Escolar Documentos
Profissional Documentos
Cultura Documentos
Y X12
1 2003 2008404 4022833212 4012009
2 2004 3359339 6732115356 4016016
3 2005 254149 509568745 4020025
4 2006 447943 898573658 4024036
Σ 8018 6069835 12163090971 16072086
n = banyaknya data = 4
x rata - rata = Σx/n = 8018 / 4 = 2004.5
y = a + bx
n ∑ xiyi−∑ x ∑ y
b=
n ∑ xi 2 −( ∑ xi )2
= 60815454855 - 48667937030
80360430 - 64288324
= 12147517825
16072106
= 755.8136951685
= 1517458.75 - 1515028.5519653
= 2430.198035
y = 2430.198035 + 755.8136952 x
= 1521615.725
APPENDIX A
PERHITUNGAN NERACA MASSA
Komponen % Berat
Al2O3.2SiO2 84.21
Fe2O3 0.18
TiO2 0.08
CaO 0.72
MgO 0.34
K2O 0.38
Na2O 0.15
CO2 13.94
Total 100
1. HAMMER CRUSHER
Fungsi : Menghancurkan kaolin dari ukuran 2 in menjadi 1/8 in
Feed ( F)
HAMMER CRUSHER Produk Solid (F')
Recycle ® Ukuran 1/8 in
Kriteria desain :
Ukuran feed : 2 in s/d 10 mesh (Perry 7ed : 20-28)
Kapasitas : 40 s/d 60 ton/jam (Perry 7ed : 20-30)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 30 C
F + R = F'
R = 0.05 F'
F = 1000 kg
F' = 1052.6316 kg
R = 0.05 F'
Neraca Massa
2. SCREEN
Fungsi : Memisahkan ukuran 1/8 in
Kriterian design :
Ukuran partikel : minimum 4.25 in (Perry 6ed : 21-15)
% oversize product : 5 % - 50% (Perry 6ed : 21-14)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 30oC (suhu kamar)
Feed masuk :
Komponen Feed (kg/jam) % berat
Al2O3.2SiO2 886.4211 84.21
Fe2O3 1.8947 0.18
TiO2 0.8421 0.08
CaO 7.5789 0.72
MgO 3.5789 0.34
K2O 4.0000 0.38
Na2O 1.5789 0.15
CO2 146.7368 13.94
Total 1052.6316 100
F' = R + P
F' = 1052.6316 kg
R = 52.6316 kg
F' = R + P
1052.6316 = 52.6316 + P
P = 1000 kg
Neraca Massa
3. ROTARY KILN
Fungsi : Kalsinasi kaolin menjadi alumina
udara panas
udara panas
Kriteria design :
Ukuran partikel : diatas 149 µm (100 mesh) (Kirk Othmer Vol 4:440)
% solid loss : 0.1 - 0.5 % (Petrochemical Handbook)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 1100oC ( (Ulrich 141)
Feed masuk :
Komponen Berat (kg/jam)
Al2O3.2SiO2 842.1000
Fe2O3 1.8000
TiO2 0.8000
CaO 7.2000
MgO 3.4000
K2O 3.8000
Na2O 1.5000
CO2 139.4000
Total 1000
Komponen BM
Al2O3.2SiO2 222
Al2O3 102
SiO2 60
Tinjauan reaksi :
Berat Al2O3.2SiO2 = 842.1000 kg
mol Al2O3.2SiO2 = 842.1000 = 3.7932 mol
222
= 7.58649 x 60 = 455.1892 kg
4. CYCLONE
Fungsi : Memisahkan padatan dan udara panas
padatan
Kriteria design :
Ukuran partikel : minimum 10 micron (ludwig : 165)
Effisiensi pemisahan : 70 - 99 % (ludwig : 165)
Kondisi operasi :
Tekanan operasi : 1 atm (Tekanan atmospheric)
Suhu operasi : Berdasarkan perhitungan kiln
Feed masuk :
Komponen Berat (kg/jam)
Al2O3 0.3869
SiO2 0.4552
Fe2O3 0.0018
TiO2 0.0008
CaO 0.0072
MgO 0.0034
K2O 0.0038
Na2O 0.0015
CO2 139.4000
Total 140.2606
Terdiri dari :
Komponen Feed (kg/jam) Kehilangan Produk (kg/jam)
padatan (kg/jam)
Al2O3 0.3869 0.0193 ###
SiO2 0.4552 0.0228 ###
Fe2O3 0.0018 0.0001 ###
TiO2 0.0008 0.0000 ###
CaO 0.0072 0.0004 ###
MgO 0.0034 0.0002 ###
K2O 0.0038 0.0002 ###
Na2O 0.0015 0.0001 ###
Total 0.8606 0.04303 ###
Neraca massa :
Komponen Masuk (kg/jam) Komponen Keluar (kg/jam)
Campuran dari rotary kiln Alumina ke rotary cooler
Al2O3 0.3869 Al2O3 ###
SiO2 0.4552 SiO2 ###
Fe2O3 0.0018 Fe2O3 ###
TiO2 0.0008 TiO2 ###
CaO 0.0072 CaO ###
MgO 0.0034 MgO ###
K2O 0.0038 K2O ###
Na2O 0.0015 Na2O ###
CO2 ### ###
140.2606
Limbah gas
Al2O3 0.0193
SiO2 0.0228
Fe2O3 0.0001
TiO2 0.0000
CaO 0.0004
MgO 0.0002
K2O 0.0002
Na2O 0.0001
CO2 ###
139.4430
Total 140.2606 140.2606
5. ROTARY COOLER
udara panas
udara bebas
Kriteria design :
Ukuran partikel : diatas 149 µm (100 mesh) (Kirk Othmer Vol 4:440)
% solid loss : 0.1 - 0.5 % (Petrochemical Handbook)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 40oC (suhu kamar)
Terdiri dari :
Komponen Padatan Kehilangan Produk padatan
(kg/jam) Padatan (kg/jam) (kg/jam)
Al2O3 386.8915 0.3869 386.5046
SiO2 455.1664 0.4552 454.7113
Fe2O3 1.7999 0.0018 1.7981
TiO2 0.8000 0.0008 0.7992
CaO 7.1996 0.0072 7.1924
MgO 3.3998 0.0034 3.3964
K2O 3.7998 0.0038 3.7960
Na2O 1.4999 0.0015 1.4984
Total 860.5570 0.8606 859.6964
Neraca massa :
Komponen Masuk (kg/jam) Komponen Keluar (kg/jam)
Alumina dari rotary kiln Alumina ke Ball mill
Al2O3 386.5239 Al2O3 386.5046
SiO2 454.7340 SiO2 454.7113
Fe2O3 1.7982 Fe2O3 1.7981
TiO2 0.7992 TiO2 0.7992
CaO 7.1928 CaO 7.1924
MgO 3.3966 MgO 3.3964
K2O 3.7962 K2O 3.7960
Na2O 1.4985 Na2O 1.4984
859.7394 859.6964
Alumina dari cyclone 1 Alumina menuju cyclone 2
Al2O3 0.3676 Al2O3 0.3869
SiO2 0.4324 SiO2 0.4552
Fe2O3 0.0017 Fe2O3 0.0018
TiO2 0.0008 TiO2 0.0008
CaO 0.0068 CaO 0.0072
MgO 0.0032 MgO 0.0034
K2O 0.0036 K2O 0.0038
Na2O 0.0014 Na2O 0.0015
0.8176 0.8606
Total 860.5570 860.5570
6. CYCLONE-2
Fungsi : Memisahkan padatan dan udara panas
padatan
Kriteria design :
Ukuran partikel : minimum 10 micron (ludwig : 165)
Effisiensi pemisahan : 70 - 99 % (ludwig : 165)
Kondisi operasi :
Tekanan operasi : 1 atm (Tekanan atmospheric)
Suhu operasi : Berdasarkan perhitungan cooler
Feed masuk :
Komponen Berat (kg/jam)
Al2O3 0.3869
SiO2 0.4552
Fe2O3 0.0018
TiO2 0.0008
CaO 0.0072
MgO 0.0034
K2O 0.0038
Na2O 0.0015
Total 0.8606
Neraca massa :
Komponen Masuk (kg/jam) Komponen Keluar (kg/jam)
Campuran dari rotary cooler Alumina ke ball mill
Al2O3 0.3869 Al2O3 0.3675
SiO2 0.4552 SiO2 0.4324
Fe2O3 0.0018 Fe2O3 0.0017
TiO2 0.0008 TiO2 0.0008
CaO 0.0072 CaO 0.0068
MgO 0.0034 MgO 0.0032
K2O 0.0038 K2O 0.0036
Na2O 0.0015 Na2O 0.0014
0.8606 0.8175
Limbah gas
Al2O3 0.0193
SiO2 0.0228
Fe2O3 0.0001
TiO2 0.0000
CaO 0.0004
MgO 0.0002
K2O 0.0002
Na2O 0.0001
0.0430
Total 0.8606 0.8606
7. BALL MILL
Fungsi : Menghaluskan bahan sampai 200 mesh
Feed (F)
Produk solid (F')
BALL MILL
Recycle ®
Kriteria design :
Kapasitas : 5, 22, 51, 105, 180 ton/hari (Perry 6ed : T. 8-18)
Ukuran ball mill (3 x 3) ft ; (4 x 3) ft ; (5 x 4) ft (Perry 6ed : T. 8-18)
Ukuran bola baja : 5 in (reduction ratio 15,6 : 1) (Brown : fig.37)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 32oC (suhu kamar)
Feed masuk :
Komponen Feed dari rotary Feed dari Feed total
cooler (kg/jam) cyclone (kg/jam) (kg/jam)
Al2O3 386.5046 0.3675 386.8721
SiO2 454.7113 0.4324 455.1437
Fe2O3 1.7981 0.0017 1.7998
TiO2 0.7992 0.0008 0.7999
CaO 7.1924 0.0068 7.1993
MgO 3.3964 0.0032 3.3997
K2O 3.7960 0.0036 3.7996
Na2O 1.4984 0.0014 1.4999
Total 859.6964 0.8175 860.5139
F + R = F'
R = 0.05 F'
F' = 905.8041
Komposisi recycle = Produk -Feed
Terdiri dari:
Komponen Feed (kg/jam) Produk (kg/jam) Recycle (kg/jam)
Al2O3 386.8721 407.2338 20.3617
SiO2 455.1437 479.0986 23.9549
Fe2O3 1.7998 1.8945 0.0947
TiO2 0.7999 0.8420 0.0421
CaO 7.1993 7.5782 0.3789
MgO 3.3997 3.5786 0.1789
K2O 3.7996 3.9996 0.2000
Na2O 1.4999 1.5788 0.0789
Total 860.5139 905.8041 45.2902
Neraca massa :
8. SCRREN
Fungsi : Memisahkan ukuran 200 mesh
Kriterian design :
Ukuran partikel : minimum 4.25 in (Perry 6ed : 21-15)
% oversize product : 5 % - 50% (Perry 6ed : 21-14)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 30oC (suhu kamar)
Feed masuk :
Komponen Feed (kg/jam) % berat
Al2O3 407.2338 44.9583
SiO2 479.0986 52.8921
Fe2O3 1.8945 0.2092
TiO2 0.8420 0.0930
CaO 7.5782 0.8366
MgO 3.5786 0.3951
K2O 3.9996 0.4416
Na2O 1.5788 0.1743
Total 905.8041 100.0000
F' = R + P
F' = 905.8041 kg
R = 45.2902 kg
F' = R + P
905.8041 = 52.6316 + P
P = 853 kg
Neraca Massa
H2O 1121.8397
Total 3926.4389 3926.4389
10. REAKTOR
Fungsi : Mereaksikan alumina dengan asam sulfat untuk membentuk aluminium sulfat
H2SO4
Kriteria design :
Diameter maksimum :4 m (Ulrich T 4-18)
Diamension Ratio , H/D : 2-Jan (Ulrich T 4-18)
Kondisi operasi :
Tekanan : 1 atm
Suhu operasi : 110oC
Feed masuk :
Komponen Berat (kg/jam) % berat
Al2O3 386.8721 44.9583
SiO2 455.1437 52.8921
Fe2O3 1.7998 0.2092
TiO2 0.7999 0.0930
CaO 7.1993 0.8366
MgO 3.3997 0.3951
K2O 3.7996 0.4416
Na2O 1.4999 0.1743
Total 860.5139 100.0000
= 3926.4389 kg
= 3.7170 kmol
= 379.1347 kg
= 1092.8000 kg
= 446.0408 kg
= 9.1029 kg
= 1.7638 kg
= 0.0360 kg
= 3.2410 kg 2.7045
= 0.7839 kg
= 0.0160 kg
H2SO4 yang bereaksi = 2 x 0.0098 = 0.0196 kmol
= 1.9206 kg
19.4021
Ti(SO4)2 yang terbentuk = 0.0098 kmol = 2.3518
= 0.1260 kmol
= 7.0553 kg
= 0.1440 kg
= 12.3468 kg
= 3.3317 kg
= 0.0680 kg
H2SO4 yang bereaksi = 1 x 0.0833 = 0.0833 kmol
= 8.1626 kg
= 3.72363 kg
= 0.0760 kg
= 3.8821 kg
= 1.4699 kg
= 2.3233 kg
= 2581.7429 kg
= 1652.1293 kg
Neraca massa :
cake
Kriteria design :
5 % filtrat terikut pada cake
Kondisi operasi :
Tekanan operasi = 1 atm
Suhu masuk = 110 oC
Suhu keluar = 99 oC
Feed masuk :
Feed Berat (kg/jam) Filtrat Berat (kg/jam) Cake Berat (kg/jam)
Al2O3 7.7374 Al2(SO4)3 1271.2163 Al2O3 7.7374
SiO2 9.1029 Si(SO4)2 1635.4829 SiO2 9.1029
Fe2O3 0.0360 Fe2(SO4)3 4.4096 Fe2O3 0.0360
TiO2 0.0160 Ti(SO4)2 2.3518 TiO2 0.0160
CaO 0.1440 CaSO4 2.6748 CaO 0.1440
MgO 0.0680 MgSO4 9.9950 MgO 0.0680
K2O 0.0760 K2SO4 6.8927 K2O 0.0760
Na2O 0.0300 Na2SO4 3.3664 Na2O 0.0300
Al2(SO4)3 1271.2163 H2O 1652.1293 CaSO4 14.4595
Si(SO4)2 1635.4829 H2SO4 166.7643
Fe2(SO4)3 4.4096
Ti(SO4)2 2.3518
CaSO4 17.1343
MgSO4 9.9950
K2SO4 6.8927
Na2SO4 3.3664
H2O 1652.1293
H2SO4 166.7643
Total 4786.9528 4755.2831 31.6698
Neraca massa :
11. THICKENER
Fungsi : Memisahkan padatan dan liquid secara sedimentasi
cake
Kriteria design :
% solid pada feed : minimum 11 % (Perry 7 ed : 18-72)
Waktu pengendapan : 3 - 5 jam (Perry 7 ed : 18-72)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Waktu tinggal : 3 jam (Perry 7 ed : 18-72)
Penurunan suhu karena alat dan bahan = 10 % dari suhu masuk (Ulrich :432)
Suhu masuk : 99 oC
Suhu keluar : 89 oC
Feed masuk :
Komponen Berat (kg/jam)
Al2(SO4)3 1207.6555
Si(SO4)2 1553.7088
Fe2(SO4)3 4.1891
Ti(SO4)2 2.2342
CaSO4 2.5411
MgSO4 9.4953
K2SO4 6.5480
Na2SO4 3.1981
H2O 1569.5229
H2SO4 158.4261
Total 4517.5189
Komponen BM
Fe2(SO4)3 400
BaS 169
Fe2S3 208
BaSO4 233
Tinjauan reaksi :
Berat Fe2(SO4)3 = 4.1891 kg
Mol Fe2(SO4)3 = 4.1891 = 0.0105 kmol
400
Penambahan Glue :
Komposisi Glue :
Al2(SO4)3 :
Berat air = 1569.5664 kg
Ca(SO4)
Berat air = 1569.5664 kg
Mg(SO4)
Berat air = 1569.5664 kg
K2(SO4)
Berat air = 1569.5664 kg
Kelarutan K2(SO4) = 22.8 kg/100 kg H2O
Na2(SO4)
Berat air = 1569.5664 kg
Kelarutan Na2(SO4) = 43 kg/100 kg H2O
Ba(SO4)
Berat air = 1569.5664 kg
Kelarutan Ba(SO4) = 0.00072 kg/100 kg H2O
Asumsi liquid terikut solid = 10 % dari liquid pada feed ( Perry ed 6 ; 19-87)
Terdiri dari :
Komponen Fraksi berat Feed (kg/jam) Liquid pada underflow (kg/jam) Liquid pada overf
Al2(SO4)3 0.26757 1207.6555 120.7655
Si(SO4)2 0.34424 1553.7088 155.3709
Ti(SO4)2 0.00050 2.2342 0.2234
Ca(SO4) 0.00056 2.5411 0.2541
Mg(SO4) 0.00210 9.4953 0.9495
K2(SO4) 0.00145 6.5480 0.6548
Na2(SO4) 0.00071 3.2034 0.3203
NaCl 0.0000011 0.0048 0.0005
H2O 0.34776 1569.5664 156.9566
H2SO4 0.03510 158.4261 15.8426
Total 1 4513.3834 451.3383
Asumsi impurities yang sedikit jumlahnya dianggap air, maka komposisi liquid overflow :
Neraca Massa
12. EVAPORATOR
H2O
Kriteria design :
F= 4062.0451
XF= 0.2676
XL = 0.4200
F. XF = 4062.0451 x 0.2676 = 1086.8899 kg
V. XV = 0
Neraca massa :
13. KRISTALISER
S (mother liquor)
Feed C (kristal Al2(SO4)3)
KRISTALISER
Feed masuk :
Komponen Berat
Al2(SO4)3 1086.8899
Si(SO4)2 1398.3379
H2O 102.6053
Total 2587.8331
Dari data diatas dapat diketahui bahwa kelarutan Al2(SO4)3 terhadap air sebesar :
102.6053 kg
Al2(SO4)3 = 23.9 x 102.6053 = 24.5227 kg
100
Dari hasil perhitungan kelarutan diketahui bahwa aluminium kristal yang hanya bisa menjadi kristal
Al2(SO4)3 = 1086.8899 - 24.5227
= 1062.3672 kg
Neraca massa :
14. CENTRIFUGE
Feed Filtrat
CENTRIFUGE
Mother liquor
Terdiri dari :
Komponen feed Berat (kg/jam) Mother liquor Berat (kg/jam) Produk
Mother Liquor
Al2(SO4)3 24.5227 Al2(SO4)3 23.2965 Al2(SO4)3
Si(SO4)2 1398.3379 Si(SO4)2 1328.4210 Si(SO4)2
H2O 102.6053 H2O 97.4750 H2O
Kristal Al2(SO4)3.18H2O
Al2(SO4)3.18H2O 1062.3672
2587.8331 1449.1926
Neraca massa :
Komponen Masuk Komponen Keluar
Mother Liquor Mother Liquor
Al2(SO4)3 24.5227 Al2(SO4)3 23.2965
Si(SO4)2 1398.3379 Si(SO4)2 1328.4210
H2O 102.6053 H2O 97.4750
1525.4659 1449.1926
Kristal Menuju Ball mill
Al2(SO4)3.18H2O 1062.3672 Al2(SO4)3 1.2261
Si(SO4)2 69.9169 kadar air
H2O 5.1303 0.004505606
Al2(SO4)3.18H2O 1062.3672 memenuhi standart
1138.6405
Total 2587.8331 2587.8331
Feed (F)
BALL MILL Produk solid (F')
Recycle ( R )
Kriteria design :
Kapasitas : 5, 22, 51, 105, 180 ton/hari (Perry 6ed : T. 8-18)
Ukuran ball mill (3 x 3) ft ; (4 x 3) ft ; (5 x 4) ft (Perry 6ed : T. 8-18)
Ukuran bola baja : 5 in (reduction ratio 15,6 : 1) (Brown : fig.37)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 32oC (suhu kamar)
Feed masuk :
Komponen Feed total
(kg/jam)
Al2(SO4)3 1.2261
Si(SO4)2 69.9169
H2O 5.1303
Al2(SO4)3.18H2O 1062.3672
Total 1138.6405
F + R = F'
R = 0.05 F'
F' = 905.8041
Terdiri dari:
Komponen Feed (kg/jam) Produk (kg/jam) Recycle (kg/jam)
Al2(SO4)3 1.2261 1.2907 0.0645
Si(SO4)2 69.9169 73.5967 3.6798
H2O 5.1303 5.4003 0.2700
Al2(SO4)3.18H2O 1062.3672 1118.2813 55.9141
Total 1138.6405 1198.5690 59.9284
1138.6405
Neraca massa :
18. SCRREN
Fungsi : Memisahkan ukuran 200 mesh
Kriterian design :
Ukuran partikel : minimum 4.25 in (Perry 6ed : 21-15)
% oversize product : 5 % - 50% (Perry 6ed : 21-14)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 30oC (suhu kamar)
Feed masuk :
Komponen Feed (kg/jam) % berat
Al2(SO4)3 1.2907 0.1077
Si(SO4)2 73.5967 6.1404
H2O 5.4003 0.4506
Al2(SO4)3.18H2O 1118.2813 93.3014
Total 1198.5690 100.0000
F' = R + P
F' = R + P
1198.5690 = 59.9284 + P
P = 1139 kg
Neraca Massa
= 1138.6405 kg/jam
= 27327.37293 kg/hari ( 24 jam proses)
= 8198.211879 ton/tahun
1903.1074
5.0048
5.0048
2.7045
Berat (kg/jam)
7.7374
9.1029
0.0360
0.0160
0.1440
0.0680
0.0760
0.0300
14.4595
31.6698
PENTING BANGET!!!!!
1470.39512
Mg 8.2606467394
2.674797414
1222.575717
398.1631728
693.8943261
Liquid pada overflow (kg/jam)
1086.8899
1398.3379
2.0108
2.2870
8.5457
5.8932
2.8831
0.0043
1412.6097
142.5835
4062.0451
Produk Berat (kg/jam)
(SO4)3 1.22613
SO4)2 69.91690
O 5.13027
(SO4)3.18H2O 1062.36724
1138.64054
2587.83313
uhi standart
kg/jam
ED ME TO DO MY FINAL TASK :)
dahulu!!!!!
Komponen % Berat
Al2O3.2SiO2 84.21
Fe2O3 0.18
TiO2 0.08
CaO 0.72
MgO 0.34
K2O 0.38
Na2O 0.15
CO2 13.94
Total 100
1. HAMMER CRUSHER
Fungsi : Menghancurkan kaolin dari ukuran 2 in menjadi 1/8 in
Feed ( F)
HAMMER CRUSHER Produk Solid (F')
Recycle ( R ) Ukuran 1/8 in
Kriteria desain :
Ukuran feed : 2 in s/d 10 mesh (Perry 7ed : 20-28)
Kapasitas : 40 s/d 60 ton/jam (Perry 7ed : 20-30)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 30 oC
F + R = F'
R = 0.05 F'
F = 3659.33 kg
F' = 3851.9311 kg
R = 0.05 F'
Neraca Massa
2. SCREEN
Fungsi : Memisahkan ukuran 1/8 in
Kriterian design :
Ukuran partikel : minimum 4.25 in (Perry 6ed : 21-15)
% oversize product : 5 % - 50% (Perry 6ed : 21-14)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 30oC (suhu kamar)
Feed masuk :
Komponen Feed (kg/jam) % berat
Al2O3.2SiO2 3243.7112 84.21
Fe2O3 6.9335 0.18
TiO2 3.0815 0.08
CaO 27.7339 0.72
MgO 13.0966 0.34
K2O 14.6373 0.38
Na2O 5.7779 0.15
CO2 536.9592 13.94
Total 3851.9311 100
Asumsi ukuran oversize = 5 % (Perry 6ed : 21-14)
Berat ukuran undersize = Feed - berat oversize
F' = R + P
F' = 3851.9311 kg
R = 192.5966 kg
F' = R + P
3851.9311 = 192.5966 + P
P = 3659.33 kg
Neraca Massa
3. ROTARY KILN
Fungsi : Kalsinasi kaolin menjadi alumina
udara panas
udara panas
Feed ROTARY KILN
produk
Kriteria design :
Ukuran partikel : diatas 149 µm (100 mesh) (Kirk Othmer Vol 4:440)
% solid loss : 0.1 - 0.5 % (Petrochemical Handbook)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 1100oC ( (Ulrich 141)
Feed masuk :
Komponen Berat (kg/jam)
Al2O3.2SiO2 3081.5256
Fe2O3 6.5868
TiO2 2.9275
CaO 26.3472
MgO 12.4417
K2O 13.9055
Na2O 5.4890
CO2 510.1112
Total 3659.3345526559
Komponen BM
Al2O3.2SiO2 222
Al2O3 102
SiO2 60
Tinjauan reaksi :
Berat Al2O3.2SiO2 = 3081.5256 kg
mol Al2O3.2SiO2 = 3081.5256 = 13.8807 mol
222
= 27.7615 x 60 = 1665.6895 kg
Neraca Massa :
4. CYCLONE- 1
Fungsi : Memisahkan padatan dan udara panas
padatan
Kriteria design :
Ukuran partikel : minimum 10 micron (ludwig : 165)
Effisiensi pemisahan : 70 - 99 % (ludwig : 165)
Kondisi operasi :
Tekanan operasi : 1 atm (Tekanan atmospheric)
Suhu operasi : Berdasarkan perhitungan kiln
Feed masuk :
Komponen Berat (kg/jam)
Al2O3 1.4158
SiO2 1.6657
Fe2O3 0.0065868022
TiO2 0.0029274676
CaO 0.0263472088
MgO 0.0124417375
K2O 0.0139054713
Na2O 0.0054890018
CO2 510.1112
Total 513.2605
Terdiri dari :
Komponen Feed (kg/jam) Kehilangan Produk (kg/jam)
padatan (kg/jam)
Al2O3 1.4158 0.0708 ###
SiO2 1.6657 0.0833 ###
Fe2O3 0.0065868022 0.0003 ###
TiO2 0.0029274676 0.0001 ###
CaO 0.0263472088 0.0013 ###
MgO 0.0124417375 0.0006 ###
K2O 0.0139054713 0.0007 ###
Na2O 0.0054890018 0.0003 ###
Total 3.1492 0.15746 ###
Neraca massa :
Komponen Masuk (kg/jam) Komponen Keluar (kg/jam)
Campuran dari rotary kiln Alumina ke rotary cooler
Al2O3 1.4158 Al2O3 ###
SiO2 1.6657 SiO2 ###
Fe2O3 0.0065868022 Fe2O3 ###
TiO2 0.0029274676 TiO2 ###
CaO 0.0263472088 CaO ###
MgO 0.0124417375 MgO ###
K2O 0.0139054713 K2O ###
Na2O 0.0054890018 Na2O ###
CO2 ### ###
513.2605
Limbah gas
Al2O3 0.0708
SiO2 0.0833
Fe2O3 0.0003
TiO2 0.0001
CaO 0.0013
MgO 0.0006
K2O 0.0007
Na2O 0.0003
CO2 510.1112
510.2687
Total 513.2605 513.2605
5. ROTARY COOLER
udara panas
udara bebas
campuran padatan ROTARY COOLER
produk
Kriteria design :
Ukuran partikel : diatas 149 µm (100 mesh) (Kirk Othmer Vol 4:440)
% solid loss : 0.1 - 0.5 % (Petrochemical Handbook)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 35oC (suhu kamar)
Terdiri dari :
Komponen Padatan Kehilangan Produk padatan
(kg/jam) Padatan (kg/jam) (kg/jam)
Al2O3 1415.7653 1.4158 1414.3495
SiO2 1665.6062 1.6656 1663.9406
Fe2O3 6.5865 0.0066 6.5799
TiO2 2.9273 0.0029 2.9244
CaO 26.3459 0.0263 26.3195
MgO 12.4411 0.0124 12.4287
K2O 13.9048 0.0139 13.8909
Na2O 5.4887 0.0055 5.4832
Total 3149.0659 3.1491 3145.9168
Neraca massa :
Komponen Masuk (kg/jam) Komponen Keluar (kg/jam)
Alumina dari rotary kiln Alumina ke Ball mill
Al2O3 1414.4203 Al2O3 1414.3495
SiO2 1664.0238 SiO2 1663.9406
Fe2O3 6.5802 Fe2O3 6.5799
TiO2 2.9245 TiO2 2.9244
CaO 26.3209 CaO 26.3195
MgO 12.4293 MgO 12.4287
K2O 13.8916 K2O 13.8909
Na2O 5.4835 Na2O 5.4832
3146.0741 3145.9168
Alumina dari cyclone 1 Alumina menuju cyclone 2
Al2O3 1.3450 Al2O3 1.4158
SiO2 1.5824 SiO2 1.6656
Fe2O3 0.0063 Fe2O3 0.0066
TiO2 0.0028 TiO2 0.0029
CaO 0.0250 CaO 0.0263
MgO 0.0118 MgO 0.0124
K2O 0.0132 K2O 0.0139
Na2O 0.0052 Na2O 0.0055
2.9918 3.1491
Total 3149.0659 3149.0659
6. CYCLONE-2
Fungsi : Memisahkan padatan dan udara panas
padatan
Kriteria design :
Ukuran partikel : minimum 10 micron (ludwig : 165)
Effisiensi pemisahan : 70 - 99 % (ludwig : 165)
Kondisi operasi :
Tekanan operasi : 1 atm (Tekanan atmospheric)
Suhu operasi : Berdasarkan perhitungan cooler
Feed masuk :
Komponen Berat (kg/jam)
Al2O3 1.4158
SiO2 1.6656
Fe2O3 0.0066
TiO2 0.0029
CaO 0.0263
MgO 0.0124
K2O 0.0139
Na2O 0.0055
Total 3.1491
Terdiri dari :
Komponen Feed (kg/jam) Kehilangan Produk (kg/jam)
padatan (kg/jam)
Al2O3 1.4158 0.0708 1.3450
SiO2 1.6656 0.0833 1.5823
Fe2O3 0.0066 0.0003 0.0063
TiO2 0.0029 0.0001 0.0028
CaO 0.0263 0.0013 0.0250
MgO 0.0124 0.0006 0.0118
K2O 0.0139 0.0007 0.0132
Na2O 0.0055 0.0003 0.0052
Total 3.1491 0.15745 2.9916
Neraca massa :
Komponen Masuk (kg/jam) Komponen Keluar (kg/jam)
Campuran dari rotary cooler Alumina ke ball mill
Al2O3 1.4158 Al2O3 1.3450
SiO2 1.6656 SiO2 1.5823
Fe2O3 0.0066 Fe2O3 0.0063
TiO2 0.0029 TiO2 0.0028
CaO 0.0263 CaO 0.0250
MgO 0.0124 MgO 0.0118
K2O 0.0139 K2O 0.0132
Na2O 0.0055 Na2O 0.0052
3.1491 2.9916
Limbah gas
Al2O3 0.0708
SiO2 0.0833
Fe2O3 0.0003
TiO2 0.0001
CaO 0.0013
MgO 0.0006
K2O 0.0007
Na2O 0.0003
0.1575
Total 3.1491 3.1491
7. BALL MILL
Fungsi : Menghaluskan bahan sampai 200 mesh
Feed (F)
BALL MILL
Produk solid (F')
BALL MILL
Recycle ( R )
Kriteria design :
Kapasitas : 5, 22, 51, 105, 180 ton/hari (Perry 6ed : T. 8-18)
Ukuran ball mill (3 x 3) ft ; (4 x 3) ft ; (5 x 4) ft (Perry 6ed : T. 8-18)
Ukuran bola baja : 5 in (reduction ratio 15,6 : 1) (Brown : fig.37)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 30oC (suhu kamar)
Feed masuk :
Komponen Feed dari rotary Feed dari Feed total
cooler (kg/jam) cyclone (kg/jam) (kg/jam)
Al2O3 1414.3495 1.3450 1415.6945
SiO2 1663.9406 1.5823 1665.5230
Fe2O3 6.5799 0.0063 6.5861
TiO2 2.9244 0.0028 2.9272
CaO 26.3195 0.0250 26.3446
MgO 12.4287 0.0118 12.4405
K2O 13.8909 0.0132 13.9041
Na2O 5.4832 0.0052 5.4885
Total 3145.9168 2.9916 3148.9084
F + R = F'
R = 0.05 F'
Terdiri dari:
Komponen Feed (kg/jam) Produk (kg/jam) Recycle (kg/jam)
Al2O3 1415.6945 1490.2048 74.5102
SiO2 1665.5230 1753.1821 87.6591
Fe2O3 6.5861 6.9328 0.3466
TiO2 2.9272 3.0812 0.1541
CaO 26.3446 27.7311 1.3866
MgO 12.4405 13.0953 0.6548
K2O 13.9041 14.6359 0.7318
Na2O 5.4885 5.7773 0.2889
Total 3148.9084 3314.6404 165.7320
Neraca massa :
8. SCRREN
Fungsi : Memisahkan ukuran 200 mesh
Kriterian design :
Ukuran partikel : minimum 4.25 in (Perry 6ed : 21-15)
% oversize product : 5 % - 50% (Perry 6ed : 21-14)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 30oC (suhu kamar)
Feed masuk :
Komponen Feed (kg/jam) % berat
Al2O3 1490.2048 44.9583
SiO2 1753.1821 52.8921
Fe2O3 6.9328 0.2092
TiO2 3.0812 0.0930
CaO 27.7311 0.8366
MgO 13.0953 0.3951
K2O 14.6359 0.4416
Na2O 5.7773 0.1743
Total 3314.6404 100.0000
F' = R + P
F' = 3314.6404 kg
R = 165.7320 kg
F' = R + P
3314.6404 = 52.6316 + P
P = 3262 kg
H2O 4105.1867
Total 14368.1535 14368.1535
10. REAKTOR
Fungsi : Mereaksikan alumina dengan asam sulfat, membentuk aluminium sulfat
H2SO4
Kriteria design :
Diameter maksimum :4 m (Ulrich T 4-18)
Diamension Ratio , H/D : 2 / 1 (Ulrich T 4-18)
Kondisi operasi :
Tekanan : 1 atm
Suhu operasi : 110oC
Feed masuk :
Komponen Berat (kg/jam) % berat
Al2O3 1415.6945 44.9583
SiO2 1665.5230 52.8921
Fe2O3 6.5861 0.2092
TiO2 2.9272 0.0930
CaO 26.3446 0.8366
MgO 12.4405 0.3951
K2O 13.9041 0.4416
Na2O 5.4885 0.1743
Total 3148.9084 100.0000
= 14368.1535 kg
= 13.6018 kmol
= 1387.3806 kg
= 28.3139 kg
= 3998.9206 kg
= 27.2035 kmol
= 1632.2125 kg
= 33.3105 kg
= 5331.8942 kg
= 0.0403 kmol
= 6.4544 kg
= 0.1317 kg
H2SO4 yang bereaksi = 3 x 0.0403 = 0.1210 kmol
= 11.8600 kg
= 0.0359 kmol
= 2.8686 kg
= 0.0585 kg
= 7.0281 kg
= 0.4610 kmol
= 25.8177 kg
CaO yang sisa = 26.3446 - 25.8177
= 0.5269 kg
= 45.1809 kg
= 0.3048 kmol
= 12.1917 kg
= 0.2488 kg
= 29.8696 kg
= 13.62600 kg
= 0.2781 kg
= 14.2058 kg
= 0.0868 kmol
= 5.3787 kg
= 0.1098 kg
= 8.5018 kg
= 9447.4611 kg
= 6045.6940 kg
Neraca massa :
cake
Kriteria design :
5 % filtrat terikut pada cake
Kondisi operasi :
Tekanan operasi = 1 atm
Suhu masuk = 110 oC
Suhu keluar = 99 oC
Feed masuk :
Feed Berat (kg/jam) Filtrat Berat (kg/jam)
Al2O3 28.3139 Al2(SO4)3 4651.8056
SiO2 33.3105 Si(SO4)2 5984.7792
Fe2O3 0.1317 Fe2(SO4)3 16.1361
TiO2 0.0585 Ti(SO4)2 8.6059
CaO 0.5269 CaSO4 9.7880
MgO 0.2488 MgSO4 36.5751
K2O 0.2781 K2SO4 25.2226
Na2O 0.1098 Na2SO4 12.3189
Al2(SO4)3 4651.8056 H2O 6045.6940
Si(SO4)2 5984.7792 H2SO4 610.2463
Fe2(SO4)3 16.1361
Ti(SO4)2 8.6059
CaSO4 62.7001
MgSO4 36.5751
K2SO4 25.2226
Na2SO4 12.3189
H2O 6045.6940
H2SO4 610.2463
Total 17517.0619 17401.1716
Total 115.8903
sebesar 5 % filtrat terikut cake : 17401.1716 x 5% = 870.0586 kg
Neraca massa :
Komponen Masuk(kg/jam) Komponen Keluar(kg/jam)
Filtrat dari reaktor Cake
Al2O3 28.3139 Al2O3 28.3139
SiO2 33.3105 SiO2 33.3105
Fe2O3 0.1317 Fe2O3 0.1317
TiO2 0.0585 TiO2 0.0585
CaO 0.5269 CaO 0.5269
MgO 0.2488 MgO 0.2488
K2O 0.2781 K2O 0.2781
Na2O 0.1098 Na2O 0.1098
Al2(SO4)3 4651.8056 Al2(SO4)3 232.5903
Si(SO4)2 5984.7792 Si(SO4)2 299.2390
Fe2(SO4)3 16.1361 Fe2(SO4)3 0.8068
Ti(SO4)2 8.6059 Ti(SO4)2 0.4303
CaSO4 62.7001 CaSO4 53.4015
MgSO4 36.5751 MgSO4 1.8288
K2SO4 25.2226 K2SO4 1.2611
Na2SO4 12.3189 Na2SO4 0.6159
H2O 6045.6940 H2O 302.2847
H2SO4 610.2463 H2SO4 30.5123
17517.0619 985.9489
Filtrat menuju Thickener
Al2(SO4)3 4419.2154
Si(SO4)2 5685.5402
Fe2(SO4)3 15.3292
Ti(SO4)2 8.1756
CaSO4 9.2986
MgSO4 34.7463
K2SO4 23.9615
Na2SO4 11.7030
H2O 5743.4093
H2SO4 579.7340
16531.1130
Total 17517.0619 17517.0619
12. THICKENER
Fungsi : Memisahkan padatan dan liquid secara sedimentasi
Feed THICKENER Filtrat
cake
Kriteria design :
% solid pada feed : minimum 11 % (Perry 7 ed : 18-72)
Waktu pengendapan : 3 - 5 jam (Perry 7 ed : 18-72)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Waktu tinggal : 3 jam (Perry 7 ed : 18-72)
Penurunan suhu karena alat dan bahan = 10 % dari suhu masuk (Ulrich :432)
Suhu masuk : 99 oC
Suhu keluar : 89 oC
Feed masuk :
Komponen Berat (kg/jam)
Al2(SO4)3 4419.2154
Si(SO4)2 5685.5402
Fe2(SO4)3 15.3292
Ti(SO4)2 8.1756
CaSO4 9.2986
MgSO4 34.7463
K2SO4 23.9615
Na2SO4 11.7030
H2O 5743.4093
H2SO4 579.7340
Total 16531.1130
Komponen BM
Fe2(SO4)3 400
BaS 169
Fe2S3 208
BaSO4 233
Tinjauan reaksi :
Berat Fe2(SO4)3 = 15.3292 kg
Mol Fe2(SO4)3 = 15.3292 = 0.0383 kmol
400
Penambahan Glue :
Komposisi Glue :
Al2(SO4)3 :
Berat air = 5743.5684 kg
Kelarutan Al2(SO4)3 = 80.8 kg/100 kg H2O
Ca(SO4)
Berat air = 5743.5684 kg
Mg(SO4)
Berat air = 5743.5684 kg
K2(SO4)
Berat air = 5743.5684 kg
Na2(SO4)
Berat air = 5743.5684 kg
Kelarutan Na2(SO4) = 43 kg/100 kg H2O
Ba(SO4)
Berat air = 5743.5684 kg
Kelarutan Ba(SO4) = 0.00072 kg/100 kg H2O
Asumsi liquid terikut solid = 10 % dari liquid pada feed ( Perry ed 6 ; 19-87)
Terdiri dari :
Asumsi impurities yang sedikit jumlahnya dianggap air, komposisi liquid overflow:
Neraca Massa
13. EVAPORATOR
Fungsi : Memekatkan bahan sampai kadar 42 %
H2O
Kriteria design :
Kondisi operasi :
Tekanan operasi : 1 atm (Atmospheric pressure)
Suhu operasi : 82oC (Kirk Othmer , Vol 2 :247)
Kadar pemekatan : 42.00% (Kirk Othmer , Vol 2 : 59)
F= 14864.3820
XF= 0.2676
XL = 0.4200
F. XF = 14864.3820 x 0.2676 = 3977.2938 kg
V. XV = 0
Neraca massa :
14. KRISTALISER
S (mother liquor)
Feed C (kristal Al2(SO4)3)
KRISTALISER
Larutan Aluminium sulfat didinginkan sampai suhu 20oC
selama pendinginan 0% total H2O menguap
Feed masuk :
Komponen Berat
Al2(SO4)3 3977.2938
Si(SO4)2 5116.9862
H2O 375.4672
Total 9469.7472
Dari hasil perhitungan kelarutan diketahui bahwa aluminium kristal yang bisa
menjadi kristal :
Al2(SO4)3 = 3977.2938 - 89.7367
= 3887.5572 kg
Neraca massa :
Mother liquor
Terdiri dari :
Komponen feed Berat (kg/jam) Mother liquor Berat (kg/jam)
Mother Liquor
Al2(SO4)3 89.7367 Al2(SO4)3 85.2498
Si(SO4)2 5116.9862 Si(SO4)2 4861.1369
H2O 375.4672 H2O 356.6938
Kristal
Al2(SO4)3 (s) 3887.5572
Total 9469.7472 5303.0805
Al2(SO4)3 4.48683
Si(SO4)2 255.84931
H2O 18.77336
Al2(SO4)3 (s) 3887.55717
4166.66667
Neraca massa :
Komponen Masuk(kg/jam) Komponen Keluar(kg/jam)
Mother Liquor Mother Liquor
Al2(SO4)3 89.7367 Al2(SO4)3 85.2498
Si(SO4)2 5116.9862 Si(SO4)2 4861.1369
H2O 375.4672 H2O 356.6938
5582.1900 5303.0805
Kristal Menuju Ball mill
Al2(SO4)3 (s) 3887.5572 Al2(SO4)3 4.4868
Si(SO4)2 255.8493
H2O 18.7734
Al2(SO4)3 (s) 3887.5572
4166.6667
Total 9469.7472 9469.7472
Feed (F)
Produk solid (F')
Recycle ( R ) BALL MILL
Kriteria design :
Kapasitas : 5, 22, 51, 105, 180 ton/hari (Perry 6ed : T. 8-18)
Ukuran ball mill (3 x 3) ft ; (4 x 3) ft ; (5 x 4) ft (Perry 6ed : T. 8-18)
Ukuran bola baja : 5 in (reduction ratio 15,6 : 1) (Brown : fig.37)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 32oC (suhu kamar)
Feed masuk :
Komponen Feed total
(kg/jam)
Al2(SO4)3 4.4868
Si(SO4)2 255.8493
H2O 18.7734
Al2(SO4)3 (s) 3887.5572
Total 4166.6667
F + R = F'
R = 0.05 F'
F' = 3314.6404
Terdiri dari:
Komponen Feed (kg/jam) Produk (kg/jam) Recycle (kg/jam)
Al2(SO4)3 4.4868 4.7230 0.2361
Si(SO4)2 255.8493 269.3151 13.4658
H2O 18.7734 19.7614 0.9881
Al2(SO4)3 (s) 3887.5572 4092.1654 204.6083
Total 4166.6667 4385.9649 219.2982
Neraca massa :
17. SCRREN
Fungsi : Memisahkan ukuran 200 mesh
Kriterian design :
Ukuran partikel : minimum 4.25 in (Perry 6ed : 21-15)
% oversize product : 5 % - 50% (Perry 6ed : 21-14)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 30oC (suhu kamar)
Feed masuk :
Komponen Feed (kg/jam) % berat
Al2(SO4)3 4.7230 0.1077
Si(SO4)2 269.3151 6.1404
H2O 19.7614 0.4506
Al2(SO4)3 (s) 4092.1654 93.3014
Total 4385.9649 100.0000
Asumsi ukuran oversize = 5 % (Perry 6ed : 21-14)
Berat ukuran undersize = Feed - berat oversize
F' = R + P
F' = 4385.9649 kg
R = 219.2982 kg
F' = R + P
4385.9649 = 219.2982 + P
P = 4166.67 kg
Neraca Massa
= 4166.6667 kg/jam
= 30000 ton/tahun
PENTING BANGET!!!!!
Mg 30.2284700407
APPENDIX B
PERHITUNGAN NERACA PANAS
∆H = n . Cp. ∆T =
∫ ( Himmelblau : 386)
T
n Cp dT
T ref
Dengan : ∆H = panas ; kkal
Komponen BM A B C D
Al2O3.2SiO2 222 40.79 0.004763 -992800
Fe2O3 160 41.17 0.01882 -979500
TiO2 80 11.81 0.00754 -41900
CaO 56 10 0.00484 -108000
MgO 40 10.86 0.001197 -208700
K2O 94 4.97
Na2O 62 5.01 0.00536
CO2 44 10.34 0.00274 -195500
Al2O3 102 22.08 0.008971 -522500
SiO2 60 10.87 0.008712 -241200
H2SO4 98 58
Al2(SO4)3 342 63.5
Si(SO4)2 284 32.4
Fe2(SO4)3 400 66.2
Ti(SO4)2 240 35.7
CaSO4 136 18.52 0.02197 -156800
MgSO4 120 26.7
K2SO4 174 33.1
Na2SO4 142 32.8
BaS 169 39.8
Fe2S3 112 10.7 0.01336
BaSO4 233 21.35 0.0141
Protein 75 5.542 0.02483 -0.00000139 -4.03E-09
NaCl 58.5 10.79 0.0042
Al2(SO4)3 342 63.5
H2O (G) 18 8.22 0.00015 0.00000134
H2O (L) 18 7.701 0.0004505 0.00000251 -8.59E-10
Data konstanta spesific heat Glue dan H2O liquid dari Sherwood Appendic A
1. ROTARY KILN
Udara masuk pada suhu : 1200 oC = 2192 oF ( dry bulb) dengan kelembaban rata - ra
didapatkan wet bub = 1991.4 oF, dimana udara mempunyai humidity sebesar :
= 0.0179 lb H2O ( Humidity Chart)
lb udara kering
Keterangan :
Entalpi masuk :
Massa bahan :
Komponen Berat (kg/jam) BM kmol
Al2O3.2SiO2 3081.5256 222 13.8807
Fe2O3 6.5868 160 0.0412
TiO2 2.9275 80 0.0366
CaO 26.3472 56 0.4705
MgO 12.4417 40 0.3110
K2O 13.9055 94 0.1479
Na2O 5.4890 62 0.0885
CO2 510.1112366402 44 11.5934
Total : 3659.3346
T ref 2
- -992800 1 -
[ 303.15
= 203.9500 + 7.1600 -
= 156.1889 kkal/kmol
T ref 2
- -979500 1 -
[ 303.15
= 205.8500 + 28.2912 -
= 179.9558 kkal/kmol
∫ Cp dT TiO2 = A ( T- Tref) B ( T2 - Tref2)
T
T ref 2
- -41900 1 -
[ 303.15
= 59.0500 + 11.3345 -
= 68.0666 kkal/kmol
T ref 2
- -108000 1 -
[ 303.15
= 50.0000 + 7.2757 -
= 51.3012 kkal/kmol
T ref 2
- -208700 1 -
[ 303.15
= 54.3000 + 1.7994 -
= 44.5542 kkal/kmol
∫ Cp dT K2O = A ( T- Tref)
T
T ref
= 4.97 (303,15 - 298,15)
= 24.8500 kkal/kmol
T ref 2
= 25.05 + 8.05742
= 33.1074 kkal/kmol
T ref 2
- -195500 1 -
[ 303.15
= 51.7000 + 4.1189 -
= 45.0040 kkal/kmol
Komponen
∫ Cp dT ( kkal/kmol)
T
T ref
Al2O3.2SiO2 156.1889
Fe2O3 179.9558
TiO2 68.0666
CaO 51.3012
MgO 44.5542
K2O 24.8500
Na2O 33.1074
CO2 45.0040
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Entalpi keluar :
Massa bahan :
T ref 2
- -522500 1 -
[ 1373.15
= 23736 + 8058.8624 -
= 30422.9007 kkal/kmol
T ref 2
- -241200 1 -
[ 1373.15
= 11685 + 7826.1965 -
= 18878.1123 kkal/kmol
T ref 2
- -979500 1 -
[ 1373.15
= 44257.7500 + 16906.4530 -
= 58592.2673 kkal/kmol
- -41900 1 -
[ 1373.15
= 12695.7500 + 6773.3611 -
= 19359.0916 kkal/kmol
T ref 2
- -108000 1 -
[ 1373.15
= 10750.0000 + 4347.8870 -
= 14814.3045 kkal/kmol
T ref 2
- -208700 1 -
[ 1373.15
= 11674.5000 + 1075.2935 -
= 12201.7966 kkal/kmol
∫ Cp dT K2O = A ( T- Tref)
T
T ref
= 4.97 (1373,15 - 298,15)
= 5342.7500 kkal/kmol
T ref 2
= 5385.75 + 4815.0153
= 10200.7653 kkal/kmol
Komponen
∫ Cp dT ( kkal/kmol)
T
T ref
Al2O3 30422.9007
SiO2 18878.1123
Fe2O3 58592.2673
TiO2 19359.0916
CaO 14814.3045
MgO 12201.7966
K2O 5342.7500
Na2O 10200.7653
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
T ref 2
- -522500 1 -
[ 1386.55
= 24032 + 8224.7361 -
= 30880.9691 kkal/kmol
T ref 2
= 19183.1575 kkal/kmol
T ref 2
- -979500 1 -
[ 1386.55
= 44809 + 17254.4346 -
= 59485.0331 kkal/kmol
T ref 2
- -41900 1 -
[ 1386.55
= 12854.0040 + 6912.7756 -
= 19656.4652 kkal/kmol
T ref 2
= 15037.0359 kkal/kmol
T ref 2
- -208700 1 -
[ 1386.55
= 11820.0240 + 1097.4260 -
= 12367.9843 kkal/kmol
∫ Cp dT K2O = A ( T- Tref)
T
T ref
= 4.97 (1386,55 - 298,15)
= 5409.3480 kkal/kmol
T ref 2
= 5452.88 + 4914.121646
= 10367.0056 kkal/kmol
T ref 2
= 10.34 ( 1386,55 - 298,15) +
- -195500 1 -
[ 1386.55
= 11254.0560 + 2512.0696 -
= 13251.4129 kkal/kmol
Komponen
∫ Cp dT ( kkal/kmol)
T
T ref
Al2O3 30880.9691
SiO2 19183.1575
Fe2O3 59485.0331
TiO2 19656.4652
CaO 15037.0359
MgO 12367.9843
K2O 5409.3480
Na2O 10367.0056
CO2 13251.4129
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Total entalpi keluar = Entalpi menuju rotary cooler + Entalpi menuju cyclone
= 960994.3431 + 2149.016545
= 963143.3596 kkal
Panas reaksi :
- [( 13.8807 x -648.7 )]
= -2155.81867 kkal
Kebutuhan udara :
Digunakan Petroleum Fuels Oil 33oAPI (0,22% sulfur) (Perry 7ed; T. 27-6)
Digunakan Petroleum Fuels Oil 33o API dengan heating value = 10562.39472
Neraca Energi :
∆ H Reaksi 2155.8186716081
Q loss 50660.784672266
Total 1015959.9630 1015959.9630
2. ROTARY COOLER
udara bebas
campuran padatan ROTARY COOLER
( 1100oC) produk
Kondisi operasi :
Tekanan operasi : 1 atm
Suhu operasi : 35 oC
Udara masuk pada suhu = 30 oC = 86 oF ( dry bulb) dengan kelembaban rata -rata = 70 %
didapatkan wet bub = 77 oF, dimana udara mempunyai humidity sebesar :
= 0.02 lb H2O ( Humidity Chart)
lb udara kering
Keterangan :
Entalpi masuk :
Massa bahan :
Komponen
∫ Cp dT ( kkal/kmol)
T
T ref
Al2O3 30880.9691
SiO2 19183.1575
Fe2O3 59485.0331
TiO2 19656.4652
CaO 15037.0359
MgO 12367.9843
K2O 5409.3480
Na2O 10367.0056
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Total entalpi masuk = entalpi dari rotary kiln + entalpi dari cyclone
= 960994.34 + 928.1612
= 961922.50
Entalpi keluar :
Massa bahan :
Komponen Berat (kg/jam) BM kmol
Al2O3 1414.3495 102 13.8662
SiO2 1663.9406 60 27.7323
Fe2O3 6.5799 160 0.0411
TiO2 2.9244 80 0.0366
CaO 26.3195 56 0.4700
MgO 12.4287 40 0.3107
K2O 13.8909 94 0.1478
Na2O 5.4832 62 0.0884
Total 3145.9168
T ref 2
- -522500 1 -
[ 308.15
= 221 + 27.1956 -
= 191.1248 kkal/kmol
T ref 2
- -241200 1 -
[ 308.15
= 109 + 26.4104 -
= 108.8573 kkal/kmol
∫ Cp dT Fe2O3 = A ( T- Tref) + B ( T2 - Tref2)
T
T ref 2
- -979500 1 -
[ 308.15
= 412 + 57.0528 -
= 362.1405 kkal/kmol
T ref 2
- -41900 1 -
[ 308.15
= 118.1000 + 22.8575 -
= 136.3970 kkal/kmol
T ref 2
- -108000 1.00 -
[ 308.15
= 100.0000 + 14.6725 -
= 102.9173 kkal/kmol
- -208700 1 -
[ 308.15
= 108.6000 + 3.6287 -
= 89.5130 kkal/kmol
∫ Cp dT K2O = A ( T- Tref)
T
T ref
= 4.97 (308,15 - 298,15)
= 49.7000 kkal/kmol
T ref 2
= 50.10 + 16.24884
= 66.3488 kkal/kmol
Komponen
∫ Cp dT ( kkal/kmol)
T
T ref
Al2O3 191.1248
SiO2 108.8573
Fe2O3 362.1405
TiO2 136.3970
CaO 102.9173
MgO 89.5130
K2O 49.7000
Na2O 66.3488
Entalpi bahan : ∆H =
∫
T
n Cp dT
n ∫ T ref
Cp dT
T ref 2
= 22.08 ( 538,11- 298,15) +
- -522500 1 -
[ 538.11
= 5298 + 900.0791 -
= 5416.8233 kkal/kmol
T ref 2
- -241200 1 -
[ 538.11
= 2608 + 874.0931 -
= 3121.6604 kkal/kmol
T ref 2
- -979500 1 -
[ 538.11
= 9879 + 1888.2498 -
= 10302.2358 kkal/kmol
T ref 2
= 2833.8751 + 756.5039 -
= 3527.7115 kkal/kmol
T ref 2
- -108000 1.00 -
[ 538.11
= 2399.5556 + 485.6073 -
= 2723.6332 kkal/kmol
T ref 2
- -208700 1 -
[ 538.11
= 2605.9173 + 120.0975 -
= 2413.8737 kkal/kmol
∫ Cp dT K2O = A ( T- Tref)
T
T ref
= 4.97 (538,11 - 298,15)
= 1192.5791 kkal/kmol
∫ Cp dT Na2O = A ( T- Tref) + B ( T2 - Tref2)
T
T ref 2
= 1202.18 + 537.779966
= 1739.9573 kkal/kmol
Komponen
∫ Cp dT ( kkal/kmol)
T
T ref
Al2O3 5416.8233
SiO2 3121.6604
Fe2O3 10302.2358
TiO2 3527.7115
CaO 2723.6332
MgO 2413.8737
K2O 1192.5791
Na2O 1739.9573
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
= 5778.3131 + 165.1156
= 5943.4287 kkal
Kebutuhan udara :
M udara = Q = 955979.076
Cp x ∆ T 0,24 x ( 287,6 - 30)
= 16953.18989 kg/jam
Neraca Energi :
Q terserap 955979.076
Total 961922.5043 961922.5043
3. REAKTOR
Kondisi operasi :
Entalpi masuk :
1. Entalpi bahan dari rotary cooler dan cyclone pada suhu 35oC : ∆ H =
n
Massa bahan :
Komponen Berat (kg/jam) BM kmol
Al2O3 1415.6945 102 13.8794
SiO2 1665.5230 60 27.7587
Fe2O3 6.5861 160 0.0412
TiO2 2.9272 80 0.0366
CaO 26.3446 56 0.4704
MgO 12.4405 40 0.3110
K2O 13.9041 94 0.1479
Na2O 5.4885 62 0.0885
Total 3148.9084
Komponen
∫ Cp dT ( kkal/kmol)
T
T ref
Al2O3 191.1248
SiO2 108.8573
Fe2O3 362.1405
TiO2 136.3970
CaO 102.9173
MgO 89.5130
K2O 49.7000
Na2O 66.3488
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Massa bahan :
∫ Cp dT H2SO4 = A ( T- Tref)
T
T ref
= 58 (303,15-298,15)
= 290 kkal/mol
T ref 2
- 0.00000251 1 -
[ 303.15
= 38.5050 + 0.6772 -
= 39.1822 kkal/kmol
Komponen
∫ Cp dT ( kkal/kmol)
T
T ref
H2SO4 290.0000
H2O 39.1822
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Total entalpi masuk : Entalpi dari Rotary Cooler + Entalpi dari Tangki H2SO4
= 5783.8080 + 39145.5381
= 44929.3460 kkal
Entalpi Keluar :
T ref 2
- -522500 1 -
[ 383.15
= 1876.8000 + 259.7575 -
= 1747.7796 kkal
T ref 2
- -241200 1 -
[ 383.15
= 923.9500 + 252.2581 -
= 996.7378 kkal
- -979500 1 -
[ 383.15
= 3499.4500 + 544.9378 -
= 3315.5687 kkal
T ref 2
- -41900 1 -
[ 383.15
= 1003.8500 + 218.3226 -
= 1190.9959 kkal
T ref 2
- -108000 1 -
[ 383.15
= 850.0000 + 140.1434 -
= 909.7836 kkal
T ref 2
= 10.86 ( 383.15 - 298.15
- -208700 1 -
[ 383.15
= 923.1000 + 34.6594 -
= 802.4715 kkal
∫ Cp dT K2O = A ( T- Tref)
T
T ref
= 4.97 ( 383.15 - 298.15
= 422.45 kkal
T ref 2
= 425.8500 + 155.2001
= 581.0501 kkal
∫ Cp dT Al2(SO4)3 = A ( T- Tref)
T
T ref
= 63.5 ( 383.15 - 298.15
= 5397.5 kkal
T ref 2
- 0 1 -
[
[ 383.15
= 2754.0000 + 0.0000 -
= 2754.0000 kkal
∫ Cp dT Fe2(SO4)3 = A ( T- Tref)
T
T ref
= 66.2 ( 383.15 - 298.15
= 5627 kkal
T ref 2
- 0 1 -
[ 383.15
= 3034.5000 + 0.0000 -
= 3034.5000 kkal
T ref 2
- -156800 1 -
[ 383.15
= 1574.2000 + 636.1468 -
= 2093.6763 kkal
∫ Cp dT MgSO4 = A ( T- Tref)
T
∫ T ref
= 26.7 ( 383.15 - 298.15
= 2269.5 kkal
∫ Cp dT K2(SO4) = A ( T- Tref)
T
T ref
= 33.1 ( 383.15 - 298.15
= 2813.5 kkal
∫ Cp dT Na2SO4 = A ( T- Tref)
T
T ref
= 32.8 ( 383.15 - 298.15
= 2788 kkal
T ref 2
- 0.00000251 1 -
[ 383.15
= 654.5850 + 13.0443 -
= 667.6293 kkal
∫ Cp dT H2SO4 = A ( T- Tref)
T
T ref
= 58 ( 383.15 - 298.15
= 4930 kkal
Komponen
∫ Cp dT ( kkal/kmol)
T
T ref
Al2O3 1747.7796
SiO2 996.7378
Fe2O3 3315.5687
TiO2 1190.9959
CaO 909.7836
MgO 802.4715
K2O 422.45
Na2O 581.0501
Al2(SO4)3 5397.5
Si(SO4)2 2754.0000
Fe2(SO4)3 5627
Ti(SO4)2 3034.5000
CaSO4 2093.6763
MgSO4 2269.5
K2(SO4) 2813.5
Na2SO4 2788
H2O 667.6293
H2SO4 4930
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Panas reaksi :
o
Data ∆H F komponen : (Perry 7ed ; T 2.220)
o
Komponen ∆H F (kkal/mol)
Al2O3 -399.09
SiO2 -202.46
Fe2O3 -198.5
TiO2 -225
CaO -151.7
MgO -143.84
K2O -86.2
Na2O -99.45
Al2(SO4)3 -820.99
Si(SO4)2 -164.2
Fe2(SO4)3 -221.3
Ti(SO4)2 -192.2
CaSO4 -336.58
MgSO4 -304.94
K2(SO4) -342.65
Na2(SO4) -330.5
H2O -68.32
H2SO4 -193.69
= -622813.461 kkal
o
∆H R
25oC
= [( 27203.5417 x -164.2 ) +( 54407.0835
= 7861823.561 kkal
= 14252.57102 kkal
= 7814.8691 kkal
= -27435.8981 kkal
= -10890.2213 kkal
o
∆H R
25oC
= [( 144.9574 x -342.65 ) +( 144.9574
= -19001.0210 kkal
= -9168.0534 kkal
= 455502.6726 kg
Neraca Energi :
4. FILTER PRESS
Fungsi : Memisahkan padatan dan air yang terikut
cake
Kriteria design :
5 % filtrat terikut pada cake
Kondisi operasi :
Tekanan operasi = 1 atm
Suhu masuk = 110 oC
Suhu keluar = 99 oC
Entalpi masuk :
∫
1. Entalpi bahan dari Reaktor pada suhu 110oC : ∆H = T
n Cp
T ref
Entalpi keluar :
T ref 2
- -522500 1 -
[ 372.15
= 1633.9200 + 222.4907 -
= 1507.9408 kkal
T ref 2
- -241200 1 -
[ 372.15
= 804.3800 + 216.0672 -
= 859.5842 kkal
T ref 2
- -979500 1 -
[ 372.15
= 3046.5800 + 466.7567 -
= 2860.0808 kkal
- -41900 1 -
[ 372.15
= 873.9400 + 187.0003 -
= 1032.9960 kkal
T ref 2
- -108000 1 -
[ 372.15
= 740.0000 + 120.0373 -
= 788.0091 kkal
T ref 2
- -208700 1 -
[ 372.15
= 803.6400 + 29.6869 -
= 694.1391 kkal
∫ Cp dT K2O = A ( T- Tref)
T
T ref
= 4.97 ( 372.15 - 298.15
= 367.78 kkal
T ref 2
= 370.7400 + 132.9339
= 503.6739 kkal
∫ Cp dT Al2(SO4)3 = A ( T- Tref)
T
T ref
= 63.5 ( 372.15 - 298.15
= 4699 kkal
T ref 2
- 0 1 -
[ 372.15
= 2397.6000 + 0.0000 -
= 2397.6000 kkal
∫ Cp dT Fe2(SO4)3 = A ( T- Tref)
T
T ref
= 66.2 ( 372.15 - 298.15
= 4898.8 kkal
∫ Cp dT Ti(SO4)2 = A ( T- Tref) + B ( T2 - Tref2)
T
T ref 2
- 0 1 -
[ 372.15
= 2641.8000 + 0.0000 -
= 2641.8000 kkal
T ref 2
- -156800 1 -
[ 372.15
= 1370.4800 + 544.8802 -
= 1810.7859 kkal
∫ Cp dT MgSO4 = A ( T- Tref)
T
T ref
= 26.7 ( 372.15 - 298.15
= 1975.8 kkal
∫ Cp dT K2(SO4) = A ( T- Tref)
T
T ref
= 33.1 ( 372.15 - 298.15
= 2449.4 kkal
∫ Cp dT Na2SO4 = A ( T- Tref)
T
T ref
= 32.8 ( 372.15 - 298.15
= 2427.2 kkal
T ref 2
- 0.00000251 1 -
[ 372.15
= 569.8740 + 11.1729 -
= 581.0469 kkal
∫ Cp dT H2SO4 = A ( T- Tref)
T
T ref
= 58 ( 372.15 - 298.15
= 4292 kkal
Komponen
∫ Cp dT ( kkal/kmol)
T
T ref
Al2O3 1747.7796
SiO2 859.5842
Fe2O3 2860.0808
TiO2 1032.9960
CaO 788.0091
MgO 694.1391
K2O 367.78
Na2O 503.6739
Al2(SO4)3 4699
Si(SO4)2 2397.6000
Fe2(SO4)3 4898.8
Ti(SO4)2 2641.8000
CaSO4 1810.7859
MgSO4 1975.8
K2(SO4) 2449.4
Na2SO4 2427.2
H2O 581.0469
H2SO4 4292
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Komponen
∫ Cp dT ( kkal/kmol)
T
T ref
Al2(SO4)3 4699
Si(SO4)2 2397.6000
Fe2(SO4)3 4898.8
Ti(SO4)2 2641.8000
CaSO4 1810.7859
MgSO4 1975.8
K2(SO4) 2449.4
Na2SO4 2427.2
H2O 581.0469
H2SO4 4292
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
= 19314.3087 + 334981.450
= 354295.759 kkal
Neraca Energi :
Q loss 52675.8444
Total 406971.6029 406971.6029
5. THICKENER
Fungsi : Memisahkan padatan dan liquid secara sedimentasi
THICKENER
Feed THICKENER Filtrat
99oC 89oC
cake 89oC
Kriteria design :
% solid pada feed : minimum 11 % (Perry 7 ed : 18-72)
Waktu pengendapan : 3 - 5 jam (Perry 7 ed : 18-72)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Waktu tinggal : 3 jam (Perry 7 ed : 18-72)
Penurunan suhu karena alat dan bahan = 10 % dari suhu masuk (Ulrich :432)
Suhu masuk : 99 oC
Suhu keluar : 89 oC
Entalpi masuk :
∫
1. Entalpi bahan dari Filter Press pada suhu 99oC :∆ H = T
n Cp
T ref
Massa bahan :
T ref
= 39.8 ( 303.15 - 298.15
= 199 kkal
∫ Cp dT Na2SO4 = A ( T- Tref)
T
T ref
= 32.8 ( 303.15 - 298.15
= 164 kkal
Komponen
∫ Cp dT ( kkal/kmol)
T
T ref
BaS 199
Na2SO4 164
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Massa bahan :
T ref 2
= 5.54 ( 303.15 - 298.15
- -0.00000139 1 -
[ 303.15
= 27.7100 + 37.3257 -
= 65.0357 kkal
T ref 2
= 10.79 ( 303.15 - 298.15
= 53.95 + 6.31
= 60.26 kkal
T ref 2
- 0.00000251 1 -
[ 303.15
= 38.5050 + 0.6772 -
= 39.1822 kkal
Komponen
∫ Cp dT ( kkal/kmol)
T
T ref
Protein 65.0357
NaCl 60.2637
H2O 39.1822
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
∆H Protein = 0.0212 kmol x 65.0357 kkal/kmol
Total entalpi masuk : Entalpi dari Filter Press + Entalpi dari Tangki BaS
= 335006.095 kkal
Entalpi Keluar :
∫ Cp dT Al2(SO4)3 = A ( T- Tref)
T
T ref
= 63.5 ( 362.15 - 298.15
= 4064 kkal
∫ Cp dT Si(SO4)2 = A ( T- Tref)
T
T ref
= 32.4 ( 362.15 - 298.15
= 2073.6 kkal
∫ Cp dT H2O = A ( T- Tref) + B ( T2 - Tref2)
T
T ref 2
- 0.00000251 1 -
[ 362.15
= 492.8640 + 9.519 -
= 502.383 kkal
Komponen
∫ Cp dT ( kkal/kmol)
T
T ref
Al2(SO4)3 4064.0000
Si(SO4)2 2073.6000
H2O 502.3829
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
T ref 2
- -0.00000139 1 -
[ 362.15
= 354.6880 + 524.6480 -
= 879.3360 kkal
T ref 2
= 10.7 ( 362.15 - 298.15
= 684.8 + 282.29
= 967.09 kkal
T ref 2
= 21.35 ( 362.15 - 298.15
= 1366.4 + 297.93
= 1664.33 kkal
Komponen
∫ Cp dT ( kkal/kmol)
T
T ref
Protein 879.3360
Fe2S3 967.0915
Ba(SO4) 1664.3274
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
∫ Cp dT Al2(SO4)3 = A ( T- Tref)
T
T ref
= 63.5 ( 362.15 - 298.15
= 4064 kkal
∫ Cp dT Si(SO4)2 = A ( T- Tref)
T
T ref
= 32.4 ( 362.15 - 298.15
= 2073.6 kkal
∫ Cp dT Ti(SO4)2 = A ( T- Tref)
T
T ref
= 35.7 ( 362.15 - 298.15
= 2284.8 kkal
∫ Cp dT CaSO4 = A ( T- Tref) + B ( T2 - Tref2)
T
T ref 2
- -156800 1 -
[ 362.15
= 1185.2800 + 464.2173 -
= 1556.5573 kkal
∫ Cp dT MgSO4 = A ( T- Tref)
T
T ref
= 26.7 ( 362.15 - 298.15
= 1708.8 kkal
∫ Cp dT K2(SO4) = A ( T- Tref)
T
T ref
= 33.1 ( 362.15 - 298.15
= 2118.4 kkal
∫ Cp dT Na2SO4 = A ( T- Tref)
T
T ref
= 32.8 ( 362.15 - 298.15
= 2099.2 kkal
T ref 2
= 10.79 ( 362.15 - 298.15
= 690.56 + 88.74
= 779.30 kkal
∫ Cp dT H2O = A ( T- Tref) + B ( T2 - Tref2)
T
T ref 2
- 0.00000251 1 -
[ 362.15
= 492.8640 + 9.5189 -
= 502.3829 kkal
∫ Cp dT H2SO4 = A ( T- Tref)
T
T ref
= 58 ( 362.15 - 298.15
= 3712 kkal
Komponen
∫ Cp dT ( kkal/kmol)
T
T ref
Al2(SO4)3 4064.0000
Si(SO4)2 2073.6000
Ti(SO4)2 2284.8000
CaSO4 1556.5573
MgSO4 1708.8
K2(SO4) 2118.4
Na2SO4 2099.2
NaCl 779.30
H2O 502.3829
H2SO4 3712
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Total entalpi keluar : Entalpi bahan ke evaporator + Entalpi bahan limbah padat
= 285766.529 kkal
Panas reaksi :
o o o
∆H R
25oC
= [ ∆H F
25oC
produk] - [ ∆H F
25oC
reaktan]
o
Data ∆H F komponen : (Perry 7ed ; T 2.220)
o
Komponen ∆H F (kkal/mol)
Fe2(SO4)3 -653.3
BaS -111.2
Fe2S3 -38.2
BaSO4 -340.2
= -28.32462 kkal
Neraca Energi :
6. EVAPORATOR
H2O Steam
Al2(SO4)3 Produk
Feed EVAPORATOR Al2(SO4)3
89oC 90oC
Steam
Kriteria design :
Kondisi operasi :
Tekanan operasi : 1 atm (Atmospheric pressure)
Suhu operasi : 90oC (Kirk Othmer , Vol 2 : 247)
Kadar pemekatan : 42.00% (Kirk Othmer , Vol 2 : 59)
Entalpi masuk :
∫
1. Entalpi bahan dari Thickener pada suhu 90oC : ∆H = T
n Cp
T ref
Entalpi Keluar :
1. Filtrat menuju Kristaliser pada suhu 90oC : ∆H =
∫
T
n Cp
T ref
Massa bahan :
∫ Cp dT Al2(SO4)3 = A ( T- Tref)
T
T ref
= 63.5 ( 363.15 - 298.15
= 4127.5 kkal
∫ Cp dT Si(SO4)2 = A ( T- Tref)
T
T ref
= 32.4 ( 363.15 - 298.15
= 2106 kkal
T ref 2
= 500.5650 + 9.682 -
= 510.247 kkal
Komponen
∫ Cp dT ( kkal/kmol)
T
T ref
Al2(SO4)3 4127.5000
Si(SO4)2 2106.0000
H2O 510.2473
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
T ref 2
- 0.00000134 1 -
[ 363.15
= 534.3000 + 3.224 -
= 537.524 kkal
= 3093723.167 kkal
= 107627.727 + 3093723.17
= 3201350.89 kkal
Kebutuhan steam :
Dipakai steam pada suhu tekanan steam 4,5 atm dan suhu 148 oC (Ulrich ;426 )
M steam = Q steam
λ steam
= 3099804.38 = 4746.293638 kg
653.1
Neraca Energi :
7. KRISTALISER
Brine 5 oC
Entalpi masuk :
∫
1. Entalpi bahan dari Evaporator pada suhu 90oC :∆ H = T
n Cp
T ref
Entalpi keluar :
1. Entalpi bahan berupa mother liquor
Komponen Berat (kg/jam) BM kmol
Al2(SO4)3 89.7367 342 0.2624
Si(SO4)2 5116.9862 220 23.2590
H2O 375.4672 18 20.8593
Total 5582.1900
∫ Cp dT Al2(SO4)3 = A ( T- Tref)
T
T ref
= 63.5 ( 293.15 - 298.15
= -317.5 kkal
∫ Cp dT Si(SO4)2 = A ( T- Tref)
T
T ref
= 32.4 ( 293.15 - 298.15
= -162 kkal
T ref 2
- 0.00000251 1 -
[ 293.15
= -38.5050 + -0.666 -
= -39.171 kkal
Komponen
∫ Cp dT ( kkal/kmol)
T
T ref
Al2(SO4)3 -317.5000
Si(SO4)2 -162.0000
H2O -39.1710
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
T ref
= 63.5 ( 293.15 - 0.00
= 18615.025 kkal
= -4668.349 + 18615.03
= 13946.68 kkal
= 1432257.90 kkal
Kebutuhan Refrigerator :
Air Refrigerator = 5 oC
Air Refigerator = 20 oC
= 125591.6834 kg
kkal/kamol.Kelvin
D
-4.03E-09
-8.59E-10
1
298.15 ]
54.9211
+ C
[ 1
T
- 1
Tref ]
0.018820 ( 303,152 - 298,15,152)
2
1
298.15 ]
54.1854
+ C
[ 1
T
- 1
Tref ]
0.007540 ( 303,152 - 298,15,152)
2
1
298.15 ]
2.3179
+ C
[ 1
T
- 1
Tref ]
0.004840 ( 303,152 - 298,15,152)
2
1
298.15 ]
5.9745
+ C
[ 1
T
- 1
Tref ]
0.001197 ( 303,152 - 298,15,152)
2
1
298.15 ]
11.5452
0.005360 ( 303,152 - 298,15,152)
2
+ C
[ 1
T
- 1
Tref ]
0.002740 ( 303,152 - 298,15,152)
2
1
298.15 ]
10.8149
kkal/kmol = 2168.017898 kkal
∫
T
Cp dT
T ref
+ C
[ 1
T
- 1
Tref ]
0.008971 ( 1373,152 - 298,15,152)
2
1
298.15 ]
1371.961626
+ C
[ 1
T
- 1
Tref ]
0.008712 ( 1373,152 - 298,15,152)
2
1
298.15 ]
633.3342471
+ C
[ 1
T
- 1
Tref ]
0.018820 ( 1373,152 - 298,15,152)
2
1
298.15 ]
2571.9357
+ C
[ 1 - 1
]
[ T Tref ]
0.007540 ( 1373,152 - 298,15,152)
2
1
298.15 ]
110.0195
+ C
[ 1
T
- 1
Tref ]
0.004840 ( 1373,152 - 298,15,152)
2
1
298.15 ]
283.5825
+ C
[ 1
T
- 1
Tref ]
0.001197 ( 1373,152 - 298,15,152)
2
1
298.15 ]
547.9969
0.005360 ( 1373,152 - 298,15,152)
2
T
Cp dT
T ref
+ C
[ 1
T
- 1
Tref ]
0.008971 ( 1386,552 - 298,15,152)
2
1
298.15 ]
1375.638998
+ C
[ 1
T
- 1
Tref ]
0.008712 ( 1386,552 - 298,15,152)
2
1
298.15 ]
635.0318206
+ C
[ 1
T
- 1
Tref ]
0.018820 ( 1386,552 - 298,15,152)
2
1
298.15 ]
2578.82947
+ C
[ 1
T
- 1
Tref ]
0.007540 ( 1386,552 - 298,15,152)
2
1
298.15 ]
110.3144
+ C
[ 1
T
- 1
Tref ]
0.004840 ( 1386,552 - 298,15,152)
2
1
298.15 ]
284.3426
+ C
[ 1
T
- 1
Tref ]
0.001197 ( 1386,552 - 298,15,152)
2
1
298.15 ]
549.4658
+ C
[ 1
T
- 1
Tref ]
0.002740 ( 1386,552 - 298,15,152)
2
1
298.15 ]
514.7128
reaktan]
2 SiO3(s)
27.7615 x -202.46 )]
+ Q loss
+ 5% Q supply
3117.394909 kg/jam
(ρ H2O = 1 gr/cc)
Btu/lb
kkal/kg
= 211.0387 lb/jam
udara bebas (30oC)
( 30oC)
Cp dT
kkal/kmol = 407.2183 kkal
1
298.15 ]
56.8708
+ C
[ 1
T
- 1
Tref ]
0.008712 ( 308,152 - 298,15,152)
2
1
298.15 ]
26.25308337
+ C
[ 1
T
- 1
Tref ]
0.018820 ( 308,152 - 298,15,152)
2
1
298.15 ]
106.6123348
+ C
[ 1
T
- 1
Tref ]
0.007540 ( 308,152 - 298,15,152)
2
1
298.15 ]
4.5605
+ C
[ 1
T
- 1
Tref ]
0.004840 ( 308,152 - 298,15,152)
2
1
298.15 ]
11.7551
+ C
[ 1 - 1
]
[ T Tref ]
0.001197 (308,152 - 298,15,152)
2
1
298.15 ]
22.7157
+ C
[ 1
T
- 1
Tref ]
0.008971 ( 538,112 - 298,15,152)
2
1
298.15 ]
781.4745
+ C
[ 1
T
- 1
Tref ]
0.008712 (538,112 - 298,15,152)
2
1
298.15 ]
360.749571
+ C
[ 1
T
- 1
Tref ]
0.018820 (538,112 - 298,15,152)
2
1
298.15 ]
1464.984265
+ C
[ 1
T
- 1
Tref ]
0.007540 ( 538,112 - 298,15,152)
2
1
298.15 ]
62.6675
+ C
[ 1
T
- 1
Tref ]
0.004840 ( 538,112 - 298,15,152)
2
1
298.15 ]
161.5297
+ C
[ 1
T
- 1
Tref ]
0.001197 (538,112 - 298,15,152)
2
1
298.15 ]
312.1411
0.005360 ( 538,112 - 298,15,152)
2
Aluminium sulfat
∫
T
Cp dT
T ref
∫
T
n Cp dT
T ref
+ C
[ 1
T
- 1
Tref ]
0.000451 (303,152 - 298,15,152)
2
1
298.15 ]
0.0000
Cp dT
+ C
[ 1
T
- 1
Tref ]
) + 0.008971 (383,152 - 298,152)
2
1
298.15 ]
388.7779
+ C
[ 1
T
- 1
Tref ]
) + 0.008712 (383,152 - 298,152)
2
1
298.15 ]
179.4703
+ C
[ 1 - 1
]
[ T Tref ]
) + 0.018820 (383,152 - 298,152)
2
1
298.15 ]
728.8191
+ C
[ 1
T
- 1
Tref ]
) + 0.007540 (383,152 - 298,152)
2
1
298.15 ]
31.1766
+ C
[ 1
T
- 1
Tref ]
) + 0.004840 (383,152 - 298,152)
2
1
298.15 ]
80.3598
+ C
[ 1
T
- 1
Tref ]
) + 0.001197 (383,152 - 298,152)
2
1
298.15 ]
155.2879
+ C
[ 1
T
- 1
Tref ]
) + 0.005360 (383,152 - 298,152)
2
+ C
[ 1
T
- 1
Tref ]
) + 0.000000 (383,152 - 298,152)
2
1
]
298.15 ]
0.0000
+ C
[ 1
T
- 1
Tref ]
) + 0.000000 (383,152 - 298,152)
2
1
298.15 ]
0.0000
+ C
[ 1
T
- 1
Tref ]
) + 0.021970 (383,152 - 298,152)
2
1
298.15 ]
116.6706
)
+ C
[ 1
T
- 1
Tref ]
) + 0.000451 (383,152 - 298,152)
2
1
298.15 ]
0.0000
)
kkal/kmol = 485.1612 kkal
reaktan]
x -68.32 )] -
x -193.69 )]
x -68.32 )] -
x -193.69 )]
x -68.32 )] -
x -193.69 )]
x -68.32 )] -
x -193.69 )]
x -68.32 )] -
x -193.69 )]
x -68.32 )] -
x -193.69 )]
x -68.32 )] -
x -193.69 )]
x -68.32 )] -
x -193.69 )]
6832540.09
30 )
dT
+ C
[ 1
T
- 1
Tref ]
) + 0.008971 (372,152 - 298,152)
2
1
298.15 ]
348.4698
+ C
[ 1
T
- 1
Tref ]
) + 0.008712 (372,152 - 298,152)
2
1
298.15 ]
160.8630
+ C
[ 1
T
- 1
Tref ]
) + 0.018820 (372,152 - 298,152)
2
1
298.15 ]
653.2559
+ C
[ 1 - 1
]
[ T Tref ]
) + 0.007540 (372,152 - 298,152)
2
1
298.15 ]
27.9443
+ C
[ 1
T
- 1
Tref ]
) + 0.004840 (372,152 - 298,152)
2
1
298.15 ]
72.0282
+ C
[ 1
T
- 1
Tref ]
) + 0.001197 (372,152 - 298,152)
2
1
298.15 ]
139.1879
)
+ C
[ 1
T
- 1
Tref ]
) + 0.005360 (372,152 - 298,152)
2
+ C
[ 1
T
- 1
Tref ]
) + (372,152 - 298,152)
2
1
298.15 ]
0.0000
)
+ C
[ 1
T
- 1
Tref ]
) + (372,152 - 298,152)
2
1
298.15 ]
0.0000
+ C
[ 1
T
- 1
Tref ]
) + 0.021970 (372,152 - 298,152)
2
1
298.15 ]
104.5743
)
)
+ C
[ 1
T
- 1
Tref ]
) + 0.000451 (372,152 - 298,152)
2
1
298.15 ]
0.0000
)
kkal/kmol = 485.1612 kkal
dT
dT
)
dT
+ C
[ 1
T
- 1
Tref ]
) + 0.024830 (303,152 - 298,152)
2
1
298.15 ]
0.0000
+ C
[ 1
T
- 1
Tref ]
) + 0.000451 (372,152 - 298,152)
2
1
298.15 ]
0.0000
kkal/kmol = 1.3796 kkal
)
+ C
[ 1
T
- 1
Tref ]
) + 0.000451 (362,152 - 298,152)
2
1
298.15 ]
0.0000
1
298.15 ]
0.0000
)
+ C
[ 1
T
- 1
Tref ]
) + 0.021970 (362,152 - 298,152)
2
1
298.15 ]
92.9400
1
298.15 ]
0.0000
reaktan]
0.1150 x -340.2 )]
0.1150 x -111.2 )]
dT
dT
+ C
[ 1
T
- 1
Tref ]
) + 0.000451 (355,152 - 298,152)
2
1
298.15 ]
0.0000
dT + n λ
+ C
[ 1
T
- 1
Tref ]
) + 0.000150 (355,152 - 298,152)
2
1
298.15 ]
0.0000
299.7019334 x 9785.142857 )
(Ulrich ;426 )
(mother liquor) 20oC
(kristal Al2(SO4)3)
20oC
dT
)
+ C
[ 1
T
- 1
Tref ]
) + 0.000451 (293,152 - 298,152)
2
1
298.15 ]
0.0000
kkal/kmol = -83.3082 kkal
0.00 )
Entalpi kristal
1525938.95
- 5)
APPENDIX C
PERHITUNGAN SPESIFIKASI ALAT
Bahan masuk :
Total bahan baku masuk : 3659.334553 kg/jam
ρ campuran = 1 x 62.43 = ……
fraksi berat
Σ ρ komponen
( 1gr/cc = 62,43lb/cuft)
ρ campuran
1
0.8421 0.0018 0.0008 0.0072 0.0034 0.0038
+ + + + +
+ + + + +
2.9000 5.1200 4.2600 3.3200 3.6500 2.3200
= 203.3034128 lb/cuft
( 1 kg = 2,2046 lb)
sehingga x = 4.6 m
Spesifikasi :
Jumlah : 1 buah
2. BELT CONVEYOR
Fungsi : Memindahkan barang dari akolin stock pile menuju hammer crusher
Perhitungan :
dengan kapasitas 3.7 ton/jam. Dari tabel Perry 6ed, tabel 7-7 dan fid 7-3
slope : α
= 51 ft
Perhitungan power :
Power total = 4 hp
Spesifikasi :
Fungsi : Memindahkan barang dari kaolin stock pile menuju hammer crusher
Belt : Widht : 14 in
Trough widht : 9 in
Skirt seal : 2 in
Panjang : 51 ft
Power : 4 hp
Jumlah : 1 buah
3. HAMMER CRUSHER
Perhitungan :
dengan kapasitas 3,7 ton/jam, Dari Perry 6ed, tabel 8-13 dipilih spesifikasi
sebagai berikut :
Spesifikasi :
Model : 505
Power : 100 hp
Jumlah : 1 buah
4. SCREEN
Perhitungan :
E = 100 (e - v)
100 x
e (100 - v)
dimana :
E = effisiensi
e = persentase jumlah undersize dalam feed
v = persentase undersize di dalam screen oversize
sehingga :
E = 100 (95 - 5)
100 x = 99.73%
95(100 - 5)
Dari Perry 6ed halaman 21-15 untuk type Screen Vibrated didapatkan spesifikasi :
Spesifikasi :
Sieve No : 7
Sieve design : 2,83 mm
Effisiensi : 99,73 %
Jumlah : 1 buah
5. SCREW CONVEYOR
Perhitungan :
= 0.25733 hp
Dari badger, fig 16-20 untuk kapasitas = 41.7703 cuft/jam digunakan ukuran :
Diameter = 9 in
Kecepatan putaran = 10 rpm
Diameter : 9 in
Power : 0.7 hp
Jumlah : 1 buah
6. ROTARY KILN
Perhitungan :
Dari neraca massa dan neraca panas :
[
D = Mc 0.5
π
. G
4
=
[ 6872.6793384461
0.785 x 450 ] 0.5
= 4.41085 ≈ 4.5 ft
Panjang shell :
N = 25 / 4.5
= 5.55556 rpm ≈ 6 rpm
Dp = 7 mesh = 2830 μm
B = 5( 2830 -0.5 ) = 0.09399
F = 8067.4517 lb/jam / 15.8963 ft2 = 507.507 ; lb/ft2.jam
S = 0.01519 ( memenuhi)
ρ = 203.3034 lb/cuft
Keterangan :
Pb = tekanan vertikal pada dasar
ρb = bulk density bahan
μ' = Koefisien gesek = 0,35 - 0,55 (Mc Cabe hal 299)
diambil = 0.45
k' = ratio tekanan normal = 0,35 - 0,6
k' = 1- sin α ( Mc cabe ed 5 persamaan 26-17)
1+ sin α
diambil nilai k ' = 0,4
0.4 = 1- sin α
1+ sin α
α = 25 o
P design : PB + PL
= 0.89844 + 0.35938
= 1.25782 psi
ts = P.D
+ C
2. f. e - P
ts = 1.3836 x 4.5 x 12
+ 1/8
2 13,700 x 0.80 - 1.3836
= 0.1284 in
Dipakai tebal shell 3/16 in
Isolasi :
Berat shell :
We = π
( Do2 - Di2) . L . Ρ
4
Dimana :
Do = Diameter luar shell = 4.53125 ft
Di = Diameter dalam shell = 4.5 ft
L = Panjang drum = 46 ft
ρ = Density shell = 489 lb/cuft (perry ed 6 hal3-95)
Berat isolasi :
We = π
( Do2 - Di2) . L . Ρ
4
Dimana :
Do = Diameter luar isolasi = 5.19792 ft
Di = Diameter dalam isolasi = 4.53125 ft
L = Panjang drum = 46 ft
ρ = Density shell = 129 lb/cuft (perry ed 6 hal3-260)
p = 16.4774 hp
Spesifikasi :
Fungsi : Kalsinasi kaolin menjadi alumina
Type : Rotary drum
Kapasitas : 8067.451736 lb/jam
Isolasi : Batu isolasi
Tebal Isolasi : 4 in
Tebal Shell : 3 / 16
Diameter : 4.5 ft
Panjang : 46 ft
Tinggi bahan : 0.675 ft
Sudut rotary : 0,87o
Time of passes: 33.17 menit
Power : 16.4774 hp
Jumlah : 1 buah
7. CYCLONE
Fungsi : untuk memisahkan padatan yang terikut udara
Type : Van Tongeren Cyclone
Dasar pemilihan efektif dan sesuai dengan jenis bahan
1 . 62.43
0.0038 0.0015 0.0015
+ +
+ +
2.3200 2.2700 0.1394
cuft
pile menuju hammer crusher
cuft/mnt
cuft/jam digunakan ukuran :
udara panas (1200oC)
lb/jam
lb/jam
(Perry 3ed hal 832)
(Perry 3ed hal 832)
; lb/ft2.jam
x 450
507.5065965682
[ 1-e -2(0,45)(0,4)(0,675)/2,25
]
y ed 6,persamaan 20-44)
(perry ed 6 hal3-95)
(perry ed 6 hal3-260)
y ed 6,persamaan 20-44)
APPENDIX A
PERHITUNGAN NERACA MASSA
Komponen % Berat
Al2O3.2SiO2 84.21
Fe2O3 0.18
TiO2 0.08
CaO 0.72
MgO 0.34
K2O 0.38
Na2O 0.15
CO2 13.94
Total 100
1. HAMMER CRUSHER
Fungsi : Menghancurkan kaolin dari ukuran 2 in menjadi 1/8 in
Feed ( F)
HAMMER CRUSHER Produk Solid (F')
Recycle ® Ukuran 1/8 in
Kriteria desain :
Ukuran feed : 2 in s/d 10 mesh (Perry 7ed : 20-28)
Kapasitas : 40 s/d 60 ton/jam (Perry 7ed : 20-30)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 30 C
F + R = F'
R = 0.05 F'
F = 1000 kg
F' = 1052.6316 kg
R = 0.05 F'
Neraca Massa
2. SCREEN
Fungsi : Memisahkan ukuran 1/8 in
Kriterian design :
Ukuran partikel : minimum 4.25 in (Perry 6ed : 21-15)
% oversize product : 5 % - 50% (Perry 6ed : 21-14)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 30oC (suhu kamar)
Feed masuk :
Komponen Feed (kg/jam) % berat
Al2O3.2SiO2 886.4211 84.21
Fe2O3 1.8947 0.18
TiO2 0.8421 0.08
CaO 7.5789 0.72
MgO 3.5789 0.34
K2O 4.0000 0.38
Na2O 1.5789 0.15
CO2 146.7368 13.94
Total 1052.6316 100
F' = R + P
F' = 1052.6316 kg
R = 52.6316 kg
F' = R + P
1052.6316 = 52.6316 + P
P = 1000 kg
Neraca Massa
3. ROTARY KILN
Fungsi : Kalsinasi kaolin menjadi alumina
udara panas
udara panas
Feed ROTARY KILN
produk
Kriteria design :
Ukuran partikel : diatas 149 µm (100 mesh) (Kirk Othmer Vol 4:440)
% solid loss : 0.1 - 0.5 % (Petrochemical Handbook)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 1100oC ( (Ulrich 141)
Feed masuk :
Komponen Berat (kg/jam)
Al2O3.2SiO2 842.1000
Fe2O3 1.8000
TiO2 0.8000
CaO 7.2000
MgO 3.4000
K2O 3.8000
Na2O 1.5000
CO2 139.4000
Total 1000
Komponen BM
Al2O3.2SiO2 222
Al2O3 102
SiO2 60
Tinjauan reaksi :
Berat Al2O3.2SiO2 = 842.1000 kg
mol Al2O3.2SiO2 = 842.1000 = 3.7932 mol
222
= 7.58649 x 60 = 455.1892 kg
4. CYCLONE
Fungsi : Memisahkan padatan dan udara panas
padatan
Kriteria design :
Ukuran partikel : minimum 10 micron (ludwig : 165)
Effisiensi pemisahan : 70 - 99 % (ludwig : 165)
Kondisi operasi :
Tekanan operasi : 1 atm (Tekanan atmospheric)
Suhu operasi : Berdasarkan perhitungan kiln
Feed masuk :
Komponen Berat (kg/jam)
Al2O3 0.3869
SiO2 0.4552
Fe2O3 0.0018
TiO2 0.0008
CaO 0.0072
MgO 0.0034
K2O 0.0038
Na2O 0.0015
CO2 139.4000
Total 140.2606
Terdiri dari :
Komponen Feed (kg/jam) Kehilangan Produk (kg/jam)
padatan (kg/jam)
Al2O3 0.3869 0.0193 ###
SiO2 0.4552 0.0228 ###
Fe2O3 0.0018 0.0001 ###
TiO2 0.0008 0.0000 ###
CaO 0.0072 0.0004 ###
MgO 0.0034 0.0002 ###
K2O 0.0038 0.0002 ###
Na2O 0.0015 0.0001 ###
Total 0.8606 0.04303 ###
Neraca massa :
Komponen Masuk (kg/jam) Komponen Keluar (kg/jam)
Campuran dari rotary kiln Alumina ke rotary cooler
Al2O3 0.3869 Al2O3 ###
SiO2 0.4552 SiO2 ###
Fe2O3 0.0018 Fe2O3 ###
TiO2 0.0008 TiO2 ###
CaO 0.0072 CaO ###
MgO 0.0034 MgO ###
K2O 0.0038 K2O ###
Na2O 0.0015 Na2O ###
CO2 ### ###
140.2606
Limbah gas
Al2O3 0.0193
SiO2 0.0228
Fe2O3 0.0001
TiO2 0.0000
CaO 0.0004
MgO 0.0002
K2O 0.0002
Na2O 0.0001
CO2 ###
139.4430
Total 140.2606 140.2606
5. ROTARY COOLER
udara panas
udara bebas
Kriteria design :
Ukuran partikel : diatas 149 µm (100 mesh) (Kirk Othmer Vol 4:440)
% solid loss : 0.1 - 0.5 % (Petrochemical Handbook)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 40oC (suhu kamar)
Terdiri dari :
Komponen Padatan Kehilangan Produk padatan
(kg/jam) Padatan (kg/jam) (kg/jam)
Al2O3 386.8915 0.3869 386.5046
SiO2 455.1664 0.4552 454.7113
Fe2O3 1.7999 0.0018 1.7981
TiO2 0.8000 0.0008 0.7992
CaO 7.1996 0.0072 7.1924
MgO 3.3998 0.0034 3.3964
K2O 3.7998 0.0038 3.7960
Na2O 1.4999 0.0015 1.4984
Total 860.5570 0.8606 859.6964
Neraca massa :
Komponen Masuk (kg/jam) Komponen Keluar (kg/jam)
Alumina dari rotary kiln Alumina ke Ball mill
Al2O3 386.5239 Al2O3 386.5046
SiO2 454.7340 SiO2 454.7113
Fe2O3 1.7982 Fe2O3 1.7981
TiO2 0.7992 TiO2 0.7992
CaO 7.1928 CaO 7.1924
MgO 3.3966 MgO 3.3964
K2O 3.7962 K2O 3.7960
Na2O 1.4985 Na2O 1.4984
859.7394 859.6964
Alumina dari cyclone 1 Alumina menuju cyclone 2
Al2O3 0.3676 Al2O3 0.3869
SiO2 0.4324 SiO2 0.4552
Fe2O3 0.0017 Fe2O3 0.0018
TiO2 0.0008 TiO2 0.0008
CaO 0.0068 CaO 0.0072
MgO 0.0032 MgO 0.0034
K2O 0.0036 K2O 0.0038
Na2O 0.0014 Na2O 0.0015
0.8176 0.8606
Total 860.5570 860.5570
6. CYCLONE-2
Fungsi : Memisahkan padatan dan udara panas
padatan
Kriteria design :
Ukuran partikel : minimum 10 micron (ludwig : 165)
Effisiensi pemisahan : 70 - 99 % (ludwig : 165)
Kondisi operasi :
Tekanan operasi : 1 atm (Tekanan atmospheric)
Suhu operasi : Berdasarkan perhitungan cooler
Feed masuk :
Komponen Berat (kg/jam)
Al2O3 0.3869
SiO2 0.4552
Fe2O3 0.0018
TiO2 0.0008
CaO 0.0072
MgO 0.0034
K2O 0.0038
Na2O 0.0015
Total 0.8606
Neraca massa :
Komponen Masuk (kg/jam) Komponen Keluar (kg/jam)
Campuran dari rotary cooler Alumina ke ball mill
Al2O3 0.3869 Al2O3 0.3675
SiO2 0.4552 SiO2 0.4324
Fe2O3 0.0018 Fe2O3 0.0017
TiO2 0.0008 TiO2 0.0008
CaO 0.0072 CaO 0.0068
MgO 0.0034 MgO 0.0032
K2O 0.0038 K2O 0.0036
Na2O 0.0015 Na2O 0.0014
0.8606 0.8175
Limbah gas
Al2O3 0.0193
SiO2 0.0228
Fe2O3 0.0001
TiO2 0.0000
CaO 0.0004
MgO 0.0002
K2O 0.0002
Na2O 0.0001
0.0430
Total 0.8606 0.8606
7. BALL MILL
Fungsi : Menghaluskan bahan sampai 200 mesh
Feed (F)
Produk solid (F')
BALL MILL
Recycle ®
Kriteria design :
Kapasitas : 5, 22, 51, 105, 180 ton/hari (Perry 6ed : T. 8-18)
Ukuran ball mill (3 x 3) ft ; (4 x 3) ft ; (5 x 4) ft (Perry 6ed : T. 8-18)
Ukuran bola baja : 5 in (reduction ratio 15,6 : 1) (Brown : fig.37)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 32oC (suhu kamar)
Feed masuk :
Komponen Feed dari rotary Feed dari Feed total
cooler (kg/jam) cyclone (kg/jam) (kg/jam)
Al2O3 386.5046 0.3675 386.8721
SiO2 454.7113 0.4324 455.1437
Fe2O3 1.7981 0.0017 1.7998
TiO2 0.7992 0.0008 0.7999
CaO 7.1924 0.0068 7.1993
MgO 3.3964 0.0032 3.3997
K2O 3.7960 0.0036 3.7996
Na2O 1.4984 0.0014 1.4999
Total 859.6964 0.8175 860.5139
F + R = F'
R = 0.05 F'
F' = 905.8041
Komposisi recycle = Produk -Feed
Terdiri dari:
Komponen Feed (kg/jam) Produk (kg/jam) Recycle (kg/jam)
Al2O3 386.8721 407.2338 20.3617
SiO2 455.1437 479.0986 23.9549
Fe2O3 1.7998 1.8945 0.0947
TiO2 0.7999 0.8420 0.0421
CaO 7.1993 7.5782 0.3789
MgO 3.3997 3.5786 0.1789
K2O 3.7996 3.9996 0.2000
Na2O 1.4999 1.5788 0.0789
Total 860.5139 905.8041 45.2902
Neraca massa :
8. SCRREN
Fungsi : Memisahkan ukuran 200 mesh
Kriterian design :
Ukuran partikel : minimum 4.25 in (Perry 6ed : 21-15)
% oversize product : 5 % - 50% (Perry 6ed : 21-14)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 30oC (suhu kamar)
Feed masuk :
Komponen Feed (kg/jam) % berat
Al2O3 407.2338 44.9583
SiO2 479.0986 52.8921
Fe2O3 1.8945 0.2092
TiO2 0.8420 0.0930
CaO 7.5782 0.8366
MgO 3.5786 0.3951
K2O 3.9996 0.4416
Na2O 1.5788 0.1743
Total 905.8041 100.0000
F' = R + P
F' = 905.8041 kg
R = 45.2902 kg
F' = R + P
905.8041 = 52.6316 + P
P = 853 kg
Neraca Massa
Asam sulfat yang dijual adalah 98 % maka dilakukan pengenceran hingga 45%
H2O 1349.3436
Total 2495.0127 2495.0127
10. REAKTOR
Fungsi : Mereaksikan alumina dengan asam sulfat untuk membentuk aluminium sulfat
H2SO4
Kriteria design :
Diameter maksimum :4 m (Ulrich T 4-18)
Diamension Ratio , H/D : 2 /1 (Ulrich T 4-18)
Kondisi operasi :
Tekanan : 1 atm
Suhu operasi : 110oC
Feed masuk :
Komponen Berat (kg/jam) % berat
Al2O3 386.8721 44.9583
SiO2 455.1437 52.8921
Fe2O3 1.7998 0.2092
TiO2 0.7999 0.0930
CaO 7.1993 0.8366
MgO 3.3997 0.3951
K2O 3.7996 0.4416
Na2O 1.4999 0.1743
Total 860.5139 100.0000
= 3.7170 kmol
= 379.1347 kg
= 7.7374 kg
= 1092.8000 kg
= 0.0110 kmol
= 1.7638 kg
= 0.0360 kg
= 3.2410 kg
= 0.1260 kmol
= 7.0553 kg
= 0.1440 kg
= 12.3468 kg
= 0.0833 kmol
= 3.3317 kg
= 0.0680 kg
= 8.1626 kg
= 3.72363 kg
= 0.0760 kg
= 3.8821 kg
= 0.0237 kmol
= 1.4699 kg
= 0.0300 kg
= 2.3233 kg
3.8821 + 2.3233
= 1122.7557 kg
= 1578.4774 kg
Neraca massa :
cake
Kriteria design :
5 % filtrat terikut pada cake
Kondisi operasi :
Tekanan operasi = 1 atm
Suhu masuk = 110 oC
Suhu keluar = 99 oC
Feed masuk :
Feed Berat (kg/jam) Filtrat Berat (kg/jam) Cake Berat (kg/jam)
Al2O3 7.7374 Al2(SO4)3 1271.2163 Al2O3 7.7374
SiO2 455.1437 Fe2(SO4)3 4.4096 SiO2 455.1437
Fe2O3 0.0360 CaSO4 2.5556 Fe2O3 0.0360
TiO2 0.7999 MgSO4 9.9950 TiO2 0.7999
CaO 0.1440 K2SO4 6.8927 CaO 0.1440
MgO 0.0680 Na2SO4 3.3664 MgO 0.0680
K2O 0.0760 H2O 1578.4774 K2O 0.0760
Na2O 0.0300 Na2O 0.0300
Al2(SO4)3 1271.2163 CaSO4 14.5787
Fe2(SO4)3 4.4096
CaSO4 17.1343
MgSO4 9.9950
K2SO4 6.8927
Na2SO4 3.3664
H2O 1578.4774
Total 3355.5267 2876.9129 478.6137
11. THICKENER
Fungsi : Memisahkan padatan dan liquid secara sedimentasi
cake
Kriteria design :
% solid pada feed : minimum 11 % (Perry 7 ed : 18-72)
Waktu pengendapan : 3 - 5 jam (Perry 7 ed : 18-72)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Waktu tinggal : 3 jam (Perry 7 ed : 18-72)
Penurunan suhu karena alat dan bahan = 10 % dari suhu masuk (Ulrich :432)
Suhu masuk : 99 oC
Suhu keluar : 89 oC
Feed masuk :
Komponen Berat (kg/jam)
Al2(SO4)3 1207.6555
Fe2(SO4)3 4.1891
CaSO4 2.4278
MgSO4 9.4953
K2SO4 6.5480
Na2SO4 3.1981
H2O 1499.5536
Total 2733.0673
Komponen BM
Fe2(SO4)3 400
BaS 169
Fe2S3 208
BaSO4 233
Tinjauan reaksi :
Berat Fe2(SO4)3 = 4.1891 kg
Mol Fe2(SO4)3 = 4.1891 = 0.0105 kmol
400
Kebutuhan BaS = 3 x 0.0105 = 0.0314 kmol
Penambahan Glue :
Komposisi Glue :
Al2(SO4)3 :
Berat air = 1499.5970 kg
Ca(SO4)
Berat air = 1499.5970 kg
Mg(SO4)
Berat air = 1499.5970 kg
Kelarutan Mg(SO4) = 74 kg/100 kg H2O
K2(SO4)
Berat air = 1499.5970 kg
Na2(SO4)
Berat air = 1499.5970 kg
Kelarutan Na2(SO4) = 43 kg/100 kg H2O
Ba(SO4)
Berat air = 1499.5970 kg
Kelarutan Ba(SO4) = 0.00072 kg/100 kg H2O
Asumsi liquid terikut solid = 10 % dari liquid pada feed ( Perry ed 6 ; 19-87)
Terdiri dari :
Komponen Fraksi berat Feed (kg/jam) Liquid pada underflow (kg/jam) Liquid pada overf
Al2(SO4)3 0.44254 1207.6555 120.7655
Ca(SO4) 0.00089 2.4278 0.2428
Mg(SO4) 0.00348 9.4953 0.9495
K2(SO4) 0.00240 6.5480 0.6548
Na2(SO4) 0.00117 3.2034 0.3203
NaCl 0.0000018 0.0048 0.0005
H2O 0.54952 1499.5970 149.9597
Total 1 2728.9318 272.8932
Asumsi impurities yang sedikit jumlahnya dianggap air, maka komposisi liquid overflow :
12. EVAPORATOR
H2O
Kriteria design :
F= 2456.0386
XF= 0.4425
XL = 0.5400
F. XF = 2456.0386 x 0.4425 = 1086.8899 kg
V. XV = 0
Neraca massa :
13. KRISTALISER
Fungsi : Kristalisasi aluminium sulfat dengan cara pendinginan
Brine 5oC
Al2(SO4)3.16H2O
Feed KRISTALISER + mother liquor
Brine 20oC
Feed masuk :
Komponen Berat
Al2(SO4)3 1086.8899 51.43717702
H2O 925.8692
Total 2012.7591
Komponen BM
Al2(SO4)3 342
H2O 18
Al2(SO4)3.16H2O 630
Tinjauan reaksi :
Feed (F)
BALL MILL Produk solid (F')
Recycle ( R )
Kriteria design :
Kapasitas : 5, 22, 51, 105, 180 ton/hari (Perry 6ed : T. 8-18)
Ukuran ball mill (3 x 3) ft ; (4 x 3) ft ; (5 x 4) ft (Perry 6ed : T. 8-18)
Ukuran bola baja : 5 in (reduction ratio 15,6 : 1) (Brown : fig.37)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 32oC (suhu kamar)
Feed masuk :
Komponen Feed total
(kg/jam)
Al2(SO4)3.16H2O 2002.1656
H2O 10.5935
Total 2012.7591
F + R = F'
R = 0.05 F'
F' = 905.8041
Terdiri dari:
Komponen Feed (kg/jam) Produk (kg/jam) Recycle (kg/jam)
Al2(SO4)3.16H2O 2002.1656 2107.5428 105.3771
H2O 10.5935 11.1510 0.5576
Total 2012.7591 2118.6938 105.9347
Neraca massa :
18. SCRREN
Fungsi : Memisahkan ukuran 200 mesh
Kriterian design :
Ukuran partikel : minimum 4.25 in (Perry 6ed : 21-15)
% oversize product : 5 % - 50% (Perry 6ed : 21-14)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 30oC (suhu kamar)
Feed masuk :
Komponen Feed (kg/jam) % berat
Al2(SO4)3.16H2O 2107.5428 99.4737
H2O 11.1510 0.5263
Total 2118.6938 100.0000
F' = R + P
F' = 2118.6938 kg
R = 105.9347 kg
F' = R + P
2118.6938 = 105.9347 + P
P = 2013 kg
Neraca Massa
= 2012.7591 kg/jam
= 14491.86553 ton/tahun
478.6137
diketahui data kelarutan terlebih dahulu!!!!!
PENTING BANGET!!!!!
1404.844919
2.555554971
1168.073304
380.4130624
662.9605238
Liquid pada overflow (kg/jam)
1086.8899
2.1850
8.5457
5.8932
2.8831
0.0043
1349.6373
2456.0386
kg/jam
ED ME TO DO MY FINAL TASK :)
dahulu!!!!!
Komponen % Berat
Al2O3.2SiO2 84.21
Fe2O3 0.18
TiO2 0.08
CaO 0.72
MgO 0.34
K2O 0.38
Na2O 0.15
CO2 13.94
Total 100
1. HAMMER CRUSHER
Fungsi : Menghancurkan kaolin dari ukuran 2 in menjadi 1/8 in
Feed ( F)
HAMMER CRUSHER Produk Solid (F')
Recycle ( R ) Ukuran 1/8 in
Kriteria desain :
Ukuran feed : 2 in s/d 10 mesh (Perry 7ed : 20-28)
Kapasitas : 40 s/d 60 ton/jam (Perry 7ed : 20-30)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 30 C
F + R = F'
R = 0.05 F'
F = 1000 kg
1000 + 0.05 F' = F'
F' = 1052.6316 kg
R = 0.05 F'
= 0.05 x 1052.6316 kg = 52.6316 kg
Komposisi produk keluar hammer crusher :
Neraca Massa
Kriterian design :
Ukuran partikel : minimum 4.25 in (Perry 6ed : 21-15)
% oversize product : 5 % - 50% (Perry 6ed : 21-14)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 30oC (suhu kamar)
Feed masuk :
Komponen Feed (kg/jam) % berat
Al2O3.2SiO2 1835.0040 84.21
Fe2O3 3.9223 0.18
TiO2 1.7433 0.08
CaO 15.6894 0.72
MgO 7.4089 0.34
K2O 8.2805 0.38
Na2O 3.2686 0.15
CO2 303.7639 13.94
Total 2179.0809 100
F' = 2179.0809 kg
R = 108.9540 kg
F' = R + P
2179.0809 = 108.9540 + P
P = 2070.1269 kg
Neraca Massa
3. ROTARY KILN
Fungsi : Kalsinasi kaolin menjadi alumina
udara panas
udara panas
Feed ROTARY KILN
produk
Kriteria design :
Ukuran partikel : diatas 149 µm (100 mesh) (Kirk Othmer Vol 4:440)
% solid loss : 0.1 - 0.5 % (Petrochemical Handbook)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 1100oC ( (Ulrich 141)
Feed masuk :
Komponen Berat (kg/jam)
Al2O3.2SiO2 1743.2538
Fe2O3 3.7262
TiO2 1.6561
CaO 14.9049
MgO 7.0384
K2O 7.8665
Na2O 3.1052
CO2 288.5757
Total 2070.1268546417
Komponen BM
Al2O3.2SiO2 222
Al2O3 102
SiO2 60
Tinjauan reaksi :
Berat Al2O3.2SiO2 = 1743.2538 kg
mol Al2O3.2SiO2 = 1743.2538 = 7.8525 mol
222
= 15.705 x 60 = 942.2994 kg
Neraca Massa :
4. CYCLONE
Fungsi : Memisahkan padatan dan udara panas
padatan
Kriteria design :
Ukuran partikel : minimum 10 micron (ludwig : 165)
Effisiensi pemisahan : 70 - 99 % (ludwig : 165)
Kondisi operasi :
Tekanan operasi : 1 atm (Tekanan atmospheric)
Suhu operasi : Berdasarkan perhitungan kiln
Feed masuk :
Komponen Berat (kg/jam)
Al2O3 0.8010
SiO2 0.9423
Fe2O3 0.0037262283
TiO2 0.0016561015
CaO 0.0149049134
MgO 0.0070384313
K2O 0.007866482
Na2O 0.0031051903
CO2 288.5757
Total 290.3572
Terdiri dari :
Komponen Feed (kg/jam) Kehilangan Produk (kg/jam)
padatan (kg/jam)
Al2O3 0.8010 0.0400 ###
SiO2 0.9423 0.0471 ###
Fe2O3 0.0037262283 0.0002 ###
TiO2 0.0016561015 0.0001 ###
CaO 0.0149049134 0.0007 ###
MgO 0.0070384313 0.0004 ###
K2O 0.007866482 0.0004 ###
Na2O 0.0031051903 0.0002 ###
Total 1.7816 0.08908 ###
Neraca massa :
Komponen Masuk (kg/jam) Komponen Keluar (kg/jam)
Campuran dari rotary kiln Alumina ke rotary cooler
Al2O3 0.8010 Al2O3 ###
SiO2 0.9423 SiO2 ###
Fe2O3 0.0037262283 Fe2O3 ###
TiO2 0.0016561015 TiO2 ###
CaO 0.0149049134 CaO ###
MgO 0.0070384313 MgO ###
K2O 0.007866482 K2O ###
Na2O 0.0031051903 Na2O ###
CO2 ### ###
290.3572
Limbah gas
Al2O3 0.0400
SiO2 0.0471
Fe2O3 0.0002
TiO2 0.0001
CaO 0.0007
MgO 0.0004
K2O 0.0004
Na2O 0.0002
CO2 288.5757
288.6648
Total 290.3572 290.3572
5. ROTARY COOLER
udara panas
udara bebas
campuran padatan ROTARY COOLER
produk
Kriteria design :
Ukuran partikel : diatas 149 µm (100 mesh) (Kirk Othmer Vol 4:440)
% solid loss : 0.1 - 0.5 % (Petrochemical Handbook)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 35oC (suhu kamar)
Terdiri dari :
Komponen Padatan Kehilangan Produk padatan
(kg/jam) Padatan (kg/jam) (kg/jam)
Al2O3 800.9144 0.8009 800.1135
SiO2 942.2522 0.9423 941.3100
Fe2O3 3.7260 0.0037 3.7223
TiO2 1.6560 0.0017 1.6544
CaO 14.9042 0.0149 14.8893
MgO 7.0381 0.0070 7.0310
K2O 7.8661 0.0079 7.8582
Na2O 3.1050 0.0031 3.1019
Total 1781.4621 1.7815 1779.6806
Neraca massa :
Komponen Masuk (kg/jam) Komponen Keluar (kg/jam)
Alumina dari rotary kiln Alumina ke Ball mill
Al2O3 800.1535 Al2O3 800.1135
SiO2 941.3571 SiO2 941.3100
Fe2O3 3.7225 Fe2O3 3.7223
TiO2 1.6544 TiO2 1.6544
CaO 14.8900 CaO 14.8893
MgO 7.0314 MgO 7.0310
K2O 7.8586 K2O 7.8582
Na2O 3.1021 Na2O 3.1019
1779.7696 1779.6806
Alumina dari cyclone 1 Alumina menuju cyclone 2
Al2O3 0.7609 Al2O3 0.8009
SiO2 0.8952 SiO2 0.9423
Fe2O3 0.0035 Fe2O3 0.0037
TiO2 0.0016 TiO2 0.0017
CaO 0.0142 CaO 0.0149
MgO 0.0067 MgO 0.0070
K2O 0.0075 K2O 0.0079
Na2O 0.0029 Na2O 0.0031
1.6925 1.7815
Total 1781.4621 1781.4621
6. CYCLONE-2
Fungsi : Memisahkan padatan dan udara panas
padatan
Kriteria design :
Ukuran partikel : minimum 10 micron (ludwig : 165)
Effisiensi pemisahan : 70 - 99 % (ludwig : 165)
Kondisi operasi :
Tekanan operasi : 1 atm (Tekanan atmospheric)
Suhu operasi : Berdasarkan perhitungan cooler
Feed masuk :
Komponen Berat (kg/jam) ρ bahan (gr/cc)
Al2O3 0.8009 3.9900
SiO2 0.9423 2.3200
Fe2O3 0.0037 5.1200
TiO2 0.0017 4.2600
CaO 0.0149 3.3200
MgO 0.0070 3.6500
K2O 0.0079 2.3200
Na2O 0.0031 2.2700
Total 1.7815
Terdiri dari :
Komponen Feed (kg/jam) Kehilangan Produk (kg/jam)
padatan (kg/jam)
Al2O3 0.8009 0.0400 0.7609
SiO2 0.9423 0.0471 0.8951
Fe2O3 0.0037 0.0002 0.0035
TiO2 0.0017 0.0001 0.0016
CaO 0.0149 0.0007 0.0142
MgO 0.0070 0.0004 0.0067
K2O 0.0079 0.0004 0.0075
Na2O 0.0031 0.0002 0.0029
Total 1.7815 0.08907 1.6924
Neraca massa :
Komponen Masuk (kg/jam) Komponen Keluar (kg/jam)
Campuran dari rotary cooler Alumina ke ball mill
Al2O3 0.8009 Al2O3 0.7609
SiO2 0.9423 SiO2 0.8951
Fe2O3 0.0037 Fe2O3 0.0035
TiO2 0.0017 TiO2 0.0016
CaO 0.0149 CaO 0.0142
MgO 0.0070 MgO 0.0067
K2O 0.0079 K2O 0.0075
Na2O 0.0031 Na2O 0.0029
1.7815 1.6924
Limbah gas
Al2O3 0.0400
SiO2 0.0471
Fe2O3 0.0002
TiO2 0.0001
CaO 0.0007
MgO 0.0004
K2O 0.0004
Na2O 0.0002
0.0891
Total 1.7815 1.7815
7. BALL MILL
Fungsi : Menghaluskan bahan sampai 200 mesh
Feed (F)
Produk solid (F')
BALL MILL
Recycle ( R )
Kriteria design :
Kapasitas : 5, 22, 51, 105, 180 ton/hari (Perry 6ed : T. 8-18)
Ukuran ball mill (3 x 3) ft ; (4 x 3) ft ; (5 x 4) ft (Perry 6ed : T. 8-18)
Ukuran bola baja : 5 in (reduction ratio 15,6 : 1) (Brown : fig.37)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 30oC (suhu kamar)
Feed masuk :
Komponen Feed dari rotary Feed dari Feed total
cooler (kg/jam) cyclone (kg/jam) (kg/jam)
Al2O3 800.1135 0.7609 800.8744
SiO2 941.3100 0.8951 942.2051
Fe2O3 3.7223 0.0035 3.7259
TiO2 1.6544 0.0016 1.6559
CaO 14.8893 0.0142 14.9034
MgO 7.0310 0.0067 7.0377
K2O 7.8582 0.0075 7.8657
Na2O 3.1019 0.0029 3.1049
Total 1779.6806 1.6924 1781.3730
R = 0.05 F'
F' = 1875.1295
Terdiri dari:
Komponen Feed (kg/jam) Produk (kg/jam) Recycle (kg/jam)
Al2O3 800.8744 843.0256 42.1513
SiO2 942.2051 991.7949 49.5897
Fe2O3 3.7259 3.9220 0.1961
TiO2 1.6559 1.7431 0.0872
CaO 14.9034 15.6878 0.7844
MgO 7.0377 7.4081 0.3704
K2O 7.8657 8.2797 0.4140
Na2O 3.1049 3.2683 0.1634
Total 1781.3730 1875.1295 93.7565
Neraca massa :
8. SCRREN
Fungsi : Memisahkan ukuran 200 mesh
Kriterian design :
Ukuran partikel : minimum 4.25 in (Perry 6ed : 21-15)
% oversize product : 5 % - 50% (Perry 6ed : 21-14)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 30oC (suhu kamar)
Feed masuk :
Komponen Feed (kg/jam) % berat
Al2O3 843.0256 44.9583
SiO2 991.7949 52.8921
Fe2O3 3.9220 0.2092
TiO2 1.7431 0.0930
CaO 15.6878 0.8366
MgO 7.4081 0.3951
K2O 8.2797 0.4416
Na2O 3.2683 0.1743
Total 1875.1295 100.0000
F' = R + P
F' = 1875.1295 kg
R = 93.7565 kg
F' = R + P
1875.1295 = 52.6316 + P
P = 1822 kg
Neraca Massa
H2O 2793.3125
Total 5164.9928 5164.9928
10. REAKTOR
Fungsi : Mereaksikan alumina dengan asam sulfat untuk membentuk aluminium sulfat
H2SO4
Kriteria design :
Diameter maksimum :4 m (Ulrich T 4-18)
Diamension Ratio , H/D : 2 /1 (Ulrich T 4-18)
Kondisi operasi :
Tekanan : 1 atm
Suhu operasi : 105oC
Feed masuk :
Komponen Berat (kg/jam) % berat
Al2O3 800.8744 44.9583
SiO2 942.2051 52.8921
Fe2O3 3.7259 0.2092
TiO2 1.6559 0.0930
CaO 14.9034 0.8366
MgO 7.0377 0.3951
K2O 7.8657 0.4416
Na2O 3.1049 0.1743
Total 1781.3730 100.0000
= 7.6947 kmol
= 784.8569 kg
= 16.0175 kg
= 2262.2345 kg
= 0.0228 kmol
= 3.6513 kg
= 0.0745 kg
= 6.7093 kg
= 0.2608 kmol
= 14.6054 kg
= 0.2981 kg
H2SO4 yang bereaksi = 1 x 0.2608 = 0.2608 kmol
= 25.5594 kg
= 0.1724 kmol
= 6.8970 kg
= 0.1408 kg
= 16.8976 kg
= 0.0820 kmol
= 7.70838 kg
= 0.1573 kg
= 8.0364 kg
= 0.0491 kmol
= 3.0428 kg
= 0.0621 kg
= 4.8096 kg
= 2324.2468 kg
= 3267.6485 kg
Neraca massa :
FILTER PRESS
Feed Filtrat
cake
Kriteria design :
5 % filtrat terikut pada cake
Kondisi operasi :
Tekanan operasi = 1 atm
Suhu masuk = 105 oC
Suhu keluar = 95 oC
Feed masuk :
Feed Berat (kg/jam) Filtrat Berat (kg/jam) Cake
Al2O3 16.0175 Al2(SO4)3 2631.5789 Al2O3
SiO2 942.2051 Fe2(SO4)3 9.1283 SiO2
Fe2O3 0.0745 CaSO4 5.2903 Fe2O3
TiO2 1.6559 MgSO4 20.6909 TiO2
CaO 0.2981 K2SO4 14.2687 CaO
MgO 0.1408 Na2SO4 6.9690 MgO
K2O 0.1573 H2O 3267.6485 K2O
Na2O 0.0621 Na2O
Al2(SO4)3 2631.5789 CaSO4
Fe2(SO4)3 9.1283
CaSO4 35.4701
MgSO4 20.6909
K2SO4 14.2687
Na2SO4 6.9690
H2O 3267.6485
Total 6946.3659 5955.5747
Neraca massa :
12. THICKENER
Fungsi : Memisahkan padatan dan liquid secara sedimentasi
cake
Kriteria design :
% solid pada feed : minimum 11 % (Perry 7 ed : 18-72)
Waktu pengendapan : 3 - 5 jam (Perry 7 ed : 18-72)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Waktu tinggal : 3 jam (Perry 7 ed : 18-72)
Penurunan suhu karena alat dan bahan = 10 % dari suhu masuk (Ulrich :432)
Feed masuk :
Komponen Berat (kg/jam)
Al2(SO4)3 2500.0000
Fe2(SO4)3 8.6719
CaSO4 5.0258
MgSO4 19.6564
K2SO4 13.5553
Na2SO4 6.6205
H2O 3104.2661
Total 5657.7960
Penambahan reaktan pembantu :
1. Untuk mengendapkan besi, maka ditambahkan barium sulfid
2. Untuk mempercepat pengendapan, ditambahkan glue
3. Penambahan glue = 0.4 tiap 1000 kg aluminium sulfat
Komponen BM
Fe2(SO4)3 400
BaS 169
Fe2S3 208
BaSO4 233
Tinjauan reaksi :
Berat Fe2(SO4)3 = 8.6719 kg
Mol Fe2(SO4)3 = 8.6719 = 0.0217 kmol
400
Penambahan Glue :
Komposisi Glue :
Al2(SO4)3 :
Berat air = 3104.3561 kg
Ca(SO4)
Berat air = 3104.3561 kg
Mg(SO4)
Berat air = 3104.3561 kg
K2(SO4)
Berat air = 3104.3561 kg
Na2(SO4)
Berat air = 3104.3561 kg
Kelarutan Na2(SO4) = 43 kg/100 kg H2O
Ba(SO4)
Berat air = 3104.3561 kg
Kelarutan Ba(SO4) = 0.00072 kg/100 kg H2O
Asumsi liquid terikut solid = 10 % dari liquid pada feed ( Perry ed 6 ; 19-87)
Asumsi impurities yang sedikit jumlahnya dianggap air, maka komposisi liquid overflow :
Neraca Massa
13. EVAPORATOR
H2O
Kriteria design :
F= 5084.3116
XF= 0.4425
XL = 0.5400
F. XF = 5084.3116 x 0.4425 = 2250.0000 kg
V. XV = 0
Neraca massa :
Komponen Masuk(kg/jam) Komponen Keluar(kg/jam)
Filtrat dari Thickener Menuju Kristaliser
Al2(SO4)3 2250.0000 Al2(SO4)3 2250.0000 0.54
H2O 2834.3116 H2O 1916.6667
5084.3116 4166.6667
Uap air :
H2O 917.6449
Total 5084.3116 5084.3116
14. KRISTALISER
Fungsi : Kristalisasi aluminium sulfat dengan cara pendinginan
Brine 5oC
Brine 20oC
Feed masuk :
Komponen Berat
Al2(SO4)3 2250.0000 106.4814815
H2O 1916.6667
Total 4166.6667
Komponen BM
Al2(SO4)3 342
H2O 18
Al2(SO4)3.16H2O 630
Tinjauan reaksi :
Feed (F)
BALL MILL Produk solid (F')
Recycle ( R )
Kriteria design :
Kapasitas : 5, 22, 51, 105, 180 ton/hari (Perry 6ed : T. 8-18)
Ukuran ball mill (3 x 3) ft ; (4 x 3) ft ; (5 x 4) ft (Perry 6ed : T. 8-18)
Ukuran bola baja : 5 in (reduction ratio 15,6 : 1) (Brown : fig.37)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 10oC (Kirk Othmer 2-60)
Feed masuk :
Komponen Feed total
(kg/jam)
Al2(SO4)3.16H2O 4144.7368
H2O 21.9298
Total 4166.6667
F + R = F'
R = 0.05 F'
F' = 1875.1295
Terdiri dari:
Komponen Feed (kg/jam) Produk (kg/jam) Recycle (kg/jam)
Al2(SO4)3.16H2O 4144.7368 4362.8809 218.1440
H2O 21.9298 23.0840 1.1542
Total 4166.6667 4385.9649 219.2982
Neraca massa :
16. SCREEN
Fungsi : Memisahkan ukuran 200 mesh
Kriterian design :
Ukuran partikel : minimum 4.25 in (Perry 6ed : 21-15)
% oversize product : 5 % - 50% (Perry 6ed : 21-14)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Suhu operasi : 30oC (suhu kamar)
Feed masuk :
Komponen Feed (kg/jam) % berat
Al2(SO4)3.16H2O 4362.8809 99.4737
H2O 23.0840 0.5263
Total 4385.9649 100.0000
F' = R + P
F' = 4385.9649 kg
R = 219.2982 kg
F' = R + P
4385.9649 = 219.2982 + P
P = 4167 kg
Neraca Massa
= 4166.6667 kg/jam
= 30000 ton/tahun
990.7911
Kelarutan
ρ bahan (gr/cc)
i 3.9900
i 0.7 2.3200
i 5.1200
i 4.2600
i 3.3200
i 3.6500
i 2.3200
i 2.2700
89 2908.207194
i
0.1619 5.290322975
74 2418.059914
24.1 787.5032964
42 1372.412384
pada underflow (kg/jam) Liquid pada overflow (kg/jam)
250.0000 2250.0000
0.5026 4.5232
1.9656 17.6907
1.3555 12.1997
0.6632 5.9684
0.0010 0.0090
310.4356 2793.9205
564.9235 5084.3116
kadar:
0.4425
kg
kg
0.54
99.47368421
0.526316
HO HAS HELPED ME TO DO MY FINAL TASK :)
APPENDIX B
PERHITUNGAN NERACA PANAS
Komponen BM A B C D
Al2O3.2SiO2 222 40.79 0.004763 -992800
Fe2O3 160 41.17 0.01882 -979500
TiO2 80 11.81 0.00754 -41900
CaO 56 10 0.00484 -108000
MgO 40 10.86 0.001197 -208700
K2O 94 4.97
Na2O 62 5.01 0.00536
CO2 44 10.34 0.00274 -195500
Al2O3 102 22.08 0.008971 -522500
SiO2 60 10.87 0.008712 -241200
H2SO4 98 58
Al2(SO4)3 342 63.5
Fe2(SO4)3 400 66.2
CaSO4 136 18.52 0.02197 -156800
MgSO4 120 26.7
K2SO4 174 33.1
Na2SO4 142 32.8
BaS 169 39.8
Fe2S3 112 10.7 0.01336
BaSO4 233 21.35 0.0141
Protein 75 5.542 0.02483 -0.00000139 -0.000000004
NaCl 58.5 10.79 0.0042
Al2(SO4)3.16H2O 630 235
H2O (G) 18 8.22 0.00015 0.00000134
H2O (L) 18 7.701 0.0004505 0.00000251 -8.59E-10
Data konstanta spesific heat Glue dan H2O liquid dari Sherwood Appendic A
1. ROTARY KILN
Entalpi masuk :
Massa bahan :
T ref 2
- -992800 1 - 1
[ 303.15 298.15
T ref 2
- -979500 1 - 1
[ 303.15 298.15
= 179.9558 kkal/kmol
T ref 2
- -41900 1 - 1
[ 303.15 298.15
= 68.0666 kkal/kmol
T ref 2
- -108000 1 - 1
[ 303.15 298.15
T ref 2
- -208700 1 - 1
[ 303.15 298.15
= 44.5542 kkal/kmol
Cp dT K2O = A ( T- Tref)
∫
T
T ref
= 24.8500 kkal/kmol
T ref 2
= 25.05 + 8.05742
= 33.1074 kkal/kmol
T ref 2
- -195500 1 - 1
[
[ 303.15 298.15
= 45.0040 kkal/kmol
Komponen Cp dT ( kkal/kmol)
∫
T
T ref
Al2O3.2SiO2 156.1889
Fe2O3 179.9558
TiO2 68.0666
CaO 51.3012
MgO 44.5542
K2O 24.8500
Na2O 33.1074
CO2 45.0040
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Entalpi keluar :
1. Entalpi bahan ke Rotary Cooler pada suhu : 1100 oC : ∆H =
∫
T
n
T ref
Massa bahan :
T ref 2
- -522500 1 - 1
[ 1373.15 298.15
= 30422.9007 kkal/kmol
T ref 2
- -241200 1 - 1
[ 1373.15 298.15
= 11685 + 7826.1965 - 633.33424706
= 18878.1123 kkal/kmol
T ref 2
- -979500 1 - 1
[ 1373.15 298.15
= 58592.2673 kkal/kmol
T ref 2
- -41900 1 - 1
[ 1373.15 298.15
= 19359.0916 kkal/kmol
T ref 2
- -108000 1 - 1
[ 1373.15 298.15
= 10750.0000 + 4347.8870 - 283.5825
= 14814.3045 kkal/kmol
T ref 2
- -208700 1 - 1
[ 1373.15 298.15
= 12201.7966 kkal/kmol
Cp dT K2O = A ( T- Tref)
∫
T
T ref
= 5342.7500 kkal/kmol
T ref 2
= 5385.75 + 4815.0153
= 10200.7653 kkal/kmol
Komponen Cp dT ( kkal/kmol)
∫
T
T ref
Al2O3 30422.9007
SiO2 18878.1123
Fe2O3 58592.2673
TiO2 19359.0916
CaO 14814.3045
MgO 12201.7966
K2O 5342.7500
Na2O 10200.7653
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
T ref 2
- -522500 1 - 1
[ 1423.15 298.15
= 32140.6723 kkal/kmol
T ref 2
- -241200 1 - 1
[ 1423.15 298.15
= 20024.4751 kkal/kmol
T ref 2
- -979500 1 - 1
[ 1423.15 298.15
= 46316 + 18222.1121 - 2596.9971437
= 61941.3650 kkal/kmol
T ref 2
- -41900 1 - 1
[ 1423.15 298.15
= 20475.6221 kkal/kmol
T ref 2
- -108000 1.00 - 1
[ 1423.15 298.15
= 15649.8935 kkal/kmol
T ref 2
- -208700 1 - 1
[ 1423.15 298.15
= 12217.5000 + 1158.9728 - 553.3367
= 12823.1361 kkal/kmol
Cp dT K2O = A ( T- Tref)
∫
T
T ref
= 5591.2500 kkal/kmol
T ref 2
= 5636.25 + 5189.7195
= 10825.9695 kkal/kmol
T ref 2
- -195500 1 - 1
[ 1386.55 298.15
= 13770.7409 kkal/kmol
Komponen Cp dT ( kkal/kmol)
∫
T
T ref
Al2O3 32140.6723
SiO2 20024.4751
Fe2O3 61941.3650
TiO2 20475.6221
CaO 15649.8935
MgO 12823.1361
K2O 5591.2500
Na2O 10825.9695
CO2 13770.7409
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Total entalpi keluar = Entalpi menuju rotary cooler + Entalpi menuju cyclone
= 543645.34539 + 1265.1670523
= 544910.51245 kkal
Panas reaksi :
o o o
∆H R
25oC
= [ ∆H F
25oC
produk] - [ ∆H F
25oC
reaktan]
o
Data ∆H F komponen : (Perry 7ed ; T 2.220)
o
Komponen ∆H F (kkal/mol)
Al2O3.2SiO2 -648.7
Al2O3 -399.09
SiO2 -202.46
o
∆H F
25oC
[( 7.8525 x -399.09 ) + ( 15.7050 x
- [( 7.8525 x -648.7 )]
= -1219.570952 kkal
Sumber panas yang digunakan adalah gas hasil pembakaran batu bara (flue gas)
C = 69.52 %
H = 5.32 %
O = 10.02 %
N = 1.28 %
S = 3.86 %
Ash = 10.00 % +
### %
- Menghitung komposisi gas panas (gas hasil pembakaran) :
Suhu = 1200 o
C = 1473.15 K
Suhu udara = 30 o
C = 303.15 K
Dari Perry edisi ke-6, Fig. 20-11,hal. 20-6 pada Tdry = 30 oC dan %H = 60% diperoleh
kg air
Humidity udara = 0.015
kg udara kering
- Reaksi pembakaran (dianggap pembakaran sempurna)
C(s) + O2(g) CO2(g)
H2(s) + ½O2(g) H2O(g)
S(s) + O2(g) SO2(g)
........ (3)
S(s) + O2(g) SO2(g)
mula-mula = 0.00120 m
bereaksi = 0.00120 m 0.00120 m 0.00120 m
setimbang = 0.00120 m 0.00120 m
1200 + 25
Menghitung Cp flue gas pada suhu t = = 612.50 o
C
2
CO2 = 0.295 k.cal/kg.oC = 12.983 k.cal/k.moloC
SO2 = 0.200 k.cal/kg.oC = 12.812 k.cal/k.moloC
H2 O = 0.449 k.cal/kg.oC = 8.082 k.cal/k.moloC
O2 = 0.260 k.cal/kg.oC = 8.320 k.cal/k.moloC
N2 = 0.300 k.cal/kg.oC = 8.406 k.cal/k.moloC
Panas flue gas
∆HG1 = m x Cp x ∆T
T1 = 1800 o
C = 2073.15 oK
Tref = 25 o
C = 298.15 o
K
∆T = 1775 o
K
Tref = 25 o
C = 298.15 o
K
Cp = 0.29 kcal/kg˚C Perry 13.04
∆HB = m x 0.29 x 5
= 1.45 m k.cal
Massa udara yang masuk = Massa udara + Massa air dalam udara
∆HU = m x Cpudara x ∆T + m x Cpair x ∆T
= 13.72 m x 0.2402 x 5 +
0.2058 m x 0.449 x 5
= 16.9410 m k.cal
Neraca Energi :
2. ROTARY COOLER
Kondisi operasi :
Tekanan operasi : 1 atm
Suhu operasi : 35 oC
Udara masuk pada suhu = 30 oC = 86 oF ( dry bulb) dengan kelembaban rata -rata = 70 %
didapatkan wet bub = 77 oF, dimana udara mempunyai humidity sebesar :
= 0.02 lb H2O ( Humidity Chart)
lb udara kering
Entalpi masuk :
Massa bahan :
Komponen Cp dT ( kkal/kmol)
∫
T
T ref
Al2O3 32140.6723
SiO2 20024.4751
Fe2O3 61941.3650
TiO2 20475.6221
CaO 15649.8935
MgO 12823.1361
K2O 5591.2500
Na2O 10825.9695
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Total entalpi masuk = entalpi dari rotary kiln + entalpi dari cyclone
= 543645.35 + 547.3585
= 544192.70
Entalpi keluar :
Massa bahan :
T ref 2
- -522500 1 - 1
[ 308.15 298.15
= 191.1248 kkal/kmol
- -241200 1 - 1
[ 308.15 298.15
= 108.8573 kkal/kmol
T ref 2
- -979500 1 - 1
[ 308.15 298.15
= 362.1405 kkal/kmol
T ref 2
- -41900 1 - 1
[ 308.15 298.15
= 136.3970 kkal/kmol
- -108000 1.00 - 1
[ 308.15 298.15
= 102.9173 kkal/kmol
T ref 2
- -208700 1 - 1
[ 308.15 298.15
= 89.5130 kkal/kmol
Cp dT K2O = A ( T- Tref)
∫
T
T ref
= 49.7000 kkal/kmol
T ref 2
= 50.10 + 16.24884
= 66.3488 kkal/kmol
Komponen Cp dT ( kkal/kmol)
∫
T
T ref
Al2O3 191.1248
SiO2 108.8573
Fe2O3 362.1405
TiO2 136.3970
CaO 102.9173
MgO 89.5130
K2O 49.7000
Na2O 66.3488
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Massa bahan :
T ref 2
- -522500 1 - 1
[ 538.11 298.15
= 5416.8233 kkal/kmol
T ref 2
- -241200 1 - 1
[ 538.11 298.15
= 3121.6604 kkal/kmol
- -979500 1 - 1
[ 538.11 298.15
= 10302.2358 kkal/kmol
T ref 2
- -41900 1 - 1
[ 538.11 298.15
= 3527.7115 kkal/kmol
T ref 2
- -108000 1.00 - 1
[ 538.11 298.15
= 2723.6332 kkal/kmol
- -208700 1 - 1
[ 538.11 298.15
= 2413.8737 kkal/kmol
Cp dT K2O = A ( T- Tref)
∫
T
T ref
= 1192.5791 kkal/kmol
T ref 2
= 1202.18 + 537.779966
= 1739.9573 kkal/kmol
Komponen Cp dT ( kkal/kmol)
∫
T
T ref
Al2O3 5416.8233
SiO2 3121.6604
Fe2O3 10302.2358
TiO2 3527.7115
CaO 2723.6332
MgO 2413.8737
K2O 1192.5791
Na2O 1739.9573
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
= 3268.8569 + 93.4077
= 3362.2647 kkal
Kebutuhan udara :
Panas yang dibutuhkan = 540830.44 kkal
M udara = Q = 540830.439
Cp x ∆ T 0,24 x ( 287,6 - 30)
= 9591.0060875 kg/jam
Neraca Energi :
Q terserap 540830.439
Total 544192.7039 544192.7039
3. REAKTOR
Kondensat
Kondisi operasi :
Entalpi masuk :
1. Entalpi bahan dari rotary cooler dan cyclone pada suhu 35oC : ∆H =
∫
T
n
T ref
Massa bahan :
Komponen Berat (kg/jam) BM kmol
Al2O3 800.8744 102 7.8517
SiO2 942.2051 60 15.7034
Fe2O3 3.7259 160 0.0233
TiO2 1.6559 80 0.0207
CaO 14.9034 56 0.2661
MgO 7.0377 40 0.1759
K2O 7.8657 94 0.0837
Na2O 3.1049 62 0.0501
Total 1781.3730
T ref
Al2O3 191.1248
SiO2 108.8573
Fe2O3 362.1405
TiO2 136.3970
CaO 102.9173
MgO 89.5130
K2O 49.7000
Na2O 66.3488
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Cp dT H2SO4 = A ( T- Tref)
∫
T
T ref
= 58 (303,15-298,15)
= 290 kkal/mol
T ref 2
- 0.00000251 1 - 1
[ 303.15 298.15
= 39.1822 kkal/kmol
Komponen Cp dT ( kkal/kmol)
∫
T
T ref
H2SO4 290.0000
H2O 39.1822
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
= 3271.9654 + 13061.5798
= 16333.5453 kkal
Entalpi Keluar :
T ref 2
= 1638.3367 kkal
T ref 2
- -241200 1 - 1
[ 378.15 298.15
= 934.1304 kkal
T ref 2
- -979500 1 - 1
[ 378.15 298.15
= 3107.7015 kkal
T ref 2
= 1119.0414 kkal
T ref 2
- -108000 1 - 1
[ 378.15 298.15
= 854.2989 kkal
T ref 2
- -208700 1 - 1
[ 378.15 298.15
= 753.0954 kkal
Cp dT K2O = A ( T- Tref)
∫
T
T ref
= 397.6 kkal
Cp dT Na2O = A ( T- Tref) + B ( T2 - Tref2) + C
∫
T
T ref 2
= 400.8000 + 144.9987
= 545.7987 kkal
Cp dT Al2(SO4)3 = A ( T- Tref)
∫
T
T ref
= 5080 kkal
Cp dT Fe2(SO4)3 = A ( T- Tref)
∫
T
T ref
= 5296 kkal
T ref 2
- -156800 1 - 1
[ 378.15 298.15
= 1964.6729 kkal
Cp dT MgSO4 = A ( T- Tref)
∫
T
∫ T ref
= 2136 kkal
Cp dT K2(SO4) = A ( T- Tref)
∫
T
T ref
= 2648 kkal
Cp dT Na2SO4 = A ( T- Tref)
∫
T
T ref
= 2624 kkal
T ref 2
- 0.00000251 1 - 1
[ 378.15 298.15
= 628.2669 kkal
Komponen Cp dT ( kkal/kmol)
∫
T
T ref
Al2O3 1638.3367
SiO2 934.1304
Fe2O3 3107.7015
TiO2 1119.0414
CaO 854.2989
MgO 753.0954
K2O 397.6
Na2O 545.7987
Al2(SO4)3 5080
Fe2(SO4)3 5296
CaSO4 1964.6729
MgSO4 2136
K2(SO4) 2648
Na2SO4 2624
H2O 628.2669
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Panas reaksi :
o o o
∆H R
25oC
= [ ∆H F
25oC
produk] - [ ∆H F
25oC
reaktan]
o
Data ∆H F komponen : (Perry 7ed ; T 2.220)
o
Komponen ∆H F (kkal/mol)
Al2O3 -399.09
SiO2 -202.46
Fe2O3 -198.5
TiO2 -225
CaO -151.7
MgO -143.84
K2O -86.2
Na2O -99.45
Al2(SO4)3 -820.99
Fe2(SO4)3 -221.3
CaSO4 -336.58
MgSO4 -304.94
K2(SO4) -342.65
Na2(SO4) -330.5
H2O -68.32
H2SO4 -193.69
o
∆H R
25oC
= [( 13601.7709 x -820.99 ) + ( 40805.3126 x -68.32
= -622813.461 kkal
= 8062.8402776 kkal
o
∆H R
25oC
= [( 260.8099 x -336.58 ) + ( 260.8099 x -68.32
= -15520.7972 kkal
o
∆H R
25oC
= [( 172.4243 x -304.94 ) + ( 172.4243 x -68.32
= -6160.7211 kkal
5) K2O + H2SO4 K2(SO4) + H2O
o
∆H R
25oC
= [( 82.0041 x -342.65 ) + ( 82.0041 x -68.32
= -10749.0920 kkal
o
∆H R
25oC
= [( 49.0771 x -330.5 ) + ( 49.0771 x -68.32
= -5186.4713 kkal
Kebutuhan steam :
Dipakai steam pada suhu tekanan steam 4,5 atm dan suhu 148 oC (Ulrich ;426 )
M steam = Q steam
λ steam
= 847876.86 = 1298.2343563 kg
653.1
Neraca Energi :
4. FILTER PRESS
Fungsi : Memisahkan padatan dan air yang terikut
cake
Kriteria design :
5 % filtrat terikut pada cake
Kondisi operasi :
Tekanan operasi = 1 atm
Suhu masuk = 105 oC
Suhu keluar = 95 oC
Entalpi masuk :
∆H =
∫
T
1. Entalpi bahan dari Reaktor pada suhu 105oC :
n Cp dT
T ref
Entalpi masuk = Entalpi keluar dari reaktor
Entalpi keluar :
T ref 2
- -522500 1 - 1
[ 368.15 298.15
= 1545.6000 + 209.2082 - 333.2151
= 1421.5931 kkal
T ref 2
- -241200 1 - 1
[ 368.15 298.15
= 810.2472 kkal
T ref 2
- -979500 1 - 1
[ 368.15 298.15
= 2696.1330 kkal
T ref 2
- -41900 1 - 1
[ 368.15 298.15
= 826.7000 + 175.8366 - 26.7210
= 975.8156 kkal
T ref 2
- -108000 1 - 1
[ 368.15 298.15
= 743.9961 kkal
T ref 2
- -208700 1 - 1
[ 368.15 298.15
= 655.0199 kkal
Cp dT K2O = A ( T- Tref)
∫
T
T ref
= 347.9 kkal
T ref 2
= 5.01 ( 368.15 - 298.15 ) +
= 350.7000 + 124.9979
= 475.6979 kkal
Cp dT Al2(SO4)3 = A ( T- Tref)
∫
T
T ref
= 4445 kkal
Cp dT Fe2(SO4)3 = A ( T- Tref)
∫
T
T ref
= 4634 kkal
T ref 2
- -156800 1 - 1
[ 368.15 298.15
= 1708.7550 kkal
Cp dT MgSO4 = A ( T- Tref)
∫
T
T ref
= 1869 kkal
Cp dT K2(SO4) = A ( T- Tref)
∫
T
T ref
= 2317 kkal
Cp dT Na2SO4 = A ( T- Tref)
∫
T
T ref
= 2296 kkal
T ref 2
- 0.00000251 1 - 1
[ 368.15 298.15
= 549.5759 kkal
Komponen Cp dT ( kkal/kmol)
∫
T
T ref
Al2O3 1638.3367
SiO2 810.2472
Fe2O3 2696.1330
TiO2 975.8156
CaO 743.9961
MgO 655.0199
K2O 347.9
Na2O 475.6979
Al2(SO4)3 4445
Fe2(SO4)3 4634
CaSO4 1708.7550
MgSO4 1869
K2(SO4) 2317
Na2SO4 2296
H2O 549.5759
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Komponen Cp dT ( kkal/kmol)
∫
T
T ref
Al2(SO4)3 4445
Fe2(SO4)3 4634
CaSO4 1708.7550
MgSO4 1869
K2(SO4) 2317
Na2SO4 2296
H2O 549.5759
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
= 20127.2852 + 128029.432
= 148156.717 kkal
Neraca Energi :
Q loss 21292.1413
Total 169448.8582 169448.8582
5. THICKENER
Fungsi : Memisahkan padatan dan liquid secara sedimentasi
cake 86oC
Kriteria design :
% solid pada feed : minimum 11 % (Perry 7 ed : 18-72)
Waktu pengendapan : 3 - 5 jam (Perry 7 ed : 18-72)
Kondisi operasi :
Tekanan operasi : 1 atm (atmospheric pressure)
Waktu tinggal : 3 jam (Perry 7 ed : 18-72)
Penurunan suhu karena alat dan bahan = 10 % dari suhu masuk (Ulrich :432)
Suhu masuk : 95 oC
Suhu keluar : 86 oC
Entalpi masuk :
∆H =
∫
T
1. Entalpi bahan dari Filter Press pada suhu 95oC :
n Cp dT
T ref
Massa bahan :
Cp dT BaS = A ( T- Tref)
∫
T
T ref
= 199 kkal
Cp dT Na2SO4 = A ( T- Tref)
∫
T
T ref
= 164 kkal
Komponen Cp dT ( kkal/kmol)
∫
T
T ref
BaS 199
Na2SO4 164
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Massa bahan :
T ref 2
- -0.00000139 1 - 1
[ 303.15 298.15
= 65.0357 kkal
T ref 2
= 10.79 ( 303.15 - 298.15 ) +
= 53.95 + 6.31
= 60.26 kkal
T ref 2
- 0.00000251 1 - 1
[ 303.15 298.15
= 39.1822 kkal
Komponen Cp dT ( kkal/kmol)
∫
T
T ref
Protein 65.0357
NaCl 60.2637
H2O 39.1822
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Total entalpi masuk : Entalpi dari Filter Press + Entalpi dari Tangki BaS
Entalpi Keluar :
Cp dT Al2(SO4)3 = A ( T- Tref)
∫
T
T ref
= 3873.5 kkal
T ref 2
- 0.00000251 1 - 1
[ 359.15 298.15
= 478.792 kkal
Komponen Cp dT ( kkal/kmol)
∫
T
T ref
Al2(SO4)3 3873.5000
H2O 478.7925
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
T ref 2
- -0.00000139 1 - 1
[ 359.15 298.15
= 835.8451 kkal
T ref 2
= 10.7 ( 359.15 - 298.15 ) +
= 652.7 + 267.84
= 920.54 kkal
Cp dT Ba(SO4) = A ( T- Tref) + B ( T2 - Tref2)
∫
T
T ref 2
= 21.35 ( 359.15 - 298.15 ) +
= 1302.35 + 282.67
= 1585.02 kkal
Komponen Cp dT ( kkal/kmol)
∫
T
T ref
Protein 835.8451
Fe2S3 920.5366
Ba(SO4) 1585.0219
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
T ref
= 3873.5 kkal
T ref 2
- -156800 1 - 1
[ 359.15 298.15
= 1480.8435 kkal
Cp dT MgSO4 = A ( T- Tref)
∫
T
T ref
= 1628.7 kkal
Cp dT K2(SO4) = A ( T- Tref)
∫
T
T ref
= 2019.1 kkal
Cp dT Na2SO4 = A ( T- Tref)
∫
T
T ref
= 2000.8 kkal
= 658.19 + 84.20
= 742.39 kkal
T ref 2
- 0.00000251 1 - 1
[ 359.15 298.15
= 478.7925 kkal
Komponen Cp dT ( kkal/kmol)
∫
T
T ref
Al2(SO4)3 3873.5000
CaSO4 1480.8435
MgSO4 1628.7
K2(SO4) 2019.1
Na2SO4 2000.8
NaCl 742.39
H2O 478.7925
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Total entalpi keluar : Entalpi bahan ke evaporator + Entalpi bahan limbah padat
= 112171.436 kkal
Panas reaksi :
o o o
∆H R
25oC
= [ ∆H F
25oC
produk] - [ ∆H F
25oC
reaktan]
o
Data ∆H F komponen : (Perry 7ed ; T 2.220)
o
Komponen ∆H F (kkal/mol)
Fe2(SO4)3 -653.3
BaS -111.2
Fe2S3 -38.2
BaSO4 -340.2
Tinjauan panas reaksi :
o
∆H F
25oC
[( 0.0383 x -38.2 ) + ( 0.1150 x
= -28.32461997 kkal
Neraca Energi :
6. EVAPORATOR
H2O Steam
Al2(SO4)3 Produk
Feed EVAPORATOR Al2(SO4)3
86oC 90oC
Steam
Kriteria design :
Kondisi operasi :
Tekanan operasi : 1 atm (Atmospheric pressure)
Suhu operasi : 90oC (Kirk Othmer , Vol 2 : 247)
Kadar pemekatan : 54.00% (Kirk Othmer , Vol 2 : 59)
Entalpi masuk :
∆H =
∫
T
1. Entalpi bahan dari Thickener pada suhu 90oC :
n Cp dT
T ref
Massa bahan :
Cp dT Al2(SO4)3 = A ( T- Tref)
∫
T
T ref
= 4127.5 kkal
T ref 2
- 0.00000251 1 - 1
[ 363.15 298.15
= 510.247 kkal
Komponen Cp dT ( kkal/kmol)
∫
T
T ref
Al2(SO4)3 4127.5000
H2O 510.2473
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
T ref gas 2
- 0.00000134 1 - 1
[ 363.15 298.15
= 537.524 kkal
= 526252.35324 kkal
= 81486.489 + 526252.35
= 607738.84 kkal
Neraca energi total :
Kebutuhan steam :
Dipakai steam pada suhu tekanan steam 4,5 atm dan suhu 148 oC (Ulrich ;426 )
M steam = Q steam
λ steam
= 533540.83 = 816.9358907 kg
653.1
Neraca Energi :
Brine 20oC
Entalpi masuk :
∆H =
∫
T
1. Entalpi bahan dari Evaporator pada suhu 86oC :
n Cp dT
T ref
Entalpi keluar :
1. Entalpi bahan berupa Kristal
Cp dT Al2(SO4)3.16H2O = A ( T- Tref)
∫
T
T ref
= -3525 kkal
Cp dT H2O = A ( T- Tref) + B ( T2 - Tref2) + C
∫
T
T ref 2
- 0.00000251 1 - 1
[ 283.15 298.15
= -117.479 kkal
Komponen Cp dT ( kkal/kmol)
∫
T
T ref
Al2(SO4)3.16H2O -3525.0000
H2O -117.4791
Entalpi bahan : ∆H =
∫
T
n Cp dT
T ref
Kebutuhan Refrigerator :
Air Refrigerator = 5 oC
Air Refigerator = 20 oC
= 12255.090835 kg
Komponen Masuk(kkal/j) Komponen Keluar(kkal/j)
Entalpi bahan dari Evaporator Mother Liquor
Al2(SO4)3.16H2O 27154.6053 Al2(SO4)3.16H2O -23190.7895
H2O 54331.8840 H2O -143.1275
81486.4893 -23333.9170
Q Kristalisasi 44078.9474 Q terserap 148899.3536
Total 125565.4367 125565.4367
1 - 1
[ T Tref ]
0.004763 ( 303,152 - 298,15,152)
2
]
54.9211
1 - 1
[ T Tref ]
0.018820 ( 303,152 - 298,15,152)
2
]
54.1854
1 - 1
[ T Tref ]
0.007540 ( 303,152 - 298,15,152)
2
]
2.3179
1 - 1
[ T Tref ]
0.004840 ( 303,152 - 298,15,152)
2
]
5.9745
1 - 1
[ T Tref ]
0.001197 ( 303,152 - 298,15,152)
2
]
11.5452
1 - 1
[ T Tref ]
0.002740 ( 303,152 - 298,15,152)
2
]
]
10.8149
1226.4721926 kkal
4.1909773496 kkal
1.4090654066 kkal
13.654293347 kkal
7.8397967051 kkal
2.0795965839 kkal
1.658142562 kkal
295.16018305 kkal
+
1552.4642476 kkal
Cp dT
1 - 1
[ T Tref ]
0.008971 ( 1373,152 - 298,15,152)
2
]
1371.9616256
1 - 1
[ T Tref ]
0.008712 ( 1373,152 - 298,15,152)
2
]
633.33424706
1 - 1
[ T Tref ]
0.018820 ( 1373,152 - 298,15,152)
2
]
2571.9357
1 - 1
[ T Tref ]
0.007540 ( 1373,152 - 298,15,152)
2
]
110.0195
1 - 1
[ T Tref ]
0.004840 ( 1373,152 - 298,15,152)
2
]
283.5825
1 - 1
[ T Tref ]
0.001197 ( 1373,152 - 298,15,152)
2
]
547.9969
296184.07258 kkal
1363.1864906 kkal
400.35699562 kkal
3939.0199699 kkal
2144.8906431 kkal
446.66615227 kkal
510.38132195 kkal
+
543645.34539 kkal
dT
1 - 1
[ T Tref ]
0.008971 ( 1423,15 - 298,15,152)
2
]
1385.3302783
1 - 1
[ T Tref ]
0.008712 ( 1423,152 - 298,15,152)
2
]
639.50557534
1 - 1
[ T Tref ]
0.018820 ( 1423,152 - 298,15,152)
2
]
2596.9971437
1 - 1
[ T Tref ]
0.007540 ( 1423,152 - 298,15,152)
2
]
111.0916
1 - 1
[ T Tref ]
0.004840 (1423,152 - 298,15,152)
2
]
286.3458
1 - 1
[ T Tref ]
0.001197 ( 1423,152 - 298,15,152)
2
]
553.3367
1 - 1
[ T Tref ]
0.002740 (1423,152 - 298,15,152)
2
]
514.7128
252.38445875 kkal
314.48416895 kkal
1.4425479344 kkal
0.4238713511 kkal
4.16536261 kkal
2.2563690641 kkal
0.4679092314 kkal
0.5422047626 kkal
689.00015964 kkal
+
1265.1670523 kkal
-202.46 )]
(30oC)
n rata -rata = 70 %
239.7652 kkal
298.7600 kkal
1.3704 kkal
0.4027 kkal
3.9571 kkal
2.1436 kkal
0.4445 kkal
0.5151 kkal
+
547.3585 kkal
1 - 1
[ T Tref ]
0.008971 ( 308,152 - 298,15,152)
2
]
56.8708
1 - 1
[ ]
[ T Tref ]
0.008712 ( 308,152 - 298,15,152)
2
]
26.25308337
1 - 1
[ T Tref ]
0.018820 ( 308,152 - 298,15,152)
2
]
106.61233483
1 - 1
[ T Tref ]
0.007540 ( 308,152 - 298,15,152)
2
]
4.5605
1 - 1
[ ]
[ T Tref ]
0.004840 ( 308,152 - 298,15,152)
2
]
11.7551
1 - 1
[ T Tref ]
0.001197 (308,152 - 298,15,152)
2
]
22.7157
1707.8084 kkal
8.4250 kkal
2.8206 kkal
27.3636 kkal
15.7342 kkal
4.1548 kkal
3.3195 kkal
+
3268.8569 kkal
1 - 1
[ T Tref ]
0.008971 ( 538,112 - 298,15,152)
2
]
781.4745
1 - 1
[ T Tref ]
0.008712 (538,112 - 298,15,152)
2
]
360.74957099
1 - 1
[ ]
[ T Tref ]
0.018820 (538,112 - 298,15,152)
2
]
1464.9842653
1 - 1
[ T Tref ]
0.007540 ( 538,112 - 298,15,152)
2
]
62.6675
1 - 1
[ T Tref ]
0.004840 ( 538,112 - 298,15,152)
2
]
161.5297
1 - 1
[ ]
[ T Tref ]
0.001197 (538,112 - 298,15,152)
2
]
312.1411
49.0232 kkal
0.2399 kkal
0.6572 kkal
0.3423 kkal
0.4247 kkal
0.0998 kkal
0.0871 kkal
+
93.4077 kkal
Cp dT
1500.6563 kkal
1709.4325 kkal
8.4330 kkal
2.8233 kkal
27.3897 kkal
15.7492 kkal
4.1588 kkal
3.3227 kkal
+
3271.9654 kkal
T
Cp dT
T ref
1 - 1
[ T Tref ]
0.000451 (303,152 - 298,15,152)
2
]
0.0000
6877.8731 kkal
6183.7067 kkal
+
+
13061.5798 kkal
1 - 1
[ T Tref ]
0.008971 (383,152 - 298,152)
2
]
370.7468
1 - 1
[ T Tref ]
0.008712 (383,152 - 298,152)
2
]
171.1466
1 - 1
[ T Tref ]
0.018820 (383,152 - 298,152)
2
]
695.0171
1 - 1
[ T Tref ]
0.007540 (383,152 - 298,152)
2
]
29.7307
1 - 1
[ T Tref ]
0.004840 (383,152 - 298,152)
2
]
76.6328
1 - 1
[ T Tref ]
0.001197 (383,152 - 298,152)
2
]
148.0858
1 - 1
[ T Tref ]
0.005360 (383,152 - 298,152)
2
1 - 1
[ T Tref ]
0.021970 (383,152 - 298,152)
2
]
111.2595
1 - 1
[ T Tref ]
0.000451 (383,152 - 298,152)
2
]
0.0000
257.2749 kkal
14669.0408 kkal
1.4474 kkal
23.1633 kkal
4.5471 kkal
2.6500 kkal
0.6654 kkal
0.5467 kkal
39088.9504 kkal
120.8593 kkal
512.4062 kkal
368.2984 kkal
217.1467 kkal
128.7784 kkal
114053.083 kkal
169448.858 kkal
-68.32 )] -
-193.69 )]
-68.32 )] -
-193.69 )]
-68.32 )] -
-193.69 )]
-68.32 )] -
-193.69 )]
-68.32 )] -
-193.69 )]
-68.32 )] -
-193.69 )]
Q loss
5 % Q supply
1 - 1
[ T Tref ]
0.008971 (372,152 - 298,152)
2
]
333.2151
1 - 1
[ T Tref ]
0.008712 (372,152 - 298,152)
2
]
153.8210
1 - 1
[ T Tref ]
0.018820 (372,152 - 298,152)
2
]
624.6588
1 - 1
[ T Tref ]
0.007540 (372,152 - 298,152)
2
]
26.7210
1 - 1
[ T Tref ]
0.004840 (372,152 - 298,152)
2
]
68.8751
1 - 1
[ T Tref ]
0.001197 (372,152 - 298,152)
2
]
133.0947
1 - 1
[ T Tref ]
0.005360 (372,152 - 298,152)
2
1 - 1
[ T Tref ]
0.021970 (372,152 - 298,152)
2
]
99.9964
1 - 1
[ T Tref ]
0.000451 (372,152 - 298,152)
2
]
0.0000
257.2749 kkal
12723.6506 kkal
1.2557 kkal
20.1986 kkal
3.9600 kkal
2.3049 kkal
0.5822 kkal
0.4764 kkal
1710.1416 kkal
5.2876 kkal
382.5141 kkal
16.1131 kkal
9.5002 kkal
5.6341 kkal
4988.3912 kkal
20127.285 kkal
32492.6901 kkal
100.4643 kkal
63.1461 kkal
306.1480 kkal
180.5032 kkal
107.0470 kkal
94779.433 kkal
128029.432 kkal
12.9429 kkal
0.0127 kkal
+
12.9556 kkal
1 - 1
[ T Tref ]
0.024830 (303,152 - 298,152)
2
]
0.0000
1 - 1
[ T Tref ]
0.000451 (372,152 - 298,152)
2
]
0.0000
0.7804 kkal
0.0103 kkal
0.1959 kkal
+
0.9866 kkal
]
0.0000
25483.5526 kkal
75391.501 kkal
+
100875.054 kkal
1 - 1
[ T Tref ]
0.024830 (362,152 - 298,152)
2
]
0.0000
10.0301 kkal
37.0631 kkal
103.089 kkal
+
150.182 kkal
1 - 1
[ T Tref ]
0.021970 (362,152 - 298,152)
2
]
89.3234
0.004200 (362,152 - 298,152)
2
1 - 1
[ T Tref ]
0.000451 (362,152 - 298,152)
2
]
0.0000
2831.5058 kkal
5.4724 kkal
26.6786 kkal
15.7296 kkal
9.3439 kkal
0.0127 kkal
8257.457 kkal
11146.200 kkal
-111.2 )]
1 - 1
[ T Tref ]
0.000451 (355,152 - 298,152)
2
]
0.0000
27154.6053 kkal
54331.884 kkal
+
81486.489 kkal
n λ
1 - 1
[ T Tref ]
0.000150 (355,152 - 298,152)
2
]
0.0000
9785.1428571 )
1 - 1
[ T Tref ]
0.000451 (293,152 - 298,152)
2
]
0.0000
-23190.7895 kkal
-143.128 kkal
+
-23333.917 kkal
)
APPENDIX C
PERHITUNGAN SPESIFIKASI ALAT
Bahan masuk :
Total bahan baku masuk : 2070.126855 kg/jam
Spesifikasi :
Fungsi = Menampung Kaolin dari Supplier
Kapasitas = 217.94 m3
Bentuk = Empat Persegi panjang
Ukuran = Panjang : 7.6 m
Lebar : 7.6 m
Tinggi : 3.8 m
Accecories = Crane Conveyor (pemindah solid)
Jumlah = 1 buah
Perhitungan :
Rate massa : 2070.126855 kg/jam = 2.1 ton/jam
dengan kapasitas 2.1 ton/jam. Dari tabel Perry 6ed, tabel 7-7 dan fig 7-3
dipilih belt dengan spesifikasi sebagai berikut :
Kapasitas maksimum : 32 ton/jam
hp tiap 10 ft (linier) : 0.34
asumsi : Jarak belt conveyor : 50 ft
Tinggi belt conveyor : 10 ft
slope : α
tg α = 10 = 0.2 maka sudut α = 11,31o
50
Panjang belt = ( (50.50) + (10.10) ) 0,5
= 51 ft
Perhitungan power :
hp/10 ft, lift = 0.34 hp/ft
hp = 51 x 0,34 hp/ft = 1.73367 ≈ 2 hp
10
Penambahan power untuk tripper = 2 hp
Power total = 4 hp
Spesifikasi :
Fungsi = Memindahkan barang dari kaolin stock pile menuju hammer crusher
Type = Troughed belt on 45o idlers with rolls of equal length
Kapasitas maksimum = 32 ton/jam
Belt = Widht : 14 in
Trough widht : 9 in
Skirt seal : 2 in
Belt speed = (2,1/32) x 100 ft/mnt = 6.5 ft/mnt
Panjang = 51 ft
Sudut elevasi = 11,31o
Power = 4 hp
Jumlah = 1 buah
Perhitungan :
Rate massa : 2179.0809 kg/jam = 2.2 ton/jam
dengan kapasitas 3,7 ton/jam, Dari Perry 6ed, tabel 8-13 dipilih spesifikasi
sebagai berikut :
Spesifikasi :
Fungsi = Menghancurkan bahan dari 2 in menjadi 1/8 in
Type = Reversible Hammer Crusher
Kapasitas Maksimum = 40 ton/jam
Model = 505
Ukuran Rotor = 30 x 30 (in)
Maksimum ukuran feed = 2,5 in
Maksimum speed = 1200 rpm
Power = 100 hp
Jumlah = 1 buah
4. SCREEN H - 113
Fungsi = Menyaring bahan dari Hammer Crusher
Type = Vibrated Screen
Dasar Pemilihan = Sesuai dengan bahan dan kapasitas
Perhitungan :
Rate massa : 2179.0809 kg/jam = 2.2 ton/jam
Ukuran yang tersaring diharapkan mempunyai ukuran 1/8 in = 3,175 mm ( 7 mesh)
Produk oversize 5 % feed
Produk Undersize 95 % feed
Produk undersize dalam oversize 5 % oversize
Perhitungan effisiensi screen :
E = 100 (e - v)
100 x
e (100 - v)
dimana :
E = effisiensi
e = persentase jumlah undersize dalam feed
v = persentase undersize di dalam screen oversize
sehingga :
E = 100 (95 - 5)
100 x = 99.73%
95(100 - 5)
Dari Perry 6ed halaman 21-15 untuk type Screen Vibrated didapatkan spesifikasi :
Spesifikasi :
Fungsi = Menyaring bahan dari Hammer Crusher
Type = Vibrated Screen
Kapasitas = 2.2 ton/jam
Speed = 50 vibration/dy ; P = 3 Hp ( Peter's 4ed;p.567)
Tyler equivalent design = 7 mesh
Sieve No = 7
Sieve design = 2,83 mm
Sieve Opening = 2,83 mm
Ukuran kawat = 1,1 mm
Effisiensi = 99.73%
Jumlah = 1 buah
Perhitungan :
Rate massa : 2070.126855 kg/jam = 4563.8 lb/jam
ρ campuran = 203.3034 lb/cuft
Volumentrik bahan : 4563.8
= 22.4485 cuft/jam = 0.4 cuft/mnt
203.3034128
= 0.1383 hp
Spesifikasi :
Fungsi = Memindahkan bahan dari screen ke Rotary Kiln
Type = Plain spout or chutes
Kapasitas = 22.4485 cuft/jam
Panjang = 20 ft
Diameter = 6 in
Kecepatan putaran = 18 rpm
Power = 0.5 hp
Jumlah = 1 buah
Perhitungan :
Dari neraca massa dan neraca panas :
Feed masuk : 2070.1269 kg/jam = 4563.848494 lb/jam
Kebutuhan Fle Gas : 344.98 kg/jam = 760.554153 lb/jam
Suhu bahan masuk : 30 oC = 86 oF
Suhu bahan keluar : 1100 oC = 2012 oF
Suhu udara masuk : 1200 oC = 2192 oF
Suhu udara keluar : 1113.4 oC = 2036.12 oF
[ ]
D = Mc 0.5
[ π
4
. G ]
=
[ 760.5541530473
0.785 x 200 ] 0.5
≈ 2.2 ft
Panjang shell :
Nt = 10 x L / Cp x Gg 0.8 x D (Perry 3ed hal 832)
Nt = 1,5 - 2
Nt = Ditetapkan 1,5, maka L/D = 10 - 40 (Ulrich hal 132)
Check :
1.5 = 10 x L / 0.3 x 800 0.8 x 2.2
L = 27.1909 ≈ 30 ft
Penentuan Kemiringan :
B = 5 (Dp)-0,5 (Perry 6ed, 20-33)
θ = 0,23 L BLG (Perry 6ed, 20-33)
± 0.6
SN 0,9
D F
Dimana : θ = time of passes ; jam
L = panjang drum ; ft
S = slope drum ; cm/m
N = speed ; rpm
D = diameter drum ; ft
B = konstanta material
G = rate massa udara ; lb/ft2.j
F = rate solid ; lb/ft2.jam
Dp = berat partikel ; μm
Dp = 7 mesh = 2830 μm
B = 5 ( 2830 -0.5 ) = 0.09399
F = 4563.8485 lb/jam / 3.8028 ft2 = 1200.14 ; lb/ft2.jam
36.5904 = 0.23 x 30 0.09399 x 30 x
+ 0.6
S x 11 0.9 x 2.2 1200.1376826499
S = 0.00992 ( memenuhi) Perry ed 3 hal 832, S sekitar 0 - 0,08
Tebal shell
Tekanan design = 1.51711 psi
Tebal Shell berdasarkan ASME Code untuk cylindical tank :
ts = P.R ( B & Y pers 13-1, hal 254)
+ C
f. e - 0,6P
ts = 1.51711 x 26 / 2
+ 1/8
4200 x 0.8 - 0.6 x 1.51711
= 0.13096 in ≈ 3/16 in
Isolasi :
Batu isolasi dipakai setebal 4 in (Perry ed 7 ; 12-42)
Diameter dalam rotary 2.20098 ft
Diameter luar rotary : 2.2 + 2 ((1/4/12)) = 2.24264 ft
maka diameter rotary terisolasi : 2.24264 + 2( 4/12) = 2.90931 ft
Berat shell :
We = π
( Do2 - Di2) . L . Ρ
4
Dimana :
Do = Diameter luar shell = 2.24264 ft
Di = Diameter dalam shell = 2.20098 ft
L = Panjang drum = 30 ft
ρ = Density shell = 489 lb/cuft (perry ed 6 hal3-95)
Berat isolasi :
We = π
( Do2 - Di2) . L . Ρ
4
Dimana :
Do = Diameter luar isolasi = 2.90931 ft
Di = Diameter dalam isolasi = 2.24264 ft
L = Panjang drum = 30 ft
ρ = Density shell = 129 lb/cuft (perry ed 6 hal3-260)
Spesifikasi :
Fungsi : Kalsinasi kaolin menjadi alumina
Type : Rotary drum
Kapasitas : 4563.848494 lb/jam
Isolasi : Batu isolasi
Tebal Isolasi : 4 in
Tebal Shell : 3/16 in
Diameter : 2.2 ft
Panjang : 30 ft
Tinggi bahan : 0.33015 ft
Sudut rotary : 0,61o
Time of passe : 36.5904 menit
Power : 0.5 hp
Jumlah : 1 buah
7. CYCLONE H - 131
Fungsi = untuk memisahkan padatan yang terikut udara
Type = Van Tongeren Cyclone
Dasar pemilihan = efektif dan sesuai dengan jenis bahan
Dpmin =
( π
9x
x
0.0000215 x
10 x 2.48368 x
0.20833
( 44.2503 - 1.800
= 0.00011034877 ft
Perencanaan Tebal Shell dan Tutup
Bahan konstruksi dipilih Carbon Steel SA-387 grade D
f = 2500 psi (Perry ed 7 tabel 6-57)
C = 1/8
Tebal shell
Tekanan design = 1 atm = 14.7 psi
Tebal Shell berdasarkan ASME Code untuk cylindical tank :
ts = P.R ( B & Y pers 13-1, hal 254)
+ C
f. e - 0,6P
ts = 14.7 x 10 / 2
+ 1/8
2500 x 0.8 - 0.6 x 14.7
= 0.161912785 = 3 / 16 in
tc = 14.7 x 10
2x 0.9659 x ( 2500 x 0.8 - 0.6 x 14.7 )
= 0.163215949 = 3 / 16 in
Spesifikasi :
Fungsi : untuk memisahkan padatan yang terikut udara
Type : Van Tongeren Cyclone
Kapasitas : 0.431195128 cuft/dt
Diameter partikel : 0.00011034877 ft
Tebal Shell : 3 / 16 in
Tebal tutup atas : 3 / 16 in
Tebal tutup bawah : 3 / 16 in
Jumlah : 1 buah
8. BLOWER G - 132
Fungsi : Memindahkan udara dari udara bebas ke B-130
Type : Centrifugal
Dasar Pemilihan : Sesuai dengan jenis bahan dan effisiensi tinggi
Spesifikasi :
Fungsi = memindahkan udara dari udara bebas
Type = Centrifugal
Bahan = Commercial steel
Rate Volumentrik = 2402.907435 cuft/mnt
Adiabatic Head = 1000 ft.lbf/lbm gas
Effisiensi motor = 80%
Power = 25 hp
Jumlah = 1 buah
Perhitungan :
Dari neraca massa dan neraca panas :
Feed masuk : 1781.4621 kg/jam = 3927.451631 lb/jam
Kebutuhan udara : 9591.006087 kg/jam = 21144.54899 lb/jam
Suhu bahan masuk : 1100 oC = 2012 oF
Suhu bahan keluar : 35 oC = 95 oF
Suhu udara masuk : 30 oC = 86 oF
Suhu udara keluar : 264.96 oC = 32 oF
[ ]
D = Mc 0.5
π
. G
4
=
[ 3927.4516313977
0.785 x 450 ] 0.5
= 3.33437 ≈ 4 ft
Panjang shell :
Penentuan Kemiringan :
B = 5 (Dp)-0,5 (Perry 6ed, 20-33)
θ = 0,23 L BLG (Perry 6ed, 20-33)
± 0.6
SN 0,9
D F
Dimana : θ = time of passes ; jam
L = panjang drum ; ft
S = slope drum ; cm/m
N = speed ; rpm
D = diameter drum ; ft
B = konstanta material
G = rate massa udara ; lb/ft2.j
F = rate solid ; lb/ft2.jam
Dp = berat partikel ; μm
Dp = 7 mesh = 2830 μm
B = 5( 2830 -0.5 ) = 0.09399
F = 3927.4516 lb/jam / 12.5600 ft2 = 312.695 ; lb/ft2.jam
ts = 17.2566 x 24 / 2
+ 1/8
4200 x 0.8 - 0.6 x 17.2566
= 0.2 in ≈ 1/4 in
Isolasi :
Batu isolasi dipakai setebal 4 in (Perry ed 7 ; 12-42)
Diameter dalam rotary 4 ft
Diameter luar rotary : 4 + 2 ((1/4/12)) = 4.04167 ft
maka diameter rotary terisolasi : 4.04167 + 2( 4/12) = 4.70833 ft
Berat shell :
We = π
( Do2 - Di2) . L . Ρ
4
Dimana :
Do = Diameter luar shell = 4.04167 ft
Di = Diameter dalam shell = 4 ft
L = Panjang drum = 25 ft
ρ = Density shell = 489 lb/cuft (perry ed 6 hal3-95)
Berat isolasi :
We = π
( Do2 - Di2) . L . Ρ
4
Dimana :
Do = Diameter luar isolasi = 4.70833 ft
Di = Diameter dalam isolasi = 4.04167 ft
L = Panjang drum = 25 ft
ρ = Density shell = 129 lb/cuft (perry ed 6 hal3-260)
Spesifikasi :
Fungsi = Mendinginkan alumina
Type = Rotary drum
Kapasitas = 3927.451631 lb/jam
Isolasi = Batu isolasi
Tebal Isolasi = 4 in
Tebal Shell = 1/4 in
Diameter = 4 ft
Panjang = 25 ft
Tinggi bahan = 0.6 ft
Sudut rotary = 0,60o
Time of passes = 25.85 menit
Power = 10 hp
Jumlah = 1 buah
Dpmin =
( π
9x
x
0.0000215 x
10 x 66.2715 x
1.04167
( 179.694 - 0.041
= 0.00002321984 ft
Tebal shell
Tekanan design = 1 atm = 14.7 psi
Tebal Shell berdasarkan ASME Code untuk cylindical tank :
ts = P.R ( B & Y pers 13-1, hal 254)
+ C
f. e - 0,6P
ts = 14.7 x 50 / 2
+ 1/8
2500 x 0.8 - 0.6 x 14.7
= 0.309563927 = 3 / 8 in
tc = 14.7 x 50
2x 0.9659 x ( 2500 x 0.8 - 0.6 x 14.7 )
= 0.316079746 = 7 / 16 in
Spesifikasi :
Fungsi : untuk memisahkan padatan yang terikut udara
Type : Van Tongeren Cyclone
Kapasitas : 287.636701 cuft/dt
Diameter partikel : 0.00002321984 ft
Tebal Shell : 3 / 8 in
Tebal tutup atas : 7 / 16 in
Tebal tutup bawah : 7 / 16 in
Jumlah : 1 buah
Perhitungan power :
hp = 0,0044 Q x P1 x ln (P2/P1) (Perry ed 6; pers 6-31b)
dimana : Q = Volumentrik gas ; cuft/mnt
P1 = Operating suction pressure ; psi
P2 = operating discharge pressure ; psi
Spesifikasi :
Fungsi : memindahkan udara dari udara bebas
Type : Centrifugal
Bahan : Commercial steel
Rate Volumentrik : 4869.253189 cuft/mnt
Adiabatic Head : 17000 ft.lbf/lbm gas
Effisiensi motor : 80%
Power : 50.2177
Jumlah : 1 buah
Perhitungan :
Rate massa : 1781.373 kg/jam = 3927.3 lb/jam
ρ campuran = 179.6234 lb/cuft
Volumentrik bahan : 3927.3
= 21.8638 cuft/jam = 0.4 cuft/mnt
179.6233677
Untuk bulk density = 179.6234 lb/cuft ; bahan termasuk kelas D
dengan F = 3 (Badger, Tabel 16-6)
Spesifikasi :
Fungsi = Memindahkan bahan dari Rotary Coller ke bucket elevator
Type = Plain spout or chutes
Kapasitas = 22 cuft/jam
Panjang = 20 ft
Diameter = 6 in
Kecepatan putaran = 18 rpm
Power = 0.5 hp
Jumlah = 1 buah
Perhitungan :
Rate massa : 1781.373 kg/jam = 2 ton/jam
Tinggi bucket : Tinggi ( Ball mill + Screen + jarak dari tanah)
: 3+ 3+ 3= 9 ft
Spesifikasi :
Fungsi = Memindahkan bahan
Type = Continous discharge Bucket elevator
Kapasitas maksimum = 14 ton/jam
Ukuran = 6 in x 4 in x 4 1/4 in
Bucket spacing = 12 in
Tinggi elevator = 9 ft
Ukuran feed (Max) = 3/4 in
Bucket speed = (2 / 14) x 225 ft/mnt = 32 ft/mnt
Putaran head shaft = (2/14)x 43 rpm = 6.1 ≈ 7 rpm
Lebar belt = 7 in
Power total = 2 hp
Jumlah = 1 buah
Spesifikasi :
Fungsi = Meghaluskan bahan hingga 200 mesh
Type = Marcy ball mill
Kapasitas maksimum = 45 ton/hari
Sieve number = 48
Ukuran sieve = 4 ft x 3 ft
Ball charge = 2.73 ton
Power = 20 hp
Mill speed = 30 rpm
Jumlah = 1 buah
Perhitungan :
Rate massa : 1875.1295 kg/jam = 2 ton/jam
Ukuran yang tersaring diharapkan mempunyai ukuran 200 mesh
Produk oversize 5 % feed
Produk Undersize 95 % feed
Prosuk undersize dalam oversize 5 % oversize
Spesifikasi :
Fungsi = Menyaring bahan dari Hammer Crusher
Type = Vibrated Screen
Kapasitas = 1.9 ton/jam
Speed = 50 vibration/dy ; P = 3 Hp ( Peter's 4ed;p.567)
Tyler equivalent design = 200 mesh
Sieve No = 200
Sieve design = 0.074
Sieve Opening = 0.074 mm
Ukuran kawat = 0.053 mm
Effisiensi = 99.73%
Jumlah = 1 buah
Perhitungan :
Rate massa : 1781.373 kg/jam = 3927.3 lb/jam
ρ campuran = 179.6234 lb/cuft
Volumentrik bahan : 3927.3
= 21.8638 cuft/jam = 0.4 cuft/mnt
179.6233677
Untuk bulk density = 179.6234 lb/cuft ; bahan termasuk kelas D
dengan F = 3 (Badger, Tabel 16-6)
Spesifikasi :
Fungsi = Memindahkan bahan dari Ball mill ke Reaktor
Type = Plain spout or chutes
Kapasitas = 21.8638 cuft/jam
Panjang = 20 ft
Diameter = 6 in
Kecepatan putaran = 18 rpm
Power = 0.5 hp
Jumlah = 1 buah
Perhitungan :
Rate massa : 1781.373 kg/jam = 2 ton/jam
Tinggi bucket : Tinggi ( Reaktor + jarak dari tanah)
: 10 + 5= 15 ft
Perhitungan Power ( Perry ed 7 tabel 21-8), kapasitas dibawah 14 ton/jam
Power pada head shaft = 1 hp
Power tambahan = 0.02 hp/ft
= 0.02 x 15 = 0.3 ≈ 0.5 hp
Power total = 1+ 0.5 = 1.5 hp
Effisiensi motor = 80%
Power total = 1.5 / 80% = 1.9 hp ≈ 2 hp
Spesifikasi :
Fungsi = Memindahkan bahan
Type = Continous discharge Bucket elevator
Kapasitas maksimum = 14 ton/jam
Ukuran = 6 in x 4 in x 4 1/4 in
Bucket spacing = 12 in
Tinggi elevator = 15 ft
Ukuran feed (Max) = 3/4 in
Bucket speed = (2 / 14) x 225 ft/mnt = 32 ft/mnt
Putaran head shaft = (2/14)x 43 rpm = 6.1 ≈ 7 rpm
Lebar belt = 7 in
Power total = 2 hp
Jumlah = 1 buah
Perhitungan :
Rate massa : 1781.373 kg/jam = 3928.055127 lb/jam
ρ campuran = 179.6234 lb/cuft
Volumentrik bahan : 3928.1
= 21.8683 cuft/jam
179.6233677
Direncanakan penyimpanan untuk 1 hari dengan 1 buah tangki, sehingga :
volume bahan : 524.8389 cuft
Bahan mengisi tangki sebesar 80%
volume tangki : 656.0486 ≈ 660 cuft
Untuk tebal tutup atas disamakan dengan tebal tutup bawah, karena tutup bawah
lebih banyak menerima beban.
Tinggi conical :
h = tg α x ( D - m) (Hesse, pers 4-17)
2
Keterangan : α = cone angle = 30o
D = diameter tangki = 7.7734 ft
m = flat spot center = 12 in = 1 ft
maka :
h = tg 30o x (D - 1) = 6.7734 x 0.577 = 1.95413 ft
2 2
Spesifikasi :
Fungsi = Menampung alumina
Type = Silo penampung
(Silinder tegak dengan tutup atas plat dan bawah conis)
Volume = 660 cuft
Diameter = 7.7734 ft
Tinggi = 11.6601 ft
Tebal shell = 3/16 in
Tebal tutup atas = 1/4 in
Tebal tutup bawah = 1/4 in
Bahan konstruksi = Carbon stell SA-283 grade C
Jumlah = 1 buah
Perhitungan :
Rate massa : 5164.9928 kg/jam = 11389.17927 lb/jam
ρ campuran = 78.4922 lb/cuft
Volumentrik bahan : 11389.2
= 145.099 cuft/jam
78.49223281
Direncanakan penyimpanan untuk 1 hari dengan 1 buah tangki, sehingga
volume bahan : 3482.3866 cuft
Bahan mengisi tangki sebesar 80%
volume tangki : 4352.9833 ≈ 4500 cuft
Menentukan ukuran tangki :
Asumsi dimensi rasio : H/D = 1.5
Volume = 1/4 π . D2 . H
4500 = 1/4 π . D2 . 1,5D
D = 15.6345 ft = 187.614 in
H = 23.4517 ft = 281.421 in
Untuk diameter = 187.614 in dari Brownel & ypoung tabel 5.7 didapt :
rc = 120
= 45.1652 in = 3.76376 ft
Untuk tebal tutup bawah datar karena tutup menumpang diatas semen, maka tebal
tutup =1/2 in (Brownell, hal 58)
Spesifikasi :
Fungsi = Menampung asam sulfat
Type = (Silinder tegak dengan tutup atas plat dan bawah conis)
Volume = 4500 cuft
Diameter = 16 ft
Tinggi = 24 ft
Tebal shell = 1/2 in
Tebal tutup atas = 1/2 in
Tebal tutup bawah = 1/2 in
Bahan konstruksi = Carbon stell SA-283 grade C
Jumlah = 1 buah
Perhitungan :
ρ H2SO4 = 78.4922 lb/cuft
Bahan masuk = 5164.9928 kg/jam = 3.1636 lb/dt
Rate volumetrik (qf) = m/ρ
= 3.1636 / 78.49
= 0.0403 ft3/dt = 18.2469 gpm
Asumsi aliran turbulen :
Di optimum untuk aliran turbulen, Nre > 2100, digunakan persamaan :
Diameter Optimum = 3.9 x qf 0.45 x ρ 0.13
dengan : qf = fluid flow rate; cuft/dt (cfs ) (Peters&Timmerhaus,
ρ = fluid density ; lb/cuft 4ed,pers 15)
Diameter Optimum = 3.9 x 0.0403 0.45 x 78.49 0.13
= 1.6211 in
Dipilih pipa 2 in , sch 40 ( Geankoplis, App. A-5 )
OD = 2.3750 in
ID = 2.0670 in = 0.1723 ft
A = 0.02330 ft 2
μ berdasarkan sg bahan :
μ bahan = sg bahan 1.2573
x μ reference = x 0.00085
sg reference 1.00
= 0.00107 lb/ft.dt
V2 1.7298 2 ft . lbf
= = 0.0465
2 x α x gc 2 x 1 x 32.2 lbm
ΔZ = Z2 - Z1 = 20 ft
Persamaan Bernoully :
ΔP g ΔV2
+ ΔZ + + ΣF = - Wf
ρ gc 2α x gc
0 + 20 + 0.0465 + 1.0190 = - Wf
21.0655 = - Wf
ft . lbf
- Wf = 21.0655
lbm
- Wf x flowrate ( cuft/dt) x ρ
hp =
550
= 21.0655 x 0.0403 x 78.4922
550
= 0.1212 hp
Kapasitas = 0.0403 x 7.4810 x 60 = 18.0909 gpm
Effisiensi pompa = 45% (Peters&Timmerhaus,4ed,fig. 14-37)
hp 0.1212
Bhp = = = 0.2693 hp
h pompa 0.4500
Effisiensi motor = 80% (Peters&Timmerhaus,4ed,fig. 14-38)
Bhp 0.2693
Power motor = = = 0.3366 hp ≈ 0.5 hp
h motor 0.8000
Spesifikasi :
Fungsi = Mengalirkan asam sulfat
Tipe = Centrifugal Pump
Bahan = Commercial Steel
Rate volumetrik = 0.0403 ft3/dt
Total Dynamic Head = 21.0655 ft . lbf / lbm
Effisiensi motor = 80%
Power = 0.5 hp
Jumlah = 1 buah
Untuk tebal tutup atas disamakan dengan tebal tutup bawah, karena tutup bawah
lebih banyak menerima beban.
Tinggi conical :
h = tg α x ( D - m) (Hesse, pers 4-17)
2
Keterangan : α = cone angle = 30o
D = diameter tangki = 3.9258 ft
m = flat spot center = 12 in = 1 ft
maka :
h = tg 30o x (D - 1) = 2.9258 x 0.577 = 0.8441 ft
2 2
Spesifikasi :
Fungsi = Menampung alumina
Type = Silo penampung
(Silinder tegak dengan tutup atas plat dan bawah conis)
Volume = 85 cuft
Diameter = 5 ft
Tinggi = 10.5 ft
Tebal shell = 3/16 in
Tebal tutup atas = 3/16 in
Tebal tutup bawah = 3/16 in
Bahan konstruksi = Carbon stell SA-283 grade C
Jumlah = 1 buah
Perhitungan :
Rate massa : 1 kg/jam = 2.205071665 lb/jam
ρ campuran = 71.8000 lb/cuft
Volumentrik bahan : 2.2
= 0.0307 cuft/jam
71.8
Direncanakan penyimpanan untuk 90 hari dengan 1 buah tangki, sehingga
volume bahan : 66.3364 cuft
Bahan mengisi tangki sebesar 80%
volume tangki : 82.9205 ≈ 85 cuft
Tinggi conical :
h = tg α x ( D - m) (Hesse, pers 4-17)
2
Keterangan : α = cone angle = 30o
D = diameter tangki = 3.9258 ft
m = flat spot center = 12 in = 1 ft
maka :
h = tg 30o x (D - 1) = 2.9258 x 0.577 = 0.8441 ft
2 2
(Silinder tegak dengan tutup atas plat dan bawah conis)
Volume = 85 cuft
Diameter = 3.9258 ft
Tinggi = 5.8888 ft
Tebal shell = 3/16 in
Tebal tutup atas = 3/16 in
Tebal tutup bawah = 3/16 in
Bahan konstruksi = Carbon stell SA-283 grade C
Jumlah = 1 buah
Perhitungan :
Rate massa : 4166.6667 kg/jam = 9187.798677 lb/jam
ρ campuran = 167.6762 lb/cuft
Volumentrik bahan : 9187.8
= 54.7949 cuft/jam
167.6762197
Direncanakan penyimpanan untuk1 hari dengan 1 buah tangki, sehingga
volume bahan : 1315.0772 cuft
Bahan mengisi tangki sebesar 80%
volume tangki : 1643.8465 ≈ 1650 cuft
ts = 12.5638 x 5.3 x 12
+ 1/8
12,650 x 0.8 - 0.6 x 12.5638
= 0.204 in
Dipakai tebal shell 1/4 in
Untuk tebal tutup atas disamakan dengan tebal tutup bawah, karena tutup bawah
lebih banyak menerima beban.
= 0.206419566 = 1/4 in
Tinggi conical :
maka :
h = tg 30o x (D - 1) = 9.5498 x 0.577 = 2.75512 ft
2 2
Spesifikasi :
Fungsi = Menampung alumina
Type = Silo penampung
(Silinder tegak dengan tutup atas plat dan bawah conis)
Volume = 1650 cuft
Diameter = 10.5498 ft
Tinggi = 15.8247 ft
Tebal shell = 1/4 in
Tebal tutup atas = 1/4 in
Tebal tutup bawah = 1/4 in
Bahan konstruksi = Carbon stell SA-283 grade C
Jumlah = 1 buah
Perhitungan :
Rate massa : 4166.6667 kg/jam = 9185.9 lb/jam
ρ campuran = 167.6762 lb/cuft
Volumentrik bahan : 9185.9
= 54.7837 cuft/jam = 0.9 cuft/mnt
167.6762197
Untuk bulk density = 167.6762 lb/cuft ; bahan termasuk kelas D
dengan F = 3 (Badger, Tabel 16-6)
= 0.27836 hp
Diameter = 9 in
Kecepatan putaran = 13 rpm
Spesifikasi :
Fungsi = Memindahkan Aluminium sulfat dari screen ke Silo
Type = Plain spout or chutes
Kapasitas = 54.7837 cuft/jam
Panjang = 20 ft
Diameter = 9 in
Kecepatan putaran = 13 rpm
Power = 1 hp
Jumlah = 1 buah
Perhitungan :
Rate massa : 4166.6667 kg/jam = 5 ton/jam
Tinggi bucket : Tinggi ( Ball mill + Screen + jarak dari tanah)
: 3+ 3+ 3= 9 ft
Spesifikasi :
Fungsi = Memindahkan bahan
Type = Continous discharge Bucket elevator
Kapasitas maksimum = 14 ton/jam
Ukuran = 6 in x 4 in x 4 1/4 in
Bucket spacing = 12 in
Tinggi elevator = 3 ft
Ukuran feed (Max) = 3/4 in
Bucket speed = (5 / 14) x 225 ft/mnt = 80 ft/mnt
Putaran head shaft = (5/14)x 43 rpm = 15.3571 = 15.5 rpm
Lebar belt = 7 in
Power total = 2 hp
Jumlah = 1 buah
Spesifikasi :
Fungsi = Meghaluskan bahan hingga 100 mesh
Type = Marcy ball mill
Kapasitas maksimum = 145 ton/hari
Sieve number = 150
Ukuran sieve = 7 ft x 5 ft
Ball charge = 13.1 ton
Power = 135 hp
Mill speed = 22.5 rpm
Jumlah = 1 buah
27. SCREEN H - 331
Fungsi = Menyaring bahan dari Ball Mill
Type = Vibrated Screen
Dasar Pemilihan = Sesuai dengan bahan dan kapasitas
Perhitungan :
Rate massa : 4385.9649 kg/jam = 4.4 ton/jam
Spesifikasi :
Fungsi = Menyaring bahan dari Hammer Crusher
Type = Vibrated Screen
Kapasitas = 4.4 ton/jam
Speed = 50 vibration/dy ; P = 3 Hp ( Peter's 4ed;p.567)
Tyler equivalent design = 100 mesh
Sieve No = 100
Sieve design = 0.149
Sieve Opening = 0.149 mm
Ukuran kawat = 0.053 mm
Effisiensi = 99.73%
Jumlah = 1 buah
Perhitungan :
Rate massa : 4166.6667 kg/jam = 9185.9 lb/jam
ρ campuran = 167.6762 lb/cuft
Volumentrik bahan : 9185.9
= 54.7837 cuft/jam = 0.9 cuft/mnt
167.6762197
Untuk bulk density = 167.6762 lb/cuft ; bahan termasuk kelas D
dengan F = 3 (Badger, Tabel 16-6)
Spesifikasi :
Fungsi = Memindahkan bahan dari Kristaliser
Type = Plain spout or chutes
Kapasitas = 54.7837 cuft/jam
Panjang = 20 ft
Diameter = 9 in
Kecepatan putaran = 13 rpm
Power = 1 hp
Jumlah = 1 buah
Perhitungan :
Rate massa : 5657.796 kg/jam = 12475.84564 lb/jam
ρ campuran = 87.2245 lb/cuft
Volumentrik bahan : 12475.8
= 143.031 cuft/jam
87.22454973
Direncanakan penyimpanan untuk 1 hari dengan 1 buah tangki, sehingga
volume bahan : 3432.7525 cuft
Bahan mengisi tangki sebesar 80%
volume tangki : 4290.9407 ≈ 4500 cuft
dimana:
ts = tebal shell minimum ; in
P = tekanan tangki ; psi
ri = jari-jari tangki ; in
C = faktor korosi ; in ( digunakan 1/8)
E = faktor pengelasan ; 0,8
f = stress allowable ; bahan konstruksi Carbon Stell SA 283
garde C, maka f : 12650 psi
ts = 17.0959 x 7.8 x 12
+ 1/8
12,650 x 0.8 - 0.6 x 17.0959
= 0.284 in
Dipakai tebal shell = 1/2 in
Untuk diameter = 187.614 in dari Brownel & ypoung tabel 5.7 didapt :
rc = 170
= 28.2246 in = 2.35205 ft
Untuk tebal tutup bawah datar karena tutup menumpang diatas semen, maka tebal
tutup = 1/2 in (Brownell, hal 58)
Spesifikasi :
Fungsi = Menampung asam sulfat
Type = (Silinder tegak dengan tutup atas plat dan bawah conis)
Volume = 4500 cuft
Diameter = 16 ft
Tinggi = 24 ft
Tebal shell = 1/2 in
Tebal tutup atas = 1/2 in
Tebal tutup bawah = 1/2 in
Bahan konstruksi = Carbon stell SA-283 grade C
Jumlah = 1 buah
= 1.39716
μ berdasarkan sg bahan :
μ bahan = sg bahan 1.3972
x μ reference = x 0.00085
sg reference 1.00
= 0.00119 lb/ft.dt
V2 1.7051 2 ft . lbf
= = 0.0451
2 x α x gc 2 x 1 x 32.2 lbm
ΔZ = Z2 - Z1 = 20 ft
Persamaan Bernoully :
ΔP g ΔV2
+ ΔZ + + ΣF = - Wf
ρ gc 2α x gc
0 + 20 + 0.0451 + 1.1226 = - Wf
21.1677 = - Wf
ft . lbf
- Wf = 21.1677
lbm
- Wf x flowrate ( cuft/dt) x ρ
hp =
550
= 21.1677 x 0.0397 x 87.2245
550
= 0.1334 hp
Kapasitas = 0.0397 x 7.4810 x 60 = 17.8330 gpm
Effisiensi pompa = 45% (Peters&Timmerhaus,4ed,fig. 14-37)
hp 0.1334
Bhp = = = 0.2964 hp
h pompa 0.4500
Effisiensi motor = 80% (Peters&Timmerhaus,4ed,fig. 14-38)
Bhp 0.2964
Power motor = = = 0.3705 hp ≈ 0.5 hp
h motor 0.8000
Spesifikasi :
Fungsi = Mengalirkan asam sulfat
Tipe = Centrifugal Pump
Bahan = Commercial Steel
Rate volumetrik = 0.0397 ft3/dt
Total Dynamic Head = 21.1677 ft . lbf / lbm
Effisiensi motor = 2%
Power = 0.5 hp
Jumlah = 1 buah
Perhitungan :
Rate massa : 1288.5699 kg/jam = 2841.388975 lb/jam
ρ campuran = 126.9797 lb/cuft
Volumentrik bahan : 2841.4
= 22.3767 cuft/jam
126.9797429
Direncanakan penyimpanan untuk 1 hari dengan 1 buah tangki, sehingga
volume bahan : 537.0411 cuft
Bahan mengisi tangki sebesar 80%
volume tangki : 671.3013 ≈ 700 cuft
= 0.172 in
Dipakai tebal shell = 1/4 in
Untuk diameter = 100.901 in dari Brownel & ypoung tabel 5.7 didapt :
rc = 108
= 12.5078 in = 1.04231 ft
Spesifikasi :
Fungsi = Menampung alumina
Type = Silo penampung
(Silinder tegak dengan tutup atas plat dan bawah conis)
Volume = 700 cuft
Diameter = 8.40838 ft
Tinggi = 12.6126 ft
Tebal shell = 1/4 in
Tebal tutup atas = 1/2 in
Tebal tutup bawah = 1/2 in
Bahan konstruksi = Carbon stell SA-283 grade C
Jumlah = 1 buah
Perhitungan :
Rate massa : 5084.3116 kg/jam = 11211.27144 lb/jam
ρ campuran = 86.6169 lb/cuft
Volumentrik bahan : 11211.3
= 129.435 cuft/jam
86.61686954
Direncanakan penyimpanan untuk 1 hari dengan 1 buah tangki, sehingga
volume bahan : 3106.4447 cuft
Bahan mengisi tangki sebesar 80%
volume tangki : 3883.0559 ≈ 4000 cuft
ts = 16.3896 x 7.5 x 12
+ 1/8
12,650 x 0.8 - 0.6 x 16.3896
= 0.271 in
Dipakai tebal shell = 5/16 in
= 25.9001 in = 2.15834 ft
Untuk tebal tutup bawah datar karena tutup menumpang diatas semen, maka tebal
tutup = 3/8in (Brownell, hal 58)
Spesifikasi :
Fungsi = Menampung asam sulfat
Type = (Silinder tegak dengan tutup atas plat dan bawah conis)
Volume = 4000 cuft
Diameter = 16 ft
Tinggi = 24 ft
Tebal shell = 5/16 in
Tebal tutup atas = 3/8 in
Tebal tutup bawah = 3/8 in
Bahan konstruksi = Carbon stell SA-283 grade C
Jumlah = 1 buah
= 1.38742
μ berdasarkan sg bahan :
μ bahan = sg bahan 1.3874
x μ reference = x 0.00085
sg reference 1.00
= 0.00118 lb/ft.dt
V2 1.5430 2 ft . lbf
= = 0.0370
2 x α x gc 2 x 1 x 32.2 lbm
ΔZ = Z2 - Z1 = 20 ft
Persamaan Bernoully :
ΔP g ΔV2
+ ΔZ + + ΣF = - Wf
ρ gc 2α x gc
0 + 20 + 0.0370 + 0.9193 = - Wf
20.9563 = - Wf
ft . lbf
- Wf = 20.9563
lbm
- Wf x flowrate ( cuft/dt) x ρ
hp =
550
= 20.9563 x 0.0360 x 86.6169
550
= 0.1187 hp
Kapasitas = 0.0360 x 7.4810 x 60 = 16.1379 gpm
Effisiensi pompa = 45% (Peters&Timmerhaus,4ed,fig. 14-37)
hp 0.1187
Bhp = = = 0.2637 hp
h pompa 0.4500
Effisiensi motor = 80% (Peters&Timmerhaus,4ed,fig. 14-38)
Bhp 0.2637
Power motor = = = 0.3296 hp ≈ 0.5 hp
h motor 0.8000
Spesifikasi :
Fungsi = Untuk mengalirkan Filtrat ke Evaporator
Tipe = Centrifugal Pump
Bahan = Commercial Steel
Rate volumetrik = 0.0360 ft3/dt
Total Dynamic Head = 20.9563 ft . lbf / lbm
Effisiensi motor = 80%
Power = 0.5 hp
Jumlah = 1 buah
μ Cα 2
t = V/A
gc (ΔP) 2
Jumlah frame = A / a
= 228316.3790 / 4331
= 52.7168 buah ≈ 53
Spesifikasi :
Fungsi = Untuk memisahkan cake dari filtratnya
Type = Plate & Frame Filter Press
Kapasitas = 6946.3659 kg/jam
Berat Solid = 1288.5699 kg/jam
Tebal Frame = 0.2301 in
Ukuran Frame = 61 x 71 in
Banyak Frame = 53 buah
35.THICKENER H - 230
Fungsi = Memisahkan padatan dengan cara sedimentasi
Type = silinder tegak, tutup bawah conis
Dasar pemilihan = Umum digunakan untuk tekanan atmospheric
Perhitungan :
Rate massa : 5657.795 kg/jam = 12475.84344 lb/jam
ρ campuran = 87.2245 lb/cuft
Volumentrik bahan : 12475.8
= 143.031 cuft/jam
87.22454973
Direncanakan waktu pemisahan 3 jam dengan 1 buah tangki, maka volume tangki :
Volume = 143.031 x 3= 429.094 cuft
Asumsi volume bahan mengisi 80% volume tangki, maka volume tangki :
Volume tangki : 429.094 / 0.8 = 536.367 cuft ≈ 540 cuft
ts = 6.0789 x 3.9 x 12
+ 1/8
12,650 x 0.8 - 0.6 x 6.07893
= 0.153 in
Dipakai tebal shell = 3/16 in
= 0.157178971 = 3/16 in
Tinggi conical :
h = tg α x ( D - m) (Hesse, pers 4-17)
2
Keterangan : α = cone angle = 30o
D = diameter tangki = 7.72922 ft
m = flat spot center = 12 in = 1 ft
maka :
h = tg 30o x (D - 1) = 6.72922 x 0.577 = 1.94138 ft
2 2
Tinggi total :
Tinggi lubang pemasukan = 1 m = 3,3 ft (Perry 7 ed: 18-66)
Tinggi tangki total = 10 ft + 3,3 ft = 13,3 ft
Panjang pengaduk = 90 % dari diameter
Panjang pengaduk = 0.9 x 7.7 = 6.9563 f
( max = 150 ft Perry 7 ed: 18-67)
Spesifikasi :
Fungsi = Memisahkan padatan dengan cara sedimentasi
Type = silinder tegak dan tutup bawah conis
Kapasitas = 540 cuft
Diameter = 7.7 ft
Tinggi = 9.2751 ft
Tebal Shell = 3/16 in
Tebal tutup bawah = 3/16 in
Panjang pengaduk = 7 ft
Speed = 25 ft/mnt (Perry 7 ed : 18-69)
Power = 16 hp (Perry 7 ed : 18-73)
Bahan konstruksi = Carbon stell SA-283 grade C
Jumlah = 1 buah
Perhitungan :
Dari appendix B :
Q = 533540.8302 kkal/jam = 2117090.014 btu/jam
Suhu operasi = 90 oC = 194 o
F
Suhu masuk = 86 C =
o
186.8 o
F
∆T = 194 - 186.8 = 7.2
Dimensi evaporator :
Luas penampang, A = Nt x a't = 175 x 0.08819 = 15.434 ft2
Diameter evaporator, D = ( 4 x A/π)0,5
= 4.43409 ft
ts = 16.1700 x 2.2 x 12
+ 1/8
18,750 x 0.8 - 0.6 x 16.17
= 0.154 in
Dipakai tebal shell = 3/16 in
= 0.158138887 = 3/16 in
Tinggi conical :
h = tg α x ( D - m) (Hesse, pers 4-17)
2
Keterangan : α = cone angle = 30o
D = diameter tangki = 4.43409 ft
m = flat spot center = 12 in = 1 ft
maka :
h = tg 30o x (D - 1) = 3.43409 x 0.577 = 0.99074 ft
2 2
Spesifikasi :
Fungsi = Memekatkan bahan samapi kadar 54 %
Type = Standart vertikal tube evaporator
Bagian shell :
Diameter evaporator = 4.5 ft
Diameter centerwall = 9 ft
Tinggi shell = 9 ft
Tebal shell = 3/16 in
Tebal tutup = 3/16 in
Tube Calandria :
Ukuran = 4 in sc 40
OD = 4.5
ID = 4,026 in
Panjang tube = 12 ft
Jumlah tube = 175 buah
Bahan konstruksi = Carbon Steel SA- 203 Grade C (2,5 Ni)
Jumlah evaporator = 1 buah
Perhitungan :
Rate massa : 4166.6667 kg/jam = 9187.798677 lb/jam
ρ campuran = 140.7751 lb/cuft
Volumentrik bahan : 9187.8
= 65.2658 cuft/jam
140.7751338
Asumsi volume bahan mengisi 70% volume tangki, maka volume tangki :
Volume tangki : 65.2658 / 0.7 = 93.2368 cuft ≈ 100 cuft
= 142.5056285 ft2/ft3
Spesifikasi :
Fungsi = Mengkristalkan aluminium sulfat
Type = Swenson - Walker Kristaliser
Kapasitas = 100 cuft
Diameter = 3.5 ft
Panjang = 11 ft
Luas Cooling area = 142.5056285 ft2/ft3
Power = 2 hp
Jumlah = 1 buah
= 1.48
μ berdasarkan sg bahan :
μ bahan = sg bahan 1.4842
x μ reference = x 0.00085
sg reference 1.00
= 0.00126 lb/ft.dt
V2 1.9707 2 ft . lbf
= = 0.0603
2 x α x gc 2 x 1 x 32.2 lbm
ΔZ = Z2 - Z1 = 20 ft
Persamaan Bernoully :
ΔP g ΔV2
+ ΔZ + + ΣF = - Wf
ρ gc 2α x gc
0 + 20 + 0.0603 + 1.32256 = - Wf
21.3829 = - Wf
ft . lbf
- Wf = 21.3829
- Wf = 21.3829
lbm
- Wf x flowrate ( cuft/dt) x ρ
hp =
550
= 21.3829 x 0.0459 x 92.6602
550
= 0.1654 hp
Kapasitas = 0.0459 x 7.4810 x 60 = 20.6102 gpm
Effisiensi pompa = 45% (Peters&Timmerhaus,4ed,fig. 14-37)
hp 0.1654
Bhp = = = 0.3676 hp
h pompa 0.4500
Effisiensi motor = 80% (Peters&Timmerhaus,4ed,fig. 14-38)
Bhp 0.3676
Power motor = = = 0.4595 hp ≈ 0.5 hp
h motor 0.8000
Spesifikasi :
Fungsi = Untuk mengalirkan Filtrat ke Evaporator
Tipe = Centrifugal Pump
Bahan = Commercial Steel
Rate volumetrik = 0.0459 ft3/dt
Total Dynamic Head = 21.3829 ft . lbf / lbm
Effisiensi motor = 80%
Power = 0.5 hp
Jumlah = 1 buah
. 62.43
0.0015 0.0015
+ +
2.2700 0.1394
stock pile menuju hammer crusher
aolin stock pile menuju hammer crusher
with rolls of equal length
8 in = 3,175 mm ( 7 mesh)
didapatkan spesifikasi :
jam digunakan ukuran :
800
1200.1376826499
) 0.5
+ 1/8
450
312.6951935826
) 0.5
+ 1/8
Coller ke bucket elevator
jam digunakan ukuran :
2
gki, maka volume tangki :
Ds3
lbf / ft2
lbf / ft2
ft . lbf
lbm
725.3978
38. REAKTOR
Kondisi operasi :
Tekanan operasi = 1 atm
Suhu operasi = 105 o
C
Waktu tinggal = 1 jam
Kondisi feed :
1. Feed alumina
ρ campuran :
78.4922 lb/cuft
Asumsi volume bahan mengisi 80% volume tangki dan digunakan 1 buah tangki.
Volume tangk74.9017 / 80%
= 93.6272 cuft
≈ ### cuft
Menentukan ukuran tangki dan ketebalannya :
Volum= ### π . D2 . H
94 = ### π . D2 . 2D
D = 3.91 ft = 46.882994 in = 1m
(Dmak = 4 m ; Ulrich ; T.4-18)
H = 7.81 ft = 93.765987 in
ts = 16.1700 x 2 x ###
+ ###
+ ###
12,650 x 0.8 - 0.6 x 16.2
= ### in
Dipakai teba= 3/16 in
Untuk tebal tutup bawah datar karena tutup menumpang diatas semen, maka tebal
tutup =1/4 in (Brownell, hal 58)
AB= ID 46.883
- icr = - 3 = ### in
2 2
BC= r - icr = 48 - 3 = 45 in
AC= (BC - AB )
2 2 0,5
= 40.1 in
b = r - AC = 48 - 40.1 = 8 in
sf = straight flan = dipilih 2 in = 2 in (B & Y T.5-6)
t = tebal dished = 3/16 in = 0.19 in
OA= t + b + sf = 0.1875 + 8+ 2 = 10.1 in
Dipakai impeler jenis turbin dengan 6 buah flat blade ( Perry 6ed; p.19-9)
Diameter impel= 1/3 diameter shell = 1.3 ft
Lebar blade (w = 0,2 diameter impeler= 0.26 ft
Panjang blade = 0,25 diameter impell= 0.33 ft
= 80% x 8 x 1.49
4
= 2.38 ≈ 3 buah
Nr = ρ x Da2 x =N 415220.534
μ
Untuk Nre > 10000 perhitungan power digunakan persamaan 5.5 Ludwig hal 190
dengan persamaan :
P= 6.3 3 5
x 92.7 x 3.3333 x 1
32.2
P= 2519 lb.ft/d = 5 hp
Perhitungan :
Kondisi feed :
1. Feed alumina
b
icr
sf
ID
r
a
= 3.9723 ft
rc = 6% Rc = 6% x 1.5 = 0.0900 in = 0.0075
Tinggi tutup ( h ) = Rc - Rc 2 - ( D2 / 4 )
= 3.9723 - ( 3.9723 ) 2-
4.4723 2/ 4
= 3.9723 - 3.2831
= 0.6892 ft
= 5.5997 ft3
= 140.4408 - ( 2 x 5.5997 )
π / 4 ( 4.4723 ) 2
= 8.2313 + ( 2 x 0.6892
= 9.6097 ft = 2.9290 m
D 4.4723 ……..(memenuhi)
= 6.7990 ft = 2.0723 m
Tinggi liquid total = Tinggi liquid dalam silinder + Tinggi tutup bawah
= 2.3 m
Dimana :
fv = Ultimate tensile stress
Sehingga :
fall = 55,000 x 0.92 x 0.25 x 1 = 12650 psi
8
VI. 1. 1. Tinggi Dinding Reaktor
144
144
= 1.2 x ( 4.8226 )
= 55.8750 psig
( Do )
Dimana :
t 0.5
B = 7,500
Pa = B x t = 7,500 = 68.5964 psig
( Do ) 109.3353
Pa > P , yaitu 68.5964 > 55.8750 ………..(memenuhi)
VI. 1. 2. Head
Bentuk : Flanged and standart dished head dengan tebal sama dengan
dinding reaktor.
t = 1 in
sf = 1½ - 3½ , diambil sf = 1½ in
= 3 /4 in
1
icr ……..(tabel 5.7, B & Y, hal 91)
Rc = 54 in ……..(tabel 5.7, B & Y, hal 91)
Hubungan - hubungan dimensional ( B & Y) :
a = ID / 2 = 53.6676 / 2 = 26.833815
AC = BC2 - AB2
OA = t + b + sf = 1 + 9.0626418 + 1.5
Dipilih pengaduk type flat blade turbine dengan jumlah blade 6 buah.
L = 1 H j
Da 4
W = 1
Da 5 E
E = 1 Dt
Da
L = Panjang blade
W = Lebar blade
= 1.4908 ft
= 0.3727 ft
= 0.2982 ft
π x Da π x 0.4544
= Da
2
Nre x N x ρ
0.001263
= 380864.9744
P = Np x N3 x Da5 x ρ
gc ……(Perry ed 6th, pers 19.4, hal 19.9)
550
= 0.5408 Hp
80%
a. Panjang poros
( 1.4908 x 12 )
b. Diameter
2 x 3.14 x 140
= 34.548453 kg.m
● fs = Tm
Zp
Zp = π x dp3
16
x dp
3
5.3151 = 3.14
16
dp = 3.0031 cm ≈ 4 cm
● Bending moment
Rb = ½ D a ……(Joshi, pers 14.11)
fm = Tm = 34.5485 = 61.7998
= 173.4898
f = Me = Me
( dp /
3
Z π x 32 )
= 173.4898 x 32 x 100
3.14 x 3.0031 3
Dicoba dp = 4.5 cm
f = 173.4898 x 32 x 100
3.14 x 4.5 3
c. Blade design
f = Tm
( bt x bw 2 ) / 6
Ditetapkan :
bt = Tebal blade = 0.8 cm = 0.31496 in
bw = W = Lebar blade = 3.5778 in = 0.2982 ft = 9.0877
Tm = 3454.8453139 kg.cm
( 0.8 x ( 9.0877 ) 2 ) / 6
Berat poros = ¼ x π x d2 x L x ρ
= 75.2241 lb
ρ blade ) x 6
x 6
= 8.436534 lb
Beban axial ( Fa )
Beban radial ( Fr )
Fr = beban karena putaran pengaduk
Penentuan bearing
= 86.9648 lb
Dimana :
Ln = Umur pemakaian bearing, diambil 50,000 jam
Maka :
Co = 1 x 86.9648 = 86.9648 lb = 86.9648 x 4.4482
= 386.8369 N
Y = 1
= 125.7862 lb
D = 90 mm
B = 18 mm
= 53.6676305228 + ( 2 x 1 / 2 ) + ( 2 x 0.5
= 55.6676305228 in
λ 653.1000
= 1298.2344 Kg/jam
K
( L2 x N x ρ
μ
)( )
⅔ C x μ
K
⅓
( ) μ 0.14
( )
μw ……….(Kern, hal 20.1)
Diketahui :
Di = ID shell = 4.4723 ft
L = 1.4908 ft
ρ = 62.5 lb/ft³
C = 0.45 Btu/lboF
hi x 4.4723 =
0.0187
0.36
( 1.4908 2 x 8400
0.3630
x 62.5
)
( 0.45 x 0.3630
0.0187
) ⅓
= 16147.6759 x 0.0041813
hi = 67.5181 Btu/jam. ft². o
F
hio = hi x ID = 67.5181 x 4.4723
OD 4.5556
1 = 1 + 1 = 1 + 1 = 0.0158
1 = 1 + Rd = 1 + 0.002 = 0.0178
UD UC 63.4781
ln T1 - t1 = U x A x θ
Dengan :
T1 = Suhu steam = 148 oC = 298 oF
t1 = Suhu bahan awal = 30 o
C = 86 o
F
t2 = Suhu akhir produk = 105 oC = 221 oF
= 10419.5488 lb
ln 298 - 86 = 56.3270 x A x 2
A = 42.1532 ft2
f e - 0.6 P
= 47.8637 psig
+ 1
= 0.2570 in
t = W x D x Rc + C
f e - 0.1 P
Rc = D - 6" = 55.6676 - 6 = 49.667631 in
= 0.6170097 in
- ε = 0.9
Asumsi :
r4
r3
r2
r1
Keterangan :
T1 = suhu spasi jacket = 298 oF = 148 oC = 421.15 oK
T4 = suhu permukaan luar isolasi = 35 o
C = 308.15 oK
r1 = jari - jari dalam reaktor = 2.2362 ft = 0.6816 m
r2 = jari - jari luar reaktor = 2.2778 ft = 0.6943 m
r3 = jari - jari luar jacket pemanas = 2.3455 ft = 0.7149 m
r4 = jari - jari luar isolasi
Q = T1 - Ts
Rtotal
= 1
= 6.3100E-06 o
F oK / W
k x Alm k 2π x L
= ln ( 0.7149 / 0.6943 )
= 0.00017948 o
K / W
Tahanan konduksi pada isolasi ( R3 )
R3 = ln r4 / r2
Kisolasi x 2π x L
= ln ( r4 / 0.6943 )
● konveksi
Tfilm = T4 + Ts = 308.15 + 303.15 = 305.65 oK
2 2
q x β x ρ2 = 1.24E+08 ( 1 / oK m3 )
μ2
NGr = L3 x ρ2 x g x B x ∆T
μ2
= 4.0666E+13
NGr x NPr = 4.0666E+13 x 0.7066 = 28734749626896
= 2.1204 W / m2 oK
● Radiasi
hr = ε τ ( T4
4
- Ts )
4
( T4 - Ts )
( 308.15 - 303.15 )
= 5.8279 W / m2 oK
( hc + hr ) A4 ( hc + hr ) 2π x r4 L
= 1
= 1
103.4364 x r4 …………..(2)
= 42393.8429 kkal/jam
Q 49270.1873
Dari pers (1) dan (2), di trial tebal isolasi sampai diperoleh :
Rtotal = R1 + R2 + R3 + R4
103.4364 x
ln ( r4 / 0.6943 )
= 0.2 in
0.00239
5. Manhole
6. Lubang attachement
Dasar perencanaan :
78.49223281
Qf = 0.0402965148 cuft/dt
= 1.6209 in
ID = 2.067 in = 0.1723 ft
OD = 2.375 in
A = 0.0233 ft2
= 1.7294642 ft/dt
Nre = D V ρ
0.00106869
Dasar perencanaan :
137.411747
Qf = 0.0309569555 cuft/dt
hal 381 :
= 1.5483 in
ID = 2.067 in = 0.1723 ft
OD = 2.375 in
A = 0.0233 ft2
= 1.3286 ft/dt
Nre = D V ρ
0.0019
Dasar perencanaan :
62.5
Qf = 0.0127203051 cuft/jam
hal 381 :
= 1.0376 in
ID = 2.067 in = 0.1723 ft
OD = 2.375 in
A = 0.0233 ft2
= 0.5459 ft/dt
Nre = D V ρ
0.00010079
ID = 2.323 in = 0.1936 ft
OD = 2.875 in
A = 0.02942 ft2
ID min = 24 in
ID max = 25 ½ in
OB = 30 ¼ in
DC = 32 ¾ in
dengan diameter 2 in .
No
Nozzle pipe A T R E K L
size
(in)
Keterangan :
No
(in)
Inlet MCA 1 4 ⅝ ½ 3⅛ 2
Inlet NaOH 3 4 ¾ ⅝ 6 10
Inlet steam 5 8 ⅞ ¾ 8½ 19
Outlet produk 3 4 ¾ ⅝ 6 10
Pengaduk 2½ 4 ¾ ⅝ 5½ 8
Attachement 2 4 ¾ ⅝ 4¾ 6
K = P x D
Dimana :
Maka :
2 x 0.5 x 12,650
kan persamaan ASME code. Karena hanya nozzle manhole dengan dia -
1.8 x 12650
Untuk reinforcement
= ( ( 2x 24 ) - 2 ) x 0.01364
= 0.6274387 in2
VI. 8. 1. Gasket
Bahan = Asbestos
Tebal = 1 / 16 in
= 1.0007864
do = 1.0007864 di
= 53.667631 + 2
= 55.667631 in
do = 1.0007864 x 55.667631 = 55.711405 in
= 0.0219 in
= 55.7676 in
Mencari b :
bo = N / 2 …..(B & Y, pers 12.88)
N = lebar gasket
Jadi :
G = 55.7676 in
bo = 0.10 / 2 = 0.050 in
Untuk bo ≤ ¼ in , b = bo = 0.050 in
Maka :
Wm2 ( HY ) = 3.14 x 0.050 x 55.7676 x 3,700
= 32395.4166 lb
= 278.6818 lb
= 14128.5669 lb
Jarak tepi (E ) = 13 / 16 in
= 3.7712
= 53.667631 + 2 ( 1.415 x ¾ + 1⅛
= 58.040131 in
Check :
= 4.832 in2
2π Y G
= 4.832 x 12,650
= 0.0472 in
Karena lebar gasket yang dipilih 0.10 > 0.0472 in, maka perenca -
naan tersebut diatas dapat dipakai.
VI. 8. 3. Flange
OD flange = C + 2E = 58.040131 + ( 2 x 13 / 16 )
= 59.6651305228 in
b. Perhitungan moment
W = Am1 + AG fa
Dimana :
Flange moment
Ma = W x hG
P = tekanan operasi
HD = 0.785 x 53.667631 2 x 5.78714
= 13084.5434 lb
hD = ½ ( C - B )
Moment
MD = HD x hD = 13084.5434 x 2.18625
= 28606.0829472186 lb. in
= Wm1 = 37766.0244 lb
= 26858.0610058438 lb. in
= 14128.5669 - 23637.4574
= -9508.8905 lb
Panjang lengan = jarak dari lingkaran baut ke lingkaran HT
Moment
MT = hT x HT = 0.525 x -9508.8905
= -4992.1675088731 lb. in
= 50471.9764441893 lb. in
c. Tebal flange
t = Y x Mo
K = OD flange
( ID )
B 53.6676
t = 20 x 50471.9764441893
13,750 x 53.6676
= 1.1696 in
VI. 9. Perencanaan Sistem Penahan
5. Berat isolasi
6. Berat steam
8. Berat attachment
Maka:
Berat dished = 2 x A x t x ρ
= 2x 17.1926 x 0.5 x 490
12
= 1228.5562859956 lb
ID shell = 4.4723 ft
x 8.2313 x 490
= 31486.4075478959 lb
= 56.292631 in = 4.6911 ft
= ¼ x 3.14 ( ( 4.6911 ) 2 -
( 4.6390 ) 2 ) x 8 x 490
= 1495.3303615 lb
Rc jacket = D - 6" = 49.6676 in = 4.1390 ft
= 18.997009 ft2
= 18.997009 x 1 x 490
12
= 1551.4224 lb
= 3046.7528 lb
= 6946.3659 kg = 15313.8575 lb
= 56.2926305228 + ( 2 x 0.2 / 12 )
= 56.3259638561 in = 4.6938 ft
h isolasi = 0.7309 +
( 2 x ( 1
12
)
)
= 0.8975 ft
Rc = OD jacket - 6" = 56.2926 - 6" = 50.2926 in
= 4.1911 ft
0.2 / 12 ) } x 17.2
= 7.5450 lb
= 1348.9015848 ft3
0.01603
= 83.6607 lb
= 6297.2815095792 lb
Berat total = 1228.5562859956 + 31486.407548 + 3046.7528 +
83.6607 + 6297.2815096
= 141635.5201 lb
Karena bejana yang digunakan tidak terlalu tinggi dan berada didalam
P = 4 Pw ( H - L ) + ∑ W
karena Pw = 0 , maka :
P = ∑ W
= 169962.6242 = 42490.6560 lb
t isolasi
= 9.2897 ft
= 60% x 9.2897 + 6
= 11.5738 ft = 138.8856 in
A = 5.34 in2
h = 8 in
b = 4 in
Sumbu 1-1
I1-1 = 56.9 in4
S1-1 = 14.2 in2
r1-1 = 3.26 in
5.34
= 7957.0516928 psi
f = 17,000 - 0.485 ( L / r ) 2
Sumbu 2-2
I2-2 = 3.8 in4
S2-2 = 1.9 in2
r2-2 = 0.84 in
1 + ( L / r ) 2
= 18,000
1 + 42.6029 2
18,000
Bahan yang dipakai mempunyai shear stress 8,000 psi. Panjang las
yang dibutuhkan ( m ) :
m = F ½ (b)2 + 2 (a)2
Dimana :
= 1.1284 in
m x L 1.13 x 8
= 3327.6985810247 psi
S1 = 1.41 x F x a = 1.41 x 42490.6560 x 6
b x m x L 8 x 1.13 x 8
= 4977.4275098071 psi
Sr = S1 2 + S2 2 = 3327.698581 2 + 4977.4275098
= 5987.3502036826 psi
600 lb/in2
b
d 0,95 d
a 0,8 b m
Ditetapkan m = n
m = 4.66 in
= 17.6 in
= 14.8 in
17.6 x 14.8
t = ( 1.5E-04 x 163.1244 x 5 2 ) ½
= 0.7821 in , diambil 1 in
VI. 11. Perancangan Pondasi
= 210.3055 lb
x ( 1 / 12 ) x 490
= 73.8630 lb
= 42774.8245 lb
Dianggap bahwa hanya ada gaya vertikal dan berat kolom itu sendiri
Check :
A = 625 in2
A 625 …..(Memenuhi)
A = 2025 in2
F = W = 42774.8245 = 21.1234 < 600 psi
A 2025 …..(Memenuhi)
t - 20 = 25
t 35
t = 70
Sehingga : ti = 70 - 20 = 50 in
Volume pondasi = ( ⅓ 70 45 2 ) - ( ⅓ 50 25
= 3524.7350 lb
= 46299.5595 lb
45 x 45
Tinggi pondasi
d = a P ½
= a ( 22.8640 x 144 ) ½
57
= 1.0067 a
tg θ = a = a = 0.9934
d 1.0067 a
20 " …..(Memenuhi)
θ = 26.56 o
25"
20"
Angker atau jangkar atau anchor bolt diperlukan untuk menahan gaya
Diambil = 10 in
Lebar lengkung = 4 in
Direncanakan, L = 20 d
d = 10 / 20 = ½ in
Jadi, panjang = 20 x ½ = 10 in
Lebar lengkung = 4 in
Diameter bolt = ¾ in
Spesifikasi :
1. Reaktor
- Pengaduk
- Jacket pemanas
- Nozzle
- Manhole
Tekanan : 1 atm
Dimensi :
- Tinggi total bejana : 9.6097 ft
- Tinggi jacket : 8 ft
2. Pengaduk
Daya motor : 5 Hp
3. Poros
4. Nozzle
pengeluaran condensate
Nozzle manhole : 24 in
Nozzle attachment : 2 in
5. Gasket
Tebal : 1/16 in
Lebar : 0.1000 in
Diameter : 55.7676 in
Bahan : Asbestos
Ukuran : ¾ in
Jumlah : 16 buah
Tebal : 1.1696 in
7. Bearing
Diameter bawah : 90 mm
8. Kolom Penyangga
Jenis : I - beam
Panjang : 11.5738 ft
9. Base Plate
Bahan : Beton
Tebal : 1 in
10. Pondasi
Bahan : Beton
Berat : 42774.8245 lb
Tinggi : 20 in
Panjang : 24 in
Lebar lengkung : 4 in
Diameter bolt : ¾ in
Jumlah : 10 buah
221 oF
Jam
0.0075 ft
0.6892 )
Liter
ft
……..(memenuhi)
Tinggi tutup bawah
23.583815 in
50.75 in
44.937358 in
9.0626418 in
buah.
in
in
in
200
m/menit.
Hp
Hp
Hp
4.5 Hp
-
m
cm3
……(Joshi, pers 14.11)
61.7998 kg
kg/cm2
0.279
tebal blade x
)
…..(SKF, hal 42)
lb/ft. jam
⅔
……….(Kern, pers 18.5)
lb/ft3
)
3.27E-03 x
…………..(2)
49270.1873 W
+
r4
in
lb/jam
cuft/jam
0.13
……..(Aliran turbulen)
lb/jam
cuft/jam
0.13
……..(Aliran turbulen)
lb/jam
lb/ft. dt
cuft/jam
0.13
……..(Aliran turbulen)
2½
……….(Foust, App C-6a)
didapat :
1.38
1.05
3.07
5.05
3.07
2.47
2.07
Berat (lb)
10
19
10
8
Hesse,
0.0246 ,
8 in
5.78714
0.302
buah.
1⅛ )
0.302
lb. in
HD
23637.4574 lb
ρbahan
Rc
) x
, sehingga :
t jacket +
0.01667
……..(B & Y, App 6-item 2)
…..(Memenuhi)
….(H & R, tabel 7.1)
…..(Memenuhi)
dengan ukuran
lb ,
"
)]
…..(Memenuhi)
12 )
…..(Memenuhi)
…..(Memenuhi)
2 )
o
F
Utilitas
======================================================
VIII -766
===========================
BAB VIII
UTILITAS
Pada pabrik Poly vinyl cholride ini diadakan suatu unit pembantu, yaitu unit utilitas sebagai unit
yang berfungsi untuk menyediakan bahan maupun tenaga pembantu sehingga membantu kelan-
caran operasi dari pabrik.
Utilitas yang terdapat dalam pabrik Poply vinyl chloride, meliputi beberapa unit yaitu :
1. Unit Penyediaan Steam
2. Unit Penyediaan Air
3. Unit Penyediaan Listrik
4. Unit Penyediaan Bahan Bakar
5. Unit Pengolahan Limbah
====================================================================================
Utilitas
======================================================
VIII -767
===========================
====================================================================================
Utilitas
======================================================
VIII -768
===========================
m s ( h - hf )
mf = x
eb . F
110435.0 1179.27773 x 100
=
70 x
= 7646.7102 lb / jam
Power Boiler :
ms ( h - hf )
hP =
970.3 x 34.5
dimana :
Angka-angka 970,3 dan 34,5 adalah suatu peyesuaian pada penguapan 34,5 lb air / jam
dari air pada 212oF menjadi uap kering pada 212oF pada tekanan 1 atm, untuk kondisi
demikian diperlukan enthalpy penguapan 970,3 Btu / lb.
110435.0 1179.27773
hp = = 3006 hp
970.3 x
Kapasitas Boiler :
m s ( h - hf )
Q = ( Severn, W.H,pers. 171 )
1000
110435.0 1179 -
= = 100630.7056 Btu / jam
1000
Faktor Evaporasi = h - hf
( Severn, W.H,pers. 173 )
970.3
1179.2777300086
970.3
0.9391
Air yang dibutuhkan = Jumlah steam yang dibutuhkan
0.9391
====================================================================================
Utilitas
======================================================
VIII -769
===========================
= 5129.4
0.9391
= 5461.9804 lb / jam
= 2482.7184 kg / jam
====================================================================================
Utilitas
======================================================
VIII -770
===========================
a. Syarat fisik.
Suhu dibawah suhu udara, warna jernih ( tidak berwarna ), tidak berasa, tidak berbau, dan
kekeruhan maksimal 1 mg SiO2 / liter.
b. Syarat kimia
Tidak mengandung zat-zat organik maupun anorganik yang terlarut dalam air dan tidak
mengandung racun.
c. Syarat mikroorganisme ( bakteriologi )
Tidak mengandung kuman maupun bakteri terutama bakteri patogen.
Kebutuhan air sanitasi untuk pabrik ini adalah untuk :
- Karyawan, asumsi kebutuhan air untuk karyawan 15 liter / hari / orang
= 15 liter / hari per orang x 2.52 m3 / hari
- Keperluan laboratorium 2 m3 / hari
- Untuk menyiram kebun dan kebersihan pabrik 10 m3 / hari
- Cadangan dan lain-lain 10 m3 / hari
+
Total kebutuhan air sanitasi 24.52 m3 / hari
VIII.2.2. Air Proses
Kebutuhan air proses untuk pabrik :
No Nama Alat Kode Alat Air ( lb / batch )
1 Reaktor R - 120 77841.6628
====================================================================================
Utilitas
======================================================
VIII -771
===========================
c. Bebas dari zat peyebab timbulnya buih ( busa ) seperti zat-zat organik, anorganik dan
minyak.
d. Kandungan logam dan impuritis seminimal mungkin.
Kebutuhan air untuk umpan Boiler
====================================================================================
Utilitas
======================================================
VIII -772
===========================
dengan :
L = panjang cooling tower, ft
W = wind correction factor.
C = konsentrasi air / ft2 cooling.
CW = wet bulb correction factor.
diperoleh :
W = 1
CW = 1
C = 2
CH = 1.25
Maka dapat diperoleh :
119.8068 x
L =
2 x 12 x 1.25
====================================================================================
Utilitas
======================================================
VIII -773
===========================
= 3.9936 ft
Spesifikasi :
Nama : Cooling Tower
Tipe : Cross Flow Induced Draft Cooling Tower.
Tinggi : 35
Panjang : 3.993558418
Jumlah deck : 12
Bahan konstruksi : Kayu jati
Jumlah : 1
====================================================================================
Utilitas
======================================================
VIII -774
===========================
Total air yang harus disupply dari water treatment = 837.1355 m3 / hari
Kehilangan akibat jalur pipa dalam perjalanan, untuk faktor keamanan maka direncanakan
kebutuhan air sungai total :
= 1.1 x kebutuhan normal = 968.0222
m3 / hari
m3 / jam
kg / jam
VIII.3.1. Spesifikasi Peralatan Pengolahan Air
1. Bak Pengendapan awal Air Sungai F - 110
Fungsi : Menampung air sungai sebelum diproses menjadi air bersih.
Bak berbentuk persegi panjang terbuat dari beton.
Rate volumetrik : 44.3677
Direncanakan : 1 bak penampung 44.3677 m3 / jam
Ditentukan : Waktu tinggal : 1 jam
Tinggi : 2Xm
Panjang : 5Xm
Lebar : 3Xm
Spesifikasi :
Fungsi : Menampung air sungai sebelum diproses menjadi air bersih.
Kapasitas : 55.46
Bentuk : empat persegi panjang terbuka.
Ukuran : Panjang 6.1352587912 m
Lebar 3.6811552747 m
Tinggi 2.4541035165 m
Bahan konstruksi : Beton
Jumlah : 1
====================================================================================
Utilitas
======================================================
VIII -775
===========================
D = 4.133985715 m
Dalam bak koagulator ini dilengkapi dengan pengaduk berke 45 rpm
Dirancang pengaduk tipe flat blade turbin dengan 6 blade dengan perbandingan Diameter
impeller dengan diameter bak (Da/DT) = 1/3
Diameter impeller,Da
ρ air = 1000
μ air = 0.84 cp
NRe = n x Da x ρ/μ
2
= 0.75 x / 0.00084
= 1695420
Dari Geankoplis figure 3.4-4, diketahui nilai Np pada Nre 1695420 adalah
Np = 6
Daya yang diperlukan untuk motor pengaduk :
P = Np x ρ x N3x Da5/ gc
= 6 x 62.158 1.3779952384 5 / 32.2
= 24.2781050017 lb.ft / dt
====================================================================================
Utilitas
======================================================
VIII -776
===========================
P = 0.0441420091 / 0.8
Dipilih motor = 0.25
Spesifikasi :
Fungsi : Sebagai tempat terjadinya koagulasi serta flokulasi
Kapasitas : 55.4596 m3
Jumlah : 1 buah
Bentuk : kolam bulat
Ukuran bak : diameter 4.133985715 m
tinggi 4.133985715 m
Motor penggerak : 0.25 hp
Bahan : beton bertulang
3. Clarifier H - 130
Fungsi = Memisahkan padatan dengan cara sedimentasi
Type = silinder tegak, tutup bawah conis
Dasar pemilihan = Umum digunakan untuk tekanan atmospheric
Perhitungan :
Volumentrik bahan : 44.3676824
Direncanakan waktu pemisahan 3 jam dengan 1 buah tangki, maka volume tangki :
Volume = 44.4 x 0
Asumsi volume bahan mengisi 80% volume tangki, maka volume tangki :
Volume tangki : 133.1030472124 166.378809015 0
====================================================================================
Utilitas
======================================================
VIII -777
===========================
Ds3 = 142.3565
Ds = 5.220602824
H = 6.2647
Perhitungan Tinggi Bahan :
Volume bahan = Valas
133.1030 = (π/4) x h x Ds 2
0.226748 Ds3
h = 4.7133
Tinggi conical :
h = tg α x ( D - dc)
2
Keterangan : α = cone angle 45o
D = diameter tangk 5.220602824 m
maka :
h = tg 45o x (D - 0,25) 4.970602824
2
Spesifikasi :
Fungsi = Memisahkan padatan dengan cara sedimentasi
Type = silinder tegak dan tutup bawah conis
Kapasitas = 166.378809
Diameter = 5.220602824
Tinggi = 6.264723389
Bahan konstruksi = Carbon stell SA-283 grade C
Jumlah = 1
====================================================================================
Utilitas
======================================================
VIII -778
===========================
307.5 m3
Volume bak penampung = 4 x3 307.5 sehingga x = 4.2503
Panjang = lebar = 2x 4.2503 8.5006 m
Spesifikasi :
Fungsi : Menampung air dari bak pengendap.
Kapasitas : 307.50 m3
Bentuk : empat persegi panjang terbuka.
Ukuran : Panjang 8.5006 m
Lebar 8.5006 m
Tinggi 4.2503 m
Bahan konstruksi : Beton
Jumlah : 1
√
Diameter bed : A
= 0.49 m
0.785
Spesifikasi :
Fungsi : Menyaring air partikel yang masih ada dari bak penampung air
jernih sekaligus menghilangkan warna dan rasa air sungai.
Kapasitas : 44
Bentuk : bejana tegak
Diameter : 0.5
Tinggi : 5.0 m
====================================================================================
Utilitas
======================================================
VIII -779
===========================
Spesifikasi :
Fungsi : Menampung air dari Sand Filter.
Kapasitas : 332.76
Bentuk : Empat persegi panjang terbuka.
Ukuran : Panjang 8.7179152914 m
Lebar 8.7179152914 m
Tinggi 4.3589576457 m
Bahan konstruksi : Beton
Jumlah : 1
====================================================================================
Utilitas
======================================================
VIII -780
===========================
Tinggi = 4.8394 m
Untuk membunuh kuman, digunakan desinfectan jenis chlorine dengan kebutuhan chlorine
= 200 mg / liter. ( Wesley : fig. 10-6 )
Jumlah chlorine yang harus ditambahkan =
, maka untuk 455.499269375 m3
455499 liter air per tahun perlu ditambahkan kaporit sebanyak :
= 200 mg / liter. x 300 hari
= 27329956162.5 mg
Spesifikasi :
Fungsi : Menampung air dari bak air bersih untuk keperluan sanitasi.dan tempat
menambahkan desinfektan ( chlorine )
Kapasitas : 455.499269375 m3
Bentuk : Persegi panjang
Ukuran : Panjang = 9.6788
Lebar = 9.6788
Tinggi = 4.8394
Bahan konstruksi : Beton
Jumlah : 1
====================================================================================
Utilitas
======================================================
VIII -781
===========================
100
Berat Ekuivalen = gr / ek
2
Berat Zeolith = ek x Berat E 50 = 70 gr
Kapasitas Zeolith = 70
Jumlah CaCO3 = 18435.50148 18.44 kg
CARA KERJA :
Air dilewatkan pada kation exchanger yang berisi resin sehingga ion positif tertukar dengan resin.
Kebutuhan Zeolith = 70 x gr = 1.2905 kg
ρ Zeolith = 0.95
Volume Zeolith = 1.2904851 liter = 0.0014 m3
Volume total = 214.70 214.70 m3
Rate Volumetrik = 214.70 8.9460287062 m3 / jam
Tangki kation berbentuk silinder dengan dimension ratio ; H / D = 2
Volume = . D2 H D = 8.9460287062
4
Diameter = 1.7851 m
Tinggi = 3.570 m
====================================================================================
Utilitas
======================================================
VIII -782
===========================
= 8.341298115
Diameter = 1.9193 m
Tinggi = 2.8789 m
: 887 ). Kandungan ini sedianya dihilangkan dengan resin Aminio Poly Styrene bentuk butiran,
agar sesuai dengan syarat air boiler.
Kandungan CaCO3 : 5
Jumlah air yang diproses : 214.7033 56724.6199298422 gallon
Jumlah CaCO3 dalam air : 0.325 18435.5014771987 gr
Dipilih bahan pelunak :
APS dengan exchanger capacity =
Amino Poly Styrenediharapkan mampu menukar semua ion CO3-2.
gram
ek ( ekuivalen ) =
Berat Ekuivalen
BM
Berat Ekuivalen =
Elektron
Untuk CaCO3, 1 mol CO3 melepas 2 elektron CO3-2, sehingga elektron = 2
BM CaCO3 = 100
100
Berat Ekuivalen = gr / ek
2
Berat Zeolith = ek x Berat E 50 = 275 gr
Kapasitas Zeolith = 275
Jumlah CaCO3 = 18435.50148 18.44 kg
CARA KERJA :
====================================================================================
Utilitas
======================================================
VIII -783
===========================
Air dilewatkan pada kation exchanger yang berisi resin sehingga ion positif tertukar dengan resin.
Kebutuhan Zeolith = 275
= 5069.76 5.0697629062 kg
Zeolith = 0.67
= 3653.738055
====================================================================================
Utilitas
======================================================
VIII -784
===========================
p
Volume tangki = D2 . 1.5 D
4
= 4.567172569
Diameter = 1.5705 m
Tinggi = 2.3557 m
====================================================================================
Utilitas
======================================================
VIII -785
===========================
UNIT REFIGERATOR
====================================================================================
Utilitas
======================================================
VIII -786
===========================
Air
Kondensor
X Air 105oF
Kompresor
Brine
Evaporator
Freon 12
53,6oF
Brine 41oF
Untuk mendinginkan brine digunakan freon 12 sebagai refrigerant. Aliran proses adalah
pada gambar diatas (Perry ed 6, fig 12-27)
Aliran dimulai dari titik X dimana cairan jenuh freon melalui expansion valve dari kondesor
Kemudian liquid refigerant ini menyerap panas di evaporator yang diberikan oleh larutan
brine, dimana larutan refigerant akan menjadi uap jenuh yang kemudian masuk ke kompresor
Disini gas ditekan dari tekanan rendah ke tekanan tinggi.
Uap jenuh yang bertekanan tinggi dan sudah mencapai temperatur kondensasi lalu masuk ke
kondesor, dan akan diserap panasnya oleh air pendingin.
Freon yang berbentuk liquid kemudian mengalir kembali ke evaporator.
Pada kondesor heat transfer area yang terjadi perbedaan temperatur 10oF antara suhu
air keluar kondensor dengan suhu kondensasi freon 12 (Perry ed 6, p 12-35)
====================================================================================
Utilitas
======================================================
VIII -787
===========================
1. Evaporator Freon - 12
Freon - 12 (l)
Evaporator
t1 = 20oC = 68oF t2 = 5oC = 41oF
Freon - 12 (g)
1. Neraca panas :
3. Tc dan tc
Tc = [ 53.6 2= 53.6 oF
tc = [ 68 2= 54.5 oF
Trial :
====================================================================================
Utilitas
======================================================
VIII -788
===========================
UD = 5- 50
dipilih : 50
Dipakai NT = 567
sehingga :
A koreksi = 567.2844743568 0.1963 = 1781.7270770598
= 50
2. Kondensor Freon - 12
Freon - 12 (g)
Kondensor
t1 = 30oC = 86oF t2 = 40,556oC = 105oF
Freon - 12 (l)
1. Neraca panas :
2. Penentuan t
====================================================================================
Utilitas
======================================================
VIII -789
===========================
T LMTD = 29 = 17.84 oF
ln [ 29 ]
3. Tc dan tc
Tc = [ 115 2= 115 oF
tc = [ 105 2= 95.5 oF
Dipakai NT = 535
sehingga :
A koreksi = 535.4065211313 0.1963 = 1681.6048
UD koreksi = 1199993.18639978 1681.60480157 x 17.84 ]
= 40
3. Kompresor
Fungsi : Menaikkan tekana freon 12 dari evporator (29 psia) menuju kondensor
Jenis : Reciprocating
Kompresor
====================================================================================
Utilitas
======================================================
VIII -790
===========================
P1 : T1 P2 : T2
Kompresor
P1 = 29 psi
T1 = 53.6 oF oK
T2 = 115 oF oK
P2 = ?
Cp = 0.15 Btu/lboF kcal/kmoloK
R = 1.987 kcal/kmoloK
T2 = T1 (P2/P1)R/Cp
P2 = 81.4 psia
ρ = 0.826 lb/cuft
w = 139238.532884282 lb/jam
Perhitungan Power :
Hp = 0,0044 Q x P1 x ln(P2/P1)
= 0.0044 x 46.82490345 x ln(81,4/29)
= 231.25 Hp
====================================================================================
Utilitas
======================================================
VIII -791
===========================
Perhitungan :
ρ air = 62.5
Bahan masuk = 44218.61 27.0792 lb/dt
= 0.43326767 cuft/dt
25.99606009
= 3.12 ft/dt
====================================================================================
Utilitas
======================================================
VIII -792
===========================
= 3.12 ft/dt
0.139
dengan : μ = 0.00085
DV 0.4206 x 62.5
NRe = =
= 96391.17177 2100 ( asumsi benar )
Dipilih pipa Commercial steel ( e = )
e/D = 0.0003566618
f = 0.006 ( Mc.Cabe ed 5 hal 88)
ft . lbf dt2.lbf
= 2.0344991963
lbm
0.4 x 3.12
= a= 1 untuk aliran turbulen
====================================================================================
Utilitas
======================================================
VIII -793
===========================
= a= 1 untuk aliran turbulen
2 x 1 x
ft . lbf
= 0.0603471948
lbm
3. Friksi karena enlargement ( ekspansi ) dari pipa ke tangki
V2 1 untuk aliran turbulen
F3 = =
2 x α x gc
32 - ft . lbf
= 0.150867987
2 x 1 x lbm
( V1 <<<< V2, maka V1 dianggap = 0 )
F = F1 + F2
= 2.0344991963 + 0.150867987
= 2.2457143782 ft . lbf / lbm
P1 = 1 atm = 2116.8
P2 = 1 atm = 2116.8
( 1 atm 144 lbf / ft2 )
( 1 atm 144 lbf / ft 2
)
DP lbf / ft2
DP = P2 - P1 = = 0
r lbm / ft3
Asumsi ΔZ = 32 ft
Persamaan Bernoully :
DP DV2
- Wf = + DZ + Σ F
2 x α x gc
= 0 + 32 2.2457143782
ft . lbf
= 34.3965823652
lbm
- Wf x flowrate ( cuft/dt) x ρ
hp =
550
34.3965823652 x 0.433267668
=
550
= 1.6935144358 hp
====================================================================================
Utilitas
======================================================
VIII -794
===========================
Bhp = = 1.881682706 hp
h pompa
Effisiensi motor = 91%
Bhp
Power motor = = 2.067783194 hp
h motor
Spesifikasi :
Fungsi : Mengalirkan bahan dari sungai ke bak penampung air sungai
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 27.0792 lb/dt
Total Dynamic Head : 34.0593362 ft lbf / lbm
Effisiensi motor : 91%
Power : 2 hp
Jumlah : 1 buah
Perhitungan :
ρ air = 62.5
Bahan masuk = 44218.61 lb/dt = 0.4333 cuft/dt
====================================================================================
Utilitas
======================================================
VIII -795
===========================
= fluid density
Diameter pipa optimum =
Dipilih pipa 5 in, sch
OD = 5.563 in
ID = 5.047 in =
A = 0.139 ft2
rate volumetri 1
Kecepatan aliran, V = x
Area pipa ft2 60 dt/mnt
25.99606009
= 3.117 ft/dt
0.139
dengan : μ = 0.00085
DVρ 0.4206 x 62.5
NRe = =
μ
= 96391.17177 2100 ( asumsi benar )
Dipiih pipa Commercial steel ( e = )
====================================================================================
Utilitas
======================================================
VIII -796
===========================
dt2.lbf
2. Friksi karena kontraksi dari tangki ke pipa
K x V2
F2 = A tangki > A pipa
2 x α x gc
0.5 x 3.117
= a= 1 untuk aliran turbulen
2 x 1 x
ft . lbf
= 0.0754339935
lbm
3. Friksi karena enlargement ( ekspansi ) dari pipa ke tangki
V2 a = 1 untuik aliran turbulen
F3 = =
2 x a x gc
3.117 2 - ft . lbf
= 0.150867987
2 x 1 x lbm
( V1 <<<< V2, maka V1 dianggap = 0 )
F = F1 + F2
= 1.7482 + 0.150867987
= 1.9745019805 ft . lbf / lbm
P1 = 1 atm = 2116.8
P2 = 1 atm = 2116.8
( 1 atm 144 lbf / ft2 )
( 1 atm 144 lbf / ft 2
)
DP lbf / ft2
DP = P2 - P1 = = 0
lbm / ft3
ft . lbf
0
lbm
Asumsi DZ = 13 ft
Persamaan Bernoully :
DP DV2
- Wf = + DZ + Σ F
2 x α x gc
= 0 + 13 1.9745019805
ft . lbf
= 15.1253699676
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp =
550
15.1253699676 x 0.433267668
=
====================================================================================
Utilitas
======================================================
VIII -797
===========================
=
550
= 0.7446970201 hp
Kapasitas = 0.4332676682 x = 194.4635275 gpm
Effisiensi pompa = 90%
hp
Bhp = = 0.8274411334 hp
h pompa
Effisiensi motor = 91%
Bhp
Power motor = = 0.909 ~ 1 hp
h motor
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak air sungai ke bak koagulasi - flokulasi
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 27.0792293
Total Dynamic Head : 15.12537
Effisiensi motor : 91%
Power : 1 hp
Jumlah : 1 buah
Perhitungan :
ρ air = 62.5
Bahan masuk = 44218.61 lb/dt
= 0.43326767
Asumsi aliran turbulen :
Di optimum untuk aliran turbulen, Nre > 2100, digunakan persamaan :
Diameter Optimum = 3.9 0.13
====================================================================================
Utilitas
======================================================
VIII -798
===========================
OD = 5.563 in
ID = 5.047 in =
A = 0.139 ft2
rate volumetri 1
Kecepatan aliran, V = x
Area pipa ft2
60 dt/mnt
25.99606009
= 3.117 ft/dt
0.139
dengan : μ = 0.00085
DVρ 0.4206 x 62.5
NRe = =
μ
= 96391.17177 2100 ( asumsi benar )
Dipiih pipa Commercial steel ( e = )
e/D = 0.0003566618 ( Mc.Cabe ed 5 hal 88)
f = 0.006
====================================================================================
Utilitas
======================================================
VIII -799
===========================
K x V2
F2 =
2 x α x gc
0.5 x 3.117
=
2 x 1 x
ft . lbf
= 0.0754339935
lbm
3. Friksi karena enlargement ( ekspansi ) dari pipa ke tangki
V2
F3 = =
2 x a x gc
3.117 2 - ft . lbf
= 0.150867987
2 x 1 x lbm
( V1 <<<< V2, maka V1 dianggap = 0 )
F = F1 + F2
= 1.7482 + 0.150867987
= 1.9745019805 ft . lbf / lbm
P1 = 1 atm 2116.8 = 14.7 x 144 lbf / ft2
P2 = 1 atm 2116.8 = 14.7 x 144 lbf / ft2
DP lbf / ft2
DP = P2 - P1 = = 0
lbm / ft3
= 0
Asumsi DZ = 20.047 ft
Persamaan Bernoully :
DP DV2
- Wf = + DZ + Σ F
2 x α x gc
= 0 + 20.04711484 1.9745019805
====================================================================================
Utilitas
======================================================
VIII -800
===========================
ft . lbf
= 22.1724848119
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp = ( Perry 6ed, pers.6-11,hal.6-5)
550
22.1724848119 x 0.433267668
=
550
= 1.0916614537 hp
Kapasitas = 0.4332676682 x = 194.4635275 gpm
Effisiensi pompa = 90%
hp
Bhp = = 1.212957171 hp
h pompa
Effisiensi motor = 92%
Bhp
Power motor = = 1.318 ~ 1.5 hp
h motor
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak air sungai ke bak koagulasi - flokulasi
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 27.0792293
Total Dynamic Head : 22.1724848
Effisiensi motor : 92%
Power : 1.5 hp
Jumlah : 1 buah
Perhitungan :
air = 62.5
====================================================================================
Utilitas
======================================================
VIII -801
===========================
OD = 5.563 in
ID = 5.047 in =
A = 0.139 ft2
rate volumetri 1
Kecepatan aliran, V = x
Area pipa ft2 60 dt/mnt
6.499015023
= 0.779 ft/dt
0.139
dengan : = 0.00085
DV 0.4206 x 62.5
NRe = =
= 24097.79294 2100 ( asumsi benar )
Dipiih pipa Commercial steel ( e = )
e/D = 0.0003566618 ( Mc.Cabe ed 5 hal 88)
f = 0.006
Digunakan persamaan Bernoully :
DP DV2
- Wf = + DZ + Σ F
2 x α x gc
====================================================================================
Utilitas
======================================================
VIII -802
===========================
2f x V2 x Le
F1 = =
gc x D
0.5 x 0.7793
=
2 x 1 x
ft . lbf
= 0.0047146246
lbm
3. Friksi karena enlargement ( ekspansi ) dari pipa ke tangki
V2
F3 = =
2 x α x gc
0.7793 2 - ft . lbf
= 0.0094292492
2 x 1 x lbm
( V1 <<<< V2, maka V1 dianggap = 0 )
F = F1 + F2
= 0.1271561998 + 0.0094292492
= 0.1413000736 ft . lbf / lbm
P1 = 1 atm = 2116.8 lbf / ft2 14.7 x 144 lbf / ft2
P2 = 1 atm = 2116.8 lbf / ft2 14.7 x 144 lbf / ft2
DP lbf / ft2
DP = P2 - P1 = = 0
lbm / ft3
ft . lbf
0
====================================================================================
Utilitas
======================================================
VIII -803
===========================
0
lbm
V2 0.7793 ft . lbf
= = 0.009429249
2 x a x gc 2 x lbm
Asumsi DZ = 16 ft
Persamaan Bernoully :
DP DV2
- Wf = + DZ + Σ F
2 x α x gc
= 0 + 16 0.1413000736
ft . lbf
= 16.1507293227
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp = ( Perry 6ed, pers.6-11,hal.6-5)
550
16.1507293227 x 0.108316917
=
550
= 0.1987951373 hp
Kapasitas = 0.1083169171 x = 48.61588188 gpm
Effisiensi pompa = 90%
hp
Bhp = = 0.220883486 hp
h pompa
Effisiensi motor = 87%
Bhp
Power motor =
h motor
= 0.253889064 hp
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak penampung air jernih ke sand filter
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 0.1083169171
====================================================================================
Utilitas
======================================================
VIII -804
===========================
Fungsi : Mengalirkan bahan dari bak air bersih ke bak penampung air sanitasi
Tipe : Centrifugal Pump
Dasar Pemilihan : Sesuai untuk bahan liquid, viskositas rendah.
Perhitungan :
air = 62.5
Bahan masuk = 1018.2339 0.62356 lb/dt
= 0.0099769722
Asumsi aliran turbulen :
Di optimum untuk aliran turbulen, Nre > 2100, digunakan persamaan :
Diameter Optimum = 3.9 x qf (Peters&Timmerhaus,4ed,pers 15)
rate volumetri 1
Kecepatan aliran, V = x
Area pipa ft2 60 dt/mnt
0.598618333
= 1.6628 ft/dt
0.006
dengan : μ = 0.00085
====================================================================================
Utilitas
======================================================
VIII -805
===========================
0.5 x 1.6628
=
2 x 1 x
ft . lbf
= 0.0214673858
lbm
3. Friksi karena enlargement ( ekspansi ) dari pipa ke tangki
V2
F3 = =
2 x α x gc
====================================================================================
Utilitas
======================================================
VIII -806
===========================
1.6628 2 - ft . lbf
= 0.0429347716
2 x 1 x lbm
( V1 <<<< V2, maka V1 dianggap = 0 )
F = F1 + F2
= 1.4911 + 0.0429347716
= 1.5555021574 ft . lbf / lbm
Asumsi DZ = 10 ft
Persamaan Bernoully :
DP DV2
- Wf = + DZ + F
2 x α x gc
= 0 + 10 1.5555021574
ft . lbf
= 11.598436929
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp = ( Perry 6ed, pers.6-11,hal.6-5)
550
11.598436929 x 0.009976972 = 0.0131496912
=
550
Kapasitas = 0.0099769722 x = 4.477964437 gpm
Effisiensi pompa = 40%
hp
Bhp = = 0.032874228 hp
h pompa
Effisiensi motor = 80%
Bhp
Power motor = = 0.041092785 ~0.25 hp
h motor
====================================================================================
Utilitas
======================================================
VIII -807
===========================
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak air bersih ke bak penamp. air sanitasi
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 1018.23387 gpm
Total Dynamic Head : 11.5984369 ft lbf / lbm
Effisiensi motor : 80%
Power : 0.25 hp
Jumlah : 1 buah
Perhitungan :
air = 62.5
Bahan masuk = 8915.914 kg/ jam = = 0.09 cuft/dt
Asumsi aliran turbulen :
Di optimum untuk aliran turbulen, Nre > 2100, digunakan persamaan :
Diameter Optimum = 3.9 0.13
====================================================================================
Utilitas
======================================================
VIII -808
===========================
A = 0.0233 ft2
rate volumetri 1
Kecepatan aliran, V = x
Area pipa ft2 60 dt/mnt
5.241653741
= 3.7494 ft/dt
0.0233
dengan : = 0.00085
====================================================================================
Utilitas
======================================================
VIII -809
===========================
0.5 x 3.7494
=
2 x 1 x
ft . lbf
= 0.1091456549
lbm
3. Friksi karena enlargement ( ekspansi ) dari pipa ke tangki
V2
F3 = =
2 x α x gc
3.7494 2 - ft . lbf
= 0.2182913098
2 x 1 x lbm
( V1 <<<< V2, maka V1 dianggap = 0 )
F = F1 + F2
= 4.4819673136 + 0.2182913098
= 4.8094042783
P1 = 1 atm = 2116.8 x 144 lbf / ft2 )
P2 = 1 atm = 2116.8 x 144 lbf / ft2 )
DP
DP = P2 - P1 = =
ft . lbf
0
lbm
V2 3.7494
= =
2 x α x gc 2 x
= 0.2182913098
Asumsi DZ = 10 ft
Persamaan Bernoully :
DP DV2
- Wf = + DZ + Σ F
2 x α x gc
= 0 + 10 4.8094042783
ft . lbf
= 15.0276955881
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp =
550
====================================================================================
Utilitas
======================================================
VIII -810
===========================
15.0276955881 x 0.087360896
=
550
= 0.1491855621 hp
Kapasitas = 0.0873608957 x
= 39.210
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak air bersih ke kation - anion exchanger
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 5.46005598 gpm
Total Dynamic Head : 15.0276956 ft lbf / lbm
Effisiensi motor : 80%
Power : 1 hp
Jumlah : 1 buah
Perhitungan :
air = 62.5
Bahan masuk = 33.221 kg/ jam = = 0.000325513 cuft/dt
====================================================================================
Utilitas
======================================================
VIII -811
===========================
rate volumetri 1
Kecepatan aliran, V = x
Area pipa ft2 60 dt/mnt
0.019530778
= 0.0140 ft/dt
0.0233
dengan : = 0.00085
DP DV2
- Wf = + DZ + Σ F
2 x α x gc
====================================================================================
Utilitas
======================================================
VIII -812
===========================
0.5 x 0.0140
=
2 x 1 x
ft . lbf
= 1.51533572538E-06
lbm
3. Friksi karena enlargement ( ekspansi ) dari pipa ke tangki
V2
F3 = =
2 x α x gc
0.0140 2 - ft . lbf
= 3.0306715E-06
2 x 1 x lbm
( V1 <<<< V2, maka V1 dianggap = 0 )
F = F1 + F2
= 6.22258870233E-05 + 3.0306715E-06
= 6.67718941994E-05 ft . lbf / lbm
P1 = 1 atm = 2116.8
P2 = 1 atm = 2116.8
( 1 atm = 14.7 x 144
( 1 atm = 14.7 x 144
DP
DP = P2 - P1 = =
====================================================================================
Utilitas
======================================================
VIII -813
===========================
DP = P2 - P1 = =
lbf / ft2
0
lbm / ft3
V2 0.0140
=
2 x α x gc 2 x
= 3.03067145075908E-06
Asumsi DZ = 10 ft
Persamaan Bernoully :
DP DV2
- Wf = + DZ + Σ F
2 x α x gc
= 0 + 10 6.677189419941E-05
ft . lbf
= 10.0000698026
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp =
550
10.0000698026 x 0.000325513 = 0.000369904 hp
=
550
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak air bersih ke kation - anion exchanger
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 0.02034456 gpm
Total Dynamic Head : 10.0000698 ft lbf / lbm
Effisiensi motor : 80%
====================================================================================
Utilitas
======================================================
VIII -814
===========================
Power : 0 hp
Jumlah : 1 buah
Perhitungan :
air = 62.5
Bahan masuk = 4717.6765 = 0.05 cuft/dt
====================================================================================
Utilitas
======================================================
VIII -815
===========================
Kecepatan aliran, V = x
Area pipa ft2 60 dt/mnt
2.773515744
= 1.9839 ft/dt
0.0233
dengan : = 0.00085
DV 0.1722 x 62.5
NRe = =
= 25126.17696 2100 ( asumsi benar )
Dipiih pipa Commercial steel ( e = )
e/D = 0.0008708621 (Mc.Cabe hal 88)
f = 0.007
Digunakan persamaan Bernoully :
DP DV2
- Wf = + DZ + Σ F
2 x α x gc
0.5 x 1.9839
=
====================================================================================
Utilitas
======================================================
VIII -816
===========================
=
2 x 1 x
ft . lbf
= 0.0305584319
lbm
3. Friksi karena enlargement ( ekspansi ) dari pipa ke tangki
V2
F3 = =
2 x α x gc
1.9839 2 - ft . lbf
= 0.0611168639
2 x 1 x lbm
( V1 <<<< V2, maka V1 dianggap = 0 )
F = F1 + F2
= 1.2548542879 + 0.0611168639
= 1.3465295837 ft . lbf / lbm
P1 = 1 atm = 2116.8
P2 = 1 atm = 2116.8
( 1 atm = 14.7 x 144
( 1 atm = 14.7 x 144
∆P
DP = P2 - P1 = =
ft . lbf
0
lbm
V 2
1.9839
=
2 x α x gc 2 x
= 0.0611168639
Asumsi DZ = 10 ft
Persamaan Bernoully :
DP DV2
- Wf = + DZ + Σ F
2 x α x gc
= 0 + 10 1.3465295837
ft . lbf
= 11.4076464475
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp =
====================================================================================
Utilitas
======================================================
VIII -817
===========================
hp =
550
11.4076464475 x 0.046225262
=
550
= 0.0199742974 hp
Kapasitas = 0.0462252624 x
= 20.747 gpm
Effisiensi pompa = 40%
hp
Bhp =
h pompa
hp
= 0.062419679 hp
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak air bersih ke bak air proses
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 0.0462252624 cuft/dt
Total Dynamic Head : 10.4934876833 ft lbf / lbm
Effisiensi motor : 80%
Power : 0.25 hp
Jumlah : 1 buah
====================================================================================
Utilitas
======================================================
VIII -818
===========================
Perhitungan :
air = 62.5
Bahan masuk = 30366.6179583333 0.2975415701 cuft/dt
rate volumetri 1
Kecepatan aliran, V = x
Area pipa ft2
60 dt/mnt
17.85249421
= 2.14 ft/dt
0.139
dengan : = 0.00085
DV 0.4206 x 62.5
NRe = =
= 66195.52462 2100 ( asumsi benar )
Dipiih pipa Commercial steel ( e = )
e/D = 0.0003566618 (Mc.Cabe hal 88)
f = 0.006
Digunakan persamaan Bernoully :
DP DV2
- Wf = + DZ + Σ F
2 x α x gc
Perhitungan friksi berdasarkan Peters & Timmerhaus, 4ed T.1, hal.484
Taksiran panjang pipa lurus = 50
Panjang ekuivalen, Le
====================================================================================
Utilitas
======================================================
VIII -819
===========================
- 3 elbow 90o = 3 x
= 37.8510
- 1 globe valve = 1 x
= 142.9926
- 1 gate valve = 1 x
= 5.4674
Panjang total pipa = 236.3110
ft . lbf
= 0.0355754037
lbm
3. Friksi karena enlargement ( ekspansi ) dari pipa ke tangki
V2
F3 = =
2 x α x gc
2.1406 2 - ft . lbf
= 0.0711508075
2 x 1 x lbm
( V1 <<<< V2, maka V1 dianggap = 0 )
F = F1 + F2
= 1.0063256385 + 0.0711508075
= 1.1130518497 ft . lbf / lbm
====================================================================================
Utilitas
======================================================
VIII -820
===========================
P1 = 1 atm = 2116.8
P2 = 1 atm = 2116.8
( 1 atm = 14.7 x 144 lbf / ft2
( 1 atm = 14.7 x 144 lbf / ft2
∆P
DP = P2 - P1 =
0 ft . lbf
=
lbm
V2 2.1406
=
2 x α x gc 2 x
= 0.0711508075
Asumsi DZ = 10 ft
Persamaan Bernoully :
DP DV2
- Wf = + DZ + Σ F
2 x α x gc
= 0 + 10 1.1130518497
ft . lbf
= 11.1842026572
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp =
550
11.1842026572 x 0.29754157
=
550
= 0.1260517129 hp
Kapasitas = 0.2975415701 x
= 133.5455829
Effisiensi pompa = 90%
hp
Bhp =
h pompa
= 0.140057459
= 0.16285751 hp
====================================================================================
Utilitas
======================================================
VIII -821
===========================
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak penampung air jernih ke bak air pendingin
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 18.5963481 gpm
Total Dynamic Head : 11.1842027 ft lbf / lbm
Effisiensi motor : 86%
Power : 0.25 hp
Jumlah : 1 buah
Perhitungan :
air = 62.5 lb/cuft
Bahan masuk = 30367 kg/ jam = cuft/dt
====================================================================================
Utilitas
======================================================
VIII -822
===========================
A = 0.139 ft2
====================================================================================
Utilitas
======================================================
VIII -823
===========================
=
0.5 x 2.1406
=
2 x 1 x
ft . lbf
= 0.0355754037
lbm
3. Friksi karena enlargement ( ekspansi ) dari pipa ke tangki
V2
F3 = =
2 x α x gc
2.1406 2 -
=
2 x 1 x
ft . lbf
= 0.0711508075
lbm
( V1 <<<< V2, maka V1 dianggap = 0 )
F = F1 + F2
= 0.9406588493 + 0.0711508075
= 1.0473850605 ft . lbf / lbm
P1 = 1 atm = 2116.8
P2 = 1 atm = 2116.8
( 1 atm = 14.7
( 1 atm = 14.7
∆P
DP = P2 - P1 =
0 lbf / ft2
=
lbm / ft3
V2 2.1406
=
2 x α x gc 2 x
= 0.0711508075
====================================================================================
Utilitas
======================================================
VIII -824
===========================
= 0.0711508075
Asumsi DZ = 10 ft
Persamaan Bernoully :
DP DV2
- Wf = + DZ
2 x α x gc
= 0 + 10 1.0473850605
ft . lbf
= 11.1185358679
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp =
550
11.1185358679 x 0.29754157
=
550
= 0.1253116144 hp
Kapasitas = 0.2975415701 x
= 133.5455829295
= 0.139235127
= 0.161901311
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak penampung air jernih ke bak air pendingin
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 18.59634813
====================================================================================
Utilitas
======================================================
VIII -825
===========================
Perhitungan :
air = 62.5
Bahan masuk = 30366.6179583333
dengan : = 0.00085
DV
NRe =
====================================================================================
Utilitas
======================================================
VIII -826
===========================
0.4636 x 2.192
=
0.00085
= 74722.7663948547 >
Dipiih pipa Commercial steel ( e = )
e/D = 0.0003566618 (Mc.Cabe hal 88)
f = 0.006
Digunakan persamaan Bernoully :
DP DV2
- Wf = + DZ + Σ F
2 x α x gc
Perhitungan friksi berdasarkan Peters & Timmerhaus, 4ed T.1, hal.484
Taksiran panjang pipa lurus = 50
Panjang ekuivalen, Le
- 3 elbow 90o = 3 x = 41.7208 ft
- 1 globe valve = 1 x = 157.6120 ft
- 1 gate valve = 1 x = 6.0263 ft
Panjang total pipa = 255.3592 ft
0.5 x 2.1922
= a = 1 untuk aliran urbulen
2 x 1 x
ft . lbf
= 0.0373118647
lbm
====================================================================================
Utilitas
======================================================
VIII -827
===========================
V2
F3 = =
2 x α x gc
a=
2.1922 2 - ft . lbf
= 0.0746237295
2 x 1 x lbm
( V1 <<<< V2, maka V1 dianggap = 0 )
F = F1 + F2
= 0.986573083 + 0.0746237295
= 1.0985086772 ft . lbf / lbm
P1 = 1 atm = 2116.8 lbf / ft2 144 lbf / ft2)
P2 = 1 atm = 2116.8 lbf / ft2 144 lbf / ft2)
∆P
DP = P2 - P1 =
V 2
2.1922
=
2 x α x gc 2 x
= 0.0746237295
Asumsi DZ = 10 ft
Persamaan Bernoully :
DP DV2
- Wf = + DZ + 0 F
2 x α x gc
= 0 + 10 1.0985086772
ft . lbf
= 11.1731324066
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp =
550
11.1731324066 x 0.304717074
=
550
= 0.1289637959 hp
Kapasitas = 0.3047170739 x
= 136.7661642706 gpm
Effisiensi pompa = 90%
hp
Bhp =
h pompa
====================================================================================
Utilitas
======================================================
VIII -828
===========================
= 0.143293107
= 0.166619891
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak penampung air jernih ke bak air pendingin
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 18.5963481
Total Dynamic Head : 11.1731324
Effisiensi motor : 86%
Power : ~ 0.25 hp
Jumlah : 1 buah
Perhitungan :
air = 62.5
Bahan masuk = 2491.0884241201 lb/dt
cuft/dt
Asumsi aliran turbulen :
Di optimum untuk aliran turbulen, Nre > 2100, digunakan persamaan :
Diameter Optimum = 3.9 0.13
====================================================================================
Utilitas
======================================================
VIII -829
===========================
====================================================================================
Utilitas
======================================================
VIII -830
===========================
0.5 x 1.0476
=
2 x 1 x
ft . lbf
= 0.0085202636
lbm
3. Friksi karena enlargement ( ekspansi ) dari pipa ke tangki
V2
F3 = =
2 x α x gc
1.0476 2 - ft . lbf
= 0.0170405272
2 x 1 x lbm
( V1 <<<< V2, maka V1 dianggap = 0 )
F = F1 + F2
= 0.3498768966 + 0.0170405272
= 0.3754376875 ft . lbf / lbm
P1 = 1 atm = 2116.8
P2 = 1 atm = 2116.8
( 1 atm = 14.7 )
( 1 atm = 14.7 )
∆P
DP = P2 - P1 =
lbf / ft 2
= 0 =
lbm / ft3
V2 1.0476
=
2 x α x gc 2 x
= 0.0170405272
====================================================================================
Utilitas
======================================================
VIII -831
===========================
= 0.0170405272
Asumsi DZ = 10 ft
Persamaan Bernoully :
DP DV2
- Wf = + DZ + 14.7 F
2 x α x gc
= 0 + 10 0.3754376875
ft . lbf
= 10.3924782147
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp =
550
10.3924782147 x 0.024408459
=
550
= 0.0096084993 hp
Kapasitas = 0.0244084594 x
= 10.9552488257 gpm
Effisiensi pompa = 90%
hp
Bhp =
h pompa
= 0.01067611
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak penampung air jernih ke bak air pendingin
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 2491.0884241201 lb/dt
Total Dynamic Head : 10.3924782147
Effisiensi motor : 86%
Power : 0.1 hp
Jumlah : 1 buah
====================================================================================
Utilitas
======================================================
VIII -832
===========================
Tenaga listrik yang dibutuhkan Pabrik ini dipenuhi dari Perusahaan Listrik Negara
( PLN ) dan Generator set ( Genset ) dan distribusi pemakaian listrik untuk memenuhi
kebutuhan pabrik adalah sebagai berikut :
- Untuk keperluan proses.
Untuk keperluan proses disediakan dari generator set, sedangkan untuk penerangan
dari PLN. Bila terjadi kerusakan pada generator set, kebutuhan listrik bisa diperoleh dari PLN.
demikian juga bila terjadi gangguan dari PLN, kebutuhan listrik untuk penerangan bisa diperoleh
dari generator set.
====================================================================================
Utilitas
======================================================
VIII -833
===========================
Power
Peralatan Utilitas
( hp )
1 Boiler S - 230 3006
2 Bak Koagulasi F - 120 0.25
3 Refrigerator 300
4 Pompa Air Sungai L - 111 0
5 Pompa Bak Koagulasi L - 121 1
6 Pompa Clarifier L - 122 1.50
7 Pompa Sand Filter L - 132 hp
8 Pompa Bak Air Pendingin L - 142 0.25
1 hp = 745.6 watt =
Jadi kebutuhan listrik untuk proses dan utilitas : 3310.36 x 0.7456
= 2468.207117 kWh
Kebutuhan listrik untuk penerangan pabrik dihitung berdasarkan kuat penerangan
untuk tiap-tiap lokasi.Dengan menggunakan perbandingan beban listrik lumen / m2, dimana 1 foot
candle = 10076 lumen / m2 dan 1 lumen =
0.0015 watt ( Perry, Conversion Table )
Kebutuhan ini dapat dilihat pada tabel VIII.4.2.
====================================================================================
Utilitas
======================================================
VIII -834
===========================
9 PERPUSTAKAAN 10 100760
10 KANTIN 15 151140
11 POLIKLINIK 10 100760
12 MUSHOLA 30 302280
13 RUANG PROSES 360 3627360
14 RUANG KONTROL 10 100760
15 LABORATORIUM 30 302280
16 UNIT P'GOLAHAN AIR 90 906840
17 UNIT PEMB. LISTRIK 50 503800
18 UNIT BOILER 50 503800
19 STORAGE PRODUK 62.5 629750
20 STORAGE BHN BAKU 62.5 629750
Untuk penerangan daerah proses, daerah perluasan, daerah utilitas, daerah bahan baku,
deerah produk, tempat parkir, bengkel, gudang, jalan dan taman digunakan merkury 250
Untuk lampu merkury 250 166666.666666667 lumen.
Jumlah lampu merkury yang dibutuhkan :
No LOKASI Lumen / m2
1 RUANG PROSES 3627360
2 DAERAH PERLUASAN 100760
3 UTILITAS 302280
4 STORAGE BAHAN BAKU 906840
5 STORAGE PRODUK 503800
6 PARKIR 503800
7 BENGKEL 629750
8 GUDANG 629750
9 JALAN ASPAL 629750
10 TAMAN 403040
Merkury 250 watt = 166667,6667 lumen 13068572
Jumlah lampu 78
====================================================================================
Utilitas
======================================================
VIII -835
===========================
= 203071704000
Jumlah lampu TL yang digunakan : /
26666.6666666667 = 8E+06 buah lampu.
Kebutuhan listrik untuk penerangan :
= 78 x 250 + 7615188.9 304627158.858 watt =
304627.158858 kWh.
Kebutuhan listrik untuk AC kantor kWh
Total kebutuhan listrik per jam + 304627.158858 + 20
= 307115.366 kWh
Untuk menjamin kelancaran supply listrik, maka supply listrik :
= 1.5 x 307115.366
= 460673.04896213 kWh
Spesifikasi :
Fungsi : Pembangkit tenaga listrik.
Kapasitas : 1253.060396 kVA
Power factor : 0.8
Bahan bakar : Minyak diesel.
Kebutuhan bahan bakar : 118.3889737 liter / jam
Jumlah : 2 buah ( 1 cadangan )
====================================================================================
Utilitas
======================================================
VIII -836
===========================
Spesifikasi :
Nama alat : Tangki Penyimpan Bahan Bakar.
Tipe : Standard Vessel API Standard 12-D ( 100,101 )
Kapasitas nominal : 2000
Diameter : 29
Tinggi : 16
Bahan konstruksi : Carbon Steel SA-283 grade C
Jumlah : 1
====================================================================================
Utilitas
======================================================
VIII -837
===========================
====================================================================================
Utilitas
======================================================
VIII -838
===========================
====================================================================================
Utilitas
======================================================
VIII -839
===========================
====================================================================================
Utilitas
======================================================
VIII -840
===========================
o
C
====================================================================================
Utilitas
======================================================
VIII -841
===========================
Btu / jam
,pers. 173 )
====================================================================================
Utilitas
======================================================
VIII -842
===========================
====================================================================================
Utilitas
======================================================
VIII -843
===========================
17491171.944
0.2
====================================================================================
Utilitas
======================================================
VIII -844
===========================
====================================================================================
Utilitas
======================================================
VIII -845
===========================
====================================================================================
Utilitas
======================================================
VIII -846
===========================
====================================================================================
Utilitas
======================================================
VIII -847
===========================
m3
====================================================================================
Utilitas
======================================================
VIII -848
===========================
====================================================================================
Utilitas
======================================================
VIII -849
===========================
====================================================================================
Utilitas
======================================================
VIII -850
===========================
10
29
19
5.4065211313
====================================================================================
Utilitas
======================================================
VIII -851
===========================
====================================================================================
Utilitas
======================================================
VIII -852
===========================
====================================================================================
Utilitas
======================================================
VIII -853
===========================
ulasi-flokulasi
====================================================================================
Utilitas
======================================================
VIII -854
===========================
====================================================================================
Utilitas
======================================================
VIII -855
===========================
====================================================================================
Utilitas
======================================================
VIII -856
===========================
====================================================================================
Utilitas
======================================================
VIII -857
===========================
)
)
====================================================================================
Utilitas
======================================================
VIII -858
===========================
11,hal.6-5)
====================================================================================
Utilitas
======================================================
VIII -859
===========================
====================================================================================
Utilitas
======================================================
VIII -860
===========================
)
)
====================================================================================
Utilitas
======================================================
VIII -861
===========================
ft . lbf
lbm
11,hal.6-5)
====================================================================================
Utilitas
======================================================
VIII -862
===========================
)
)
ft . lbf
lbm
11,hal.6-5)
hp
====================================================================================
Utilitas
======================================================
VIII -863
===========================
n exchanger
====================================================================================
Utilitas
======================================================
VIII -864
===========================
====================================================================================
Utilitas
======================================================
VIII -865
===========================
====================================================================================
Utilitas
======================================================
VIII -866
===========================
rsih ke proses
====================================================================================
Utilitas
======================================================
VIII -867
===========================
====================================================================================
Utilitas
======================================================
VIII -868
===========================
r pendingin
====================================================================================
Utilitas
======================================================
VIII -869
===========================
====================================================================================
Utilitas
======================================================
VIII -870
===========================
====================================================================================
Utilitas
======================================================
VIII -871
===========================
====================================================================================
Utilitas
======================================================
VIII -872
===========================
r pendingin
====================================================================================
Utilitas
======================================================
VIII -873
===========================
====================================================================================
Utilitas
======================================================
VIII -874
===========================
0.7456
====================================================================================
Utilitas
======================================================
VIII -875
===========================
buah lampu.
liter / jam
====================================================================================
Utilitas
======================================================
VIII -876
===========================
====================================================================================
Utilitas
======================================================
VIII -877
===========================
====================================================================================
Utilitas
======================================================
VIII -878
===========================
====================================================================================
Utilitas
======================================================
VIII -879
===========================
====================================================================================
Utilitas
======================================================
VIII -880
===========================
====================================================================================
BAB VIII
UTILITAS
Pada pabrik Aluminium Sulfat ini diadakan suatu unit pembantu, yaitu unit utilitas sebagai unit
yang berfungsi untuk menyediakan bahan maupun tenaga pembantu sehingga membantu kelan-
caran operasi dari pabrik.
Utilitas yang terdapat dalam pabrik Aluminium sulfat, meliputi beberapa unit yaitu :
1. Unit Penyediaan Steam
2. Unit Penyediaan Air
3. Unit Penyediaan Listrik
4. Unit Penyediaan Bahan Bakar
5. Unit Pengolahan Limbah
VIII.1. Unit Penyediaan Steam
Steam pada pabrik Aluminium sulfat digunakan untuk proses Reaksi
Power Boiler :
ms ( h - hf )
hP = ( Severn, W.H,pers. 172 hal. 140 )
970.3 x 34.5
dimana :
Angka-angka 970,3 dan 34,5 adalah suatu peyesuaian pada penguapan 34,5 lb air / jam
dari air pada 212oF menjadi uap kering pada 212oF pada tekanan 1 atm, untuk kondisi
demikian diperlukan enthalpy penguapan 970,3 Btu / lb.
5129.4 1179.28 - 268.0567
hp = = 139.6260336 hp
970.3 x 34.5
Kapasitas Boiler :
ms ( h - hf )
Q = ( Severn, W.H,pers. 171 )
1000
5129.4 1179.28 - 268.0567
= = 4674.030345 Btu / jam
1000
Faktor Evaporasi = h - hf
( Severn, W.H,pers. 173 )
970.3
= 1179.28 - 268.057
970.3
= 0.9391
= 86 - 68 = 18 oF
Temperature range = T1 - T2
= 105.001 - 86 = 19 oF
dengan :
L = panjang cooling tower, ft
W = wind correction factor.
C = konsentrasi air / ft2 cooling.
CW = wet bulb correction factor.
diperoleh :
W = 1 ( Perry 3ed, fig.56, hal.3-794 )
CW = 1 ( Perry 3ed, fig.54, hal.3-794 )
C = 2 ( Perry 3ed, fig.48, hal.3-792 )
CH = 1.25 ( Perry 3ed, fig.55, hal.3-794 )
Maka dapat diperoleh :
122.6960 x 1
L =
2 x 12 x 1 x 1.25
= 4.0899 ft
Spesifikasi :
Nama : Cooling Tower
Tipe : Cross Flow Induced Draft Cooling Tower.
Tinggi : 35 ft
Panjang : 4.08987 ft
Jumlah deck : 12 buah
Bahan konstruksi : Kayu jati
Jumlah : 1 buah
Total air yang harus disupply dari water treatment 897.3312 m3 / hari
Kehilangan akibat jalur pipa dalam perjalanan, untuk faktor keamanan maka direncanakan
kebutuhan air sungai total :
= 1.1 x kebutuhan normal = 1.1 x 897.3312
= 987.0643 m3 / hari
= 41.1277 m3 / jam
= 41127.678 kg / jam
3. Clarifier H - 130
Fungsi = Memisahkan padatan dengan cara sedimentasi
Type = silinder tegak, tutup bawah conis
Dasar pemilihan = Umum digunakan untuk tekanan atmospheric
Perhitungan :
Volumentrik bahan : 41.1277 m3/jam
Direncanakan waktu pemisahan 3 jam dengan 1 buah tangki, maka volume tangki :
Volume = 41.1 x 3= 123.383 m3
Asumsi volume bahan mengisi 80% volume tangki, maka volume tangki :
Volume tangki : 123.383 / 0.8 = 154.229 m3
Tinggi conical :
h = tg α x ( D - dc) (Hesse, pers 4-17)
2
Keterangan : α = cone angle = 45o
D = diameter tangki = 5.09031 m
maka :
h = tg 45o x (D - 0,25) = 1.0000 x 4.84031 = 2.42016 m
2 2
Spesifikasi :
Fungsi = Memisahkan padatan dengan cara sedimentasi
Type = silinder tegak dan tutup bawah conis
Kapasitas = 154.229 m3
Diameter = 5.09031 m
Tinggi = 6.10837 m
Bahan konstruksi = Carbon stell SA-283 grade C
Jumlah = 1 buah
√
Diameter bed : A
= 1.550199 ft = 0.47 m
0.785
Tinggi lapisan dalam kolom, diasumsikan :
Lapisan Gravel = 0.3 m ( Sugiharto : 121 )
Lapisan Pasir = 0.7 m ( Sugiharto : 121 )
Tinggi air = 3.0 m ( Sugiharto : 121 )
Tinggi lapisan = 4.0 m
Kenaikan akibat back wash = 25% x 4.0 = 1 m
Tinggi total lapisan = 5.0 m
Spesifikasi :
Fungsi : Menyaring air partikel yang masih ada dari bak penampung air
jernih sekaligus menghilangkan warna dan rasa air sungai.
Kapasitas : 41 m3 / jam
Bentuk : bejana tegak
Diameter : 0.5 m
Tinggi : 5.0 m
Bahan konstruksi : Carbon Steel SA - 283 grade P
Jumlah : 1 buah
Spesifikasi :
Fungsi : Menampung air dari Sand Filter.
Kapasitas : 308.46 m3
Bentuk : Empat persegi panjang terbuka.
Ukuran : Panjang = 8.500532 m
Lebar = 8.500532 m
Tinggi = 4.250266 m
Bahan konstruksi : Beton
Jumlah : 1 buah
CARA KERJA :
Air dilewatkan pada kation exchanger yang berisi resin sehingga ion positif tertukar dengan resin.
Kebutuhan Zeolith = 70 x 10.9093 = 763.65 gr = 0.76365 kg
ρ Zeolith = 0.95 kg / liter ( Perry 6 ; T.16-4 )
ed
: 887 ). Kandungan ini sedianya dihilangkan dengan resin Aminio Poly Styrene bentuk butiran,
agar sesuai dengan syarat air boiler.
Kandungan CaCO3 : 5 grain/gal = 0.325 gr/gal ( 1 grain = 0,000065 kg )
Jumlah air yang diproses : 127.0516 m3
= 33567.04178 gallon
Jumlah CaCO3 dalam air : 0.325 x 33567.04178 = 10909.28857914 gr
Dipilih bahan pelunak :
APS dengan exchanger capacity = 5.5 ek / kg CaCO3 ( Perry 6ed, T.16-4 )
Amino Poly Styrenediharapkan mampu menukar semua ion CO3-2.
gram
ek ( ekuivalen ) = ( Underwood : 55 )
Berat Ekuivalen
BM
Berat Ekuivalen = ( Underwood : 51 )
Elektron
Untuk CaCO3, 1 mol CO3 melepas 2 elektron CO3-2, sehingga elektron = 2
BM CaCO3 = 100
100
Berat Ekuivalen = = 50 gr / ek
2
Berat Zeolith = ek x Berat Ekuivalen = 5.5 x 50 = 275 gr
Kapasitas Zeolith = 275 gr / kg
Jumlah CaCO3 = 10909.28858 gr = 10.91 kg
CARA KERJA :
Air dilewatkan pada kation exchanger yang berisi resin sehingga ion positif tertukar dengan resin.
Kebutuhan Zeolith = 275 x 10.9093 = 3000.05 gr = 3.00005 kg
Zeolith = 0.67 kg / liter ( Perry 6ed ; T.16-4 )
Volume Zeolith = 3.00005 / 0.67 = 4.47769 liter = 0.0044777 m3
Volume total = 127.05 + 0.00448 = 127.06 m3
Rate Volumetrik = 127.06 m3 / hari = 5.294 m3 / jam
Tangki kation berbentuk silinder dengan dimension ratio ; H / D 2
Volume = . D2 H = D2 . 2 D = 5.294 m3
4 4
Diameter = 1.4989 m
Tinggi = 3.00 m
Bahan konstruksi : Stainless steel plate type 316
Jumlah : 1 buah
Spesifikasi :
Fungsi : Menampung air lunak dari demineralizer.
Kapasitas : 6.6173 m3
Bentuk : empat persegi panjang terbuka.
Ukuran : Panjang = 2.364994 m
Lebar = 2.364994 m
Tinggi = 1.182497 m
Bahan konstruksi : Beton
Jumlah : 1 buah
UNIT REFIGERATOR
Air 86oC
Kondensor
X Air 105oC
Kompresor
Brine 68oC
Evaporator
Freon 12 Freon 12
53,6oC 53,6oC
Brine 41oC
Untuk mendinginkan brine digunakan freon 12 sebagai refrigerant. Aliran proses adalah
pada gambar diatas (Perry ed 6, fig 12-27)
Aliran dimulai dari titik X dimanacairan jenuh freon melalui expansion valve dari kondesor
Kemudian liquid refigerant ini menyerap panas di evaporator yang diberikan oleh larutan
brine, dimana larutan refigerant akan menjadi uap jenuh yang kemudian masuk ke kompresor
Disini gas ditekan dari tekanan rendah ke tekanan tinggi.
Uap jenuh yang bertekanan tinggi dan sudah mencapai temperatur kondensasi lalu masuk ke
kondesor, dana kan diserap panasnya oleh air pendingin.
Freon yang berbentuk liquid kemudian mengalir kembali ke evaporator.
Pada kondesor heat transfer area yang terjadi perbedaan temperatur 10oF antara suhu
air keluar kondensor dengan suhu kondensasi freon 12 (Perry ed 6, p 12-35)
1. Evaporator Freon - 12
Freon - 12 (l) T1 = 12oc = 53,6oF
Evaporator
t1 = 20oC = 68oF t2 = 5oC = 41oF
1. Neraca panas :
2. Penentuan t
3. Tc dan tc
Trial :
Dipakai NT = 279
sehingga :
= 50
2. Kondensor Freon - 12
Freon - 12 (g) T1 = 46oc =115oF
Kondensor
t1 = 30oC = 86oF t2 = 40,556oC = 105oF
1. Neraca panas :
2. Penentuan t
T LMTD = 29 - 10 = 17.84 oF
ln [ 29 / 10 ]
3. Tc dan tc
Tc = [ 115 + 115 ] / 2= 115 o
F
tc = [ 105 + 86 ] / 2= 95.5 o
F
Trial :
Dipakai NT = 264
sehingga :
= 40
3. Kompresor
Fungsi : Menaikkan tekana freon 12 dari evporator (29 psia) menuju kondensor
Jenis : Reciprocating
P1 : T1 P2 : T2
Kompresor
P1 = 29 psi
T1 = 53.6 oF = 285.1500 oK
T2 = 115 oF = 319.2611 oK
P2 = ?
Cp = 0.15 Btu/lboF = 18.15 kcal/kmoloK
R = 1.987 kcal/kmoloK
T2 = T1 (P2/P1)R/Cp
P2 = 81.4 psia
ρ = 0.826 lb/cuft
w = 68561.42 lb/jam
Perhitungan Power :
Hp = 0,0044 Q x P1 x ln(P2/P1) (Perry ed 6. pers 6-31)
= 0.0044 x 23.05670674 x 29 x ln(81,4/29)
= 231.25 Hp
24.0977 1
= x = 2.89 ft/dt
0.139 60
dengan : μ = 0.00085 lb/ft dt
DV 0.4206 x 2.89 x 62.5
NRe = =
0.00085
= 89352.08828 > 2100 ( asumsi benar )
Dipilih pipa Commercial steel ( e = 0.00015 )
e / D = 0.000357
f = 0.006 ( Mc.Cabe ed 5 hal 88)
Digunakan persamaan Bernoully :
DP g DV2
- Wf = + DZ + + Σ F
gc 2 x α x gc
Asumsi ΔZ = 32 ft
Persamaan Bernoully :
DP g DV2
- Wf = + DZ + + Σ F
gc 2 x α x gc
= 0 + 32 + 0.129638 + 1.9297
ft . lbf
= 34.0593
lbm
- Wf x flowrate ( cuft/dt) x ρ
hp = ( Perry 6ed, pers.6-11,hal.6-5)
hp = ( Perry 6ed, pers.6-11,hal.6-5)
550
34.05934 x 0.40163 x 62.5
=
550
= 1.554452 hp
Kapasitas = 0.40163 x 60 x 7.4805 = 180.263 gpm
Effisiensi pompa = 90% (Peters&Timmerhaus,4ed,fig. 14-37)
hp 1.554452
Bhp = = = 1.72717 hp
h pompa 90%
Effisiensi motor = 91% (Peters&Timmerhaus,4ed,fig. 14-38)
Bhp 1.727169
Power motor = = = 1.89799 ~ 2 hp
h motor 91%
Spesifikasi :
Fungsi : Mengalirkan bahan dari sungai ke bak penampung air sungai
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 25.1017 gpm
Total Dynamic Head : 34.0593 ft lbf / lbm
Effisiensi motor : 91%
Power : 2 hp
Jumlah : 1 buah
Perhitungan :
ρ air = 62.5 lb/cuft
Bahan masuk = 40989.49 kg/ jam = 25.1017 lb/dt = 0.4016278 cuft/dt
Asumsi aliran turbulen :
Di optimum untuk aliran turbulen, Nre > 2100, digunakan persamaan :
Diameter Optimum = 3.9 x qf 0.45 0.1 (Peters&Timmerhaus,4ed,pers +15)
x
dengan : qf = fluid flow rate ; cuft/dt (cfs )
= fluid density ; lb/cuft
Diameter pipa optimum = 4.4284 in
Dipilih pipa 5 in, sch 40 ( Brownel & Young appndx K hal 389) )
OD = 5.563 in
ID = 5.047 in = 0.4206 ft
A = 0.139 ft 2
24.0977 1
= x = 2.889 ft/dt
0.139 60
dengan : μ = 0.00085 lb/ft dt
DVρ 0.4206 x 2.889 x 62.5
NRe = =
μ 0.00085
= 89352.08828 > 2100 ( asumsi benar )
Dipiih pipa Commercial steel ( e = 0.00015 )
e / D = 0.000357 ( Mc.Cabe ed 5 hal 88)
f = 0.006
Asumsi DZ = 13 ft
Persamaan Bernoully :
DP g DV2
- Wf = + DZ + + Σ F
gc 2 x α x gc
= 0 + 13 + 0.129638 + 1.94266
ft . lbf
= 14.9709
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp = ( Perry 6ed, pers.6-11,hal.6-5)
550
14.97087 x 0.40163 x 62.5
=
550
= 0.683263 hp
Kapasitas = 0.40163 x 60 x 7.4805 = 180.263 gpm
Effisiensi pompa = 90% (Peters&Timmerhaus,4ed,fig. 14-37)
hp 0.683263
Bhp = = = 0.75918 hp
h pompa 90%
Effisiensi motor = 91% (Peters&Timmerhaus,4ed,fig. 14-38)
Bhp 0.759181
Power motor = = = 0.834 ~ 1 hp
h motor 91%
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak air sungai ke bak koagulasi - flokulasi
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 25.1017 gpm
Total Dynamic Head : 14.9709 ft lbf / lbm
Effisiensi motor : 91%
Power : 1 hp
Jumlah : 1 buah
Perhitungan :
ρ air = 62.5 lb/cuft
Bahan masuk = 40989.49 kg/ jam = 25.1017 lb/dt = 0.4016278 cuft/dt
Asumsi aliran turbulen :
Di optimum untuk aliran turbulen, Nre > 2100, digunakan persamaan :
Diameter Optimum = 3.9 x qf 0.45 x 0.1 (Peters&Timmerhaus,4ed,pers 15)
dengan : qf = fluid flow rate ; cuft/dt (cfs )
= fluid density ; lb/cuft
Diameter pipa optimum = 4.4284 in
Dipilih pipa 5 in, sch 40 ( Brownel & Young appndx K hal 389) )
OD = 5.563 in
ID = 5.047 in = 0.4206 ft
A = 0.139 ft2
rate volumetrik cuft/mnt 1
Kecepatan aliran, V = x
Kecepatan aliran, V = x
Area pipa ft2 60 dt/mnt
24.0977 1
= x = 2.889 ft/dt
0.139 60
dengan : μ = 0.00085 lb/ft dt
DVρ 0.4206 x 2.889 x 62.5
NRe = =
μ 0.00085
= 89352.08828 > 2100 ( asumsi benar )
Dipiih pipa Commercial steel ( e = 0.00015 )
e / D = 0.000357 ( Mc.Cabe ed 5 hal 88)
f = 0.006
Asumsi DZ = 20 ft
Persamaan Bernoully :
DP g DV2
- Wf = + DZ + + Σ F
gc 2 x α x gc
= 0 + 20 + 0.129638 + 1.94266
ft . lbf
= 21.6191
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp = ( Perry 6ed, pers.6-11,hal.6-5)
550
21.61909 x 0.40163 x 62.5
=
550
= 0.986685 hp
Kapasitas = 0.40163 x 60 x 7.4805 = 180.263 gpm
Effisiensi pompa = 90% (Peters&Timmerhaus,4ed,fig. 14-37)
hp 0.986685
Bhp = = = 1.09632 hp
h pompa 90%
Effisiensi motor = 92% (Peters&Timmerhaus,4ed,fig. 14-38)
Bhp 1.096317
Power motor = = = 1.192 ~ 1.5 hp
h motor 92%
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak air sungai ke bak koagulasi - flokulasi
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 25.1017 gpm
Total Dynamic Head : 21.6191 ft lbf / lbm
Effisiensi motor : 92%
Power : 1.5 hp
Jumlah : 1 buah
Perhitungan :
air = 62.5 lb/cuft
Bahan masuk = 10247.372 kg/ jam = 6.2754 = lb/dt = 0.10041 cuft/dt
Asumsi DZ = 16 ft
Persamaan Bernoully :
DP g DV2
- Wf = + DZ + + Σ F
gc 2 x α x gc
= 0 + 16 + 0.008102 + 0.12142
ft . lbf
= 16.1295
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp = ( Perry 6ed, pers.6-11,hal.6-5)
550
16.12952 x 0.10041 x 62.5
=
550
= 0.184036 hp
Kapasitas = 0.10041 x 60 x 7.4805 = 45.0656 gpm
Effisiensi pompa = 90% (Peters&Timmerhaus,4ed,fig. 14-37)
hp 0.184036
Bhp = = = 0.20448 hp
h pompa 90%
Effisiensi motor = 87% (Peters&Timmerhaus,4ed,fig. 14-38)
Bhp 0.204484
Power motor = = = 0.23504 ~ 0.25 hp
h motor 87%
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak penampung air jernih ke sand filter
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 6.27543 gpm
Total Dynamic Head : 16.1295 ft lbf / lbm
Effisiensi motor : 87%
Power : 0.25 hp
Jumlah : 1 buah
Perhitungan :
air = 62.5 lb/cuft
Bahan masuk = 992.6950 kg/ jam = 0.60792 lb/dt = 0.00972673 cuft/dt
Asumsi aliran turbulen :
Di optimum untuk aliran turbulen, Nre > 2100, digunakan persamaan :
Diameter Optimum = 3.9 x qf 0.45 x 0.1 (Peters&Timmerhaus,4ed,pers 15)
dengan : qf = fluid flow rate ; cuft/dt (cfs )
= fluid density ; lb/cuft
F = F1 + F2 + F3
= 1.49112 + 0.0204 + 0.04081 = 1.55233 ft . lbf / lbm
P1 = 1 atm = 2116.8 lbf / ft2 ( 1 atm = 14.7 x 144 lbf / ft2 )
P2 = 1 atm = 2116.8 lbf / ft2 ( 1 atm = 14.7 x 144 lbf / ft2 )
DP lbf / ft2 ft . lbf
DP = P2 - P1 = 0 lbf / ft2; = 0 = 0
lbm / ft 3
lbm
V2 1.6211 2 ft . lbf
= = 0.04081
2 x α x gc 2 x 1 x 32.2 lbm
Asumsi DZ = 10 ft
Persamaan Bernoully :
DP g DV2
- Wf = + DZ + + F
gc 2 x α x gc
= 0 + 10 + 0.040808 + 1.55233
ft . lbf
= 11.5931
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp = ( Perry 6ed, pers.6-11,hal.6-5)
550
11.59314 x 0.00973 x 62.5 = 0.01281 hp
=
550
Kapasitas = 0.00973 x 60 x 7.4805 = 4.36565 gpm
Effisiensi pompa = 40% (Peters & Timmerhaus,4ed,fig. 14-37)
hp 0.012814
Bhp = =
= 0.03204 hp
h pompa 40%
Effisiensi motor = 80% (Peters&Timmerhaus,4ed,fig. 14-38)
Bhp 0.032035
Power motor = = = 0.04004 ~ 0.25 hp
h motor 80%
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak air bersih ke bak penamp. air sanitasi
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 992.695 gpm
Total Dynamic Head : 11.5931 ft lbf / lbm
Effisiensi motor : 80%
Power : 0.25 hp
Jumlah : 1 buah
Perhitungan :
air = 62.5 lb/cuft
Bahan masuk = 5276.031 kg/ jam = 3.2310 lb/dt = 0.05169619 cuft/dt
Asumsi aliran turbulen :
Di optimum untuk aliran turbulen, Nre > 2100, digunakan persamaan :
Diameter Optimum = 3.9 x qf 0.45 x 0.1 (Peters&Timmerhaus,4ed,pers 15)
dengan : qf = fluid flow rate ; cuft/dt (cfs )
= fluid density ; lb/cuft
Diameter pipa optimum = 1.7603 in
Dipilih pipa 2 in, sch 80 ( Mc.Cabe app.6)
OD = 2.375 in
ID = 2.067 in = 0.1722 ft
A = 0.0233 ft2
ft . lbf
= 0.03822
lbm
3. Friksi karena enlargement ( ekspansi ) dari pipa ke tangki
V2 DV22 - DV12
F3 = = a= 1 untuk aliran turbulen
2 x α x gc 2 x α x gc
2.2187 2 - 0 2 ft . lbf
= = 0.07644
2 x 1 x 32.2 lbm
( V1 <<<< V2, maka V1 dianggap = 0 )
F = F1 + F2 + F3
= 1.56946 + 0.03822 + 0.07644 = 1.68412 ft . lbf / lbm
Asumsi DZ = 10 ft
Persamaan Bernoully :
DP g DV2
- Wf = + DZ + + Σ F
gc 2 x α x gc
= 0 + 10 + 0.07644 + 1.68412
ft . lbf
= 11.7606
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp = ( Perry 6ed, pers.6-11,hal.6-5)
550
11.76056 x 0.0517 x 62.5 = 0.06909 hp
=
550
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak air bersih ke kation - anion exchanger
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 3.23101 gpm
Total Dynamic Head : 11.7606 ft lbf / lbm
Effisiensi motor : 80%
Power : 0.25 hp
Jumlah : 1 buah
ft . lbf
= 1.52E-06
lbm
3. Friksi karena enlargement ( ekspansi ) dari pipa ke tangki
V2 DV22 - DV12
F3 = = a= 1 untuk aliran turbulen
2 x α x gc 2 x α x gc
0.0140 2 - 0 2 ft . lbf
= = 3E-06
2 x 1 x 32.2 lbm
( V1 <<<< V2, maka V1 dianggap = 0 )
F = F1 + F2 + F3
= 6.2E-05 + 1.5E-06 + 3E-06 = 6.7E-05 ft . lbf / lbm
Asumsi DZ = 10 ft
Persamaan Bernoully :
DP g DV2
- Wf = + DZ + + Σ F
gc 2 x α x gc
= 0 + 10 + 3.03E-06 + 6.7E-05
ft . lbf
= 10.0001
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp = ( Perry 6ed, pers.6-11,hal.6-5)
550
10.00007 x 0.00033 x 62.5 = 0.00037 hp
=
550
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak air bersih ke kation - anion exchanger
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 0.02034 gpm
Total Dynamic Head : 10.0001 ft lbf / lbm
Effisiensi motor : 80%
Power : 0.25 hp
Jumlah : 1 buah
Perhitungan :
air = 62.5 lb/cuft
Bahan masuk = 2793.3125 kg/ jam = 1.71061 lb/dt = 0.0273697 cuft/dt
V2 1.1747 2 ft . lbf
= = 0.02143
2 x α x gc 2 x 1 x 32.2 lbm
Asumsi DZ = 10 ft
Persamaan Bernoully :
DP g DV2
- Wf = + DZ + + Σ F
gc 2 x α x gc
= 0 + 10 + 0.021426 + 0.47206
ft . lbf
= 10.4935
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp = ( Perry 6ed, pers.6-11,hal.6-5)
550
10.49349 x 0.02737 x 62.5
=
550
= 0.010879 hp
Kapasitas = 0.02737 x 60 x 7.4805 = 12.284 gpm
Effisiensi pompa = 40% (Peters&Timmerhaus,4ed,fig. 14-37)
hp 0.010879
Bhp = = = 0.0272 hp
Bhp = = = 0.0272 hp
h pompa 40%
Effisiensi motor = 80% (Peters&Timmerhaus,4ed,fig. 14-38)
Bhp 0.027197
Power motor = = = 0.034 ~ 0.25 hp
h motor 80%
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak air bersih ke bak air proses
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 1.71061 gpm
Total Dynamic Head : 10.4935 ft lbf / lbm
Effisiensi motor : 80%
Power : 0.3 hp
Jumlah : 1 buah
Perhitungan :
air = 62.5 lb/cuft
Bahan masuk = 31098.93842 kg/ jam = 19.04481712 lb/dt = 0.3047171 cuft/dt
Asumsi aliran turbulen :
Di optimum untuk aliran turbulen, Nre > 2100, digunakan persamaan :
Diameter Optimum = 3.9 x qf 0.45 x 0.1 (Peters&Timmerhaus,4ed,pers 15)
dengan : qf = fluid flow rate ; cuft/dt (cfs )
= fluid density ; lb/cuft
Diameter pipa optimum = 3.9110 in
Dipilih pipa 5 in, sch 40 ( Brownel & Young appndx K hal 389) )
OD = 5.563 in
ID = 5.047 in = 0.4206 ft
A = 0.139 ft2
Asumsi DZ = 10 ft
Persamaan Bernoully :
DP g DV2
- Wf = + DZ + + Σ F
gc 2 x α x gc
= 0 + 10 + 0.074624 + 1.11826
ft . lbf
= 11.1929
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp = ( Perry 6ed, pers.6-11,hal.6-5)
550
11.19289 x 0.30472 x 62.5
=
550
= 0.129192 hp
Kapasitas = 0.30472 x 60 x 7.4805 = 136.766 gpm
Effisiensi pompa = 90% (Peters&Timmerhaus,4ed,fig. 14-37)
hp 0.129192
Bhp = =
= 0.14355 hp
h pompa 90%
Effisiensi motor = 86% (Peters&Timmerhaus,4ed,fig. 14-38)
Bhp 0.143546
Power motor = = = 0.16691 ~ 0.25 hp
h motor 86%
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak penampung air jernih ke bak air pendingin
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 19.0448 gpm
Total Dynamic Head : 11.1929 ft lbf / lbm
Effisiensi motor : 86%
Power : 0.25 hp
Jumlah : 1 buah
Perhitungan :
air = 62.5 lb/cuft
Bahan masuk = 31098.93842 kg/ jam = 19.04481712 lb/dt = 0.3047171 cuft/dt
Asumsi aliran turbulen :
Di optimum untuk aliran turbulen, Nre > 2100, digunakan persamaan :
Diameter Optimum = 3.9 x qf 0.45 x 0.1 (Peters&Timmerhaus,4ed,pers 15)
dengan : qf = fluid flow rate ; cuft/dt (cfs )
= fluid density ; lb/cuft
Asumsi DZ = 10 ft
Persamaan Bernoully :
DP g DV2
- Wf = + DZ + + 0 F
gc 2 x α x gc
= 0 + 10 + 0.074624 + 1.09851
ft . lbf
= 11.1731
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp = ( Perry 6ed, pers.6-11,hal.6-5)
550
11.17314 x 0.30472 x 62.5
=
550
= 0.128964 hp
Kapasitas = 0.30472 x 60 x 7.4805 = 136.766 gpm
Effisiensi pompa = 90% (Peters&Timmerhaus,4ed,fig. 14-37)
hp 0.128964
Bhp = =
= 0.14329 hp
h pompa 90%
Effisiensi motor = 86% (Peters&Timmerhaus,4ed,fig. 14-38)
Bhp 0.143293
Power motor = = = 0.16662 ~ 0.25 hp
h motor 86%
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak penampung air jernih ke bak air pendingin
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 19.0448 gpm
Total Dynamic Head : 11.1731 ft lbf / lbm
Effisiensi motor : 86%
Power : 0.25 hp
Jumlah : 1 buah
Perhitungan :
air = 62.5 lb/cuft
Bahan masuk = 31098.93842 kg/ jam = 19.04481712 lb/dt = 0.3047171 cuft/dt
Asumsi aliran turbulen :
Di optimum untuk aliran turbulen, Nre > 2100, digunakan persamaan :
Diameter Optimum = 3.9 x qf 0.45 x 0.1 (Peters&Timmerhaus,4ed,pers 15)
dengan : qf = fluid flow rate ; cuft/dt (cfs )
= fluid density ; lb/cuft
Asumsi DZ = 10 ft
Persamaan Bernoully :
DP g DV2
- Wf = + DZ + + 0 F
gc 2 x α x gc
= 0 + 10 + 0.074624 + 1.09851
ft . lbf
= 11.1731
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp = ( Perry 6ed, pers.6-11,hal.6-5)
550
11.17314 x 0.30472 x 62.5
=
550
= 0.128964 hp
Kapasitas = 0.30472 x 60 x 7.4805 = 136.766 gpm
Effisiensi pompa = 90% (Peters&Timmerhaus,4ed,fig. 14-37)
hp 0.128964
Bhp = =
= 0.14329 hp
h pompa 90%
Effisiensi motor = 86% (Peters&Timmerhaus,4ed,fig. 14-38)
Bhp 0.143293
Power motor = = = 0.16662 ~ 0.25 hp
h motor 86%
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak penampung air jernih ke bak air pendingin
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 19.0448 gpm
Total Dynamic Head : 11.1731 ft lbf / lbm
Effisiensi motor : 86%
Power : 0.25 hp
Jumlah : 1 buah
Perhitungan :
air = 62.5 lb/cuft
Bahan masuk = 2491.088424 kg/ jam = 1.525528712 lb/dt = 0.0244085 cuft/dt
Asumsi aliran turbulen :
Di optimum untuk aliran turbulen, Nre > 2100, digunakan persamaan :
Diameter Optimum = 3.9 x qf 0.45 x 0.1 (Peters&Timmerhaus,4ed,pers 15)
dengan : qf = fluid flow rate ; cuft/dt (cfs )
= fluid density ; lb/cuft
Asumsi DZ = 10 ft
Persamaan Bernoully :
DP g DV2
- Wf = + DZ + + 15 F
gc 2 x α x gc
= 0 + 10 + 0.017041 + 0.37544
ft . lbf
= 10.3925
lbm
- Wf x flowrate ( cuft/s ) x ρ
hp = ( Perry 6ed, pers.6-11,hal.6-5)
550
10.39248 x 0.02441 x 62.5
=
550
= 0.009608 hp
Kapasitas = 0.02441 x 60 x 7.4805 = 10.9552 gpm
Effisiensi pompa = 90% (Peters&Timmerhaus,4ed,fig. 14-37)
hp 0.009608
Bhp = =
= 0.01068 hp
h pompa 90%
Effisiensi motor = 86% (Peters&Timmerhaus,4ed,fig. 14-38)
Bhp 0.010676
Power motor = = = 0.01241 ~ 0.25 hp
h motor 86%
Spesifikasi :
Fungsi : Mengalirkan bahan dari bak penampung air jernih ke bak air pendingin
Tipe : Centrifugal Pump
Bahan : Commercial Steel
Rate volumetrik : 1.52553 gpm
Total Dynamic Head : 10.3925 ft lbf / lbm
Effisiensi motor : 86%
Power : 0.25 hp
Jumlah : 1 buah
Untuk penerangan daerah proses, daerah perluasan, daerah utilitas, daerah bahan baku,
deerah produk, tempat parkir, bengkel, gudang, jalan dan taman digunakan merkury 250 watt.
Untuk lampu merkury 250 watt mempunyai Lumen Output = 166666.6666667 lumen.
Jumlah lampu merkury yang dibutuhkan :
No LOKASI Lumen / m2
1 RUANG PROSES 3627360
2 DAERAH PERLUASAN 100760
3 UTILITAS 302280
4 STORAGE BAHAN BAKU 906840
5 STORAGE PRODUK 503800
6 PARKIR 503800
7 BENGKEL 629750
8 GUDANG 629750
9 JALAN ASPAL 629750
10 TAMAN 403040
Merkury 250 watt = 166667,6667 lumen 13068572
Jumlah lampu 78
Spesifikasi :
Fungsi : Pembangkit tenaga listrik.
Kapasitas : 1253.0603956 kVA
Power factor : 0.8
Bahan bakar : Minyak diesel.
Kebutuhan bahan bakar : 118.389 liter / jam
Jumlah : 2 buah ( 1 cadangan )
Spesifikasi :
Nama alat : Tangki Penyimpan Bahan Bakar.
Tipe : Standard Vessel API Standard 12-D ( 100,101 )
Kapasitas nominal : 2000 bbl
Diameter : 29 in
Tinggi : 16 ft
Bahan konstruksi : Carbon Steel SA-283 grade C
Jumlah : 1 buah
+
bagai unit
17912988.530975
0.2
ton /
watt.
APPENDIX D
Harga Peralatan berubah menurut waktu resmi sesuai dengan kondisi ekono-
mi dunia. Untuk memperkirakan harga peralatan saat ini, digunakan indeks se-
Dengan :
Design & Economics for Chemical Engineering". Sedangkan cost indeks ber-
dasarkan Marshall and swift (All Industry), Chemical Engineering, Mei 2003,
tabel D-1.
Tahun Indeks
1996 1039.1
1997 1056.8
1998 1061.9
1999 1068.3
2000 1089
2001 1093.9
2002 1104.2
2003 1123.6
2004 1178.5
2005 1244.5
No. X Y X2 Y2 XY
1. 1996 1039.1 3984016 1,079,728.81 2,074,043.60
2. 1997 1056.8 3988009 1,116,826.24 2,110,429.60
n S XY - SXSY SY - aSX
a = b =
n S X 2 - ( S X )2 n
15608.00 -367410.55151588
a = b =
825.00 10
= 18.9188 = -36741.0552
Persamaan umum : Y = ax + b
Y = 1,266.7897
Ip
Cp,v = x Co,v
Ir
Pompa ( L -121 )
Harga (2009 )
1,266.7897
Cp,v = x 1,500
1,104.20
= US $ 1,721
1,664,46
26 Refrigerator 1 279,207
Total 916,262
= US $ 2,580,724
= Rp 29,678,327,942 ( 1 US $ = 11,500
127 249,750,000
= Rp. 3,246,750,000
= Rp. 7,452,456,677
= Rp. 227,681,317
= Rp. 68,304,395,139
= Rp. 343,283
Biaya BaS/tahun = Rp. 343,283 x 300
= Rp. 102,985,019
d. Glue = 1 kg/jam
= Rp. 10,800,000
Jadi total harga bahan baku = Rp. 75,870,636,834
a. Al2(SO4)3
= Rp. 150,000,000
a. Air
= Rp. 134,599,673
b. Bahan Bakar
d.. Listrik
= Rp. 601,469
2,121,676.20
2,135,531.70
2,178,000.00
2,188,893.90
2,210,608.40
2,250,570.80
2,361,714.00
2,495,222.50
22,126,690.70
, 5th ed., fig.12-23)
5,000
21,028
184,326
19,181
3,442
164,221
6,052
1,128
150,681
9,642
26,874
3,442
4,589
149,142
19,181
3,442
4,589
48,415
1,721
14,668
35,593
1,721
79,905
17,335
80,307
1,147
10,325
10,325
48,312
80,307
1,721
244,229
54,980
3,442
4,589
108,988
19,181
3,442
17,848
1,664,463
arga ($)
6,883
1,500
6,883
1,500
6,883
52,000
1,500
3,442
22,945
1,500
3,442
25,000
3,442
25,000
1,500
2,524
244,229
2,753
2,180
1,500
2,983
1,500
2,983
2,983
210,000
279,207
916,262
11,500 )
Jumlah Gaji
( Rp )
15,000,000
12,500,000
10,000,000
2,000,000
8,500,000
8,500,000
4,000,000
4,000,000
4,000,000
4,000,000
4,000,000
4,000,000
4,000,000
3,500,000
3,000,000
3,000,000
3,000,000
3,000,000
3,000,000
3,000,000
3,000,000
3,000,000
3,000,000
3,000,000
3,000,000
3,000,000
37,500,000
10,000,000
3,750,000
5,000,000
20,000,000
3,750,000
6,250,000
6,250,000
3,750,000
10,000,000
3,750,000
3,750,000
6,000,000
4,000,000
2,000,000
249,750,000
24
24
24
300
BAB XI
ANALISA EKONOMI
ting, karena dengan perhitungan ekonomi ini dapat diketahui apakah pabrik
3. Pendapatan total
Untuk mengetahui besar tidaknya titik impas, maka perlu diadakan penaf-
siran terhadap :
a. Biaya tetap
b. Biaya semi tetap
c. Biaya variabel
harga. Perhitungan harga alat dapat dilihat pada tabel D.1., pada appendix D.
Fixed Capital Investment (FCI) = Direct Cost (DC) + Indirect Cost (IC)
FCI = Rp. 81,157,863,273 + 17,065,038,566.49
Biaya Overhead
= Rp. 110,616,697,554
4. Kapasitas Produksi
Tahun ke - I = 80%
sebesar 10% dari modal pinjaman untuk keperluan pembelian tanah dan
modal pinjaman.
7. Laju inflasi = 10%
Besarnya biaya operasi untuk kapasitas produksi yang lain dapat dilihat pada
tabel berikut :
Tabel XI.1 Biaya Total Produksi Dalam Berbagai Kapasitas
80% 83,495,651,202
100% 104,369,564,002
100% 104,369,564,002
Investasi pabrik tergantung pada masa konstruksi seperti ditunjukkan pada tabel
100
-2 82,631,818,436 8263181844 8,263,181,844
Metode ini menghitung tingkat bunga yang menyamakan nilai sekarang in-
vestasi dengan nilai sekarang penerimaan kas bersih yang akan datang.
10
∑ =C F = Modal sendiri
n −1 ( i +1 )n
TRIAL i
i = 20 % i = 60 %
Tahun Cash Flow
Disc. Discounted Disc. Discounted
Modal : 60,675,363,823
17,756,768,185 x - 0.6
=
73,967,177,450 -0.4
x = 0.503974878
Dari perhitungan diatas diperoleh harga i = 50% per tahun. Harga i yang
diperoleh lebih besar dari pada harga i yang ditetapkan untuk bunga pinjaman
yaitu 20.0% . Hal ini membuktikan bahwa pabrik ini layak untuk didiri-
TRIAL i
i = 20 % i = 60 %
Tahun Net Cash Flow
Disc. Discounted Disc. Discounted
modal : 18,179,000,056
Dari perhitungan diatas diperoleh harga i = ### per tahun. Harga i yang
diperoleh lebih besar dari pada harga i yang ditetapkan untuk bunga pinjaman
yaitu 20.0% . Hal ini membuktikan bahwa pabrik ini layak untuk di-
1 21,428,600,993 21,428,600,993
2 27,913,010,402 49,341,611,395
3 28,465,463,131 77,807,074,526
4 29,017,915,860 106,824,990,386
5 29,570,368,589 136,395,358,975
6 30,122,821,318 166,518,180,293
7 30,675,274,047 197,193,454,340
8 31,227,726,776 228,421,181,116
9 31,780,179,505 260,201,360,621
10 32,332,632,234 292,533,992,855
Y −Y 1 X −X 1
=
Y 2 −Y 1 X 2 −X 1
Maka :
TCI = 118,045,454,909
Y2 - Y1 = 29,570,368,589
Y - Y1 = 11,220,464,523
X2 - X1 = 1
X = 3.3794
Analisa untuk titik impas digunakan untuk mengetahui posisi kapasitas dima-
1. Biaya variabel ( Cv )
Maka,
0.3 Csv + FC
BEP =
S - 0.7 Csv - Cv
= 0.452519
0 18 24 0
1000
F
C
800
T
C
600 S
B
400 E
P
200
0
0 10 20 30 40 50 60 70 80 90 100
Kapasitas Produksi
(%)
42,496,363,767
4,249,636,377 38,246,727,391 120,000,000,000 83,495,651,202 9,122,290,184
4,249,636,377 33,997,091,014 150,000,000,000 104,369,564,002 9,122,290,184
4,249,636,377 29,747,454,637 150,000,000,000 104,369,564,002 9,122,290,184
4,249,636,377 25,497,818,260 150,000,000,000 104,369,564,002 9,122,290,184
4,249,636,377 21,248,181,884 150,000,000,000 104,369,564,002 9,122,290,184
4,249,636,377 16,998,545,507 150,000,000,000 104,369,564,002 9,122,290,184
4,249,636,377 12,748,909,130 150,000,000,000 104,369,564,002 9,122,290,184
4,249,636,377 8,499,272,753 150,000,000,000 104,369,564,002 9,122,290,184
4,249,636,377 4,249,636,377 150,000,000,000 104,369,564,002 9,122,290,184
4,249,636,377 0 150,000,000,000 104,369,564,002 9,122,290,184
uksi Total Penghasilan / keuntungan
Cash flow
Bunga Sebelum pajak Pajak Setelah pajak
17,178,964,617
23,663,374,025
24,215,826,754
24,768,279,483
25,320,732,212
25,873,184,941
26,425,637,670
26,978,090,399
27,530,543,128
28,082,995,857
A. Biaya Langsung (Direct Cost) normalized percentage o
Fixed Capital Investment (FCI) = Direct Cost (DC) + Indirect Cost (IC)
30 74195819854.2874
6
9
10