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ANALISIS PROSES TEKNIK KIMIA

DOSEN :

DR.-ING ANTON IRAWAN, ST.,MT

SRI AGUSTINA, ST., MT., ME., PHD

MATERI KULIAH
1. Pengantar analisis proses industry kimia dan 1. Analisis alat penukar kalor
struktur diagram alir proses industry kimia (proses dan integrasi alat
2. Analisa neraca massa dan energy pada proses)
industry kimia 2. Analisis proses Reaktor
3. Analisis bahan baku dan produk industry 3. Analisis proses di Unit
kimia Pemisahan (distilasi,
4. Analisis kondisi proses pada industry kimia absorber, ekstraktor)
5. Analisis tanki dan bejana proses pada 4. Analisa ekonomi pada
industry kimia system proses
6. Analisis proses system perpipaan pada 5. Optimasi proses industry
industry kimia kimia
7. Analisis proses alat transportasi fluida
(pompa dan kompresor) pada industry kimia

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Daftar Buku Referensi

■ Seider, W.D., Lewin, D.R., Seader, J.D., Widagdo, S., Gani, R., NG K.A.,
Product and Process Design Princples”, John Wiley, Fourth Edition,
2017
■ Turton, R., Shaeiwitz, J.A., Bhattacharyya, D., Whiting, W.B.,” Analysis,
Synthesis, and Design of Chemical Processes”, Prentice Hall, Fifith
Edition, 2018
■ Martin, M.M.,”Industrial Chemical Process Analysis and
Design”Elsevier, 2016
■ Felder, R.M., Rousseau, R.W., Bullard, L.G.,” Elementary Principles of
Chemical Processes” Wiley, Fourth edition, 2016
■ Smith, R.,” Chemical Process- Design and Integration”, Second
Edition, Wiley, 2016

Penilaian
■ Tugas 40%
■ Kuis 10%
■ UTS 25%
■ UAS 25%
■ T = Belum Memenuhi Seluruh Komponen Penilaian. Batas
Waktu Memenuhi 2 Minggu stlh UAS
■ K = Tidak Mengikuti 4 Kali Tatap Muka Perkuliahan

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Pengantar Analisis Proses Industri

Kimia dan Struktur Diagram Alir
Proses Industri Kimia

(INTRODUCTION & PROCESS FLOW DIAGRAMS)

Chemists vs Chemical Engineers

Chemists Chemical Engineers

 Design reaction  Design a process to

pathways to produce scale the chemist’s
a chemical from raw process to mass
materials produce the product

 Work in the laboratory  Work in a chemical

setting to produce plant to produce
material on the gram material in the ton and
to kilogram scale beyond range

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Molecules that Chemicals Engineers work with

■ Small and Simple
Helium (He)
Ammonia (NH3)
Hydrogen Flouride (HF)
Trinitrotoluene (C6H2(NO2)3CH3)
■ Large and Complicated
Insulin C257H383N65O77S6
■ Large and Simple
Polyvinyl Chloride (-CH2-CHCl-)n

How to Produce Chemicals

■ Two methods to obtain a desired chemical

– Design a reactor to produce a chemical from raw

materials

– To isolate the compound that exists in combination

with other substances through separation processes

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Chemical Reactions

Reactor
Products
Raw Raw
Materials Materials
Energy Byproducts
Catalysts Energy
Catalysts

Separations
Exploits differences of material properties
■ Molecular Property ■ Separation Process
– Boiling Point – Distillation
– Freezing Point – Crystallization
– Particle size – Filtration
– Affinity to a stationary phase – Chromatography
– Density – Centrifuge
– Selective affinity to solid – Adsorption
particles

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Separations: Unit Operations

■ Use separation Most common types:
processes to: • Distillation
• Purify raw • Flash distillation
materials • Batch distillation
• Purify products • Column distillation
• Purify and • Absorption
separate • Stripping
unreacted feed. • Extraction
• Chromatography

Mass and Energy Balances

Balance Equation
Input + generation – Output = Accumulation

Control
Volume

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Mass and Energy Balances

■ For non-reacting systems
Generation = 0
■ For systems operated at steady state
Accumulation = 0

Mass and Energy Balances reduce to :

Input = Output

Diagrams for understanding chemical

process
■ As visual information, to present material and is least likely
to be misinterpreted
■ The most effective way of communicating information about
a process
■ Design is an evolutionary process:

Input/output diagram → Generic diagram → BFD → PFD → P&ID.

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■ Input/output is a crude block flow diagram in which only

feed and product streams are identified.

■ Generic Diagram Break the process into its basic elements

such as reaction and separation , and recycle sections.

■ BFD include the material balance calculations.

■ PFD complete mass and energy balance and preliminary

equipment specs.

■ P&ID includes the mechanical and instrumentation details.

3 Main Levels of Diagrams

Block Flow Diagram (BFD)

Process Flow Diagram (PFD)

Piping and Instrumentation Diagram (P&ID) –
often referred to as Mechanical Flow Diagram

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BFD Level of
Conceptual
Level of Understanding
Complexity Increases
Increases
PFD

P&ID

The Block Flow Diagram (BFD)

Shows overall processing picture of a chemical

complex

Useful as an orientation tool

Used to sketch out and screen potential process

alternatives.

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■ Block Flow Process Diagram (BFPD)

– BFPD forms the starting point for developing PFD
– BFPD is helpful in conceptualizing new processes

■ Block Flow Plant Diagram

– Gives a general view of a large complex plant

Block Flow Diagrams

Conventions and Formats for BFD
1. Operations shown by blocks
2. Major flow lines shown with arrows
3. Flow goes from left to right whenever possible
4. Light streams toward top with heavy stream toward bottom
5. Critical information unique to process supplied
6. If lines cross, then horizontal line is continuous
7. Simplified material balance provided

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Basic flow diagram

The Block
Flow Process
Diagram

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The Block Flow Plant Diagram

The Process Flow Diagrams (PFD)

■ A PFD contains the bulk of the Chem Eng data

necessary for the design of a chemical process.
■ Basic information provided by a PFD:
– Process Topology
– Stream Information
– Equipment Information

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■ A typical commercial PFD will contain the following

information:
– All major pieces of equipment in the process will be
represented along with a descriptive name and number.
– All process flow streams will be shown and identified
with a number. A description of the process conditions
and chemical composition of each stream will be
included.
– All utility streams supplied to major equipment that
provides a process function will be shown.
– Basic control loops will be shown.

Design

■ Using software – AUTOCAD and VISIO

■ Developed special for process engineering
■ Typical component data in the software:
– Instrument ID
– Drawing number
– Dimensions

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Symbols
for
Drawing
PFD

The Process Flow Diagram (PFD)

Process Unit Symbology

Symbol Description

Heat exchanger

H2O Water cooler

S Steam heater

Cooling coil

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The “Process Flow Diagram” (PFD)

Process Unit Symbology

Symbol Description

Heater coil

Centrifugal pump

Turbine type compressor

Pressure gauge

The “Process Flow Diagram” (PFD)

Process Unit Symbology

Symbol Name Description

Stripper Convert liquid mixture into gas

phase

Absorber Convert mixture gas into

liquid phase

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The “Process Flow Diagram” (PFD)

Process Unit Symbology

Symbol Name Description

Distillation Separate liquid into

miscellaneous component
column fractions.

Liquid mixer Mix liquid components.

or

The ”Process Flow Diagram” (PFD)

Process Unit Symbology

Symbol Name Description

Reaction Location of chemical process

or reaction occurs
chamber

Horizontal tank Store liquid or gas.

or cylinder

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The “Process Flow Diagram” (PFD)

Process Unit Symbology

Symbol Name Description

Boiler Heating purposes.

Centrifuge Physically separated liquid

mixture (exp: oil-liquid)

The “Process Flow Diagram” (PFD)

Valve Symbology
Symbol Name

Gate Valve

Globe Valve

Ball Valve

Check Valve

Butterfly Valve

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The “Process Flow Diagram” (PFD) (b)

(a)

Valve Symbology

Symbol Name

Relief Valve (d)

(c)
Needle Valve (a)
(d)
3-Way Valve (c)

(e)
Angle Valve (e)

Butterfly Valve (b)

Equipment Numbering
■ XX-YZZ A/B/…
– XX represents a 1- or 2-letter designation for the
equipment (P = pump)

– Y is the 1 or 2 digit unit number (1-99)

– ZZ designates the equipment number for the unit (1-99)

– A/B/… represents the presence of spare equipment

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Example

The Process Flow Diagram (PFD)

Stream Description
- Mainly reactors and towers, etc.

 Use Flags when necessary

 Can include full stream data

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Stream Numbering and Drawing

■ Number streams from left to right as much as
possible
■ Horizontal lines are dominant

■ Add arrows for

– Change in direction
– Inlet of equipment

■ Since diagrams are small not much stream information can

be included

■ Include important data – around reactors and towers, etc.

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The Process Flow Diagram (PFD)

Example

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Stream Information - Full stream data

Stream 1 2 3 4 5 6 7 8 9 10
Number

Temperature 25.0 35.0 35.0 35.0 35.0 60.3 41 38 54.0 45.1

(oC)

Pressure (psi) 28 32.2 31.0 31.0 30.2 45.1 31.3 24.0 39.0 2.6

Vapor fraction

Example

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Equipment Information

■ Equipment are identified by number and a

label (name) positioned above the equipment
on the PFD

■ Basic data such as size and key data are

included in a separate table

Equipment Summary

Vessel V-101 V-102

Temperature (ºC) 55 38
Pressure (bar) 2.0 24
Orientation Horizontal Vertical
MOC CS CS
Size
Height/Length (m) 5.9 3.5
Diameter (m) 1.9 1.1
Internals s.p. (splash plate)

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PFD Summary

■ PFD, Equipment Summary Table, and Flow

Summary Table represent a “true” PFD
■ This information is sufficient for a preliminary
estimation of capital investment and cost of
manufacture to be made

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Piping and instrumentation diagrams

(P&ID)
■ The drawing is started after the order
placement and approximately at the same time
to the procurement of the components.
■ The information given is subdivided into basic
information
■ Contains: plant construction information
(piping, process, instrumentation, and other
diagrams)

■ Information includes:
– Appliances and machinery
– Pipes or means of transport (e.g. moving
belts)
– Valves and fittings
– Information on dimension, nominal
pressures and material classification
– Any insulation, electric pipe heater, gradients
& materials

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■ Example:
– Simple pump group
– Atmosphere Vessel
– Pump unit with automatic flushing device
– Tubular heat exchanger
– Hydrochloric acid metering system

Example: Simple pump group

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P&ID

Main apparatus
■ Steps in procurement of the main apparatus:
1) process-related design
– Applied knowledge of thermal, chemical,
mechanical, biological process engineering.
– Hydrodynamic: The reactor diameter and its
height, Heat exchangers, Design of compressors:
thermodynamic aspect
– All results recorded in technical data sheet

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2) strength related design

– Calculation on wall thickness
3) production-related design
– Carried out within detail engineering
– Assigned to subcontractors

Layout

■ Generally very complex

■ Occur only after submission of P&I drawing –
within the detail engineering

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Quotation
■ A request for quotation (RFQ) is a standard
business activity inviting suppliers to bid
specific products or services.
■ Include payment terms, quality level per item
or contract length etc.
■ To receive accurate quotation, therefore it also
includes the full specifications of the
items/services.

Quotation

■ The more detailed the specifications should

minimize potential problems regarding products or
services specification.
■ Acting as legal binding documentation for the
suppliers.
■ Best suited for products and services that are as
standardised to make each supplier's quote
comparable.

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