Pararel

UNIVERSITAS INDONESIA
PRELIMINARY DESIGN OF PRODUCING BENZENE FROM

FAST PYROLISIS OF EMPTY FRUIT BUNCHES
Assignment 3
GROUP 15
GROUP PERSONNEL:
ANDIKAPUTRA B.W. (1406607893)
FARACITRA AKUWALIFAH (1406607861)
MUSTIKA SARASWATI (1406552906)
NADIRA KAMILIA PERMATASARI (1406607956)
NADYA SAARAH AMELINDA (1406552824)
CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
DEPOK
OCTOBER 2017
EXECUTIVE SUMMARY
Our plant produces benzene through the main process called catalytic fast
pyrolysis. Empty fruit bunches (EFB) is use for main raw material. The catalyst that
we used is HZSM-5, an upgrading catalyst of zeolite that can break the carbon-
carbon bonds. Zeolites as catalytic cracking catalysts have been used extensively in
the oil and gas industry in the recent years and the application of HZSM-5 in the
catalytic cracking of hydrocarbons is more than other zeolite types. This is due to
the fact that they have higher activation and specific structure in their pore sizes.
The process in order to produce the benzene starts from the pre-treatment,
the catalytic fast pyrolysis process. The pre-treatment starts with cut the EFB into
small size then hydrolysis EFB with H2SO4. After the pre-treatment process, lignin
will be delivery to reactor fast pyrolysis. Our reactor will be operated in high
temperature.
In order to produces benzene, we need to calculate the size of all the
equipment in our plant. The sizing also related to the economical aspect later. This
sizing is including the dimension and material construction. There are 20 equipment
and 9 types of equipment that we have sized. The types of equipment are tank, belt
conveyor, grinder, pump, compressor, heat exchanger, distillation, reactor, and heat
exchanger.
The sizing of the equipments are done by calculating it using the mass rate,
flow rate, temperature, residence time, fluid properties and other properties.
Eventhough the sizing is not 100% accurate, but it will give more clear picture.
There are different equation used for each equipments. For tanks, the sizing is done
in order to find the dimension by knowing the flow rate or the volume of each batch.
For reactor, the sizing will depends on the kinetic reaction. For utilities such as
pumps and heat exchanger, the sizing will consists of designing the work needed,
material choosen, the heat transfer, head ,etc. For other supporting equipments, the
sizing usually consists of the dimension, temperature, pressure and other thing.
Sizing all of the equipment we need some data from Super Pro 9.0,
simulation software, such as flow rate, temperature, and pressure. The sizing will
make a result in specification table. You can see the detail in Chapter 1 and the
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calculation in Appendix. For material construction, we also determine them by
considering the working fluid that involved in the process and also the operating
condition. We determine whether it is high pressure, high temperature, or corrosive.
Almost all of our equipment is operating in low pressure and low temperature that
is why we choose stainless steel as the main materials. In our process, the most
corrosive fluid that we have is only water.
Not only sizing the equipment but also making Process and Instrumentation
Design (P&ID) for the entire plant and for each process. From P&ID could be
generated controller and valve that we need for each process. P&ID shows all of
piping including the physical sequence of branches, reducers, valves, equipment,
instrumentation and control interlocks. P&IDs play a significant role in the
maintenance and modification of the process that it describes. It is critical to
demonstrate the physical sequence of equipment and systems, as well as how these
systems connect. Controller is designed to make the work easier and to maintain
the process on the designated condition. Controller takes place in three different
types, which are sensor, transmitter, controller and actuator. The sensor is used to
determine if the fixed variable is still in acceptable range, if its not acceptable the
sensor will send signal through the transmitter to the controller to activate the
actuator to activate in order to maintain the wanted variable. Controller is described
by each equipment, sub-process and as a whole.
Our plant needs water utility in the process. The water requirement for the
plant is derived from Way Kuala River which has 1.2 km distance with our plant.
To ensure a continuous supply of water, it was built on the location of the water
reservoir (water intake) which is also a pre-treatment of river water. This processing
includes filtering waste and impurities carried along the water. Furthermore, water
is pumped to the factory to be processed and used as needed.. There is a
specialization of water treatment for raw material, because we need to demineralize
the water first. The steps for water treatment are sedimentation, clarification,
filtration, and demineralization.
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LIST OF CONTENT
EXECUTIVE SUMMARY ................................................................................... ii

LIST OF FIGURES ............................................................................................. vi
LIST OF TABLES .............................................................................................. vii
CHAPTER 1 ...........................................................................................................8
EQUIPMENT SIZING ..........................................................................................8
1.1. Reactor ...................................................................................................... 8
1.1.1. Fast Pyrolysis Reactor ....................................................................... 8
1.1.2. Hydrolysis Reactor ............................................................................ 8
1.1.3. Catalyst Regenerator ......................................................................... 9
1.2. Storage Tank ............................................................................................. 9
1.2.1. Biomass Warehouse .......................................................................... 9
1.2.2. Benzene Tank .................................................................................. 10
1.2.3. Demine Water Tank ........................................................................ 10
1.2.4. Coagulant Tank ............................................................................... 11
1.2.5. Filtration Tank ................................................................................. 12
1.2.6. Ion Exchanger Tank ........................................................................ 12
1.3. Heat Exchanger ...................................................................................... 13
1.3.1. Heat Exchanger (E-100) .................................................................. 13
1.3.2. Heat Exchanger (E-101) .................................................................. 14
1.3.3. Heat Exhanger (H-100) ................................................................... 15
1.4. Distillation .............................................................................................. 16
1.4.1. Distillation Column ......................................................................... 16
1.4.2. Distillation Column ......................................................................... 18
1.5. Three Phase Separator ............................................................................ 18
1.6. Conveyor ................................................................................................ 20
1.6.1. Elevator Conveyor .......................................................................... 20
1.6.2. Belt Conveyor ................................................................................. 20
1.7. Hammer Mills......................................................................................... 21
1.8. Filter Plate & Frame ............................................................................... 21
1.9. Cyclone ................................................................................................... 22
1.9.1. Cyclone (Cy-100) ............................................................................ 22
1.9.2. Cyclone (Cy-101) ............................................................................ 23
1.10. Flue Gas Compressor (C-100) ............................................................ 24
1.11. Pump ................................................................................................... 24
1.11.1. Screw Pump (P-101) ....................................................................... 24
1.11.2. Water Pump (P-102) ....................................................................... 25
1.11.3. Water Pump (P-103) ....................................................................... 25
CHAPTER 2 .........................................................................................................27
UTILITY ...............................................................................................................27
2.1. Process Synthesis and Selection ............................................................. 27
CHAPTER 6 CONCLUSION .............................................................................31
REFERENCES .....................................................................................................32
APPENDIENCE ...................................................................................................33
Appendix A. Fast Phyrolisis Reactor Sizing Calculation .............................. 33
Appendix B. Hydrolysis Reactor ................................................................... 37
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Appendix C. Catalyst Regenerator ................................................................ 42
Appendix D. Biomass Warehouse Sizing ...................................................... 45
Appendix E. Benzene Warehouse Sizing ...................................................... 46
Appendix F. Demine Water Tank .................................................................. 50
Appendix G. Coagulant Tank ........................................................................ 53
Appendix H. Filtration Tank Sizing .............................................................. 54
Appendix I. Ion Exchange Tank .................................................................... 56
Appendix J. Heat Exhanger Sizing ................................................................ 60
Appendix K. Distillation Column Sizing Calculation ................................... 66
Appendix L. Three Phase Separator Sizing Calculation................................ 71
Appendix M. Conveyor Sizing Calculation .................................................. 75
Appendix N. Hammer Mills Sizing Calculation ........................................... 78
Appendix O. Filter Plate and Frame ............... Error! Bookmark not defined.
Appendix P. Cyclone Sizing Calculation ...................................................... 80
Appendix Q. Compressor Sizing Calculation ................................................ 81
Appendix R. Pump Sizing Calculation ........................................................ 85
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LIST OF FIGURES
FIgure 1. 1. Chemical structures of major biomass components.Error! Bookmark

not defined.
FIgure 1. 2. Benzene Structure ............................... Error! Bookmark not defined.
FIgure 1. 3. Wide Range of End Uses for BTX ..... Error! Bookmark not defined.
FIgure 1. 4. Capacities of Petrochemical Producers in Indonesia.................. Error!
Bookmark not defined.
FIgure 1. 5. Physical Structure of Lignocellulosic biomassError! Bookmark not
defined.
FIgure 1. 6. Location of Teluk Betung Industrial AreaError! Bookmark not
defined.
FIgure 1. 7. Location of South Teluk Betung Industrial AreaError! Bookmark
not defined.
FIgure 2. 1. Conversion Technologies for BiomassError! Bookmark not defined.
FIgure 2. 2. Biomass Gasifier Technology ............ Error! Bookmark not defined.
FIgure 2. 3. Typical product weight yields. ........... Error! Bookmark not defined.
FIgure 2. 4. Biomass Production ............................ Error! Bookmark not defined.
FIgure 2. 5. Technical Approach: CFP Process Design OptionsError! Bookmark
not defined.
FIgure 2. 6. Benzene process ................................. Error! Bookmark not defined.
FIgure 2. 7. Pathway from Lignin to Benzene ....... Error! Bookmark not defined.
FIgure 2. 8. Catalytic reaction route for the convention of pyrolysis vapors. Error!
FIgure 2. 9. Fluidized bed reactor for CFP. ........... Error! Bookmark not defined.
FIgure 2. 10. Process Block Flow Diagrams of in situ CFP and ex situ CFP.
................................................................................ Error! Bookmark not defined.
FIgure 2. 11. Reaction Pathway of Lignin Catalytic Fast Pyrolysis. ............. Error!
FIgure 2. 12. Aromatic selectivity from CFP of glucose over different zeolites.
................................................................................ Error! Bookmark not defined.
FIgure 2. 13. Example of Benzene Production Distillation.Error! Bookmark not
defined.
FIgure 4. 1. Pinch Design....................................... Error! Bookmark not defined.
Figure 5. 1 Way Kuala River Location .................. Error! Bookmark not defined.
Figure 5. 2. Water Treatment Process .................... Error! Bookmark not defined.
Figure 5. 3. Drying Process .................................... Error! Bookmark not defined.
vi Universitas Indonesia
LIST OF TABLES
Table 1.1 Fast Pyrolysis Reactor Specification ...................................................... 8
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8
CHAPTER 1
EQUIPMENT SIZING
1.1. Reactor
1.1.1. Fast Pyrolysis Reactor
Table 1.1. Fast Pyrolysis Reactor Specification
Equipment Specification
Item Reactor
Name Pyrolysis Reactor
Type Packed Bed Reactor
Code
Function Reacting lignin into BTX
Material SA 283 Grade C
Operation Data
Temperature (OC) 600
Pressure (bar) 1.04
Operation Data
Volume (m3) 116.04
Diameter (m) 4.05
Height (m) 14.19
Shell Thickness (in) 0.344
Catalyst
Type ZSM-5
Volume (m3) 74.27
Weight (kg) 53474.99
1.1.2. Hydrolysis Reactor

Table 1.2. Hydrolysis Reactor Specification
Equipment Name Reactor
Equipment Code H-100
Function Reacting H2SO4 and EFB into
Lignin, Cellulose and
Hemicellulose
Quantity 1
Equipment Type CSTR Reactor
Material Carbon Steel
Operation Data
Flow rate (ton/day) 6000
o
Material Temperature ( C) 162
Pressure (atm) 1.013
9
Table 1.3. Hydrolysis Reactor Specification (continued)

Construction Data
Volume (m3) 20.598
Height (m) 6.984
Diameter (m) 3.492
Wall Thickness (inch) 1.05
Pdesign (atm) 2.27
Impeller sizing (rpm) 100
1.1.3. Catalyst Regenerator

Table 1.4. Catalyst Regenerator Specification
Equipment Name Catalyst Regenerator
Equipment Code R-100
Function Regenerate catalyst
Number of Unit 1
Material SS 316
Operation Data
Regenerator Temperature
700
(oC)
Catalyst Circulation Rate
40
(kg/m2s)
Pressure (atm) 1
Dimension
Regenerator Height (m) 6.59
Regenerator Diameter (m) 2.20
Regenerator Volume (m) 24.96
Regenerator Thickness (m) 9.35
1.2. Storage Tank

1.2.1. Biomass Warehouse
Table 1.5. Biomass Warehouse Specification
Equipment Name Biomass Warehouse
Equipment Code R-101
Function To storage biomass (empty fruit
bunches) as feed
Number of Unit 1
Material Concrete
Rectangle building with a triangular
Type
prism roofs
Storage Time Daily
10
Table 1.6. Biomass Warehouse Specification (continued)

Operation Data
Temperature (oC) 25
Pressure (atm) 1
Bulk Density (kg/m3) 355
Dimension
Capacity (m3) 9390
Length (m) 36.85
Width (m) 27.64
Height (m) 9.215
1.2.2. Benzene Tank

Table 1.7. Benzene Storage Tank Specification
Equipment Name Benzene Storage Tank
Equipment Code
Function To storage benzene as product
Number of Unit 1
Material Stainless steel
Type Cylinder
Storage Time Weekly
Operation Data
Temperature (oC) 25
Design Pressure (atm) 5.24
Bulk Density (kg/m3) 876
Dimension
Capacity (m3) 98.78
Diameter (m) 19.35
Height (m) 41.94
Wall Thickness (mm) 9.398
Head Thickness (mm) 5.3
1.2.3. Demine Water Tank

Table 1.8. Specification of Storage Tank for Demineralize Water
Equipment Name Demineralize Water Tank
Equipment Code
Storage Type Liquid Storage
Function Storage for Demineralize Water
Number of Unit 1
Material Carbon Steel SA 167
Table
11
Cylinder Vertical Concrete
Type of Tank
Foundation
Type od Head Flat Head
Operation Data
o
Temperature ( C) 25
Pressure (atm) 1
Mass Flow (kg/day) 76314
Bulk Density (kg/m )3 1004
Dimension
Capacity (kg/day) 76314
Volume tank (m3) 83.61
Volume of Liquid in Tank
76
(m3)
Tank Diameter (m) 8.53
Tank Height (m) 17.062
Height of Liquid in Tank
(m) 15.335
Design Pressure (bar) 2.88
Hydrostatic pressure (bar) 1.51
Shell Thickness (in) 0.52
Head Thickness (in) 1.84
1.2.4. Coagulant Tank

Table 1.9. Specification of Coagulant Tank
Equipment Name Coagulant Tank
Equipment Code
Number of Vessel 1
Type Rigid Base Circular
Determination of Diameter of the Water Tank
Mass Flow Rate 3197.5 kg/h
Density 1004 kg/m3
Volume 221.73 m3
Height 4.40 m
Diameter 8.40 m
Free board 0.40 m
Wall Thickness 6 mm
Design of Base
Thickness of base 6 mm
12
1.2.5. Filtration Tank

In water utility, we need to pretreatment the water to get demineralized
water. Before the water is processed in ion exchanger tank to remove the cation and
anion concentration, the water need to be free from the Suspended Solid (SS) which
will be processed in filtration tank. From the sizing calculation explain in Appendix
H we get the specification of the filtration tank unit, as follows
Table 1.10. Filtration Tank Spesification
Equipment Name Filtration Tank
Equipment Code T-502
Function To Filter Suspended Solid (SS)
Number of Unit 4
Filter Specification
Filter Type Slow Sand Filter
Total Surface Area (m2) 267.1425
Max. Surface Per filter
50
(m2)
Number of Filters 6
Surface Area per Filter
44.53
(m2)
Dimension
Filtration Rate (m/h) 0.2
Required Tank Area (m2) 356.19
Long (m) 25
Width (m) 15
Height (m) 2.4
1.2.6. Ion Exchanger Tank

The ion exchanger is the essential equipment in water pretreatment process.
The final product of our water utility would be demineralized water. This is because
the water that would be sent to oxygen plant which will be used in absorption
column required the demine water. If cation or anion is not removed, there will be
a contamination in absorption process. From the sizing calculation, the specification
of the ion exchanger is shown on table below
Table 1.11. Ion Exchanger Tank Spesification
Equipment Name Ion Exchanger
13
Equipment Code
Function To remove Cation and
Anion
Number of Unit 2
Operation Data
Cation Concentration 250 mq/L
Use degasifier (Yes/No) Yes
Anion Concentration 150.25 mq/L
Running time 15 h
Throughput Flow rate 19200 m3
Ionic Load
Cation Load 4800000 eq
Anion Load 2884800 eq
Operating Capacity
Cation regeneration with HCl 1 eq/L
Anion regeneration with NaOH 0.5 eq/L
Resin Volumes
SAC 4800000 L
SBA 5769600 L
Specific Flow Rate
SAC 5.1 h-1
SBA 4.72 h-1
1.3. Heat Exchanger

1.3.1. Heat Exchanger (E-100)
Table 1.12. Heat Exchanger Specification
Unit: E-100
Operating Condition
Data Shell Side Tube Side Unit
Fluid Stream 43 6
Fluid Flow 22308 1328 kg/h
Temperature in 123 5 C
Temperature out 243 100 C
Operating pressure 1000 1000 kPa
No. of passes 1 2
Fouling factor 0,00009 0,00009 m2 C/W
14
Heat Duty 429 kW

LMTD 72 C
Overall U 619 W/m2 C
Dimension
Type of unit Fixed tube
Material SS-316 atau SA-240

Heat Transfer Area 29,868 m2
Tube OD 19,500 mm
Tube Length 4,880 m
Shell ID 0,540 m
Tube Pitch 24 mm
Tube Thickness 1,650 mm
Number of tubes 50
Tube arrangement Triangular
1.3.2. Heat Exchanger (E-101)

Unit: E-101
Operating Condition
Fluid Stream 33 5
No. of passes 1 2
Heat Duty 429 kW
LMTD 119 C
15

Dimension

Tube OD 19,500 mm
Tube Length 4,880 m
Shell IDE 0,540 m
Tube Pitch 24 mm
Number of tubes 30
1.3.3. Heat Exchanger (H-100)

Unit: H-100
Operating Condition
Fluid Stream 5 3

No. of passes 1 4
Heat Duty 432 kW
LMTD 137 C
Dimension
16

Tube OD 20,150 mm
Tube Length 4,880 m
Shell ID 0,540 m
Tube Pitch 25 mm
Number of tubes 5
1.4. Distillation
1.4.1. Distillation Column
17
Table 1.15. Distillation Column Specification
Equipment Name Distillation column
Equipment Code D-200
Function To separate BTX from phenol and
high-boiling aromatics compunds
Operating Data
Feed Flow Rate 16794.70 kg/h
Reflux Ratio 14.6
Column Pressure 9 bar
Number of Actual Tray 27
Condenser Temperature 30 oC
Boiler Temperature 314 oC
Stage Efficiency 80%
Construction Data
Column Height 16.46 m
Column Diameter 1.09 m
Plate Type SS Sieve tray
Material SA-283 Grade C
Shell Thickness 5.71 cm
Head Type Torispherical
Head Thickness 1.21 cm
18
1.4.2. Distillation Column

Table 1.16. Distillation Column Specification
Equipment Name Distillation column
Equipment Code D-200
Function To separate Benzene from Toluene
and Xylene
Operating Data
Feed Flow Rate 180899.4 kg/h
Reflux Ratio 0.75
Column Pressure 4.7 bar
Number of Actual Tray 15
Condenser Temperature 14 oC
Boiler Temperature 249 oC
Stage Efficiency 80%
Construction Data
Column Height 10.67 m
Column Diameter 0.96 m
Plate Type SS Sieve tray
Material SA-283 Grade C
Shell Thickness 5.71 cm
Head Type Torispherical
Head Thickness 1.21Cm
1.5. Three Phase Separator

Table 1.17. Three Phase Separator Specification
19
Name Separator
Code V-102
Separate organics aromatics, water and
Function volatile gas
Number of Units 1
Type Vertical 3 Phase Separator
Material SS-304
Operational Data
Pressure (kPa) 900
Temperature (oC) 5
Gas Flowrate
(MMSCFD) 1.40
Oil Flowrate (BOPD) 1.29
Water Flowrate (BWPD) 0.378
Construction Data
Minimum Diameter (m) 2.12
Maximum Diameter (m) 612
Gas Capacity Constraint 580.82
Retention Time
Constraint 674
Diameter (m) 3.1
Height (m) 18.13
L/D 7.76
Vessel Liquid Level -
beta 50%
Vessel Thickness
P (psia) 14.5
20
R (in) 0.5
S (psi) 20000
E 0.85
t (in) 0.392
t (m) 0.0099
Vessel Cover
Bottom Flat
Top Torispherical
1.6. Conveyor
1.6.1. Elevator Conveyor
Table 1.18. Elevator Conveyor Specification
Equipment Name Elevator Conveyor
Equipment Code
Function Delivering biomass feed (empty
fruit bunches) from storage tank to
grinder
Quantity 1
Equipment Type Elevator Conveyor
Operation Data
Flow rate (ton/h) 416.67
Material Temperature (oC) 25
Pressure (atm) 1 atm
Construction Data
Conveyor Length (ft) 22.96
Belt Width (Inch) 42
Power (hp) 2.815
Conveyor Speed (ft/min) 83.41
1.6.2. Belt Conveyor

Table 1.19. Belt Conveyor Specification
Equipment Name Conveyor
Equipment Code
Function Delivering biomass feed (empty fruit
bunches) from grinder to hyrolysis
reactor
Quantity 1
21
Equipment Type Belt Conveyor

Operation Data
Flow rate (ton/hr) 250
o
Material Temperature ( C) 25
Pressure (atm) 1
Construction Data
Conveyor Length (ft) 26.24
Belth width (in) 42
Power (hp) 2.128
Conveyor Speed (ft/min) 170
1.7. Hammer Mills

Table 1.20. Hammer Mills Specification
Equipment Name Hammer Mill
Equipment Code
Function Grinder
Number of unit 1
Type Hammer Mill Grinder
Operation Data
Rotate Speed (r/min) 800
Pressure (atm) 1
Capacity (ton/h) 50-70
Output Size (mm) 0.01-1
Power Requirement
377.502 kWh/hour
(kWh/hour)
Dimension
Width (m) 2.1
Height (m) 1.8
Length (m) 1.8
1.8. Filter Plate & Frame

This section explains the sizing and specifications for plate & frame filters
used in benzene production plant.
Table 1.21. Filter Plate & Frame
Equipment Specifications
Equipment Name Plate and Frame Filtration
Equipment Code P&F-101
22
Separate lignin from other

Function component such as hemicellulose,
cellulose, etc.
Number of Unit 1
Hydraulic pressure/mechanical
Type
pressure
Operation Data
Temperature 162 oC
Pressure 1.013 bar
Flow rates 4,880,000 kg/hour
Construction Data
Filter Area 93 m2
Filtrate Volumetric 22.514 L
Number of filter plates 64
Number of filter cells 65
The thickness of filter cake (cm) 15
1.9. Cyclone
1.9.1. Cyclone (Cy-100)
Table 1.22. Cyclone Specification
Equipment Name Cyclone
Equipment Code Cy-100
Function Gas-solid separator
Number of unit 1
Type Cyclone Separator
Operation Data
Pressure (kPa) 1.013
o
Temperature ( C) 600
Volumetric flow rate 626526
Particle diatemer (m) 0.005
Grade efficiency (%) 97
Pressure drop (millibar) 130
Construction Data
D0 (m) 0.15
DB (m) 0.2
W (m) 0.08
S (m) 0.2
Hc (m) 0.3
H (m) 0.8
23
A (m) 0.15
B (m) 0.08
Figure 0.1. Cyclone V-102

(Source: Walas, 1990)
1.9.2. Cyclone (Cy-101)

Table 1.23. Cyclone Specification
Equipment Name Cyclone
Equipment Code Cy-101
Function Gas-solid separator
Number of unit 1
Type Cyclone Separator
Operation Data
Pressure (kPa) 1.013
o
Temperature ( C) 700
Volumetric flow rate 560428
Particle diameter (m) 0.005
Grade efficiency (%) 97
Pressure drop (milibar) 130
Dimension
D0 (m) 0.15
DB (m) 0.2
W (m) 0.08
S (m) 0.2
24
Hc (m) 0.3
H (m) 0.8
A (m) 0.15
B (m) 0.08
Figure 0.2. Cyclone V-102

(Source: Walas, 1990)
1.10. Flue Gas Compressor (C-100)

Table 1.24. Flue Gas Compressor Specification
Equipment Name Gas Compressor
Equipment Code C-100
To compress air that will use
Function And flash drum
for HE
Amount 1
Operation Data
Inlet Temperature (K) 353
Discharge Temperature (K) 664,4735
Inlet mass flow rate 222,789
(ton/day)
1.11. Pump
1.11.1. Screw Pump (P-101)
Table 1.25. Screw Pump (P-101) Specification
25
Equipment code P-101

Pump Type Screw Pump
Function Pump outlet fast pyrolysis reactor
Mode of Operation Continuous
Operation Data
Water Liquid
Mass flow (kg/s) 26.83
Flow rate (m3/s) 0.02641
Density (kg/m3) 1007
Temperature (C) 5
Differential Pressure (Pa) 57,000
Specification Design
NPSHa (m) 47.09
NPSHr (m) 45.51
Head (m) 92.03
FHP (kW) 2.42
BHP (kW) 24.20
1.11.2. Water Pump (P-102)

Table 1.26. Water Pump (P-102) Specification
Pump Type Centrifugal Pump
Function Pump for water to Heat Exchanger (B6)
Operation Data
Water Liquid
Temperature (C) 5
NPSHa (m) 9.37
NPSHr (m) 10.05
Head (m) 60.49
FHP (kW) 43.48
BHP (kW) 49.40
1.11.3. Water Pump (P-103)

Table 1.27. Water Pump (P-103) Specification
26
Pump Type Centrifugal Pump
Function Pump for water to Heat Exchanger (B7)
Operation Data
Water Liquid
Temperature (C) 5
NPSHa (m) 12.49
NPSHr (m) 10.05
Head (m) 48.23
FHP (kW) 91.31
BHP (kW) 121.75
27
CHAPTER 2
UTILITY
2.1. Process Synthesis and Selection

2.2. Table 2.1. Plant Control Tabulation of Benzene Production Plant
Operation Controlled
Function Control Procedure
Unit Parameter
To ensure that the optimum temperature for Increase the CV-101 opening if the temperature
the fast pyrolysis is kept maintained because indicator shows the value that is higher that set point so
the pyrolysis reaction is an exothermic the cooling water flow rate to the reactor jacket increase
Temperature reaction and the temperature will always and the heat that can be transferred from reactor to
increase by the heat released while the cooling water will be increased too and vice versa.
Fluidized
reaction occur if the temperature is not
Bed
controlled.
Reactor (R-
The pressure controller will close the PRV-100 if the
101)
pressure indicator shows the value which is below the
To ensure the safety of the reactor. The
maximum pressure allowed in the reactor. If the
Pressure reaction will produce gas phase and gas with
pressure is too high, the PRV-100 will be opened and
high temperature will be very dangerous.
the gas phase will be sent to flare so the pressure in the
reactor can be reduced.
To ensure that the optimum temperature for
When the temperature of the of the CSTR is not fit with
the hydrolysis is kept maintained because the
the wanted condition, the TI will give an electric signal
hydrolysis reaction is an exothermic reaction
Temperature to TC and then transfer that signal into a pneumatic
CSTR and the temperature will always increase by
signal to flow control valve at the cooling water until
Reactor (R- the heat released while the reaction occur if
the condition become normal
100) the temperature is not controlled.
When the pressure of the CSTR is higher than the
Pressure To ensure the safety of the reactor. design pressure, the pressure control valve will open to
reduce the pressure on the CSTR
28
Table 2.1. Plant Control Tabulation of Benzene Production Plant (Continued)

Operation Controlled
Function Control Procedure
Unit Parameter
When the outlet pump flow is higher than design, the
Flow To ensure the flow that comes out is not valve will be closed. But, if the outlet pump flow is
Pump excessive lower than design, the valve will be opened.
When the temperature of the of the distillation is not fit
To ensure the vapor is generated according with the wanted condition, the TC will give an
Temperature
to specifications pneumatic signal to control valve and then adjusting the
cooling air flow rate into the condenser.
If the pressure drops the pressure control reacts to
closing the control valve if many of the accumulated
Distillation To ensure stable equilibrium condition of the
Pressure vapors increase the pressure again. If the pressure rises
(V-100,V- material in the column
the pressure control reacts to open the valve control the
101)
vapor is discharged out lowering the pressure back.
The control valve receives the control signal then
corrects by performing the final action according to the
To ensure the surface height of the
Level decisions and commands of the control unit. if the
distillation column remains at its set
liquid level is less than the desired value then the valve
will open, and vice versa.
If the flow rate shown by flow indicator is below the
To ensure that the pressure of downstream of
specification, the controller will send an electric signal
the compressor is meet the required
Compressor to increase the power given to the compressor motor,
Flow rate specification so we can ensure there will be
(C-100) so it will give higher power to the stream and the
no back pressure happen in the downstream
pressure and flow rate of the stream will be increased
of the compressor.
too and vice versa.
Heat If the temperature of the outlet stream is below the
To ensure that the required temperature is
Exchanger specification, the control valves (CV-102, CV-105,
Temperature met by the heat transfer between the process
(E-101, E- CV-110, CV-113, CV-114) opening will be increased
stream and cold utility stream.
102) so that the flow rate of cold utility stream will be higher
29
and the heat that can be transferred will be increased

too and vice versa.
Table 2.2. Water Utility of Benzene Production Plant
Final
Equipment Process Controller Manipulated
Unit Sensor Control Sequence of Instrumentation
Name Variable P/PI/PID Variable
Element
When the outlet pump flow is
Flow Cooling Flow higher than design, the valve
Pump P-100 Flow Element & Flow Control Water Flow Indicator will be closed. But, if the outlet
Flowmeter Rate Controller pump flow is lower than design,
the valve will be opened.
Reduce liquid level in column
Liquid Level
Coagulant Mechanical Proportional by opening the Level Control
T 101 Level Product Flow Indicator
Tank Float Integral LT Valve on the bottom product of
Rate Conttoller
the column.
Liquid Level
Filtration Mechanical Proportional by opening the Level Control
V- 100 Level Product Flow Indicator
Tank Float Integral LT Valve on the bottom product of
Rate Conttoller
the column.
Table 2.2. Water Utility of Benzene Production Plant (Continued)
30
Final
Equipment Process Controller Manipulated
Unit Sensor Control Sequence of Instrumentation
Name Variable P/PI/PID Variable
Element
Liquid Level
Kation Mechanical Proportional by opening the Level Control
V-102 Level Product Flow Indicator
Exchanger Float Integral LT Valve on the bottom product
Rate Conttoller
of the column.
Liquid Level
Anion Mechanical Proportional by opening the Level Control
V-103 Level Product Flow Indicator
Exchanger Float Integral LT Valve on the bottom product
Rate Conttoller
of the column.
Liquid Level
Mechanical Proportional by opening the Level Control
Water Tank T-102 Level Product Flow Indicator
Float Integral LT Valve on the bottom product
Rate Conttoller
of the column.
CHAPTER 6
CONCLUSION
Based on the explanation in the previous chapter, some points below:

1. Indonesia demand of Benzene is always increasing and the supply is not fill
up the demand. As in 2016, the demand of benzene is about 620.587 ton.
The supply is 291.597 per year.
2. Palm bunch is used as raw material and the plant is going to be built in Teluk
Betung, Lampung with production capacity of benzene 333.791932 ton/day
3. Catalytic Fast Pyrolysis is used for the method. The process is include
Biomass Pre-treatment, Grinding, Catalytic Fast Pyrolysis, Heat
Exchanging, Compressing, Condensing, and Distillation
4. After simulation with Aspen Plus, the amount of benzene is 73434.22
ton/year with the raw material is 66555.1976 kg/hr and Empty palm fruit is
about 642673.43 ton/year. Product yield based on benzene is 0.55. The
energy required to get benzene in this process is 7.473 106 kj/day.
5. Heat Exchanger Network Analysis is used to optimize the hot and cold
stream of the utility. Pinch design is used to determine the temperature
where there is no heat transfer of cold and hot stream by using two
methods, cascade curve and composite curve.
6. Utility system in benzene plant consist of water, air, electricity, and fuel.
7. Total water consumption of our plant as the cooling feed is 91576,8 /
source is treated water from Way Kuala river.
8. Fuel needed in benzene plant is 2000 L/h fuel for generator to back up the
electricity
9. Air utility is used for drying process and for catalyst regeneration plant
requirement is 16455.36 (kg/day)
10. Total electricity needed in plant is 116.070 kWh/ day which will be
consumed as the power source of the main equipment in this plant, and
electricity is used for process of producing benzene from biomass.
31 Universitas Indonesia
32
REFERENCES
Kern, D. Q., 1965, Process Heat Transfer, McGraw-Hill Book Company, Japan.
Liebermann, N.P., and Liebermann, E.T., 2008, A Working Guide to Process
Equipment, 3ed, McGraw-Hill, New York.
Shuler, M.L. dan Kargi, F., 2002, Bioprocess Engineering, 2, Prentice Hall, New Jersey
Smith, Robin. 2005. Chemical Process Design and Integration, 2nd edition. Centre of
Process Integration, University of Manchester, UK.
Tarleton, E. S. and Wakeman, R.J., 2007, Solid/Liquid Separation : Equipment
Selection and Process Design, Elsevier Ltd., Burlington, Great Britain.
Turton, R., Bailie, R.C., Whiting, W.B., 2009, Analysis, Synthesis, and Design of
Chemical Processes, 3ed., Prentice-Hall Inc., New Jersey.
Vilbrandt, F. C. 1959. Chemical Engineering Plant Design. United State: McGraw-
Hill Inc.
33
APPENDIENCES
Appendix A. Fast Phyrolisis Reactor Sizing Calculation
To determine the dimensions of the reactor, it will be done by calculating the

differential equation of the Packed Bed Reactor (PBR). The kinetics of the reaction
rate formulas are required to further perform calculation and determine the
dimensions of the reactor. Since the kinetic of the reaction is not exist in literature,
the calculation is done by scaling the size that refers from journal. The calculation
assumes efficient reduction is neglected. Carbon Steel is used as the material. For
carbon steel SA-283 Grade C itself, it has corrosion factor value 0,125 and
fallowable equal to 12,650.
Sizing
Step 1 : Collect Literatures Data
Total Mass Flow 46000 kg/hr

Diameter Reactor 3.816 m
Height Reactor 11.44 m
Catalyst ZSM-5
(Source : Fluidized Catalytic Cracking to convert Biomass from Stephen Boust)

Step 2: Calculate Tanks Volume (Journal Data)
= + +
= 0.0847 3
= 0.0847 3
= 0.7854 3
= 0.0847 3 + 0.0847 3 + 0.7854 3
By assuming Ls = 4D,
= (0.0847 + 0.0847 + (0.7854 x 4))3
= (0.0847 + 0.0847 + (0.7854 x 4))3.8163
= 96.706 m3
Step 3: Calculate Tanks Volume Actual
34
Flow rate actual this plant is 55730 kg/h and the journal is 46000 kg/hr. By
assuming the actual flow rate is 1.2 times than journals, so the volume actual this
plant is 1.2 bigger than journals as well.
Vtank actual = 1.2Vtank journal
Vtank actual = 1.2 x 8.544 m3
Vtank actual = 116.04 m3
Step 4: Calculate Diameter Actual
= + +
= 0.0847 3 + 0.0847 3 + 0.7854 3
= (0.0847 + 0.0847 + (0.7854 x 4))3
116.04 m3 = (0.0847 + 0.0847 + (0.7854 x 4))3
3 = 66.686 m3
D = 4.055 m
Step 5: Calculate Ls
Ls = 3.5D
Ls = 4 x 1.728 m
Ls = 14.19 m
Step 6: Calculate Volume Liquid
In this case, the tank volume is assumed
100
=
80
So the liquid volume is calculated as below
80
=
100
80
= 116.04
100
= 92.838 m3
Step 7: Calculate Liquid Height on the Tank
= + d
2
92.838 m3 = 4.706 D3 +
4
= 6.827
35
Step 8: Calculate Pressure Vessel Design

Poperate = 14.5 psi
Ptotal = Phydrolisis + Poperate
Ptotal = (. / . ) + 1.5 psi
9.18
Ptotal = (268.56 32.17 6.827 ) + 145 psi = 26.47 psi
Pdesign = 105% . Ptotal

Pdesign = 105% . 26.47 psi = 27.79 psi
Step 9: Calculate Wall Thickness

( . )
= +
2(. ) ( 0.6 )
(27.79 159.63 )
= + 0.125
2(12,650 0.8)( 0.6 27.79 )
= 0.344
Step 10: Calculate Teoritical Volume, Diameter and Length
- Teoritical Volume
Teoritical volume = liquid volume
Teoritical volume = 92.83 m3
- Teoritical Diameter
1
2 =
4
1
2 (3.5) = 92.83 m3
4
D3 = 59.13 m3
DTeoritical = 3.89 m
- Teoritical Length
L = 3.5D
L =3.5 (3.89) m
L = 7.791 m
Step 11: Calculate Catalyst Volume and Weight
Condition :
Catalyst filled 80% of the reactor
Catalyst is ZSM-5
36
Density of catalyst is 720 kg/m3

- Catalyst Volume
80
VCat = VReactor (100)
80
VCat = 92.838 m3 (100)
VCat = 74.27 m3
- Catalyst Weight
WCat = VCat
WCat = 74.27 m3 x 720 kg/m3
WCat = 53474 kg
37
Appendix B. Hydrolysis Reactor
a. General Description
The Hydrolysis process will be done in a CSTR. Besides, because this
process will be done in a high temperature, this reactor should have had a jacket to
prevent the heat go outside the system.
b. Material Construction
The material that will be used in here is specified to sugar product and also
the food product. Usually in industry, for those kind of product, the carbon steel
would be used because it will not sticky to the product and will protect the product
from contaminant.
c. Sizing
For hydrolysis tank, used CSTR tank to mix Biomass with H2SO4 as well
within 60 minutes of reaction. In CSTR that are going to used
, there will be a dished head in head and bottom reactor with assumption if the
reaction will undergo in perfect mixing.
- Operating condition
Temperature : 162oC
Pressure : 1 atm
- Volume of CSTR
To calculate the volume of CSTR, the flow rate of each material input to hydrolysis
tank should be known before. As for those flow rate has been calculated in mass
balance and will be written below.
No Stream Mass Flow (kg/h) Mass Percentage (%)
1 Empty Fruit 46.2%

25000
Bunch
2 H2SO4 0.02% 29166,67 53.8%
After the flow rate has been known, the entering condition of the fluid like flow
rate, pressure, and temperature is needed. As for the assumptions R is equal to 8,314
38
3
kPa.dm /mol K and vo is calculated below
1
= ( )

1 0.4615 0.5384
= +
112 1830
1
= 0.00441512

= 226.494 kg/m3
so, the is
54166,67 /
= = = 66.431 dm3/s
226,494 /3
Assumptions:
1. Optimum vapor space is equal to 20%
2. Ratio between diameter and height is equal to 1 : 2 (Perry, 1999)

3. Conversion number is 0,75
From those assumptions above, the volume that needed for the reactor can be
calculated by equation
.
= . =
.
= 0.028 66. 4312 3 s
= 1.860 mol/s
In the calculation above there were no fraction gas (yA0) because in this
reaction there will not be a gas.
Based on the literature, in hydrolysis reaction with H2SO4 as a catalyst, there

is kinetic reaction (ko) that equal to 0.00205 and the energy activation is equal to
7,69 J/mol (Muhaimin, 2011). From those data the other values can be calculated
as below.

= .
7.69
= 0.0205 8.314 423.15
39
= 0.02054
= . [ ]
= 0.02054 [0.004120879] = 8.4657105 mol/dm3.s

1
= 11812.26 dm3.s/mol

.
=

1.860 0.75
=
8.46 105
= 16478.85 dm3 = 16.478 3
Adding the optimum vapor space
= (10080)
= 16.478(10080)
= 20.598 3
Adding the top and bottom cover, assumption of value D : Ls is 1 : 2
= 0.0847 3
= 0.0847 3
= 0.7854 3
= + +
30.63 3 = 0.0847 3 + 0.0847 3 + 0.7854 3
20.598 3 = 0.0847 3 + 0.0847 3 + 0.7854 (2)3
3 = 42.597 3
D = 3.492 m = 137.49 in
- Liquid Height
40
= +
1
30.63 3 = 0.0847 3 + 2
4
1
33.439.63 3 = 0.0847 (3.497)3 + (3.497)2
4
= 4.032
= 2 = 6.984
- Pressure Vessel Design

Poperate = 1 atm = 14.7 psi
Ptotal = Phydrolisis + Poperate
Ptotal = (. / . ) + 14.7
Ptotal = (860.14 9.18/32.17 4.037) + 14.7 = 31.824 psi
Pdesign = 105% . Ptotal
Pdesign = 105% . 71.68 psi = 33.41 psi = 2.27 atm
- Determining Tank Length

To calculate the tank length, selection of material is needed. In order to resistant
from corrosion, Carbon Steel (SA-285 Grade B) is suitable as the material. For SA-
285 Grade B itself, it has corrosion factor value 0,04 and fallowable equal to 12,500.
From those data, the wall thickness can be calculated.
( . ) +
=
2(. ) ( 0.6 )
(75.26 156.94 ) + 0,04

=
2(12,500 0.45) ( 0.6 33.415 )
= 1.05
- Impeller Sizing
To mix the streams well, the tank uses six-blade 45 open turbine, as for the standard
design for this impeller according to Walas, 1990 is:
Di : Dt = 1 : 3
W : Di = 1 : 8
41
C:W=1:3
Where Di = impeller diameter
Dt = tank diameter
W = agitator width
C = distance from bottom of the tank
Impeller diameter = 0.333 x tank diameter
Di = 0.333 x 3.492 m = 1.33 m
Impeller width = 0.125 x impeller diameter
W = 0.125 X 1.33 m = 0.16 m
Impeller distance from the bottom of tank = 0.333 x impeller width
C = 0.333 x 0.16 = 0.055 m

=

4.60 0.86014
=
3.987
= 0.9932 1
Impellers speed = 100 rpm = 1.67 rps
42
Appendix C. Catalyst Regenerator
The reactor is used for catalyst regeneration by combusting the coke in the
pore of the catalyst by hot air. The reactor is modelled as plug flow reactor (Bai,
Zhu, Jin, & Yu, 1998). For this model, the rate law of coke combustion is

= (1 ) )

= 2
Where,
Cc = Coke content on catalyst (%wt)
x = length of the reactor (m)
= cross section average voidage
Gs = total catalyst flowrate (kg/m2s)
PO2 = partial pressure of O2 (atm)
Kc = 1.65 x 108 exp ( -1.612 x 105/RT)
R = 8.314 kJ/kmol K
Initial coke content on catalyst is assumed 0.05%wt and the final is
0.008%wt. Cross-section average voidage is assumed 0.8 and total catalyst flow
rate is 40 kg/m2.s.
The derivation of the equation is:

= 2 (1 ) (64)

And the equation above is solved using polymath
43
From the polymath, the length of the reactor for coke combustion is 6.586 m
The diameter of the reactor is about 1/3-1/5 L. So that
6.586
= = = 2.195
3 3

= +
( ) (0.6 )
S is allowable stress (74514.7 psi for SS 316). E is joint efficiency 0.8 (Walas 1988).
CA is corrosion allowance. For carbon steel the value of corrosion allowance is
0.00889 m.
14.7 1.0977
= + 0.00889
(74514.7 0.8) (0.6 14.7 )
44
= 0.00935 = 9.350
45
Appendix D. Biomass Warehouse Sizing
This warehouse is used for stocking the raw materials (empty fruit bunches).
The raw materials are stocked monthly from the supplier around Way Kuala.
Before we know the warehouse specifications we have to know some data

which are:
a. Bulk density of empty fruit bunches = 355 kg/m3
b. The process will be done continuously
c. The amount of raw materials is = 100,000 kg/day = 4166.67 kg/hr
Basic Planning
Construction materials = Concrete
= /
= 100,000 / 30 /
= 3,000,000
= 3,000

=

3,000,000
= = 8450.70 3
355 /3
10%, 90%
1
= 8450.70 3 = 9389.67 3
0.9
= (
Length : Width : Height ratio = 4:3:1
Warehouse Specification
Length = 36.85 m
Width = 27.64 m
Height = 9.21 m
46
Appendix E. Benzene Warehouse Sizing
This warehouse is used for stocking the benzene product. Before we know
the warehouse specifications we have to know some data, which are:
a. Overall density of benzene = 876 kg/m3
b. The process will be done continuously
c. The amount of benzene production is 9271.6 kg/hr
The storage tank for benzene product use cylindrical tanks because cylinder
tank is easier to fabricate and has strong structural shape. The upper end of this
cylindrical tank has ellipsoidal shape, while the bottom end of this cylindrical tank
has flat shape. The material used for the storage tank is stainless steel. Carbon steel
is avoided because it cant withstand acidity and corrosion.
Tank Volume
The first step for sizing the equipment is calculating the tank volume. The
calculation will be done based on the input specified in storage tank. For one day,
the benzene that will produced is 11,125.92 kg. If the storage tank can hold benzene
for 1 weeks, then the mass of benzene that is stored in the storage tank is 77,881.44
kg. By knowing the mass flow rate of benzene, can calculated the volumetric flow
rate for storage tank.

11,125.92 7
= = = 88.90 3

876 3

By considering the safety factor of storage tank which is 10% of the total
volume, it means that the storage tank capacity (working volume) cannot exceed
90% of the total volume. Therefore, the total volume is:
88.90 3
= = 98.78 3
0,9
Diameter and Height of the Tank

To calculate the height and diameter of cylindrical tank, can used
cylinder volume formula, which is:
47
1
= 2
4
Based on the rule of thumb of cylindrical storage tank, the ratio of height
and diameter of the tank is 2:1, therefore Hcylinder = 2D, and the cylinder volume
formula can be modified into:
1
= 23
4
The tank total volume is the sum of cylinder volume and ellipsoidal head
volume. The volume of ellipsoidal head is:
1 2
=
4
According to Walas (1990), the ratio between head height and diameter is
1:6, therefore Hh = 1/6 D, and the ellipsoidal head volume formula can be modified
into:
1 2 1 1
= = 3
4 6 24
Therefore, the total tank volume is;
1 1 13
= + = 23 + 3 = 3
4 24 24
By arranging above equation, the tank diameter can be obtained:
3 24

=
13
3 24(406.5 3 )
=
13
= 19.35 762.20
Based on the previous rule of thumb, the tank height can be obtained from
diameter, and it is calculated below:
= 2 6.2 = 38.71
1
= 6.2 = 3.22
6
= 12.4 + 1.03 = 41.94 = 1651.43
Design Pressure
48
Design pressure is needed to decide what type of tank that is going to be

used. Design pressure is affected by height of fluid, density of fluid and gravity, as
mentioned in the equation below:

=

88.90 3
= 41.94
98.78 3
= 37.75
The pressure of the tank is:
= . .

= 876 9.81 41.94 = 360470.359 = 3.56
3
The design pressure is calculated by considering the safety factor of 15%.
= 1.15 (1 + 3.56 ) = 5.24 = 77.119
Thickness of Wall and Head

Wall and head thickness of storage tank is influenced by several factors, such as
corrosion factor, maximum allowable stress, joint efficiency and equipment age.
These data are varies based on the material used, for example the corrosion factor
of stainless steel is smaller than carbon steel, because stainless steel can withstand
corrosion more than carbon steel. Tank wall thickness can be calculated by using
this equation:

= + ( )
0.6
While storage tank head thickness is calculated by the following equation:

= 20.2 + ( ) (98)
Where:
t = Material thickness
P = Pressure gauge
R = Shell radius
Di = Shell inner diameter
49
1 2
K = ellipsoidal formula factor = 6 [2 + (2) ]
S = Maximum allowable stress

E = Joint efficiency
C = Corrosion factor
A = Planned equipment age
Material = Stainless Steel
Corrosion factor (C) = 0.0042 in/year
Allowable working stress (S) = 16,250 lb/in2
Connection efficiency (E) = 0.85
Planned equipment age (A) = 30 years
Therefore, the storage tank wall thickness is:
77.1197 762.20
= + (0.0042 30 ) (99)
(16250 2 0.85)(0.6 77.1197 )

= 0.57 14.478
While the storage tank head thickness is:
1 762.20 2
77.1197 762.20 [2+( ) ]
6 2 1651.43
= + (0.0042 30 ) (100)
(216,250 2 0.85)(0,2 77.11 )

= 0.37 9.398 (101)
50
Appendix F. Demine Water Tank
To sizing the water demine tank produced from the water pre-tereatment process,
followed algorithm as shown in figure above
1. Determine operating condition
The water is processed in atmospheric pressure and room temperature
because of the input is water which do not need pressure for storing the water.
Hence the operating condition is shown on table below
Temperature = 25oC
Pressure = 1 atm = 14.7 psi
2. Determine type and material of tank
Next, needed to choose the material and type that will be used for the tank.
For the material, the consideration is based on the economic aspect. Hence, the
material chosen is carbon steel is chosen due to its competitive price and quality with
other materials. Besides, it also depends on the function which to store water, the non
corrosive fluid and it do not need to store in certain temperature. Another reason is the
good strength of carbon steel and it is easy to get.
For the type of tank, consider the operating condition which do not need
pressure for storing so the type of vessel choosen will be cylinder vertical with concrete
foundation. The type of head is flat head.
3. Estimate liquid volume in tank

To estimate the tank volume, needed to know the capacity and the density
of the liquid stored. The capacity is based on the water needed in our plant. The
calculation is provided from the after HEN calculation for cold utility
= 1004 /3
= 76314 /

=

76314

= = 76 3
1004 /3
4. Assume tank space to determine tank volume

51
Assumption will be used to design the storage tank is listed below

a. The volume of the tank space is 10%
b. Height ratio cylinder with a diameter of the cylinder is 2:1
c. Close the top and bottom cap shaped dished head (flat).
To determine the tank volume, assumed that the volume of tank is 10%
greater than the liquid volume in tank. This assumption is also based on the safety
aspect to prevent the unforeseen circumstances. Another Hence, the tank volume
would be
= 1.1
= 76 3 1.1 = 83.61 3
5. Calculate tank diameter and height

Tank diameter would be determined based on assumption of H/D = 2. This
based on the rule of thumb got from literature (Wallas), where H is height and D is
diameter. Hence the calculation would be
1 2
= ( )
2
1
= 2 2
4
= (2)1/3
= (2 3.14 83.61 3 )1/3 = 8.53
Therefore,
= 2 8.53 = 17.062
6. Calculate Design Pressure

Height of liquid in tank is assumed to be 90% of the total height of the tank.
Hence the liquid height would be
= 90% 17.062 = 15.355
To determine the design pressure we calculate the hydrostatic pressure of
the liquid in tank
=
= 1004 /3 9.8 / 2 15.355
= 151087 = 1.51
52
With a safety margin of 15%, then

= 1.15 (1 + 1.51) = 2.88 = 41.87
7. Determine Shell and Head Thickness

Used construction material made of stainless steel with specification type
304, grade 3 (SA-167) (App. D, Brownell, p: 342)
fallowable = 18,750.00
Corrosion factor (CA) = 0.042
Connection for welding selected type double welded butt joint
Welding efficiency. (E) = 0.80 (Table 13.2, Brownell)
To calculate the shell thickness (ts) we use the equation from Brownell, page 254
[ + ]
=
[2 ( 0.6 )]
41.86 336.11 + 0.0042
( ) = = 0.52
2 (16750 0.8 0.6 41.86 )
Therefore or flat head thickness we could determine the thickness used in

the equation from the literature. The head thickness based on rule of thumb is 3.5
times thicker from the shell thickness. The head thickness would be
( ) = 3.5 = 3.5 0.52 = 1.84
Equipment Demine Tank

Code T-402
Number of Unit 2
Diameter (m) 8.53
Height of Tank (m) 17.062
Shelll Thickness (in) 0.52
Head Thickness (in) 1.84
53
Appendix G. Coagulant Tank
The calculation for sizing coagulant tank is based on the data of rigid based
material. The table below shows the data that is used
Table B.1. Rigid Base Material Data Sheet

Free board (m) 0.40
Wall Thickness (mm) 6
Thickness of base (mm) 6
Then we could calculate the height of the tank with free board data. The
diameter of the coagulant tank we determined is 8.4 m with 4.4 m height. There
will be four tanks due to the big amount of water to be processed in our plant per
day. Hence, we divided the mass flow rate to 4 tanks. The mass flow rate of each
tank would be 3197.5 kg/h.
54
Appendix H. Filtration Tank Sizing
Filtration involves the removal of suspended and colloidal particles from the water
by passing it through a layer or bed of a porous granular material, such as sand.
Rate of filtration (loading rate) is the flow rate of water applied per unit area of the
filter. It is the velocity of the water approaching the face of the filter and define as:

=

Where va = face velocity, m/d = loading rate, m3/d.m2
Q = flow rate onto filter surface, m3/d
As = surface area of filter, m2
In this filtration method, we choose Sand Filter as granular material and
Slow Sand Filter (SSF) as the technology. Design criteria for SSF according to UK
expertise is define in this table.
Table B.2. Design Criteria For SSF

Recommended Level (UK
Parameter
experience)
Design Life 10-15 years
Period of operation 24 h/day
Filtration rate 0.1 0.2 m/h
5 200 m2/ filter (min. of two
Filter bed area
filters)
Height of filter bed
Initial 0.8-0.9 m
Minimum 0.5-0.6 m
Effective size 0.15-0.3 mm
Uniformity coefficient <3
Height of underdrains + gravel 0.3-0.5 m
layer
Height of supernatant water 1m
(source: Addis Abba University)
The calculation of SSF design shown below:
1. Calculate the required tank area
55
Before calculate the tank area, the flow rate of water based on water
requirement in our plant is 7631 m3/day. Hence, the required tank area
calculation (Atank) would be as follows
1
= ( )

3 1
7631

= (0.15 ) = 2119.72 2

24

For this area, we can use tank with 25 m long and 15 m wide. From typical
table above, the height of the tank require could be calculated from provided
data
- System underdrain + gravel = 0.4 m
- Filter bed = 0.85 m
- Supernatant water = 1 m
So the total tank height is 2.25 m
Thus, the dimension of the tank become 25 m long, 15 m wide and 2,25 m
height
Finally we can calculate the number (n) of filters by divided surface area of
(A) and maximum surface per filter which known as 50 m2. The total
surface area of filter couldbe calculated fro equation below. The design
loading rate based on the table above. We take 160 m3/m2 day

=

7631 3 /
= = 47.69 2
3
160 2

47.69 2
= = 0.953 1
50 2
56
Appendix I. Ion Exchange Tank
In the sizing calculation of ion exchanger, the result would be the resin volumes. It
is calculated based on the surface area requirement for demineralization process of
total water needed in our plant. Hence, the algorithm calculation will be as follows
Calculate
Examine Water Decide the use
Cation
Analysis of degasifier
Concentration
Calculate anion Decide Calculate

concentration reasonable throughput Q
after degasifier running time (t) (m3)
Consider the
Calculate resin
Calculate ionic aproximate
volume
load per cycle operating
required
capacity
Figure B.1. Algorithm for Ion Exchanger Sizing Calculation
1. Examine water analysis

All ion exchange systems are designed for a given feed water. Some
variations of the feed water analysis are acceptable, and should be taken into
account, but an ion exchange system cannot be designed efficiently for vastly
different water types. For instance, a demineralization system designed for the
treatment of deep well water is completely different from a system designed to treat
reverse osmosis permeate.
The first thing to do is thus obtain a reliable water analysis. When the water
analysis is not constant, for example due to seasonal variations, we could not take
an "average composition" as the basis of design. Instead, use the "most probable"
case, design with this water, and check as a second step what will happen with the
"minimum" and "maximum"' waters. Henc, the composition of water we used for
the calculation is the normalyzed worst water analysis. The data for cation shown
on table below. The concentration is in mg/l or meg/l as CaCO3
57
Table B.3. Cation Composition of Ion Exchanger Feed

Concentration
Cations
(mg/l)
Calcium (Ca) 100
Magnesium (Mg) 50
Sodium (Na) 90
Potassium (K) 10
Total 250
Meanwhile for the anion the water analyisis shown below

Table B.4. Anion Composition of Ion Exchanger Feed
Concentration
Anions
(mg/l)
Bicarbontate (HCO3) 100
Sulphate (SO4) 50
Chloride (Cl) 75
Nitrate (NO3) 25
Total 250
The water analysis will determine what resin combination is required
2. Calculate cation concentration Cc [meq/L]

As seen on the table of cation composition, the cation concentration would
be 250 mg/l as CaCO3
= 250 /
3. Decide about the use of a degasifier

Based on literature, it mentioned that if the bicarbonate content is greater
than 0.6 to 1.0 mg/l a degasifier may be justified. As seen on the table of the anion
composition, the HCO3 concentration is 100 mg/l, greater than the requirement.
Hence, a degasifier is recommended. It would remove HCO3 and residual CO2 after
degassifier estimated to be 0.25 mg/l.
4. Calculate the anion concentration Ca [meq/L]: it contains

Cl, SO4=, NO3, SiO2, HCO3 or residual CO2 after degasser if any. Due to the
58
use of degasifier, there is a change of anion concentration. Degassifier produced

residual CO2 that makes the composition of anion would be
= 4 + + 3 + 2
= 50 + 75 + 25 + 0.25 = 150.25 /
5. Decide about a reasonable running time t in hours between regenerations.
Our plant would be operated in continous operation. So, the operating hour would
be 24 hours per day. Then for the running time we chose to be 24 hours.
= 24
6. Using the flow rate f in m3/h calculate the throughput Q [m3]
= 800 3 /
3
= = 800 . 24 = 19200 3

7. Calculate the ionic load per cycle in eq (concentration in meq/L times

throughput in m3):
o [] = = 250 . 19200 = 4800000

o [] = = 150.25 . 19200 = 2884800

8. Consider the approximate operating capaciy of the resins as follows

o SAC: capc = 1.0 eq/L with HCl regeneration or
SAC: capc = 0.8 eq/L with H2SO4 regeneration
o SBA: capa = 0.5 eq/L
9. The resin volume V required (in litres) is equal to the ionic load [eq] divided
by the operating capacity [eq/L]:
o SAC:
4800000
= = = 4800000 .
1
2884800
= = = 5769600
0.5
10. At the end of this calculation, we must make sure that the specific flow rate
of both resin columns is compatible with the general recommendations of the resin
producer.
59
The specific flow rate in h1 (often expressed in bed volumes per hour
BV/h) is equal to the flow rate in m3/h divided by the resin volume in m3. The usual
range is 5 to 50 h1. For a compact plant with minimum investment cost, use a
specific flow rate around 30 to 35 h1. If the specific flow rates calculated from
the resin volumes Vc and Va are too high, increase the running time t. If they are
too low, reduce the running time t.
60
Appendix J. Heat Exhanger Sizing
The type of heat exchanger that will be used is shell and tube (STHE),
because STHE can transfer heat with higher efficiency, and also the tube side is
easy to clean. The material for the STHE is carbon steel, because it has high thermal
conductivity and relatively cheap, but has long life span. These are the step to design
STHE
1. Determine the specification of fluid. The specifications are flow rate (kg/h) of
hot fluid and cold fluid, the temperature (C) inlet and outlet of the fluids, the
duty, and the location of fluids that pass the tube or shell, and the type of flow
in heat exchanger which are co-current or counter current. To determine the
duty, we use this equation
= mc Cc (t 2 t1 ) = mh Ch (T2 T1 )
If there is a phase change, we use
= . . ( ) + .
2. Determine physical properties of fluids, which are heat capacity (kJ/kg/K),
density (kg/m3), viscosity (Pa.s), thermal conductivity, and fouling factor
(W/m2/K). The fouling factor can be obtained from table below.
Figure B.2. Fouling Factors Coefficients

3. Assume value of overall coefficient, Uc (W/m2.K)
61
The value of overall coefficient can be obtained from table below
Figure B.3. Overal Heat Transfer Coefficients
4. Calculate the LMTD, correction factor, and t.

(T1 t 2 ) (T2 t1 )
LMTD =
T t
ln(T1 t2 )
2 1
1 2
=
2 1
2 1
=
1 1
t = LMTD x FT
Value of FT is obtained from Fig. 2.19 in Chemical Engineering Design vol 6,
2005
5. Calculate the heat transfer area

=
.
62
6. Decide the type of shell and tube heat exchanger (fixed tubesheet, U-tube etc.),
outside diameter tube, inside diameter tube, tube thickness, length of tube,
number of pass, dan pitch type. Use the standard tube counts table for this
purpose.
Figure B.4. Heat Exchanger Tube Layouts

(Source: NPTEL, Chemical Engineering Design)
7. Calculate the number of tube
- Cross Flow Area of Tube
= . .
- Number of tube

=

- Tube cross sectional area

= . (2 )
4
- Area per pass

= .

- Tube side superfacial velocity
1
= .
3600
- Tube side velocity

, =

Tube side velocity about 5-15 m/s for high pressure gas and 1-4 m/s for
liquid
8. Calculate the diameter of shell
- Diameter bundle, Db
63
1
1
= ( )
1
The value of K1 dan n1 are obtained from table 12.4 in Chemical
Engineering Design vol 6, 2005
- Diameter shell Ds
= +
The value of shell bundle clearance is obtained from figure 12.10 in
Chemical Engineering Design vol 6, 2005
9. Estimate tube side heat transfer coefficient
- Reynlods Number, Prandtl Number, and L/D

=

=

=

- Tube side heat transfer coefficient, hi

= . . (Pr)0.33 ( )

The value of jH is obtainable from figure 2.23 in Chemical Engineering
Design vol 6, 2005
10. Estimate shell side heat transfer coefficient
- Baffle spacing dan tube pitch
Baffle Spacing, lB = baffle spacing coefficient x inside diameter shell
Tube pitch, pt = tube pitch coefficient x outside diameter tube
The value of baffle spacing coefficient is 0.2 0.5 while tube pitch
coefficient is 1.25 1.35
- Shell Cross Flow Area

= . .

- Equivalent Diameter, de
1.10
For triangular pitch: = (2 0.9172 )

64
1.27
For square pitch: = (2 0.7852 )

- Shell-side superfacial velocity

1
= .
3600
- Shell side velocity

, =

Tube side velocity about 5-15 m/s for high pressure gas and 0.3-1 m/s for
liquid
- Reynold Number & Prandtl Number

=

=

- Shell side heat transfer coefficient, hs

= . . (Pr)0.33 .

The value of jH is obtainable from figure 2.29 in Chemical Engineering Design
vol 6, 2005
11. Calculate the overall heat transfer coefficient, Uo

1 1 () ln 1
= ( + ) + +
2
+
Where K is thermal conductivity for heat exchanger material. For carbon steel
K = 45 Wm-1 oC-1
12. Calculate pressure drop in shell side and tube side
- Pressure drop in tube
2
= [8 ( ) + 2.5]
2
The value of jF is obtainable from figure 2.24 in Chemical Engineering
Design vol 6, 2005
- Pressure drop in shell
65
2
= 8 . . .
2
Pressure drop must be below 0.5 bar. If the pressure drop above 0.5 bar, we must
change the value of Uc in step 3.
66
Appendix K. Distillation Column Sizing Calculation
1. Determine Heavy key and Light key of the components

2. Determine tdew and tbubble
The mole fraction of components is known by the HYSYS Simulation. After
that, calculate the vapour presure of each component by the Antoine equation
and calculate value of m by the equation of Psat/Ptotal and fraction mole of each
components in bottom.
Calculate the bubble temperature by trial-error in excel, so tbubble is

=

3. Calculate the minimum tray (Nm) and optimum tray (Nopt).

To find the minimum tray, can use two ways those are by graphically and the
equation below, where:
log[ ( ) ( ) ]
=
log( )
To get the Nopt is by using graphically method using the figure below:
Figure Relation between optimum-to-minmum ratio and Fensk

separation factor of alfa values
(Source: Mc Cabe, 1993)
1) Determine the value of log[ ( ) ( ) ( ) ],

( ) .
67
2) Plot the data to the graph

3) Drawn a line to the left, so get Nopt/NM.
4. Calculate the Value of RM and Ropt.
Figure A. 1 Optimum-minimum reflux ratio relationship to the

column's feed, distillate, and bottoms composition
4) Determine the value of log[ ( ) ( ) ( ) ],

( ) .
5) Plot the data to the graph
6) Drawn a line to the left, so get the
5. Determining .
The method is finding the value of / on the feed, and the value
of with use Figure A.3 below
68
Figure A. 2 Underwood's teta vs key ratios in feed


6. Determining , and , that will be used for determining value of

by using Figure A.4 below

Figure A. 3 Underwood's teta vs (a-o)/a for heavy key and heavier

components
7. Calculate RM and Ropt with equation below:

69

+ 1 =

Calculation of Column Diameter
1. Calculate the velocity of vapor at the stripping and rectifying section.

=

Using the graph below, we can know the value of K which will be used
to calculate the velocity of vapor and liquid.
Figure G.1. Correlation of FLV and K
2. Calculate the area needed for the column.

1
=
1 0.1
4
=

70
Calculation of Column Height

1. Assume that the external reflux ratio (RD)
2. Calculate the minimum reflux ratio (RDm)
(RD) is 1.5 times RDm
3. Use Gilliand equation and graph to get the number of stage and calculate with
the equation below

+ 1
Figure G.2. Gilliand equation and graph

4. Calculate the number of stage with equation +1
5. Assume that a plate spacing is 0.5 m

6. Calculate the height of Column
71
Appendix L. Three Phase Separator Sizing Calculation
Table lalayes.
Properties Value
Gas Flowrate (MMSCFD) 0.0464
Oil Flowrate (BOPD) 66.717
Water Flowrate (BWPD) 6.124
Total Liquid (BPD) 72.84
ATM Press. 14.7
Op Press (psig) 2529.46
Op Temp (F) 140
Gas Compressibility Z 0.95
Retention Time (min) t 10.00
Remove drops >__micron from gas 150
Remove H2O drops >__micron from oil 500
Remove oil drops >__micron from H2O 200
Vessel Liquid Level - beta 50%
Gas Molecular Weight 2.018
Oil Specific Gravity 0.84
Water Specific Gravity 1
Gas Viscosity m 0.009
Oil Viscosity ml 3.2
H2O Viscosity mw 0.69
72
1. Calculation Design Specification Information

Table lalayes. Design Spesification Information
Variable Value Units

g = (P+Pa)(MW) 0.84 lb/cu ft
10.73*(T+460)*(z)
l = 62.4(sp. gr.) 52.42 lb/cu ft
w = 62.4(sp. Gr H2O.) 62.40 lb/cu ft
Dp= 0.00003937(micron)/12 0.000492 ft
Dw= 0.00003937(micron)/12 0.001640 ft
Do = 0.00003937(micron)/12 0.000656 ft
m=MMSCFD(1e6)(MW) 0.00286
379.4(24)(3600) lb/sec
Qa=m/rg 0.00341 acfs
Ql 0.00434 cu ft/sec
Qw 0.0004 cu ft/sec
Qm=Qa+Ql+Qw 0.01 cu ft/sec
pm=(rl*Ql+rg*Qg+rw*Qw)/Qm 31.32 lb/cu ft
Fractional area of liquids - alpha 0.5
2. Calculate CD and Minimum Diameter
Trial No. 1 2 3 4 5 6
Assume CD 2.01 1.18 1.03 1.00 0.99 0.99
Vt = (4gDp(l-g)/3CDg)0.5 0.80 1.05 1.12 1.14 1.15 1.15
Re = 1488(DpVtg)/ 54.89 71.58 76.69 78.00 78.32 78.40
Calculated CD 1.18 1.03 1.00 0.99 0.99 0.98
0.5

= 12 ( ) = 0.7
2.4( + )
3. Determine The Frictional Height Of Water In The Vessel
73
d x Leff (for gas capacity) 0.05
d2 x Leff (for liquid capacity) 1041
Fractional area of water

0.042
w=tQw/t(Qw+Ql)
Fractional height of water w 0.087
Fractional area of water w 0.042
4. Calculate Maximum Vessel Diameter for Water Settling
Variable Value Unit
Vtw = 1488gDw2(pw-pl)/18 l 0.02 ft/sec
Max Height of Oil Pad, Ho 160.91 in max
Maximum diameter = Ho/(-w) 390 in max
5. Calculate Maximum Vessel Diamter for Oil Settling
Variable Value Unit

Vtw = 1488gDw2(pw-pl)/18 w 0.0166 ft/sec
Max Height of water, Hw 119.40 in max
Maximum diameter = Hw/ w 1373 in max
Maksimum Vessel Diameter = 390 inch
6. Calculate Vessel Gas and Liquid Capacity Requirements

0.5

= 420 [ ] [( ) ]
1
2 = 1.42[( ) + (( )]
74
7. Determine Appropriate Diameter and S-S Length
Diameter
15 16 17 18 19 20
(in)
Leff (gas) 0.00301 0.00282 0.00266 0.00251 0.00238 0.00226
Lss (gas) 1.25 1.34 1.42 1.50 1.59 1.67
Leff
4.62 4.06 3.60 3.21 2.88 2.60
(liquid)
Lss
6.17 5.42 4.80 4.28 3.84 3.47
(liquid)
Lss (ft) 7 6 5 5 4 4
L/D 5.20 4.13 3.53 3.00 2.53 2.10
Since L/D must be in the range of 3-5, the chosen length and diameter for the 3-
phase separator are 6 ft and 16 in.
75
Appendix M. Conveyor Sizing Calculation
- Belt Conveyor 1
Belt conveyor is used to transfer Empty Fruit Bunch from Grinding process
to Hydrolysis Reactor.
Operation Condition of Belt Conveyor

Mass Flow Rate 250 Tonne/hr
Length 26.24 Ft
Angle Elevation 30 Degree
Belt Width 42 Inch
Data Capacity for Belt Conveyor

(Source : Wallas,2017)
Velocity of Conveyor

=( ) 100 /

So, the velocity of conveyor :
76
250 /
= (238.5 /) 100 min=104.82 / = 174.70 ft/min
Power
= +

= (0.4 + )( )
300 100
L = Length of Conveyor
W = Capacity (ton/hr)
Figure 1.2. Pempty
77
(Source : Wallas, 1998)

26.24 250
= (0.4 + ) (100) = 1.218 hp
300
= 0.9
= 1.218 + 0.9 = 2.128
- Belt Conveyor 2
Belt conveyor is used to transfer Empty Fruit Bunch from Warehouse to
Grinder.
Operation Condition of Belt Conveyor

Mass Flow Rate 416.67 Tonne/hr
Length 22.96 Ft
Angle Elevation 30 Degree
Belt Width 42 Inch
Velocity of Conveyor

=( ) 100 /

So, the velocity of conveyor :
416.67 /
= ( 499.5 / ) 100 min=104.82 / min = 83.41 /
Power
= +

= (0.4 + )( )
300 100
L = Length of Conveyor
W = Capacity (ton/hr)
22.96 416.67
= (0.4 + )( ) = 1.985 hp
300 100
= 0.83
= 1.985 + 0.83 = 2.815
78
Appendix N. Hammer Mills Sizing Calculation
Hammer Mills
We need the empty fruit bunch for hydrolysis is about 0.33 mm size in
particles. So we choose to use hammer mills according to tabel
Operating Ranges for Commonly Used Size Reduction Equipment
(Source : Walas, 1990)
The power requirement for hammer mills is based on the extent of size
reduction that expressed by the following equation
1 1
( ) = 10 ( )

Where d and di are the final and initial diameter (m), and Wi is work
index for the material. The work index for Empty fruit bunch is 13.81.
1 1
( ) = 10 (13.81 )( ) = 0.906857 /
300 20000
If the mass flow rate of empty fruit bunch is 416.67 ton/hour, the total power
requirement is

( ) = 0.906 416.67 = 377.503

To choose the dimension of hammer mills that we need, we look to the vendor
(SBM-Mining and Construction) PC4012-90 with the dimension 1800 mm x 1650
mm x 1800 mm.
79
(Source: SBM-Mining and Construction Machinery, 2013)
80
Appendix O. Cyclone Sizing Calculation
To design a cyclone Cy-101, Cy-102, Cy-103, first we should calculate the

pressure drop with the equation below
4 2
= (135)
2
= 4.313 (/100)2 (136)

Assumed that the inlet velocity is 50-150 ft/sec (Walas, 2012) and g is the
density of gas.
2
40.000324 3 (150 )

= (137)
232.2 2

= 0.4529 (138)
Number of turns inside the cyclone is represented by the equation below.
= [0.1079 0.00077 + 1.924(106 ) 2 ] (139)
= [0.1079 0.00077 150 + 1.924(106 ) 1502 ]150 (140)
= 22.563 (141)
To obtain the particle diameter, we can use the equation:
0.5
9
= [4 ( )] (142)

4( )2
= (143)
9
4(21.05540.000324) 10 2
= (304800) (144)

91.285.105

= 0.002461 (145)

= 0.002461. (146)
= 8.3302 = 2.540 (147)

= = 0.635 (148)
4

0 = = 1.270 (149)
2

= = 1.270 (150)
2
= 2 = 5.079 (151)
= 2 + (8) = 5.397 (152)

= = 0.635 (153)
4
81
Appendix Q. Compressor Sizing Calculation
There are some steps to sizing our compressor. We have five steps to calculate
operating data what we need to know. This is our step to size every compressor we
have.
A. Determine the type of compressor, (based on volume inlet and discharge
pressure)
B. Determine heat capacity each inlet flow to compressor
C. Calculate te compressor power
D. Calculate the temperature discharge
E. Calculate the compressor head
We use centrifugal compressor to transport gas from a process to another process.

We choose centrifugal compressor because this compressor able to transport gas in
a large flow. Furthermore, we need continuous flow to transport gas to maximize
working of other unit. We use general range of application of compressor graph to
determine which compressor we use.
82
General Range of Application of Compressor

(Source: Kern, 2010)
Based on this graph, we know that our volume inlet flow and
discharge pressure are in centrifugal range are. This is our volume flow
inlet and discharge pressure table.
Compressor Specifications
Volume Discharge
Inlet Flow Pressure
Compressor (kg/hour) (kPa)
C-100 222789,365 800
After we know what type compressor we will use, we

calculate compressor power, discharge temperature and compressor
head. This is our detail calculation of first compressor (C-101), which
use to transport gas to membrane.
Compressor Power
83
Z = compressibility factor
= universal gas constant
T
R1 = inlet temperature, K
= standard pressure
= standard temperature
E = overall efficiency
q = gas flow rate
W = work (kJ/mol)
P2 = pressure outlet
P1 = pressure inlet
Y = heat capacity ratio
(Source: Authors Personal Data)
Discharge Temperature
After we calculate the compressor power, we need to calculate the outlet

temperature from compressor. Here is the equation is to calculate discharge
temperature in compressor:
Compressor Head
Compressor head is like a compressor ability to reach maximum height of

other unit to transport gas. Here is the equation is to calculate compressor head in
compressor:
84
By the same calculation with the first compressor calculation, we can

calculate compressor power, discharge temperature and compressor head
for another compressor. This is the result table for each compressor
Compressor Sizing
Volume Discharge Compressor Discharge
Compressor Inlet Flow Pressure Power Temperature

C-100 224912 800 10.08 391,4735
(m3/min) (kPa) (kWh) (kPa)
Table Flue Gas (C-101) Specification
Compression ratio 4.0

Compressor Head (m) 122207.7
Efficiency (Ep) 0.785
Pressure inlet (kPa) 100
Pressure outlet (kPa) 900
Power (kW) 10,09
85
Appendix R. Pump Sizing Calculation
Pump may be classified in two general types, dynamic and positive

displacement. Here is the upper limit of pressure and capacity of different types of
pumps.
Types of Pump
(Source: Wallas, 2012)

Positive displacement pumps are those in which energy is imparted to the
liquid in a fixed displacement volume, such as a casing or a cylinder, by the rotary
motion of gears, screws, or vanes, or by reciprocating pistons or plungers.
Centrifugal pumps are dynamic pumps. Energy is imparted to the liquid by means
of a disk with curved vanes rotating on a shaft called the impeller. The impeller
imparts kinetic energy to the fluid by means of its shape and high rotational
velocity. This energy is transformed to pressure energy when the fluid reaches the
pump casing. From so many difference type of pump we decide to use centrifugal
pump based on the characterization.
For the material, there are a few material available utilized to for this
equipment. One of the most common is by stainless steel S316 and Carbon steel.
carbon steel as the material for the pump for a noncorrosive fluid (water etc) and
stainless steel for the pump for corrosive fluid. In our plant there is no corrosive
material so we decided to use carbon steel as material of pump in our plant.
86
Pump is used in order to move liquid from one unit to another. For our plant,
the total pumps we need are around 6 pumps. Here is the brief description of each
pump usage.
We selected centrifugal pump as our type of pump in our plant because the
flow rate and viscosity is low, and there is no high temperature of mixture in our
plant. We used calculation based on handbook chemical engineering and
mechanical fluids course. The material that we are going to use is carbon steel.
First we input all of our data that needed such as mass flow, density,
pressure suction and discharge (or pressure at destination), vapor pressure,
temperature suction, and static head in the excel.
In sizing pump, we use that all the pump efficiency is 75%
= (173)
Then we can calculate head by using this equation

= (174)
Head Actual

= (175)

FHP

= (176)

BHP

= (177)

NPSHA
NPSH is calculated by many factor. The most important variable here is the
length t of pipe itself, equivalent length of valve and bending.
1() 2 2
= (2 1 ) 2 (178)

NPSHR

= (179)

So power of the pump will calculate use of this equation
87
2
= = ( + + )+ (180)
2
Pump Summarize Calculation

Hydraulic
Q Temperature Density
Pump Head NPSHA NPSHR Power
(m3/h) (oC) (kg/m3)
(kW)
Cy-102 299.167 5 1007 60.49 9.37 10.05 49.40
Cy-103 299.167 5 1007 48.23 12.49 10.05 121.75
Cy-101 299.167 5 1007 92.03 47.09 45.51 24.20
88
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UNIVERSITAS INDONESIA

PRELIMINARY DESIGN OF PRODUCING BENZENE FROM

CHEMICAL ENGINEERING DEPARTMENT

iii Universitas Indonesia

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

FIgure 1. 1. Chemical structures of major biomass components.Error! Bookmark

Table 1.1 Fast Pyrolysis Reactor Specification ...................................................... 8

1.1.2. Hydrolysis Reactor

Table 1.3. Hydrolysis Reactor Specification (continued)

1.1.3. Catalyst Regenerator

1.2. Storage Tank

Table 1.6. Biomass Warehouse Specification (continued)

1.2.2. Benzene Tank

1.2.3. Demine Water Tank

1.2.4. Coagulant Tank

1.2.5. Filtration Tank

1.2.6. Ion Exchanger Tank

Table 1.11. Ion Exchanger Tank Spesification

1.3. Heat Exchanger

Heat Duty 429 kW

Material SS-316 atau SA-240

1.3.2. Heat Exchanger (E-101)

Overall U 620 W/m2 C

Material SS-316 atau SA-240

1.3.3. Heat Exchanger (H-100)

Temperature in 125 125 C

Type of unit Fixed tube

Material SS-316 atau SA-240

Table 1.15. Distillation Column Specification

1.4.2. Distillation Column

1.5. Three Phase Separator

1.6.2. Belt Conveyor

Equipment Type Belt Conveyor

1.7. Hammer Mills

1.8. Filter Plate & Frame

Separate lignin from other

Figure 0.1. Cyclone V-102

1.9.2. Cyclone (Cy-101)

Figure 0.2. Cyclone V-102

1.10. Flue Gas Compressor (C-100)

Equipment code P-101

1.11.2. Water Pump (P-102)

1.11.3. Water Pump (P-103)

2.1. Process Synthesis and Selection

Table 2.1. Plant Control Tabulation of Benzene Production Plant (Continued)

and the heat that can be transferred will be increased

Table 2.2. Water Utility of Benzene Production Plant

Table 2.2. Water Utility of Benzene Production Plant (Continued)

Based on the explanation in the previous chapter, some points below:

To determine the dimensions of the reactor, it will be done by calculating the

Total Mass Flow 46000 kg/hr

Height Reactor 11.44 m

(Source : Fluidized Catalytic Cracking to convert Biomass from Stephen Boust)

Step 3: Calculate Tanks Volume Actual

Step 8: Calculate Pressure Vessel Design

Pdesign = 105% . Ptotal

Step 9: Calculate Wall Thickness

Density of catalyst is 720 kg/m3

Appendix B. Hydrolysis Reactor

No Stream Mass Flow (kg/h) Mass Percentage (%)

1 Empty Fruit 46.2%

2 H2SO4 0.02% 29166,67 53.8%

1. Optimum vapor space is equal to 20%