................................... 56
Figure B.4. Polymath Programming Graph .......................................................... 56
Figure B.5. Equation used for the design or sizing of fixed bed reactor .............. 61
Figure B.6. Design for Various Packing ............................................................... 64
Figure B.7. Flooding Line Graph .......................................................................... 65
Figure C.1. Shell and Tube Overall Coefficient ................................................... 71
Figure C.2. Air Cooled Exchangers and Immersed Oil Overall Coefficient ........ 71
Figure C.3. Coomon Tube Layouts....................................................................... 72
Figure C.4. Heat exchangers tube-layouts ............................................................ 72
Figure C.5. Type of Heat Exchanger Baffles ........................................................ 73
Figure C.6. Temperature Correction Factor : two shell passes ; four or multiple
passes .................................................................................................................... 76
Figure C.7. Tube Sheet Layouts (square pitch) .................................................... 77
Figure C.8. HE Layouts ........................................................................................ 78
Figure C.9 jH Factor ............................................................................................. 83
Figure E.1 Impeller shapes related to specific speed ............................................ 92
LIST OF TABLES
Table 1.1. Tabulation of degumming process ......................................................... 1
Table 1.2. Tabulation of bleaching process ............................................................ 2
Table 1.3. Tabulation of hydrotreating process ...................................................... 2
Table 1.4. Tabulation of steam methane reforming process ................................... 4
Table 1.7. Startup procedure ................................................................................. 12
Table 1.8. Emergency Shutdown .......................................................................... 14
Table 2.1 Specification Data of Storage Tank ...................................................... 15
Table 2.2. Specification Data of Storage Tank ..................................................... 16
Table 2.3 Specification Data of Storage Tank ...................................................... 17
Table. 2.4. Specification Data of Storage Tank .................................................... 18
Table. 2.5. Specification Data of Degumming Tank ............................................ 19
Table. 2.6. Specification Data of Shift Converter Reactor ................................... 20
Table. 2.7. Specification Data of Absorber Column ............................................. 21
Table. 2.8. Specification Data of Steam Methane Reformer ................................ 22
Table. 2.9. Specification Data of Hydrotreating Ractor Design ........................... 23
Table. 2.10. Specification Data of Heat Exchanger E-101 ................................... 24
Table. 2.15. Specification Data of Fired Heater E-103 ......................................... 29
Table. 2.16. Specification Data of Fired Heater E-104 ......................................... 30
Table 2.18. Specification Data of Compressor C-102 .......................................... 33
Table 2.19. Specification Data of Pump P-101..................................................... 34
Table A.1. List of Materials that Selected for Each Storage Tank ....................... 40
Table B.1. Sizing Shift Converter Reformer ........................................................ 62
Table B.2. Composition of the Incoming Gas ....................................................... 63
Table B.2. Steam Methane Reformer ................................................................... 69
Table C.1. Composition Properties ....................................................................... 79
vi
CHAPTER 1
CONTROL AND INSTRUMENT DESIGN
1.1.
Plant Control Tabulation

Table 1.1. Tabulation of degumming process
No Device
Control
Manipulated
Variable
Variable
Location
of Control
Valve
Sequence of
Instrumentation
Degumming Process
1
T-101
Level of Oil
Flow of crude After pump If the level of tank is
Tank
oil
and before
low, valve before
heater
heater will be closed

and the other valve
will be opened. It
make the oil go back
until the level is
normal enough
E-101
Temperature Temperature
Inlet of the
Increase the flow of
outlet of
heater
heating fluid if the
heating fluid
Heat
temperature of oil
Exchanger
going to degumming
tank does not react
the set point
V-101
Level of
Flow of
After pump If the level of mixing
Degumming
degummed
tank is low, valve
Tank
oil
before heater will be

closed and the other
valve will be opened.
It make the oil go
back until the level is
normal enough
1
Table 1.2. Tabulation of bleaching process
Location
No Device
Control
Manipulated
of
Sequence of
Variable
Variable
Control
Instrumentation
Valve
Bleaching Coloumn
1
E-102
Temperature
Temperature
outlet of Heat heating fluid
Inlet of
Increase the flow of
the heater
Exchanger
temperature of oil
going to adsorber
coloumn does not
react the set point
V-102
Level of
Flow of
After
If the level of adsorber
Bleaching
bleached oil
pump
coloumn is low, valve
Tank
before heater will be

closed and the other
valve will be opened.
It make the oil go back
until the level is
normal enough
Table 1.3. Tabulation of hydrotreating process
No Device
Control
Manipulated
Location
Sequence of
Variable
Variable
of Control
Instrumentation
Valve
Hydrotreating Reactor
1
E-107
Temperature
Temperature
Inlet of
Increasing the flow of
outlet of
of heating
the heater
Heat
fluid
Exchanger
temperature of oil
going to hydrogenation
reactor does not reach
the set point
Table 1.3. Tabulation of hydrotreating process (Contd)
C-102
Flow of
Pressure
Before
If the pressure outlet of
Hydrogen
outlet of
entering
comprossor is
Compressor
compresso decreasing, the valve

r
will be closed slowly

in order to make the
flow of hydrogen
entering the
compressor decrease.
R-104
Flow
Flow of
Before the
Increasing or
Control
Bleached Oil
reactor
decreasing the flow of

degummed oil if the
flow of oil going to
reactor is not suitable
R-104
Pressure of
pressure
Pressure
If the pressure is to
hydrothreati
safety valve
Relieve
high, the pressure
ng reactor
safety valve will be

opened to release the
excess gas until the
normal pressure. If the
reactor does not
release the gas, the
reactor will be hold
the over pressure and
the equipment will be
broken soon.
R-104
Level of
Flow of
After
If the level is too low,
Hydrotreatin
Green Diesel
hydrotreat
the valve will be
g Reactor
outlet
ing reactor closed slowly until the

normal level.
Table 1.4. Tabulation of steam methane reforming process
No
Device
Control
Manipulate
Variable
d Variable
Location of
Control
Valve
Sequence of
Instrumentation
Steam Methane Reformer

1 C-101
Flow of Gas
Pressure
Before
If the pressure outlet
Inlet
outlet of
entering
of comprossor is
Separator
Compressor
compressor
decreasing, the valve

will be closed slowly
in order to make the
flow of hydrogen
entering the
compressor decrease.
2 E-103
Temperatur
Temperature
Inlet of the
Increasing the flow
e outlet of
of heating
heater
of heating fluid if the
Heat
fluid
temperature of oil
Exchanger
going to the next

process does not
reach the set point
3 E-104
Temperatur
Temperature
Inlet of the
Increasing the flow
e outlet of
of heating
heater
Heat
fluid
temperature of oil
Exchanger
going to the next

process does not
reach the set point
4 E-105
Temperatur
Temperature
Inlet of the
Increasing the flow
e outlet of
of heating
heater
Heat
fluid
Exchanger
temperature of oil
going to the next
process does not
reach the set point
Table 1.6 Tabulation of steam methane reforming process (Contd)
5 E-106
Temperatur
Temperature
Inlet of the
Increasing the flow
e outlet of
of heating
heater
Heat
fluid
temperature of oil
Exchanger
going to the next

process does not
reach the set point
6 R-101
Pressure
Flow of gas
After
If the pressure is too
outlet
reactor
low, the valve will

be closed slowly
until the normal
coloumn level.
7 R-101
Pressure
Pressure
Pressure
safety valve
Relieve
high, the pressure

normal pressure. If
the coloumn does not
not release the gas,
the coloumn will be
hold the over
pressure and the
equipment will be
broken soon.
8 R-102
Pressure
Flow of gas
After
outlet
reactor
low, the valve will

be closed slowly
until the normal
coloumn level.
9 R-102
Pressure
Pressure
Pressure
safety valve
Relieve
high, the pressure

normal pressure. If
the coloumn will be
hold the over
pressure and the
equipment will be
broken soon.
10 R-103
Pressure
Flow of gas
After
outlet
reactor
low, the valve will

be closed slowly
until the normal
coloumn level.
11 R-103
Pressure
Pressure
Pressure
safety valve
Relieve
high, the pressure

normal pressure. If
the coloumn will be
hold the over
pressure and the
equipment will be
broken soon.
12 V-103
Pressure
Flow of gas
After
outlet
reactor
low, the valve will

be closed slowly
until the normal
coloumn level.
13 V-103
Pressure
Pressure
Pressure
safety valve
Relieve
high, the pressure

normal pressure. If
the coloumn will be
hold the over
pressure and the
equipment will be
broken soon.
1.2.
Process & Instrumental Design
P-101
Feed Pump
T-101
Crude Oil Tank
E-101
Heat Exchanger
V-101
Degumming tank
P-102
Feed Pump
Fosforic Acid
Steam
T-101
CPO /
NYAMPLUNG /
JATHROPA
LT
V-101
LI C
101
LT
FIC
101
PI
101
LI C
LI C
101
FIC
102
TT
101
FT
101
PI
102
FT
102
V-96
9
E- 101
Degummed
Oil
7
P- 102
P-101
Gum
8
5
Condensate
NAME
DEPARTEMEN TEKNIK KIMIA

FAKULTAS TEKNIK
P&ID DEGUMMING UNIT
RENEWABLE BIODIESEL FROM CPO,

JATROPHA OIL & NYAMPLUNG S OIL
SIGNATURE
DATE
GROUP 21
NAME
CORRECTED BY
PICTURE NO.
NO REVISION
WITHOUT SCALE
E-102
Heat Exchanger
V-102
Bleaching Unit
P-103
Pump
V-102
Steam
TIC
102
TT
102
Degummed Oil
E- 102
LT
102
LIC
102
FIC
103
3
M
PI
103
FT
103
6
5
Bleached Oil
P-103
Condensate
NAME
FAKULTAS TEKNIK
P&ID BLEACHING UNIT

SIGNATURE
DATE
GROUP 21
NAME
CORRECTED BY
PICTURE NO.
NO REVISION
WITHOUT SCALE
10
C-101
Compressor
E-103
Feed Heater
R-101
E-104
Heater
R-102
Shift Converter
E-105
Cooler
V-103
Carbon Dioxide Absorber
R-13
Methanator
E-106
Heater
15
Steam
Hydrogen
PIC
103
TI C
PT
105
103
TT
105
102
Steam
12
14
E-106
PIC
103
R-103
TI C
105
PT
Steam
103
TT
105
102
11
PIC
102
E-105
Metanator Liquid
Product
16
V-103
TI C
104
S-2
PT
102
Natural Gas
Condensate
TT
104
102
PIC
PT
13
Carbon Dioxide
PIC
101
Steam
E-104
Condensate
PT
R-102
101
PIC
C-101
Shift Liquid
Product
10
E- 103
Condensate
R-101
Reformer Liquid
Product
NAME

FAKULTAS TEKNIK
P&ID STEAM METHANA REFORMER

SIGNATURE
DATE
GROUP 21
NAME
CORRECTED BY
PICTURE NO.
1st Revision
WITHOUT SCALE
11
E-107
Heater
R-104
Hidrotreating Reactor
C-102
Compressor
V-108
Green Diesel Tank
PT
102
11
PIC
102
104
Hydrogen
Excess Reactant
PIC
PT
104
C-102
PIC
102
6
FC
104
LT
104
R-104
Steam
LIC
104
FIC
107
TT
107
Bleached Oil
1
E-107
V-108
Condensate
NAME

FAKULTAS TEKNIK
P&ID HYDROTHREATING UNIT

SIGNATURE
DATE
GROUP 21
NAME
CORRECTED BY
PICTURE NO.
NO REVISION
WITHOUT SCALE
12
1.3.
Start up, Normal and Shutdown Procedure
1.3.1. Start Up Procedure

Start up actions occurs every day beside Saturday and Sunday, this
makes 330 days plant startup per year. Startup will be explained step by step in
Table 1.7 below.
Table 1.7. Startup procedure
No
Procedure
Safety
Description
Precautions
All piping and instrument

are completed as P&ID.
1
Electrical set start up. All

electrical cords are
Instrument set start up
connected and no faulty

cord.
Ensure functionality of
2
control valves,
All equipment and
controllers, emergency
instrument set start up
shutdown system, etc.

All electrical
3
Install and activate

electrical system
cords are
Electrical set start up
connected and no
faulty cord
Activate steam utilities
Desired
Heater start up for

heating water utilities
temperature has
been reached
Pre-treatment
Pre-treatment startup
equipment start up to
All pre treatment
produce CPO from
equipment is safe
palm fruit, nyamplung, to operate

jathropa
6
Activate plant process
Starting all controller

13
instrument and checking
on plant and checking
alarm panel
alarm function
Starting reactor and
Activate main process

equipment
other process
All equipment
equipment after CPO
connected and no
level is adequate for
leakage
process
1.3.1.1.Start Up Procedures for Each Section

Start-up procedures in this system are divided into four parts based on
the number of units in our plant. Below are the procedures:
a. Degumming Unit
1. Check all of the systems are installed correctly
2. Check the controller of the system
3. Check the temperature at 65C and the process lasts for 15 minutes
b. Bleaching Unit
3. Check substances that give color to the oil
4. Check all the equipment safe to operate
c. Hydrotreating
3. Processes implement reactions of hydrotreatment promoted by catalysts
Nickel Molybdenum with buffer Alumina
4. The hydrotreatment reactions are generally carried out in the presence of
hydrogen
5. Check temperature at 300C and pressure at 2 atm
d. Steam Methane Reforming
14
3. Check the steam flow from its temperature whether it is suitable or not for
entering the steam methane reformer
4. Reduced localized temperature
1.3.2. Shut Down Procedure

Manual shutdown. Manual shut down occur every end of year. It
occurs according to procedure:
1. Decrease the flow rate of feed CPO, Nyamplung oil, and Jathropa oil
gradually until the flows stop
2. Let all the flue gas flow until there is no excess flue gas in the piping line
3. Turn off all the equipment, such as heat exchanger, steam methane
reformer, and pump.
4. Uninstall the catalyst from all unit.
Emergency shutdown. Emergency shutdown only happen if theres
special condition occurs. Emergency shutdown relies on plant process control
instrument and alarm. The condition and procedure are shown in Table 1.8.
Table 1.8. Emergency Shutdown
No
1
Condition
Reactor temperature condition
reach too high or too low
Reactor flow condition reach
too high
Hydrotreating temperature
condition reach too high or

too low
4
5
Procedure
Shut the ball valve that related to the flow,

and maintenance or change with reserve
equipment if available
Steam Methane Reforming

flow condition reach too high
Pump failures
CHAPTER 2
EQUIPMENT SIZING
2.1.
Main Equiment
2.1.1. Storage Tank

2.1.1.1.Crude Palm Oil Storage Tank T-101
Table 2.1 Specification Data of Storage Tank
Identification
Item :
Storage Tank
Item Number :
T-101
Name of Equipment :
Crude Palm Oil Storage Tank
Item Amount :
10
Function :
Storing of Crude Palm Oil

Composition
Crude Palm Oil:
100%
Operation Data
Capacity :
44.70 ton/hr
Pressure :
2.576 atm
Temperature :
25oC
Storage Time :
7 days
Specification Design
Type :
Cylindrical Tank with Ellipsoidal Top

and Flat Bottom
Joint :
Double Welded Butt Joint
Material :
SA-283, Grade C
Volume :
949 m3
Diameter Tank :
7.48 m
Height Tank :
16.21 m
Wall Thickness :
0.97 inch
Head Thickness :
1.40 inch
15
16
2.1.1.2.Jatropha Oil Storage Tank T-101

Table 2.2. Specification Data of Storage Tank
Identification
Item :
Storage Tank
Item Number :
T-101
Name of Equipment :
Jatropha Oil Storage Tank
Item Amount :
10
Function :
Storing of Jatropha Oil

Composition
Crude Palm Oil:
100%
Operation Data
Capacity :
44.70 ton/hr
Pressure :
2.5645 atm
Temperature :
25oC
Storage Time :
7 days
Type :

and Flat Bottom
Joint :
Material :
SA-283, Grade C
Volume :
968 m3
Diameter Tank :
7.53 m
Height Tank :
16.32 m
Wall Thickness :
0.97 inch
Head Thickness :
1.40 inch
17
2.1.1.3.Nyamplung Oil Storage Tank T-101

Table 2.3 Specification Data of Storage Tank
Identification
Item :
Storage Tank
Item Number :
T-101
Name of Equipment :
Nyamplung Oil Storage Tank
Item Amount :
10
Function :
Storing of Nyamplung Oil

Composition
Crude Palm Oil:
100%
Operation Data
Capacity :
44.70 ton/hr
Pressure :
2.565 atm
Temperature :
25oC
Storage Time :
7 days
Type :

and Flat Bottom
Joint :
Material :
SA-283, Grade C
Volume :
961 m3
Diameter Tank :
7.51 m
Height Tank :
16.27 m
Wall Thickness :
0.97 inch
Head Thickness :
1.40 inch
18
2.1.1.4.Renewable Biodiesel Storage Tank T-102

Table. 2.4. Specification Data of Storage Tank
Identification
Item :
Storage Tank
Item Number :
T-102
Name of Equipment :
Renewable Biodiesel Storage Tank
Item Amount :
Function :
Storing of Renewable Biodiesel

Product
Composition
Crude Palm Oil:
100%
Operation Data
Capacity :
37,88 ton/hr
Pressure :
1.863 atm
Temperature :
25oC
Storage Time :
7 days
Type :

and Flat Bottom
Joint :
Material :
SA-283, Grade C
Volume :
640 m3
Diameter Tank :
3.83 m
Height Tank :
8.94 m
Wall Thickness :
0.64 inch
Head Thickness :
0.80 inch
19
2.1.1.5.Degumming Tank V-101

Table. 2.5. Specification Data of Degumming Tank
Identification
Item
Mixer Tank
Item number
V-101
Equipment name
Degumming Tank
Number of Unit
Function
Reacting phosporic acid with gum
Mode Operation
Continue
Composition (%)
Oil
11.39 kg/h
Phosporic Acid
27,005.35 kg/h
Operating condition
Capacity
45,560 kg/h
Pressure
168.2 kPa
Temperature
64.12 oC
Type
Ellipsoidal vertical tank
Material
Stainless Steel 316
Volume
59.33 m3
Diameter tank
3.19 m
Height tank
8.51 m
Height of cylinder
6.38 m
Height of ellipsoidal
1.06 m
Wall thickness
4.29 mm
Head thickness
4.29 mm
Spesification Design
20
Table. 2.5. Specification Data of Degumming Tank (Contd)
Stirrer Design
Utilities
Impeller type
Axial four blade
Number of impeller
Impeller diameter
1.06 m
Impeller level width
0.213 m
Impeller to bottom
1.06 m
Diameter stick
0.353 m
Diameter baffle
0.266 m
Impeller speed
2 rps
Power
0.114 kW/h
2.1.2. Reactor
2.1.2.1.Shift Converter Reactor R-102
Table. 2.6. Specification Data of Shift Converter Reactor
Identification
Item
Shift Converter
Item Number
R-102
Function:
To produce syngas from Natural Gas and Steam
Type of Reactor
Multitubular Packed Bed Reactor

Operating Condition
Pressure
bar
4,16
Temperature
427
Dimension
Reaction Rate
kgmol/kg cat.h
0,378978
Residence Time
min
10,73
Volume Reactor
m3
16,35581
Catalyst Weight
kg
0,57
No. of Tubes
Tube Diameter
cm
1,733461
Diameter
cm
173,3461
Height
6,933845
Thickness
cm
5,0225
21
2.1.2.2.Absorber Column V-103

Table. 2.7. Specification Data of Absorber Column
Identification
Name
Absorber Column
Item Number
V-103
Function
To separating H2 and CO2 from Shift

converter unit
Number of unit
Material
Carbon Steel SA-283 Grade C
Type
Packing
Packing Width and Height
Tower Diameter
12.60 m
Height of packing
20.51 m
Permissible tensile stress
950 kg/cm2
Mechanical Design
Working pressure
101300 N/m2
Design pressure,p
106365 N/m2
0.106365 N/mm2
Permissible stress
95 N/mm2
Joint Efficiency (j)
0.85
Corrosion allowance
3 mm
Outer diameter, Do
12.659 m
Input Amine. T
150 oC
Input CO2, T
75oC
Output Amine, T
80 oC
Output CO2, T
95oC
22
2.1.2.3.Steam Methane Reformer R-101

Table. 2.8. Specification Data of Steam Methane Reformer
Identification
Item
Item Number
R-101
Function:
To produce syngas from Natural Gas and

Steam
Type of Reactor
Multitubular Packed Bed Reactor

Operating Condition
Pressure
bar
4,5
Temperature
760
Dimension
Reaction Rate
kgmol/kg cat.h
4,08045
Residence Time
min
10,73
Volume Reactor
m3
57,39
Catalyst Weight
kg
523.23
No. of Tubes
Tube Diameter
cm
2,63
Diameter
cm
263,41
Height
10,54
Thickness
cm
5,0225
23
2.1.2.4.Hydrotreating Reactor Design

Table. 2.9. Specification Data of Hydrotreating Ractor Design
Unit:
CRV-100 Hydrotreating Reactor
Function:
To Produce Green Diesel

Triglycerides and Hydrogen
via
Operating Condition
Type of Reactor
Packed Bed Reactor
Pressure
bar
34.378
Temperature
300
Catalyst Volume
m3
8.33
Dimension
Residence Time
8.62
Volume
m3
10.42
Number of Tubes
414
Tube Diameter
in
1.968
Diameter
1.744
Height
4.366
Thickness
mm
Shell Thickness
mm
4.9
Material
Stainless Steel 316 SS
24
2.2.
Supporting Equipment
2.2.1. Heat Exchanger

2.2.1.1.Heat Exchanger E-101
Table. 2.10. Specification Data of Heat Exchanger E-101
Equipment Specification
Equipment Name
Heat Exchanger
Equipment Code
E-101
Increase the temperature of CPO
Function
before entering degumming process
Amount
Material
Carbon Steel
Type
Shell and Tube

Operating Data
Shell
Tube
kg/h
10000.00
4594.85
Temperature Inlet
155.00
25.00
Temperature Outlet
134.00
65.00
Operating Pressure
kPa
300.00
200.00
Flow Rate
Construction Data
LMTD
99.1969
UA
W/m C
5.7046
Duty
kW
122.1208
Heat Transfer Area
4.1637
Number of Passes
Shell ID
1-2
m
0.49
Tube Arrangement
Triangular
Number of Tubes
220
Tube Length
4.00
Tube OD
0.0191
Tube BWG
Tube Pitch
14.0000
m
0.0254
25

Equipment Name
Heat Exchanger
Equipment Code
E-102
Increase the temperature of CPO
Function
before entering bleaching process
Amount
Material
Carbon Steel
Type
Shell and Tube

Operating Data
Shell
Tube
kg/h
10000.00
5138.21
Temperature Inlet
155.00
64.23
Temperature Outlet
134.00
100.00
Operating Pressure
kPa
300.00
200.00
Flow Rate
Construction Data
LMTD
62.0925
UA
W/m C
32.0492
Duty
kW
122.1208
Heat Transfer Area
6.7828
Number of Passes
Shell ID
1-2
m
0.30
Tube Arrangement
Triangular
Number of Tubes
32
Tube Length
8.00
Tube OD
0.0191
Tube BWG
Tube Pitch
14.0000
m
0.0238
26

Equipment Name
Heat Exchanger
Equipment Code
E-107
Increase the temperature of oil before
Function
entering the reactor
Amount
Material
Type
Shell and Tube

Operating Data
Shell
Tube
kg/h
90000.00
41928.91
Temperature Inlet
400.00
102.44
Temperature Outlet
294.84
300.00
Operating Pressure
kPa
800.00
700.00
Flow Rate
Construction Data
LMTD
141.1967
UA ()
W/m C
20.2749
Duty ()
kW
5504.0209
Heat Transfer Area
165.4549
Number of Passes
Shell ID
1-2
m
0.49
Tube Arrangement
Triangular
Number of Tubes
264
Tube Length
12.00
Tube OD
0.0191
Tube BWG
Tube Pitch
14
m
0.0238
27
2.2.1.4. Heat Exchanger

Equipment Name
Heat Exchanger
Equipment Code
E-105
Decrease the temperature of shift
Function
product before entering absorption

process
Amount
Material
Carbon Steel
Type
Shell and Tube

Operating Data
Shell
Tube
kg/h
2135.00
36787.10
Temperature Inlet
430.00
25.00
Temperature Outlet
38.00
41.50
Operating Pressure
kPa
340.00
Construction Data
100.00
Flow Rate
LMTD
110.5275
UA ()
W/m C
743.3854
Duty ()
kW
727.5363
Heat Transfer Area
27.5850
Number of Passes
Shell ID
1-2
m
0.39
Tube Arrangement
Triangular
Number of Tubes
154
Tube Length
4.00
Tube OD
0.0191
Tube BWG
Tube Pitch
14.0000
m
0.0238
28
2.2.1.5.Heat Exchanger
Equipment Name
Heat Exchanger
Equipment Code
E-106
Decrease the temperature of
Function
methanator feed before entering

reactor
Amount
Material
Carbon Steel
Type
Shell and Tube

Operating Data
Shell
Tube
kg/h
18000.00
1845.43
Temperature Inlet
280.00
138.00
Temperature Outlet
262.75
260.00
Operating Pressure
kPa
340.00
Construction Data
100.00
Flow Rate
LMTD
57.2235
UA ()
W/m C
743.3854
Duty ()
kW
269.8557
Heat Transfer Area
18.4039
Number of Passes
Shell ID
1-2
m
0.30
Tube Arrangement
Triangular
Number of Tubes
90
Tube Length
4.00
Tube OD
0.0191
Tube BWG
Tube Pitch
14.0000
m
0.0238
29
2.2.1.6.Fired Heater E-103

Table. 2.15. Specification Data of Fired Heater E-103
Equipment Name
Fired Heater
Equipment Code
E-103
Increase the temperature of mixed
Function
feed before entering reformer process
Amount
Material
Stainless Steel
Type
Shell and Tube

Operating Data
Shell
Flow Rate
kg/h
2135.00
Temperature Inlet
140
Temperature Outlet
760
Operating Pressure
kPa
500
Radiant Section
Tube OD
in
8.626
Tube Thickness
in
0.05118
Number
of
Tubes
(Radiant)
Number of Tubes (Shield)
Combustion
(Fraction
40
12
0.15
Excess Air)
Firebox Diameter
ft
19.98
Flue Gas Temperature
2077,1
0.5087
Btu/hr
3.37 x 107
Emmisivity
Radiation Heat Transfer
30
Table. 2.15. Specification Data of Fired Heater E-103 (Contd)
Convection Section
Tube BWG
14.0000
Tube Pitch
0.0238
Wall Temperature
959
Number of Rows
Number of Tubes per Row
1472
LMTD
430.28
Btu/hr
3.37 x 107
Convection Heat Transfer
2.2.1.7.Fired Heater E-104

Table. 2.16. Specification Data of Fired Heater E-104
Equipment Name
Fired Heater
Equipment Code
E-104
Increase the temperature of shift feed
Function
before entering water-gas-shift

process
Amount
Material
Stainless Steel
Type
Shell and Tube

Operating Data
Shell
Flow Rate
kg/h
2135.00
Temperature Inlet
760
Temperature Outlet
1050
Operating Pressure
kPa
500
31
Table. 2.16. Specification Data of Fired Heater E-104 (Contd)
Radiant Section
Tube OD
in
8.626
Tube Thickness
in
0.05118
Number
of
Tubes
(Radiant)
Number of Tubes (Shield)
Combustion
40
12
(Fraction
0.15
Excess Air)
Firebox Diameter
ft
19.98
2077,1
0.5087
Btu/hr
3.37 x 107
Emmisivity
Radiation Heat Transfer
Convection Section
Tube BWG
8.626
Tube Pitch
0.5
Wall Temperature
959
Number of Rows
Number of Tubes per Row
1472
LMTD
430.28
Btu/hr
3.37 x 107
Convection Heat Transfer
32
2.2.2. Compressor
2.2.2.1.Compressor C-101
Table 2.17. Specification Data of Compressor C-101
Name
Feed Methane Compressor
Code
C-101
Function
To help methane flow to feed mixer
Total
Vendor
Ingersoll Rand
Model
UP5 22-7
Type
Rotary Screw Air Compressor
Material
Carbon Steel
Frequency (Hz)
50
Nominal Power (kW)
22
Flow (m3/min)
3.54
Length/Width/Height (cm)
128/92/105
Weight (kg)
540
Operation Data
Flow rate (m3/h)
2.672
Mass flow (kg/h)
800
Suction Pressure (kPa)
520
Discharge Pressure (kPa)
824
Temperature Inlet (oC)
20
Temperature Outlet (oC)
63.25
Power (kW)
21.6
33
2.2.2.2.Compressor C-102
Table 2.18. Specification Data of Compressor C-102
Name
Hydrogen Compressor
Code
C-102
Function
To help hydrogen flow from methanator

to hydrogenation reactor
Total
Vendor
Ingersoll Rand
Model
M300-2S
Type
Rotary Screw Air Compressor
Material
Carbon Steel
Frequency (Hz)
50
Nominal Power (kW)
300
Flow (m3/min)
60.2
Length/Width/Height (cm)
400/193/215
Weight (kg)
5540
Operation Data
Flow rate (m3/h)
5.391
Mass flow (kg/h)
1578
241
544.9
Temperature Inlet (oC)
280
Temperature Outlet (oC)
440.7
Power (kW)
290.2
34
2.2.3. Pump
2.2.3.1.Pump P-101
Table 2.19. Specification Data of Pump P-101
Name
Oil Feed Pump
Code
P-101
Function
To help oil to flow to heat exchanger then

mixer
Number of unit
Type
Centrifugal Pump
Operation Data
Liquid Volume Flow (m3/h)
49.96
Temperature (oC)
25
101.3
202.6
Head (ft)
54.714
NPSHA (ft)
0.111
Efficiency
0.75
Hydraulic Power (kW)
2.35
BHP (kW)
3.14
Spesific Speed (rpm)
1327.109
Jenis Impeller
Radial Vane
35
2.2.3.2.Pump P-102
Name
Refined Oil Pump
Code
P-102
Function
To help refined oil to flow to heat exchanger

then adsorption column
Number of unit
Type
Centrifugal Pump
Operation Data
50.76
Temperature (oC)
64.15
66.85
168.2
Head (ft)
54.724
NPSHA (ft)
0.111
Efficiency
0.75
2.39
BHP (kW)
3.19
1336.109
Jenis Impeller
Radial Vane
36
2.2.3.3.Pump P-103
Name
Refined Bleached Oil Pump
Code
P-103
Function
To help oil to flow to heat exchanger then

hydrogenation column
Number of unit
Type
Centrifugal Pump
Operation Data
49.96
Temperature (oC)
100
101.3
2758
Head (ft)
960.21
NPSHA (ft)
0.111
Efficiency
0.75
39.699
BHP (kW)
52.932
151.618
Jenis Impeller
Radial Vane
37
2.2.3.4.Pump P-104
Name
Green Diesel Pump
Code
P-104
Function
To help green diesel to flow
Number of unit
Type
Centrifugal Pump
Operation Data
34.01
Temperature (oC)
349.4
101.3
202.6
Head (ft)
54.714
NPSHA (ft)
0.111
Efficiency
0.75
1.6
BHP (kW)
2.138
1094.523
Jenis Impeller
Radial Vane
CONCLUSION
Each equipment is sized to suit the need of the process. The main aspects
considered are volume, height, diameter, and energy.
The main equipment that uses multiple units to accommodate the process are
storage tank, hydrotreating reactor and unit separator.
The supporting equipment that used are pump, compressor, heat exchanger
and cooler.
The complete main equipment and its intrumentation is depicted in P&ID
The controller needed to be arranged based on the risk of the variable that
being controlled.
38
REFERENCES
Branan. 2012. Rules of Thumb for Chemical Engineer. 5th edition. USA: Stephen
Hall.
Brownell, L.E & Edwin H.Y. 1959. Process Equipment Design: Vessel Design.
John Wiley & Sons.
Walas, S.M. 1990. Chemical Process Equipment. Selection and Design.
Massachusetts Institute of Technology: Butterworth-Heineman Series in Chemical
Engineering.
39
APPENDIX A
A.1. Storage Tank

In the process of producing renewable biodiesel, because of not continues
supplies, storage tank are needed to store the raw materials and product. We have
to determine the size and dimension based on the flow rate of each material that
goes in and out the storage tanks.
We use three different types of storage tank to store three different type
crude oil for process that is crude palm oil, jatropha oil and nyamplung oil.
Moreover, we need storage tank for renewable diesel produced.
Material Selection
The raw material storage tanks form are cylindrical tanks because a
cylinder shape has a great structural strength and easier to fabricate. The top end
of storage tanks use ellipsoidal shape, while the bottom end is flat and stand
directly upon the ground. We use carbon steel as the material for storage tanks.
Table A.1. List of Materials that Selected for Each Storage Tank
No.
Storage Tank
Material Specification
1.
SA-283, Grade C
2.
SA-283, Grade C
3.
SA-283, Grade C
4.
Renewable Biodiesel Storage Tank SA-283, Grade C
A.1.1. Volume of Storage Tank

For sizing the storage tanks, we estimate that the capacity of crude oil
storage tanks are able to fulfill the needs of material for a week depending on the
supply attendants. So, we determine one week as a batch.
40
41

Crude Palm Oil mass flow rate is 44700 kg/hour. So the storage tanks have
to store 7,509,600 kg/batch crude palm oil. The calculation of storage tanks
volume needed to store :
kg
7,509,600 week
m3
= =
= 8540.43
kg
week
879.3 3
m
To store the crude palm oil, we will use 10 storage tank. so, the crude palm oil
volume per tank is :
=
m3
3
week = 854.04 m
10
week
8,540.43
To calculate the total volume of storage tanks, safety factor has to be

considered. Safety factor of the tank is 10% of the total volume. This is based
on literature saying that for tanks which volume is above 3,8 m3, only 90%
volume is filled.
=
m3
3
week = 948.94 m
0.9
week
854.04

Jatropha Oil mass flow rate is 44700 kg/hour. So the storage tanks have to
store 7,509,600 kg/batch jatropha oil. The calculation of storage tanks volume
needed to store :
kg
7,509,600 week
m3
= =
= 8711.83
kg
week
862 3
m
To store the jatropha oil, we will use 10 storage tank. so, the jatropha oil
=
m3
3
week = 871.18 m
10
week
8,711.83

42
volume is filled.
=
m3
3
week = 967.98 m
0.9
week
871.18

Nyamplung Oil mass flow rate is 44700 kg/hour. So the storage tanks have
to store 7,509,600 kg/batch nyamplung oil. The calculation of storage tanks

kg
7,509,600 week
m3
= =
= 8641.66
kg
week
869 3
m
To store the nyamplung oil, we will use 10 storage tank. so, the nyamplung oil
=
m3
3
week = 864.17 m
10
week
8,641.66

volume is filled.
=
m3
3
week = 960.18 m
0.9
week
864.17

Renewable biodiesel produced have mass flow rate is 37880 kg/hour. For,
renewable biodiesel we determine 1 day for a batch. So the storage tanks have
to store 909,120 kg/batch renewable biodiesel. The calculation of storage tanks
kg
909,120 week
m3
= =
= 1150.78
kg
week
790 3
m
43
To store the renewable biodiesel product, we will use 2 storage tank. so, the
renewable biodiesel volume per tank is :
=
m3
3
week = 575.39 m
2
week
1150.78

volume is filled.
=
m3
3
week = 639.32 m
0.9
week
575.39
A.1.2. Diameter and Height of Storage Tank

Based on rule of thumb, the ratio of height and diameter of tank for
cylindrical tanks is 2:1. Therefore, H = 2D. The volume of cylinder can be
calculated as :
1
1
= 2 = 3
4
2
The shape of tanks top cover is ellipsoidal and the bottom cover is flat, with
major axis ratio of 2:1. The volume of heads (cover and pedestal) is
3
24
. The tank
volume is:
3 3 133
=
+
=
2
24
24
44
Figure A.1. Types of head of storage tank

(Source: Perrys Chemical Engineering Handbook, 1999)
We use the equation of cylinder tank volume to determine the diameter of

cylinder.
3
24
13
The height of tank is an addition of cylinder and head of tank height. The cylinder
height is 2D as stated before. The head height is D/6.

Using the equation, the diameter of tank is :
3
3 2 8540.43
24
=
= 7.48
13
13
=
The cyclinder height is:
= 2 = 2 7.48 = 14.96
The head height is:
=
7.48
=
= 1.247
6
6
The total height is:

= + = 16.207
45

3 2 8711.83
24
=
= 7.53
13
13
=
= 2 = 2 7.53 = 15.06
The head height is:
=
7.53
=
= 1.255
6
6

= + = 16.315

3 2 8641.66
24
=
= 7.51
13
13
=
= 2 = 2 7.51 = 15.02
The head height is:
=
7.51
=
= 1.252
6
6

= + = 16.27

3
3 2 1150.78
24
=
= 3.83
13
13
=
= 2 = 2 3.83 = 7.66
The head height is:
=
7.66
=
= 1.27
6
6

46
= + = 8.937
A.1.3. Design Pressure

Pressure design of storage tank determines the type of storage tank used.
Height of fluid in the tank is calculated as follows:
=
The pressure of the tank is:

=
In calculating the design pressure, we assuming that the pressure safety factor is
15%.
= 115% (1 + )
Crude Palm Oil

=
854.04 16.207
= 14.59
948.94
= 879.3 9,81 14.59 = 1.24

= 115% (1 + 1.24) = 2.576
Jatropha Oil
=
871.18 16.315
= 14.68
967.98
= 862 9,81 14.68 = 1.23

= 115% (1 + 1.23) = 2.5645
Nyamplung Oil
=
864.17 16.27
= 14.64
960.18
= 869 9,81 14.64 = 1.23

= 115% (1 + 1.23) = 2.5645
Renewable Biodiesel
=
575.39 8.937
= 8.04
639.32
= 790 9,81 8.04 = 0.62

= 115% (1 + 0.62) = 1.863
47
A.1.4. Wall and Head Thickness

To calculate the wall and head thickness, there are several data we needs
to be determined such as corrosion factor, maximum allowable stress, joint
efficiency, and equipment age. These data determined based on the material
selected for each storage tank. Carbon steel has a bigger corrosion factor than
stainless steel, since carbon steel is more prone to corrosion. Corrosion factors of
stainless steel are also different depending on the grade of stainless steel.
Calculation of storage tanks wall thickness is based on circumferential
stress (longitudinal joint). We can use the following formula (Towler, 1990):
=
+
0.6
While head thickness of storage tank could be calculated with the following
formula:
=

+
2 0.2
where,
t = material thickness
P = pressure gauge
R= shell radius
Di= shell inner diameter
K = ellipsoidal formula factor
S = maximum allowable stress
E = joint efficiency = 0.85
C = corrosion factor = 0.015
A = planned equipment age = 30 year
Crude Palm Oil

=
37.86 147.24
+ 0.015 30 = 0.969
12,650 0.85 0.6 37.86
37.86 294.48 1.833

+ 0.015 30 = 1.40
2 12.650 0.85 0.2 37.86
48
Jatropha Oil
=
37.69 148.23
+ 0.015 30 = 0.971
12,650 0.85 0.6 37.69
=
37.69 296.46 1.833

+ 0.015 30
2 12.650 0.85 0.2 37.69
= 1.40
Nyamplung Oil
=
37.69 147.83
+ 0.015 30 = 0.969
12,650 0.85 0.6 37.69
=
37.69 295.66 1.833

+ 0.015 30
2 12,650 0.85 0.2 37.69
= 1.40
Renewable Biodiesel
=
27.38 75.39
+ 0.015 30 = 0.642
12,650 0.85 0.6 27.38
=
27.38 150.78 1.833

+ 0.015 30
2 12,650 0.85 0.2 27.38
= 0.802
A.2. Degumming Tank
Volume
Flow rate into the tank 46560 kg/h, to gain the volume we could divide the mass
rate with total density.
kg
46560 h
= =
= 53.39 3
872 3
So, the volume tank is 53.39 m3. Base on literature if volume above 3,8
3volume of each tank only filled 90%. The headspace is 10% thus the working
volume which calculated before is 90%. The use of headspace is a safety unit for
sudden increment volume.
=
53.39
= 59.33 3
0.9
Diameter and height of mixing tank

49
Comparison of high tank with tank diameter (Hs: D) = 2:1. The volume will be
represented by using ellipsoidal shape, the diameter and height of tank could be
calculated.
1
1
= 2 = 23
4
4
Cover and pedestal tank of ellipsoidal shape with major to minor axis ratio of 2:1,
so high head is h=16 (Walas, 1990). Volume of 2 cover is:
1
1
1
1
= 2 2 = 2 2 =
3
4
4
6
12
Tank volume is:
1
1
7
= + = 23 + 3 =
3
4
12
12
Tank diameter is:
3 12 59.33
3 12
=
=
= 3.19
7
7
Height of cylinder is Hs= 2D = 6,38 m

1
Height of cover ellipsoidal is Hh = = 1.06

6
Height tank is Ht = Hs + (2xHh) = 6.38 + (2x1.06) = 8.51
Pressure Design
Height of fluid in the tank

=

53.39 8.51
=
= 7.66
59.33
Pressure
= = 872 9.8 7.66 = 0.646 = 9.494
Thick of Wall and Head
Material choosen is stainless steel because condition of solution must be at pH

4,5. Avoiding corrosion, stainless steel used for this case
Thick of wall
Assumption of corrosion factor is (C) = 0,0042 in/year
Allowable working stress is (S) = 16.250 lb/in2 (Walas, 1990)
Assumptions connection efficiency is (E) = 0,85
50
Planned of tool age (A) = 30 years

Thick of cylinder is
=
=
+
0.6
9.494 62.99
+ 0.0042 30 = 0.169 = 4.29
16.250 0.85 (0.6 9.494)
Thick wall head (cap)

Assumption of corrosion factor is (C) = 0,0042 in/year
Allowable working stress is (S) = 16.250 lb/in2 (Walas, 1990)
Assumptions connection efficiency is (E) = 0,85
Planned of tool age (A) = 30 years
Thick of wall head is
=
=
+
0.2
9.494 62.99
+ 0.0042 30 = 0.169 = 4.29
16.250 0.85 (0.2 9.494)
Impeller
Type: axial four blade, this kind of impeller is chosen based on literature, if
viscosity < 5000 cp propeller is common used. This solution has 79 cp
Assumption of rotation speed (N): 120 rpm = 2 rps
Assumption of 80% efficiency motors
Mixer is designed with the following standards: (Walas, 1988)
Da : Dt = 1 : 3
Dt : J = 12
W : Da = 1 : 5
where:
Da : Db = 6 : 1
Da = stirrer diameter
C : Dt = 1 : 3
Dt = the diameter of the tank
Db = stick diameter
W = width of leaf stirrer
C = the distance from bottom of the tank
Reynold number is
=
1
Stirrer diameter is = = 3.19 = 1.06

51
Stirrer leaf widhth is = = 1.06 = 0.213

5
Strirrer height from the bottom = = 3.19 = 1.06

1
Diameter of stick = = = 1.06 = 0.353

Diameter baffle =
1
12
1
12
3.19 = 0.266
Where
Da = diameter impeller (ft)
N = rotation speed (rps)
= density (lb/ft3)
= viscosity (lb/(ft.s))
=
0.353 2 4.49
= 63.40
0.05
Figure A.1. Power Number

(Source: Walas, 1990)
Then, the power is

= 103 ( 3 5 )
= 103 (3 4.49 23 1.06) = 0.114 /
52
APPENDIX B
B.1. Hydrotreating Reactor
Fixed-Bed Reactors (FBRs) are the most commonly used reactor systems
in commercial hydrotreating operations. They are easy and simple to operate.
However, the simplicity of operation limits their use to the HDS of light feeds.
For example, in case of naphtha hydrodesulfurization, the reaction is carried out in
two-phases (gas-solid) fixed-bed reactors since at the reaction conditions the
naphtha is completely vaporized. On the contrary, for heavier feeds three phases
are commonly found: hydrogen, a liquid-gas mixture of the partially vaporized
feed, and the solid catalyst. The latter system is called a trickle-bed reactor (TBR),
which is a reactor in which a liquid phase and a gas phase flow co-currently
downward through a fixed bed of catalyst particles while reactions take place.The
gas is the continuous phase, and the liquid is the disperse phase (Quann et al.,
1988). A schematic representation of the phenomena occurring in a TBR based on
three-film theory is presented in Figure 3.3 (Korsten and Hoffmann, 1996;
Bhaskar et al., 2004). It is common to assume that mass transfer resistance in the
gas film can be neglected and that no reaction occurs in the gas phase, so that for
the reactions to occur, the hydrogen has to be transferred from the gas phase to the
liquid phase, whose concentration is in equilibrium with the bulk partial pressure
and then adsorbed onto the catalyst surface to react with other reactants. The gas
reaction products are then transported to the gas phase, while the main liquid
hydrotreated reaction product is transported to the liquid phase.
In Hydrotreating Reactor there will be two main reaction which are
reaction of tryglycerides and H2 also reaction between tryglicerides and H2, those
reaction can be combine into one that will produce the green diesel itself. The
volume of reactor is equal to the amount of catalyst used. It is because common
reactor for hydrotreating reactor is fixed bed reactor. In this process, catalyst used
is Nickel-Molybdenum alumina supported.
The material for the hydrotreating reactor was chosen to be Stainless Steel
316 SS. Due to the temperature conditions at about 250C, metal dusting not
comes into consideration. This leads to a construction material of carbon steel,
which is the least expensive material (Peters, 2003). However, since the process
53
streams at this stage produce some amount of CO2, sweet corrosion is believed to
be a problem. That is why we chose Stainless Steel as a material for hydrotreating
reactor.
Figure B.1. Fixed Bed Reactor

Source: Handbook of Petroleum Processing
1.
Hydrotreating Reactor (CRV-100)
Catalyst Weight
1
2 57 104 6 + 21 2 317 36 + 3 2 + 62 + 23 8 , 1 = 1
1
+
k1 = 0.008554 m3 kmol-1 s-1
Assumption:
Rate law of these reaction follow one order rate reaction in Packed Bed
Reactor. Equation for rate law in Packed Bed Reactor is

=
0
Where: = /
54
Equation for one order rate reaction:

=
So
/
=
0
The derivation of equation
/
=
= (1 )
= ( )
= (1 + )
(1 )
=

(1 + )

( )
=

(1 + )

So,
(1 )
( )
=
.
.
(1 + ) (1 + )
(1 )( )
=
2
[ (1 + )
]

55
This equation will be used to determine how much catalyst needed for each
reaction.
Molar flow Tryglycerides :
= 144 /
Molar flow Hidrogen :
= 570 /
144
=
= 0.2017 /
+ 144 + 570
= yA0 . = (0.2017)(3 + 1 1 1) = 0.4034

Feed volume flow :
= 4,351 3
Bulk density, = 3200 /3
Then we use polymath to determine conversion vs catalyst weight:
Figure B.2. Polymath Programming
56
Figure B.3. Polymath Programming Result
Figure B.4. Polymath Programming Graph
57
As the result of the polymath, the higher catalyst weight, the higher of
conversion. Therefore, we choose the conversion is 18% because the high
conversion needs a lot of catalyst. As we know that catalyst is expensive and the
lifetime is just about one year. For example, for 85% conversion needs 500,000 kg
catalyst, that is too much. So we just need 18% conversion plus we will recycle
the methane that is not converted into the syngas. At 18% conversion, we need
catalyst 37,000 kg.
Dimension of Reactor
Volume of catalyst that fills the reactor can be calculated as follow:
=
30,000 kg
=
= 8.33 3
3600 kg/m3
Then we assume that the catalyst fills 80% of reactor volume. So we can estimate
the reactor volume needed as follow:
=
100
8.33 3 = 10.42 3
80
Assume that L:D = 2.5:1 (Rule of Thumbs)

1 2
= 10.42 3
4
1
2 (2.5) = 10.42 3
4
3 = 16.672 3
= 1.744
The length is
= 2 = 4.36
Retention Time
10.42 3
3600
=
=
= 8.62
0 4,351 m3 /h
1
Wall thickness can be obtained by using method in Wallas.
58
Thickness (t) =
(P + ) x R
+ CA (Corrosion Allowance)
SxE 0,6P
Head Thickness (t) =
PxD
+ CA
2SxE 0.2(P)
With : P = operation pressure (Psig)

Pc = pressure because of catalyst weight
R = reactor radius (inch)
E = Joint efficiency, it assumed that the joint effieciency is 0.8
S = allowable stress
Due to the high pressures and temperatures in the primary reformer tubes,
a 25% chromium-20% nickel alloy is the preferred tube material. The
allowable stress is very dependent on the material that used for the vessel.
From the Perrys Chemical engineer handbook the allowable stress for the
conrete is 9.8 Mpa or 145,054 psi.
The pressure because of catalyst is :
=
Thickness (t) =
(30,000)(9.8)
=
=
= 123,287 = 17.87
0.25(1.744)2
(145 + 17.87) 34.33

+ 0.15 = 0.198
(145,054)(0.8) (0.6)(145 + 17.87)
= 5
Head Thickness (t) =
(145 + 4.1) x 68.66

+ 0.15 = 0.193
2x145,054x0.8 + 1.8x145
= 4.9
Tubes calculation
The maximum conventional heat flux through primary reformer tube walls
is approximately 5,921.176 kcal/ ft2hr with industry averages. Using this value
and the heat duty through the reformer calculated by Aspen, the primary reformer
tube size was calculated as follows:
=
=
8.895 107
= 15,174.35 2
5,921.176 2
Then, number of tubes needed is
59
= 413.4 414
Height of tube
Based on rule of thumbs, height of reactor is 1.25 times of tubes, so
=
1
1
=
4.36 = 3.488
1.25
1.25
Pinch tube selection and diameter of tubes

We choose square pinch of tubes because it is more easy to be cleaned.
The arrangement is at the picture below
Where :
= = 1.5
As we know, diameter of reactor is 1.744 m2, then the length of square is allowing
at phytagoras rule :
2 + 2 = 2
2 2 = 1.7442
2 =
=
1.7442
2
1.7442
= 1.233
2
Assuming the cover of the shell size is 10 cm = 0.01 m

Then tube line is
= 1.233 2(0.01) = 1.213
60
As we know that the number of tubes are 414, so

=
414 = (
1.213
1.213
+ 1) (
+ 1)
1.213 2
414 = (
+ )
1.213 + 2
414 = (
)
414 =
1.213 +
20.347 = 1.213 +
19.347 = 1.213
= 0.0627
So, we can calculate diameter of tubes
=
0.0627
=
1.25
1.25
= 0.05 = 1.968
B.2. Shift Converter Reactor R-102

Water Gas Shift (WGS) is reversible reaction. So both the forward and
reverse reaction is with thermodynamic equilibrium. The true dimensionless
equilibrium constant can predict from Gibbs free energy as denoted by the
following reaction.
=
All fixed Bed catalytic reactor assumed to behave like ideal plug flow reactor.
Equation used for the design or sizing of fixed bed reactor is:
61
Figure B.5. Equation used for the design or sizing of fixed bed reactor
Here is process condition, mole fraction, and molar flow of feed of water gas shift
reactor from Aspen Hysys simulation.
187,5
Feed Flowrate :
kgmol/h
0,052083 kgmol/s
8,314
4,16
bar
1050
Species Fraksi mol P parsial K

CO2
0,055
0,2288
H2O
0,2237
0,930592 0,908513
H2
0,5735
2,38576
CO
0,1178
0,490048 0,252871
9,59E-05
= 1 + + 2 2 + 2 2 +
2 2
2
= 1 + (0,252871 0,490048) + (9,59E 05 2,38576) + (0 0,2288)

+
(0,908513 0,930592)
= 1,4785
2,38576
Constant rate law
kj = 34.21
Rate Law
62
R1= 0,3799 kgmol/kg cat. S

The Calculation for sizing shift converter reformer is using Microsoft Excel and
the result is shown in the sizing table
Table B.1. Sizing Shift Converter Reformer
weight of catalyst
0,57
Cat Vol
13,90244 m3
Vol Reactor
16,35581 m3
A Reaktor total
0,016889 ft2
Tube
D Reaktor
kg cat
100
1,733461 m
173,3461 cm
6,933845 m
D tube
1,733461 cm
1,06
Residence time
in
0,018924 h
69,14921 s
1,152487 min
thickness
1,977392 in
5,0225
thicknes head
cm
3,829613 in
9,6478
cm
TUBE THICKNESS 0,129954 in
B.3. Absorber Calculation

The calculation manually doing which it will be suited to the rule of thumb.
Firstly, should do design the absorber by know the composition of incoming
gas from model simulation we have done.
Basis: 1 hour of operation
63
Table B.2. Composition of the Incoming Gas
Component
Kmols
Fraction Molecular Weight
Methane
84.72
0.03
16
Hydrogen 1799.7352 0.6373
2
H2O
451.5576
0.1599
18
CO
152.496
0.054
28
CO2
335.4912
0.1188
44
TOTAL
2824
1
1. The average of molecular weight of the incoming gas

1 1 + 2 2 + 3 3 + 4 4
=
MW = 6422.906 kg/kmols
2. Density of gas mixture

Given that Tin= 38oC, so the density of gas mixture will be calculated
by following:
gas = 251.7014855 Kg/m3

3. Amine and gas Flowrate Calculation
CO2 absorbed = 335.4912 kmoles = 14761.6128 kgs
Total CO2 absorbed by amine = 1003.2 Kgs
Based on the calculation:
0.407667 W needs 13758.41 Kgs
Then The value of W = 9.37477 Kgs/s
Amine flowrate (A ) = 9.37477 Kgs/s
Densitas (A) = 1040 Kg/m3
Gas Flowrate (G) = 5038.413 Kgs/s
Densitas (G) = 251.7015 Kg/m3
4. Column Selection
In this case of absorber, there are two kind of column, tray column
and packing column. We have choosen packing column for the reason:
64
The gas material which enter to the absorber column is a

corrosive gas.
From economic side, packing column is cheaper than tray column.
The pressure drop result of packing column is lower than tray

column. The contact between gas and liquid in packing column is
more perfect due to the higher area contact.
5. Material Selection
Then choose the following packing as given in the Richardson and
Coulson as seen in the Figure below
Figure B.6. Design for Various Packing
Based the table, the material selected is Racing Rings Ceramic,

because if it compared to the other material, Rashing Rings ceramic is
the best on because of it has corrosif endurance, it will be good to the
corrosif liquid.
Material
= 3 Ceramic. Rasching Rings
Nominal Size
= 76 mm
Bulk Density
= 561 kg/m3
Surface area
= 68 m2/m3
Packing factor = 65 m-1

Voidage
= 75%
65
6. Diameter Calculation
The calculationof it is based on Richardson and Coulson, volume 6.
Firstly we have to calculate below
0.5
= ( ) {( )}
FLV = 0.0009154
Then we have to plot the result to the flooding line graph to get the value
K4. From the plot of K4 Vs FLV. We get K4 at the flooding line 3.2
Figure B.7. Flooding Line Graph
G*= 49.913 Kg/m2s

Designing for a pressure drop of 42 mm water per m of packing. We
Have
K4 = 2.1
% Loading = 81.00925873%
G* = 40.4342758 Kg/m2s
Cross Section Area required

66
A = 124.60 2
Diameter required
D = 12.6 m
Hence the diameter which is calculated from this approach is 12.6 meter
7. Diameter Calculation
The number stage of packing column absorbtion tower can be
calculated by using the graph below from Richard and Coulson. From the
graph, we get the number of stage is about two stages.
8. Height of Packing Calculation
Volumetric Flowrate entering gas
= 20.017 m3/s
Gas Velocity at the bottom of tower
= 0.16 m/s
Mass Flowrate at the top of tower = 4439.84 Kgs/s
Volumetric Flowrate at the top of tower
= 17.64 m3/s
Gas velocity at the top of tower
= 0.14 m s
67
Liquid Flow
= 0.075 Kgs/ m2/s
Then We have to calculate the co-relation by the formula below
KG = 0.136
Area of Packing/ft height
A = 8597.9151 m
Height of Packing require
H = 20.51 m
9. Height of Packing Calculation
Inner Diameter = 12.60 meter
Height of pack req = 20.51 meter
Skirt Height = 2 meter
Density of mat column = 7700 kg/m3
Wind pressure = 130 kg/m2
Material Selection
Carbon Steel
Permissible tensile stress (f) = 950 kg/cm2
Thickness of shell = 3.008 mm
68
B.4. Steam Methane Reformer R-101

Before calculating the volume of the reactor, we should calculate the rate of
reaction by the kinetic equation of Steam Methane Reforming below (Datta, et al.
2000)
3
2
4 2 (1
)
4 2
=

(2 2 ) (1 + 2 2 )
2
The rate equations that were obtained based on the rate determining steps for
CH4 + H2O = 3H2 + CO. The rate of reaction use a kgmol/kg cat. S unit ( Hoang,
2005).
Where
= 1 + + 2 2 + 2 2 +
2 2
2
Qr = 4,561
With parameter kinetic, equilibrium constant and adsorption constant below.
3
1
2
1
1 = 2.5 ( 4 2
) 2
1
Reaction rate is rate = 4,08045 kgmol/kgcat.h

With the molar flow of 2135 kgmol/h, we can calculate the total weight of the
catalyst below
Weight of catalyst = 2135/ 4,08045 = 523.23 kg
By using bulk density of Ni/Mo-Al2O4 catalyst at 0.041 g/ml, we can
calculate the catalyst volume. Then, the volume of the reactor is (with 80% of
catalyst volume). After that, we calculate the number of tubes needed. Then,
calculate number of tubes needed. After that, we calculate the diameter and length
of reactor by 1:4 ratio. Then, we calculate the diameter of each tube. From the
literature we read, the construction materials used is a 25% chromium-20% nickel
alloy is preferred tube material (Low-alloy steels SA-203 grade D). The thickness
of reactor can be calculated by using a thickness calculation for tall vertical
vessel. The corrosion allowance is 1/32.
69
The value of S can be found onTable 13.1, Process Equipment Design by

Brownell. A welded-joint efficiency (E) of 0.85 is specified by the ASME code.
The material we used for our reactor is Low-alloy steels SA 203 grade D. After
that, we can use a torispherical heads for our reactor design and calculate the head
thickness.
The Calculation for sizing steam methane reformer is using Microsoft Excel and
the result is shown in the sizing table
Table B.2. Steam Methane Reformer
weight of catalyst
kg cat
Cat Vol
48,780488
m3
Vol Reactor
57,388809
m3
A Reaktor total
0,03
ft2
Tube
D Reaktor
100
2,6341016
263,41016
cm
10,536406
D tube
2,6341016
cm
1,06
in
0,0287566
105,0765
1,751275
min
1,9773921
in
5,0225
cm
3,829613
in
9,6478
cm
Residence time
thickness
thicknes head
TUBE THICKNESS 0,1299539
in
70
APPENDIX C
Heat Exchanger Design Procedure
Step 1. Obtain the required thermos-physical properties of hot and cold
fluids at the caloric temperature or arithmetic mean temperature. Calculate
these properties at the caloric temperature if the variation of viscosity
with temperature is large. The detailed calculation procedure of caloric
temperature available is in reference.
r=
Tc Tho Tci
=
Th Thi Tco
Step 2. Perform energy balance and find out the heat duty (Q) of the
exchanger
Q c = Q h = mc Cc (t 2 t1 ) = mh Ch (T2 T1 )
Step 3. Assume a reasonable value of overall heat transfer coefficient
(Uo,assm). The value of Uo,assm with respect to the process hot and cold
fluids.
71
Figure C.1. Shell and Tube Overall Coefficient
Figure C.2. Air Cooled Exchangers and Immersed Oil Overall Coefficient
Step 4. Decide tentative number of shell and tube passes (np). Determine
the LMTD and the correction factor FT. FT normally should be greater
than 0.75 for the steady operation of the exchangers. Otherwise it is
required to increase the number of passes to obtain higher FT values.
TLMTD =
(Thi Tco ) (Tho Tci )

(T Tco )
ln hi
(Tho Tci )
Step 5. Calculate heat transfer area (A) required:

A=
Q
U0,assm LMTD FT
Step 6. Select tube material, decide the tube diameter (ID = di, OD =
d0), its wall thickness (in terms of BWG or SWG) and tube length (L).
Calculate the number of tubes (nt) required to provide the heat transfer area
(A).
nt =
A
do L
Calculate tube side fluid velocity

u=
4 m(np nt )
di 2
72
Re =
4 m(np nt )
104
di
Step 7. Decide type of shell and tube exchanger (fixed tubesheet, U-tube
etc.). Select the tube pitch (PT), determine inside shell diameter (Ds)
that
can
accommodate
the calculated number of tubes (nt). Use the
standard tube counts table for this purpose.
Figure C.3. Coomon Tube Layouts
Figure C.4. Heat exchangers tube-layouts
Step 8. Assign fluid to shell side or tube side. Select the type of baffle
(segmental, doughnut etc.), its size (i.e. percentage cut, 25% baffles are
widely used), spacing (B) and number. The baffle spacing is usually chosen
to be within 0.2 Ds to Ds.
73
Figure C.5. Type of Heat Exchanger Baffles
Step 9. Determine the tube side film heat transfer coefficient (hi) using the
suitable form of Sieder-Tate equation in laminar and turbulent flow regimes.
Estimate the shell-side film heat transfer coefficient (ho) from:
ho D c 13 0.14
( )
( )
jH =
k
And find the hio from:

hio = hi
ID
OD
Step 10. Calculate overall heat transfer coefficient (Uo,cal)

UC =
hio ho
hio + ho
With the design overall coefficient is

UD =
Q
A T
The dirt factor is calculated from:

Rd =
UC UD
UC UD
74
Step 11. Pressure drop calculation will be the tube side pressure drop (PT)
and the shell side pressure drop (PS). Pressure drop in the straight section
of the tube (frictional loss) (Pt) and return (Pn) due to change of
direction of fluid. So the total of each pressure drop: PT = Pt + Pn
P =
fG2 De (N + 1)
5,22 1010 De st
If the tube-side pressure drop exceeds the allowable pressure drop for the
process system,
we can decrease the number of tube passes or increase number of tubes per
pass.
P =
LfG2
5,22 1010 Ds st
If the shell-side pressure drop exceeds the allowable pressure drop

P =
LfG2
5,22 1010 Ds st
The procedure is the same for all heat exchanger, the calculation is using
Microsoft Excel and the result is shown in the sizing table. Below will be shown
the calculation for one heat exchanger.
Material Selection for Heat Exchanger

For heat exchanger using low pressure and medium pressure steam as
heating fluid , we used carbon steel as material because temperature of process is
not too high. Moreover, Fluid that we used is Oil that cant cause corrosion. We
choose Carbon Steel SA-283 with Grade C because this material is commonly
used. Carbon steel is used because highly durable, low cost and easy to
manufactured.
Due to the high temperature like fired heater used for heating feed to steam
methane reformer. Therefore, carbon steels cannot be used as pipe material
because this material cannot be used in high temperature conditions. Carbon steel
can be used as material for temperature conditions bellow 1400oF. Materials that
can be used as wall material which can also be used in high temperature
conditions are stainless steel. Therefore, the proper material for low pH and high
75
temperature is stainless steel (SS)316L. Grade 316 is the standard molybdenum

bearing grade, second importance to 304 amongst the austenitic stainless steel.
The molybdenum gives 316 better overall corrosion resistant properties than grade
304 particular resist to pitting and crevice corrosion in chlorine environment.
C.1. Heat Exchanger E-101
Heat Balance
CPO,
25+65
2
= 450 , c = 2200 J/kg-K

Q = m.c.T
= (44,700 kg/h) (2200 J/kg-K) (338-298) K
= 3,933,600,000 J/h
Steam,
W =
152 + 145
2
= 148.50 ,
c = 4180 J/kg-K
3,933,600,000 J/h
(4180 J/kgK)(428407) K
= 44812,03 kg/h
Determine the LMTD
T1 = 155oC
t2 = 65oC
T2 = 134oC
t1 = 25oC
LMTD =
R=
S=
(1 2 )(2 1 )
(1 2 )
(2 1 )
(2 1 )
(1 1 )

ln( 1 2 )
2 1
(155134)
=
(6525)
(6525)
(15525)
(15565)(13425)
(15565)
ln((13425))
= 99.2oC
= 0.525
= 0.308
Determine the temperature difference

76
It could be obtained from the graph that shows temperature correction factor. The
available existing graphs are for two shell passes, four, multiple of four tube
passes, etc.
The example graph that is used in this case could be seen below :
Figure C.6. Temperature Correction Factor : two shell passes ; four or multiple passes
(Source: Kern)
The temperature correction factor (FT) that is obtained from Figure C.6 is 1.
The properties of tube and pitch could be obtained from Table and Table
From the following table could be obtained the exact value of tube outer diameter,
square pitch length, shell inner diameter, amount of passes, and the last one in
amount of tubes. Actually there is no calculation done before choosing the value
of tube and pitch properties, but the chosen one should logically makes sense.
In this case, the selected tube OD is 0.75 in = 0.019m
Square pitch length = 1 in = 0.0254 m
Shell inner diameter = 19.25 in = 0.49 m
Amount of passes = 2
So that the amount of tubes is 220
77
Figure C.7. Tube Sheet Layouts (square pitch)

(Source: Kern)
Besides that, the other tubes properties could be obtained from the following
78
Figure C.8. HE Layouts

(Source: Kern)
The table above is used by using the previous selected tube OD. As the tube OD is
considered to be then the BWG value could be obtained. The BWG value is
chosen randomly, so that the following properties that are in the same row could
be obtained.
79
The BWG value = 14

The wall thickness = 0.083 in = 0.0021m
Tube inner diameter = 0.584 in= 0.015m
Flow area per tube = 0.268 in2 = 1.73 x 10-4 m2
Surface/lin (outside) = 0.1963 ft2 = 0.018 m2
Surface/lin (inside) = 0.1529 ft2 = 0.014 m2
Then back to hysys. Heat Exchanger E-106 is the one that is used to show the
general Heat Exchanger sizing calculation. All the datas below are obtained from
the composition and properties part in Hysys.
Table C.1. Composition Properties
Hot (shell)
W (flowrate)
T1
T2
T average
SG
c
Q
Steam
2.7 kg/s
155 oC
134 oC
144.5 oC
1
1.85 kJ/kg oC
1651
Cold (tube)
W
t1
t2
T average
SG
c
Q
CPO
13.16 kg/s
25 oC
65 oC
45 oC
0.88
2.2 kJ/kg oC
1048
(Source: Authors Documantation)
SG or specific gravity value is obtained by dividing the mass density of the stream
which is in kg/m3. So that obtaining the specific gravity is by dividing it with the
basis 1000 kg/m3 (water).
c is heat capacity. It is obtained from the properties parts in Hysys, which is heat
capacity (kJ/kgmol oC). Then the Q value could be obtained using the equation
below :
Q = W x c x (TShell in - TShell out) for shell
= 2.7 kg/s x 1.85 kJ/kgoC x (155 oC - 134 oC)
= 104.895 kJ/s
Q = W x c x (TTube out TTube in) for shell
= 13.16 kg/s x 2.2 kJ/kgmol oC x (65 oC 25 oC)
80
= 1158,08 kJ/s
Determine the flow area
Shell flow area = [ Shell ID x (tube pitch tube OD) x baffle space ] / (144 x
tube pitch )
In order to make the calculation easier, then all of the variables above are
converted so that the unit is on International Unit.
tube pitch tube OD = 1 in 0.75 in = 0.25 in = 0.25 in x 0.0254 m/in = 0.00635
m
baffle space = 5 in = 5in x 0.0254 m/in = 0.127 m
tube pitch = 1 in = 0.0254 m
So that the shell flow area = (0.49 m x 0.00635 m x 0.127 m) / (144 x 0.0254 m )
= 0.00011 m2
Tube flow area = ( Flow area per tube x amount of tubes ) / (144 x amount of
passes)
= (1.73 x 10-4 m2 x 220) / (144 x 2)

= 0.00013 m2
Calculate the other possible flow rate by using the following equation :
Hot stream (in shell) = Qcold / [chot x (T1-T2)]

= (1158.08 kJ/s) / [ 1.85 kJ/kgmol oC x (155 oC - 134 oC) ] = 2.9806 kg/s
Cold stream (in tube) = Qhot / [ccold x (t2-t1)]
= (104.895 kJ/s) / [ 2.2 kJ/kgmol oC x (65 oC 25 oC) ]
= 11.9 kg/s
In the next calculation, the higher flowrate will be used. So that comparing the
flowrate from the hysys and calculation should be done before continuing the
calculation.
Hot stream (in shell) W from hysys = 2.7 kg/s
W from calculation = 2.9806 kg/s
Cold stream (in tube) W from hysys = 13.16 kg/s
W from calculation = 11.9 kg/s
81
The tube length is selected as 8, 10, 12, 16, or 20 feet. Likewise, the outer
diameter is specified as , 3/8, , 5/8, , 1, 1, or 1 inch. Usually, the tubes
are typically specified to be 14 BWG. The most common tube lengths are 16 and
20 feet and the most common tube OD values are or 1 inch. So, selecting one of
the values in each set will get the calculation to estimate the approximate number
of tubes start.
To determine the shell size, once the number of tubes has to be known, then select
a pitch and the number of passes have to be done. Typical initial guesses are 1 or
2 tube passes. A square pitch is chosen for reasons of convenience in cleaning the
outside of the tubes; when the tubes are in-line, cleaning us relatively
straightforward. The standard choice is a pitch equal to 1.25 inches for 1-inch OD
tubes, and a pitch of 1 inch for inch OD tubes. Tubes on a triangular pitch
cannot be cleaned by tools, but rather by passing a chemical solution through on
the shell-side. It is due to triangular pitches allow for the packing or more tubes
into a given space, they are more common when cleaning the outside is not a
major issue. Rectangular pitches are uncommon. According to this explanation,
the square pitches type is chosen.
Find the G value
It could be obtained by calculating using this formula :

G = W / flow area
Both shell and tube calculation are same.
Shell G = (2.9806 kg/s) / 0.00011 m2 = 27096.36 kg/m2.s
Tube G = (13.16 kg/s) / 0.00013 m2 = 101230,77 kg/m2.s
Calculate the De
Shell
OD2
De = 4 x
=4x
(The pitch)2 ( x 4 )
x OD x 12
(0.0254 m)2 (3.14 x
0.019m2
)
4
3.14 x 0.019 m x 12
= 0.00202 m
Tube
82
De = tube inner diameter = 0.015 m
Check the viscosity from Hysys
Steam = 1
CPO = 0.88
Find the *
* steam = x 2.42 = 1 x 2.42 = 2.42
* CPO = x 2.42 = 0.88 x 2.42 = 2.1296
Calculate the Reynolds Number (Re)
It is done by using this equation :

Re = (De x G) / *
Stream in shell
Re = (0.00202 m x 27096.36 kg/m2.s) / 2.71 = 20.197
Stream in tube
Re = (0.015 m x 101230,77 kg/m2.s) / 2.42 = 627.463
Find jH
jH value could be obtained from the graph in Figure below
83
Figure C.9 jH Factor

(Source: Kern)
jH in shell and Jh in tube got the same value which is 1000
Check the thermal conductivity from hysys
Steam (hot stream in shell) k = 0.02963 W/m K

CPO (cold stream in tube) k = 0.1721 W/m K
Calculate ho/ and hi/
Shell
ho/ =
jH x k
c x
De x (
)1/3
1000 x 0.02963 W/mK

0.00202 m x (
1.85 kJ/kgmol oC x 2.42

0.02963 W/m K
)1/3
= 6371
Tube
84
hi/ =
jH x k
c x
De x (
)1/3
1000 x 0.1721 W/m K

0.015 m x (
2.2 kJ/kgmol oC x 2.1296

0.1721 W/m K
)1/3
= 13005
Calculate the hio/, which is

hio/ =
hi
x
tubeID
tube OD
= 13005 x (0.0015 m / 0.0019 m ) = 10267
Calculate Uc
Uc = (hi/ x hio/) / (hi/ + hio/)

= (13005 x 10267) / (13005+10267)
= 5730
Calculate Ud
Way to calculate Ud is started by choosing the higher value between Q shell and
Q tube, which in E-106, the Q shell is 1087 kJ/s and Q tube is 1048 kJ/s. So that
the Q shell is used to continue the Ud calculation.
Ud = Q / (LMTD x Ft x contact area)
= (1651 kJ/s) / (99,2oC x 0.99 x 192.5 m2)
= 0.39
Calculate the pressure drop

2
=
5.22 1010
Shell
P = 8.3 psi
Tube
P = 6.4 psi
The pressure drop of shell and tube meet the requirement as are below 10 psi
C.2. Fired Heater

A fired heater is a direct-fired heat exchanger that uses the hot gases of
combustion to raise the temperature of a feed flowing through coils of tubes
aligned throughout the heater. Depending on the use, these are also called
furnaces or process heaters. Some heaters simply deliver the feed at a
predetermined temperature to the next stage of the reaction process; others
85
perform reactions on the feed while it travels through the tubes. Fired heaters are
used throughout hydrocarbon and chemical processing industries such as
refineries, gas plants, petrochemicals, chemicals and synthetics, olefins, ammonia
and fertilizer plants. Most of the unit operations require one or more fired heaters
as start-up heater, fired reboiler, cracking furnace, process heater, process heater
vaporizer, crude oil heater or reformer furnace.
A typical fired heater will have following four sections: (1) Radiant section, (2)
Shield section, (3) Convection section, and (4) Breeching and stack. A fired heater
may be a box (rectangular c/s) or vertical (cylindrical c/s) in shape. Same way, a
fired heater may be classified depending on location of the burners and type of the
draft.
I. Radiant Section Design
A. Radiant Heat Transfer in Radiant Section:
Applying basic radiation concepts to process-type heater design, Lobo & Evans
developed a generally applicable rating method that is followed with various
modifications, by many heater designers. Direct radiation in the radiant section of
a direct fired heater can be described by the equation shown below.
B. Heat Balance In The Radiant Section:

There are four primary sources of heat input as well as four sources of heat output
to the radiant section. We can now set up the heat balance equation as follows:
Qfuel + Qair + QSteam + QRFG = QR + QS + QLoss + Qout
86
Where,
C. Total Heat Transfer in Radiant Section (if Shield Section is present)
Where,
II. Convection Section Design

A. Overall Heat Transfer Coefficient, Uo
Where,
And,
87
Where,
And the resistances are computed as,
Where,
B. Inside film heat transfer coefficient, hi :

The inside film coefficient needed for the thermal calculations may be estimated
by several different methods. The API RP530, Appendix C provides the following
methods, For liquid flow with Re 10,000,
And for vapor flow with Re 15,000.
88
C. Effective outside heat transfer coefficient (he) for Fin tubes
Where,
III. Excel Programming

Design of different sections of fired heater has beenperformed using Microsoft
Excel Programming. For the calculation purpose, different calculation methods an
equations are used in the programming.
89
APPENDIX D
D.1. Compressor C-101
With used Hysys for sizing compressor, we got
(), (1 ),
(2 ), (), R, , MW and mass flow ().

a. Pressure Ratio
=
2 6.132
=
= 1.195
1 5.132
b. Discharge Temperature
= 1 [1 +
= 293 [1 +
(2 1 )1 1
]
(1.195)1.31911,319 1
]
0,75
= 320.2
c. Power
= + [(1 2 ) + (
12 22
)]
2
= 21.60
D.2. Compressor C-102

With used Hysys for sizing compressor, we got
(), (1 ),
(2 ), (), R, , MW and mass flow ().

a. Pressure Ratio
=
2 3.378
=
= 1.42
1 2.378
b. Discharge Temperature
= 1 [1 +
(2 1 )1 1
]
(1.42)1,33411,334 1
= 553 [1 +
]
0,75
= 620.66
90
c. Power
= + [(1 2 ) + (
12 22
)]
2
= 290.2
91
APPENDIX E
E.1. Pump P-101
Requirred differentual head is determined as follows:
Absolute Total pressure at pump suction
Bottom of stripper
14.7 psia
Elevation
0.75 psia
Friction piping
-0.5 psia
Friction valve
-0.2 psia
14.75 psia
Absolute Total pressure at pump discharge
Rich Amine to HE
29.39 psia
Elevation
2.754 psia
Friction piping
3 psia
Friction valve
2 psia
Friction filter
0 psia
37.144 psia
Differential pressure between suction and discharge is 22.394 psi

Head =
P
x 2.31 = 49.74 ft
SG
Required Head = Head + 10% Safety factor = 54.714 ft
NPSHA
Bottom of stripper
Elevation
Friction piping
Friction valve
Fluid vapor pressure
14.7
0.75
-0.5
-0.2
-14.7
0.05
psia
psia
psia
psia
psia
psia
So, NPSHA is 0.111

Hydraulic Power
220 USGPM
92
Head
SG
Hydraulic Power
54.71457 ft
1.04
3.161286 hp
2.357371 kW
Actual Horse Power

Hydraulic Power
3.161286 hp
Eff
0.75
BHP
4.215048 BHP
3.143162 kW
Spesific Speed
Nsd =
(rpm)Q(GPM)
3
[H(ft)]4
= 1327.109
Figure E.1 Impeller shapes related to specific speed
From Figure E.1 , it can be seen thay type of impeller for this pump is Radial
Vane.
93
E.2. Pump P-102

Bottom of stripper
9.696 psia
Elevation
0.75 psia
Friction piping
-0.5 psia
Friction valve
-0.2 psia
14.75 psia
Rich Amine to HE
24.39 psia
Elevation
2.754 psia
Friction piping
3 psia
Friction valve
2 psia
Friction filter
0 psia
32.144 psia
Differential pressure between suction and discharge is 22.398 psia.

Head =
P
x 2.31 = 49.74 ft
SG
NPSHA
Bottom of stripper
Elevation
Friction piping
Friction valve
9.696
0.75
-0.5
-0.2
-9.696
0.05
psia
psia
psia
psia
psia
psia
So, NPSHA is 0.111
94
Hydraulic Power
Q
Head
SG
Hydraulic Power
223.344
54.71457
1.04
3.2091
2.3936
USGPM
ft
hp
kW
Actual Horse Power

Hydraulic Power
3.161286 hp
Eff
0.75
BHP
4.2798 BHP
3.1915 kW
Spesific Speed
Nsd =
(rpm)Q(GPM)
3
[H(ft)]4
= 1336.978
Vane.
E.3. Pump P-103
Bottom of stripper
14.7 psia
Elevation
0.75 psia
Friction piping
-0.5 psia
Friction valve
-0.2 psia
14.75 psia
Rich Amine to HE
400 psia
Elevation
2.754 psia
Friction piping
3 psia
Friction valve
2 psia
Friction filter
0 psia
37.144 psia
Differential pressure between suction and discharge is 407.754 psia

95
Head =
P
x 2.31 = 872.92 ft
SG
NPSHA
Bottom of stripper
Elevation
Friction piping
Friction valve
14.7
0.75
-0.5
-0.2
-14.7
0.05
psia
psia
psia
psia
psia
psia
So, NPSHA is 0.111

Hydraulic Power
Q
Head
SG
Hydraulic Power
211.112
960.2146
1.04
53.23371
39.69936
USGPM
ft
hp
kW
Actual Horse Power

Hydraulic Power
53.23371 hp
Eff
0.75
BHP
70.98361 BHP
52.93248 kW
Spesific Speed
Nsd =
(rpm)Q(GPM)
3
[H(ft)]4
= 151.6187
Vane.
96
E.4. Pump P-104

Bottom of stripper
14.7 psia
Elevation
0.75 psia
Friction piping
-0.5 psia
Friction valve
-0.2 psia
14.75 psia
Rich Amine to HE
29.39 psia
Elevation
2.754 psia
Friction piping
3 psia
Friction valve
2 psia
Friction filter
0 psia
37.144 psia
Differential pressure between suction and discharge is 22.444 psi

Head =
P
x 2.31 = 49.74 ft
SG
NPSHA
Bottom of stripper
Elevation
Friction piping
Friction valve
14.7
0.75
-0.5
-0.2
-14.7
0.05
psia
psia
psia
psia
psia
psia
So, NPSHA is 0.111

Hydraulic Power
Q
Head
149.644 USGPM
54.71457 ft
97
SG
Hydraulic Power
1.04
2.15 hp
1.6 kW
Actual Horse Power

Hydraulic Power
3.161286 hp
Eff
0.75
BHP
2.867 BHP
2.138 kW
Spesific Speed
Nsd =
(rpm)Q(GPM)
3
[H(ft)]4
= 1094.523
Vane.

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UNIVERSITAS INDONESIA

RENEWABLE BIODIESEL FROM

MUHAMMAD HAFIZ AL RASYID

CHEMICAL ENGINEERING DEPARTMENT

In order to design renewable diesel plant, we have to make Piping and

EXECUTIVE SUMMARY .................................................................................... ii

Plant Control Tabulation .......................................................................... 1

Piping and Instrument Diagram .............. Error! Bookmark not defined.

Start up, Normal and Shutdown Procedure ............................................ 12

Start Up Procedure .......................................................................... 12

Start Up Procedures for Each Section ..................................... 13

Shut Down Procedure ..................................................................... 14

Main Equiment ....................................................................................... 15

Storage Tank ................................................................................... 15

Crude Palm Oil Storage Tank T-101 ................................................................ 15

Heat Exchanger E-101 ...................................................................................... 24

Plant Control Tabulation

Flow of crude After pump If the level of tank is

low, valve before

heater will be closed

Increase the flow of

heating fluid if the

After pump If the level of mixing

tank is low, valve

before heater will be

Table 1.2. Tabulation of bleaching process

outlet of Heat heating fluid

Increase the flow of

heating fluid if the

If the level of adsorber

coloumn is low, valve

before heater will be

Table 1.3. Tabulation of hydrotreating process

Increasing the flow of

heating fluid if the

Table 1.3. Tabulation of hydrotreating process (Contd)

If the pressure outlet of

compresso decreasing, the valve

will be closed slowly

decreasing the flow of

high, the pressure

safety valve will be

If the level is too low,

the valve will be

ing reactor closed slowly until the

Table 1.4. Tabulation of steam methane reforming process

Steam Methane Reformer

If the pressure outlet

decreasing, the valve

Increasing the flow

of heating fluid if the

going to the next

Increasing the flow

of heating fluid if the

going to the next

Increasing the flow

of heating fluid if the

Table 1.6 Tabulation of steam methane reforming process (Contd)

Increasing the flow

of heating fluid if the

going to the next

If the pressure is too

low, the valve will

If the pressure is too