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TK01 - Report - Final

This document presents a preliminary design for a plant that produces gasoline through a process involving offshore photovoltaic electrolysis of seawater, methanol synthesis from the resulting hydrogen and CO2 from Natuna, and a methanol-to-gasoline reaction. The plant is located in West Kalimantan and has a production capacity of 167,261 barrels per year. An economic analysis finds an IRR of 6.46% and payback period of 11.8 years. Process design work included heat exchanger network design, equipment sizing, hazard analysis, and cost estimation. Sensitivity analysis identified gasoline price as the most important factor for improving profitability.

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Hafiz Hakim
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0% found this document useful (0 votes)
470 views264 pages

TK01 - Report - Final

This document presents a preliminary design for a plant that produces gasoline through a process involving offshore photovoltaic electrolysis of seawater, methanol synthesis from the resulting hydrogen and CO2 from Natuna, and a methanol-to-gasoline reaction. The plant is located in West Kalimantan and has a production capacity of 167,261 barrels per year. An economic analysis finds an IRR of 6.46% and payback period of 11.8 years. Process design work included heat exchanger network design, equipment sizing, hazard analysis, and cost estimation. Sensitivity analysis identified gasoline price as the most important factor for improving profitability.

Uploaded by

Hafiz Hakim
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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UNIVERSITAS INDONESIA

PRELIMINARY DESIGN OF COMBINED OFFSHORE PV


ELECTROLYSIS AND NATUNA GAS TO GASOLINE

Final Report
GROUP 1

GROUP PERSONNEL:
Billi (1506724575)
Natasya Mareta Mualim (1506673385)
Nico Nathanael (1506737016)
Salma Amaliani Putri (1506673334)

CHEMICAL ENGINEERING DEPARTMENT


ENGINEERING FACULTY
UNIVERSITY OF INDONESIA
DEPOK
DECEMBER 2018
LIST OF GROUP MEMBER

1. Name : Billi
NPM : 1506724575
DOB : Palembang, 25th September 1997
Address : Merbau Street No. 1326 Palembang

2. Name : Natasya Mareta Mualim


NPM : 1506673385
DOB : Jakarta, 30th March 1997
Address : Damar 3 Blok C No 100

3. Name : Nico Nathanael


NPM : 1506737016
DOB : Jakarta, 3rd June 1997
Address : Kelapa Puan XIII AF7 No 5, Gading Serpong 15810

4. Name : Salma Amaliani Putri


NPM : 1506673334
DOB : Jakarta, 27th June 1997
Address : Unitex Melati 2 No 10 Tajur Bogor 15146

ii Universitas Indonesia
FOREWORD

First of all, we would like thanks to God for his blessings and for giving us
the courage and strength to finish writing the final report of our Plant Design
assignment. This final report presents our plant, which is Combined Offshore PV
Electrolysis and Natuna to Gasoline. Throughout the process of writing and
conducting the product development, we encountered many great challenges and
valuable lessons, and so, we would like to thank:
1. Prof. Dr. Ir. Widodo W. Purwanto, DEA, for his supervision and guidance.
We are very grateful to have you as our supervisor,
2. Dr. rer. Nat. Ir. Yuswan Muharam, M.T., Dr. Tania Surya Utami, S.T., M.T.,
and Dr. Bambang Heru Susanto, S.T., M.T. for all of your feedbacks and
input,
3. Our families who have supported us financially and morally, and of course
for putting up with us through thick and thin,
4. Our friends from Chemical Engineering Department batch 2015, especially
for our Chemical Engineering friends for the great and tough times we spent
together,
5. And other people who have helped and supported us along the way.
Lastly, we hope that this report may bring benefits and contribute to the
development of food, science, and technology. We realize that this report may lack
a few things, therefore we are very open to criticism and suggestions.

Depok, 17th December 2018

iii Universitas Indonesia


ABSTRACT

COMBINED OFFSHORE PV ELECTROLYSIS AND NATUNA GAS TO


GASOLINE
Ali Hamdani, Bella Novia Berliana, Billi, Jihan Mutiah, Jeremy Adidya
Chemical Engineering Department, Faculty of Engineering, Universitas
Indonesia, Depok, West Java, Indonesia

As a way to counter diminishing oil production, utilization of alternative energy


sources to substitute the currently used gasoline is needed. This plant focuses on
utilizing carbon dioxide and seawater to produce gasoline through electrolysis
followed by methanol-to-gasoline technology. The plant operates in West
Kalimantan, producing gasoline as the main product, with production capacity of
167,261 barrels/year. With the sold price of 1059 USD/ton accompanied by by-
product of DME-isobutane and oxygen, the plant is expected to have an IRR of
6.46% and payback period of 11.8 years.

Keywords: electrolysis, methanol-to-gasoline, synfuel

iv Universitas Indonesia
EXECUTIVE SUMMARY

According to Acton (2013), a diminishing production capacity of world oil


production will be expected in a few decades from now. Since demand rises rapidly,
it has become foreseeable that in the fairly short time, gasoline production will not
meet demand. Thus, it is therefore very important to develop processes that allow
utilization of alternative energy sources to substitute the currently used gasoline.
Through the process selection including process route, PV technology,
reactor, and catalyst, this plant utilizes CO2 from Natuna and sea water in process
of electrolysis of water followed by methanol synthesis and methanol-to-gasoline.
The plant operates in West Kalimantan, producing gasoline as the main product.
Through 0.7% share of demand-supply gap and benchmarking with commercial
DME plant, the plant production capacity is 167,261 barrels/year or 2.25 ton/hour.
The production consists of five steps, which are photovoltaic electrolysis,
methanol synthesis, DME synthesis, gasoline synthesis, and gasoline purification.
Hydrogen obtained through electrolysis reacts with CO2 in Cu-Al-Zn-catalyzed
reactor to produce methanol and water. Dehydration of methanol then takes place
in gamma-alumina packed bed reactor. Then dimethylether reacts to produce crude
gasoline, and this product purified in two distillation columns. The yield of gasoline
produced is 0.492 kg gasoline/ kg sea water and 0.438 kg gasoline/ kg CO2.
Before implementation of HEN, there are 15 heat exchangers used for the
process. After HEN, the amount is enlarged into 19, with 8 using the exchange of
energy among process fluids, 6 cold utilities, and 5 hot utilities. The cold utility
requirement is 4.83 MW and the hot is 0.76 MW Implementation of HEN shows
significant energy recovery, reducing hot utilities up to 91.2% and cold up to 61.9%.
Cold utilities are supplied with cooling water in the source of sea water,
with the amount for make up 72,376 kg/h. Steam requirement is 1,478.03 kg/h. The
electricity is mixed supplied using photovoltaic technologies and Perusahaan
Listrik Negara (PLN), dominated with electrolysis, in the amount of 25.4 MW. Fuel
is needed for the steam generation in form of natural gas with amount of 67.8 kg/h.
Sizing is then conducted to all equipments, which include 3 reactors, which
are methanol synthesis reactor, DME synthesis reactor, gasoline synthesis reactor,

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3 distillation columns, 19 heat exchangers, 3 two-phase separators, 1 three-phase
separator, 1 reverse osmosis unit, 2 filters, 1 electrolyzer, 16 pumps, 1 storage tank,
and 9 compressor systems. The equipments operating in utility area include 2 tanks,
2 clarifiers, 8 pumps, 1 cooling tower, 1 deaerator, and 1 boiler. Process control is
conducted with the aim of seven objectives in process control through the usage of
5 control variables. Process and Instrumentation Diagram, or also known as P&ID,
is made for the entire plant and each process.
HAZID analysis identifies that most processes in the plant have major level
of severity, unlikely level of frequency, and overall medium hazard index. It is
supported by the fact that the plant is constituted by flammable materials with
hazardous operating conditions, such as high pressure and temperature. It identifies
that area 200 has the highest hazard index, followed by area 300 and 400. HAZOP
analysis identifies that reactors are the equipments to be most concerned Through
the HSE aspect provided, HSE management by operational detail, MSDS, PPE, and
emergency procedure is to be concerned. The plant will be built with area of 12 ha
in 10 areas, which include water treatment and electrolysis, methanol synthesis,
DME and gasoline synthesis, gasoline purification, gasoline storage, photovoltaic
array, utility, waste water treatment, fire station, and non-technical section.
Capital investment is estimated using Modular Guthrie method, by which
all cost are mostly estimated according to the total bare-module cost of process
equipments. The total equipment cost is calculated to be USD 35,094,953. The total
capital investment is estimated to be USD 79,115,914. Operational cost is estimated
with the span of direct production cost, fixed cost, overhead cost, and general
expenses, with the amount of USD 13,985,281. In cost breakdown, major share is
38.74% for capital investment, 35.80% for utility, and 10.05% for maintenance.
Capital source is fulfilled by bank loan with the amount of 70% and investor 30%.
There are three products of this plant, consisting of gasoline, DME-isobutane, and
oxygen. The fuel will be sold to Pertamina main fuel terminal at a price of 1059
USD/ton with a capacity of 2.213 ton/hour. The DME-isobutane will be sold at 653
USD/ton with a capacity of 0.192 ton/hour and the oxygen will be sold at 156
USD/ton with a capacity of 5.748 ton/hour.

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Profitability analysis is conducted to evaluate the feasibility of this project.
The analysis gives the value of internal rate of return (IRR) to 6.46% with return
on investment (ROI) of 1.44%. The net present value (NPV) is –USD 12,470,000.
With such revenue, the payback period is 11.8 years and the BEP value can be
calculated to be 198,545 tonnes gasoline, 17,226 tonnes DME-isobutane, and
515,698 tonnes oxygen. Based on the value of profitability parameter, the plant has
not been an interesting investment for investor.
Sensitivity analysis is conducted to the costs with the highest share in cost
breakdown, which are gasoline price, oxygen price, and maintenance cost. The
result shows that gasoline price is the most sensitive among others, and can be the
concern for enhancing profitability parameter. The economic aspect can be
enhanced with the aid of government in the form of incentive, typically in reducing
electricity utility cost, increasing product price, and reducing loan interest.

vii Universitas Indonesia


LIST OF CONTENT

LIST OF GROUP MEMBER .............................................................................. ii


FOREWORD ........................................................................................................ iii
ABSTRACT. ......................................................................................................... iv
EXECUTIVE SUMMARY................................................................................... v
LIST OF CONTENT ......................................................................................... viii
LIST OF TABLES ............................................................................................... xi
LIST OF FIGURES ........................................................................................... xiv
CHAPTER 1. INTRODUCTION ........................................................................ 1
1.1 Background .............................................................................................. 1
1.2 Literature Review ..................................................................................... 2
1.2.1 Nature of Synfuel ............................................................................ 2
1.2.2 Overview of Synfuel Production .................................................... 4
1.2.3 Methanol-to-Gasoline ..................................................................... 5
1.2.4 Photovoltaic Electrolysis ................................................................ 6
1.3 Analysis .................................................................................................. 10
1.3.1 Raw Material Analysis .................................................................. 10
1.3.2 Market and Production Capacity Analysis ................................... 14
1.3.3 Plant Location ............................................................................... 15
CHAPTER 2. PROCESS SYNTHESIS ............................................................ 17
2.1 Process Selection .................................................................................... 17
2.1.1. Process Route Selection ................................................................ 17
2.1.2. Photovoltaic Electrolysis Technology Types Selection ................ 25
2.1.3. Catalyst and Reactor Selection ..................................................... 27
2.2 Process Description ................................................................................ 29
2.2.1. Photovoltaic Electrolysis (Area 100) ............................................ 30
2.2.2. Methanol Synthesis (Area 200) .................................................... 32
2.2.3. DME Synthesis (Area 300) ........................................................... 33
2.2.4. Gasoline Synthesis (Area 300)...................................................... 34
2.2.5. Gasoline Purification (Area 400) .................................................. 36
2.3. Mass and Energy Balance ...................................................................... 37
2.3.1. Mass Balance ................................................................................ 37
2.3.2. Energy Balance ............................................................................. 39
2.3.3. Product Conversion Efficiency ..................................................... 39
2.3.4. Product Yield ................................................................................ 40
2.3.5. Overall Energy Consumption ....................................................... 40
2.4. Heat Exchanger Network ....................................................................... 40
2.4.1. Composite Curve Method ............................................................. 41
2.4.2. Problem Table Algorithm Method ................................................ 42
2.4.3. Heat Exchanger Network Design .................................................. 47
2.5. Utility ..................................................................................................... 48
2.5.1. Water ............................................................................................. 49
2.5.2. Steam............................................................................................. 51
2.5.3. Electricity ...................................................................................... 53
2.5.4. Fuel ............................................................................................... 55
2.5.5. Waste Water Treatment ................................................................ 56
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2.6. Block Flow Diagram .............................................................................. 58
2.7. Process Flow Diagram ........................................................................... 58
CHAPTER 3. EQUIPMENT SIZING .............................................................. 59
3.1. Process Equipment Sizing ...................................................................... 59
3.1.1. Reactor .......................................................................................... 59
3.1.2. Distillation Column ....................................................................... 62
3.1.3. Separator ............................................................................................. 64
3.1.4. Compressor ......................................................................................... 67
3.1.5. Pump ................................................................................................... 71
3.1.6. Heat Exchanger ............................................................................. 75
3.1.7. Filtration Unit................................................................................ 78
3.1.8. Reverse Osmosis Unit ................................................................... 80
3.1.9. AEL Electrolyzer ................................................................................ 80
3.1.10. Photovoltaic Array and Battery Bank ............................................... 81
3.2. Utility Equipment Sizing ........................................................................ 81
3.2.1. Cooling Tower .............................................................................. 81
3.2.2. Deaerator ....................................................................................... 84
3.2.3. Boiler............................................................................................. 84
3.2.4. Clarifier ......................................................................................... 85
3.2.5. Tank .............................................................................................. 86
CHAPTER 4. PROCESS CONTROL AND P&ID ......................................... 88
4.1. Process Control ...................................................................................... 88
4.2. Pipeline Specification ............................................................................. 94
4.3. Piping and Instrumentation Diagram (P&ID) ........................................ 98
CHAPTER 5. HEALTH, SAFETY, AND ENVIRONMENTAL
PROTECTION .................................................................................................... 99
5.1. HSE Aspect ............................................................................................ 99
5.1.1. Hazard Identification Study (HAZID) .......................................... 99
5.1.2. Hazard and Operability Study (HAZOP) .................................... 105
5.2. HSE Management ................................................................................ 115
5.2.1. Operational Details ..................................................................... 115
5.2.2. Personal Protective Equipment ................................................... 120
5.2.3. Material Safety Data Sheet (MSDS) ........................................... 122
5.2.4. Area Classification ...................................................................... 125
5.2.5. Emergency Action Plan .............................................................. 128
5.3. Waste Management .............................................................................. 132
5.3.1. Solid Waste ................................................................................. 132
5.3.2. Liquid Waste ............................................................................... 134
5.3.3. Gas Waste ................................................................................... 135
5.3.4. Sound .......................................................................................... 135
CHAPTER 6. PLANT LAYOUT .................................................................... 137
6.1. Plant Location ...................................................................................... 137
6.2. Plant Layout ......................................................................................... 137
6.2.1. General Consideration of Plant Layout ....................................... 137
6.2.2. Safe Range Between Equipment ................................................. 138
6.2.3. Area Classification Layout ......................................................... 141
6.2.4. Overall 2D Plant Layout ............................................................. 142
6.2.5. Overall 3D Plant Layout ............................................................. 142

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CHAPTER 7. ECONOMIC ANALYSIS ........................................................ 143
7.1. Assumption in Cost Estimation ............................................................ 143
7.2. Capital Expenditure (CAPEX) ............................................................. 143
7.2.1. Cost Index ................................................................................... 143
7.2.2. Capital Expenditure Calculation Scope ............................................ 145
7.2.3. Total Bare Module Cost .............................................................. 146
7.2.4. Land and Site Development Cost (Csite).................................... 148
7.2.5. Building Cost (Cbuilding)........................................................... 149
7.2.6. Contingency and Contractor Fee................................................. 151
7.2.7. Plant Startup Cost ....................................................................... 151
7.2.8. Working Capital .......................................................................... 151
7.2.9. Summary of Capital Expenditure ................................................ 151
7.3. Operational Cost ...................................................................................... 152
7.3.1. Direct Production Cost ................................................................ 152
7.3.2. Fixed Cost: Local Tax and Insurance ......................................... 156
7.3.3. Plant Overhead Cost ................................................................... 160
7.3.4. General Expenses ........................................................................ 160
7.3.5. Depreciation ................................................................................ 163
7.3.6. Total Operating Cost ................................................................... 166
7.3.7. Benchmark .................................................................................. 169
7.4. Profitability Analysis ............................................................................ 169
7.4.1. Investment Feasibility Analysis .................................................. 169
7.4.2. Revenue....................................................................................... 171
7.4.3. Cost Breakdown .......................................................................... 171
7.4.4. Cash Flow ................................................................................... 172
7.4.5. Determining WACC ................................................................... 174
7.4.6. ROI .............................................................................................. 175
7.4.7. IRR .............................................................................................. 175
7.4.8. NPV............................................................................................. 176
7.4.9. Payback Period ............................................................................ 176
7.4.10. Break Even Point ........................................................................ 177
7.5. Sensitivity Analysis .............................................................................. 177
7.5.1. IRR Sensitivity Analysis ............................................................. 178
7.5.2. NPV Sensitivity Analysis ........................................................... 178
7.5.3. Payback and Sensitivity Analysis ............................................... 179
7.5.4. Recommendation for Enhancing Profitability Parameter ........... 179
CHAPTER 8. CONCLUSION ......................................................................... 180
REFERENCES .................................................................................................. 182
APPENDICES ................................................................................................... 184
APPENDIX A. MASS BALANCE .............................................................. 184
APPENDIX B. PROCESS FLOW DIAGRAM .......................................... 192
APPENDIX C. PIPING AND INSTRUMENTATION DIAGRAM ........ 199
APPENDIX D. EQUIPMENT SIZING PROCEDURE ............................ 206
APPENDIX E. MSDS ................................................................................... 240
APPENDIX F. EQUIPMENT PURCHASE COST PROCEDURE ......... 244
APPENDIX G. CASH FLOW ..................................................................... 248

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LIST OF TABLES

Table 1.1. Disadvantage and advantage of synfuel ............................................ 4


Table 1.2. Electrolysis characteristics .............................................................. 10
Table 1.3. Solar potential energy during the wet and the dry season............... 12
Table 1.1. Solar potential energy during the wet and the dry season............... 13
Table 1.2. The major ions of seawater ............................................................. 13
Table 1.3. Tambelan Islands Water Characteristics, 2010 ............................... 13
Table 1.4. Current refinery capacity in Indonesia ............................................ 14
Table 1.5. Production capacity ......................................................................... 15
Table 2.1. Comparison of Methanol-to-Gasoline to Fischer-Tropsch ............. 21
Table 2.2. Scoring criteria for process route selection ..................................... 23
Table 2.3. Parameter comparison of process routes ......................................... 24
Table 2.4. Scoring of process routes ................................................................ 24
Table 2.5. Photovoltaic technology comparison .............................................. 26
Table 2.6. Criteria evaluation of electrolysis ................................................... 27
Table 2.7. Key operating conditions for CO2 to methanol process .................. 33
Table 2.8. Parameter values for Methanol Dehydration kinetic model ........... 34
Table 2.9. Key operating conditions for Methanol to DME Process ............... 34
Table 2.10. Selectivity of DME to Hydrocarbon Synthesis at specified operating
conditions 35
Table 2.11. Key operating conditions for DME to Gasoline process ................ 35
Table 2.12. Key operating condition for Gasoline Purification ......................... 36
Table 2.13. Overall Mass Balance ..................................................................... 37
Table 2.14. Overall Energy Balance .................................................................. 39
Table 2.15. Classification of Stream .................................................................. 40
Table 2.16. Shifted Temperature of Area 200.................................................... 43
Table 2.17. Shifted Temperature of Area 300-400 ............................................ 43
Table 2.18. Calculation of CP for Area 200 ...................................................... 43
Table 2.19. Calculation of CP for Area 300-400 ............................................... 43
Table 2.20. Temperature Interval Balance for Area 200 ................................... 44
Table 2.21. Temperature Interval Balance for Area 300-400 ............................ 45
Table 2.22. Minimum Hot and Cold Utility Requirement ................................. 47
Table 2.23. Heat Exchanger Network Design Rule ........................................... 47
Table 2.24. Post-HEN Heat Duty Calculation for Area 200 .............................. 47
Table 2.25. Post-HEN Heat Duty Calculation for Area 300-400 ...................... 48
Table 2.26. Cooling Water Requirement Before HEN ...................................... 50
Table 2.27. Calculation of Makeup Cooling Water Before HEN ...................... 50
Table 2.28. Cooling Water Requirement After HEN ......................................... 50
Table 2.29. Calculation of Makeup for Cooling Water After HEN ................... 51
Table 2.30. Steam Requirement in Plant Before HEN ...................................... 52
Table 2.31. Steam Requirement in Plant After HEN ......................................... 53
Table 2.32. Electricity Requirement Before HEN ............................................. 54
Table 2.33. Electricity Requirement After HEN ................................................ 54
Table 3.1. Methanol Synthesis Reactor Specification ..................................... 59
Table 3.2. DME Synthesis Reactor Specification ............................................ 60
Table 3.3. Gasoline Synthesis Reactor Specification ...................................... 61
Table 3.4. Methanol Purification Column Specification ................................. 62
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Table 3.5. Deethanizer Column Specification ................................................. 63
Table 3.6. Methanol Purification Column Specification ................................. 64
Table 3.7. First Stage Methanol Separator Specification ................................. 64
Table 3.8. Second Stage Methanol Separator Specification ............................ 65
Table 3.9. DME Reactor Effluent Separator Specification .............................. 66
Table 3.10. Three-Phase Separator Specification .............................................. 67
Table 3.11. Compressor K-201 Specification .................................................... 68
Table 3.12. Compressor K-202 Specification .................................................... 68
Table 3.13. Compressor K-204 Specification .................................................... 68
Table 3.14. Compressor K-205 Specification .................................................... 69
Table 3.15. Compressor K-206 Specification .................................................... 69
Table 3.16. Compressor K-207 Specification .................................................... 70
Table 3.17. Compressor K-401 Specification .................................................... 70
Table 3.18. Pump Specification (P-101) ............................................................ 71
Table 3.19. Pump Specification (P-102) ............................................................ 71
Table 3.20. Pump Specification (P-103) ............................................................ 72
Table 3.21. Pump Specification (P-201) ............................................................ 72
Table 3.22. Pump Specification (P-202) ............................................................ 73
Table 3.23. Pump Specification (P-301) ............................................................ 73
Table 3.24. Pump Specification (P-401) ............................................................ 74
Table 3.25. Pump Specification (P-402) ............................................................ 74
Table 3.26. Heat Exchanger Specification (E-201) ........................................... 76
Table 3.27. Heat Exchanger Specification (E-202) ........................................... 77
Table 3.28. Heat Exchanger Specification (E-203) ........................................... 78
Table 3.29. Sand Filter Specification ................................................................. 79
Table 3.30. Cartridge Filter Specification .......................................................... 79
Table 3.31. Reverse Osmosis Specification ....................................................... 80
Table 3.32. Electrolyzer Specification ............................................................... 81
Table 3.33. Photovoltaic Array Specification .................................................... 81
Table 3.34. Battery Bank Specification ............................................................. 81
Table 3.35. Cooling tower specification based on Shinwa Cooling Tower ....... 82
Table 3.36. Cooling tower specification based on calculation........................... 83
Table 3.37. Deaerator Specification ................................................................... 84
Table 3.38. Boiler specification ......................................................................... 84
Table 3.39. Primary Clarifier Specification ....................................................... 85
Table 3.40. Secondary Clarifier Specification ................................................... 86
Table 3.41. Aeration Tank Specification ........................................................... 86
Table 3.42. Sludge Tank Specification .............................................................. 87
Table 7.1. Cost Index ..................................................................................... 144
Table 7.2. Bare-Module Factors of Equipments ............................................ 146
Table 7.3. Equipment Cost ............................................................................. 147
Table 7.4. Land Cost ...................................................................................... 149
Table 7.5. Land and Site Development Cost (Csite) ....................................... 149
Table 7.6. Building Cost ................................................................................ 149
Table 7.7. Supporting Equipment Cost .......................................................... 150
Table 7.8. Utility Installation Cost ................................................................. 150
Table 7.9. Contingency and Contractor Fee................................................... 151
Table 7.10. Plant Startup Cost ......................................................................... 151

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Table 7.11. Working Capital ............................................................................ 151
Table 7.12. Summary of Capital Expenditure .................................................. 152
Table 7.13. Raw Material Cost ........................................................................ 153
Table 7.14. Catalysts Cost................................................................................ 153
Table 7.15. Minimum wage at West Kalimantan ............................................ 154
Table 7.16. Direct Cost Labor Salary .............................................................. 154
Table 7.17. Electricity Main Equipment Cost .................................................. 155
Table 7.18. Electricity Support Equipment Cost ............................................. 155
Table 7.19. Water Requirement Cost ............................................................... 155
Table 7.20. Fuel Requirement Cost ................................................................. 156
Table 7.21. Summary of Utility Cost ............................................................... 156
Table 7.22. Maintenance Cost .......................................................................... 156
Table 7.23. Insurance Cost ............................................................................... 156
Table 7.24. Land and Building Cost and Tax .................................................. 157
Table 7.25. Salary and Tax .............................................................................. 158
Table 7.26. Summary of Fixed Cost ................................................................ 160
Table 7.27. Plant Overhead Cost ..................................................................... 160
Table 7.28. PPE Cost ....................................................................................... 160
Table 7.29. Executive Salary and Clerical Wage ............................................. 161
Table 7.30. Market Research Cost ................................................................... 162
Table 7.31. Printed Media Cost ....................................................................... 162
Table 7.32. Online Advertisement Cost ........................................................... 162
Table 7.33. Marketing Cost.............................................................................. 162
Table 7.34. Website Development Cost ........................................................... 162
Table 7.35. Annual Communication Cost ........................................................ 162
Table 7.36. Summary of General Expenses ..................................................... 163
Table 7.37. MACRS Class Lives and Recovery Periods ................................. 163
Table 7.38. GDS Recovery Rate ...................................................................... 164
Table 7.39. Depretiation ................................................................................... 165
Table 7.40. Salvage Value ............................................................................... 166
Table 7.41. Summary of Total Operating Cost ................................................ 167
Table 7.42. Benchmark .................................................................................... 169
Table 7.43. Source Proportion of Capital Investment ...................................... 170
Table 7.44. Loan Interest from Bank ............................................................... 170
Table 7.45. Loan Interest from Investor........................................................... 170
Table 7.46. Total Loan Interest from Bank and Investor ................................. 171
Table 7.47. Revenue Calculation ..................................................................... 171
Table 7.48. Cost Breakdown ............................................................................ 171
Table 7.49. WACC Calculation ....................................................................... 175

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LIST OF FIGURES

Figure 1.1. Synthetic and conventional fuel comparison .................................... 3


Figure 1.2. Schematic of typical MTG fixed bed process flow........................... 6
Figure 1.3. Photovoltaic devices ......................................................................... 7
Figure 1.4. Chemical structure of a PV cell ........................................................ 7
Figure 1.5. Flow of electrons on two poles ......................................................... 8
Figure 1.6. Flow process on p-n junction principle ............................................. 8
Figure 1.7. The location of Natuna gas field in Indonesia ................................ 11
Figure 1.8. Profile of estimated solar energy potential in Indonesia (a) wet and
(b) dry season ........................................................................................................ 12
Figure 1.9. Indonesia’s annual national commercial gasoline .......................... 14
Figure 2.1. Illustration of product distribution from Fischer-Tropsch and
Methanol-to-Gasoline processes ........................................................................... 21
Figure 2.2. Zeolite membrane reactor scheme .................................................. 28
Figure 2.3. Composite Curve of Hot and Cold Stream in Area 200 ................. 42
Figure 2.4. Composite Curve of Hot and Cold Stream in Area 300-400 .......... 42
Figure 2.5. Problem Table Cascade for Area 200 ............................................. 45
Figure 2.6. Problem Table Cascade for Area 300-400 ...................................... 46
Figure 2.7. Pinch Design for Area 200 .............................................................. 48
Figure 2.8. Pinch Design for Area 300-400 ...................................................... 48
Figure 2.9. Plant Location for Seawater Source ................................................ 49
Figure 2.10. Block flow diagram of the process ................................................. 58
Figure 3.1. Methanol Synthesis Reactor Specification ..................................... 59
Figure 3.2. DMESynthesis Reactor Specification ............................................. 60
Figure 3.3. Gasoline Synthesis Reactor Specification ...................................... 61
Figure 3.4. Methanol Purifcation Column Specification................................... 62
Figure 3.5. Deethanizer Column Specification ................................................. 63
Figure 3.6. Debutanizer Column Specification ................................................. 63
Figure 3.7. First Stage Methanol Separator Specification ................................. 64
Figure 3.8. Second Stage Methanol Separator Specification ............................ 65
Figure 3.9. DME Reactor Effluent Separator Specification .............................. 66
Figure 3.10. Three-Phase Separator Specification .............................................. 67
Figure 3.11. Heat Exhanger Specification (E-201) ............................................. 75
Figure 3.12. Heat Exhanger Specification (E-202) ............................................. 76
Figure 3.13. Heat Exhanger Specification (E-203) ............................................. 77
Figure 3.14. Sand Water Filter Specification ...................................................... 79
Figure 3.15. Cooling Tower Specification .......................................................... 82
Figure 3.16. Cooling Tower Scheme ................................................................... 83
Figure 3.17. Cooling Tower Type ....................................................................... 83
Figure 3.18. Boiler Specification ........................................................................ 84
Figure 7.1. Chemical Engineering Plant Cost Index (CEPCI) ........................ 144
Figure 7.2. Forecast of Chemical Engineering Plant Cost Index (CEPCI) ..... 145
Figure 7.3. Cost Breakdown ............................................................................ 172
Figure 7.4. Cash Flow ..................................................................................... 173
Figure 7.5. Cumulative Cash Flow .................................................................. 174
Figure 7.6. Effect of Parameter Deviation on IRR .......................................... 178

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Figure 7.7. Effect of Parameter Deviation on NPV......................................... 178
Figure 7.8. Effect of Parameter Deviation on PBP ......................................... 179

xv Universitas Indonesia
CHAPTER 1
INTRODUCTION

1.1 Background
High costs of extracting and processing fossil fuels and their depleting
reserves as well as the limited global reserves of crude oil have generated a deep
interest in alternative fuels. An increase in share of liquid synthetic fuels,
particularly those from wastes, in the market of liquid fuels consumed by the fuel
and energy sector is a significant part of the sustainable development that leads to
the improved national energy security by diversifying the sources of fuel supply
and reducing the dependence on the crude oil import at simultaneously positive
impact on the environment by proper waste management (Kijenski, et al., 2013).
The market of alternative fuels, in particular synthetic hydrocarbons, is forecast to
grow dynamically and to become a crude oil substitute, mainly in the context of
trends in community and global legislative works.
Current evaluation of the world oil production predicts the production to
peak around the year 2010 (Acton, 2013). As the world production capacity is
believed to behave like a bell curve the expectations are that we will have
diminishing production capacity within a few decades from now. Demand on the
other hand rises rapidly and it has become foreseeable that in fairly short time,
gasoline production will not meet demand.
In 2015, 21% of Greenhouse Gas Emission comes from industry – primarily
come from burning fossil fuels for energy, also from other chemical reaction and
purification process (United States Environmental Protection Agency, 2015). The
amount of CO2, as one of the component in greenhouse gases needs to be reduced.
Too many greenhouse gases trapped in the atmosphere will increase earth
temperature, and causing global warming. Therefore, CO2 from industrial process
need to be utilized for another use to reduce global warming.
Other than that, CO2 can also be obtained from Natuna, which is one of the
major natural gas reserve in Indonesia is found in the Natuna "D-Alpha" gas field.
This is not only a large gas deposit (222 TCF) but is also interesting because it is
composed predominantly of CO2 (71%). The last development scheme proposed by

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the oil companies Exxon and Pertamina for the utilization of this gas, before the
crisis of 1997, was for the CH4 to be sold as LNG, while the CO2 was to be injected
back below the ocean floor. However, the marketing of natural gas depends on long-
term and high-risk contracts or requires strong commitment between the producer
and the buyer, even long before the development stage.
It is therefore very important to develop processes that allow utilization of
alternative energy sources to provide fuel that can immediately substitute the
currently used gasoline and diesel distilled from petroleum oil. Such fuel which is
compatible with combustion engines as they are today will render the need for
major time consuming, technical developments and infrastructural changes.
Invention in the fuel production process from waste CO2 and water as raw
material is then conducted to solve the stated problem. Currently there are two
major processes that have been used on industrial scale to produce synthetic liquid
hydrocarbon fuel, which are Fischer-Tropsch and Methanol-to-Gasoline processes,
in which synthetic gas (mixture of H2 and CO) is needed as intermediate species.
The CO gas is provided through CO2 gas from Natuna, while hydrogen is produced
through water electrolysis with the aid of solar energy. Hence, this invention of
overall solar-to-fuel process is expected to be an exemplary alternative process to
produce liquid fuel from utilization of renewable energy sources.
1.2 Literature Review
1.2.1 Nature of Synfuel
Synthetic fuel or synfuel provides to be a viable alternative to traditional
oil-based fuels. Synthetic fuel is any fuel that is produced from coal, natural gas, or
biomass feedstock through chemical conversion. The substance created by the
conversion has the same chemical properties as crude oil or processed fuels. Raw
materials that are used to create synthetic fuel have to be subjected to intense
chemical and physical changes to meet the parameter of being a synthetic fuel. The
usage of synfuel produces lower levels of particulates and no sulphur, resulting in
reduced localized air pollution. Synthetic fuel emits carbon dioxide when it’s
burned, but also captures carbon dioxide as its being made, so it’s considered carbon
neutral. Some synthetic fuels processes can be converted to sustainable production
practices more easily than others, depending on the process equipment selected.

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This is an important design consideration as these facilities are implemented, as


additional room must be left in the plant layout to accommodate whatever future
plant change requirements in terms of materials handling and gasification might be
necessary to accommodate a future change in production profile.
There are basically 2 categories of synthetic fuels, which are synthetic crude
oils and Fischer-Tropsch liquids. Synthetic crude oils can be used for the same
purpose such as conventional crude oil. The synthetic crude oil must be refined and
processed to produce various forms of commercial fuels such as diesel, gasoline,
and kerosene. Fischer-Tropsch liquids can also produce various forms of
commercial fuels, and also can produce industrial lubricants, kerosene, and other
products. Fischer-Tropsch liquids burn much cleaner than syncrude products. These
synfuels almost have no particulate emissions, and it contains less nitrogen oxide
and less carbon monoxide emissions than traditional oil-based fuels.
Fuels produced by various synthetic fuels process have a wide range of
potential environmental performance, although the fuels tend to be uniform based
on the type of synthetic fuels process that is used in production. Fischer-Tropsch
diesel and jet fuels has a significant amount of reductions in criterias such as SOx,
NOx, particulate matter, and hydrocarbon emissions. These fuels produced have
higher level of purity and also enable use of advanced emissions control equipment.
The composition of synthetic fuels and natural fuels are the same, which are
mixtures of hydrocarbons. The standard is 66% saturated hydrocarbons (linear and
cyclic chains), 30% aromatics (benzene derivatives), and 4% olefins (unsaturated
hydrocarbons). FT fuels have demonstrated excellent cold-flow performance in
both terrestrial and aviation applications. Testing has demonstrated no issues with
injector fouling, in both very hot and cold environments.

Figure 1.1. Synthetic and conventional fuel comparison


(Source: Illinois Clean Fuels, 2018)

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Synthetic fuel can be easily transported, stored, and replenished. The


existing network of fuel stations and distribution would work fine with the synthetic
fuel. It is also compatible with the exiting engine technology. In the future, synthetic
fuels are a great alternative to traditional oil based fuels, once the environmental
impacts in the production are mitigated. Synthetic fuels are better for the long run
since the energy yield is higher than biofuels and it is also cleaner for the
environment than the conventional fuel.
Table 1.1. Disadvantage and advantage of synfuel
Disadvantage Advantage
Low to medium net energy yield Large supply of feed in many countries
High carbon dioxide emission in Can be used as vehicle fuel
production (if the production uses coal)
High water use Less pollution due to its purity
(Source: Venngage, 2017)
One of the positive defining characteristics of synfuel production is the
ability to use multiple feedstocks to produce the same product from the same plant.
In the case of hybrid BCTL plants, some facilities are already planning to use a
significant biomass component alongside coal. Ultimately, given the right location
with good biomass availability, and sufficiently high oil prices, synthetic fuels
plants can be transitioned from coal or gas, over to a 100% biomass feedstock. This
provides a path forward towards a renewable fuel source and possibly more
sustainable, even if the plant originally produced fuels solely from coal, making the
infrastructure forwards-compatible even if the original fossil feedstock runs out.
1.2.2 Overview of Synfuel Production
There are two well-known processes in chemically converting non-fossil
feedstock into synfuel. They are Fischer-Tropsch and Methanol-to-Gasoline
reactions. In these two processes, a mixture of CO and H2 known as syn-gas are
converted into value-added hydrocarbons in the liquid phase. Fischer-Tropsch
synthesis is a series of chemical reactions that convert syn-gas into liquid
hydrocarbons mainly consisted of saturated linear hydrocarbons with carbon
number higher than 40. The basic chemical reaction can be represented as follow.
2H2 + CO → −CH2 − +H2 O
First discovered by Franz Fischer and Hans Tropsch in 1920s, Fischer-
Tropsch synthesis has been very successful. A number of FT plants have been

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commercialized, although some have been shut down due to economic concerns or
other issues. The popularity of FT synthesis has been hampered by the high cost
and the large scale infrastructures required.
Methanol-to-Gasoline is another option for producing synfuel. With the
progressive technological improvements over the past 100 years, and in particular
the development of “Mega Methanol” technology, the cost of methanol production
has come down to be economically beneficial for large production capacity (Lange,
2001). Methanol as a liquid can be easily transported and stored, and large scale
infrastructures, large pipelines or special tanks are not required.
Commercial MTG plants are generally an order of magnitude smaller in
scale than FT plants. Commercial methanol plants have a wider and more diverse
distribution with the smallest plant being only approximately 1/30 the scale of the
largest methanol plant, whereas for an FT commercial plant, the plant size varies
only by a factor of 10. This implies that the much smaller and diverse scale of
methanol synthesis and MTG process makes synfuel production more applicable.
1.2.3 Methanol-to-Gasoline
Methanol is the simplest alcohol in the form of a colorless liquid with slight
alcoholic odor. Methanol can be made at various scales from various sources such
as natural gas, coal and/ or biomass or even the utilization of CO2. In fact, any
hydrocarbon sources can be used for methanol production via syn-gas derived from
steam gasification or reforming of the hydrocarbons.
Commercially, Methanol-to-Gasoline uses methanol as feedstock and
ZSM-5 zeolite as catalyst to produce gasoline range hydrocarbons. It is the first
major breakthrough in the development of synthetic fuel since the advent of FT
synthesis, providing a new route for the production of synthetic transportation fuel
from sources that are independent of conventional petroleum sources.
The first reported observation of synthetic gasoline from methanol is
credited to ExxonMobil in early 1970s, when two teams accidentally discovered
the formation of hydrocarbons from methanol over ZSM-5 zeolite. Aromatic
hydrocarbons were observed by one team at the Mobil Chemical who were trying
to convert methanol to ethylene oxide. Another team of Mobil’s Central Research
Laboratory also discovered the formation of hydrocarbons when working on

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isobutene methylation with methanol in the presence of ZSM-5 zeolite. The


aromatic hydrocarbons were found to be similar to premium gasoline, and virtually
absent of hydrocarbon higher than C10, suitable for use of gasoline fuel.
The first commercial MTG plant was built in New Zealand with a fixed-bed
process shown below. The plant had a production capacity of 14500 barrels per day
based on methanol converted from syngas via natural gas (Chang, 1992).

Figure 1.2. Schematic of typical MTG fixed bed process flow


(Source: Chang, 1992)
The first stage of reaction involved the dehydration of crude methanol over
a slightly acidic catalyst to produce an equilibrium mixture of methanol, dimethyl
ether, and water. In the second stage, the resulting mixture was introduced over
ZSM-5 catalyst to produce light olefins which underwent further transformation
into higher hydrocarbons rich in iso-paraffins and aromatics, sulphur-free, and
unleaded. Nowadays, more advanced technologies regarding MTG operation are
developed, some of which are Haldor Topsoe’s Improved Gasoline Synthesis
(TIGAS) and Primus’ STG+ Technology. By optimizing the overall process,
complexity is reduced, selectivity is escalated, and cost is minimized.
1.2.4 Photovoltaic Electrolysis
A photovoltaic (PV) system is a system composed of one or more solar
panels (which has a chemical composition) combined with an inverter and other
electrical and mechanical hardware that use energy from the wun to generate
electricity. Photovoltaic (solar cells) convert sunlight directly into electricity by
providing electron movement between (+) and (-) poles as a result of the photons
that hit them. They are made of semiconductor materials which is silicon. When

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the light from the sun, photons falls onto a solar panel and absorbed by these
materials, the solar energy knocks electrons loose from their atoms, allowing the
electrons to flow through and create an electric current. This process of converting
light (photons) to electricity (voltage) is called the photovoltaic (PV) effect.

Figure 1.3. Photovoltaic devices


(Source: www.science.nasa.gov, 2002)
A number of solar cells electrically connected to each other and mounted in
a support structure or frame is called a photovoltaic module that hold about 40 cells.
Modules are designed to supply electricity at a certain voltage, such as a common
12 volts system. Each module produces a relatively small amount of energy, but
can be linked together with other modules to produce higher amounts of energy as
a photovoltaic array. A number of these modules are mounted in PV arrays that can
measure up to several meters on a side. These flat-plate PV arrays can be mounted
at a fixed angle facing south, or they can be mounted on a tracking device that
follows the sun, allowing them to capture the most sunlight over the course of a
day. Several connected PV arrays can provide enough power for a household; for
large electric utility or industrial applications depend on how much light strikes the
module, hundreds of arrays can be interconnected to form a single, large PV system.

Figure 1.4. Chemical structure of a PV cell


(Source: http://cleangreenenergyzone.com, 2018)
Photovoltaic (PV) cell consists of several chemical structure, as follow.
 SiO2; Basic element of semiconductor segments. This chemical is used in
the making of the transistors and diodes that are used in electronic circuits.

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 Silicon Wafer; Responsible for creating a semiconductor environment. The


process of separation to the poles occurs with SiO2.
 Flow of Electrons; The extra electrons that come out as a result of the
photons move from (-) pole to (+) pole and generate electricity.
To get around this limitation (the photovoltaic response of single-junction
cells is limited to the portion of the sun's spectrum) is to use two (or more) different
cells, with more than one band gap and more than one junction, to generate a
voltage. These are referred to as multijunction cells (also called cascade or tandem
cells). Multijunction devices can achieve a higher total conversion efficiency
because they can convert more of the energy spectrum of light to electricity.

Figure 1.5. Flow of electrons on two poles


(Source: http://cleangreenenergyzone.com, 2018)
Based on the figure, it can be observed that on the PV cell which has light
on it the (-) pole intensity increases and as a result of this, there is also an increase
in the voltage in the voltmeter. The photons in the light cause the number of
electrons on the silicon surface to increase by activating them and this causes the
two poles to generate electricity. But, a silicon surface cannot completely transform
the power of the light which falls on it into electricity. The main reason for this is
that even though there are many colors in light only the red color is transformed.

Figure 1.6. Flow process on p-n junction principle


(Source: http://cleangreenenergyzone.com, 2018)
The working principle of photovoltaic solar cells produce electricity is same
with the p-n junction diode principle. The cells which are made of semiconductor
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matter absorb the light that is reflected on them and transform it into electric energy.
The major process here is provided by the flow of the extra electrons in the (-) pole
to the holes in the (+) pole by means of the photons. During this flow the generation
of electricity occurs. A multijunction device is a stack of individual single-junction
cells in descending order of band gap. The top cell captures the high-energy photons
and passes the rest of the photons on to be absorbed by lower-band-gap cells.
The amount of electric energy produced by photovoltaic cells are in
proportion to the power and angle of light that comes to the unit area, which are:
 The light that comes with a right angle provides more power generation
 The light that comes from a higher level provides more power generation
Nowadays, the sun cells have the best conversion rate work with 15-40%
efficiency. For example, let's assume that on a PV with a 10 cm2 surface area, a
light with 10W of power falls. The maximum electric power would be 3W.
Generally, generated PV cells generate a maximum voltage of 0.5 V. By connecting
these cells as parallel or series, the current and voltage can be changed.
There are 4 types of PV cells according to their manufacturing technology:
a) Single or Mono Crystalline Cells; Made of pure silicon surface and a thin
structure, which have high efficiency. Monocrystalline cells have two
different manufacturing technologies that are silicon and gallium arsenide.
b) Polycrystalline; Has a crystalline structure in the form of a thin film.
Cadmium telluride (CdTe) or Copper indium diselenide (CIS) is used in the
structure. But, the efficiency is not more than 10%.
c) Amorphous silicon; Has a non-crystalline structure. Rate of efficiency is not
very high, used in small devices such as calculators and digital dictionaries.
d) Hybrid Solar Cell; One of the newest technologies. Organic and chemical
substances are used together in its structure. Even though it has quite a high
rate of energy efficiency, it is not yet in the industrial manufacturing phase.
Electrolysis be used to convert water into hydrogen and oxygen. There are
three different types of electrolysis: alkaline electrolysis (AEL), proton exchange
membrane (PEM) electrolysis and solid oxide electrolysis cell (SOEC). AEL and
PEM have currently reached commercialization whereas SOECs are still in the
research phase. (Kjartansdóttir & Møller, 2014).

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The electrolysis cell in AEL consists of an anode and a cathode that are
immersed in a liquid alkaline. They are separated by an ionic conducting
diaphragm, which serves as a boundary to prevent the hydrogen and oxygen from
mixing. When a voltage is applied to the electrodes, the water decomposes in
hydrogen and hydroxyl molecules at the cathode. The charge carrier is the OH- ion,
which migrates through the diaphragm and forms water and oxygen at the anode.
In PEM electrolysis, the cell consists of an acidic solid membrane, enclosed
by an anode and a cathode on each side. Due to the current applied, the water that
is fed to the anode side decomposes into oxygen and hydrogen. The hydrogen atom
migrates through the membrane because of the presence of sulfonic acid in the
membrane. Because of the acidity of the membrane, noble element catalysts such
as palladium or iridium are required, significantly increasing the cost.
With SOEC, the electrolyte consists of a ceramic material that conducts
oxygen ions. The high temperatures required are caused by the ionic conductivity
characteristics of the membrane. At the cathode, water is split into hydrogen and
oxygen atoms. The oxygen atoms migrate through the electrolyte and form oxygen
gas at the anode. The hydrogen atoms form hydrogen gas at the cathode and are
collected there. Because of severe operating conditions, expensive materials are
required such as yttrium and zirconium, which drastically increase the cost.
Table 1.2. Electrolysis characteristics

Indicator AEL PEM SOEC


o
Temperature ( C) 40-90 20-100 700-1000
Pressure (bar) 4-60 30-200 1
Electrolyte Liquid alkalie KOH Solid acid polymer Ceramid metal
Anode material Ni Ti, Ir (catalyst) Ni doped YSZ
Cathode material Stainless steel mesh Carbon, Pt (catalyst) LSM
Charge carrier OH- H+ O2-
Life-time (hours) 50,000-100,000 <40,000 1,000-5,000
(Source: Gandia, Arzamedi, & Dieguez, 2013; Smolinka, 2014)
1.3 Analysis
1.3.1 Raw Material Analysis
1.3.1.1 Natuna Gas CO2
Natuna gas field is located in the Greater Sarawak Basin (East Natuna)
about 1,100 km north of Jakarta and 225 km northeast of the Natuna Islands. It was

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discovered by Italy's Agip in 1973 and be in Indonesia's northernmost territory in


the South China Sea at a water depth of 145 m.

Figure 1.7. The location of Natuna gas field in Indonesia


(Source: Global CCS Institute, 2018)
The Natuna becomes the largest undeveloped gas discovery in Southeast
Asia with an estimated resource of 46 Tcf of recoverable methane. The Natuna gas
field is called Esso Natuna's D-Alpha which has Pertamina as its production sharing
block in 1980. Esso Natuna has drilled five exploratory wells in the field and
conducted 15 production tests, analyses of which show the reservoir is highly
productive. The tests show the Natuna's gas composition consists of 71% CO2, 28%
methane and heavier hydrocarbons, and 0.5% of hydrogen sulfide and nitrogen.
The huge amount of CO2 in Natuna gas gives a big opportunity to develop
a synfuel industry that utilizes CO2 as one of its main raw materials. CO2 is obtained
from separation process using carbondioxide-reforming to separate CO2 and
methane. It is also powered by single stage cryogenic technology that using
separated CO2 as CO2 injection to separate aquifier and multi stage cryogenic
technology that makes CO2 is recycled to the reservoir. Aside from returning back
to reservoir, CO2 can be captured and transported through three 1,050 mm parallel
X70 carbon-steel pipelines with a maximum pipeline pressure of 18 MPa. The
pipelines can carry the CO2 along 200 km to the injection platforms or sites.
1.3.1.2 Solar Energy
Indonesia has many locations that potentially good to obtain solar energy.
The order of the most potential locations is Kalimantan (eastern, middle, western
part), Papua (eastern, middle part), Sulawesi (southeast and middle part), Sumatera
(northern and western part), then Java (western and middle part) (Puwarto, 2006).
In general, solar energy potential in Indonesia is distinguished into two
different areas, which are the western and the eastern. The Western part of

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Indonesia features with an average irradiation of 4.5 kW h m-2 d-1, while the Eastern
part by an average irradiation of 5.1 kW h m-2 d-1. The solar irradiation is spatially-
varying from 1.3 to 3.6 kW h m-2 per day (Rumbayan et al., 2012).

(a)

(b)
Figure 1.8. Profile of estimated solar energy potential in Indonesia (a) wet and (b) dry
season
(Source: Wahyuono, 2018)
Based on the needs of CO2 from Natuna gas, the location of solar potential
can be focused around Natuna island. The nearest island is Kalimantan. Table
below shows the solar potential energy during the wet and the dry season.
Table 1.3. Solar potential energy during the wet and the dry season
Solar Power (kWh)
Province
Wet Dry
Aceh Darussalam 300 293
Central Kalimantan 281 361
East Kalimantan 280 337
North Sumatra 336 335
Riau 305 331
South Kalimantan 288 381
South Sumatra 301 365
West Kalimantan 283 356
West Sumatra 313 334
(Source: Wahyuono, 2018)
The majority of land in Indonesia receives high potential of global solar
irradiation with its value ranging between 4.6 kWh/m2 and 7.2 kWh/m2 (Rumbayan
et al., 2012). It is clearly shows that all places in Indonesia has good solar potential.

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The solar radiation particularly in West Kalimantan, maintains the intensity


throughout the year, as can be seen below.
Table 1.1. Solar potential energy during the wet and the dry season
Solar Radiation Solar Radiation
Month Month
Intensity (W/m2) Intensity (W/m2)
January 169-189 July 182-210
February 177-202 August 187-215
March 183-211 September 179-208
April 177-219 October 179-199
May 183-213 November 176-191
June 174-205 December 165-179
(Source: Wahyuono, 2018)
1.3.1.3. Sea Water
Water, which is supplied through sea water, is required to produce hydrogen
from PV electrolysis. The major components of sea water are described as follow.
Table 1.2. The major ions of seawater

(Source: Wiesenburg, 1987)


To be specific, sea water that will be used for this plant is from around
Kalimantan Island, especially West Kalimantan. Near there, there is Tambelan
islands which has the same current around Natuna islands and West Kalimantan.
The containment from the sea water around those place is shown in table below.
Table 1.3. Tambelan Islands Water Characteristics, 2010

(Source: Suherman, 2012)


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1.3.2 Market and Production Capacity Analysis


Gasoline is an important commodity of the world. It is used for many
applications primarily for engine fuel in vehicles. Refineries and companies that
produce the finished motor gasoline sold in retail gasoline fuel stations may add
various liquids so that gasoline burns cleaner and meets are pollution control
standards. Finished motor gasoline are gasoline that already meet the basic
requirements for fuel to be able for use in spark ignition engines. In Indonesia the
population growth is getting higher which results in higher demand of gasoline.

Figure 1.9. Indonesia’s annual national commercial gasoline


(Source: BPH Migas, 2017)
To determine the market capacity of the product, it is needed to know about
the gasoline demand and production. Indonesia currently has six oil refineries, all
operated by the nation's state-owned energy company Pertamina. I Gusti Nyoman
Wiratmaja, Director General of Oil & Gas at Indonesia's Energy and Mineral
Resources Ministry, predicts that the Indonesian people will consume 2.6 million
bpd of fuel by 2025. This condition will result in fuel import to fulfill the fuel
demand of Indonesia. In order to fulfill this condition fuel is imported.
Table 1.4. Current refinery capacity in Indonesia
Refinery Location Capacity (1000 bpd)
Dumai Riau 170.0
Plaju South Sumatra 109.0
Cilacap Central Java 340.0
Balikpapan East Kalimantan 260.0
Balongan West Java 125.0
Tuban East Java 92.0
Combined Total 1,096.0
(Source: Investor Daily, 2017)
The plant will distribute the gasoline across Kalimantan Island. According
to Badan Pusat Statistik, the total motored vehicle rises up to 83% of its initial value

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of 473,000 units in 2005 to 866,000 units in 2010. With the growth assumed to be
constant, it is predicted that the amount of vehicles owned by the population will
increase to 5,315,000 by 2025. With the data of average consumption of fuel per
vehicle to be 480 gallons per year or 11.42 barrels per year, the demand in 2025 is
estimated to be 60,716,000 barrels.
The realization of gasoline in Kalimantan from domestic sources at 2017 is
5,004,944 kilolitres or 31,481,098 barrels. The growth of gasoline realization from
domestic source is 1.96%. Through the data collected, the production capacity is
taken to be 0.7% of the gap between supply and demand, and the calculation is
shown as follow.
Table 1.5. Production capacity
Variable Value Unit Converting Factor
Amount of vehicle in 2010 866,000
Amount of vehicle in 2025 5,315,000 Annual growth of 83%
Average consumption per
Gasoline demand in 2025 60,716,000 barrel/year
vehicle of 11.42 barrels per year
Gasoline supply in 2017 31,481,000 barrel/year
Gasoline supply in 2025 36,771,000 barrel/year Annual growth of 1.96%
Demand – supply gap 23,946,000 barrel/year
167,621 barrel/year
Production capacity 17,527 tonne/year Share 0.7%
2.25 tonne/hour
The production capacity obtained through demand-supply gap needs to be
benchmarked with the real similar plant, which is determined to be DME plant. Fuel
DME Production Co, a company of Mitsubishi Gas Chemical, has fabricated a
DME production plant in Niigata Factory (Japan), with a capacity of 215 tonne/day
or 8.9 tonne/hour. On the other hand, Oberon California produces DME with
capacity of 2,250 gallons/day or 2.1 tonne/hour.
The low level capacity of benchmarking data is taken, with consideration of
minimization of electricity supply outside PV. The plant will produce 2.25
tonne/hour of gasoline to be distributed to fuel retail stations around Kalimantan.
1.3.3 Plant Location
There are several factors that must be considered in determining plant
location because it will affect the continuity of the production in the future. The
factors can be separated into consideration of close to raw material, solar power

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potential availability, proximity to markets, and land development availability.


Based on those factors, the best location that suited this plant is in West Kalimantan.

Table 1.6. Plant location


a) Close to Raw Material
The plant is located near the raw material of CO2 and sea water. Natuna gas
is a gas field that is located in East Natuna (coordinates: 3.509886, 109.057440)
which consists of methane with 71% amount of CO2. The CO2 that removed from
methane is very useful in economically and preventing greenhouse effect to be the
raw material for this plant rather than recycling back it to its field.
b) Solar Power Potential Availability
Based on potential solar energy, West Kalimantan has potential energy
about 283 kWh in wet season and 356 kWh in dry season. West Kalimantan,
especially near its shoreline, also has a hot temperature about 30oC-34oC with the
greatest sunlight intensity hours about 200 hours each month.
c) Proximity to Markets
Due to a huge amount of demand in consuming gasoline in Kalimantan and
only few plants that distribute gasoline in Kalimantan, this plant has a huge chance
to take a market in. Besides that, this plant also has a new technology that uses CO2
that can bring more profit and can bring huge development in the future because
CO2 is a component that exist and can be easily found everywhere.
d) Land Development Availability
The chosen location has more area to do expansion project in the future that
considers about the demands of gasoline that will increase in the future. The
expansion project also can spread its market in the future in order to supply
domestically or to do export. So, the production later will need additional
constructions to fulfill the demands.

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CHAPTER 2
PROCESS SYNTHESIS

2.1 Process Selection


2.1.1. Process Route Selection
2.1.1.1. Overview of Process Routes
According to the stated literature, the two common ways of producing
synfuel is by Fishcer-Tropsch and Methanol-to-Gasoline reactions. Combined with
the other processes preceding these steps, there are several alternatives of routes
that can convert CO2 to gasoline. These routes are evaluated based on the specified
criteria, and the best route is chosen.
2.1.1.2. Reverse Water Gas Shift Reaction (RWGS)
The reverse water–gas shift reaction is a key reaction in the catalytic
hydrogenation of carbon dioxide. The aim is to convert CO2 to CO, so a mixture of
syn-gas will be formed. It is a mildly endothermic reaction with enthalpy and free
energy changes of ∆H298K = 41.2 kJ/mol and ∆G298K = 28.6 kJ/mol.
CO2 + H2 ↔ CO + H2 O
CO as the reaction product then combines with hydrogen produced from
water-splitting electrolysis, and forms what is known as syn-gas. The syn-gas then
goes through further processes to be converted into synfuel, either via Fischer-
Tropsch or Methanol-to-Gasoline reactions.
Reverse water gas shift reaction has been known from over two centuries,
but there is still the need to develop improved catalysts, since for example iron-
chromium are active at temperatures of 400oC or greater, but at this temperature the
equilibrium constant is low and there is a significant problem in driving the reaction
to completion. The equilibrium can be shifted to the right by one following ways.
 Increasing CO2 concentration to force the complete consumption of H2
 Operating at high H2 concentration to force complete consumption of CO2
 Removing water vapor from the reactor with desiccant bed or membrane
permeoselective to water, thereby driving the reaction to the right.
Several common catalysts used for reverse water gas shift reaction is
described as follow.

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 Copper-based catalysts particularly CuO/ZnO modified by alumina


zirconia, titania, and/or silica
 Iron-based catalysts, essentially modifications of commercial high
temperature Fe-Cr catalyst
 Cerium-based catalysts
In practice, the principle of converting CO2 to CO in reverse water gas shift
reaction can be substituted with a process of co-electrolysis of both H2O and CO2.
The co-electrolysis process is briefly described on the following section.
2.1.1.3. Co-electrolysis of H2O and CO2
Research for co-electrolysis process of H2O and CO2 is being worked on to
produce syn-gas more effectively. Delacourt et al. (2008) designed the cell similar
to a proton exchange membrane fuel cell (PEMFC), but with a silver or gold catalyst
at the cathode, and a pH buffer layer between the cathode catalyst layer and the
membrane. This cell is expected to accommodate the simultaneous electrolysis
process of H2O and CO2 to produce H2 and CO as syn-gas.
The reactions for CO and H2 evolution at the cathode are written as follow.
3𝐶𝑂2 + 𝐻2 𝑂 + 2𝑒̅ → 𝐶𝑂 + 2𝐻𝐶𝑂3−
2𝐶𝑂2 + 2𝐻2 𝑂 + 2𝑒̅ → 𝐻2 + 2𝐻𝐶𝑂3−
On the other side, oxygen evolution at the anode is written as follow.
2𝐻2 𝑂 → 𝑂2 + 4𝐻 + + 4𝑒̅
The reaction in oxygen evolution generates proton that are transported
through the cation exchange membrane towards the cathode. At the boundary
between the buffer layer and the cation exchange membrane, the protons react with
the bicorbonate ions coming from the cathode, following the equation below.
𝐻 + + 𝐻𝐶𝑂3− ↔ 𝐶𝑂2 + 𝐻2 𝑂
The configuration derived from PEMFC was shown to be unfavorable for
CO2 reduction, leading to H2 evolution only. Depart from this problem, a modified
configuration based on the insertion of a pH-buffer layer between the cathode
catalyst layer and the membrane was made for a great enhancement of the cathode
selectivity for CO2 reduction to CO.
The cell is briefly composed of two blocks in which channels have been
machined and which are used as current collectors as well as to feed reactants to

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the anode and cathode. The cathode block is made of graphite. The anode block is
made of polytetrafluoroethylene (PTFE). This method of producing syn-gas is still
under research and has not applied in actual industry yet.
2.1.1.4. CO2 to Methanol
Depending on the reaction conditions and catalyst selectivity, methanol can
be either produced directly from CO2 and H2 or via CO which is formed in the
competing RWGS. The direct reaction is formulated as follow.
𝐶𝑂2 + 3𝐻2 ↔ 𝐶𝐻3 𝑂𝐻 + 𝐻2 𝑂
The indirect reaction, which is aided by RWGS is formulated as follow.
𝐶𝑂2 + 𝐻2 ↔ 𝐶𝑂 + 𝐻2 𝑂
𝐶𝑂 + 2𝐻2 ↔ 𝐶𝐻3 𝑂𝐻
CO2 hydrogenation to methanol is exothermic, while the competing reverse
water-gas shift is endothermic. Moreover, CO produced by RWGS may undergo
exothermic hydrogenation to form methanol.
For comparison, RWGS reactor who carries on an equilibrium reaction
makes only a part of the CO2 reduced to CO. In the subsequent methanol synthesis,
less water is formed compared to a feed containing only carbon dioxide. This is
beneficial for the downstream process since less water has to be separated from the
methanol. The required hydrogen for the methanol synthesis also decreases, but the
increase of hydrogen for the RWGS reaction is equal. The main question is whether
the reduced water content in the produced methanol outweighs the extra energy
required for the carbon dioxide reduction.
In accordance to Le Chatelier’s principle, high-pressure and low-
temperature reaction conditions are favorable to achieve high CO2 conversion and
methanol selectivity. Current trend uses low-pressure methanol synthesis with
highly active and economic Cu-ZnO based catalysts (Hansen, et al., 2008).
Employing a reaction pressure of 360 bar was reported to achieve outstanding CO2
conversion (>95%) and methanol selectivity (>98%). The catalyst employed to
achieve this was a Cu/ZnO/Al2O3 catalyst. Energy-demanding high-pressure
conditions are not necessarily disadvantageous in this reaction because of smaller
geometrical requirements for the reactor and plant area, which lowers the capital

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cost and possibly improve safety aspects. However, this full one-pass conversion
method has not been implemented in industry yet.
2.1.1.5. Fischer-Tropsch
The Fischer-Tropsch process is a series of catalyzed chemical reaction that
converts syngas to hydrocarbons of various lengths, which is a synthetic equivalent
of crude oil, often called syncrude. It is a surface polymerization reaction that takes
place on the surface of the catalysts in situ.
The reaction shown below is the most basic reaction that takes place in the
Fischer-Tropsch reactor, where the term term -CH2- represents a methylene group
of normal paraffin.
2𝐻2 + 𝐶𝑂 → −𝐶𝐻2 − +𝐻2 𝑂
To be more specific, these reactions summarize the general forms of the
reactions that take place in Fischer-Tropsch synthesis of hydrocarbons.
Alkanes : 𝑛𝐶𝑂 + (2𝑛 + 1)𝐻2 → 𝐻(𝐶𝐻2 )𝑛 𝐻 + 𝑛𝐻2 𝑂
Alkenes : 𝑛𝐶𝑂 + 2𝑛𝐻2 → (𝐶𝐻2 )𝑛 + 𝑛𝐻2 𝑂
Alcohol : 𝑛𝐶𝑂 + 2𝑛𝐻2 → 𝐻(𝐶𝐻2 )𝑛 𝑂𝐻 + (𝑛 − 1)𝐻2 𝑂
Carbonyls : 𝑛𝐶𝑂 + (2𝑛 − 1)𝐻2 → (𝐶𝐻2 )𝑛 𝑂 + (𝑛 − 1)𝐻2 𝑂
As an important process parameter, product compositions are influenced by
several aspects, including temperature, feed gas composition, pressure, catalyst
type, and catalyst composition. Fischer-Tropsch reaction is highly exothermic, and
heat removal is a key aspect of reactor design. Reactors that have commercial
relevance for the Fischer-Tropsch can be broadly classified into two-phase high-
temperature FT or three-phase low-temperature FT, and in moving or stationary
catalyst bed reactors.
As a product of Fischer-Tropsch, the synthetic crude oil also known as syn-
crude requires additional separation and purification process to produce synfuel.
This additional refining adds significant costs, and usable fuel represents only 10%-
20% of the synthetic crude. In general. Fischer-Tropsch processes are economic
only at a very large scale.
2.1.1.6. Methanol-to-Gasoline
The methanol-to-gasoline process converts methanol to gasoline through
intermediate dimethyl ether (DME). This process is invented by ExxonMobil as an

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alternative procedure to produce synfuel next to Fischer-Tropsch process. In


practice, this process is conducted in a system with several reactors in series.
Feed methanol can be commercially produced from syngas or by CO2 to
methanol reaction. The methanol then reacts in the presence of catalyst to form
synfuel. In terms of mechanism, methanol is partially dehydrated to give dimethyl
ether, following the reaction below.
2𝐶𝐻3 𝑂𝐻 → 𝐶𝐻3 𝑂𝐶𝐻3 + 𝐻2 𝑂
Dimethyl ether and excess methanol are fed to gasoline synthesis reactor,
where catalytic conversion into hydrocarbons occur. The Methanol-to-Gasoline
process is proven to be highly selective for gasoline production with nearly
complete conversion of the methanol and good overall energy efficiency.
Unlike the Fischer-Tropsch process, the Methanol-to-Gasoline process
yields high quality gasoline that requires little additional processing. Figure below
illustrates the product distribution by carbon chain length from typical Fischer-
Tropsch and Methanol-to-Gasoline processes.

Figure 2.1. Illustration of product distribution from Fischer-Tropsch and Methanol-to-Gasoline


processes
(Source: Gal, Eli, et. al., 2015)
For comparison, table below describes the key differences of Fischer-
Tropsch process and Methanol-to-Gasoline process in producing synfuel.
Table 2.1. Comparison of Methanol-to-Gasoline to Fischer-Tropsch
Indicators Methanol-to-Gasoline Fischer-Tropsch
Molecular size and shape- Unselective CO and Fe
Catalyst
selective ZSM5 Catalyst
(Source: Gal, Eli et. al., 2015)
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Table 2.1. Comparison of Methanol-to-Gasoline and Fischer Tropsch (Cont’d)


Indicators Methanol-to-Gasoline Fischer-Tropsch
Narrow, gasoline-like and
Product Range Wide, crude oil
some light gases
Aromatics, naphthenes,
Product Molecular Types Linear paraffins, wax
isoparaffins
Selectivity to Gasoline Excellent Poor
Complexity Simple Complex
Economics Lower cost Higher cost
(Source: Gal, Eli et. al., 2015)
2.1.1.7. Process Route Selection
There are several pathways that can be followed to produce gasoline from
water and carbon dioxide as raw material. One pathway consists of several
processes which connect one to another. Five alternatives for process pathways are
listed below.
A. RWGS → Fischer-Tropsch
B. RWGS → Methanol Synthesis → Methanol-to-Gasoline
C. Co-electrolysis → Fischer-Tropsch
D. Co-electrolysis → Methanol Synthesis → Methanol-to-Gasoline
E. CO2 to Methanol → Methanol-to-Gasoline
In order to select one out of five routes presented, a comprehensive scoring
criteria must be built. The scoring criteria, together with the weight percentage are
listed in the following table.
Through the scoring process based on 4 criteria, the selected process route
is electrolysis of water followed by CO2 to methanol and methanol-to-gasoline
process. Further selection regarding photovoltaic electrolysis type, reactor type, and
catalyst type are described next.

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Table 2.2. Scoring criteria for process route selection

Weight Scoring Criteria


Parameter
(%) 1 2 3 4 5
Some stages have All stages have been
All stages are still on Some stages are All stages have been
Maturity 40 been applied applied as a whole
research still on research applied industrially
industrially industrially
Very complex, >8 Compact, <4 major
Complexity 25 >5 major stages 5 major stages 4 major stages
major stages stages
Low selectivity to High selectivity to High selectivity to Very high
Very low selectivity
Selectivity 15 gasoline,lots of gasoline, lots of gasoline, little selectivity to
to gasoline
byproducts byproducts byproducts gasoline
Little possible step Many possible step
No possible step Little possible step Several possible
improvements, not improvements,
improvements, not improvements, step improvements.,
Flexibility 10 applied for highly applied for
applied for different applied for different applied for different
different raw different raw
raw materials raw materials raw materials
materials materials

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Table 2.3. Parameter comparison of process routes
Indicator Process Routes Comparison
Maturity Fischer-Tropsch and Methanol-to-Gasoline have been applied in commercial plant. Co-electrolysis of H2O and CO2 are still on research.
Route A consists of >5 major stages: Electrolysis, RWGS, Fischer-Tropsch, Fractionation, Purification Stages
Route B consists of 5 major stages: Electrolysis, RWGS, Methanol Synthesis, Methanol-to-Gasoline, Purification Stages
Complexity Route C consists of 4 major stages: Co-electrolysis, Fischer-Tropsch, Fractionation, Purification Stages
Route D consists of 4 major stages: Co-electrolysis, Methanol Synthesis, Methanol-to-Gasoline, Purification
Route E consists of major 4 stages: Electrolysis, CO2 to Methanol, Methanol-to-Gasoline, Purification
The product distribution in Fischer-Tropsch process is kinetically controlled and the hydrocarbons formed are mainly long unbranched
Selectivity alkanes (up to C200) that require upgrading reactions.
The MTG process is shape selective-controlled and products aromatics and alkane/alkene hydrocarbons shorter than C10.
There are more possible improvements for MTG process than Fischer-Tropsch, typically in cycle of regeneration and catalyst selection.
Flexibility
Co-electrolysis is applied only if raw material consists of high percentage of CO2, and since it is still on research, there is less flexibility.

Table 2.4. Scoring of process routes


Weight Route A Route B Route C Route D Route E
Parameter
(%) Rating Score Rating Score Rating Score Rating Score Rating Score
Maturity 40 4 1.6 4 1.6 2 0.8 2 0.8 4 1.6
Complexity 25 2 0.5 3 0.75 4 1.0 4 1.0 4 1.0
Selectivity 20 2 0.4 4 0.8 2 0.4 4 0.8 4 0.8
Flexibility 15 3 0.45 4 0.6 1 0.15 2 0.3 4 0.6
Total 2.95 3.75 2.35 2.90 4.00
Rank 3 2 5 4 1

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2.1.2. Photovoltaic Electrolysis Technology Types Selection


Photovoltaic electrolysis is placed on the land to capture sunlight radiation
intensity to convert it into electricity and to produce hydrogen by electrolysis
process. The consideration to place it on land and not making it floats is the
maintenance convenience and the regulation about sea, which is way more
complicated than regulation on the land. The land PV electrolysis has the easiest
maintenance and simplest way to manage policies. Therefore, the types selection
for PV electrolysis are based on material complexity and electrolysis.
2.1.2.1. Material Complexity
Photovoltaic modules have so many different materials complexity. They
will be differentiated by their efficiency, maturity, and more. The table below shows
the comparison between the exists PV modules.
Based on the efficiency, maturity, and cost, polycrystalline silicon (pc-Si)
is chosen. Polycrystalline panels use solar cells that are cut from multifaceted
silicon crystals. They are less uniform in appearance than monocrystalline cells,
resembling pieces of shattered glass. Polycrystalline silicon (pc-Si) has pretty good
efficiency around 13-15% with low cost under 14 USD/W and very mature in
market especially handling large scale production.
2.1.2.2. Type of Electrolysis
A multi criteria analysis is performed to determine the most suitable
electrolyser. The first criterion is the size of the electrolyser. The second criterion
is the dynamic operation performance of the electrolyser. The power source of the
process is determined to be solar PV. This means that at least parts of the process
will be operated dynamically. The start-up time of the equipment is therefore of
major importance. The third criterion is the capital cost of the electrolyser. The
process will run automatically and there will therefore not be any operational costs.
The fourth criterion is the lifetime of the electrolyser. The lifetime indirectly
influences the costs but is of even bigger importance in this application since the
process is to operate in remote locations where maintenance is difficult. The fifth
criterion is the operating conditions. A low temperature and pressure are preferable
since they require less energy and therefore decrease the number of solar panels
required. The final criterion is the efficiency of the electrolyser.

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Table 2.5. Photovoltaic technology comparison
1st Generation PV 2nd Generation PV 3rd Generation PV
Copper
Single- Single- IPV compound Organic
Indium Codmium
crystaline crystaline Amorphous multijunction, or
Technology Units Gollium Telluride DSSC
silicon (sc- silicon (sc- silicon (oSi) concentrated Polymer
Diselectrude solar cells
Si) Si) PV (CPV) (CPV)
(CIS/CIGS)
10.4 Single
Best research solar cell
% 24.7 - junction 20.3 16.5 43.5 11.1 11.1
efficiency
13.2 tandem
Confirmed solar cell
% 20.24 14-18 6-8 10-12 8-10 35-41 8.8 8.3
efficiency
Commercial PV 7-11
% 15-19 13-15 5-8 8-11 2530 1.6 1
module efficiency
Confirmed maximum
% 23 16 7.1/10 12.1 11.2 25 - -
PV Module efficiency
Current PV module
USD/W > 1.4 < 1.4 ~0.8 ~0.9 ~0.9 - - -
cost
Maximum PV module
W 320 300 120 120 120 - -
output power
PV module size m2 2 1.4-2.5 1.4 0.6-1 0.72 - - -
Area needed per kW m2 7 8 15 10 11 - - -
Early Early
Mature Mature Early Just commercial
development development
State of with large with large development idea at small R&D R&D
- phase, phase, small
Commercialisation scale scale phase, medium scale phase phase
medium scale scale
production production scale production production
production production
(Source : solarmarket.pk, 2015)

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Table 2.6. Criteria evaluation of electrolysis


Dynamic Capital Operating
Technology Size Lifetime Efficiency
Operation Cost Conditions
AEL - +/- ++ ++ ++ +
PEM +/- + - + + +
SOEC ? -- -- - - ++
(Source: Kjartansdóttir & Møller, 2014)
AEL has the best score on average on all criteria. The main disadvantage is
the increased size, but it would not be a big problem for the plant. Also, the slightly
lower efficiency is a downside. The advantages of reduced cost and improved
lifetime are however decisive.
A problem with the dynamic operation of AEL is that if the electrolyser is
turned off, the dissolved hydrogen and oxygen molecules present in the solution
will tend to migrate through the membrane and undergo the reverse reaction,
resulting in an increase in an undesired increase in pressure of the system. A
possible solution is to keep the electrolyser running at a lower level during process
downtime. However, since the electrolyser is by far the biggest component of the
process, this will require a huge battery capacity. Another option is to short-circuit
the system after turning it down, providing an energetically favorable route for the
electrons through the electrodes. Since the solubility of oxygen in water is
significantly higher than the solubility of hydrogen, there will be oxygen remaining
in the liquid after all the hydrogen has reacted. For safety purposes, a pressure
relieve valve should be present in the oxygen collector at the top, which can blow
off the surplus oxygen. This amount of energy is not relevant to store, but the short
circuit could be connected to the battery for safe dissipation of the energy.
2.1.3. Catalyst and Reactor Selection
2.1.3.1. Methanol Sythesis
For the conversion of CO2 to methanol there are 2 common reactors used,
which are the tubular catalytic reactor and the zeolite membrane reactor. In a tubular
reactor, fluid flows through at high velocities. As the reactants flow they are
converted to products. At these high velocities, the products are unable to diffuse
back and there is little or no back mixing. The conditions are referred to as plug
flow. This reduces the occurrence of side reactions and increases the yield of the
desired product. With a constant flow rate, the conditions at any one point remain

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constant with time and changes in time of the reaction are measured in terms of the
position along the length of the tube. The reaction rate is faster at the pipe inlet
because the concentration of reactants is at its highest and the reaction rate reduces
as the reactants flow through the pipe due to the decrease in concentration of the
reactant. While traditional fixed-bed tubular reactors usually give low yield and
selectivity of methanol, a membrane reactor couples a chemical reaction and a
membrane-based separation process in the same unit so as to intensify the whole
process. Membrane reactor, in which a reactor coupled with a selective membrane
with a suitable molecular weight cut-off, is capable of keeping reactant and other
larger components, while low-molecular-weight-molecules, are allowed to pass
freely through the membrane. Catalytic membrane reactor (CMR) deposit active
catalyst on the selective layer or utilize material that can have both catalyst and
membrane function. Thus, the reaction is occurring on the selective layer, let
product through the membrane while reject reactant. The zeolite membrane
requirements are usually to operate at 350°-550° C and it has 2 product streams,
which is H2 and CO2 with high purity. The cost for the membrane reactor is higher,
while the tubular catalytic reactor is cheaper and by using tubular catalytic reactor
the wanted product’s requirement is already meet. Hence, the tubular catalytic
reactor is used.

Figure 2.2. Zeolite membrane reactor scheme


(Source: University of Cincinnati, 2011)
The catalyst used is the Cu/Zn/Al catalyst and the required loading is 2000
kg. A Cu/Zn/Al-catalyst, containing copper oxide and Zinc oxide as catalytically
active components and aluminum oxide as a thermo-stabilizing component. The
Cu/Zn-atomic ratio is within a range of 2.8 and 3.8, preferably within 2.8 and 3.2,
and the portion of Al2O3 is 8 to 12 wt.-%. It has been found, that by decreasing the

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atomic ratio of Cu/Zn, this effects may be obtained as to specific activity and
selectivity, in particular at temperatures below 250° C. Further, thermal stability is
improved. Therefore, the object of the invention is to provide Cu/Zn/Al-catalysts
having a high specific activity, selectivity and thermal stability.
2.1.3.2. DME Synthesis
The chosen reactor for dehydration of methanol is an adiabatic packed bed
reactor. The reactor consists of a cylindrical jacket in which the catalyst is loosely
packed on a screen and is traversed in the axial direction. To avoid catalyst abrasion
by partial fluidization, catalyst packing is always traversed from top to bottom. The
catalyst used for this conversion is gamma alumina (γ-Al2O3) catalyst at 482°F
(250°C) and 140 psia (9.7 bar). Among various alumina-based catalysts, the γ-
Al2O3 catalyst generally exhibits the best catalytic performance and hydrothermal
stability for vapor-phase dehydration of methanol to DME. The catalytic vapor-
phase dehydration of methanol to DME is an exothermic reaction. The reactor heat
is recovered with an intercooler for steam generation to allow for the adiabatic
temperature rise with a targeted maximum reactor temperature of 482°F (250°C).
DME is assumed to exit the methanol-to-DME reactor in equilibrium with methanol
at the reactor exit temperature (88.5% conversion of methanol).
2.1.3.3. Gasoline Synthesis
Adiabatic packed bed reactors containing metal modified beta-zeolite (H-
BEA) catalyst is used for the conversion of DME to gasoline. It has been
demonstrated that the H-BEA catalyst exhibits some of the highest productivities
and selectivity among zeolites studied for the homologation of DME to branched
paraffins and olefins. DME is preferentially converted to C4 and C7 hydrocarbons.
Comparing to other zeolites Pt/H-BEA is considered to be a promising catalyst for
hydroisomerization of n-C7. Zeolite beta consists of an intergrowth of two distinct
structures termed Polymorphs A and B. The polymorphs grow as two-dimensional
sheets and the sheets randomly alternate between the two. Both polymorphs have a
three dimensional network of 12-ring pores. The intergrowth of the polymorphs
does not significantly affect the pores in two of the dimensions, but in the direction
of the faulting, the pore becomes tortuous, but not blocked.
2.2 Process Description

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2.2.1. Photovoltaic Electrolysis (Area 100)


This area is equipped with water treatment followed by photovoltaic
electrolysis of water to produce hydrogen and oxygen. Before the RO process,
seawater is taken by intake system to deliver seawater into the plant. There are
different kinds of intake methods based on hydrology water quality in the intake
area, geology conditions, meteorological data and natural disaster, such as Beach
Well Intake, Subsurface Water Intake, and Open Sea Water Intake, etc. In this plant,
seawater are taken from Open Sea Water. But, inorganic suspended solids, sand,
oil, clays, bacteria, and dissolved organic matters are susceptible to foul the reverse
osmosis (RO) membranes.
In order to prevent the fouling of RO membrane, seawater desalination
usually adopt these pre-filters, including multi-media filter, activated filter, 10um
and 5um precision security filters. The multi-media filter and activated carbon filter
filled with refined quartz sand and cocoa-nut activated carbon respectively to
remove suspended solids, colloid particles, residual chlorine, microorganism, odor
and other particles in raw water. The coagulant is added by dosing pump before raw
water entering into the multimedia filter. Then, flocculus formed by coagulant and
colloids is removed through the filter to reach the requirements on RO feed water.
To prevent the particles in raw water and pipes from entering into HP pump
and RO module, two security filters are selected one after another as RO pre-
treatment. The precision of 2 sets of filters is 5um and 1um respectively. Under
normal working conditions, filter elements should be changed in time when the
pressure difference between inlet and outlet of the filter is above 1 bar. Filter
structure can allow changing filter element rapidly.
RO system uses the semi-permeable membrane to remove organic material,
colloidal particles, a bacterium from the feed water, producing desalinated fresh
water. The semi-permeable membrane separates water and salt solution, water
would permeate for the salt solution side under the osmotic pressure. If certain
pressure larger than osmotic pressure is applied to the salt solution, water would
permeate in the opposite direction. This phenomenon is called reverse osmosis. RO
permeate is purified, removing 98% TDS from the feed water. RO brine is
concentrated with TDS about two times of the feed water. The size of each RO

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membrane pore is about .001 microns, which is about 1/100,000th the diameter of
a human hair. After the RO process, chemicals are added to stabilize the desalinated
seawater. The operating conditions of RO are 1-5 bar and 25-45oC. For this plant,
the used pressure is 1 bar and the used temperature is 25oC.
The selected type of electricity generation, solar PV, is an intermittent
source. The logical solution is to design a process that also operates dynamically.
However, the assumption is made that there is solar irradiance one fourth of the
time. This effectively increases the capital costs of the design by four times for a
certain capacity. Therefore, to investigate the possibility of continuous operation of
the process can by adding an energy storage device and storage vessels between the
sub processes as a buffer for when no electricity is generated.
The energy generation is a process that is dynamic by definition because of
the intermittent nature of solar irradiance. The intermittency in energy supply could
be solved by adding a battery which is large enough to supply the process with
electricity when there is no solar irradiance. If the intermittency of energy supply
is solved, the entirety of the process can run continuously. The electrolysis is the
process with the highest electricity requirement.
In this plant, the part of the process that operates continuously works well
with the dynamically operated parts. Since the feedstock of seawater can be
considered as continuous sources with a virtually infinite buffer, the source has only
shifted one process further downstream. The buffer is now desalinated water instead
of seawater. The desalination also doesn’t require waste heat from the process and
is truly capable of running on the power of a relatively small battery. When water
enters the process, this water is pressurized to 30 bar, then the water enters the
alkaline electrolyser where the water is split into hydrogen and oxygen.
Electrolysis process investigated the performance of AEL (Alkaline
Electrolysis) coupled to solar PV. This electrolyzer has two electrodes operating in
a liquid alkaline electrolyte solution of potassium hydroxide (KOH). These
electrodes are separated by a diaphragm, separating the product gases and
transporting the hydroxide ions (OH−) from one electrode to the other. The
diaphragm further serves as a boundary to prevent the hydrogen and oxygen gas
from mixing. When a voltage is applied to the electrodes, the water decomposes in

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hydrogen and hydroxyl molecules at the cathode. The charge carrier in this type of
electrolyser is the OH- ion, which migrates through the diaphragm and forms water
and oxygen at the anode. The water electrolysis reaction forming hydrogen in
Alkaline Electrolysis is given by this rection:
The overall reaction of water splitting is given by:
1
𝐻2 𝑂(𝑔) → 𝐻2 (𝑔) + 𝑂2 (𝑔)
2
In the anode, oxidation occurs according to:
1
𝐻2 𝑂(𝑔) → 𝑂 + 2𝐻 + (𝑎𝑞) + 2𝑒 −
2 2 (𝑔)
In the cathode, the following reaction is:
2𝐻 + (𝑎𝑞) + 2𝑒 − → 2𝐻2 (𝑔)

This reaction operates at temperature 40-90°C and pressure 0.1 to 3 MPa


with nickel coated steel electrodes and asbestos or asbestos-free polymer
diaphragm. But, an operating temperature and pressure of 25°C and 1 bar was used
in the process when the seawater enters the pump. According to (Allebrod,
Mogensen, Hjelm, & Ebbesen, 2013), higher temperatures and pressures lead to
increased performance, but the degradation mechanisms were stronger at these
elevated pressures and temperatures. The pressure is set at 30 bar and temperature
of 40oC because of increased performance and because pressurizing a liquid using
a pump is cheaper than pressurizing a gas using a compressor.
2.2.2. Methanol Synthesis (Area 200)
Carbon dioxide is converted to methanol through hydrogenation, the
hydrogen that is needed for the CO2 hydrogenation is derived from sea water
electrolysis that is done with electricity derived from solar power. The process is
done in high pressure so both of the feeds (CO2 and hydrogen) should be
compressed before entering the process.
Methanol is formed from CO2 hydrogenation under three-phase conditions,
CO + 2H2 ↔ CH3OH ∆𝐻 0 298 = −90.7 𝑘𝐽/𝑚𝑜𝑙𝐶𝑂
CO2 + H2 ↔ CO + H2O ∆𝐻 0 298 = +41.2 𝑘𝐽/𝑚𝑜𝑙𝐶𝑂
CO2 + 3H2 ↔ CH3OH + H2O ∆𝐻 0 298 = +41.2 𝑘𝐽/𝑚𝑜𝑙𝐶𝑂
The unit for the process consists of methanol synthesis, gas separation, and
product purification. The inlet gas is heated up to a temperature level so that the
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reactor can operate adiabatically. The thermal energy required for crude methanol
heating and distillation separation is recovered from the outlet stream after the
methanol synthesis reactor. To obtain high purity of methanol the liquid stream is
set to below atmospheric pressure after the first flash separator. A small portion of
the recycling gas is purged in order to avoid by products accumulations. The
methanol synthesis operating pressure is at 60 bar, and heat exchangers such as
preheaters and gas coolers also the flash separators temperatures were set to allow
methanol production and recovery without any addition of external heat. The first
stage of gas/liquid separation is conducted at high pressure and low temperature to
minimize the recycled gas compression duty. The catalyst used is a Cu-Zn/Al2O3.
The selectivity of methanol using this catalyst and operating conditions are 77.8%.
Table 2.7. Key operating conditions for CO2 to methanol process
Parameter Value Unit
H2/CO2 Inlet Ratio 3.0
o
Methanol Reactor Inlet Temperature 138.5 C
Methanol Reactor Inlet Pressure 60 bar
1st Flash Separator Inlet Temperature 20 o
C
1st Flash Separator Inlet Pressure 60 bar
2nd Flash Separator Inlet Temperature 14.43 o
C
2nd Flash Separator Inlet Pressure 0.2 bar
o
Distillation Column Inlet Temperature 85 C
Distillation Column Inlet Pressure 1.3 bar
Methanol Mole Fraction of Overhead Product 0.99
(Source: Atsonios, et al., 2015, reproduced)
2.2.3. DME Synthesis (Area 300)
By means of producing high-octane hydrocarbons from methanol, DME as
an intermediate must be produced in this process. From storage, methanol is sent to
an adiabatic packed bed reactor to convert the methanol to DME on commercially
available gamma alumina (γ-Al2O3) catalyst at 225oC and 9.9 bar. Among various
alumina-based catalysts, the γ-Al2O3 catalyst generally exhibits the best catalytic
performance and hydrothermal stability for vapor-phase dehydration of methanol
to DME (Mollavali, 2008: 3265). The catalytic vapor-phase dehydration of
methanol to DME is an exothermic reaction, with the equation described as follow.
2𝐶𝐻3 𝑂𝐻 ↔ 𝐶𝐻3 𝑂𝐶𝐻3 + 𝐻2 𝑂
According to Sierra (2013), the kinetic modelling most suitable for the
dehydration of methanol over γ-Al2O3 is formulated below.
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𝑃𝐷𝑀𝐸 𝑃𝐻2 𝑂 −𝐾 𝑃 𝑛 −𝐾 𝑚 𝑞
𝑟𝐷𝑀𝐸 = 𝑘 (𝑃𝑀𝑒𝑂𝐻 2 − ) 𝑒 𝐻2𝑂 𝐻2𝑂 𝑒 𝑀𝑒𝑂𝐻𝑃𝑀𝑒𝑂𝐻 𝑒 −𝐾𝐷𝑀𝐸 𝑃𝐷𝑀𝐸
𝐾
Table 2.8. Parameter values for Methanol Dehydration kinetic model
Kinetic Parameters Value Unit
K 2.64.10-7 mol.gcat-1h-1Pa-2
Ea 263.6 kJ.mol-1
KH2O 0.171 Pa-0.36
ΔHH2O 3.60 kJ.mol-1
KMeOH 1.68.10-9 Pa-0.86
ΔHMeOH 2.01 kJ.mol-1
KDME 3.47.10-4 Pa-0.86
ΔHDME 7.20 kJ.mol-1
N 0.36
M 1.86
Q 0.86
(Source: Sierra, et al., 2013)
By the same research, it is found that a methanol conversion of 88.5% can
be obtained with operating condition of 225oC and 9.9 bar. The reactor product
stream containing mostly dimethyl ether and water is then transferred into a flash
separator at 9.24 bar and 121.1oC. This value is chosen to allow significant
separation between vapor phase comprising mostly DME and liquid phase of water.
Water is then transferred to be restored to electrolysis area, and the mixture of gas
is combined with recycled gas to further goes through gasoline synthesis process.
Table 2.9. Key operating conditions for Methanol to DME Process
Operating Condition Value Unit
o
Methanol Dehydration Reactor Inlet Temperature 225 C
Methanol Dehydration Reactor Inlet Pressure 9.997 bar
o
Flash Separator Inlet Temperature 121.1 C
Flash Separator Inlet Pressure 9.239 bar
(Source: Sierra, et al., 2013)
2.2.4. Gasoline Synthesis (Area 300)
Hydrocarbon formation from DME is accomplished in packed bed reactors
containing metal modified beta-zeolite (H-BEA) catalyst. In this reactor, high-
octane gasoline is produced by the combination of acid-catalyzed homologation of
DME and methylation of olefins. It has been demonstrated that the H-BEA catalyst
exhibits some of the highest productivities and selectivities among zeolites studied
for the homologation of DME to branched paraffins and olefins (Ahn, 2009).

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DME is preferentially converted to C4 and C8 hydrocarbons, with a high


percentage of gasoline-range hydrocarbons. According to the study by Tan (2015),
it is found that a 40% single-pass conversion of dimethyl ether happens at the
temperature of 176.7oC and pressure of 8,89 bar, with the selectivity listed below.
Table 2.10. Selectivity of DME to Hydrocarbon Synthesis at specified operating conditions
Carbon Carbon Selectivity Species Selectivity
Species
Number (%) (%)
C1 1.0 Methane 1.0
Ethane 0.3
C2 0.5
Ethylene 0.2
C3 1.2 Propane 1.2
C4 3.7 Iso-Butane 3.7
Iso-Pentane 2.9
C5 5.0
2-Methylbutene 2.1
2-Methylpentane 4.9
C6 6.0
2-Methylpentene 1.1
2,2,3-trimethylbutane 28.2
C7 39.8 n-Heptane 9.6
2-Methylhexane 2.0
2,2,3,3-Tetramethylbutane 6.6
C8 41.3 2,4,4-Trimethyl-1-pentene 1.7
2,2,4-Trimethylpentane 33.0
C9 1.0 Nonane 1.0
Aromatics 0.5 Hexamethylbenzene 0.5
(Source: Tan, et al., 2015)
The yields from the process are heavily weighted toward branched C7
molecules, with octane ratings greater than 100. The effluent from the hydrocarbon
synthesis is sent to a three-phase separator via a cooler to separate water, crude
gasoline, and light hydrocarbons. Water is recycled to the electrolysis process,
while light hydrocarbons comprising DME is recycled to the gasoline synthesis
reactor. The gasoline-range liquid phase hydrocarbons is then pumped and heated
to be purified in gasoline purification area.
Table 2.11. Key operating conditions for DME to Gasoline process
Operating Condition Value Unit
o
Gasoline Synthesis Reactor Inlet Temperature 176.7 C
Gasoline Synthesis Reactor Inlet Pressure 8.894 bar
o
Three-phase Separator Inlet Temperature 43.44 C
Three-phase Separator Inlet Pressure 5.102 bar
(Source: Tan, et al., 2015)

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2.2.5. Gasoline Purification (Area 400)


Purification process is conducted with multistage tray distillation, which
separates the components based on the relative volatility. The gasoline purification
process consists of two distillation columns, namely Deethanizer and Debutanizer.
The design used in this model is noticeably simpler than the current separations
employed in hydrocarbon recovery process in petroleum refineries.
The water-free crude hydrocarbons product is first sent to the first
distillation column, Deethanizer, where liquid C4+ and gasoline-range
hydrocarbons are separated from the light ends (C3-) and unconverted DME. The
inlet stream operating condition is set to be 78.33oC and 21.53 bar according to Tan
et al. (2015) for significant separation of components The top product comprising
mostly DME is recycled to the hydrocarbon synthesis reactor for overall conversion
increase. The Deethanizer bottom product is subsequently sent to the second
column to remove C4.
In Debutanizer column, C4 is separated from gasoline-range hydrocarbons.
The Debutanizer overhead containing mainly isobutene is transferred to further
processing unit as byproduct. Gasoline as the bottom product contains only
paraffins (87%-wt), olefins (12.5%-wt), and a small fraction of aromatics (0.5%-
wt). The high-octane number of the gasoline is attributed to its high concentration
of branched paraffins (99% of the total paraffins). Furthermore, no durene is formed
in this process. The produced gasoline is then cooled and stored for sale.
Table 2.12. Key operating condition for Gasoline Purification
Operating Condition Value Unit
o
Deethanizer Column Inlet Temperature 78.33 C
Deethanizer Column Inlet Pressure 2153 kPa
Isobutane Mole Fraction of Deethanizer Top Product 0.015
DME Mole Fraction of Deethanizer Bottom Product 0.015
(Source: Tan, et al., 2015)

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2.3. Mass and Energy Balance


2.3.1. Mass Balance
Table 2.13. Overall Mass Balance
Mass Flow In (kg/hr) Mass Flow Out (kg/hr)
Component Stream Stream Stream Stream Stream Stream Stream 307 Stream 405 Stream 421 Stream
101 (H2O 203 (CO2 104 106 112 113 (Water (Waste (Light 428
in) in) (Waste) (Waste) (Waste) (Oxygen) Disposal) Disposal) Hydrocarbon) (Gasoline)
CO 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
CO2 0.00 5250.00 0.00 0.00 0.00 0.00 0.00 0.01 0.00 0.00
Methanol 0.00 0.00 0.00 0.00 22.61 0.00 54.14 0.00 0.00 0.00
H2O 5169.87 0.00 0.05 4628.48 290.72 0.00 553.32 318.16 0.01 0.00
Hydrogen 0.00 0.00 0.00 0.00 4.85 50.54 0.00 0.00 0.00 0.00
diM-Ether 0.00 0.00 0.00 0.00 0.00 0.00 1.33 0.06 5.48 0.00
Methane 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.01 0.00 0.00
Ethane 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Ethylene 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Propane 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.01 0.00 0.00
i-Butane 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 79.23 0.39
i-Pentane 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.11 69.15
2M-1-butene 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.04 50.12
2-Mpentane 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 118.76
2M1C5= 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 26.68
223-Mbutane 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 687.87
n-Heptane 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 234.99
2-Mhexane 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 48.88
2233-Mbutane 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 161.67
244M1pentene 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 41.62
224M3Epentane 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 807.64
n-Nonane 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 36.86
Hex-M-Benz 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 12.29

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Table 2. 13. Overall mass balance (cont’d)


Mass Flow In (kg/hr) Mass Flow Out (kg/hr)
Stream Stream Stream Stream Stream Stream 307 Stream Stream 421 Stream
Component Stream 101
203 (CO2 104 106 112 113 (Water 405 (Waste (Light 428
(H2O in)
in) (Waste) (Waste) (Waste) (Oxygen) Disposal) Disposal) Hydrocarbon) (Gasoline)
Phosphate 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Nitrat 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Silicate (SiO32-) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Chloride (Cl-) 3.56 0.00 0.00 3.54 0.00 0.00 0.00 0.00 0.00 0.00
Sodium (Na+) 1.98 0.00 0.00 1.97 0.00 0.00 0.00 0.00 0.00 0.00
Sulfate (SO42-) 0.50 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Magnesium (Mg2+) 0.24 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Calcium (Ca2+) 0.08 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Potassium (K+) 0.07 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Bicarbonate(HCO3-) 0.03 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Strontium (Sr2+) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Bromide (Br-) 0.01 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Borate (BO33-) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Fluoride (F-) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Total dissolved solids
(TDS) 6.47 0.00 0.00 1359.43 0.00 0.00 0.00 0.00 0.00 0.00
DO 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Oxygen 0.00 0.00 0.00 0.00 4.85 1941.91 0.00 0.00 0.00 0.00
Others 174.58 0.00 174.58 0.00 0.00 0.00 0.00 0.00 0.00 0.00
TOTAL 5357.37 5250.00 174.63 4495.07 323.03 1992.45 608.79 318.25 84.86 2296.93
TOTAL STREAM 10,607.37 10,607.37

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2.3.2. Energy Balance
Table 2.14. Overall Energy Balance
Enthalpy Flow In Enthalpy Flow Out Heat Duty
Equipment
(MJ/h) (MJ/h) (MJ/h)
P-101 -948,864.23 -948,819.77 44.46
F-101 -948,819.77 -948,617.00 202.77
F-102 -948,617.00 -948,414.23 202.77
P-102 -948,414.23 -948,241.09 173.14
F-103 -948,241.09 -947,577.82 663.27
R-101 -947,577.82 -419,419.57 528,158.25
P-103 -28,936.70 -28,913.49 23.21
K-201 1,332.00 9,201.00 7,869.00
K-202 -376,400.00 -369,983.00 6,417.00
E-201 -1,721,000.00 -1,669,000.00 52,000.00
E-202 -1,669,000.00 -1,849,800.00 -180,800.00
K-204 -27,540.00 -23,746.00 3,794.00
E-203 -486,946.00 -488,000.00 -1,054.00
P-201 -488,006.23 -488,000.00 6.23
E-204 -487,930.00 -430,600.00 57,330.00
T-201 con -197,100.00 -122,300.00
-430,600.00
T-201 reb -282,100.00 73,680.00
P-301 -197,142.39 -197,100.00 42.39
E-301 -197,100.00 -160,100.00 36,980.00
E-302 -160,100.00 -183,200.00 -23,050.00
E-303 -237,600.00 -225,800.00 11,740.00
K-401 -106,800.00 -106,190.00 634.40
E-401 -179,100.00 -207,900.00 -28,810.00
P-401 -61,050.00 -60,980.00 72.37
E-402 -60,980.00 -59,820.00 1,158.00
T-401 con -19,720.00 -8,598.00
-59,820.00
T-401 reb -34,770.00 13,930.00
P-404 -34,770.00 -34,786.38 6.23
T-402 con -1,789.00 -1,242.00
-34,760.00
T-402 reb -32,420.00 1,803.00
TOTAL -12,734,783.44 -12,303,706.33 431,076.49
2.3.3. Product Conversion Efficiency
The product conversion efficiency is reviewed by how far the combination
of raw materials could produce usable product streams. In this process, it is
calculated by the amount of gasoline and oxygen produced per amount of sea water
and CO2 introduced.

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ṁgasoline + ṁoxygen
Conversion Efficiency =
ṁCO2 + ṁsea water
2296 + 1992
Conversion Efficiency =
5250 + 5357
Conversion Efficiency = 82.4%
2.3.4. Product Yield
Yield is reviewed by how much gasoline could be produced per amount of
raw material introduced.
ṁgasoline kg gasoline
Yield Gasoline = = 0.492
sea water ṁsea water kg sea water
ṁgasoline kg gasoline
YieldGasoline = = 0.438
CO2 ṁCO2 kg CO2
2.3.5. Overall Energy Consumption
The energy consumption per unit product can be calculated by the amount
of energy per amount of gasoline produced in the process.
Total Heat Duty MJ
Energy Consumption = = 23.46
ṁgasoline kg gasoline
2.4. Heat Exchanger Network
As a way to reduce exergy losses due to temperature difference, an
arrangement of heat exchanger must be made. A good heat recovery can be
achieved through effective use of heat exchangers. The basic aim is to accomplish
exchanger duty by utilizing the process fluid while minimizing the usage of utilities.
From equipment energy balance, classification of stream into hot and cold
fluid can be made as shown on the following table. The term hot fluid refers to fluid
which undergoes temperature decrease, or enthalpy decrease, or negative value of
heat duty. The hot fluid acts as the source of heat to the cold fluid. On the other
hand, the term cold fluid refers to fluid which undergoes temperature increase, or
enthalpy increase, or positive value of heat duty. It acts as the sink of heat.
Table 2.15. Classification of Stream
T Supply T Target Heat Duty Heat Duty
Equipment Type
(oC) (oC) (MJ/h) (kW)
E-201 71.36 138.50 6,500 1,805.56 COLD
E-202 195.30 50.00 -22,600 -6,277.78 HOT

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Table 2.15. Classification of Stream (cont’d)
T Supply T Target Heat Duty Heat Duty
Equipment TTypeype
(oC) (oC) (MJ/h) (kW)
E-203 31.02 24.20 -132 -36.60 HOT
E-204 24.21 85.00 7,166 1,990.63 COLD
T-201 CON 65.00 64.00 -15,288 -4,246.53 HOT
T-201 REB 99.85 100.85 9,210 2,558.33 COLD
E-301 65.26 225.00 4,623 1,284.03 COLD
E-302 361.60 126.70 -2,881 -800.35 HOT
E-303 91.91 176.70 1,468 407.64 COLD
E-401 190.60 57.22 -3,601 -1,000.35 HOT
E-402 58.12 78.33 145 40.21 COLD
T-401 CON 36.41 35.41 -1,075 -298.54 HOT
T-401 REB 191.60 192.60 1,741 483.68 COLD
T-402 CON 78.19 77.19 -155 -43.13 HOT
T-402 REB 205.50 206.50 225 62.60 COLD
A minimum temperature approach for heat transfer process is next to be
considered. Actually the value of ΔTmin can influence the effectiveness of the
designed heat exchanger network. However, determining the optimum value of
ΔTmin is not included on this project. Determination of ΔTmin follows Heuristic 26
of Seider, et. al. (2003). It is stated that a value of 20oF (11oC) is taken for process
temperatures at or above ambient up to 300oF. Since the process temperature is a
little higher than limit of 300oF, minimum temperature approach of 15oC is taken.
Due to the huge amount of heat exchangers presented, the heat exchanger
network is divided into two sections, which are area 200 and area 300-400 heat
exchanger network. The main consideration is the difficult operability and
controlling if all exchangers are connected through only one network. Moreover,
reboiler and condenser for area 400 are not included in the network due to the far
temperature range opposing pinch.
2.4.1. Composite Curve Method
Composite curve plots the relation between temperature and enthalpy or
heat of both the cold and hot streams. Multiple hot streams will be identified as a
single pseudo-stream, and so as the multiple cold streams. Through the composite
curve, the amount of heat which can be exchanged through the process fluids can

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be visually analyzed. The hot composite curve relies on heat availability in the
process while the cold composite curve shows the heat demand in the process.

Figure 2.3. Composite Curve of Hot and Cold Stream in Area 200
The red curve represents hot streams and the blue curve represents cold
streams. The left-end side denotes minimum cold utility requirement (Qcmin), while
the right-end side denotes minimum hot utility requirement (Qhmin). Through the
generated curve, it can be inferred that the minimum cold utility requirement is
approximately 4,300 kW and the minimum hot utility requirement is approximately
120 kW. This value is then validated by the problem table algorithm method.
By similar way, the composite curve for area 300-400 depicts a large portion
of heat recovery relative to the overall duty presented. The minimum cold utility
requirement is approximately 160 kW and the hot utility is approximately 90 kW.

Figure 2.4. Composite Curve of Hot and Cold Stream in Area 300-400
2.4.2. Problem Table Algorithm Method
Since composite curve is not able to calculate energy targets precisely, a
different method without the necessity of graphical construction is to be developed.
It is the problem table algorithm. The initial step is determining the shifted
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temperature with the shifting amount of 0.5 x ΔTmin. The cold fluid temperature is
added by 7.5oC and the hot fluid temperature is subtracted by 5oC for ΔTmin of 15oC.
Table 2.16. Shifted Temperature of Area 200
No Equipment Type Tin (oC) Tout (oC) T*in (oC) T*out (oC)
1 E-201 COLD 71.36 138.50 78.86 146.00
2 E-202 HOT 195.30 50.00 187.80 42.50
3 E-203 HOT 31.02 24.20 23.52 16.70
4 E-204 COLD 24.21 85.00 31.71 92.50
5 T-201 CON HOT 65.00 64.00 57.50 56.50
6 T-201 REB COLD 99.85 100.85 107.35 108.35
Table 2.17. Shifted Temperature of Area 300-400
No Equipment Type Tin (oC) Tout (oC) T*in (oC) T*out (oC)
1 E-301 COLD 65.26 225.00 72.76 232.50
2 E-302 HOT 361.60 126.70 354.10 119.20
3 E-303 COLD 91.91 176.70 99.41 184.20
4 E-401 HOT 190.60 57.22 183.10 49.72
5 E-402 COLD 58.12 78.33 65.62 85.83
It is noted that for stream undergoing phase change, such as reboiler and
condenser of distillation column, the value of ΔT is taken to be 1oC so that the heat
capacity equals latent heat. CP is defined as the product of mass flowrate and heat
capacity, and is calculated through the division of duty by temperature difference.
Table 2.18. Calculation of CP for Area 200
Heat Duty CP
No Equipment Type Tin (oC) Tout (oC)
(kW) (kW/oC)
1 E-201 COLD 71.36 138.50 1,805.56 26.89
2 E-202 HOT 195.30 50.00 -6,277.78 43.21
3 E-203 HOT 31.02 24.20 -36.60 5.37
4 E-204 COLD 24.21 85.00 1,990.63 32.75
5 T-201 CON HOT 65.00 64.00 -4,246.53 4,246.53
6 T-201 REB COLD 99.85 100.85 2,558.33 2,558.33

Table 2.19. Calculation of CP for Area 300-400


Heat Duty CP
No Equipment Type Tin (oC) Tout (oC)
(kW) (kW/oC)
1 E-301 COLD 65.26 225.00 1,284.03 8.04
2 E-302 HOT 361.60 126.70 -800.35 3.41
3 E-303 COLD 91.91 176.70 407.64 4.81
4 E-401 HOT 190.60 57.22 -1,000.35 7.50
5 E-402 COLD 58.12 78.33 40.21 1.99

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In each shifted temperature interval, a simple energy balance is calculated.

∆𝐻 = (∑ 𝐶𝑃𝑐𝑜𝑙𝑑 − ∑ 𝐶𝑃ℎ𝑜𝑡 )∆𝑇

The heat balance within each shifted interval allows maximum heat
recovery within each interval. However, recovery must also be allowed between
intervals. So, cascading any surplus heat down the temperature scale from interval
to interval is conducted. Temperature interval balance for area 200 is shown below.
Table 2.20. Temperature Interval Balance for Area 200
Shift
T(i+1)-Ti CPnet Deficit/
Temperature Interval ∆H (kW)
(oC) (kW/oC) Surplus
(oC)
187.8
1 41.80 -43.21 -1806.00 surplus
146
2 37.65 -16.31 -614.19 surplus
108.35
3 1.00 2542.02 2542.02 deficit
107.35
4 14.85 -16.31 -242.25 surplus
92.5
5 13.64 16.43 224.14 deficit
78.86
6 21.36 -10.46 -223.42 surplus
57.5
7 1.00 -4256.99 -4256.99 surplus
56.5
8 14.00 -10.46 -146.44 surplus
42.5
9 10.79 32.75 353.33 deficit
31.71
10 8.19 0.0 0.0 deficit
23.52
11 6.82 -5.37 -36.60 surplus
16.7
Cascading surplus down the temperature is possible because any excess heat
available from the hot streams in an interval is hot enough to supply a deficit in the
cold streams in the next interval down. However, some of the heat flows are
negative, which is infeasible. Heat cannot be transferred up the temperature scale.
To make the cascade feasible, sufficient heat must be added from hot utility.

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Temperature ΔH (kW) ΔH (kW)
(oC)
HOT
UTILITY
187.8 ▼ 0 ▼ 121.8
1805.995 1805.995
146 ▼ 1806.0 ▼ 1927.8
614.1931 614.1931
108.35 ▼ 2420.2 ▼ 2542.0
-2542.02 -2542.02
107.35 ▼ -121.8 ▼ 0
242.2515 242.2515
92.5 ▼ 120.4 ▼ 242.3
-224.142 -224.142
78.86 ▼ -103.7 ▼ 18.1
223.4192 223.4192
57.5 ▼ 119.7 ▼ 241.5
4256.987 4256.987
56.5 ▼ 4376.7 ▼ 4498.5
146.4358 146.4358
42.5 ▼ 4523.1 ▼ 4645.0
-353.329 -353.3286
31.71 ▼ 4169.8 ▼ 4291.6
0 0
23.52 ▼ 4169.8 ▼ 4291.6
36.59722 36.59722
16.7 ▼ 4206.4 ▼ 4328.2
COLD
UTILITY
(a) (b)
Figure 2.5. Problem Table Cascade for Area 200
The pinch temperature is marked with grey shading, with the value of
114.85oC for hot pinch and 99.85oC for cold pinch. Through the cascade, it is
inferred that the minimum hot and cold utility requirement are consecutively 121.8
kW and 4,328.2 kW. It is noted that the value obtained through this method
corresponds with the ones approximated through composite curve method.
By the similar way of calculation, the problem table algorithm and cascade
for area 300-400 can be made as follow.
Table 2.21. Temperature Interval Balance for Area 300-400
Shift
T(i+1)-Ti CPnet
Temperature Interval ∆H (kW) Deficit/
(oC) (kW/oC)
(oC) Surplus
354.1
1 121.60 -3.41 -414.31 surplus
232.5
2 48.30 4.63 223.68 deficit
184.2
3 1.10 9.44 10.38 deficit
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Table 2.21. Temperature Interval Balance for Area 300-400 (cont’d)
Shift
T(i+1)-Ti CPnet Deficit/
Temperature Interval ∆H (kW)
(oC) (kW/oC) Surplus
(oC)
183.1
4 63.90 1.94 123.88 deficit
119.2
5 19.79 5.35 105.80 deficit
99.41
6 13.58 0.54 7.31 deficit
85.83
7 13.07 2.53 33.04 deficit
72.76
8 7.14 -5.51 -39.34 surplus
65.62
9 15.90 7.5 -119.25 surplus
49.72

Temperature ΔH (kW) ΔH (kW)


(oC)
HOT
UTILITY
354.1 ▼ 0 ▼ 89.78
-414.31 -414.31
232.5 ▼ 414.31 ▼ 504.09
223.68 223.68
184.2 ▼ 190.63 ▼ 280.41
10.38 10.38
183.1 ▼ 180.25 ▼ 270.03
123.88 123.88
119.2 ▼ 56.37 ▼ 146.14
105.80 105.80
99.41 ▼ -49.43 ▼ 40.35
7.31 7.31
85.83 ▼ -56.74 ▼ 33.04
33.04 33.04
72.76 ▼ -89.78 ▼ 0
-39.34 -39.34
65.62 ▼ -50.43 ▼ 39.35
-119.25 -119.25
49.72 ▼ 68.82 ▼ 158.59
COLD
UTILITY
(a) (b)
Figure 2.6. Problem Table Cascade for Area 300-400
The pinch temperature is marked with grey shading, with the value of
80.26oC for hot pinch and 65.26oC for cold pinch. The minimum hot and cold utility
requirement are consecutively 89.77 kW and 158.59 kW.

46 Universitas Indonesia
The energy targets provided by problem table algorithm corresponds with
the value approximated through the composite curve method. The minimum cold
and hot utility requirements are summarized in the following table.
Table 2.22. Minimum Hot and Cold Utility Requirement
Type of Utility Area Utility Requirement (kW)
Hot 200 121.8
Cold 200 4328.2
Hot 300-400 89.8
Cold 300-400 158.6
2.4.3. Heat Exchanger Network Design
After determining the energy targets, the next step to be conducted is
designing the network based on pinch design method. The general idea is to design
the heat transfer among fluids to achieve the minimum hot and cold utility
requirement set before. The design follows two basic rules as follow.
Table 2.23. Heat Exchanger Network Design Rule
Region CP S
Above Pinch CPH ≤ CPC SH ≤ SC
Below Pinch CPH ≥ CPC SH ≥ SC
(Source: Smith, 2005, reproduced)
In area 200, the original 5 heat exchangers are to be replaced with 4 heat
exchangers encountering heat exchange of process fluids, and 4 other heat
exchangers which use utilities. The heat duty calculation of each exchanger is
specified on the following table. It is noted that the total of hot and cold utility
requirement corresponds to the value calculated in energy targets determination.
Table 2.24. Post-HEN Heat Duty Calculation for Area 200
HOT COLD
Tin Tout CP Q Q CP Tin Tout
(oC) (oC) (kW/oC) (kW) (kW) o
(kW/ C) o
( C) (oC)
1 174.06 114.85 43 2,558 2,558 2,558 99.85 100.85
2 195.30 174.06 43 918 918 27 99.85 133.97
H1 0 122 27 133.97 138.50
3 114.85 97.12 43 766 766 27 71.36 99.85
4 97.12 51.04 43 1,991 1,991 33 24.21 85.00
C1 51.04 50.00 43 45 0
C2 65.00 64.00 4,247 4,247 0
C3 31.02 24.20 5 37 0

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Figure 2.7. Pinch Design for Area 200
For area 300-400, the original 5 heat exchangers are to be replaced with 4
heat exchangers encountering heat exchange of process fluids, and 3 other heat
exchangers which use utilities. The heat duty calculation of each exchanger is
tabulated below. It is noted that the total of hot and cold utility requirement
corresponds to the value calculated in energy targets determination section.
Table 2.25. Post-HEN Heat Duty Calculation for Area 300-400
HOT COLD
Tin Tout CP Q Q CP Tin Tout
(oC) (oC) (kW/oC) (kW) (kW) (kW/oC) (oC) (oC)
1 190.60 80.26 7.50 828 828 8.04 65.26 168.21
2 246.34 126.70 3.41 408 408 4.81 91.91 176.70
3 361.60 246.34 3.41 393 393 8.04 168.21 217.07
H1 0 64 8.04 217.07 225.00
H2 0 26 1.99 65.26 78.33
4 80.26 78.37 7.50 14 14 1.99 58.12 65.26
C1 78.37 57.22 7.50 159 0

Figure 2.8. Pinch Design for Area 300-400


2.5. Utility
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2.5.1. Water
Water requirement per day must be calculated to determine the amount of
water which have to provide for the plant. The plant needs water as requirements
for cooling water and steam. The water sources is taken from the ocean,
approximately 8 km near Kalimantan Island, especially West Kalimantan. Before
using it for the utilities, the seawater must get treatments to remove the impurities.

Figure 2.9. Plant Location for Seawater Source


Cooling water is assumed that Tin of cooling water is 25oC and Tout 45oC.
These temperatures are chosen based on literature and average temperature used in
many plants. Cooling water is used for heat exchange between cooling water stream
and hot process streams. Therefore, the water loss from evaporation, drift loss, and
blow down could exist. The numbers of calculating them is the number of makeup
water that is needed by this plant.
The water loss from evaporation is calculated by
𝑊𝑒 = 0.00085𝑊𝑐 (∆𝑇)
𝑊𝑐 = inlet water to cooling tower
𝑊𝑒 = water loss from evaporation
∆𝑇 = temperature difference between inlet and outlet water
The water loss from drift loss is usually 0.1-0.2% from the total inlet cooling
water. This plant assumes 0.2% drift loss.
𝑊𝑑 = % 𝑑𝑟𝑖𝑓𝑡 𝑙𝑜𝑠𝑠 × 𝑊𝑒
Water losses from blow down depend on the amount of cooling water cycle,
usually between 3-5 cycles. This plant assumes 4 cycles. Then, it is calculated by
𝑊𝑒
𝑊𝑏 =
𝐶−1

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𝑊𝑏 = water losses from blow down
𝐶 = number of cycle
The total make up cooling water required can then be calculated
Makeup Cooling Water = 𝑊𝑒 + 𝑊𝑑 + 𝑊𝑏
2.5.1.1. Before HEN
The calculation of cooling water requirement before the implementation of
heat exchanger network as well as the makeup cooling water are shown below.
Table 2.26. Cooling Water Requirement Before HEN
T in T out Cp water Mass flow
Equipment Q (MW) Q (kJ/h)
(oC) (oC) (KJ/kg.K) (kg/h)
E-202 25 45 6.28 22,599,000 4.18 270,335
E-203 25 45 0.04 131,000 4.18 1,576
T-201 CON 25 45 0.50 15,288,000 4.18 182,865
E-302 25 45 0.80 2,881,000 4.18 3,446
E-401 25 45 1.00 3,601,000 4.18 4,307,715
E-401 CON 25 45 0.30 1,075,000 4.18 1,285,586
E-402 CON 25 45 0.04 155,000 4.18 186
TOTAL (kg/h) 545,174

Table 2.27. Calculation of Makeup Cooling Water Before HEN


Losses Number Amount (kg/h)
Water loss from evaporation (We) 20oC 9,268
Drift loss (0.1-0.2%) (Wd) 0.20% 1,090
Blowdown (amount of cooling water cycle 3-5) (Wb) 4 181,724
Total Makeup Cooling Water (kg/h) 192,083
2.5.1.2. After HEN
The calculation of cooling water requirement after the implementation of
heat exchanger network as well as the makeup cooling water in area 600 process
are tabulated in the following tables.
Table 2.28. Cooling Water Requirement After HEN
T in T out Cp water Mass flow
Equipment Q (MW) Q (kJ/h)
(oC) (oC) (KJ/kg.K) (kg/h)
E-202 25 45 0.05 162,345 4.18 1,941.92
E-203 25 45 0.04 131,750 4.18 1,575.96
T-201 CON 25 45 4.25 15,287,500 4.18 182,864.83
E-401 25 45 0.16 570,940 4.18 6,829.42
T-401 CON 25 45 0.30 1,074,600 4.18 12,854.07
T-402 CON 25 45 0.04 159,345 4.18 1,906.04
TOTAL (kg/h) 207,972.24

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Table 2.29. Calculation of Makeup for Cooling Water After HEN
Losses Number Amount (kg/h)
Water loss from evaporation (We) 20oC 3,535.53
Drift loss (0.1-0.2%) (Wd) 0.20% 415.95
Blowdown (amount of cooling water cycle 3-5) (Wb) 4 69,324.08
Total Makeup Cooling Water (kg/h) 73,275.55
From table above, it can be concluded that the cooling water requirement is
70769.41019 kg/hr which is becomes based amount for continuous cooling tower
system. Meanwhile, the total amount of water in the first run is
Total water req 1st run (kg/h) = cooling water req + feed water req
Total water req 1st run (kg/h) = 73,275.55 + 207,972.24
Total water req 1st run (kg/h) = 281,247.79
Water requirement before HEN equals 192,083 kg/hr, and it is reduced until
73,276 kg/hr after HEN. The process flow diagram of cooling water circulation
through the cooling tower is illustrated in appendix.
The water is supplied from the ocean, which has high total hardness.
Therefore, this plant needs to do the water treatment before using the seawater. The
method to treat the seawater is by desalination unit with some filter and reverse
osmosis unit. To ensure a continuous supply of water, it was built on the location
of the water intake which is also a pre-treatment of seawater. This process contains
of filtering water and impurities carried along. Moreover, water is pumped to the
plant to be processed and used as needed.
In the water treatment unit, the raw seawater will be processed in two
filtration membrane. After that, the semi-purifies stream is combined with process
waste water streams to be filtered in reverse osmosis process. The purified water is
then supplied as the makeup cooling water and steam, while the impurities are
treated in waste water treatment area. The process flow diagram of water treatment
process is illustrated in the Appendix.
2.5.2. Steam
In this plant, there are some heating system which uses steams as the hot
fluids for heating systems. The steam will be heated by boiler and heater before
supplied to the equipment. Steam requirement calculation needs to be done before

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selecting what kind of boiler or steam generator to use for the plant. Basically, the
steam is needed as heating medium for heater and reboiler in distillation column.
For the calculation, it is assumed that the system uses Low Pressure Steam
and High Pressure Steam. The conventions of low, medium and high pressure steam
vary according to the pressure and temperature of the steam. Steam below 50 psig
(3.5 barg) is termed as low pressure steam, steam above 50 psig (3.5 barg) until 250
psig (17.5 barg) is termed as medium pressure steam, steam above 250 psig (17.5
barg) is termed as high pressure steam, and steam above 600 psig (40 barg) can be
defined as ultra-high pressure steam.
Table 2.30. Steam Requirement in Plant Before HEN
Specific
Stream Stream T in T out Latent m steam
Equipment Q (MJ/h)
In Out (oC) (oC) Heat (kg/h)
(MJ/kg)
E-201 205 206 71.36 138.5 52,000.00 2.11 3,084.30
E-204 220 221 24.21 85 57,330.00 2.11 3,400.44
T-201 reb 221 225 99.85 99.85 73,680.00 2.11 4,370.21
E-301 302 303 65.26 225 36,980.00 1.79 2,580.67
E-303 310 311 91.91 176.7 11,740.00 1.79 819.28
E-402 407 408 58.12 78.33 1,158.00 2.11 68.68
T-401 reb 408 414 191.6 191.6 13,930.00 1.79 972.11
T-402 reb 415 421 205.5 205.5 1,803.00 1.79 125.82
Total Steam Needed (ton/hr) 15,421.52
The steam used is Low Pressure Steam (4 kg/cm2, 151.35oC) for E-201, E-
204, T-201 reb and E-402 and High Pressure steam (30 kg/cm2, 234.65oC) for E-
301, E-303, T-401 reb and T-402 reb. Steam selection is based on temperature
difference of cold stream that would be heated. By assuming that 90% of steam
condensate can be reused, the total addition of water can be calculated as follow.
Make-up water for boiler = 0,1 x 15,421.52 = 1,542 kg/h
After conducting HEN analysis, the remaining steam requirement is
calculated as shown in the following table.

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Table 2.31. Steam Requirement in Plant After HEN
Specific
Stream Stream T in T out Latent m steam
Equipment Q (MJ/hr)
In Out (oC) (oC) Heat (kg/h)
(MJ/kg)
E-201 205 206 133.97 138.5 436.50 2.11 207.12
E-301 302 303 217.1 225 229.50 1.79 128.13
E-402 407 408 65.3 78.3 94.50 2.11 44.84
T-401 reb 408 414 191.6 191.6 1,741.25 1.79 972.11
T-402 reb 415 421 205.5 205.5 225.38 1.79 125.82
Total Steam Needed (Ton/h) 1,478.03
After implementation of HEN, there are some hot streams whose heat are
exchanged with some cold streams. Therefore, the before HEN and after HEN
calculation is different. The steam used is Low Pressure Steam (4 kg/cm2,
151.35oC) for E-201 and E-402 and High Pressure Steam (30 kg/cm2, 234.65oC)
for heater E-301, T-401 reb and T-402 reb. The consideration is based on the
minimum temperature approach provided by the process fluid in heat exchangers.
With the significant reduce in steam need, HEN makes steam usage more effective
and efficient in this plant. By assuming that 90% of steam condensate can be reused,
the total addition of water per hour can be calculated as follow.
Make-up water for boiler = 0.1 x 1,478.03 = 147.8 kg/h
The process flow diagram for steam generation is shown in the appendix.
2.5.3. Electricity
In this plant, the time operation is 24 hours and 330 days per year. The plant
uses the combination of PLN supply and photovoltaic array for electricity supply.
PV array has the area of 7 hectares that will provide the electricity of 22 MW. The
electricity from PV will power up the electrolyzer that has power up to 20,213.83
kW. So that, the electricity of electrolyzer that needs from PLN is about 1,810.89
kW or 43,461.36 kWh per day. Based on process equipment, the electricity need
before HEN is 22,024 MW, which is reduced to 21,014 MW after HEN. The
detailed data of electricity need is tabulated in the following table.
2.5.3.1. Electricity Before HEN
The calculation of electricity requirement before implementation of heat
exchanger network is tabulated as follow.

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Table 2.32. Electricity Requirement Before HEN
Usage Energy Duty Power Power
Equipment Code
Time (h) (MJ/h) (kW) (kWh/ day)
Seawater Pump P-101 24.00 5.56 1.54 37.05
Filtration Unit F-101 24.00 25.35 7.04 168.98
Catridge Filter F-102 24.00 25.35 7.04 168.98
Purified Water Pump P-102 24.00 21.64 6.01 144.28
Reverse Osmosis F-103 24.00 82.91 23.03 552.72
AEL Electrolyzer R-101 24.00 72,769.78 20,213.83 485,131.88
Recycle Water Pump P-103 24.00 2.90 0.81 19.34
H2 Stream Compressor K-201 24.00 983.63 273.23 6,557.50
CO2 Stream Compressor K-202 24.00 802.13 222.81 5,347.50
Recycle Stream Compressor K-204 24.00 474.25 131.74 3,161.67
Methanol Pump P-201 24.00 0.78 0.22 5.19
Methanol Intermediate Pump P-301 24.00 5.30 1.47 35.33
Recycle Compressor K-401 24.00 79.30 22.03 528.67
Crude Gasoline Pump P-401 24.00 9.05 2.51 60.31
Gasoline Pump P-404 24.00 0.78 0.22 5.19
Seawater Pump P-501 24.00 122.28 33.97 815.19
Filtration Unit F-501 24.00 557.63 154.90 3,717.53
Catridge Filter F-502 24.00 557.63 154.90 3,717.53
Purified Water Pump P-502 24.00 476.12 132.26 3,174.17
Reverse Osmosis F-503 24.00 1,823.99 506.66 12,159.91
Waste Water Pump P-507 24.00 15.95 4.43 106.36
Waste Water Pump P-508 24.00 15.95 4.43 106.36
Waste Water Pump P-509 24.00 15.95 4.43 106.36
Cooling Tower Pump P-601 24.00 95.72 26.59 638.15
Steam Generation Pump P-701 24.00 29.01 88.63 2,127.18
TOTAL 22,024.72 528,593.31
2.5.3.2. Electricity After HEN
The electricity requirement after the implementation of heat exchanger
network will not be any different for the main process. The calculation of electricity
requirement after HEN is tabulated as follow.
Table 2.33. Electricity Requirement After HEN
Usage Energy
Power
Equipment Code Time Duty Power (kW)
(kWh/ day)
(h) (MJ/h)
Seawater Pump P-101 24.00 5.56 1.54 37.05
Filtration Unit F-101 24.00 25.35 7.04 168.98
Catridge Filter F-102 24.00 25.35 7.04 168.98
Purified Water Pump P-102 24.00 21.64 6.01 144.28
Reverse Osmosis F-103 24.00 82.91 23.03 552.72
AEL Electrolyzer R-101 24.00 72,769.78 20,213.83 485,131.88
Recycle Water Pump P-103 24.00 2.90 0.81 19.34

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Table 2.33. Electricity Requirement After HEN (cont’d)
Usage Energy
Power
Equipment Code Time Duty Power (kW)
(kWh/ day)
(h) (MJ/h)
H2 Stream Compressor K-201 24.00 983.63 273.23 6,557.50
CO2 Stream Compressor K-202 24.00 802.13 222.81 5,347.50
Recycle Stream Compressor K-204 24.00 474.25 131.74 3,161.67
Methanol Pump P-201 24.00 0.78 0.22 5.19
Methanol Intermediate Pump P-301 24.00 5.30 1.47 35.33
Recycle Compressor K-401 24.00 79.30 22.03 528.67
Crude Gasoline Pump P-401 24.00 9.05 2.51 60.31
Gasoline Pump P-404 24.00 0.78 0.22 5.19
Seawater Pump P-501 24.00 11.12 3.09 74.11
Filtration Unit F-501 24.00 50.69 14.08 337.96
Catridge Filter F-502 24.00 50.69 14.08 337.96
Purified Water Pump P-502 24.00 43.28 12.02 288.56
Reverse Osmosis F-503 24.00 165.82 46.06 1,105.45
Waste Water Pump P-507 24.00 1.45 0.40 9.67
Waste Water Pump P-508 24.00 1.45 0.40 9.67
Waste Water Pump P-509 24.00 1.45 0.40 9.67
Cooling Tower Pump P-601 24.00 8.70 2.42 58.01
Steam Generation Pump P-701 24.00 29.01 8.06 193.38
TOTAL 21,014.54 504,349.01
2.5.4. Fuel
Fuel is needed for steam generation process in boiler. Boiler is a closed
vessel which combustion heat is streamed to water until it becomes heated water or
steam in the form of energy work. There are several type of fuel that can be used,
which is solid fuel, liquid fuel, and gas fuel. But in this plant, the fuel that used is
natural gas, because it is readily available, cleanly burnt, and is typically less
expensive than other fuel. Natural gas is chosen as the fuel for steam generation in
boiler while diesel is chosen as a fuel for electricity generator.
For the steam generation process, the amount of steam needed in overall
process has already determined. The generated steam for this process produced by
boiling water in boiler. Water source is seawater from Kalimantan Island near the
place where this plant is going to be built. Before the seawater is ready to be the
boiler feed water, it needs to be process through several treatment in order to meet
the specification of boiler feed water. Seawater as the boiler feed water in
temperatur of 25oC and 1 bar will be converted to low pressure steam and high

55 Universitas Indonesia
pressure steam. Then, the steam will be heated until temperature reach 152oC (low
pressure steam) and 235oC (high pressure steam).
For the first time operation, this plant is using full source of the BFW from
the seawater of Kalimantan Island. The generated steam is used for the heater and
reboiler of distillation column. It is assumed that 90% of the steam is condensed
and could be recyled as the BFW. In order to meet the steam needed in the process
make up water is also supplied to the boiler, the make up water and condensate
reboiler are mixed first before enter the feed stream of boiler.
Boilers are generating low and high pressure steam. The low pressure steam
produced is divided into two streams, one of them is compressed achieve 30 kg/cm2,
then the steam could be used at the heater unit and reboiler in distillation column.
For the heater and reboiler in this plant, the mass flowrate of steam needed
is 1,478.03 kg/h, with heating value of natural gas is approximately 45,938.5 kJ/kg
and also the specific latent heat of steam is 1,781.2 kJ/kg. The assumed burning
efficiency is taken to be 0.85. From these data, we can know calculate the amount
of fuel needed for boiler, with the final calculation result of 67.8 kg/h.
∆hsteam x ṁSteam
ṁfuel =
Eff x HHV Natural Gas
kJ
1,791.2 x 1,478.03 kg/hr
kg
ṁfuel =
0.85 x 45,938.5 kJ/kg
ṁfuel = 67.8 kg/hr
2.5.5. Waste Water Treatment
The waste water is fed into an activated sludge process waste water
treatment with aeration tank. The waste water mostly consists of methanol and
TDS, which needs to be processed before being disposed to the environment.
In activated sludge process wastewater containing organic matter is aerated
in an aeration basin in which micro-organisms metabolize the suspended and
soluble organic matter. Part of organic matter is synthesized into new cells, oxidized
to CO2 and water to derive energy. In activated sludge systems the new cells formed
in the reaction are removed from the liquid stream in the form of a flocculent sludge
in settling tanks. A part of this settled biomass, described as activated sludge is
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returned to the aeration tank and the remaining forms waste or excess sludge. The
process involves solid – liquid separation followed by aeration in the presence of a
microbial suspension, removal of sludge and transporting it to a burner, and
discharge of clarified effluent to be disposed to the environment.
From the results it is found that the concentration of contaminants got
decreased up to 90% after the biological treatment. This suggests that the process
chosen for the treatment of waste water effluents is satisfactory for disposal to the
ocean. After the process, the amount of sludge is 25.88% of the feed. The sludge is
then transported to a burner to be further processed and burned for disposal. The
treated waste water is then disposed to the sea. The process flow diagram of waste
water treatment process is illustrated on appendix.

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2.6. Block Flow Diagram

Figure 2.10. Block flow diagram of the process

2.7. Process Flow Diagram


The process flow diagram, specifically after the implementation of heat exchanger network, is shown on the appendix.

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59

CHAPTER 3
EQUIPMENT SIZING

3.1. Process Equipment Sizing


3.1.1. Reactor
There are three reactors operating in the plant, which are methanol synthesis
reactor, DME synthesis reactor, and gasoline synthesis reactor.
3.1.1.1. Methanol Synthesis Reactor (R-201)
Methanol is formed through CO2 hydrogenation undergoing three reactions.
CO + 2H2 ↔ CH3OH
CO2 + H2 ↔ CO + H2O
CO2 + 3H2 ↔ CH3OH + H2O
The three reactions happen simultaneously in a packed bed reactor with
catalyst CuO-ZnO supported by Al2O3. Moderate temperature leads to usage of
carbon steel for material. The design of the reactor is tabulated below.

Figure 3.1. Methanol Synthesis Reactor Specification

Table 3.1. Methanol Synthesis Reactor Specification


Equipment Specification
Equipment Name Methanol Synthesis Reactor
Equipment Code R-201
Function To convert CO2 and H2 into methanol
Operating Data
Type Adiabatic Packed Bed Reactor
Catalyst CuO-ZnO/Al2O3
Pressure (bar) 60
Temperature (oC) 138.5

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Table 3.1. Methanol Synthesis Reactor Specification (cont’d)


Catalyst Weight (kg) 3210
Catalyst Volume (m3) 1.672
Reactor Volume (m3) 2.788
Residence Time (s) 3.323
Construction Data
Material SA-516
Diameter (m) 0.80
Height (m) 5.55
Shell Thickness (mm) 27.12
Head Type Hemispherical
Head Thickness (mm) 16.29
3.1.1.2. DME Synthesis Reactor (R-301)
This reactor provides methanol dehydration through the following reaction.
2𝐶𝐻3 𝑂𝐻 ↔ 𝐶𝐻3 𝑂𝐶𝐻3 + 𝐻2 𝑂
The reaction takes place in an adiabatic packed bed reactor. High
temperature operation leads to implementation of stainless steel as material.

Figure 3.2. DMESynthesis Reactor Specification

Table 3.2. DME Synthesis Reactor Specification


Equipment Specification
Equipment Name DME Synthesis Reactor
Equipment Code R-301
Function To convert methanol into DME
Operating Data
Type Adiabatic Packed Bed Reactor
Catalyst γ-Al2O3
Pressure (bar) 10
Temperature (oC) 225.0
Catalyst Weight (kg) 4850
Catalyst Volume (m3) 5.052

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Table 3.2. DME Synthesis Reactor Specification (cont’d)


Reactor Volume (m3) 8.424
Residence Time (s) 44.33
Construction Data
Material SA-516
Diameter (m) 1.20
Height (m) 7.45
Shell Thickness (mm) 11.71
Head Type Torispherical
Head Thickness (mm) 8.85
3.1.1.3. Gasoline Synthesis Reactor (R-302)
This reactor provides conversion of dimethyl ether into gasoline-range
hydrocarbons. The reaction takes place in an adiabatic packed bed reactor with
construction material of carbon steel due to moderate temperature.

Figure 3.3. Gasoline Synthesis Reactor Specification

Table 3.3. Gasoline Synthesis Reactor Specification


Equipment Specification
Equipment Name Gasoline Synthesis Reactor
Equipment Code R-302
Function To convert DME into gasoline
Operating Data
Type Adiabatic Packed Bed Reactor
Pressure (bar) 8.96
Temperature (oC) 176.7
Catalyst Weight (kg) 1185
Catalyst Volume (m3) 0.617
Reactor Volume (m3) 1.029
Residence Time (s) 2.717
Construction Data
Material SA-516
Diameter (m) 0.80
Height (m) 2.05
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Table 3.3. Methanol Synthesis Reactor Specification (cont’d)


Shell Thickness (mm) 9.42
Head Type Torispherical
Head Thickness (mm) 7.70
3.1.2. Distillation Column
There are three distillation columns operating in the plant. They are
methanol purification, deethanizer, and debutanizer column. Selection of material
is mainly based on the operating temperature, with the guide on the appendix.

Figure 3.4. Methanol Purifcation Column Specification

Table 3.4. Methanol Purification Column Specification


Equipment Specification
Equipment Name Methanol Purification Column
Equipment Code T-201
Function To separate methanol and water
Operating Data
Feed Flow Rate (kg/h) 5621
Reflux Ratio 3
Column Pressure (bar) 1.10
Number of Actual Tray 13
o
Condenser Temperature ( C) 65.1
Reboiler Temperature (oC) 102.3
Stage Efficiency (%) 65.8
Construction Data
Material SA-516
Column Height (m) 8.30
Column Diameter (m) 1.345
Plate Type Sieve Tray
Shell Thickness (mm) 3.640
Head Type Torispherical
Head Thickness (mm) 6.494

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Figure 3.5. Deethanizer Column Specification

Table 3.5. Deethanizer Column Specification


Equipment Specification
Equipment Name Deethanizer Column
Equipment Code T-401
Function To separate light ends (C2-) from crude gasoline
Operating Data
Feed Flow Rate (kg/h) 2786
Reflux Ratio 4.5
Column Pressure (bar) 21.53
Number of Actual Tray 24
Condenser Temperature (oC) 53.69
Reboiler Temperature (oC) 191.40
Stage Efficiency (%) 75.1
Construction Data
Material SA-516
Column Height (m) 7.50
Column Diameter (m) 0.672
Plate Type Sieve Tray
Shell Thickness (mm) 10.952
Head Type Ellipsoidal
Head Thickness (mm) 10.906

Figure 3.6. Debutanizer Column Specification


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Table 3.6. Methanol Purification Column Specification


Equipment Specification
Equipment Name Debutanizer Column
Equipment Code T-401
To separate isobutane and DME from
Function
gasoline
Operating Data
Feed Flow Rate (kg/h) 2361
Reflux Ratio 5
Column Pressure (bar) 13.79
Number of Actual Tray 20
o
Condenser Temperature ( C) 121.6
o
Reboiler Temperature ( C) 203.8
Stage Efficiency (%) 66.7
Construction Data
Material SA-516
Column Height (m) 6.30
Column Diameter (m) 0.456
Plate Type Sieve Tray
Shell Thickness (mm) 8.167
Head Type Ellipsoidal
Head Thickness (mm) 8.154
3.1.3. Separator
3.1.3.1. Two-Phase Separator
There are three two-phase separators operating in the plant whose
specification is tabulated below. Detailed calculation is provided in appendix.

Figure 3.7. First Stage Methanol Separator Specification

Table 3.7. First Stage Methanol Separator Specification


Equipment Specification
Equipment Name First Stage Methanol Separator
Equipment Code S-201
Function To separate methanol from unconverted CO2 and H2

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Table 3. 7. First Stage Methanol Separator Specification (cont’d)


Operating Data
Pressure (bar) 60.0
Temperature (oC) 50.0
Vapor flowrate (kg/h) 30140
Liquid flowrate (kg/h) 6070
Settling velocity (m/s) 0.402
Construction Data
Diameter (m) 1.461
Height (m) 3.207
Liquid level (m) 1.015
Inlet level (m) 1.745
Material SA-516
Vessel thickness (mm) 41.574
Top head type Hemispherical
Top head thickness (mm) 21.791
Bottom head type Flat
Bottom head thickness (mm) 13.498

Figure 3.8. Second Stage Methanol Separator Specification

Table 3.8. Second Stage Methanol Separator Specification


Equipment Specification
Equipment Name Second Stage Methanol Separator
Equipment Code S-202
Function To separate methanol from unconverted CO2 & H2
Operating Data
Pressure (bar) 0.20
Temperature (oC) 31.02
Vapor flowrate (kg/h) 449.2
Liquid flowrate (kg/h) 5621
Settling velocity (m/s) 4.127

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Table 3.8. Second Stage Methanol Separator Specification (cont’d)


Construction Data
Diameter (m) 1.019
Height (m) 3.165
Liquid level (m) 1.637
Inlet level (m) 2.146
Material SA-516
Vessel thickness (mm) 6.319
Top head type Torispherical
Top head thickness (mm) 6.002
Bottom head type Flat
Bottom head thickness (mm) 5.206

Figure 3.9. DME Reactor Effluent Separator Specification

Table 3.9. DME Reactor Effluent Separator Specification


Equipment Specification
Equipment Name DME Reactor Effluent Separator
Equipment Code S-301
Function To separate water from DME
Operating Data
Pressure (bar) 9.653
Temperature (oC) 126.7
Vapor flowrate (kg/h) 2713
Liquid flowrate (kg/h) 608.8
Settling velocity (m/s) 0.607
Construction Data
Diameter (m) 0.945
Height (m) 1.879
Liquid level (m) 0.461
Inlet level (m) 0.933
Material SA-516
Vessel thickness (mm) 9.911
Top head type Torispherical

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Table 3. 9. DME Reactor Effluent Separator Specification (cont’d)


Construction Data
Top head thickness (mm) 6.014
Bottom head type Flat
Bottom head thickness (mm) 7.005
3.1.3.2. Three-Phase Separator

Figure 3.10. Three-Phase Separator Specification

Table 3.10. Three-Phase Separator Specification


Equipment Specification
Equipment Name Three-Phase Separator
Equipment Code S-401
Function To separate crude gasoline from light gas & water
Operating Data
Pressure (bar) 7.239
o
Temperature ( C) 57.22
Vapor flowrate (kg/h) 4863
Oil flowrate (kg/h) 2786
Water flowrate (kg/h) 318.9
Drag coefficient 3.80
Construction Data
Diameter (m) 0.762
Length (m) 1.707
Liquid level (m) 0.853
Material SA-516
Vessel thickness (mm) 9.911
Head type Torispherical
Top head thickness (mm) 8.362
3.1.4. Compressor
A compressor is a device that converts power (using an electric motor,
diesel or gasoline engine, etc.) into potential energy stored in pressurized fluids. It
is used to optimize transportation of gas.

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Table 3.11. Compressor K-201 Specification


Equipment Specification
Equipment Name Gas Compressor
Equipment Code K-201
Function Compressing H2 to meet the required
operating condition of the process
Amount 1
Material Carbon Steel
Operating Data
Inlet temperature, K 313
Outlet Temperature,K 406.8
Inlet flow rate, m3/h 2545
Compression ratio 2
Compressor head, m 102,616.5
Efficiency (%) 75
Pressure inlet, bar 30
Pressure outlet, bar 60
Power. Kw 273.2

Table 3.12. Compressor K-202 Specification


Equipment Specification
Equipment Name Gas Compressor
Equipment Code K-202
Function Compressing CO2 to meet the required
operating condition of the process
Amount 1
Material Carbon Steel
Operating Data
Inlet temperature, K 293
Outlet Temperature, K 471.6
Inlet flow rate, m3/h 2200
Compression ratio 6
Compressor head, m 101,114.9
Efficiency (%) 75
Pressure inlet, bar 10
Pressure outlet, bar 60
Power. Kw 222.8

Table 3.13. Compressor K-204 Specification


Equipment Specification
Equipment Name Gas Compressor
Equipment Code K-204
Function Compressing recycled stream to meet the
required operating condition to be able to flow
in the main pipe of the process
Amount 1
Material Carbon Steel

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Table 3.13. Compressor K-204 Specification (cont’d)


Operating Data
Inlet temperature, K 304.02
Outlet Temperature, K 427.1
Inlet flow rate, m3/h 14,530
Compression ratio 4
Compressor head, m 351.3
Efficiency (%) 75
Pressure inlet, bar 0.2
Pressure outlet, bar 0.8
Power. Kw 21.45

Table 3.14. Compressor K-205 Specification


Equipment Specification
Equipment Name Gas Compressor
Equipment Code K-205
Function Compressing recycled stream to meet the
required operating condition to be able to flow
in the main pipe of the process
Amount 1
Material Carbon Steel
Operating Data
Inlet temperature, K 427.1
Outlet Temperature, K 573.7
Inlet flow rate, m3/h 14,530
Compression ratio 4
Compressor head, m 489.7
Efficiency (%) 75
Pressure inlet, bar 0.8
Pressure outlet, bar 3.2
Power. Kw 29.51

Table 3.15. Compressor K-206 Specification


Equipment Specification
Equipment Name Gas Compressor
Equipment Code K-206
Function Compressing recycled stream to meet the
required operating condition to be able to flow
in the main pipe of the process
Amount 1
Material Carbon Steel
Operating Data
Inlet temperature, K 573.7
Outlet Temperature, K 743
Inlet flow rate, m3/h 14,530
Compression ratio 4
Compressor head, m 657.8

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Table 3.15. Compressor K-206 Specification (cont’d)


Efficiency (%) 75
Pressure inlet, bar 3.2
Pressure outlet, bar 12.8
Power. Kw 39.02

Table 3.16. Compressor K-207 Specification


Equipment Specification
Equipment Name Gas Compressor
Equipment Code K-207
Function Compressing recycled stream to meet the
required operating condition to be able to flow
in the main pipe of the process
Amount 1
Material Carbon Steel
Operating Data
Inlet temperature, K 743
Outlet Temperature, K 959
Inlet flow rate, m3/h 14,530
Compression ratio 4.6
Compressor head, m 852
Efficiency (%) 75
Pressure inlet, bar 12.8
Pressure outlet, bar 60
Power. Kw 56.69

Table 3.17. Compressor K-401 Specification


Equipment Specification
Equipment Name Gas Compressor
Equipment Code K-401
Function Compressing recycled stream to meet the
required operating condition to be able to flow
in the main pipe of the process
Amount 1
Material Carbon Steel
Operating Data
Inlet temperature, K 330.22
Outlet Temperature, K 343.67
Inlet flow rate, m3/h 2759
Compression ratio 1.28
Compressor head, m 3902
Efficiency (%) 75
Pressure inlet, bar 7.239
Pressure outlet, bar 9.239
Power. Kw 22.03

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3.1.5. Pump
Centrifugal pumps convert energy of an electric motor or turbine into
velocity or kinetic energy and then into pressure energy. The energy changes occur
around two main parts of the pump, impeller and volute or diffuser. Pump impeller
is the rotating part that converts driver energy into the kinetic energy. The volute or
diffuser is the stationary part that converts the kinetic to pressure energy. The pump
driver can be either electric motor or a steam turbine depending upon application.
There are 8 pumps in area 100, 2 pump in area 200, 1 pump in area 300, and
5 pumps in area 400. Therefore, the total pumps in main process area are 16 pumps.
Below are specification of several pumps. Overall pump specification might refer
to Assignment 3 report and final spreadsheet.
Table 3.18. Pump Specification (P-101)
Equipment Specification
Equipment Name Seawater Pump
Equipment Code P-101
Type Centrifugal Pump
Operation Data
Temperature (K) 298.15
𝑘𝑔
Density ( ) 1,030
𝑚3
Pressure Inlet (bar) 1
Pressure Outlet (bar) 10
Vapor Pressure (bar) 0.024
𝑘𝑔
Flow rate ( ) 22.6113
𝑠
𝑚3
Flow rate( ) 0.0220
𝑠
𝑚2
Friction Loss ( ) 43.9234
𝑠2
Efficiency (%) 75
Pipe Length (m) 100
Fluid Seawater
Design Specification
Power (W) 27,667.5189
Head (m) 93.6439
NPSHa (m) 5.3184

Table 3.19. Pump Specification (P-102)


Equipment Specification
Equipment Name Wastewater Pump
Equipment Code P-102
Type Centrifugal Pump
Operation Data
Temperature (K) 313.15

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Table 3.19. Pump Specification (P-102) (cont’d)


𝑘𝑔
Density ( ) 1,010
𝑚3
Pressure Inlet (bar) 10
Pressure Outlet (bar) 15
Vapor Pressure (bar) 0.024
𝑘𝑔
Flow rate ( ) 0.3685
𝑠
𝑚3
Flow rate( ) 0.0004
𝑠
𝑚2
Friction Loss ( ) 1.3438
𝑠2
Efficiency (%) 75
Pipe Length (m) 3
Fluid Waste of Seawater
Design Specification
Power (W) 243.9051
Head (m) 50.6524
NPSHa (m) 9.8573

Table 3.20. Pump Specification (P-103)


Equipment Specification
Equipment Name Mixed Waste Water Pump
Equipment Code P-103
Type Centrifugal Pump
Operation Data
Temperature (K) 303.15
𝑘𝑔
Density ( ) 995
𝑚3
Pressure Inlet (bar) 5
Pressure Outlet (bar) 10
Vapor Pressure (bar) 0.4608
𝑘𝑔
Flow rate ( ) 22.7707
𝑠
𝑚3
Flow rate( ) 0.0229
𝑠
𝑚2
Friction Loss ( ) 1.3641
𝑠2
Efficiency (%) 75
Pipe Length (m) 3
Fluid Mixed Water
Design Specification
Power (W) 15,298.1868
Head (m) 51.4160
NPSHa (m) 5.5264

Table 3.21. Pump Specification (P-201)


Equipment Specification
Equipment Name Methanol Pump
Equipment Code P-201
Type Centrifugal Pump
Operation Data
Temperature (K) 297.35
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Table 3.21. Pump Specification (P-201) (cont’d)


𝑘𝑔
Density ( ) 865.8490
𝑚3
Pressure Inlet (bar) 0.2
Pressure Outlet (bar) 1.1
Vapor Pressure (bar) 0.263
𝑘𝑔
Flow rate ( ) 1.5614
𝑠
𝑚3
Flow rate ( ) 0.0018
𝑠
𝑚2
Friction Loss ( ) 2.0900
𝑠2
Efficiency (%) 75
Pipe Length (m) 4
Fluid Methanol and Water
Design Specification
Power (W) 220.7525
Head (m) 10.8198
NPSHa (m) 8.6285

Table 3.22. Pump Specification (P-202)


Equipment Specification
Equipment Name Methanol Reflux Pump
Equipment Code P-202
Type Centrifugal Pump
Operation Data
Temperature (K) 338.15
𝑘𝑔
Density ( ) 743.6441
𝑚3
Pressure Inlet (bar) 1
Pressure Outlet (bar) 1.1
Vapor Pressure (bar) 0.3884
𝑘𝑔
Flow rate ( ) 1.4935
𝑠
𝑚3
Flow rate ( ) 0.0020
𝑠
𝑚2
Friction Loss ( ) 1.8251
𝑠2
Efficiency (%) 75
Pipe Length (m) 3
Fluid Methanol
Design Specification
Power (W) 30.4128
Head (m) 1.5584
NPSHa (m) 8.3878

Table 3.23. Pump Specification (P-301)


Equipment Specification
Equipment Name Methanol Intermediate Pump
Equipment Code P-301
Type Centrifugal Pump
Operation Data
Temperature (K) 338.15
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Table 3.23. Pump Specification (P-301) (cont’d)


𝑘𝑔
Density ( ) 743.6441
𝑚3
Pressure Inlet (bar) 1
Pressure Outlet (bar) 1.1
Vapor Pressure (bar) 0.3884
𝑘𝑔
Flow rate ( ) 0.9228
𝑠
𝑚3
Flow rate ( ) 0.0012
𝑠
𝑚2
Friction Loss ( ) 1.8251
𝑠2
Efficiency (%) 75
Pipe Length (m) 3
Fluid Methanol
Design Specification
Power (W) 1,474.2676
Head (m) 122.2684
NPSHa (m) 8.3878

Table 3.24. Pump Specification (P-401)


Equipment Specification
Equipment Name Crude Gasoline Pump
Equipment Code P-401
Type Centrifugal Pump
Operation Data
Temperature (K) 330.37
𝑘𝑔
Density ( ) 635.0138
𝑚3
Pressure Inlet (bar) 7.239
Pressure Outlet (bar) 21.7
Vapor Pressure (bar) 0.5190
𝑘𝑔
Flow rate ( ) 0.7738
𝑠
𝑚3
Flow rate ( ) 0.0012
𝑠
𝑚2
Friction Loss ( ) 2.8498
𝑠2
Efficiency (%) 75
Pipe Length (m) 4
Fluid Crude Gasoline
Design Specification
Power (W) 2,352.4769
Head (m) 232.6656
NPSHa (m) 7.6513

Table 3.25. Pump Specification (P-402)


Equipment Specification
Equipment Name Deethanizer Reflux Pump
Equipment Code P-402
Type Centrifugal Pump
Operation Data
Temperature (K) 297.64
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Table 3.25. Pump Specification (P-402) (cont’d)


𝑘𝑔
Density ( ) 562.3597
𝑚3
Pressure Inlet (bar) 13.79
Pressure Outlet (bar) 21.53
Vapor Pressure (bar) 0.1744
𝑘𝑔
Flow rate ( ) 0.4211
𝑠
𝑚3
Flow rate ( ) 0.0007
𝑠
𝑚2
Friction Loss ( ) 2.4135
𝑠2
Efficiency (%) 75
Pipe Length (m) 3
Fluid Reflux dim-Ether
Design Specification
Power (W) 774.0458
Head (m) 140.6895
NPSHa (m) 14.9748
3.1.6. Heat Exchanger
There are 8 heat exchangers in area 200, 4 in area 300, and 7 in area 400.
Therefore, the total amount of heat exchangers in this plant are 19. Sizing and
drawing is conducted using HTRI, with some exchangers shown below. For overall
sizing of heat exchanger, refer to Assignment 3 Report.

Figure 3.11. Heat Exhanger Specification (E-201)


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Table 3.26. Heat Exchanger Specification (E-201)

Figure 3.12. Heat Exhanger Specification (E-202)


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Table 3.27. Heat Exchanger Specification (E-202)

Figure 3.13. Heat Exhanger Specification (E-203)


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Table 3.28. Heat Exchanger Specification (E-203)

3.1.7. Filtration Unit


3.1.7.1. Multimedia Filter
Filtration in water purification is a common operation in order to get rid
with Suspended Solid (SS), including particulate BOD in water (Metcalf, 1984).
Materials used in the medium can vary: sand, anthracite (crushed anthracite coal),
carbon active granular, powdered active carbon and garnet stones. The most
commonly used in Africa and Asia are sand and gravel as a primary filter, consider
another type is quite expensive (Kawamura, 1991). Sand water filter is needed to
filter the micro solid particle. The vendor of this filter come from Watts, whose
technology is micro filter from zeolit, sand, anhtracite, and garnet. The specification
of sand water filter from Watts can be determined based on water flowrate.

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Figure 3.14. Sand Water Filter Specification


(Source: Watts, Water Filter Specification)

Table 3.29. Sand Filter Specification


Equipment Specification
Equipment Name Sand Filter
Equipment Code F-101
Function to reduce water turbidity, remove water
suspended and colloid particles
Quantity 2 (1 standby)
Equipment Type Circular, horizontal vessel
Effective Cross Section 6.154 m2
Area
Piping Diameter 150 mm
Operation Data
Flow Rate 81.4 m3/hr = 358.39 gpm
Design Pressure 2.5 – 6 bar
Inlet Pressure 5 bar
Design Temperature 20 – 120 oC
Temperature 27 oC
Filter Precision 20 – 100 microns
Diameter 2800 mm
Height 3250 mm
Material Carbon Steel, epoxy coating
Sand Filter Type Fine Sand + Coarse Sand
3.1.7.2. Cartridge Filter
Table 3.30. Cartridge Filter Specification
Equipment Specification
Equipment Name Cartridge Filter
Equipment Code F-102
Function To remove micro particle and clay in seawater
Quantity 2 (1 standby)
Equipment Type Circular, horizontal vessel
Operation Data
Flow Rate 81.4 m3/hr = 358.39 gpm
Inlet Pressure 5 bar
Temperature 25 oC
Filter Precision 5 microns

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Table 3.30. Cartridge Filter Specification (cont’d)


Construction Data
Material Carbon steel of IS 2062 grade material with 4.5 mm
thick inside lining
Filter Type Polypropylene fibers wound on polypropylene core
3.1.8. Reverse Osmosis Unit
Reverse Osmosis is a process in which dissolved inorganic solids (such as
salts) are removed from a solution (such as water). This is accomplished by
household water pressure pushing the tap water through a semipermeable
membrane. Reverse Osmosis technology has been utilized in many industrial
application, especially in offshore operation to supply clean water needs.
Reverse osmosis is used to treat seawater before being used as electrolyzer
feed water and boiler feed water (BFW). The sizing steps are based on vendor
product (DOW), feed water source and specified product quality.
Table 3.31. Reverse Osmosis Specification
Equipment Specification
Equipment Name Reverse Osmosis
Equipment Code RO501
Membrane Type (DOW) SW30HR
Feed Source Sea Water, Open Intake
SDI <5
Permeate Flow (gpm) 360.926
Recovery (%) 90
Design Specification
Flow Configuration Plug Flow
Active Membrane Area (ft2) 440
Average Flux (gfd) 19
Number of Element (Ne) 69
Number of Pressure Vessels 12
Number of Stages 3
Staging Ratio 4:2:1
3.1.9. AEL Electrolyzer
The electrolysis cell in AEL consists of an anode and a cathode that are
immersed in a liquid alkaline. They are separated from each other by an ionic
conducting diaphragm. The diaphragm further serves as a boundary to prevent the
hydrogen and oxygen gas from mixing. When a voltage is applied to the electrodes,
the water decomposes in hydrogen and hydroxyl molecules at the cathode. The
charge carrier in this type of electrolyzer is the OH- ion, which migrates through
the diaphragm and forms water and oxygen at the anode.

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Table 3.32. Electrolyzer Specification


Equipment Specification
Equipment Name Electrolyzer
Equipment Code V-101
Function to separate H2 and O2 from water
Quantity 1
Type AEL
Electrolite Liquid KOH
Operation Data
Flow Rate 725 kg/h
Design Pressure 30 bar
Design Temperature 40-90 oC
Temperature 70 oC
ΔH (J/mol) -281911.4
ΔS (J/mol C) 66.873352
Efficiency (%) 80
Construction Data
Area 242,925.34 m2
Material Platina
3.1.10. Photovoltaic Array and Battery Bank
Table 3.33. Photovoltaic Array Specification
Equipment Specification
Equipment Name Photovoltaic
Function to convert the sunlight to the electricity
Quantity 364212.5 panel = 13111650 cells
Total Solar Panel Area 70,000 m2 (1.6 m2/panel)
Current density 120 A/cm2
Energy 22000 kW

Table 3.34. Battery Bank Specification


Equipment Specification
Equipment Name Battery Bank
to storage the electricity from
Function
photovoltaic
Quantity 557
Voltage 12 Volt = 55687.4 A
Energy 514038 Wh/days

3.2. Utility Equipment Sizing


3.2.1. Cooling Tower
The cooling tower specification for water utility shows in figure below.

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Figure 3.15. Cooling Tower Specification


(Source: PT Shinwa Cooling Tower)
Based on the amount of water flow that this plant needs, which is 73,275.55
L/h or equals to 1,221.2592 L/min, the cooling tower specification that is suitable
for this plant is model number SNC-U280ASSY. The following operation
information are listed below.
 Cooling tower capacity basis: 24 hours/day
 Cooling tower minimum inlet temperature is 35-37.8oC
 The advantages of Shinwa Cooling Tower are energy saving, space saving,
compact design, and high efficiency.
Table 3.35. Cooling tower specification based on Shinwa Cooling Tower
Variable Value
Equipment Specification
Equipment Name Cooling Tower
Equipment Code CT-501
Operating Data and Properties
Inlet Temperature (oC) 35-37.8
o
Outlet Temperature ( C) 29.5-32.2
o
Wet Bulb Temperature ( C) 27-28.3
Water Flowrate (L/min) 1,221.2592
Construction Data
Model No. SNC-U280ASSY
Length (mm) 3,570
Width (mm) 2,150
Height (mm) 3,790
Type Counter Flow Splash Fill
Cooling tower can also be designed and get the specifications which are
more specified as listed below.

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Table 3.36. Cooling tower specification based on calculation


Variable Value
Equipment Specification
Equipment Name Cooling Tower
Equipment Code CT-501
Operating Data and Properties
Inlet Temperature (oC) 45
o
Outlet Temperature ( C) 25
o
Wet Bulb Temperature ( C) 20
Water Flowrate (L/min) 1,221.2592
Construction Data
Induced draft counterflow
Type
tower with fill
Height of Transfer Unit (m) 2,8
Number of Transfer Unit 2.01
Tower Packing Height (m) 5.58
Area of Cross Sectional
7.54
Surface (m2)
Selected Area (m2) 6.63

5,58 m

Figure 3.16. Cooling Tower Scheme

Figure 3.17. Cooling Tower Type


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3.2.2. Deaerator
Table 3.37. Deaerator Specification
Deaerator Specification
Code D-601
Remove gases soluble in water, such as O2 and CO2 to
Function
preventive corrosion and deposite
Material Stainless Steel 316
Type Vertical with Head Torispherical
Pressure Design (psi) 168.310
Amount (column) 1.000
Volume /capacity (m3) 0.443
Tank Diameter (m) 0.914
Tank height (m) 4.572
Shell thickness (mm) 6.726
Head thickness (mm) 13.459
3.2.3. Boiler
Boiler is the main equipment in hot utility, typically to generate steam from
boiler feed water. The fuel consumption is calculated in previous section, giving a
value of 542 kg/h. The specification for boiler is tabulated as follow.

Figure 3.18. Boiler Specification

Table 3.38. Boiler specification


Variable Value
Equipment Specification
Equipment Name Boiler
Equipment Code B-601
Operating Data and Properties
Type of Fuel Natural Gas
Fuel Consumption (kg/h) 542
LHV (kJ/kg) 47141
3
qv (kW/m ) 530

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Table 3.38. Boiler Specification (cont’d)


Operating Data and Properties
qf (kW/m2) 2130
2
qb (kW/m ) 1400
2
Fgrate (m ) 3.335
Construction Data
Inner Case Material SS-304
Furnace Wall Material Fire brick
V (m3) 13.401
Hfu+Hb 4.019
b (m) 1.741
Hb (m) 0.694
Hfu (m) 3.325
a (m) 1.915
α 30
β 45
γ 50
E (m) 0.8
d (m) 0.173
3.2.4. Clarifier
Clarifier is used to separate solid and liquid in a flow, because of previous
process the flow contains dissolved solid. It must be separated because it is the
reason of plugging and fouling in a pipeline.
3.2.4.1. Primary Clarifier
Table 3.39. Primary Clarifier Specification
Specification Amount Unit
Clarifier mass flow rate 0.9 ton/h
Volumetric flow rate 0.8878 m3/h
Clarifier volume 0.9766 m3
Clarifier height 5 M
D2/D1 0.4 M
Y 3.3331 M
y/(y+h) 0.4 m/m
D1 0.7302 M
D2 0.2921 M
Amount of unit 1 unit
3.2.4.2. Secondary Clarifier

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Table 3.40. Secondary Clarifier Specification


Specification Amount Unit
Clarifier mass flow rate 0.19 ton/h
Volumetric flow rate 0.1849 m3/h
Clarifier volume 0.2034 m3
Clarifier height 5 M
D2/D1 0.4 M
Y 3.3331 M
y/(y+h) 0.4 m/m
D1 0.3332 M
D2 0.1333 M
Amount of unit 1 Unit
3.2.5. Tank
Storage tanks and process tanks are general purpose industrial containers
that can have many configurations depending upon dimensions, orientation,
placement, and wall configuration. Materials of construction will dictate the
application that is suitable for the tank.
3.2.5.1. Aeration Tank
Table 3.41. Aeration Tank Specification
Equipment Specification
Equipment Name Aeration Tank
Equipment Code T-801
Function To treat the wastewater using activated sludge
Material HDPE
Quantity 1
Operating Conditions
Pressure (kPa) 35
Temperature (oC) 100
Design Specification
Type of Fluid Waste water
Mass Flow (kg/h) 106.254
3
Density (kg/m ) 1,200
3
Volume (m /week) 14.876
Volume tank (m3) 16.363
Horizontal/vertical Horizontal with Concrete Foundation
L/D 0.8
D (m) 2.933
L (m) 2.346
Thickness (mm) >12
Open/closed vessel Open
Vessel Head Type Dished Head

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2.5.1. Sludge Tank


Table 3.42. Sludge Tank Specification
Equipment Specification
Equipment Name Sludge Tank
Equipment Code T-802
Function To store sludge from 2 streams to be
transported to the burner
Material HDPE
Quantity 1
Operating Conditions
Pressure (kPa) 35
o
Temperature ( C) 100
Design Specification
Type of Fluid Sludge
Design Specification
Mass Flow (kg/h) 28.96
3
Density (kg/m ) 1,400
3
Volume (m /week) 3.475
Volume tank (m3) 3.822
Horizontal/vertical Horizontal with Concrete Foundation
L/D 0.8
D (m) 1.815
L (m) 1.452
Thickness (mm) >12
Open/closed vessel Closed
Vessel Head Type Dished Head

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CHAPTER 4
PROCESS CONTROL AND P&ID

4.1. Process Control


As the process requires process variable control, the plant needs to have a process control system. It is an engineering discipline
dealing with architectures, mechanisms and algorithms to maintain the output of a specific process within a desired range. Therefore, process
control is a very important aspect in an industry. It enables automation, enabling operators to operate the process from the control room.
The process control is conducted with the aim of seven objectives in process control through the usage of 5 control variables, which
are temperature, pressure, level/ volume, flow, and analyzer.

Table 4. 1. Plant Control of Area 100


Process Controlled Controlling
Controller Function Control Procedure
Equipment Parameter Parameter
Control the flow of the stream to Flow transmitter will emit pneumatic signal to control
Flow Indicator
Flow Rate Flow prevent feed loss in high pressure the flow rate before entering pump and reverse osmosis
Filter (F- Control
pump and reverse osmosis is capable
101, F-102,
Control the concentration of waste Analyzer Indicator Controller will emit pneumatic
and F-103) Filter waste Analyzer
Concentration before being pump to the ocean and signal to Analyzer to control the concentration of waste
flow Indicator Control
waste water treatment emit through the ocean and waste water treatment
Flow Indicator Control the flow of the stream to Flow transmitter will emit pneumatic signal to control
Flow Rate Flow
Control prevent feed loss in electrolyzer the flow rate before entering the electrolyzer is capable
Electrolyzer
Level transmitter will emit pneumatic signal to
(R-101) Level Indicator Control flow rate of the stream to
Level Inlet flow prevent flooding if it reach more than 80% of volume
Control electrolyzer
capacity of electrolyzer

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Table 4. 2. Plant Control of Area 200


Process Controlled Controlling
Controller Function Control Procedure
Equipment Parameter Parameter
Compressor Control the flow of the stream to Flow transmitter will emit pneumatic signal to control the
Flow Rate Flow Indicator
(K-201 and Flow prevent the unbalance concentration flow rate if the ratio of H2 and CO2 bigger than the recycle
Outlet Control
K-202) of mixing process stream
Compressor Control the concentration of stream Analyzer will emit pneumatic signal to Analyzer Indicator
Concentration Flow Indicator
(K-201 and Inlet flow which have been mixed with recycle Control to control concentration of mixing before entering
of mixing Control
K-202) stream reactor through flow rate outlet compressor
Control the ratio flow rate of stream Flow Flow will emit pneumatic signal to Flow Indicator
Ratio of Flow Indicator
Flow which have been mixed with recycle Control to control the flow rate ratio of mixing before entering
mixing Control
stream reactor
Flow Indicator Control the flow of the stream to Flow transmitter will emit pneumatic signal to control the
Methanol Flow Rate Flow
Control prevent feed loss in reactor flow rate before entering reactor is capable
Synthesis
Reboiler Temperature Control the temperature of stream Flow of reboiler hot fluid though heat exchanger will
Reactor
Temperature Hot Fluid Indicator before entering reactor to adjust the increase should the temperature not achieve the operating
(R-201)
Flow Control operating condition condition (50oC)
When the pressure exceed 1.2 atm, pressure transmitter will
Pressure Safety Control the pressure of reactor by
Pressure Vent Flow give an electic signal to PSV to open valve to reduce the
Valve reducing exceed pressure
pressure inside reactor
Reboiler Temperature Control the temperature of stream Flow of reboiler hot fluid though heat exchanger will
Temperature Hot Fluid Indicator before entering separator to adjust increase should the temperature not achieve the operating
Separator Flow Control the operating condition condition (50oC)
(S-201) Pressure Pressure transmitter will give electric signal to PIC and close
Vapor Control the pressure of separator by
Pressure Indicator the pressure valve to reduce flow of output separator if the
output flow reducing exceed pressure
Control pressure is lower than 60 bar
Pressure Pressure in the separator should not < 1 bar. Therefore, the
Vapor Control the pressure of separator by
Pressure Indicator pressure transmitter will give electric signal to PIC and close
output flow reducing exceed pressure
Separator Control the pressure valve to reduce flow of output separator
(S-202) Control Flow of product out from When the level of column reach higher than 80% of bottom
Liquid Level Indicator
Level separator to prevent flooding inside space in column, the valve will open to emit the flow rate to
output flow Control
column prevent the flooding output separator

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Table 4. 2. Plant Control of 200 (cont’d)


Process Controlled Controlling
Controller Function Control Procedure
Equipment Parameter Parameter
Flow Indicator Control the flow of the stream to Flow transmitter will emit pneumatic signal to control the
Flow Rate Inlet Flow
Distillation Control prevent feed loss in distillation column flow rate before entering distillation is capable
Column (T- Control Flow of product out from When the level is higher than 80% of bottom space in
Bottom Level Indicator
201 Level separator to prevent flooding inside column, the valve will open to emit the flow rate to
output flow Control
distillation column prevent the flooding output distillation column
Analyzer Control the concentration of methanol Analyzer Indicator Controller will emit pneumatic signal
HE hot fluid
Concentration Indicator before being entering to the next to Analyzer to control the concentration of methanol
Knock Out flow
Control process output the KO drum
Drum (D-
Temperature Control the temperature of stream Flow of reboiler hot fluid though heat exchanger will
201) Reboiler Hot
Temperature Indicator output KO drum to adjust the operating increase should the temperature not achieve the
Fluid Flow
Control condition in the next process operating condition (65oC)

Table 4. 3. Plant Control of Area 300


Process Controlled Controlling
Controller Function Control Procedure
Equipment Parameter Parameter
Flow Indicator Control the flow of the stream to Flow transmitter will emit pneumatic signal to control the
Flow Rate Flow
Control prevent feed loss in reactor flow rate before entering reactor is capable
DME Control the temperature of stream Flow of reboiler hot fluid though heat exchanger will
Reboiler Hot Temperature
Reactor Temperature before entering reactor to adjust increase should the temperature not achieve the operating
Fluid Flow Indicator Control
Vessel (R- the operating condition condition (225oC)
301) When the pressure exceed 1.2 atm, the pressure transmitter
Opening Pressure Safety Control the pressure of reactor by
Pressure will give an electric signal to PSV and open the pressure
Valve Valve reducing exceed pressure
relief valve to reduce the pressure inside reactor
Control the temperature of stream Flow of reboiler hot fluid though heat exchanger will
Reboiler Hot Temperature
Temperature before entering separator to adjust increase should the temperature not achieve the operating
Two-phase Fluid Flow Indicator Control
the operating condition condition (130oC)
Separator
Control Flow of product out from When the level of column reach higher than 80% of bottom
(S-301) Level Indicator
Level Liquid Level separator to prevent flooding space in column, the valve will open to emit the flow rate
Control
inside column to prevent the flooding output separator

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Table 4. 3. Plant Control of Area 300 (cont’d)


Process Controlled Controlling
Controller Function Control Procedure
Equipment Parameter Parameter
When the pressure exceed 1.2 atm, the pressure
Pressure Safety Control the pressure of reactor by transmitter will give an electric signal to PSV and
Pressure Vent flow
Valve reducing exceed pressure open the pressure relief valve to reduce the pressure
Gasoline inside reactor
Synthesis Reactor Flow Indicator Control the flow of the stream to Flow transmitter will emit pneumatic signal to control
Flow Rate Flow
(R-302) Control prevent feed loss in reactor the flow rate before entering reactor is capable
Control the temperature of stream Flow of reboiler hot fluid though heat exchanger will
Reboiler Hot Temperature
Temperature before entering reactor to adjust the increase should the temperature not achieve the
Fluid Flow Indicator Control
operating condition operating condition (180oC)

Table 4. 4. Plant Control of Area 400


Process Controlled Controlling
Controller Function Control Procedure
Equipment Parameter Parameter
Three Phase Flow Indicator Control the flow of the stream to Flow transmitter will emit pneumatic signal to control
Flow Rate Flow
Separator (S-401) Control prevent feed loss in separator the flow rate before entering separator is capable
Temperature Control the temperature of stream Flow of reboiler hot fluid though heat exchanger will
Reboiler Hot
Temperature Indicator before entering separator to adjust increase should the temperature not achieve the
Fluid Flow
Three Phase Control the operating condition operating condition (60oC)
Separator (S-401) Control Flow of product out from When the level of column reach higher than 80% of
Level Indicator
Level Liquid Level separator to prevent flooding inside bottom space in column, the valve will open to emit
Control
column the flow rate to prevent the flooding output separator
Temperature Control the temperature of stream Flow of reboiler hot fluid though heat exchanger will
Reboiler Hot
Temperature Indicator before entering distillation column increase should the temperature not achieve the
Fluid Flow
Control to adjust the operating condition operating condition (80oC)
Deethanizer When the level of column reach higher than 80% of
Level Indicator Control Flow of distillation column
Column Level Liquid Level bottom space in column, the valve will open to emit
Control to prevent flooding inside column
(T-401) the flow rate to prevent the flooding output column
Control the pressure of distillation When pressure exceed 1.2 atm, pressure transmitter
Opening Pressure Safety
Pressure column by reducing exceed will give an electric signal to PSV and open it to
Valve Valve
pressure reduce the pressure inside column
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Table 4. 4. Plant Control of Area 400 (cont’d)


Process Controlled Controlling
Controller Function Control Procedure
Equipment Parameter Parameter
Level Control Flow out of the distillation When the level of column reach higher than 80% of bottom
Level Liquid Level Indicator column to prevent flooding inside space in drum, the valve will open to emit the flow rate to
Deethanizer
Control KO drum prevent the flooding output drum
KO Drum
Pressure in the KO drum should not less than 1 bar. Therefore,
(S-402) Pressure Control the pressure of KO drum by
Pressure Vent Flow the pressure transmitter will give electric signal to PSV and
Safety Valve reducing exceed pressure
close the pressure valve to reduce flow of output drum
When the pressure exceed 1.2 atm, the pressure transmitter
Opening Pressure Control the pressure of distillation
Pressure will give an electric signal to PSV and open the pressure relief
Valve Safety Valve column by reducing exceed pressure
valve to reduce the pressure inside column
Debutanizer Level When the level of column reach higher than 80% of bottom
Control Flow of distillation column
Column (T- Level Liquid Level Indicator space in column, the valve will open to emit the flow rate to
to prevent flooding inside column
402) Control prevent the flooding output column
Pressure in the column should not be less than 1 bar. If so,
Pressure Control the pressure of distillation
Pressure Vent Flow pressure transmitter will give electric signal to PSV and close
Safety Valve column by reducing exceed pressure
the pressure valve to reduce flow of output column
Debutanizer Level Control Flow out of the distillation When the level of column reach higher than 80% of bottom
KO Drum Level Liquid Level Indicator column to prevent flooding inside space in drum, the valve will open to emit the flow rate to
(S-403) Control KO drum prevent the flooding output drum
Temperature Control the temperature of stream Flow of reboiler hot fluid though heat exchanger will increase
Gasoline Reboiler Hot
Temperature Indicator before entering storage to adjust the should the temperature not achieve the operating condition
Storage Fluid Flow
Control operating condition (205oC)

Table 4. 5. Plant Control of Area 500


Process Controlled Controlling
Controller Function Control Procedure
Equipment Parameter Parameter
Flow Indicator Control the flow of the stream to Flow transmitter will emit pneumatic signal to control the flow
Flow Rate Flow
Cooling Control prevent feed loss in cooling tower rate before entering cooling tower is capable
Tower (CT- Reboiler Temperature Control the temperature of stream Flow of reboiler hot fluid though heat exchanger will increase
501) Temperature Hot Fluid Indicator before entering cooling tower to should the temperature not achieve the operating condition
Flow Control adjust the operating condition (40oC)
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Table 4. 6. Plant Control of Area 600


Process Controlled Controlling
Controller Function Control Procedure
Equipment Parameter Parameter
Control the flow of the stream to Flow transmitter will emit pneumatic signal to control the
Flow Rate Flow Indicator
Flow prevent the unbalance concentration flow rate if the ratio of purified water is bigger than the
Outlet Control
of mixing process recycle stream
Valve Analyzer will emit pneumatic signal to Analyzer
Control the concentration of stream
(VLV-602 Concentration Flow Indicator Indicator Control to control the concentration of mixing
Analyzer which have been mixed with recycle
and Pump of mixing Control before entering deaerator by controlling the flow rate
stream
outlet valve
Ratio of Flow Indicator Control ratio flow rate of stream Flow Flow will emit pneumatic signal to Flow Indicator
Flow
mixing Control which is mixed with recycle stream Control to control mixing ratio before entering deaerator
Analyzer Control the concentration of stream Analyzer will emit pneumatic signal to Analyzer
Deaerator
Concentration Analyzer Indicator output deaerator to ensure the no Indicator Control to control the flow of stream before
(D-601)
Control light gas (CO2, etc) output entering deaerator
Flow Indicator Control the flow of the stream to Flow transmitter will emit pneumatic signal to control the
Flow Rate Flow
Control prevent feed loss in boiler flow rate before entering boiler is capable
Boiler
Temperature Control the temperature of stream Flow of natural gas though the furnace will increase
(B-601) Natural Gas
Temperature Indicator output boiler to ensure the boiler should the temperature not achieve the operating
Feed Flow
Control output has become steam condition (1500oC)

Table 4. 7. Plant Control of Area 700


Process Controlled Controlling
Controller Function Control Procedure
Equipment Parameter Parameter
Primary Analyzer Analyzer Indicator Controller will emit pneumatic signal
Tank Waste Control the concentration of waste
Clarifier (C- Concentration Indicator to Analyzer to control the concentration of waste emit
Flow before being pump to the sludge tank
701) Control through the sludge tank
Aeration Control Flow out of the aeration tank When the level of column reach higher than 80% of
Liquid Level Indicator
Tank (T- Level to prevent flooding inside aeration bottom space in tank, the valve will open to emit the flow
Output Flow Control
701) tank rate to prevent the flooding output tank
Secondary Analyzer Analyzer Indicator Controller will emit pneumatic signal
Tank Waste Control the concentration of waste
Clarifier (C- Concentration Indicator to Analyzer to control the concentration of waste emit
Flow before being pump to the sludge tank
701) Control through the sludge tank
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4.2. Pipeline Specification
A pipe is a tubular section or hollow cylinder, usually but not necessarily of circular cross-section, used mainly to convey substances
which can flow such as liquids and gases (fluids), slurries, powders and masses of small solids. It can also be used for structural applications.
It is used in plants to transport fluids from one point to another.
Table 4. 8. Pipeline Specification Area 100
Inner Diameter Outer Diameter Nominal Pipe Size Length Pressure Drop
Pipe Name Material Schedule
(mm) (mm) (inch) (ft) (psi/100 ft)
101 Carbon Steel A53 A106 API5L 278.52 288.83 12.00 40 15.00 0.3024
102 Carbon Steel A53 A106 API5L 279.52 289.83 12.00 40 15.00 0.3024
103 Carbon Steel A53 A106 API5L 276.24 286.55 12.00 40 15.00 0.3152
104 Carbon Steel A53 A106 API5L 35.56 41.04 3.00 40 15.00 1.8674
105 Carbon Steel A53 A106 API5L 273.95 284.26 12.00 40 15.00 0.1542
106 Carbon Steel A53 A106 API5L 35.56 41.04 3.00 40 15.00 1.8674
107 Carbon Steel A53 A106 API5L 50.28 55.77 3.00 40 15.00 1.2076
108 Carbon Steel A53 A106 API5L 279.45 289.77 12.00 40 15.00 0.1506
109 Carbon Steel A53 A106 API5L 280.45 290.77 12.00 40 15.00 0.1506
110 Carbon Steel A53 A106 API5L 281.45 291.77 12.00 40 15.00 0.1506
111 Carbon Steel A53 A106 API5L 282.45 292.77 12.00 40 15.00 0.1506
112 Carbon Steel A53 A106 API5L 78.47 84.49 4.00 40 15.00 0.7015
113 Carbon Steel A53 A106 API5L 26.17 31.65 3.00 40 15.00 2.7403
114 Carbon Steel A53 A106 API5L 73.98 79.47 3.00 40 15.00 0.7541
115 Carbon Steel A53 A106 API5L 263.22 273.53 12.00 40 15.00 0.1618
116 Carbon Steel A53 A106 API5L 264.22 274.53 12.00 40 15.00 0.1618
117 Carbon Steel A53 A106 API5L 11.81 17.29 3.00 20 15.00 7.5423
118 Carbon Steel A53 A106 API5L 52.02 57.51 3.00 20 15.00 1.1638
119 Carbon Steel A53 A106 API5L 53.02 58.51 3.00 20 15.00 1.1638
120 Carbon Steel A53 A106 API5L 92.12 98.14 4.00 40 30.00 1.1529
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Table 4. 9. Pipeline Specification Area 200
Inner Diameter Outer Diameter Nominal Pipe Size Length Pressure Drop
Stream No. Material Schedule
(mm) (mm) (inch) (ft) (psi/100 ft)
201 Carbon Steel A53 A106 API5L 334.36 347.06 16.00 80 50.00 0.0013
202 Carbon Steel A53 A106 API5L 334.36 347.06 16.00 80 350.00 0.0013
203 Carbon Steel A53 A106 API5L 311.06 322.19 14.00 40 30.00 0.2153
204 Carbon Steel A53 A106 API5L 311.06 322.19 14.00 80 30.00 0.2153
205 Carbon Steel A53 A106 API5L 214.05 223.33 10.00 80 30.00 0.7004
206 Carbon Steel A53 A106 API5L 222.80 232.07 10.00 80 30.00 0.7004
207 Carbon Steel A53 A106 API5L 232.83 242.10 10.00 80 30.00 0.7004
208 Carbon Steel A53 A106 API5L 234.10 243.37 10.00 80 30.00 0.7004
209 Carbon Steel A53 A106 API5L 231.31 240.58 10.00 80 25.00 1.1081
210 Carbon Steel A53 A106 API5L 222.33 231.60 10.00 80 30.00 1.1081
211 Carbon Steel A53 A106 API5L 204.08 212.26 8.00 80 30.00 0.2587
212 Carbon Steel A53 A106 API5L 199.56 207.74 8.00 80 30.00 0.2587
213 Carbon Steel A53 A106 API5L 185.59 193.77 8.00 80 30.00 0.2587
214 Carbon Steel A53 A106 API5L 185.28 193.46 8.00 80 25.00 0.2587
215 Carbon Steel A53 A106 API5L 193.68 201.86 8.00 20 50.00 0.2587
216 Carbon Steel A53 A106 API5L 50.43 55.92 2.00 20 10.00 0.2654
217 Carbon Steel A53 A106 API5L 803.19 820.67 34.00 20 10.00 0.2654
218 Carbon Steel A53 A106 API5L 801.75 819.22 34.00 20 50.00 0.0002
219 Carbon Steel A53 A106 API5L 80.54 86.56 4.00 80 30.00 0.8626
220 Carbon Steel A53 A106 API5L 195.17 203.35 8.00 80 30.00 0.3139
221 Carbon Steel A53 A106 API5L 658.64 676.11 32.00 80 50.00 0.0001
222 Carbon Steel A53 A106 API5L 48.10 53.59 2.00 20 10.00 0.3809
223 Carbon Steel A53 A106 API5L 47.93 53.42 2.00 20 10.00 0.3809
224 Carbon Steel A53 A106 API5L 47.93 53.42 2.00 20 10.00 0.3809
225 Carbon Steel A53 A106 API5L 1,220.15 1,239.20 42.00 20 25.00 0.3809

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Table 4. 10. Pipeline Specification Area 300
Inner Diameter Outer Diameter Nominal Pipe Length Pressure Drop
Pipe Name Material Schedule
(mm) (mm) Size (inch) (ft) (psi/100 ft)
301 Carbon Steel A53 A106 API5L 39.76 45.24 2.00 40 15.00 0.4284
302 Carbon Steel A53 A106 API5L 39.75 45.23 2.00 40 10.00 0.4284
303 Carbon Steel A53 A106 API5L 137.30 144.41 6.00 40 10.00 0.4284
304 Carbon Steel A53 A106 API5L 262.91 273.22 12.00 40 10.00 0.4284
305 Carbon Steel A53 A106 API5L 381.00 393.70 16.00 40 10.00 0.4284
306 Carbon Steel A53 A106 API5L 445.89 460.98 20.00 40 15.00 0.0004
307 Carbon Steel A53 A106 API5L 355.33 368.03 16.00 40 10.00 0.0004
308 Carbon Steel A53 A106 API5L 285.60 298.30 12.00 40 10.00 0.0004
309 Carbon Steel A53 A106 API5L 285.18 297.88 12.00 40 10.00 0.0016
310 Carbon Steel A53 A106 API5L 15.48 20.96 2.00 40 10.00 0.7280
311 Carbon Steel A53 A106 API5L 429.87 460.98 20.00 40 15.00 0.0010
312 Carbon Steel A53 A106 API5L 501.81 519.28 24.00 40 15.00 0.0010
313 Carbon Steel A53 A106 API5L 507.21 524.69 24.00 40 15.00 0.0010

Table 4. 11. Pipeline Specification Area 400


Inner Diameter Outer Diameter Nominal Pipe Length Pressure Drop
Pipe Name Material Schedule
(mm) (mm) Size (inch) (ft) (psi/100 ft)
401 Carbon Steel A53 A106 API5L 448.88 466.36 20.00 40 15.00 0.0009
402 Carbon Steel A53 A106 API5L 555.80 570.89 24.00 40 15.00 0.0005
403 Carbon Steel A53 A106 API5L 346.08 358.78 16.00 40 10.00 0.0047
404 Carbon Steel A53 A106 API5L 343.60 356.30 16.00 40 30.00 0.0012
405 Carbon Steel A53 A106 API5L 308.69 319.81 14.00 40 30.00 0.0010
406 Carbon Steel A53 A106 API5L 10.71 16.20 2.00 40 50.00 2.8790
407 Carbon Steel A53 A106 API5L 39.96 45.44 2.00 40 15.00 0.3729
408 Carbon Steel A53 A106 API5L 39.91 45.39 2.00 80 15.00 0.3729
409 Carbon Steel A53 A106 API5L 34.87 40.35 2.00 40 15.00 0.3729
410 Carbon Steel A53 A106 API5L 40.67 46.15 2.00 80 15.00 0.3729
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Table 4. 12. Pipeline Specification Area 400 (cont’d)
Inner Diameter Outer Diameter Nominal Pipe Length Pressure Drop
Pipe Name Material Schedule
(mm) (mm) Size (inch) (ft) (psi/100 ft)
413 Carbon Steel A53 A106 API5L 16.93 22.41 2.00 80 30.00 1.0056
414 Carbon Steel A53 A106 API5L 16.34 21.83 2.00 80 30.00 0.7936
418 Carbon Steel A53 A106 API5L 40.28 45.77 2.00 80 15.00 0.3167
419 Carbon Steel A53 A106 API5L 40.28 45.77 2.00 80 15.00 0.3167
422 Carbon Steel A53 A106 API5L 11.36 16.85 2.00 80 30.00 1.6092
429 Carbon Steel A53 A106 API5L 40.31 45.80 2.00 80 30.00 0.2955

Table 4. 13. Pipeline Specification Area 500


Inner Diameter Outer Diameter Nominal Pipe Length Pressure Drop
Pipe Name Material Schedule
(mm) (mm) Size (inch) (ft) (psi/100 ft)
501 Carbon Steel A53 A106 API5L 90.87 96.89 4.00 40 50.00 1.5630
502 Carbon Steel A53 A106 API5L 21.36 26.85 2.00 40 10.00 0.0076
503 Carbon Steel A53 A106 API5L 88.87 94.87 4.00 40 10.00 0.0180
504 Carbon Steel A53 A106 API5L 21.36 26.86 3.00 40 10.00 0.0085
505 Carbon Steel A53 A106 API5L 21.36 26.86 3.00 40 10.00 0.0085
506 Carbon Steel A53 A106 API5L 21.36 26.86 3.00 40 10.00 0.0085
507 Carbon Steel A53 A106 API5L 21.36 26.86 3.00 40 10.00 0.0085

Table 4. 14. Pipeline Specification Area 600


Inner Diameter Outer Diameter Nominal Pipe Length Pressure Drop
Stream No. Material Schedule
(mm) (mm) Size (inch) (ft) (psi/100 ft)
600 Carbon Steel A53 A106 API5L 35.43 40.93 3.00 40 10.00 5.0020
601 Carbon Steel A53 A106 API5L 11.81 17.31 3.00 40 10.00 20.1056
603 Carbon Steel A53 A106 API5L 37.35 42.85 3.00 40 10.00 4.6839
604 Carbon Steel A53 A106 API5L 38.35 43.85 3.00 40 10.00 4.6839
605 Carbon Steel A53 A106 API5L 39.35 44.85 3.00 40 10.00 4.6839
606 Carbon Steel A53 A106 API5L 39.35 44.85 3.00 40 10.00 4.6839
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Table 4. 15. Pipeline Specification Area 600 (cont’d)
Inner Diameter Outer Diameter Nominal Pipe Length Pressure Drop
Stream No. Material Schedule
(mm) (mm) Size (inch) (ft) (psi/100 ft)
607 Carbon Steel A53 A106 API5L 15.42 20.92 3.00 40 10.00 14.2876
608 Carbon Steel A53 A106 API5L 34.01 39.51 3.00 40 10.00 5.2632
609 Carbon Steel A53 A106 API5L 34.01 39.51 3.00 40 10.00 5.2632

Table 4. 16. Pipeline Specification Area 700


Inner Diameter Outer Diameter Nominal Pipe Length Pressure Drop
Stream No. Material Schedule
(mm) (mm) Size (inch) (ft) (psi/100 ft)
701 Carbon Steel A53 A106 API5L 10.28 15.78 3.00 40 10.00 24.0592
702 Carbon Steel A53 A106 API5L 9.87 15.37 3.00 40 10.00 24.0592
703 Carbon Steel A53 A106 API5L 4.69 10.19 2.00 40 10.00 16.8086
704 Carbon Steel A53 A106 API5L 5.69 11.19 2.00 40 10.00 16.8086
705 Carbon Steel A53 A106 API5L 1.43 6.93 2.00 40 10.00 161.7493
706 Carbon Steel A53 A106 API5L 3.70 9.20 2.00 40 10.00 43.9962
707 Carbon Steel A53 A106 API5L 4.19 9.69 2.00 40 10.00 4.6727
708 Carbon Steel A53 A106 API5L 7.65 13.15 2.00 40 30.00 6.3124
709 Carbon Steel A53 A106 API5L 7.65 13.15 2.00 40 30.00 6.3124
710 Carbon Steel A53 A106 API5L 9.02 14.52 2.00 40 30.00 7.1199
711 Carbon Steel A53 A106 API5L 9.02 14.52 2.00 40 30.00 7.1199
712 Carbon Steel A53 A106 API5L 9.02 14.52 2.00 40 30.00 7.1199

4.3. Piping and Instrumentation Diagram (P&ID)


Piping and Instrumentation Diagram for each process is shown in the appendix. It includes the information about piping specification
and control system.

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CHAPTER 5
HEALTH, SAFETY, AND ENVIRONMENTAL PROTECTION

5.1. HSE Aspect


5.1.1. Hazard Identification Study (HAZID)
Hazard identification is a qualitative technique for the early identification
of potential hazards and threats affecting people and environment. The major
benefit of a HAZID study is to provide essential input to project development
decisions. It is a means of identifying and describing HSE hazards and threats at the
earliest practicable stage of a development. HAZID is typically conducted during
the FEED (Front End Engineering Design) stage of a project. HAZID considers
both internal and external events such as weather effects and seeks to broaden
hazard understanding of those involved by encouraging lateral thinking.
HAZID is a consequence-driven, and it assumes that an event will occur and
consequently requires rigorous analysis of the sequence of events for it to occur.
Identification of hazards cover various aspects such as the environment, assets, and
human resource. The general scheme of HAZID process is illustrated as follow.

Figure 5. 1. The HAZID Process Scheme


(Source: Halliburton, 2015)
The objectives of HAZID are listed as follow.
1. To identify hazards to the host facilities due to design, and to evaluate potential
consequences should the hazards be realized.
2. To establish safeguards to manage hazards, to identify areas where further
understanding of safeguard effectiveness is needed.

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3. To make recommendations to reduce the likelihood of hazard occurrence, or to


mitigate the potential consequences.
Hazards are identified on the overall plant area, whose are is divided into
several nodes to facilitate more detailed identification. The parameter for effect and
frequency are tabulated as follow.
Table 5. 1. Hazard Severity Parameter for HAZID
Parameter Minor Major Severe
Human
No injury Medium injury Fatal injury
Resources
Losses under USD Losses around USD Losses over USD
Assets
100,000 100,000-1,000,000 1,000,000
Environment No damage Small damage Massive damage
(Source: McKay, 2017)
Table 1. 2. Hazard Frequency Parameter for HAZID
Parameter Most Likely Likely Unlikely
Unlikely (Once or not at all Likely (1-10 times Very Likely (more than
Frequency
in 10 years) in 10 years) 10 times in 10 years)
(Source: McKay, 2017)
The identification of hazard is stimulated by guidewords, which formulate
scenarios where the design intent may be violated and therefore centers on the
lateral thought processes. The objective is to define how an event could happen and
what would then be the consequence. Hazard index is then measured as the product
of severity and frequency, tabulated below.
Table 1. 3. Hazard Index Based on Frequency and Severity
Severity
Frequency Minor Major Severe
Very Likely Medium High Extreme
Likely Low High Extreme
Unlikely Low Medium High
(Source: Queensland Coke & Energy, 2005)
The HAZID analysis of the plant is described in the following table.

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Table 1. 4. Plant Hazard Identification (HAZID)
Guidewor Existing Frequen Hazard
No Cause Consequences Severity Action Comments
d Controls cy Index
Water Treatment and Electrolysis
High inlet pressure and
1 Damage Membrane damage Inlet flow control Major Unlikely Medium Monitoring inlet flow regularly
flow to filtration unit
Ignition source
- Small electrodes’ gap
Fire and explosion in control, distant Ensuring no ignition sources
Fire and inducing electrical spark
2 electrolyzer and oxygen and Severe Unlikely High nearby, ensuring strict working
Explosion - Ignition source nearby
nearby equipments hydrogen stream procedure
- Oxygen and hydrogen mix
gap
Bad construction, external Collapsing solar Regular Inspecting regularly, ensuring
3 Damage Major Unlikely Medium
weather factor collector unit maintenance usage of PPE
Methanol Synthesis
Friction in moving parts of Very Applying silencer, using
4 Noise Nuisance noise issue - Minor Medium
pump Likely earplug as PPE
Mechanical damage Inspecting pressure and
5 Damage High reactor pressure Pressure control Severe Unlikely High
and explosion temperature control regularly
Dew point corrosion Inspecting pressure and
Fire and Ignition source nearby, in reactor leading to Temperature temperature control regularly,
6 Severe Unlikely High
Explosion temperature control failure leakage and control maintenance, ensuring no
explosion ignition source nearby
Separator tremble Inspecting pressure and
7 Damage High separator pressure Pressure control Severe Unlikely High
and explosion temperature control regularly
High pressure and
Heat exchanger Inspecting pressure and
Fire and temperature of heat Temperature
8 leakage and Severe Unlikely High temperature regularly, regular
Explosion exchangers, corrosion of control
explosion cleaning and maintenance
tube, shell, or other parts
Gas phase in pump
Cavitation and pump Inspecting and monitoring
9 Damage operation due to level Level control Major Likely High
damage suction flow and source level
control failure

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Table 1. 4. Plant Hazard Identification (HAZID) (cont’d)
Existing Hazard
No Guideword Cause Consequences Severity Frequency Action Comments
Controls Index

Blocked pump suction/


discharge, overly high Strict working procedure,
Pressure
10 Damage pressure, improper impeller Pimp explosion Major Likely High ensuring no ignition source
control
adjustment in assembly, nearby
ignition source nearby
DME and Gasoline Synthesis
Mechanical
Pressure Inspecting pressure and
11 Damage High reactor pressure damage and Severe Unlikely High
control temperature control regularly
explosion
Dew point Inspecting pressure and
Fire and Ignition source nearby, corrosion in reactor Temperature temperature control regularly,
12 Severe Unlikely High
Explosion temperature control failure leading to leakage control maintenance, ensuring no
and explosion ignition source nearby
Separator tremble Pressure Inspecting pressure and
13 Damage High separator pressure Severe Unlikely High
and explosion control temperature control regularly
High pressure and temperature Heat exchanger Inspecting pressure and
Fire and Temperature
14 of heat exchangers, corrosion leakage and Severe Unlikely High temperature regularly, regular
Explosion control
of tube, shell, or other parts explosion cleaning and maintenance
Gasoline Purification
Mechanical
High distillation column and Pressure Inspecting pressure and
15 Damage damage and Severe Unlikely High
separator pressure control temperature control regularly
explosion
Inspecting pressure and
High pressure and temperature Heat exchanger
Fire and Temperature temperature regularly, regular
16 of heat exchangers, corrosion leakage and Severe Unlikely High
Explosion control cleaning and maintenance,
of tube, shell, or other parts explosion
hydrant system

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Table 1. 4. Plant Hazard Identification (HAZID) (cont’d)
Existing Hazard
No Guideword Cause Consequences Severity Frequency Action Comments
Controls Index
Gas phase in pump Inspecting and
Cavitation and
17 Damage operation due to level Level control Minor Likely Low monitoring suction flow
pump damage
control failure and source level
Blocked pump suction/
discharge, overly high Strict working procedure,
Pressure
18 Damage pressure, improper impeller Pimp explosion Major Likely High ensuring no ignition
control
adjustment in assembly, source nearby
ignition source nearby
Gasoline Storage
Storage vessel Inspecting and
Fire and Ignition source nearby, Regular
19 leakage and Severe Likely Extreme monitoring storage
Explosion vessel corrosion monitoring
explosion regularly, hydrant system
Utility and Wastewater Treatment
Pressure and Inspecting and
High temperature and Boiler blowout and
20 Damage temperature Severe Unlikely High monitoring temperature
pressure explosion
control and pressure regularly
Regular inspection and
Fire and Flammable composition of Fire and explosion Flue gas
21 Severe Unlikely High monitoring, ensuring no
Explosion gases in boiler around boiler control
ignition source nearby
Cleaning up the
Clarifier tank Level and flow sedimentation regularly,
22 Overflow No sediment cleanup Minor Likely Low
overflow control inspection of level
control
Entire Site Overview
Material
Regular corrosion
Piping Corroding substance inside Corrosion leading to selection,
23 Major Likely High inspection, applying
Corrosion pipe, external weather factor leakage corrosion
corrosion inhibitor
allowance

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Table 1. 4. Plant Hazard Identification (HAZID) (cont’d)
Existing Hazard
No Guideword Cause Consequences Severity Frequency Action Comments
Controls Index
Potential for direct
High structures on site transfer Lightning protection of
24 Weather lightning hits on site - Severe Unlikely High
static electricity from lightning vulnerable equipments
equipment
Potential for over- All structures on site will
High wind/ adverse
25 Weather loading/ damage to - Major Unlikely Medium be wind rated for maximum
environmental conditions
site structures expected local conditions
Local area has no record of
26 Weather High rainfall conditions Flooding - Minor Unlikely Low flooding, equipments are
resistant to external water
Control Room
Tight working
System Error in control system or Operational Implementing working
27 procedure, Severe Likely Extreme
Error equipment, human error disruption procedure more strictly
training
Laboratory
Hazardous
Chemical spill, unwanted Working Tight laboratory working
28 Toxic substance affecting Major Likely High
reaction procedure procedure
people in laboratory
Tight laboratory working
Chemical reaction leading to Explosion in Working
29 Explosion Major Unlikely Medium procedure, providing fire
explosion laboratory procedure
extinguisher
Office and Technical Building
Evacuation
Electrical spark, fire spread Fire in office and HSE training for office and
30 Fire guide, fire Severe Unlikely High
from plant technical building technical building workers
hydrant
Hazardous substance leakage Toxic due to gas HSE training for office and
31 Toxic PPE Severe Unlikely High
from plant exposure technical building workers

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5.1.2. Hazard and Operability Study (HAZOP)


Hazard and Operability Study (HAZOP) is a structured, systematic
examination of a process or operation that takes place and is still in the planning
stages in which aims to identify and evaluate problems that may pose a danger to
the individual employees, equipment operation, or efficiency of the process
operation. HAZOP is the identification of irregularities or deviations that occur in
the operation of an industrial installation, along with the consequent undesirable
effects concerning safety, operability, and environment. The possible deviations are
generated by rigorous questioning, prompted by a series of standard ‘guideword’
applied to intended design. HAZOP is done on planning stage for new installation
and before doing equipment modification or adding new installation. HAZOP is
usually called systematic analysis for industry critical installation design, the
effects, and potential deviations that occur together with possible hazard potential
occurrence. The goals after doing HAZOP are:
 To identify safety, hazard, and operational problems that are related to
process which immediately threatens safety of workers or operation.
 To determine the severity of identified problem effect.
 To identify and evaluate the engineering and procedural safeguards.
 To recommend additional engineering and procedural safeguards.
HAZOP is performed by a group of experts from multiple disciplines and
led by an experienced safety specialist or training consultants. The main HAZOP
procedures are:
 Collecting all process lineation for each process in the plant.
 Process breakdown into little and more detail sub-process. To clarify the
breakdown of sub-process is given nodes in upper-ends of each sub-process.
There is no particular rule about limiting the distance of process.
 Searching all possibilities of deviation in each process through uses of
systematic questions (HAZOP model for question is made by using
keywords, intended to make the analysis process easier).
 Scoring for each negative effects that caused by every deviation mentioned
before. The criterion of harmful degrees for those negative effects is

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determined by safety and efficiencies operational condition of the plant in


normal condition.
 Determination of overcome action to every deviation happened.
There are two groups of keywords to emphasize systematic question in
HAZOP procedure, which are:
1. Primary Keywords
Primary keyword is every word that is related to condition or parameter of
a process. For example: flow, pressure, temperature, viscosity, corrosion, erosion,
level, density, relief, composition, addition, and reaction.
2. Secondary Keywords
Secondary keyword is every word which is merged with primary keyword
will shows probability of deviation that can happen for example: no, more, less,
reverse, and as well as.
HAZOP analysis of the plant is shown in the tables below.

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Table 1. 5. Plant Hazard and Operability Study (HAZOP)
Operation Unit
Parameter Deviation Possible Causes Consequence/ Hazard Prevention/ Action Control
Units Code
Material quantity target is Flow
Pump fails (electrical or Controlling the flow of the
Low not accomplished, sales Indicator
mechanical), valve shut stream
interrupted Control
The product specification
Controlling the flow of the
Flow is overwhelmed and can
F-101, Overworked pump, valve is stream to prevent feed loss in Flow
not be controlled, possible
Filter F-102, High not working (open widely, high pressure pump and reverse Indicator
overheating pump, the
F-103 uncontrolled) osmosis and installing safety Control
impurities harms the next
valve
process, flooding
Controlling the concentration of Analyzer
The source is disturbed (by High impurities that will
Concentration High waste before being pump to the Indicator
ocean wave, waste, sands) harms next process
ocean and waste water treatment Control
Pump fails (electrical or
Sales interrupted, lack of Flow
mechanical), valve shut, lack Controlling the flow of the
Low H2 amount that is needed Indicator
of water in stream output stream
for the next process Control
either from filter or recycle
Flow
Controlling the flow of the
Overflow and overworked Flow
stream to prevent feed loss in
High pump, valve is not working Flooding Indicator
electrolyzer and installing safety
(open widely, uncontrolled) Control
valve
The production of H2 is Control flow rate of the stream
Electrolyzer R-101 Level
Feed stream low, leak in the decreased, sales to electrolyzer with level
Low Indicator
unit itself interrupted, under pressure transmitter that emit pneumatic
Control
unit signal
Control flow rate of the stream
Level
Possibly to have reversible to electrolyzer with level
Valve is not working (open Level
reaction or reacts transmitter that emit pneumatic
High widely, uncontrolled), Indicator
uncontrollable, signal to prevent flooding if it
overflow pump Control
overpressure unit, flooding reach more than 80% of volume
capacity of electrolyzer

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Table 1. 5. Plant Hazard and Operability Study (HAZOP) (cont’d)
Operation Unit Deviatio
Parameter Possible Causes Consequence/ Hazard Prevention/ Action Control
Units Code n
Right angle No solar tracking
Photovoltaic Solar power that can be Install solar tracking Temperature
PV deviation between No controller for this
Array absorbed is reduced control Control
sun and concentrate equipment
Controlling ratio flow rate
No composition Low quality product due to Flow
of stream with recycle
Ratio of mixing No controller to have a composition that does not Indicator
stream, install analyzer
proportionally product proportional Control
control
Material quantity target is Flow
Pump fails (electrical or Controlling the flow of
Low not accomplished, sales Indicator
mechanical), valve shut the stream
interrupted Control
The product specification
Flow Overworked pump, Control the flow of the
is overwhelmed and can Flow
valve is not working stream to prevent feed
Methanol High not be controlled, possible Indicator
(open widely, loss in reactor and
Synthesis overheating pump, Control
uncontrolled) installing safety valve
Reactor; flooding
DME Reactor R-201; Controlling reboiler hot
Temperature of operation
Vessel; R-301; Flow of reboiler hot fluid fluid flow, increasing Temperature
condition does not achieve,
Gasoline R-302 Low is low, under heated valve opening of air, Indicator
low quality specification,
Synthesis stream decreasing flowrate of Control
low production
Reactor cooling water
Control the temperature
Temperature
of stream before entering
Overheated stream, flow reactor to adjust the Temperature
Overheated unit, low
High of reboiler hot fluid is operating condition, Indicator
quality product
high decreasing valve opening Control
of air, increasing flowrate
of cooling water
Too little vapor inside, Disruption of reaction
Increasing rotation of Pressure
Pressure Low output pressure from conversion, under pressure
compressor motor shaft Control
compressor is too low unit

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Table 1. 5. Plant Hazard and Operability Study (HAZOP) (cont’d)
Operation Unit
Parameter Deviation Possible Causes Consequence/ Hazard Prevention/ Action Control
Units Code
Methanol
Control the pressure of
Synthesis
reactor by reducing
Reactor; DME Too many vapor
R-201; Disruption of reaction exceed pressure, installing
Reactor inside, output pressure Pressure
R-301; Pressure High conversion, explosion, over pressure safety valve,
Vessel; from compressor is too Control
R-302 pressure unit opening pressure relief
Gasoline high
valve, reducing rotation of
Synthesis
compressor motor shaft
Reactor
Concentration of
Low quality product, low
D-201, methanol from Analyzer
Knock Out quality reflux so that it has Controlling the reflux
S-402, Concentration Low previous process is low Indicator
Drum many loops in the process concentration
S-403 quality, heat exchanger Control
before gaining the product
hot fluid flow is low
Temperature of operation
Flow of reboiler hot Controlling reboiler hot Temperature
condition does not achieve,
Low fluid is low, under fluid flow, increasing Indicator
low quality specification,
heated stream valve opening of air Control
low production
Control the temperature
Temperature
of stream before entering
D-201, Overheated stream, Temperature
Knock Out Overheated unit, low reactor to adjust the
S-402, High flow of reboiler hot Indicator
Drum quality product operating condition,
S-403 fluid is high Control
decreasing valve opening
of air
Control flow rate of the
The reflux product is Level
Feed stream low, leak stream to with level
Level Low decreased, low quality Indicator
in the unit itself transmitter that emit
product Control
pneumatic signal

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Table 1. 5. Plant Hazard and Operability Study (HAZOP) (cont’d)
Operation Unit
Parameter Deviation Possible Causes Consequence/ Hazard Prevention/ Action Control
Units Code
Control flow rate of the
stream to with level
transmitter that emit
Valve is not working
pneumatic signal to Level
(open widely,
Level High Flooding prevent flooding if it Indicator
uncontrolled),
D-201, reach more than 80% of Control
Knock Out overflow pump
S-402, volume capacity of
Drum
S-403 bottom space in drum,
opening valve
Too little vapor inside,
Disruption of reaction
output pressure from Increasing rotation of Pressure
Pressure Low conversion, under pressure
reactor/distillation compressor motor shaft Control
unit
column is too low
Control the pressure of
reactor by reducing
Too many vapor
exceed pressure, installing
D-201, inside, output pressure Disruption of reaction
Knock Out pressure safety valve, Pressure
S-402, Pressure High from conversion, explosion, over
Drum opening pressure relief Control
S-403 reactor/distillation pressure unit
valve, reducing rotation of
column is too high
compressor motor shaft,
installing vent flow
Install pressure indicator
Flash
and transmitter to
Separator; S-201,
maintain desirable
Two Phase S-202; Temperature
Pressure Low Low feed temperature High liquid level pressure, with a
Separator; S-301; Controller
connection to heat
Three Phase S-401
exchnger to increase feed
Separator
temperature

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Table 1. 5. Plant Hazard and Operability Study (HAZOP) (cont’d)
Operation Unit
Parameter Deviation Possible Causes Consequence/ Hazard Prevention/ Action Control
Units Code
Install pressure indicator
Routine
Low Leakage Hazardous material spill to control vessel pressure
Flash inspection
Pressure and routine inspection
Separator; S-201,
Installation of pressure Pressure
Two Phase S-202; High Blockage in vapor steam Risk of drum explosion
alarm Control
Separator; S-301;
Inlet stream temperature’s Install temperature
Three Phase S-401 Low No separation occurs Level Control
too high controller at the feed
Separator Level
Install temperature
High Inlet temperature too cold No separation occurs Level Control
controller at the feed
Methanol Low efficiency of
Pressure
Purification Low Vapor line leakage separation and product Install low pressure alarm
Control
Column; T-201; losses
Deethanizer T-401; Pressure Low efficiency of
Vapor pressure high, Install high pressure
Column; T-402 separation, Rapture of Pressure
High pressure indicator controller alarm, install pressure
Debutanizer column or ather related Control
fail relief valve
Column equipment, product losses
Instrumentation failure, Install temperature
Pressure change, Product
Less steam flow, Loss of indicator, Instruct
loss, Changes in product
heating (steam leakage), operator on procedure, Temperature
Low quality, Ineffective
Low steam pressure and Upgrade isolation, Control
Methanol separating process, Phase
temperature, Ineffective Attention to heat input
Purification effect
isolation and out control
Column; T-201;
Instrumentation failure,
Deethanizer T-401; Temperature
More steam flow, Separation cannot be done, Install temperature
Column; T-402
Exchanger tube failure, Changes in product quality, indicator controller,
Debutanizer
High steam pressure, Column flooding, Film Instruct operator on Temperature
Column High
Cooling water in condenser boiling in column and procedure, Attention to Control
failure, Reboiler control reboiler , Phase effect, heat input and output
failure, Heating medium Pressure changes control
leak into process

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Table 1. 5. Plant Hazard and Operability Study (HAZOP) (cont’d)
Operation Unit
Parameter Deviation Possible Causes Consequence/ Hazard Prevention/ Action Control
Units Code
Pipe blockage, Control
Install low level alarm, check
valve Shut, valve fail,
Disruption of separation maintenance procedure,
tube leakage and
Low process, Column dry out, decreasing valve opening of Level Control
Methanol blocking, pump failure
change in product quality liquid stream, make bypass,
Purification so too little liquid
emergency plant shut down
Column; T-201; inside
Deethanizer T-401; Level Install high level alarm,
Control valve is fully Disruption of separation
Column; T-402 checking maintenance
opened, Increase process, flooding in the
Debutanizer procedure and schedule,
pumping capacity, column, change in
Column High install control valve, install Level Control
Control valves failure product quality,
flow indicator, make bypasss,
so too much liquid temperature decrease, rise
increasing valve opening of
inside in bottom liquid level
liquid stream
E-204, Less flow of cooling Temperature of process Install High Temperature Temperature
Low
E-208, water, pipe blockage fluid remains constant Alarm Control
E-405, Flow High cooling flow,
Temperature of process Install Low Temperature Temperature
E-407; High failure of cooling
fluid decrease Alarm Control
E-404, water valve
E-406; High on Failure of cooling Pressure
Reboiler; Pressure Bursting of tube Install High Pressure Alarm
E-201, tube side water valve Control
Reflux heater;
E-202, High in
Condenser; Leakage of tube and Contamination of process Proper maintenance and Operator
E-203, Contamination process
Heat cooling water goes in fluid operator alert Control
E-301, fluid line
Exchanger
E-302,
E-303,
E-304, Corrosion hardness of cooling Less cooling and crack of Operator
E-401, Corrosion Proper maintenance
of tube water tube Control
E-402,
E-403

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Table 1. 5. Plant Hazard and Operability Study (HAZOP) (cont’d)
Operation Unit
Parameter Deviation Possible Causes Consequence/ Hazard Prevention/ Action Control
Units Code
P-101, None Pump clogged Process flow is hampered
P-102, Pump blockage, Processing liquid supply
P-103, plugging or blocking in hampered, low water supply to Installing a control valve
Low
P-104, pump so feed flowrate next unit and there might before pump to maintain
P-105, is too low possibility of cavitation the flow, regular
P-201, Flow High water supply to next unit. maintenance and control Flow Control
P-202, When the fluid flow is too fast, periodically and clean the
P-301, Excessive impeller
the pump will run out of fluid pump
P-401, High performance, feed
Pump and could cause heat and fires at
P-402, flowrate is too high
the pump so the pump can be
P-403, broken
P-404, Cavitation may occur, reverse
P-405, Suction pressure is too Control pressure
Low flow occur, pump can't distribute
P-406, low periodically
the liquid to the next process
P-501, Pressure
Pressure
Decrease the inlet flow to Control
P-601, Suction pressure is too
P-701, High Pumps quickly broken pump, switch into
high
P-702 secondary pump
K-201, Compressor work is too Pressure controlling by Pressure
Low
K-202, low installing the safety valve Control
K-203, Pressure does not fit the
Compressor Pressure Flow controlling by
K-204, Compressor work is too specification of the compressor
High installing input and output Flow Control
K-401, high
valve
K-601
Primary Decreasing valve opening
Low Too little liquid inside Ineffective solid removal Level Control
Clarifier; C-701; of outlet
Level
Secondary C-702 Increasing valve opening
High Too much liquid inside Overflow tank Level Control
Clarifier of outlet
Temperature
Boiler B-601 Temperature Low Lack of heat supplier Steam is not superheated Monitoring temperature
control

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Table 1. 5. Plant Hazard and Operability Study (HAZOP) (cont’d)
Operation Unit
Parameter Deviation Possible Causes Consequence/ Hazard Prevention/ Action Control
Units Code
Failure of makeup Circulation of water to Monitor the amount of water in
Deaerator D-601 Flow Low Flow control
water pump produce steam is reduced deaerator
Pressure
Pressure drop along
The level decreased, dry Indicator
Low the pipe, leakage Installing low level alarm
out tank Control,
Aeration unit
T-701; Level Control
Tank; Sludge Flow
T-702 Control valve
Tank Installing high level alarm,
failure, suction Flooding/overflow of
High installing high level trip to shut Level Control
pressure in pump is wastewater
down the pump
increased
Pump failure, flange Flow
leakage or valve Indicator
Low Low quality product Installing low level alarm on TIC
stub blanked but Control, Flow
Cooling leaking Control
CT-501 Flow
Tower Flow
Control valve fails Indicator
High Flooding Installing high level alarm on TIC
open Control, Flow
Control
Temperature of operation
Flow of reboiler hot Controlling reboiler hot fluid flow, Temperature
condition does not achieve,
Low fluid is low, under increasing valve opening of air, Indicator
low quality specification,
heated stream decreasing flowrate of feed Control
low production
Cooling
CT-501 Temperature Control the temperature of stream
Tower
Overheated stream, before entering reactor to adjust the Temperature
Overheated unit, low
High flow of reboiler hot operating condition, decreasing Indicator
quality product
fluid is high valve opening of air, increasing Control
flowrate of feed
Analyzer
Disinfection Concentrati Waste and emission to the Installing analyzer (concentration)
DU-701 High Unit failure Indicator
Unit on environment control
Control

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5.2. HSE Management
5.2.1. Operational Details
Standard operational procedure is needed in the plant to ensure the unit
operation will operate with standard condition. These standard operational
procedures are broken down into 2 parts, start up (the steps needed to start the
process and plant operation) and shut down (the steps needed to stop the process
and plant operation). In the start-up process, it is needed to execute each step
accordingly to ensure no leakage, damages, and troubles in the plant operation. In
the shutdown process, this plant needs to execute each step accordingly to ensure
there are no reaction, contact, and other activities in the plant.
Several operating activities would be conducted at the same time during the
start-up and shut- down period; while others need a predeceasing activity to be
executed. It is necessary to pay special attention to the Vendor’s or Licensor’s
instruction manuals and the operating manual shall be reviewed carefully to be in
congruent with the Vendor’s or Licensor’s instructions. All start-up and shut-down
procedures shall be prepared in detailed step-wise activities which will be
performed by the operators with simplified start-up/shut-down sketches.
5.2.1.1. Commissioning
Before doing the regular activities involving start-up and shut-down
procedures, commissioning is needed prior plant operation. Commissioning is
needed to ensure the system is working accordingly and ready for operation.
Commissioning included mechanical, utilities, and operational testing. The
procedures described shall be carried out at the completion of construction and
before initial operation of the unit or the very first operational procedure.
a. Mechanical Completion and Integrity Checking
It involves checking that everything has been built and it there as per
specification. Electrical, instrumentation, and control systems checkout down by
appropriately qualified personnel (Electricians and instrumentation technicians).
All instrumentation system should be checked against the design data as well as to
be checked for installation, calibration and operation to verification of alarms and
trips. The purpose of this activity is to ensure that all instrumentation, alarm
settings, microprocessor signals and hardwire trips pertaining to the installation are

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functional. This will also check that signals from the field instrumentation are
displayed locally and are being correctly relayed to the computer interface rack, as
well as to the computer system. In all steps make sure that the operator is wearing
the standard PPE and have memorized MSDS and evacuation route. The general
start up activity for every segment in the production process includes inspection,
pressure testing, cleaning and flushing, and machinery checkout.
The inspection of each equipment for corrosion and leak-hole, intact piping
connectivity and installation, and network integrity and alarm system is a procedure
that must be carried before every start up.
 Check line by line against flowsheet and locate all items. All piping and
instrument must be completed as per P&ID.
 Identify the location of instruments and the connectivity of each item
 Instrument calibration is verified.
 All instruments must be installed.
 All piping and equipment is compatible with designed pressure.
 All piping and equipment is protected against corrosion.
 Planned instrumentation is installed and operative.
The purpose of pressure testing is to confirm the mechanical integrity of the
plant, verifying capability of containing the pressures it has been designed to hold,
ensure there are no leaks and verify that the plant can be reliably made leak free,
identify any vulnerabilities well before the plant is placed into service, and to meet
the requirements of legislation, local, international and industry standards. It is to
prove the strength of the materials and weld integrity after completion of the
construction, usually using hydrostatic testing.
Isometric drawings of all systems to be tested should be displayed on a
board and marked up as each section is tested. Hydro testing of piping and
equipment according to code requirements to confirm mechanical strength should
be carried out on groups of equipment naturally suggested by design pressure and
function. All piping should be hydro tested. Major equipment that has already been
tested as part of manufacturing may be isolated by blanks.
In cleaning and fluhing, check the process thoroughly to ensure screens have
been installed in front of pump suctions. Regardless of whether pipes are cleaned

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with water, steam, air or nitrogen, flow velocities should be high enough to ensure
that pipes will be suitably scoured. Need to ensure that the debris from one piece of
equipment will not simply be flushed into another.
Machinery check out is the final check of each equipment. It includes:
 Indicate the location of all critical valves including valves at critical vent
and drain locations
 Check control valves, valves, and globe valves to see that they are installed
properly with respect to flow. Ensure functioning control valves, switching
valves, controllers, emergency shutdown system, etc. Ensure manual valves
are in proper positions.
 Check power supply’s functionality.
 Pumps are ready for operation: aligned, lubricated, proper rotation.
 All plant lines and equipment must be flushed, cleaned, and dewatered.
 Complete functional testing all rotating equipment.
 Do final inspection of vessels and column.
 Ensure there is no leak or any disfunctional.
b. Utilities Commissioning
Utilities commissioning usually represents the first phase of commissioning,
as these usually need to operational first, before the rest of the plant can be
commissioned. Below are the steps taken to complete urilities commissioning:
 Check supply pressures of all services (steam, cooling water).
 At the most distant points, open drains, vent valves or pipe flanges and purge
until fluids come out clean and rust free.
 Purge/blow out lines to each piece of equipment.
 Circulate water to waste water system until water lines clear and clean.
 Flush waste water and drain systems to ensure no blockages.
 Check operation of steam traps.
 Drain condensate to waste water until it is clean.
c. Operational Testing
Operational testing is not necessarily be done every start up, but it is
required to maintain the sustainability of production, to ensure plants productivity.
Periodically of 2-3 weeks, production process is ideally sufficient for an operational
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testing. Before operational testing carried out, mechanical dry running of individual
pieces of equipment and hot testing must be complete first. Tests should continue
for several days to give all shifts a chance to conduct the same tests. All shifts
should be given the opportunity to start up and shutdown each closed loop test.
5.2.1.2. Start-up Procedure
After the commissioning phase is completed, the plant can be declared ready
by the start-up phase. The general start-up procedure is listed below.
 Make sure all the raw material is enough for the operation
 Check the electricity supply.
 Load catalyst into the reactor. The reactor should be purged beforehand.
 All parameters in instrument which need controls must be set, such as
pressure, temperature, and level. This step is done to ensure the equipment
is under controlled.
 The reactor is then prepared to be ready for the process. This step involves
maintaining temperature and pressure to avoid process shock in the reactor.
 Open all inlet valves for process fluid flow in the plant.
 Open utility valve for cooling water and steam.
 Turn on all rotating equipment such as pump and compressor.
 Monitor strictly for the first five hours to ensure the process condition is
similar to that of specified in the design.
 Start-up procedure can be repeated if there is significant process deviation.
Start-up procedure of each equipment may refer to Assignment 4 Report.
5.2.1.3. Shutdown Procedure
Generally, there are three type of shutdown implementing in the plant,
which are initiated shutdown, process shutdown, and emergency shutdown.
Initiated shutdown is done to maintain the process equipment in plant. The
procedure is the same as stopping equipment when the process is done.
 Close all the inlet raw material valve
 Shut down heating and cooling sources
 Purge with steam or gas to remove contaminants
 Eliminating undesirable materials (cleaning process)
 After an hour, stabilize the temperature of reactor and other equipments.
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 Pressure trapped between two closed valves or closed process equipment


loops should be released immediately
 Bring the vessel to atmospheric pressure
 Shut down the electricity
A process shutdown is defined as the automatic isolation and deactivation
of all or part of a process. During a PSD, the process remains pressurized. In the
plant, PSD consists of field-mounted sensors, valves and trip relays, a system logic
unit for processing of incoming signals, alarm and HMI units. The system can
process all input signals and activate outputs in accordance with the applicable
Cause and Effect. PSD is integrated with the control system, such as pressure
control and temperature control. When the pressure is far from its set point, and
potentially harms the equipment, human, or environment, the PSD will
automatically initiate. For example, when the temperature of the reactor is far from
the maximum temperature allowed, there will be an alarm on the operating room
for the operator to take action, but if in some cases, the level is still getting higher,
until the highest point. PSD will automatically initiate to prevent the losses.
The term Emergency Shutdown System (ESD) refers to the method of
minimizing the consequences of emergency situations, related to typically
uncontrolled flooding or outbreak of fire in hazardous areas. Risk analyses have
concluded that the ESD system needs a high Safety Integrity Level, typically SIL 2
or 3. An emergency shutdown system represent a layer of protection mitigating and
preventing the occurrence of hazardous situation. An ESD system must be highly
reliable. During emergency, it is a must to shut down the plant in safeties way. The
situations that initiate the emergency shutdown, such as
 Electric power failure
 The temperature of fermentor outlet is higher than design temperature
 Manual alarm
 Pump or compressor failure
Emergency shutdown is conducted with the main objectives listed as follow.
 To shut down the plant safely
 To minimize the emission
 To prevent overpressure condition in the equipment
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 To protect equipment from damage


The emergency shutdown procedure is conducted with the steps as follow.
 Shutdown all transportation of gas and liquid
 Decrease the pressure and temperature of any equipment
 Perform electrical isolation
 Start all safety equipment
Shutdown procedure of each equipment may refer to Assignment 4 Report.
5.2.2. Personal Protective Equipment
Personal protective equipment, commonly referred to as PPE, is equipment
worn to minimize exposure to hazards that cause serious workplace injuries and
illnesses. These injuries and illnesses may result from contact with chemical,
radiological, physical, electrical, mechanical, or other workplace hazards. Personal
protective equipment may include items such as gloves, safety glasses and shoes,
earplugs or muffs, hard hats, respirators, or coveralls, vests and full body suits. All
personal protective equipment should be safely designed and constructed, and
should be maintained in a clean and reliable fashion. It should fit comfortably,
encouraging worker use. If the personal protective equipment does not fit properly,
it can make the difference between being safely covered or dangerously exposed.
When engineering, work practice, and administrative controls are not feasible or do
not provide sufficient protection, employers must provide personal protective
equipment to their workers and ensure its proper use.
Furthermore, American National Standard Institute (ANSI) has been
preparing safety standard for kind of PPE. Personal protection equipment can be
divided into 2 categories:
 General Equipment: personal protection equipment as minimum
requirements to enter the plant are safety helmet, mask, and safety shoes.
 Special Equipment: Personal Protection Equipment (PPE) is used in
accordance with the needs of employees in the workplace each based on
hazard and risk. For example: safety goggles, welding goggles, respirator,
mask, ear protection, gloves, earplugs, and so on.
There are some types of personal protection equipment summarized in the
table below.

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Table 1. 6. Personal Protection Equipment


PPE Example (Picture) Protects Hazards

Chemical liquid splashes,


dust, against intense light,
Safety Glasses Eyes
UV rays, flying objects such
as wood chips, metal pieces

Helmet Head Falling materials

Earplugs or
Hearing Excessive noise
earmuffs

Corrosive, toxic materials,


Gloves Hands
electric wires

Mask and Toxic gases, vapours, fumes


Lungs
respirator or dust

Safety wear Toxic and corrosive


Skin
(coveralls) materials, electricals

Corrosive, toxic material,


Safety Shoes Feet
against crushing of toes

Personal protective equipments need to be used when there are certain


hazards in areas of the plant. In order to minimize the risk of an accident happening
there are several personal protective equipments required in each area.
Table 1. 7. Personal Protection Equipment Required per Area
No Area Classification PPE Required
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Water treatment and Safety glasses, helmet, gloves, coveralls, safety


1
electrolysis shoes
Safety glasses, helmet, earplugs, gloves, respirator,
2 Methanol synthesis
coveralls, safety shoes
Safety glasses, helmet, earplugs, gloves, respirator,
3 DME synthesis
coveralls, safety shoes
Safety glasses, helmet, earplugs, gloves, respirator,
4 Gasoline synthesis
coveralls, safety shoes
5 Gasoline storage Respirator. Helmet
6 Photovoltaic array Safety glasses
Safety glasses, helmet, earplugs, gloves, respirator,
7 Utility area
coveralls, safety shoes
Safety glasses, helmet, earplugs, gloves, respirator,
8 Wastewater treatment
coveralls, safety shoes
10 Fire station Helmet, coveralls, safety shoes
5.2.3. Material Safety Data Sheet (MSDS)
A Material Safety Data Sheet (MSDS) is a document that contains
information on the potential hazards and how to work safely with the chemical
product. It is an essential starting point for the development of a complete health
and safety program. It also contains information on the use, storage, handling and
emergency procedures all related to the hazards of the material. The MSDS contains
much more information about the material than the label. MSDSs are prepared by
the supplier or manufacturer of the material. It is intended to tell what the hazards
of the product are, how to use the product safely, what to expect if the
recommendations are not followed, what to do if accidents occur, how to recognize
symptoms of overexposure, and what to do if such incidents occur.
There are nine (9) categories of information that must be present on an
MSDS. These categories are specified in the Controlled Products Regulations.
1. Product Information: product identifier (name), manufacturer and suppliers
names, addresses, and emergency phone numbers
2. Hazardous Ingredients
3. Physical Data
4. Fire or Explosion Hazard Data
5. Reactivity Data: information on the chemical instability of a product and the
substances it may react with
6. Toxicological Properties: health effects

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7. Preventive Measures
8. First Aid Measures
9. Preparation: who is responsible and date of preparation of MSDS
Traditionally the intended readers of MSDSs were occupational hygienists
and safety professionals. Now the audience also includes employers, workers,
supervisors, nurses, doctors, emergency responders and workers. To ensure that
MSDS users can quickly find the information that they need, the information should
be in an easy-to-read format and written in a clear, precise and understandable manner.
For most people who work with controlled products, there are some sections
that are more important than others. There are several procedures in understanding
MSDS, such as read the name of the chemical, know the hazards, understand safe
handling and storage instructions, as well as understand what to do in an emergency.
One of the requirements manufacturers have in supplying the chemicals is to
put a proper and complete label on the container, which provide information regarding
the hazards associated with using the material. There are two common symbols used
on labels to quickly provide information of the relative hazards of a material. One is
called the National Fire Protection Association (NFPA) warning diamond.

Figure 1. 2. NPFA Warning Diamond


(Source: NPFA, 2014)
The other is the Hazard Materials Information System (HMIS) system. Both
systems use numerical rating of hazards in each of three colored sections (health,
fire/flammability, and reactivity hazard).

Figure 1. 3. HMIS Labeling System


(Source: HMIS, 2014)
Hazard classification based on NPFA uses numbers spanning from 0 to 4.
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Table 1. 8. Hazard Classification


Type No Description
0 No significant risk to health
1 Irritation or minor reversible injury possible.
2 Temporary or minor injury may occur.
Health
Major injury likely unless prompt action is taken and medical treatment
(Blue) 3
is given.
Life-threatening, major or permanent damage may result from single or
4
repeated overexposures.
0 Materials that will not burn.
Materials that must be preheated before ignition will occur. Includes
1
liquids, solids and semi solids having a flash point above 200°F.
Materials which must be moderately heated or exposed to high ambient
2 temperatures before ignition will occur. Includes liquids having a flash
Fire/ point at or above 100°F but below 200°F.
Flammability Materials capable of ignition under almost all normal temperature
(Red) conditions. Includes flammable liquids with flash points below 73°F and
3
boiling points above 100°F, as well as liquids with flash points between
73°F and 100°F.
Flammable gases, or very volatile flammable liquids with flash points
4 below 73°F, and boiling points below 100°F. Materials may ignite
spontaneously with air.
Materials that are normally stable, even under fire conditions, and will
0 not react with water, polymerize, decompose, condense, or self-react.
Non-explosives.
Materials that are normally stable but can become unstable (self-react) at
1 high temperatures and pressures. Materials may react non-violently with
water or undergo hazardous polymerization in the absence of inhibitors.
Materials that are unstable and may undergo violent chemical changes at
2 normal temperature and pressure with low risk for explosion. Materials
Reactivity
may react violently with water or form peroxides upon exposure to air.
(Yellow)
Materials that may form explosive mixtures with water and are capable
of detonation or explosive reaction in the presence of a strong initiating
3 source. Materials may polymerize, decompose, self-react, or undergo
other chemical change abnormal temperature and pressure with moderate
risk of explosion.
Materials that are readily capable of explosive water reaction, detonation
4 or explosive decomposition, polymerization, or self-reaction at normal
temperature and pressure.
(Source: NPFA, 2014)
Table 1. 9. NFPA Parameter for Personal Protection
Symbol Description
OX Oxidizer: allows chemical to burn without air supply
₩ Reacts with water in an unusual or dangerous manner
SA Simple asphyxiant gas (N2, He, Ne, Ar, Kr, Xe)
(Source: NFPA, 2014)

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The main substances involved in the plant include hydrogen, water, oxygen,
carbon dioxide, carbon monoxide, methanol, dimethyl ether, isobutane, and
gasoline. The material safety data sheets are described in the appendix.
5.2.4. Area Classification
Area classification is a method of analyzing and classifying the environment
where explosive gas atmospheres may occur. The main purpose is to facilitate the
proper selection and installation of apparatus to be used safely in that environment,
taking into account the properties of the flammable materials that will be present.
DSEAR specifically extends the original scope of this analysis, to take into account
non-electrical sources of ignition, and mobile equipment that creates ignition risk.
Hazardous areas are classified into zones based on an assessment of the
frequency of the occurrence and duration of an explosive gas atmosphere.
 Zone 0: An area in which an explosive gas atmosphere is present
continuously or for long periods;
 Zone 1: An area in which an explosive gas atmosphere is likely to occur in
normal operation;
 Zone 2: An area in which an explosive gas atmosphere is not likely to occur
in normal operation and, if it occurs, will only exist for a short time.
Various sources have tried to place time limits on to these zones, but none
have been officially adopted. The most common values used are:
 Zone 0: Explosive atmosphere for more than 1000h/yr.
 Zone 1: Explosive atmosphere for more than 10, but less than 1000 h/yr.
 Zone 2: Explosive atmosphere for less than 10h/yr, but still sufficiently
likely as to require controls over ignition sources.
Based on the overall look of the plant layout, therefore it can be showed the
zone classification as below. It is noted that the detail description of the plant layout
is discussed in the following section.

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Zone 2
Zone 2 Zone 2 Zone 2
Zone
0 Zone 2 Zone 2
Zone 2
Zone 1
Zone

Zone 2 Zone 2 0
Zone
1 Zone 2
Zone
0 Zone 2 Zone 2

Figure 1. 4. Plant Area Classification


From the figure above, it can be seen that area 200, area 300, and area 400
are very critical due to high pressure processes with exotherm conditions, so that
they are classified into Zone 0. While, area 100 and area 600 are classified into
Zone 1. Then, the rest of the areas, which are photovoltaic area, area 500, area 700,
and other facilities area are classified into Zone 2.
Other than classified by the frequency of the occurrence and duration of an
explosive gas atmosphere, this plant is also classified the area based on its location
as the explanation below.
1. Water Treatment and Electrolysis Area
This area refers to area 100, but more focusing in filtration and reverse
osmosis process. This area is very crucial because the water as one of the raw
material is processed in this area. In this area, there is electrolyzer which is
important unit/area to produce H2 which is needed as one of the materials that is
used in the next process to produce gasoline. This area is classified into Zone 1.
2. Methanol Synthesis Area
This area refers to area 200 which will produce methanol, which is useful
for the next process, DME synthesis. This area is classified into Zone 0.
3. DME and Gasoline Synthesis Area
This area refers to area 300 which produces DME and gasoline. This area is
classified into Zone 0.
4. Gasoline Purification Area
This area refers to area 400, which is the last main process area where
gasoline is produced. This area is classified into Zone 0.
5. Gasoline Storage

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This area refers to area where gasoline is stored in pressure vessel, before it
is transported/distributed with gasoline trucks. This area is classified into Zone 0.
6. Photovoltaic Array
This area is needed mostly by area 100 to generate electrolyzer. This area is
in 144 acres and located near the sea because of the maximum optimization of
sunlight radiation is discovered there. This area is classified into Zone 2.
7. Utility Area
The utility area consists of cooling water system (area 500) and steam
generation (area 600). Area 500 is functioned to produce cooling water as a fluid
that is needed in some of the heat exchanger systems. This area is classified into
Zone 2. Area 600 is functioned to produce steam which is some of the heat
exchanger systems are needed. This area is classified into Zone 1.
8. Wastewater Treatment Area
Wastewater treatment area or area 700 is an area that is needed to treat the
wastewater. The treatment to the wastewater is going to the disposal and or
disinfection unit to prevent pollutions problem before it is being released to the
environment. This area is classified into Zone 2.
9. Control Room, Laboratory, Technical Building, and Office
Control room area is functioned as a controller to all of the plant process
area, including main process area and utility area. This area is very critical to the
safety and production of the plant so it should be placed in a very safe zone.
Laboratory area is needed to check the product specification and makes sure the
product is suitable to a standard before it is distributed to the consumers. Office and
technical building area are needed to fulfill the administration business, sales and
marketing, IT, HSE, supply chain, and other support departments. These areas are
classified into Zone 2.
10. Fire Station
Fire station is an area that is needed as a part of emergency and safety
procedure in a plant to handle the area which potentially explodes or causes a fire.
This area is classified into Zone 2.

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5.2.5. Emergency Action Plan


An Emergency Action Plan (EAP) is a written procedure detailing the
appropriate response to various types of emergencies. It is an eligible written
document which has been required with the OSHA standards. An EAP can be useful
in a wide range of emergencies. The response for many emergencies will include
similar components, but they will also have unique components that will require
careful planning and execution. Emergency Action Plans, it is important to identify
the emergencies most likely to impact your organization and plan accordingly.
An EAP is an essential component of an organization’s safety procedures.
Creating an EAP and training employees on how to follow it can greatly reduce
employee injuries, property damage, and can ensure the safety of visitors in the
event of an emergency. Poorly prepared plan will lead to a disorganized evacuation
of emergency response that can harm the company because of employee injury and
property damage. Putting together a comprehensive emergency action plan that
deals with those issues specific to your worksite is not difficult. It involves taking
what was learned from your workplace evaluation and describing how employees
will respond to different types of emergencies, considering a specific worksite
layout, structural features, and emergency systems. Most organizations find it
beneficial to include a diverse group of representatives (management and
employees) in this planning process and to meet frequently to review progress and
allocate development tasks. There are several key components of an emergency
action plan:
 Evacuation Procedures, Escape Routes, and Floor Plans
 Medical Emergency Plan
 Fire Fighting Strategy
 Emergency Operation Training
 Policies for updating and maintaining the EAP
5.2.5.1. Evacuation Procedures, Escape Routes, and Floor Plans
In the event of an emergency, people need to respond quickly; knowing
where to go and how to get there is often an important part of a quick response.
Depending on the type of emergency, people will either need to exit the building as
quickly as possible or be prepared to navigate to a safer part of the building. It is

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important each person knows exactly where to go in the event of an emergency. An


EAP should contain an up-to-date floor plan for the entire property. The floor plan
should include clearly marked evacuation routes and all emergency exits should be
easily identifiable. There are several categories of emergencies:
 Emergencies Within the Building
For emergencies occurring inside of the facility (e.g., fires, power outages,
etc.), the main goal is to get everyone out of harm way. To achieve this goal,
staff should be aware of the fastest and safest way out of the building.
 Emergencies Outside of the Building
In most cases, when an emergency starts outside of the building, the safest
thing to do is find a safe place within the building. Most often, emergencies
outside of the building will be weather-related or natural disasters.
 Health Emergencies
If someone inside of the building is injured or harmed in some way, an EAP
should be initiated quickly. Staff should be prepared to respond to a wide
range of plausible health scares such as a heart attack, seizure, possible
drowning and more.
5.2.5.2. Medical Emergency Plan
Whenever an employee or visitor is injured or develops a medical
emergency condition on plant property, follow the protocol below and notify your
immediate supervisor as soon as possible. Medical emergency instruction:
 Dial the plant infirmary and inform the nurse of emergency and its location
in the plant.
 If the nurse cannot be reached, dial emergency call, and inform any hospital
or fire department of the medical emergency. Give the dispatcher the nature
and location in the plant of medical emergency.
 Unless you have been designated by management to be a first aid responder,
do not provide first aid. Make the victim as comfortable as possible until
medical help arrives.
5.2.5.3. Fire Fighting Strategy
Fire-fighting strategy should consider the following items.
 Appointment of fire wardens, with subsequent training.

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 Location plans of safety shower, fire hoses, extinguishers, and water


sources.
 Access for emergency services.
 Provision of firewater lagoons.
Fire-fighting strategy involves the following basic procedures.
 Arriving at the scene of the fire as rapidly as possible.
 Assessing the nature of the fire by determining its intensity and extent, the
type and abundance of fuel, the danger of entering the fire area, and the most
effective techniques for extinguishing the fire.
 Locating and rescuing endangered persons.
 Containing the fire by protecting adjacent areas; ventilating the fire area to
allow for the escape of heat and toxic gases.
 Extinguishing the fire.
The procedure carried on if a fire is occurred in our plant known as AReFo:
 Alert: Alert the occupants around the fire source by voice or pull the fire
alarm (if available and not already activated), in order to warn occupants to
evacuate.
 Report: Dial emergency numbers to call for report and help. In Indonesia
the emergency numbers are 110 – Police, 118 or 119 – Ambulance, 113 or
1131 – Fire Department, and 112 – to Indonesia’s emergency center.
Provide the following information:
o Business name and street address.
o Nature of fire.
o Fire location (building and floor).
o Type of fire alarm (detector, pull station, sprinkler waterflow).
o Location of fire alarm (building and floor).
o Name of person reporting fire.
o Telephone number for return call.
 Follow: Plant evacuation team will direct evacuation of employees and must
be followed in order to prevent any misshapen during evacuation.
5.2.5.4. Emergency Operation Training

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In training, information about emergency operating procedures is


distributed widely and personally to every employee working on the plant or office.
The emergency procedure must entail instructions for dealing with fires, leaks, and
spills, also medical emergencies and escape procedures. By teaching each employee
this, in the case of accidents occurring, every one of them should be able to:
 Raise the alarm and call the fire brigade.
 Tackle fire or control spills and leaks if entirely safe to proceed.
 Evacuate the site or nearby premises.
All procedure regarding emergency action instructions must be memorized
by all workers in order to save every life in case of accidents. These instructions
consist of a four–step procedure that employees should follow during a fire
accident. This procedure must be memorized by all employees. Experience has
shown that the best response to a plant fire is first, sound the alarm, then let others
know there is a fire, then combat the fire if possible, and the last, evacuate if
necessary. The plan works best when expressed as an easily recalled acronym, such
as SAFE:
 S: Sound the alarm: Either sound it yourself or call out to someone else to
sound it. This allows the fire department to be on its way while other
activities are being performed.
 A: Alert others: Quickly tell others in the area of the fire. Do this in a calm,
firm manner. Do not cause a panic. Secure the area for the fire department.
Close all doors and windows to prevent the spread of smoke and flames.
Call security to give verification and information about location of fire.
 F: Fight the fire: Do this only in the case of a manageable fire, one that you
have the training and experience to fight. For example, fire in a wastebasket.
If it possible two employees should fight the fire together using two fire
extinguishers. If you have any doubt about your ability to fight the fire, then
do not attempt to combat it.
 E: Evacuate the area: If necessary, the burned are should be evacuated until
the authorities come. Alarm which used for evacuation system is an alarm
system standard from OSHA. It applies to provide an early warning for

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emergency actions or reaction time for employees to safely escape the work
place, the immediate work area, or both.
5.3. Waste Management
Industrial activities usually give a residue from processing which is called
as waste. Waste of processing in industry has to be handling well or else it may give
damage that affect environment or sustainability of production in plant.
Government gives boundary for every industrial plant to process their waste based
on Human Safety Environment. The waste have been classified based on the type
or phase, which are liquid waste, gas waste, and sound (noise) waste. Management
for the waste will be explained below.
5.3.1. Solid Waste
Steam generation through combustion in boiler generates solid waste
materials known as slag which is in the form of ash. Ash itself is classified as bottom
ash and fly ash. Fly ash contains heavy metals, dioxin and other characteristic
pollutants, therefore in some countries it is considered as hazardous waste. It is said
to have higher potential risk than bottom as because the fly ash comprises higher
concentration of heavy metals.
In order to handle fly ash, there are several different methods that can be
applied. The current main techniques are solidification/stabilization and thermal
methods. There are two types of S/S process, such as cement solidification and
chemical stabilization. Cement solidification requires the mixing of fly ash and
cement with water in an appropriate proportion in order to immobilize the fly ash
after cement hydration process. The chemical stabilization process is the adding of
chemical stabilizers to change the physical and chemical properties of the fly ash.
The existing forms of heavy metals in the fly ash are changed by pH control,
precipitation and adsorption, in order to reduce mobility of metals, and realize
stabilization. The plant uses this process because it does not require any additional
material which is cement and also the mass and volume of fly ash will not change
as much as the cement solidification does. The stabilizing agents that is used is
gypsum. After going through the S/S treatment, the fly ash can go to sanitary
landfills when it meets the heavy metals leaching toxicity criteria.

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Thermal methods are divided into three major categories such as


vitrification, sintering and fusion. Vitrification is a chemical process whereby a
mixture of glass precursor materials and hazardous waste are melted or fused at
high temperatures to generate an amorphous, single phase product. Sintering is a
chemical process whereby a mixture of hazardous waste and small glassy are
melted at high temperature to get a glass waste form. Fusion is a chemical process
whereby the fly ash are melted or fused at high temperature in fuel furnace to form
either a crystalline or heterogeneous product. During the fusion process, organic
pollutants such as dioxins in fly ash can be decomposed, burned and gasification,
while the inorganic pollutants are melted to glassy slag. Heavy metals residue in
the fly ash is surrounded by a sintered glassy network structure, which effectively
control the leaching of heavy metals. This method can reduce the volume of waste
by 60% or more, and the products are resistant to leaching, which can be used as
building materials or raw materials for production of glass, ceramics.
Ash is widely used for various purposes but mainly to be used as a
replacement for materials that have a relatively low unit cost. The use of ash for hot
mix asphalt has been utilized in the United States, Japan and some European
countries. After screening and magnetic separation, ferrous and nonferrous metals
are removed from mixed ash which will then be mixed with other aggregates to be
used as a mixture of asphalt pavement. As long as there is proper handling, ash used
as asphalt will not cause environmental pollution. Besides, fly ash also contains
large amounts of SiO2 and Al2O3 and CaO which makes it to have a similar
composition of raw materials for cement production. Therefore it can also be used
as the raw materials for cement. However, washing pre-treatment of fly ash to
reduce water-soluble substances like chloride before cement curing will
significantly enhance the compressive strength and reduce the leaching toxicity of
the products. Ash can also be used for landfill cover as the environmental protection
facilities such as barrier layer and leachate recovery system. The pretreatment
process for ash such as screening, magnetic separation and particle size distribution
is unnecessary if used as landfill cover, therefore, it is a very good choice to utilize
ash for this purpose.

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Before the ash is sold to the nearby cement factory, it has to be first treated
to meet the specification. Based on the list of treatment discussed above, this plant
uses the treatment of separation which will then be followed by stabilization using
thermal. After that, the ash will be ready to be transported to the nearby cement
factory and used as landfill cover. The thermal stabilization is preferred rather than
the solidification because it does not require any mixing process with cement and
the operational cost is lower.
5.3.2. Liquid Waste
Wastewater treatment is the process of converting wastewater into bilge
water that can be discharged back into the environment. Its treatment aims at
reducing the contaminants to acceptable levels to make the water safe for discharge
back into the environment. There are two kinds of wastewater treatment, such as
chemical/ physical treatment and biological wastewater treatment. Physical waste
treatment plants use chemical reactions as well as physical processes to treat
wastewater. Biological waste treatment use biological matter and bacteria to break
down waste matter. The plant uses activated sludge for the biological treatment to
breakdown methanol.
The waste water is fed into an activated sludge process waste water
treatment with aeration tank. The waste water mostly consists of methanol and
TDS, which needs to be processed before being disposed to the environment. In
activated sludge process wastewater containing organic matter is aerated in an
aeration basin in which micro-organisms metabolize the suspended and soluble
organic matter. Part of organic matter is synthesized into new cells, oxidized to CO2
and water to derive energy. In activated sludge systems the new cells formed in the
reaction are removed from the liquid stream in the form of a flocculent sludge in
settling tanks. A part of this settled biomass, described as activated sludge is
returned to the aeration tank and the remaining forms waste or excess sludge. The
process involves solid – liquid separation followed by aeration in the presence of a
microbial suspension, removal of sludge and transporting it to a burner, and
discharge of clarified effluent to be disposed to the environment.
The concentration of contaminants decreases up to 90% after the biological
treatment. This suggests that the process chosen for the treatment of waste water

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effluents is satisfactory for disposal to the ocean. After the process, the amount of
sludge is 25.88% of the feed. The sludge is then transported to a burner to be further
processed and burned for disposal. The treated waste water is then disposed to the
sea. The process flow diagram of waste water treatment process is illustrated in
Appendix.
5.3.3. Gas Waste
Through the plant process there are no gases disposed, all the gases are
recycled. The consideration for recycling is that all the gas produced can be used as
a feed to certain processes, such as CO2 to Area 200 for methanol synthesis and
light hydrocarbons and DME to Area 300 for gasoline synthesis. Recycling is done
for economic purposes. If there are certain conditions that need attention such as an
increase in the pressure of a flow, there are valves that will release some of the
gases in the flow to the vent or to flare.
The gas waste from this plant is produced as the flue gas from the
combustion of natural gas and air in steam generator. It consists of mostly nitrogen
derived from the combustion of air, carbon dioxide (CO2), and water vapor as well
as excess oxygen (also derived from the combustion air). It further contains a small
percentage of a number of pollutants, such as particulate matter, carbon monoxide,
nitrogen oxides, and sulfur oxides. The standard temperature and pressure for the
flue gas is 50oC and 1 atm. The flue gas for this plant has met the standard
temperature and pressure. The gas residue can be emitted directly to atmosphere
because the amount of pollutans is very small.
These gas emissions have met the standards of Minister Environment
Decree No. Kep.13/Menlh/3/1995 about quality standards stationary source
emissions or BSN Standards (5000 ppm). From the standards, we can be directly
released gas waste into the environment by way of venting for CO2 emission and
hydrogen can be directly discharge into the air because it is not dangerous emission.
5.3.4. Sound
Sound is generated by rotating equipments. Operation of rotary tools in the
plant, such as pumps and compressor motors drive is a source of noise. The noise
level rotary tools are depending on the type of rotary tools, capacity, performance,
area and equipment operating effectiveness of treatment or preventive maintenance

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programs are conducted. To reduce the noise level, performed regular maintenance
and replacing parts causing noise.
Noise not only damage the health of personnel, can also damage to the
mechanical system on the appliance. To reduce the noise level, performed regular
maintenance and replacing parts causing noise. Workers need to use ear plugs if
they’re entering the plant area. Tools such as damper can be applied for equipments
or tools that can generate noise.
The noise standards set by the Ministry of Health is 60-70 dB and according
to the Ministry of Manpower Decree No. Kep.51/MEN/1999, the TLV (Threshold
Limit Value) for noise hazard is 85 dBA. Noise level exceeding the limit can cause
disorder includes physiological and psychological disorder. To overcome those
disorders, control of noise is needed by following procedures:
 Eliminate noise transmission to workers. To eliminate or reduce the
transmission of noise to do with insulation workers labor or machinery is to
shut down or isolate the machine or equipment that emits noise. Basically
to cover the noisy machines are as follows: Close the engine as close as
possible, rework the doors and all the holes are acoustic. If necessary, isolate
the machine from the floor to reduce vibration propagation.
 Eliminate the noise from the sound source. Eliminating noise from the
sound source can be done by putting the marinade in a vibration source.
 Providing protection to employees. Efforts to protect employees from noise
in the work environment can be applied by wearing ear protection devices
or personal protective equipment, in the form of ear plugs and ear muffs.

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CHAPTER 6
PLANT LAYOUT

6.1. Plant Location


Plant location is one of the important things in plant design consideration,
because it will be related to the operation process in a plant. There are several
factors that must be considered because it will affect the continuity of the
production of the plant in the future. The factors can be separated into consideration
of close to raw material, solar power potential availability, proximity to markets,
and land development availability. Based on those factors, the best location that
suited this plant is in West Kalimantan.

Figure 2. 1. Plant Location


6.2. Plant Layout
6.2.1. General Consideration of Plant Layout
Plant layout or plot plan is made with the aim of reducing potential hazard,
maintenance cost, number of workers, construction cost, and the overall operating
cost. It is implemented with a plot of all equipments and machine, storage,
buildings, and operational route.
The initial principle is to get wind flow direction, and classify the area based
on potential hazard. All equipments which produce flammable materials are located
in downwind side, while the ones which do not handle flammable and hazardous
substances are located in the upwind side. Beside equipments handling flammable
material, equipments located on the downwind side include blowdown tank,
burning flare, and settling pond. The equipments located on the upwind side include
plant offices, laboratories, other non-technical facilities, boiler house, electrical
substation, water treatment plant, cooling towers, parking lot, and ignition sources.

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Figure 2. 2. Wind Flow Direction in West Kalimantan


(Source: BMKG, 2018)
After that, classification of area is made to produce a simple area
classification layout. The equipments is then arranged in the layout through the
consideration of minimum safe spacing between equipments and based on wind
flow direction which is to Northwest (BMKG, 2018). With the addition of piping
information and operational route, an overall 2D plant layout is produced. It is then
be converted into an overall 3D plant layout.
6.2.2. Safe Range Between Equipment
As mentioned in the previous section, important thing to consider in plotting
equipments is safe range between equipment. This factor usually called battery
limit. The definition of battery limit comprises one or more geographic boundaries,
imaginary or real, enclosing a plant or unit being engineered and/or erected,
established for the purpose of providing a means of specifically identifying certain
portions of the plant, related groups of equipment, or associated facilities. A battery
limit is a defined boundary between two areas of responsibility, which may be
physical (e.g. a flange on a pipe); or represented by a map coordinate; or some other
means (for example a point in time). These should be described in the most
appropriate way (for example, a drawing, map, or verbal description). Battery limit
drawings or definitions are often contained in an interface document. There are two
types of battery limit, inside battery limit (IBL) and outside battery limit (OBL).
Inside Battery Limits is defined as all equipment and associated components
(piping, etc.) that act upon the primary feed stream of a process. ISBL is functional-
based and refers to equipment and other components that are solely dedicated to a
single process whether or not the equipment is physically located within the

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geographical boundaries of the unit. Outside Battery Limits (OSBL) is defined as


utilities, common facilities, and other equipment and components not included in
the ISBL definition. OSBL refers to systems (equipment pieces and associated
components) that support several units. Typical OSBL equipment includes cooling
towers, water treatment facilities, tanks farms, etc.
Rules of thumb for safe range between equipment are applied for
constructing a plant layout. It can be inferred through the following figures.

Figure 2. 3. Outside battery limit values


(Source: Process Control: GAPS Guidelines, 2010)

Figure 2. 4. Inside battery limit values


(Source: Process Control: GAPS Guidelines, 2010)

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Figure 2. 5. Battery limit between storage tanks and vessels


(Source: Process Control: GAPS Guidelines, 2010)
The value of minimum distance between equipments and areas are gathered
through the preceding figures, and tabulated as follow.
Table 2. 1. Spacing between Equipments
Equipment Series Distance
Area
From To (m)
Pump Filter 15
Filter F-101 Filter F-102 3
Filter F-102 Pump P-102 5
Water
Pump P-102 Pump P-103 1.5
Treatment
Pump P-103 Reverse Osmosis F-103 1.5
and
Reverse Osmosis F-103 Electrolyzer R-101 5
Electrolysis
Compressor K-201 Heat Exchanger E-201 9
(100)
Compressor K-202 Heat Exchanger E-201 9
Compressor K-203 Heat Exchanger E-201 9
Heat Exchanger E-201 Heat Exchanger E-202 1.5
Heat Exchanger E-202 Heat Exchanger E-203 1.5
Heat Exchanger E-203 Reactor R-201 4.5
Reactor R-201 Reboiler E-204 4.5
Reboiler E-204 Heat Exchanger E-205 1.5
Heat Exchanger E-205 Heat Exchanger E-206 1.5
Methanol
Heat Exchanger E-206 Separator S-201 3
Synthesis
Separator S-201 Compressor K-203 15
(200)
Separator S-201 Separator S-202 4.5
Separator S-202 Compressor K-204 15
Separator S-202 Heat Exchanger E-207 3
Heat Exchanger E-207 Pump P-201 7.5
Pump P-201 Distillation Column T-201 4.5

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Table 2. 1. Spacing between Equipments (cont’d)


Equipment Series Distance
Area
From To (m)
Pump P-301 Heat Exchanger E-301 4.5
Heat Exchanger E-301 Heat Exchanger E-302 1.5
Gasoline Heat Exchanger E-302 Heat Exchanger E-303 1.5
Synthesis Heat Exchanger E-303 Reactor R-301 3
(300) Heat Exchanger E-302 Heat Exchanger E-304 1.5
Heat Exchanger E-304 Separator S-301 3
Heat Exchanger E-304 Reactor R-302 3
Heat Exchanger E-401 Heat Exchanger E-402 1.5
Three Phase Separator S- 3
Heat Exchanger E-402
401
Gasoline Heat Exchanger E-401 Heat Exchanger E-403 1.5
Purification Heat Exchanger E-403 Distillation Column T-401 3
(400) Distillation Column T-401 Pump P-404 4.5
Pump P-404 Distillation Column T-402 4.5
Separator S-401 Compressor K-401 15
Distillation Column T-401 Compressor K-402 15
6.2.3. Area Classification Layout
Through the classification of area described in previous section, a brief plant
layout plotting all areas are to be made. The plant has the overall area of 12 Hectare.
The detailed area for each section is tabulated in detail in previous section. It
consists of 10 areas, including photovoltaic array, water treatment and electrolysis,
methanol synthesis, DME and gasoline synthesis, gasoline purification, steam
generation, cooling tower, waste water treatment, fire station, and product storage.
Table 2. 2. Area for Each Section
Length Width
Area Classifications Area (m2)
(m) (m)
Water Treatment and Electrolysis Area 250 19 4,750
Methanol Synthesis Area 180 150 27,000
DME Synthesis Area 140.5 90 13,000.5
Gasoline Synthesis Area 130 150 19,500
Gasoline Storage 90 70.5 6,700.5
Photovoltaic Array 500 10 5,000
Utilities Area 80 110.5 9,200
Wastewater Treatment Area 110.5 80 9,200
Tech. Building and Control Room 220.9 120.5 28,600.3
Fire Station 120.6 70.2 9,000.72
Total 120,252.02

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6.2.4. Overall 2D Plant Layout


The plant has several stages in the process from unloading raw material to
end product and waste management. This plant separates the process into many
sections. First, the processes begin with taking seawater from the ocean to the first
area for electrolysis and produce hydrogen. In the second area the feed CO2 from
the supplier and the hydrogen is used as feed for methanol synthesis. Then, the
methanol is moved to the third area for gasoline synthesis. In the fourth area, the
gasoline is treated to meet the standards (purification) and some produced gases are
recycled to the third area for gasoline synthesis. Then, the gasoline goes to the
storage tank for later transportation. The other areas are utility for steam generation,
electricity, and waste water treatment. The plant layout is shown in the appendix.
6.2.5. Overall 3D Plant Layout
Based on the 2D plant layout, a 3D plant layout is shown on the appendix.

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CHAPTER 7
ECONOMIC ANALYSIS

7.1. Assumption in Cost Estimation


In order to make economic analysis of the project, cost estimation is to be
made. Cost estimation conducted is preliminary estimate based on the individual
factors method of Guthrie (1974), with the accuracy in the range of 20%. Before
cost estimation is conducted, there are several assumptions that must be made.
 The plant will be constructed from the beginning to the end of 2020.
 The manufacturing process is expected to be operating in early 2021 until
the end of 2040, with the life span of 20 years.
 Exchange rate of currency is assumed to be the same value extracted on 1st
December 2018, which is IDR 14,540/ 1 USD.
 One year consists of 330 operating days.
 The production capacity of main product of high-octane gasoline is constant
at 2.213 tonnes/hour or 17,527 tonnes/year. The production capacity of
dimethylether-isobutane byproduct is 0.192 tonnes/hour or 1,521
tonnes/year. The production capacity of oxygen byproduct is 5.748
tonnes/hour or 45,524 tonnes/year.
 Product delivery point where revenue is collected is on the plant gate.
 The overall process is not covered by external license, thus no royalties cost
included in cost estimation.
 MARR is assumed to be the same as weighted average cost of capital
(WACC) without addition of risk factor.
 Income tax is constant at the rate of 25%.
 Depreciation is calculated using MACRS method, specifically by using sub-
method of general depreciation system (GDS).
7.2. Capital Expenditure (CAPEX)
7.2.1. Cost Index
In order to estimate the cost of material relative to the specified time of
observation, cost index is needed. Through the use of cost index, equipment’s price
in the year of purchase can be estimated.
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Cost Index at Present


Present Cost = Original Cost ×
Cost Index at Origin
The cost index used in this project follows Chemical Engineering Plant Cost
Index (CEPCI), as it is more suitable for commodity chemicals. The index data
through the span of 2000 to 2012 is tabulated as follow.
Table 7.1. Cost Index
Year CEPCI
1995 381.1
1996 381.7
1997 386.5
1998 389.5
1999 390.6
2000 394.1
2001 394.3
2002 395.6
2003 402
2004 444.2
2005 468.2
2006 499.6
2007 525.4
2008 575.4
2009 521.9
2010 550.8
2011 585.7
2012 584.6
2013 567.3
2014 576.1
2015 556.8
2016 541.7
2017 567.5
(Source: CEPCI Online, 2018)
The cost index data is then visually graphed to infer a brief trendline.
650
600 y = 11.179x + 347.62
550
CEPCI

500
450
400
350
1995
1997
1999
2001
2003
2005
2007
2009
2011
2013
2015
2017

Year

CEPCI Linear (CEPCI)

Figure 7.1. Chemical Engineering Plant Cost Index (CEPCI)


(Source: CEPCI Online, 2017)

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The cost index for year 2020 is then estimated through the extrapolation of
the collected cost index data, giving an index value of 681 in 2020.
1000
800

CEPCI
600
400
200
0

1999

2017
1995
1997

2001
2003
2005
2007
2009
2011
2013
2015

2019
2021
2023
2025
2027
2029
Year

Figure 7.2. Forecast of Chemical Engineering Plant Cost Index (CEPCI)


7.2.2. Capital Expenditure Calculation Scope
Capital investment is the initial cost required by a project to design, to build,
and to start a manufacturing process. It is a single-occasion cost which will not
happen periodically. For brief explanation, capital investment includes all cost
which must be spent so that a project can start. Capital investment can be gained
either through investors or investment banks, or the combination of them.
The calculation of capital expenditure follows the preliminary method
proposed by Guthrie, with the simple equation provided as follow.
𝐶𝑇𝐶𝐼 = 𝐶𝑇𝑃𝐼 + 𝐶𝑊𝐶 = 1.18 𝑥 (𝐶𝑇𝐵𝑀 + 𝐶𝑆𝑖𝑡𝑒 + 𝐶𝐵𝑢𝑖𝑙𝑑𝑖𝑛𝑔 + 𝐶𝑂𝑓𝑓𝑠𝑖𝑡𝑒 ) + 𝐶𝑊𝐶
CTBM = Total bare module cost
CSite = field development/ site cost
CBuilding = building cost
COffsite = offsite facilities cost, etc.
CWC = working capital
The nomenclature used in the formula interprets total bare module cost, site
cost, building cost, and offsite facilities cost to be classified as fixed capital. The
factor of 0.18 implied from the formula refers to the estimation cost of contingency
and contractor fee. It is noted that the cost for startup is not included in this equation,
and must be included in the overall capital investment.
There are some terminologies on the classification of capital expenditure.
Direct permanent investment (DPI) refers to the cost associated with process
equipment, site, service, and utilities. Total depreciable capital (TDC) refers to the
addition of contingency and contractor fee to the direct permanent investment.
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Lastly, total permanent investment (TPI) includes the total depreciable capital with
the additional factor of plant startup cost. The summation of total perment
investment and working capital makes up for the whole total capital investment.
7.2.3. Total Bare Module Cost
Total bare-module cost, CTBM, refers to the summation of bare-module costs
for all items of process equipment, including fabricated equipment, process
machinery, spares, storage tanks, and surge tanks. The bare-module cost is based
on the f.o.b. equipment purchase cost, to which is factored in direct field materials
and labor, and indirect expenses such as freight, insurance, taxes, and overhead.
The f.o.b. price must be adjusted to the time the equipment will be bought, as the
price of equipment might fluctuate in time. The approach is to convert by cost index.
7.2.3.1. Purchase Cost Calculation
The purchase cost is mostly calculated through the equation provided by
Seider, et al. (2003), from various scientific sources. For not widely used
equipments, the purchase cost is obtained thorough real cost provided by vendor,
corrected by pressure, time, and capacity correction factor. The procedure for
purchase cost calculation is described in the appendices.
7.2.3.2. Total Bare-Module Factor Estimation
The purchase f.o.b. equipment price data obtained through equation,
historical data, or real data is converted into installed price with the factor known
as bare-module factor. This factor includes all cost contributing to the equipments
prior to the installment in the plant.
Table 7.2. Bare-Module Factors of Equipments

(Source: Seider, et al., 2003)

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The purchase cost estimated beforehand is multiplied with the bare-module


factor to obtain the installed cost of equipments. Calculation is tabulated as follow.
Table 7.3. Equipment Cost
Cost Index in Price in Basis Price in 2020 Total Price
Code Quantity FBM
Basis Year Year (USD) (USD)
REACTOR
R-201 1 394 32,345 55,906 4.16 232,567
R-301 1 394 33,407 57,741 4.16 240,203
R-302 1 394 17,343 29,975 4.16 124,697
DISTILLATION COLUMN
T-201 1 394 62,784 108,517 4.16 451,429
T-401 1 394 38,813 67,086 4.16 279,077
T-402 1 394 31,761 54,897 4.16 228,371
S-201 1 394 46,611 80,564 4.16 335,146
S-202 1 394 14,900 25,753 4.16 107,132
S-301 1 394 12,924 22,338 4.16 92,924
S-401 1 394 5,331 9,214 3.05 28,101
COMPRESSOR
K-201 1 394 154,075 266,308 2.15 572,561
K-202 1 394 130,882 226,220 2.15 486,373
K-203 1 394 51,123 88,363 2.15 189,980
K-204 1 394 20,123 34,781 2.15 74,779
K-205 1 394 25,973 44,893 2.15 96,519
K-206 1 394 32,477 56,134 2.15 120,689
K-207 1 394 43,788 75,684 2.15 162,721
K-401 1 394 20,557 35,531 2.15 76,392
PUMP
P-101 2 394 5,026 8,687 3.3 57,331
P-102 2 394 2,132 3,685 3.3 24,319
P-103 2 394 4,664 8,061 3.3 53,203
P-104 2 394 3,199 5,529 3.3 36,491
P-105 2 394 2,688 4,645 3.3 30,659
P-106 2 394 1,993 3,444 3.3 22,730
P-107 2 394 2,452 4,238 3.3 27,970
P-108 2 394 3,028 5,234 3.3 34,547
P-201 2 394 1,944 3,361 3.3 22,181
P-202 2 394 2,144 3,705 3.3 24,455
P-301 2 394 1,904 3,291 3.3 21,718
P-401 2 394 1,924 3,325 3.3 21,945
P-402 2 394 1,907 3,297 3.3 21,757
P-403 2 394 1,933 3,341 3.3 22,051
P-404 2 394 3,516 6,077 3.3 40,106
P-405 2 394 3,007 5,198 3.3 34,307
P-501 2 394 4,389 7,585 3.3 50,063
P-502 2 394 4,328 7,480 3.3 49,370
P-601 2 394 2,216 3,831 3.3 25,283
P-701 2 394 5,561 9,611 3.3 63,435
P-702 2 394 5,635 9,739 3.3 64,280

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Table 1.3. Equipment Cost (cont’d)


Cost Index in Price in Basis Price in 2020 Total Price
Code Quantity FBM
Basis Year Year (USD) (USD)
P-703 2 394 10,429 18,026 3.3 118,970
P-704 2 394 10,176 17,588 3.3 116,079
P-705 2 394 6,954 12,020 3.3 79,334
F-101 2 394 146,000 252,350 2.32 1,170,905
F-102 2 394 33,700 58,248 2.32 270,271
F-103 12 394 800 1,383 2.45 40,653
ELECTROLYZER
R-101 1 538.4 3,156,489.18 3,992,513 1 3,992,513
COOLING TOWER
CT-501 1 394 6,954.77 12,021 2.55 30,653
DEAERATOR
D-601 1 394 1,600 2,765 4.16 11,504
BOILER
B-601 1 394 121,300 209,658 1.86 389,964
CLARIFIER
C-701 1 394 34,700 59,976 2.03 121,752
C-702 1 394 30,500 52,717 2.03 107,016
TANK
T-701 1 394 14,200 24,544 3.49 85,657
T-702 1 394 5,000 8,642 3.49 30,161
T-402 1 394 5,600 9,679 3.49 33,780
T-403 2 394 1,500 2,593 3.49 18,097
HEAT EXCHANGER
E-201 1 394 51,100 88,323 3.17 279,983
E-202 1 394 52,100 90,051 3.17 285,462
E-203 1 394 44,700 77,261 3.17 244,916
E-204 1 394 58,800 101,631 3.17 322,172
E-205 1 394 42,000 72,594 3.17 230,123
E-206 1 394 56,000 96,792 3.17 306,830
E-207 1 394 46,200 79,853 3.17 253,135
E-208 1 394 45,200 78,125 3.17 247,656
E-301 1 394 37,300 64,470 3.17 204,371
E-302 1 394 43,500 75,187 3.17 238,341
E-303 1 394 40,400 69,828 3.17 221,356
E-304 1 394 40,400 69,828 3.17 221,356
E-401 1 394 48,800 84,347 3.17 267,381
E-402 1 394 45,800 79,162 3.17 250,943
HEAT EXCHANGER
E-403 1 394 41,200 71,211 3.17 225,739
E-404 1 394 45,600 78,816 3.17 249,847
E-405 1 394 60,600 104,743 3.17 332,034
E-406 1 394 37,400 64,643 3.17 204,919
E-407 1 394 60,600 104,743 3.17 332,034
PHOTOVOLTAIC ARRAY
PV (set) 1 556.8 15,462,181 18,911,181 1 18,911,181
Total Equipment Cost (USD) 35,094,953

7.2.4. Land and Site Development Cost (Csite)


Being originally excluded from thee direct permanent investment, land cost
is calculated alongside site development cost in the simplification of Guthrie
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method. Located in West Kalimantan, the plant has an overall area of 198,000 m2.
The cost for land is estimated as follow.
Table 7.4. Land Cost
Price per m2 (IDR) Price per m2 (USD) Area (m2) Total Cost (USD)
225,000 15.47 198,000 3,064,000
For site development costs, in lieu of a detailed estimate, which is not
normally prepared at this stage of cost estimation, a value of 10-20% of CTBM may
be assigned for a grass-roots plant and 4-6% for an addition to an integrated
complex. For this calculation, the site development cost is estimated in the portion
of 15% CTBM, to give a value a total value of 5,264,243 USD.
Table 7.5. Land and Site Development Cost (Csite)
Component Cost (USD)
Land Cost 3,064,000
Site Development Cost 5,264,243
Csite 8,238,700
7.2.5. Building Cost (Cbuilding)
Building costs, Cbuildings, include process buildings and non-process
buildings. If the equipment is housed, the cost of process buildings may be
estimated at 10% of CTBM. If a grass-roots plant is being considered, the non-process
buildings may be estimated at 20% of CTBM. If the process is to be an addition to an
integrated complex, the non-process buildings may be estimated at 5% of CTBM.
The building cost can also be estimated through direct calculation with the
information of price per m2 of building. The calculation of building cost as well as
rechecking through the stated factor is tabulated as follow.
Table 7.6. Building Cost
2
Price per m Price per m2 Total Cost
Component Area (m2)
(IDR) (USD) (USD)
Building 3,500,000 206.33 38,000 7.840
Foundation 10% of land cost 306,400
Contractors 3% of land cost 91,900
Building Cost 8,238,700
Rechecked Building Cost 20% of CTBM 7,018,991
(Source: Sartala, 2012, Reproduced)
It is found that the building cost estimation through direct calculation with
unit price value and factor of total bare-module factor gives a quite similar result.
7.2.6. Offsite Facilities Cost (Coffsite)

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Offiste facilities include supporting equipments for clerical work and utility
installation cost. The utility plant is estimated in the main process equipment. The
estimation of supporting equipment cost is tabulated as follow.
Table 7.7. Supporting Equipment Cost
Total
Unit Price Total Price
Equipment Specification Quantity Price
(IDR) (IDR)
(USD)
PHILIPS/31093 TrunkLinea
LED Lamps 60 65,000 3,900,000 268
Wall Lamp LED
Dispenser Sanex D188 350 W 7 390,000 2,730,000 188
Internet
Fastnet/Combo Supreme 1 709,000 709,000 49
Upkeep
Interphone COMMAX TP-1L 2km 1 435,000 435,000 30
CCTV Set (4 Hikvision/8 Camera Turbo
9 4,570,000 41,130,000 2,829
pcs) HD [2.0 MP]
Fire
LIBERTY LP 20P 2kg 8 350,000 2,800,000 193
Extinguisher
Toilet Set Rialto/Duoblock 5007 8 2,500,000 20,000,000 1,376
Pantry Set Sarfaz A 3 1,500,000 4,500,000 309
Dining Set Dongxin/CA128 10 2,500,000 25,000,000 1,719
Television Sharp LC-32 LE 6 1,550,000 9,300,000 640
Telephone Alcatel/T22 Single Line 20 229,000 4,580,000 315
Air POLYTRON PAC18VK
10 4,685,000 46,850,000 3,222
Conditioner 2PK
Desktop HP/20-C005D PC All-In-
50 4,300,000 215,000,000 14,787
Computers One
Projector and
Epson EB-S31 10 5,200,000 52,000,000 3,576
Screen
Whiteboard Sakana EE 10 1,050,000 10,500,000 722
Sofa Chairman VEO-02 4 4,500,000 18,000,000 1,238
Office Chairs Ergosit/Iso Black 40 298,000 11,920,000 820
Office Desks Lunar/LMC 82 20 620,000 12,400,000 853
Meeting
EURO NVS-98 4 5,200,000 20,800,000 1,431
Table
Fax Panasonic KX-FP 701 5 1,500,000 7,500,000 516
Printer and HP/3635 Printer [Print, Scan,
4 4,026,000 16,104,000 1,108
Scanner Copy]
Locker Emporium EL-12 2 2,050,000 4,100,000 282
Laboratory
1 30,000,000 30,000,000 2,063
Set
Office Car 3 300,000,000 900,000,000 61,898
Other Facilities 292,051,600 20,086
Total Supporting Equipment Cost 1,752,309,600 120,516
The cost associated with utility installation is tabulated as follow.
Table 7.8. Utility Installation Cost
Utilities Notes Cost (IDR) Cost (USD)
Electricity Industrial 183,000,000 12,586
Water PDAM – Large Industry 75,000,000 5,158
Telephone Telkom 30,000,000 2,063
Internet First media 5,000,000 344
Hydrant Sumber Teknik Proteksindo 400,000,000 27,510
Total Utility Installation Cost 693,000,000 47,662
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The estimation of supporting equipments and utility installation gives a


value of 168,178 USD for offsite facilities cost estimate.
7.2.6. Contingency and Contractor Fee
Contingency and contractor fee is consecutively estimated at 15% and 3%
of total depreciable income. It is calculated as follow.
Table 7.9. Contingency and Contractor Fee
Component Notes Cost (USD)
Direct Permanent Investment Sum of CTBM, Csite, Cbuilding, Coffsite 51,830,075
Contingency 15%CDPI 7,774,511
Contractor Fee 3%CDPI 1,554,902
7.2.7. Plant Startup Cost
Plant startup cost accounts for two main objects, which are (1) those
incurred by the contractor in checking equipment performance, calibrating
controllers and other plant equipment, and commissioning the plant, and (2) those
incurred by the plant operating personnel when starting up and shutting down the
plant. It is estimated at 10% of CTDC.
Table 7.10. Plant Startup Cost
Component Notes Cost (USD)
Sum of CDPI, contingency,
Total Depreciable Capital 61,159,488
andcontractor fee
Plant Startup Cost 10%CTDC 6,115,949
7.2.8. Working Capital
Working capital refers to the cost needed to start the manufacture process.
It includes all operating cost expended until the project gets the first revenue. After
the revenue is obtained, the calculation of capital investment I sover and operating
cost stars to be calculated. Working capital is estimated at 15% of total capital
investment (TCI), or 17.6% of total permanent investment (TPI).
Table 7.11. Working Capital
Component Notes Cost (USD)
Total Permanent Investment Sum of CTDC and plant startup cost 67,275,437
Working Capital 17.6%CTPI 11,840,477
7.2.9. Summary of Capital Expenditure
The summary of capital expenditure estimation is tabulated as follow. It
gives the total capital expenditure in the value of 79,115,914 USD.

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Table 7.12. Summary of Capital Expenditure


Component Cost (USD) Share (%)
Equipment Cost 35,094,953 44.36
Site Cost 8,328,243 10.53
Building Cost 8,238,700 10.41
Offsite Facilities 168,178 0.21
Direct Permanent Investment 51,830,075
Contingency 7,774,511 9.83
Contractor Fee 1,554,902 1.97
Total Depreciable Capital 61,159,488
Plant Startup 6,115,949 7.73
Total Permanent Investment 67,275,437
Working Capital 11,840,477 14.97
Total Capital Investment 79,115,914 100.00
7.3. Operational Cost
Operating cost are cost incurred during plant operation such as the cost of
materials, labor, utilities cost, insurance, salary tax, building tax, depreciation,
distribution and marketing as well as administration. Operational cost is usually
paid in every year of production. There are some factors that is needed to be
calculated such as direct production cost, fixed charge, and plant overhead cost.
These costs are called manufacturing cost. The operational cost is conducted into
two types which are manufacturing cost and general expense.
7.3.1. Direct Production Cost
7.3.1.1. Raw Material Cost
Raw materials used for this plant’s production of gasoline from electrolysis
and MTG process are consisted of carbon dioxide, solar energy, and seawater.
However, solar energy and seawater are available freely in nature. Therefore, the
list of raw material cost that will be used during production processes, including the
shipping cost is shown below.

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Table 7.13. Raw Material Cost


Needs per Needs per Price of Raw Shipping Cost Shipping Total Total Cost Total Cost in 1st
Raw
Supplier month year Material per per tonne per Distance Shipping per year Year with 10%
Material
(tonne) (tonne) tonne (USD) km (USD) (km) Cost (USD) (USD) inventory (USD)
Carbon ExxonMobil and/or
57.75 635.25 10.3 1.4 200 177,870.00 184,413.08 202,854.38
dioxide Pertamina, Natuna
PT. Insoclay
Acidatama
KOH 1.5 16.50 800 0.25 860 3,547.50 16,747.50 18,422.25
Indonesia,
Tangerang
Total (USD) 181,417.50 201,160.58 221,276.63
7.3.1.2. Catalysts Material
This plant needs catalysts which are placed inside reactors. The lifetime of the catalyst is 3 years. Therefore, they need new
regeneration every 3 years to maintain the quality of the products. The catalysts which are needed for this plant are listed to defined the their
costs which will be listed as below.
Table 7.14. Catalysts Cost
Needs per 3 Price of Raw Shipping Cost Shipping Total Cost in 1st 3
Catalyst Total Shipping Total Cost per
Supplier years Material per per tonne per Distance Year with 10%
Material Cost (USD) 3 year (USD)
(tonne) tonne (USD) km (USD) (km) inventory (USD)
Tianjin Hutong Global
Cu/Zn/Al catalyst 3.21 20,000 5 2,400.00 38,520.00 102,720 112,992
Trade Co., Ltd., China
Shijiazhuang Chenshi
γ-Al2O3 catalyst Import and Export, 4.85 530 5 2,400.00 58,200.00 60,771 66,848
Co., Ltd.
metal modified
Tianjin Hutong Global
beta-zeolite (H- 1.19 350 5 2,400.00 14,280.00 14,697 16,166
Trade Co., Ltd., China
BETA) catalyst
Total (USD) 111,000.00 178,187 196,006

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7.3.1.3. Labor Salary


Labors needed for our plant can be classified into direct and indirect labor.
Direct labors are workers who is in charge of operational process of production
activity in plant, while indirect labors are in charge of activities other than
production such as marketing, accountant, etc. Salary for every worker should
follow regulation of minimum regional wage at the location of this plant. Here is
data for UMK (Upah Minimum Kabupaten) in West Kalimantan of recent years.
Table 7.15. Minimum wage at West Kalimantan
Year Minimum wage (Rp) Minimum wage (USD)
2015 1,739,400.00 119.93
2016 1,882,900.00 129.83
2017 2,046,900.00 141.14
2018 2,220,476.51 153.10
2019 2,408,772.25 166.09
2020 2,613,035.41 180.17
(Source: Pemprov Kalimantan Website)
From data above minimum wage for West Kalimantan in 2020 can be
estimated has value of $180.17 per month. Then workers needed for operation of
our plant are listed below.
Table 7.16. Direct Cost Labor Salary
Amount Salary per month per person Total Salary
Position
(person) (USD) (USD)
Operator 72 207 14,904
Control Room Labor 6 207 16,135
Analyst 6 221 17,210
TOTAL DIRECT LABOR COST 48,249
7.3.1.4. Utility Cost
Utility costs are needed to support main process of plant, it can be
categorized to electricity, water, and fuel cost. Besides photovoltaics to generate
50% power of electrolyzer, electricity of our plant is also obtained from PLN with
classification of i-1/3500 VA s.d. 14 kVA as the cost of electric per kWh is 0.0767
USD. Water cost consisted of water consumption by workers. Fuel is used to
produce steam at boiler, type of fuel used is coal with current price is 1.1 USD per
liter. Here are the summary of utilities cost.

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Table 7.17. Electricity Main Equipment Cost


Power Working Total Total
Total Cost/year
Equipments Qty (kW) per Time/week Power/week Power/year
(USD)
unit (h) (kWh) (kWh)
Pump 24 15.01 168.00 60,527.25 2,853,427.50 218,782.35
Multimedia
2 56.33 168.00 18,926.88 892,267.20 68,413.27
Filter
Catridge Filter 2 56.33 168.00 18,926.88 892,267.20 68,413.27
Reverse
12 184.24 168.00 371,427.84 17,510,169.60 1,342,566.46
Osmosis
AEL
1 10,106.91 168.00 1,697,961.62 80,046,761.85 6,137,467.56
Electrolyzer
Compressor 9 73.84 168.00 111,652.80 5,263,632.00 403,581.23
Cooling Tower 1 15.20 168.00 2,553.60 120,384.00 9,230.27
Deaerator 1 32.00 168.00 5,376.00 253,440.00 19,432.14
Boiler 1 66.25 168.00 11,130.00 524,700.00 40,230.60
Primary
1 34.00 168.00 5,712.00 269,280.00 20,646.65
Clarifier
Secondary
1 34.00 168.00 5,712.00 269,280.00 20,646.65
Clarifier
Furnace 1 78.00 168.00 13,104.00 617,760.00 47,365.84
Control
45 50.00 168.00 378,000.00 17,820,000.00 1,366,322.25
Instruments
TOTAL ELECTRICITY COST FOR MAIN EQUIPMENTS 9,763,099
Beside electric requirement for process equipment in the plant, supporting
equipment at office such as computer, air conditioner, lamp, etc. also considered in
total electric cost calculation.
Table 7.18. Electricity Support Equipment Cost
Power Working Total Total Total
Equipments Qty (kW) Time/week Power/week Power/year Cost/year
per unit (h) (kWh) (kWh) (USD)
Computer 45 13.5 48 29,160.00 1,374,685.71 105,402.00
Telephone 20 0.2 168 672.00 31,680.00 2,429.02
CCTV 30 0.75 168 3,780.00 178,200.00 13,663.22
Photocopy
Machine,
5 2.5 48 600.00 28,285.71 2,168.77
Scanner, and
Printer
Projector and
10 2 48 960.00 45,257.14 3,470.02
screen
Dispenser 7 0.7 168 823.20 38,808.00 2,975.55
Television 6 3 48 864.00 40,731.43 3,123.02
Lamp 80 1.44 168 19,353.60 912,384.00 69,955.70
TOTAL ELECTRICITY COST FOR SUPPORT EQUIPMENTS 203,187

Table 7.19. Water Requirement Cost


Water Needs L/day m3/year Cost (USD/m3) Total Cost (USD)
Employees 10020 3306.6 1.027972028 3,399
TOTAL PRICE FOR WATER (USD)/year 3,399.09
Type of fuel used for this plant is coal which is used to produce steam by
boiler. From energy balance, fuel requirement of plant is 1.627 tonne/day.
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Table 7.20. Fuel Requirement Cost


No Fuel Supply Equipment Code Mass Flow (tonnes/day)
1 Boiler B-601 1.627
Working day/year 330
Total fuel needed (tonnes) /year 537
Total fuel needed (L) /year 704,052
Total Price Boiler Fuel (USD)/year 774,457
Therefore, it can be summarized fot the total utilities cost as follow.
Table 7.21. Summary of Utility Cost
Details USD/Year
Total electricity cost for main equipments 9,763,099
Total electricity cost for support equipments 203,187
Total price for water 3,399.09
Total price boiler fuel 774,457
Total Utilities 10,744,142.05
7.3.1.5. Maintenance Cost
Processing equipment must be kept in acceptable working order, with
repairs and replacement of parts made as needed. Maintenance is required for
production plant, office, and supporting equipment in order to achieve continuously
and optimal production activity. Maintenance cost for designed gasoline plant per
year can be estimated as follow.
Table 7.22. Maintenance Cost
Type Cost Maintenance Cost
(USD) (USD)
Supporting Facilities Maintenance (3% of Supporting 122,539 3,676
Facilities Cost)
Factory, Warehouses and Buildings (1% of cost of Csite, 16,682,900 166,829
DCs, and Cbuilding)
Equipments Maintenance (15% of Total Bare Modul Cost) 35,094,953 3,158,546
Total (USD) 3,329,050.99
7.3.2. Fixed Cost: Local Tax and Insurance
Insurance is cost that paid to insurance company that cooperate with plant.
Insurance is the way to protect the company assets, both movable and fixed. For
calculating the insurance, the assumption based on PP No 84 Year 2010, that is
stated the assumption below.
Table 7.23. Insurance Cost
Insurance Type Measurement Amount (USD) Annual Cost (USD)
Plant Insurance 0.5% of Fc Cost 79,115,913.73 395,579.57
Employee's Insurance 6% of Salary 64,650.24 3,879.01
Total Insurance 399,458.58
Paying attention to the tax of land & building and salary is important. The
amount is shown below.
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Table 7.24. Land and Building Cost and Tax


Description Area (m2) Cost per m2 (USD) Cost (USD)
NJOP Earth 198,000 15.47 3,063,961.49
NJOP Building 38,000 206.33 7,840,440.17
Total NJOP 10,904,401.65
NJOPKTP 1.10
NJOP for PBB 10,904,400.55
NJKP (40% NJOP) 4,361,760.22
Debted PBB (0.5% NJKP) 21,808.80

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Table 7.25. Salary and Tax
Salary per
Total
Amount month per Insurance Bruto Position Net Income Net Income Taxable Salary Tax
Position Insurance
(person) person per month Income Cost per Month per year Income per year
per year
(USD)
President Director 1 8,359 501.54 6,018.48 8,860.54 443.03 8,417.51 101,010.16 94,322.96 4,716.15
Vice President
1 6,965 417.90 5,014.80 7,382.90 369.15 7,013.76 84,165.06 77,477.86 3,873.89
Director
Secretary of
1 488 29.28 351.36 517.28 25.86 491.42 5,896.99 0 0
President Director
Finance Accounting
1 1,393 83.58 1,002.96 1,476.58 73.83 1,402.75 16,833.01 10,145.81 507.29
Manager
Assistant Finance
1 1,045 62.70 752.40 1,107.70 55.39 1,052.32 12,627.78 5,940.58 297.03
Manager
Legal Manager 1 2,229 133.74 1,604.88 2,362.74 118.14 2,244.60 26,935.24 20,248.04 1,012.40
Legal Staff 2 418 25.08 601.92 443.08 22.15 420.93 5,051.11 0 0
SCM Manager 2 1,741 104.46 2,507.04 1,845.46 92.27 1,753.19 21,038.24 14,351.04 1,435.10
Security 14 279 16.74 2,812.32 295.74 14.79 280.95 3,371.44 0 0
Cleaning Service 15 279 16.74 3,013.20 295.74 14.79 280.95 3,371.44 0 0
Procurement &
1 348 20.88 250.56 368.88 18.44 350.44 4,205.23 0 0
Contract Supervisor
Human Resources
1 3,483 208.98 2,507.76 3,691.98 184.60 3,507.38 42,088.57 35,401.37 1,770.07
Manager
Human Resources
Planning and
1 3,483 208.98 2,507.76 3,691.98 184.60 3,507.38 42,088.57 35,401.37 1,770.07
Recruitment
Coordinator
HSE Manager 1 871 52.26 627.12 923.26 46.16 877.10 10,525.16 3,837.96 191.90
Safety Engineer 5 418 25.08 1,504.80 443.08 22.15 420.93 5,051.11 0 0
Production &
Maintenance 5 5,224 313.44 18,806.40 5,537.44 276.87 5,260.57 63,126.82 56,439.62 14,109.90
Manager

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Table 2.13. Salary and Tax (cont’d)
Salary per
Total
Amount month per Insurance Bruto Position Net Income Net Income Taxable Salary Tax
Position Insurance
(person) person per month Income Cost per Month per year Income per year
per year
(USD)
Process Engineer 10 592 35.52 4,262.40 627.52 31.38 596.14 7,153.73 466.53 233.26
Staff Engineer 10 348 20.88 2,505.60 368.88 18.44 350.44 4,205.23 0 0
Laboratory Manager 1 5,224 313.44 3,761.28 5,537.44 276.87 5,260.57 63,126.82 56,439.62 2,821.98
Laboratory Staff 2 418 25.08 601.92 443.08 22.15 420.93 5,051.11 0 0
Product Planning &
Development 1 2,438 146.28 1,755.36 2,584.28 129.21 2,455.07 29,460.79 22,773.59 1,138.68
Manager
Quality Control
2 348 20.88 501.12 368.88 18.44 350.44 4,205.23 0 0
Team
Quality Control
1 348 20.88 250.56 368.88 18.44 350.44 4,205.23 0 0
Supervisor
Marketing Manager 1 871 52.26 627.12 923.26 46.16 877.10 10,525.16 3,837.96 191.90
Marketing Staff 2 348 20.88 501.12 368.88 18.44 350.44 4,205.23 0 0
Total 83 47,958 2,877.48 64,650.24 50,835.48 2,541.77 48,293.71 579,524.47 412,344.47 26,500.45

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Therefore, the total fixed cost can be summarized as table below.


Table 7.26. Summary of Fixed Cost
Types of Fixed Cost Cost (USD)
Insurance 399,459
Property Tax 21,809
Salary Tax 26,500
TOTAL 447,768
7.3.3. Plant Overhead Cost
Plant overhead cost covers the cost that is needed for safety measures during
production process.
Table 7.27. Plant Overhead Cost
Price per Unit Total Price per Unit Total Price Estimation per
Equipments Qty
(USD) (USD) Year (USD)
First Aid Kit 10 7.41 74.10 222.30
Hydrant 20 88.86 1,777.20 1,777.20
TOTAL 1,999.50

Table 7.28. PPE Cost


Unit Price per Unit Amount of Unit Total Cost
Helmet USD 2 72 USD 150
Ear plug USD 2 72 USD 125
Gloves USD 6 72 USD 451
Respirator USD 5 72 USD 360
Safety wear USD 12 72 USD 878
Safety shoes USD 10 72 USD 720
Total USD 2,685
7.3.4. General Expenses
General expenses are other costs that should be paid other than production
activities of plant. General expenses consist of executive and administrative cost
such as engineering and legal. Office maintenance and distribution cost of product
from plant to fuel retail station, loan interest, and research and development cost.
7.3.4.1. Executive Salary and Clerical Wage
Executive salary is the salary of executors in the plant. The executor’s of the
plant main job is to ensure the plant activity for production. This cost also includes
administrative cost as the supporting function of the plant. In order for the plant to
run and make the products reach the consumer. Therefore, the list of the cost is
shown in table below.

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Table 7.29. Executive Salary and Clerical Wage


Salary/ Bonus and Total
Amount
Qualification Month Allowance Salary/Year
(Person)
(USD) (USD) (USD)
President Director 1 8,359 - 100,303
Secretary of 1 488 - 5,851
Stakeholder President Director
Vice President 1 6,965 - 83,586
Director
Finance 1 1,393 - 16,717
Accounting
Finance
Manager
Department
Assistant Finance 1 1,045 - 12,538
Manager
Legal Legal Manager 1 2,229 - 26,747
Department Legal Staff 2 418 - 10,030
General Support 2 1,741 - 41,793
and Service SCM Manager
Department
Security 10 279 - 33,434
Security 4 279 - 13,374
General Support
Cleaning Service 15 279 - 50,151
and Service
Procurement & 1 348 - 4,179
Department
Contract
Supervisor
HR Manager 1 3,483 - 41,793
HRD
HR Planning & 1 3,483 - 41,793
Department
Recruitment
HSE HSE Manager 1 871 - 10,448
Department Safety Engineer 5 418 - 25,076
Production and
Production and Maintenance 5 5,224 - 313,447
Maintenance Manager
Department Process Engineer 10 592 - 71,048
Staff Engineer 10 348 - 41,793
Research and Laboratory
1 5,224 - 62,689
Development Manager
Department Laboratory Staff 2 418 - 10,030
Product Planning
and Development 1 2,438 - 29,255
Product
Manager
Planning and
Quality Control
Development 2 348 - 8,359
team
Department
Quality Control
1 348 - 4,179
Supervisor
Sales and Marketing
1 871 - 10,448
Marketing Manager
Department Marketing Staff 2 348 - 8,359
TOTAL INDIRECT WORKER COST (USD) 1,077,421
7.3.4.2. Marketing and Communication
Marketing and communication is used to introduce and explain the product
to the parties involved in the product supply chain. The cost for marketing and
communication is shown on the table below.
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Table 7.30. Market Research Cost

Market Research Total Cost (USD)


Consultant Market Research 1,045
TOTAL MARKET RESEARCH 1,045

Table 7.31. Printed Media Cost


Printed Media Type Total Cost (USD)
Proposal Full colour display 104
TOTAL PRINTED MEDIA PUBLICATION COST 104

Table 7.32. Online Advertisement Cost


Registration
Online Platform Cost/day (USD/day) Total Cost (USD)
Price
Social Media
(Fanspage, FB, Twitter, 0 0 0
Instagram)
Website 10 2 12
TOTAL ONLINE ADVERTISEMENT COST 12

Table 7.33. Marketing Cost


Media Type Total Cost/year (USD/year)
Market Research 1,045
Printed 104
Electronic 858
TOTAL MARKETING COST PER YEAR 2,007

Table 7.34. Website Development Cost

Types Total Cost/year (USD/year)


Creating Website Cost 10
Design Website Cost 836
Annual Cost 12
TOTAL WEBSITE DEVELOPMENT COST 858

Table 7.35. Annual Communication Cost


Communication Types Total Cost/year (USD/year)
Mail 0.12
Internet and Telephone Operation 0.12
Internet and Telephone Installation 139.31
Annual Communication Cost 139.54
Therefore, it can be summarized the total of general expenses which is
shown in table below.

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Table 7.36. Summary of General Expenses


Types of General Expenses USD/year
Marketing 2,007.00
Communication 139.54
Executive Salary and Clerical Wage 1,077,421.00
TOTAL 1,079,567.54
7.3.5. Depreciation
Depreciation is basically the reduction of assets value which is calculated
after the assets are purchased. The capital investment in the beginning of the project
will lose its fraction of value into salvage value at the end of the project. In each
annuity, the depreciation needs to be calculated to provide a balance from the initial
capital investment to the final salvage value.
Depreciation is calculated throughout the process equipments, supporting
equipments, and buildings, with the method of Modified Accelerated Cost
Recovery System (MACRS), with the specific sub-method of General Depreciation
System (GDS). Under MACRS, tangible depreciable property is categorized into
asset classes. The property in each class is then assigned a class life.
Table 7.37. MACRS Class Lives and Recovery Periods

(Source: Sullivan, et al., 2015)


Through the information on the table above, process equipments are
categorized in GDS period of 5 years, and supporting equipments are categorized
in GDS period of 7 years. These two categories follow double declining balance –
straight line method, with the depreciation factor tabulated as follow.

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Table 7.38. GDS Recovery Rate

(Source: Sullivan, et al., 2015)


Buildings are calculated in the category of non-residential real property, and
it follows the straight line method with the period of 39 years. The calculation for
depreciation is tabulated as follow.

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Table 7.39. Depretiation
Process Equipment Supporting Equipment Building
No. of Total
Depreciation Book Value Depreciation Book Value Depreciation Book Value
Year Year Factor Factor Factor Depreciation
(USD) (USD) (USD) (USD) (USD) (USD)
2020 0 0 0 35,094,953 0 0 168,178 0 0 8,238,700 0
2021 1 0.2000 7,018,991 28,075,963 0.1429 24,033 144,145 0.0128 105,624 8,133,076 7,148,648
2022 2 0.3200 11,230,385 16,845,578 0.2449 41,187 102,959 0.0256 211,249 7,921,827 11,482,821
2023 3 0.1920 6,738,231 10,107,347 0.1749 29,414 73,544 0.0256 211,249 7,710,578 6,978,894
2024 4 0.1152 4,042,939 6,064,408 0.1249 21,005 52,539 0.0256 211,249 7,499,329 4,275,193
2025 5 0.1152 4,042,939 2,021,469 0.0893 15,018 37,521 0.0256 211,249 7,288,081 4,269,206
2026 6 0.0576 2,021,469 0 0.0892 15,001 22,519 0.0256 211,249 7,076,832 2,247,720
2027 7 0 0 0 0.0893 15,018 7,501 0.0256 211,249 6,865,583 226,267
2028 8 0 0 0 0.0446 7,501 0 0.0256 211,249 6,654,335 218,749
2029 9 0 0 0 0 0 0 0.0256 211,249 6,443,086 211,249
2030 10 0 0 0 0 0 0 0.0256 211,249 6,231,837 211,249
2031 11 0 0 0 0 0 0 0.0256 211,249 6,020,588 211,249
2032 12 0 0 0 0 0 0 0.0256 211,249 5,809,340 211,249
2033 13 0 0 0 0 0 0 0.0256 211,249 5,598,091 211,249
2034 14 0 0 0 0 0 0 0.0256 211,249 5,386,842 211,249
2035 15 0 0 0 0 0 0 0.0256 211,249 5,175,594 211,249
2036 16 0 0 0 0 0 0 0.0256 211,249 4,964,345 211,249
2037 17 0 0 0 0 0 0 0.0256 211,249 4,753,096 211,249
2038 18 0 0 0 0 0 0 0.0256 211,249 4,541,847 211,249
2039 19 0 0 0 0 0 0 0.0256 211,249 4,330,599 211,249
2040 20 0 0 0 0 0 0 0.0128 105,624 4,224,974 105,624

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The salvage value in year 2040 is obtained through non-residential real


property and land.
Table 7.40. Salvage Value
Component Value (USD)
Building Salvage Value 4,224,994
Land Salvage Value 3,064,000
Total Salvage Value 7,288,974
7.3.6. Total Operating Cost
Operating cost consists of direct production cost, fixed cost, plant overhead
cost, and general expense. The total OPEX can be obtained by sums up those cost
excluding maintenance and depretiation. The summary of total OPEX can be shown
in table below.

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Table 7.41. Summary of Total Operating Cost
PRODUCTION COST 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031
Raw Material 221,277 201,161 201,161 201,161 201,161 201,161 201,161 201,161 201,161 201,161 201,161
DIRECT
Catalyst 196,006 178,187 178,187 178,187
PRODUCTION
Labor Salary 227,136 227,136 227,136 227,136 227,136 227,136 227,136 227,136 227,136 227,136 227,136
COST
Utility 9,787,716 9,787,716 9,787,716 9,787,716 9,787,716 9,787,716 9,787,716 9,787,716 9,787,716 9,787,716 9,787,716
Local Tax 55,878 55,878 55,878 55,878 55,878 55,878 55,878 55,878 55,878 55,878 55,878
FIXED COST
Insurance 399,459 399,459 399,459 399,459 399,459 399,459 399,459 399,459 399,459 399,459 399,459
PLANT
Safety and
OVERHEAD 2,000 2,000 2,000 2,000 2,000 2,000 2,000 2,000 2,000 2,000 2,000
Protection
COST
Executive
1,077,421.00 1,077,421 1,077,421 1,077,421 1,077,421 1,077,421 1,077,421 1,077,421 1,077,421 1,077,421 1,077,421
Salary
GENERAL
Marketing 2,007 2,007 2,007 2,007 2,007 2,007 2,007 2,007 2,007 2,007 2,007
EXPENSE
Communication 139.54 139.54 139.54 139.54 139.54 139.54 139.54 139.54 139.54 139.54 139.54
Loan Interest 7,891,812 7,102,631 6,313,450 5,524,269 4,735,087 3,945,906 3,156,725 2,367,544 1,578,362 789,181 0
TOTAL OPEX (excluding
19,858,705 18,853,402 18,064,220 17,453,226 16,485,858 15,696,677 15,085,683 14,118,314 13,329,133 12,718,139 11,750,771
Maintenance and Depreciation)
MAINTENANCE 2,748,764 2,748,764 2,748,764 2,748,764 2,748,764 2,748,764 2,748,764 2,748,764 2,748,764 2,748,764 2,748,764
DEPRECIATION 7,148,648 11,482,821 6,978,894 4,275,193 4,269,206 2,247,720 226,267 218,749 211,249 211,249 211,249

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Table 2.29. Summary of Total Operating Cost (cont’d)

PRODUCTION COST 2032 2033 2034 2035 2036 2037 2038 2039 2040 2032 2033
Raw Material 201,161 201,161 201,161 201,161 201,161 201,161 201,161 201,161 201,161 201,161 201,161
DIRECT
Catalyst 178,187.00 178,187.00 178,187.00 178,187.00
PRODUCTION
COST Labor Salary 227,136 227,136 227,136 227,136 227,136 227,136 227,136 227,136 227,136 227,136 227,136
Utility 9,787,716 9,787,716 9,787,716 9,787,716 9,787,716 9,787,716 9,787,716 9,787,716 9,787,716 9,787,716 9,787,716
Local Tax 55,878 55,878 55,878 55,878 55,878 55,878 55,878 55,878 55,878 55,878 55,878
FIXED COST
Insurance 399,459 399,459 399,459 399,459 399,459 399,459 399,459 399,459 399,459 399,459 399,459
PLANT
OVERHEAD Safety and
COST Protection 2,000 2,000 2,000 2,000 2,000 2,000 2,000 2,000 2,000 2,000 2,000
Executive
Salary 1,077,421 1,077,421 1,077,421 1,077,421 1,077,421 1,077,421 1,077,421 1,077,421 1,077,421 1,077,421 1,077,421
GENERAL Marketing 2,007 2,007 2,007 2,007 2,007 2,007 2,007 2,007 2,007 2,007 2,007
EXPENSE
Communication 139.54 139.54 139.54 139.54 139.54 139.54 139.54 139.54 139.54 139.54 139.54
Loan Interest 0 0 0 0 0 0 0 0 0 0 0
TOTAL OPEX (excluding
11,750,771 11,928,958 11,750,771 11,750,771 11,928,958 11,750,771 11,750,771 11,928,958 11,750,771 11,750,771 11,928,958
Maintenance and Depreciation)
MAINTENANCE 2,748,764 2,748,764 2,748,764 2,748,764 2,748,764 2,748,764 2,748,764 2,748,764 2,748,764 2,748,764 2,748,764
DEPRECIATION 211,249 211,249 211,249 211,249 211,249 211,249 211,249 211,249 105,624 211,249 211,249

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7.3.7. Benchmark
The benchmark to the other plant is needed to see the comparison that has
the same in type of product, which is gasoline. The comparison plants are shown in
table below.
Table 7.42. Benchmark
Capacity
CAPEX Revenue
Year Lifetime Gasoline
Plant Refinery Location (USD (USD
Operating (years) (1000
billion) billion)
bpd)
Dumai Riau 1984 30 4.49 20.50 170.0
South
Plaju 2012 30 5.6 36.49 109.0
Sumatra
PT. Central
Cilacap 2010 30 6.67 41.76 340.0
Pertamina Java
East
Balikpapan 2002 30 5.18 32.95 260.0
Kalimantan
Balongan West Java 2013 30 3.62 41.23 125.0
Tuban East Java 2003 30 4.52 32.75 92.0
7.4. Profitability Analysis
Profitability analysis is a component that forecasts/anticipates the sales and
profit potential. Profitability analysis contains of 5 points to determine if the project
is profitable or not, which are rate of investment, internal rate of return, net present
value, payback period, and breakeven point.
7.4.1. Investment Feasibility Analysis
Cost estimation is conducted to be analyzed by economic calculation.
Through economic analysis, the issue regarding project feasibility and profitability
can be analyzed. Basically, all the analysis is held through a media named cash
flow, which gives a lot of economic information about the project. Moreover,
through economic analysis, the appropriate product price can be determined as well
as the cost breakdown. To make an economic analysis, economic foundation
including project source, revenue, cost breakdown, and cash flow must be produced
and arranged beforehand.
7.4.1.1. Capital Loan
As mentioned in the earlier section, capital investment is usually obtained
through the combination of bank and investor as the capital provider. In this project,
the capital investment is assumed to be obtained from bank with the fraction of 70%
and from the investor with another fraction of 30%. The bank chosen is BNI with

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the lower interest rate compared to other banks, and the capital obtained from
investor is assumed to have interest paid periodically by a factor of 10.5%.
Table 7.43. Source Proportion of Capital Investment
Capital Source Percentage (%) Capital Share (USD) Interest Rate (%)
BNI 70 55,381,140 9.75
Investor 30 23,734,774 10.5
The loan is paid with the assumption of 10 years, with each year paid the
same value of initial loan. This mechanism provides the small value of loan
payment. The detailed calculation regarding loan interest is provided below.
Table 7.44. Loan Interest from Bank
Initial Loan Loan Interest Loan Payment Total Payment Loan after
Year
(USD) (USD) (USD) (USD) Payment (USD)
0 55,381,140 - - - 55,381,140
1 55,381,140 5,399,661 5,538,114 10,937,775 49,843,026
2 49,843,026 4,859,695 5,538,114 10,397,809 44,304,912
3 44,304,912 4,319,729 5,538,114 9,857,843 38,766,798
4 38,766,798 3,779,763 5,538,114 9,317,877 33,228,684
5 33,228,684 3,239,797 5,538,114 8,777,911 27,690,570
6 27,690,570 2,699,831 5,538,114 8,237,945 22,152,456
7 22,152,456 2,159,864 5,538,114 7,697,978 16,614,342
8 16,614,342 1,619,898 5,538,114 7,158,012 11,076,228
9 11,076,228 1,079,932 5,538,114 6,618,046 5,538,114
10 5,538,114 539,966 5,538,114 6,078,080 0

Table 7.45. Loan Interest from Investor


Initial Loan Loan Interest Loan Payment Total Payment Loan after
Year
(USD) (USD) (USD) (USD) Payment (USD)
0 23,734,774 23,734,774
1 23,734,774 2,492,151 2,373,477 4,865,629 21,361,297
2 21,361,297 2,242,936 2,373,477 4,616,414 18,987,819
3 18,987,819 1,993,721 2,373,477 4,367,198 16,614,342
4 16,614,342 1,744,506 2,373,477 4,117,983 14,240,864
5 14,240,864 1,495,291 2,373,477 3,868,768 11,867,387
6 11,867,387 1,246,076 2,373,477 3,619,553 9,493,910
7 9,493,910 996,861 2,373,477 3,370,338 7,120,432
8 7,120,432 747,645 2,373,477 3,121,123 4,746,955
9 4,746,955 498,430 2,373,477 2,871,908 2,373,477
10 2,373,477 249,215 2,373,477 2,622,693 0

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Table 7.46. Total Loan Interest from Bank and Investor

Year Interest
1 7,891,812
2 7,102,631
3 6,313,450
4 5,524,269
5 4,735,087
6 3,945,906
7 3,156,725
8 2,367,544
9 1,578,362
10 789,181
Total 43,404,968
7.4.2. Revenue
The plant produces high-octane gasoline as main product, DME-isobutane
and oxygen as byproduct. The calculation of revenue considers the production
capacity and market price of product and byproducts. The revenue is determined to
be 20,791,552 USD/year, with detail calculation provided in the following table.
Table 7.47. Revenue Calculation
Capacity Capacity Price Revenue
Product
(ton/h) (ton/year) (USD/ton) (USD)
Gasoline 2.213 17,527 740 12,969,950
DME-Isobutane 0.192 1,521 653 992,978
Oxygen 5.748 45,524 150 6,828,624
Total Revenue 20,791,552
7.4.3. Cost Breakdown
For the basic of sensitivity analysis, it is important to know which expense
shares the most to produce one unit of product. Hence, cost breakdown analysis
must be conducted. The share percentage is calculated on the basis of annual cost.
Since capital investment comes only in year 2020 and 2040 as salvage value, the
amount of capital investment annually needs to be calculated by a factor of A/P for
capital investment and A/F for salvage value. The calculation process is tabulated
below.
Table 7.48. Cost Breakdown

Component Average Annual Cost (USD) Share Percentage (%)


Capital Investment 10,592,039 38.74
Raw Material 221,277 0.81
Catalyst 65,335 0.24

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Table 7.48. Cost Breakdown (cont’d)


Component Average Annual Cost (USD) Share Percentage (%)
Labour Salary 227,136 0.83
Utility 9,787,716 35.80
Maintenance 2,748,764 10.05
Local Tax 46,937 0.17
Insurance 399,459 1.46
Safety and Protection 2,000 0.01
Executive Salary 1,077,421 3.94
Marketing and Communication 2,147 0.01
Loan Interest 2,170,248 7.94
TOTAL 27,340,478 100.00

Executive Salary Marketing and Loan Interest


Insurance Safety and 4% Communication 8%
1% Protection 0%
0%
Maintenance
10% Capital
Local Tax Investment
0% 39%

Utility
36%

Raw Material
Labour 1%
Salary Catalyst
1% 0%

Figure 7.3. Cost Breakdown


7.4.4. Cash Flow
Cash flow visualizes the inflow and outflow in the form of cash through
period of time from the beginning to the end of the project. In making cash flow,
the component used are listed below.
 Year
 Capacity and Price
 Revenue = Total income
 OPEX
 Maintenance Cost
 Depreciation
 Cash Expenses
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 Total Expenses = Cash Expenses + Depreciation


 Before Tax Cash Flow = Gross Profit = Revenue – Cash Expenses (without
depreciation)
 Net Profit Before Tax (NPBT) = Revenue – Total Expenses
 Net Profit After Tax (NPAT) = Revenue – Total Expenses – Income Tax
 Income Tax = (Revenue – Total Expenses) x Tax
 After Tax Cash Flow = Net profit + Depreciation = Revenue – Cash
Expenses – Income Tax
 Cumulative Cash Flow
To simplify, there are two segments in the cash flow, which are after tax
cash flow and before tax cash flow. The inflow of the cash flow comes from the
revenue of selling the product, and the outflow of the cash flow comes from capital
and operating cost. To calculate income tax, depreciation must be included as it will
be reducing factor to the income tax. Income tax is taken with the rate of 25%. The
profit after inclusion of depreciation is called the net profit. Production capacity is
determined to be 70% and 90% in the initial operation (first two years), followed
by full capacity, and closed by 90% and 70% at the end of production time (last two
years).
The cash flow is tabulated in the appendix, and visually represented here.
20,000,000

0
2026

2031
2020
2021
2022
2023
2024
2025

2027
2028
2029
2030

2032
2033
2034
2035
2036
2037
2038
2039
2040

-20,000,000

-40,000,000

-60,000,000

-80,000,000

-100,000,000
Year

Before Tax Cash Flow After Tax Cash Flow

Figure 7.4. Cash Flow

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Figure 7.5. Cumulative Cash Flow


It can be seen that in the first three years, negative cash flow happens in the
project. As the project goes on, a positive cash flow is obtained. Whether the project
is advantageous economically will be analysed in profitability analysis using the
cash flow.
7.4.5. Determining WACC
Profitability analysis in the next section needs the term Weighted Average
Cost Capital (WACC). Basically, WACC is the measure of minimum return of
capital investment that must be paid by the company to the investor, bank, or
another capital investment provider. In profitability analysis, Minimum Attractive
Rate of Return is calculated as the same value as WACC.
To calculate WACC, the formula used is stated as follow.
𝐸 𝐷
𝑊𝐴𝐶𝐶 = 𝑅𝑒 + 𝑅
𝐸+𝐷 𝐸+𝐷 𝑑
𝑅𝑒 = Riskfree Rate − 𝛽(market return − riskfree rate)
𝑅𝑑 = bank interest rate(1 − tax rate)
with:
𝐸
= rate of equity = fraction of investment coming from investor
𝐸+𝐷
𝐷
= rate of debt = fraction of investment coming from loan
𝐸+𝐷

𝑅𝑒 = cost of equity
𝑅𝑑 = cost of debt
Cost of debt refers to the effective rate a company pays on its current debt.
On the other hand, cost of equity is the return a firm theoretically pays to its equity
investors to compensate for the risk they undertake by investing their capital. For

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calculation, risk-free rate and market return is obtained from data of market risk
premia for Indonesia up to October 2018, with risk-free rate equals 8.60% and
market return equals 10.65%. Beta equity is taken for basic chemical product as the
closest estimate to the product category with the value of 1.2. The calculation
process gives WACC value to 8.54%, as can be seen on the table below.
Table 7.49. WACC Calculation

Item Value
Risk-free Rate (%) 8.60

Beta Equity 1.2


Equity Market Return (%) 10.65

Cost of Equity (%) 11.06

Rate of Equity (%) 30

Bank Interest Rate (%) 9.95

Tax Rate (%) 25


Debt
Cost of Debt (%) 7.46

Rate of Debt (%) 70


WACC (%) 8.54
7.4.6. ROI
Return on Investment (ROI) is the annual profit generated by one unit of
capital invested. The formula for calculating ROI is as follows:
𝑎𝑛𝑛𝑢𝑎𝑙 𝑛𝑒𝑡 𝑝𝑟𝑜𝑓𝑖𝑡
%𝑅𝑂𝐼 = ( 𝑖𝑛𝑣𝑒𝑠𝑡𝑒𝑑 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 ) 𝑥100

Annual net profit net profit used is obtained either before or after taxes.
Annual Net Profit used is the after tax annual net profit of $2.950.267,85 and
invested capital of $11.682.610,51. the calculation is shown by equation below.
$1,466,641
%𝑅𝑂𝐼 = ( ) 𝑥100 = 1.85%
$79,115,914
So the ROI obtained from this plant was 1.85%. From the ROI calculation,
we can see that our plant is attractive to investors because it has a pretty high rate
of return value. The ROI is calculated from the after tax cash flow.
7.4.7. IRR
Internal Rate of Return (IRR) is a measure of the maximum interest rate
paid on a project and still break even at the end of the project life. In other words,
the IRR is the interest rate when NPV = 0 so that the formula used to calculate the
IRR is:

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𝑛=𝑇
𝐶𝐹𝑛
𝑁𝑃𝑉 = ∑ − 𝑇𝐶𝐼 = 0
(1 + 𝑟)𝑛
𝑛=1

with the value of r is the IRR. Calculating cash flow by Microsoft Excel, we obtain
IRR of 6.46% from our plant. If we compare the IRR with MARR (6.46% (IRR) >
8.54% (MARR)), the difference is low but at a negative value (-2.08%).
7.4.8. NPV
Net Present Value (NPV) shows the net benefits received by a project over
the life of the project at a certain interest rate. NPV can also be interpreted as the
present value of the cash flows generated by the investment. In calculating the NPV
is necessary to determine the relevant interest rate.
A project can be counted as feasible if the NPV>0, which means the project
is profitable or provide benefits if implemented. If NPV<0, the project is not eligible
to run because it does not generate profit. Cash flow in year-n drawn into present
value with a reasonable interest rate by using the following formula:
𝐶𝐹𝑛
𝐶𝐹𝑛,0 =
(1 + 𝑖)𝑛
The NPV value is -$12,470,403, the rule of thumb of NPV is the NPV
should be positive with high interest (higher than 10%). If the NPV is negative the
project will be stopped. Our NPV is negative. It means that the project cannot be
implemented.
7.4.9. Payback Period
Payback Period is the duration (in years) of an investment will be returned.
Here is the formula for calculating payback period taking into account the Time
Value of Money:
𝑃𝑎𝑦𝑏𝑎𝑐𝑘 𝑝𝑒𝑟𝑖𝑜𝑑
𝑑𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑏𝑙𝑒 𝑓𝑖𝑥𝑒𝑑 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 + 𝑖𝑛𝑡𝑒𝑟𝑒𝑠𝑡 𝑜𝑛 𝑇𝐶𝐼 𝑑𝑢𝑟𝑖𝑛𝑔 𝑒𝑠𝑡𝑖𝑚𝑎𝑡𝑒𝑑 𝑠𝑒𝑟𝑣𝑖𝑐𝑒 𝑙𝑖𝑓𝑒
=
𝑝𝑟𝑜𝑓𝑖𝑡 𝑑𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛
𝑎𝑣𝑒𝑟𝑎𝑔𝑒 + 𝑎𝑣𝑒𝑟𝑎𝑔𝑒
𝑦𝑒𝑎𝑟 𝑦𝑒𝑎𝑟
If the payback period is less than a pre-determined period, the project is
acceptable. If the payback period exceeds the predetermined period, the project is
rejected. The payback period for this plant is 11.8 years. The payback period
matches the rule of thumb. According to the rule of thumb. the tolerable payback
period is about 10 years and should be done after all the loan are fully paid.

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7.4.10. Break Even Point


Breakeven point is a measurement system that calculates the margin of
safety by comparing the amount of revenues or units that must be sold to cover
fixed and variable costs associated with making the sales. A project will be
profitable by equating its total revenue with its total expense. The breakeven point
is a point where the total costs (expenses) and total sales (revenue) are equal, which
means there are no net profit or loss at this point.
The purpose of the BEP is to calculate the amount of sales or revenue
required to make excess revenues, also known as profits after the fixed and variable
costs are met. To calculate BEP the equation used is:
𝑅𝑒𝑣𝑒𝑛𝑢𝑒 − 𝑇𝑜𝑡𝑎𝑙 𝐶𝑜𝑠𝑡𝑠 = 0
𝑇𝑜𝑡𝑎𝑙 𝑐𝑜𝑠𝑡𝑠 = (𝑉𝑎𝑟𝑖𝑎𝑏𝑙𝑒 𝑐𝑜𝑠𝑡𝑠 𝑥 𝑁) + 𝐹𝑖𝑥𝑒𝑑 𝐶𝑜𝑠𝑡𝑠
𝑅𝑒𝑣𝑒𝑛𝑢𝑒 = 𝑃𝑟𝑖𝑐𝑒 𝑝𝑒𝑟 𝑢𝑛𝑖𝑡 𝑥 𝑁
𝐹𝑖𝑥𝑒𝑑 𝐶𝑜𝑠𝑡𝑠
𝑁=
𝑃𝑟𝑖𝑐𝑒 𝑝𝑒𝑟 𝑈𝑛𝑖𝑡 − 𝑉𝑎𝑟𝑖𝑎𝑏𝑙𝑒 𝐶𝑜𝑠𝑡𝑠
The BEP for the products are:
 Fuel: 198,545 tons
 DME-isobutane: 17,226 tons
 Oxygen: 515,698 tons
7.5. Sensitivity Analysis
The variable that used to analyze the most sensitive factor and see the effect
towards the cash flow is maintenance cost, loan interest, and executive salary. Even
though there utility cost is higher than the maintenance cost, utility price rarely
becomes fluctuated. Parameters that used in the sensitivity analysis are NPV, IRR,
and Payback Period. Below is the result.

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7.5.1. IRR Sensitivity Analysis

Deviation vs IRR
12.00%
10.00%
IRR 8.00%
6.00% Gasoline
4.00%
Oxygen
2.00%
0.00% Maintenance
-100% -50% 0% 50%
Deviation

Figure 7.6. Effect of Parameter Deviation on IRR


From the chart above, IRR affected greatly by gasoline product price. It can
be seen that increasing gasoline price will impact on increased change of IRR, while
oxygen price and maintenance cost don’t increase significantly. This plant is not
attractive to the investors and bank when the IRR is lower than MARR which is
6.46%, so the selling price cannot be decreased.
7.5.2. NPV Sensitivity Analysis

Deviation vs NPV
20,000,000.00

0.00 Gasoline
NPV

-100% -50% 0% 50%


-20,000,000.00 Oxygen
Maintenance
-40,000,000.00
Deviation

Figure 7.7. Effect of Parameter Deviation on NPV


From the graph above, the gasoline price is an important factor because the
increasing value of the gasoline price will change into a higher NPV. But, when the
maintenance cost change 20% lower than the current price product, it will be
resulted on a positive NVP, where the negative NVP is not allowed for a project
(not eligible to be implemented).

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7.5.3. Payback and Sensitivity Analysis

Deviation vs PayBack Period


20

PBP
10 Gasoline
0 Oxygen
-100% -50% 0% 50% Maintenance
Deviation

Figure 7.8. Effect of Parameter Deviation on PBP


On this graph, increasing product price will decrease payback period, except
maintenance cost because the NPV of maintenance will be positive when the
changes of deviation is lower. Increasing gasoline and oxygen price will not affect
payback period. But that means the shorter the payback period, the investment that
is put on the first year will be return shortly.
Based on three figures above, it can be concluded that the most sensitive
factor is gasoline product price. The fluctuating product prices will give a massive
impact for the profitability of this plant. The most insensitive factor is maintenance
cost. This happens because gasoline is the main product from this plant.
7.5.4. Recommendation for Enhancing Profitability Parameter
Beside increasing product price and reducing maintenance cost as shown
through the sensitivity analysis, there are some ways that can be done to enhance
the profitability parameter, so that the plant can be economically feasible.
According to Peraturan Menteri ESDM Nomor 12 Tahun 2017, for plants
utilizing renewable energy, the cost associated with electricity as utility from PLN
is reduced to 15%. The other way is the plan by government to fund the capital
invesment with a small 7% of interest. With the aid of these solutions, accompanied
by other small change of cost and product price, this project may be feasible in the
future.

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CHAPTER 8
CONCLUSION

Based on the overall plant design. several important conclusions are listed
as follow.
 This plant utilizes CO2 from Natuna and sea water in process of electrolysis
of water followed by methanol synthesis and methanol-to-gasoline.
 The plant operates in West Kalimantan, producing gasoline as the main
product, with production capacity of 167,261 barrels/year or 2.25 ton/hour.
 The production consists of five steps, which are photovoltaic electrolysis,
methanol synthesis, DME synthesis, gasoline synthesis, and gasoline
purification.
 The yield of gasoline produced is 0.492 kg gasoline/ kg sea water and 0.438
kg gasoline/ kg CO2.
 Implementation of HEN increases number of heat exchangers from 15 to
19, reducing hot utilites up to 91.2% and cold utilities up to 61.9%.
 The cold utility requirement is 4.83 MW and the hot is 0.76 MW.
 Cold utilities are supplied in the source of sea water, with the amount for
make up 72,376 kg/h. Steam requirement is 1,478.03 kg/h. Electricity is
mixed supplied using PV and PLN in the amount of 25.4 MW. Fuel of
natural gas is needed for the steam generation with amount of 67.8 kg/h.
 Main process equipments include 3 reactors, which are methanol synthesis,
DME synthesis, gasoline synthesis reactor, 3 distillation columns, 19 heat
exchangers, 3 two-phase separators, 1 three-phase separator, 1 reverse
osmosis unit, 2 filters, 1 electrolyzer, 16 pumps, 1 storage tank, and 9
compressor systems. The equipments operating in utility area include 2
tanks, 2 clarifiers, 8 pumps, 1 cooling tower, 1 deaerator, and 1 boiler.
 Most processes in the plant have major level of severity, unlikely level of
frequency, and overall medium hazard index. Area 200 has the highest
hazard index, followed by area 300 and 400.
 The plant will be built with area of 12 ha in 10 areas, which include water
treatment and electrolysis, methanol synthesis, DME and gasoline synthesis,
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gasoline purification, gasoline storage, photovoltaic array, utility, waste


water treatment, fire station, and non-technical section.
 Total capital investment is estimated to be USD 79,115,914. Average
operational cost is estimated to be USD 13,985,281.
 In cost breakdown, major share is 38.74% for capital investment, 35.80%
for utility, and 10.05% for maintenance.
 Capital source is fulfilled by bank loan with the amount of 70% and investor
30%.
 There are three products of this plant, consisting of gasoline, DME-
isobutane, and oxygen. The fuel will be sold to Pertamina main fuel terminal
at a price of 1059 USD/ton with a capacity of 2.213 ton/hour. The DME-
isobutane will be sold at 653 USD/ton with a capacity of 0.192 ton/hour and
the oxygen will be sold at 156 USD/ton with a capacity of 5.748 ton/hour.
 Profitability analysis gives IRR of 6.46%, ROI of 1.44%, NPV of –USD
12,470,000, and payback period of 11.8 years. VEP value is 198,545 tonnes
gasoline, 17,226 tonnes DME-isobutane, and 515,698 tonnes oxygen. Based
on profitability parameter, the plant has not been an interesting investment.
 In sensitivity analysis, gasoline price is the most sensitive among others.
 The economic aspect can be enhanced with the aid of government in the
form of incentive, typically in reducing electricity utility cost, increasing
product price, and reducing loan interest.

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REFERENCES

Ahn, J., Temel, B. and Iglesia, E. (2009) ‘Selective homologation routes to


2,2,3trimethylbutane on solid acids’ Angew. Chem. Int. Ed Engl. Vol. 48,
No.21, pp. 3814–3816.
Atsonios, K., et al. (2016) Thermocatalytic CO2 Hydrogenation for Methanol and
Ethanol Production: Process Improvements. International Journal of
Hydrogen Energy. Vol. 41. pp 792-806.
Branan, Carl. (2002). Rules of Thumb for Chemical Engineers. Houston: El Sevier.
Centi, G. and Siglinda P. (2009) Opportunities and Prospects in the Chemical
Recycling of Carbon Dioxide to Fuels. Journal of Catalysis Today. Vol. 149.
pp. 191-205.
Mollavali, M., et al. (2008) ‘Intrinsic Kinetics Study of Dimethyl Ether Synthesis
from Methanol on γ-Al2O3 Catalysts’ Ind. Eng. Chem. Res. Vol. 47, No. 9,
pp. 3265–3273.
Mignard, D. and C. Pritchard. Processes for the Synthesis of Liquid Fuels from CO2
and Marine Energy. Institution of Chemical Engineers. Vol. 84. Pp 828-836.
Natuna discovery | Global CCS Institute. 2018. 6.2 Natuna discovery | Global CCS
Institute. [ONLINE] Available at:
https://hub.globalccsinstitute.com/publications/assessment-capture-and-
storage-potential-co2-co-produced-natural-gas-south-east-asia/62-natuna-
discovery. [Accessed 03 December 2018].
Seider, W. D., Seader, J. D. and Lewin, D. R. (2003). Product and Process Design
Principles, John Wiley and Sons, Inc.
Sierra, I, et al. (2013) Kinetic Modelling for the Dehydration of Methanol to
Dimethyl Ether over Gamma-Alumina, Chemical Engineering
Transactions, Vol. 32, pp. 613-618.
Smith, Robin. (2005). Chemical Process Design and Integration, 2nd edition.
Centre of Process Integration, University of Manchester, UK.
Tan, E. (2015) Thermochemical Research Pathway to High-Octane Gasoline
Blendstock Through Methanol/ Dimethyl Ether Intermediates, Pacific
Northwest National Laboratory.

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Vilbrandt, F. C. (1959). Chemical Engineering Plant Design. United State:
McGraw-Hill Inc.
William G. Sullivan. 2019. Engineering Economy, 17th Edition. Virginia
Polytechnic Institute and State University.

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APPENDICES

APPENDIX A. MASS BALANCE


Table A.1. Mass balance of F-101 (Filtration 1)
Mass Flow In
Mass Flow Out (kg/hr)
Component (kg/hr)
102 103 104
Phosphate 0.00 0.00 0.00
Nitrate 0.00 0.00 0.00
Silicate (SiO32-) 0.00 0.00 0.00
Chloride (Cl-) 24.80 24.80 0.00
Sodium (Na+) 13.79 13.79 0.00
Sulfate (SO42-) 3.46 3.46 0.00
Magnesium (Mg2+) 1.65 1.65 0.00
Calcium (Ca2+) 0.52 0.52 0.00
Potassium (K+) 0.50 0.50 0.00
Bicarbonate(HCO3-) 0.18 0.18 0.00
Strontium (Sr2+) 0.02 0.02 0.00
Bromide (Br-) 0.08 0.08 0.00
Borate (BO33-) 0.03 0.03 0.00
Fluoride (F-) 0.00 0.00 0.00
Total dissolved solids
45.05 45.05 0.00
(TDS)
DO 0.01 0.01 0.00
Others 1,216.30 608.15 608.15
Water 36,019.48 36,019.30 0.18
Hydrogen 0.00 0.00 0.00
Oxygen 0.00 0.00 0.00
Methanol 0.00 0.00 0.00
Total 37,325.87 36,717.54 608.33

Table A.2. Mass balance of F-102 (Filtration 2)


Mass Flow In
Mass Flow Out (kg/hr)
Component (kg/hr)
103 105 106
Phosphate 0.00 0.00 0.00
Nitrate 0.00 0.00 0.00
Silicate (SiO32-) 0.00 0.00 0.00
Chloride (Cl-) 24.80 24.80 0.00
Sodium (Na+) 13.79 13.79 0.00
Sulfate (SO42-) 3.46 3.46 0.00
Magnesium (Mg2+) 1.65 1.65 0.00
Calcium (Ca2+) 0.52 0.52 0.00
Potassium (K+) 0.50 0.50 0.00
Bicarbonate(HCO3-) 0.18 0.18 0.00

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Strontium (Sr2+) 0.02 0.02 0.00


Bromide (Br-) 0.08 0.08 0.00
Borate (BO33-) 0.03 0.03 0.00
Fluoride (F-) 0.00 0.00 0.00
Total dissolved solids
45.05 45.05 0.00
(TDS)
DO 0.01 0.01 0.00
Others 608.15 0.00 608.15
Water 36,019.30 36,019.12 0.18
Hydrogen 0.00 0.00 0.00
Oxygen 0.00 0.00 0.00
Methanol 0.00 0.00 0.00
Total 36,717.54 36,109.21 608.33

Table A.3. Mass balance of F-103 (Reverse Osmosis)


Mass Flow Out
Mass Flow In (kg/hr)
Component (kg/hr)
105 114 110
Phosphate 0.00 0.00 0.00
Nitrate 0.00 0.00 0.00
Silicate (SiO32-) 0.00 0.00 0.00
Chloride (Cl-) 24.80 0.00 24.80
Sodium (Na+) 13.79 0.00 13.79
Sulfate (SO42-) 3.46 0.00 0.00
Magnesium (Mg2+) 1.65 0.00 0.00
Calcium (Ca2+) 0.52 0.00 0.00
Potassium (K+) 0.50 0.00 0.00
Bicarbonate(HCO3-) 0.18 0.00 0.00
Strontium (Sr2+) 0.02 0.00 0.00
Bromide (Br-) 0.08 0.00 0.00
Borate (BO33-) 0.03 0.00 0.00
Fluoride (F-) 0.00 0.00 0.00
Total dissolved solids
45.05 0.00 0.00
(TDS)
DO 0.01 0.00 0.00
Others 0.00 0.00 0.00
Water 36,019.12 18,124 54,230.51
Hydrogen 0.00 0.00 0.00
Oxygen 0.00 0.00 0.00
Methanol 0.00 276 276
Total 36,109.21 18,400 54,506.52

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Table A.4. Mass balance R-101 (AEL Electrolyzer)


Mass Flow In
Mass Flow Out (kg/hr)
Component (kg/hr)
110 111 112 113
Phosphate 0.00 0.00 0.00 0.00
Nitrate 0.00 0.00 0.00 0.00
Silicate (SiO32-) 0.00 0.00 0.00 0.00
Chloride (Cl-) 24.80 0.00 24.80 0.00
Sodium (Na+) 13.79 0.00 13.79 0.00
Sulfate (SO42-) 0.00 0.00 0.00 0.00
Magnesium (Mg2+) 0.00 0.00 0.00 0.00
Calcium (Ca2+) 0.00 0.00 0.00 0.00
Potassium (K+) 0.00 0.00 0.00 0.00
Bicarbonate(HCO3-) 0.00 0.00 0.00 0.00
Strontium (Sr2+) 0.00 0.00 0.00 0.00
Bromide (Br-) 0.00 0.00 0.00 0.00
Borate (BO33-) 0.00 0.00 0.00 0.00
Fluoride (F-) 0.00 0.00 0.00 0.00
Total dissolved solids
0.00 0.00 0.00 0.00
(TDS)
DO 0.00 0.00 0.00 0.00
Others 0.00 0.00 0.00 0.00
Water 54,230.51 0.00 1,881.31 0.00
Hydrogen 0.00 5,794.23 77.87 367.90
Oxygen 0.00 5.79 77.87 45,986.96
Methanol 276 0.00 276 0.00
Total 54,506.52 5,800.02 2,351.64 46,354.85

Table A.5. Mass balance of M-201 (H2O and CO2 Mixer)


Mass Flow In (kg/hr) Mass Flow Out (kg/hr)
Component
202 204 211 205
CO 0.00 0.00 102,188.83 102,188.83
CO2 0.00 42,000.00 102,703.48 144,703.48
Methanol 0.00 0.00 6,276.99 6,276.99
H2O 0.00 0.00 1,199.03 1,199.03
Hydrogen 5,800.00 0.00 29,497.99 35,297.99
Total 289,666.33 289,666.33

Table A.6. Mass balance of R-201 (Methanol Synthesis Reactor)


Mass Flow In
Mass Flow Out (kg/hr)
Component (kg/hr)
203 204
CO 102,188.83 106,766.18

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CO2 144,703.48 100,568.92


Methanol 6,276.99 33,173.73
H2O 1,199.03 19,265.25
Hydrogen 35,297.99 29,891.71
Total 289,665.79 289,665.79

Table A.7. Mass balance of S-201 (Methanol Product Separator 1)


Mass Flow In
Mass Flow Out (kg/hr)
Component (kg/hr)
213 214 216
CO 42.12 42.11 0.01
CO2 1,140.61 1,130.20 10.41
Methanol 29,007.81 2,110.31 26,897.50
H2O 18,361.03 299.95 18,061.08
Hydrogen 11.25 11.25 0.00
Total 48,562.82 48,562.82

Table A.8. Mass balance of S-202 (Methanol Product Separator 2)


Mass Flow In
Mass Flow Out (kg/hr)
Component (kg/hr)
208 209 212
CO 106,766.18 106,724.06 42.12
CO2 100,568.92 99,428.31 1,140.61
Methanol 33,173.73 4,165.92 29,007.81
H2O 19,265.25 904.21 18,361.03
Hydrogen 29,891.71 29,880.47 11.25
Total 289,665.79 289,665.79

Table A.9. Mass balance of T-201 (Methanol Purification Column)


Mass Flow In
Mass Flow Out (kg/hr)
Component (kg/hr)
219 222 226
CO 0.01 0.01 0.00
CO2 10.41 10.41 0.00
Methanol 26,897.50 26,412.37 485.13
H2O 18,061.08 150.04 17,911.04
Hydrogen 0.00 0.00 0.00
Total 44,969.00 44,969.00

Table A.10. Mass balance of R-301 (DME Synthesis Reactor)


Mass Flow In
Mass Flow Out (kg/hr)
Component (kg/hr)
303 304
CO 0.01 0.04
CO2 10.41 10.36

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Methanol 26,412.37 1,848.87


H2O 150.04 7,055.30
Hydrogen 0.00 0.00
diM-Ether 0.00 17,658.38
Total 26,572.83 26,572.95

Table A.11. Mass balance of S-401 (Two Phase Separator)


Mass Flow In
Mass Flow Out (kg/hr)
Component (kg/hr)
305 306 307
CO 0.04 0.04 0.00
CO2 10.36 10.35 0.01
Methanol 1,848.87 1,415.77 433.10
H2O 7,055.30 2,628.77 4,426.53
Hydrogen 0.00 0.00 0.00
diM-Ether 17,658.38 17,647.73 10.65
TOTAL 26,572.95 26,572.95

Table A.12. Mass balance of M-401 (Gasoline Synthesis Reactor Feed Mixer)
Mass Flow In (kg/hr) Mass Flow Out (kg/hr)
Component
306 308 309 310
CO 0.04 0.98 0.01 1.03
CO2 10.35 207.06 6.71 224.12
Methanol 1,415.77 0.00 0.00 1,415.77
H2O 2,628.77 346.69 22.59 2,998.06
Hydrogen 0.00 0.00 0.00 0.00
diM-Ether 17,647.73 17,402.98 3,934.65 38,985.36
Methane 0.00 2,107.18 25.90 2,133.09
Ethane 0.00 1,036.20 59.07 1,095.27
Ethylene 0.00 722.38 29.21 751.59
Propane 0.00 3,578.16 591.01 4,169.17
i-Butane 0.00 2,112.61 92.80 2,205.40
i-Pentane 0.00 565.10 0.00 565.10
2M-1-butene 0.00 377.70 0.00 377.70
2-Mpentane 0.00 378.58 0.00 378.58
2M1C5= 0.00 80.53 0.00 80.53
223-Mbutane 0.00 1,201.79 0.00 1,201.79
n-Heptane 0.00 224.69 0.00 224.69
2-Mhexane 0.00 61.98 0.00 61.98
2233-Mbutane 0.00 128.77 0.00 128.77
244M1pentene 0.00 37.45 0.00 37.45
224M3Epentane 0.00 801.51 0.00 801.51
n-Nonane 0.00 5.64 0.00 5.64
Hex-M-Benz 0.00 0.03 0.00 0.03
TOTAL 57,842.61 57,842.61

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Table A.13. Mass balance of R-402 (Gasoline Synthesis Reactor Vessel)


Mass Flow In
Mass Flow Out (kg/hr)
Component (kg/hr)
311 312
CO 1.03 1.00
CO2 224.12 218.03
Methanol 1,415.77 0.00
H2O 2,998.06 2,916.50
Hydrogen 0.00 0.00
diM-Ether 38,985.36 21,204.11
Methane 2,133.09 2,173.42
Ethane 1,095.27 1,124.49
Ethylene 751.59 770.48
Propane 4,169.17 4,291.82
i-Butane 2,205.40 2,873.26
i-Pentane 565.10 1,120.20
2M-1-butene 377.70 780.52
2-Mpentane 378.58 1,332.18
2M1C5= 80.53 294.72
223-Mbutane 1,201.79 6,716.45
n-Heptane 224.69 2,107.04
2-Mhexane 61.98 453.73
2233-Mbutane 128.77 1,423.59
244M1pentene 37.45 370.85
224M3Epentane 801.51 7,271.30
n-Nonane 5.64 300.56
Hex-M-Benz 0.03 98.38
TOTAL 57,842.61 57,842.61

Table A.14. Mass balance of S-401 (Two Phase Separator)


Mass Flow In
Mass Flow Out (kg/hr)
Component (kg/hr)
402 403 405 406
CO 1.00 0.99 0.00 0.01
CO2 218.03 211.26 0.06 6.70
Methanol 0.00 0.00 0.00 0.00
H2O 2,916.50 348.59 2,545.31 22.60
Hydrogen 0.00 0.00 0.00 0.00
diM-Ether 21,204.11 17,242.29 0.51 3,961.31
Methane 2,173.42 2,147.51 0.05 25.86
Ethane 1,124.49 1,065.46 0.03 59.00
Ethylene 770.48 741.32 0.00 29.16
Propane 4,291.82 3,700.27 0.04 591.50
i-Butane 2,873.26 2,143.87 0.00 729.39

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i-Pentane 1,120.20 566.13 0.00 554.07


2M-1-butene 780.52 379.23 0.00 401.29
2-Mpentane 1,332.18 382.10 0.00 950.08
2M1C5= 294.72 81.29 0.00 213.44
223-Mbutane 6,716.45 1,213.49 0.00 5,502.96
n-Heptane 2,107.04 227.14 0.00 1,879.89
2-Mhexane 453.73 62.65 0.00 391.08
2233-Mbutane 1,423.59 130.20 0.00 1,293.38
244M1pentene 370.85 37.86 0.00 332.99
224M3Epentane 7,271.30 810.17 0.00 6,461.13
n-Nonane 300.56 5.71 0.00 294.85
Hex-M-Benz 98.38 0.03 0.00 98.36
TOTAL 57,842.61 57,842.61

Table A.15. Mass balance of T-401 (Deethanizer Column)


Mass Flow In (kg/hr) Mass Flow Out (kg/hr)
Component
408 411 416
CO 0.01 0.01 0.00
CO2 6.70 6.70 0.00
Methanol 0.00 0.00 0.00
H2O 22.60 22.52 0.08
Hydrogen 0.00 0.00 0.00
diM-Ether 3,961.31 3,917.49 43.81
Methane 25.86 25.86 0.00
Ethane 59.00 59.00 0.00
Ethylene 29.16 29.16 0.00
Propane 591.50 591.48 0.02
i-Butane 729.39 92.47 636.92
i-Pentane 554.07 0.00 554.07
2M-1-butene 401.29 0.00 401.29
2-Mpentane 950.08 0.00 950.08
223-Mbutane 5,502.96 0.00 5,502.96
n-Heptane 1,879.89 0.00 1,879.89
2-Mhexane 391.08 0.00 391.08
2233-Mbutane 1,293.38 0.00 1,293.38
244M1pentene 332.99 0.00 332.99
224M3Epentane 6,461.13 0.00 6,461.13
n-Nonane 294.85 0.00 294.85
Hex-M-Benz 98.36 0.00 98.36
TOTAL 23,799.04 23,799.04

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Table A.16. Mass balance of T-402 (Debutanizer Column)


Mass Flow In (kg/hr) Mass Flow Out (kg/hr)
Component
418 421 428
CO 0.00 0.00 0.00
CO2 0.00 0.00 0.00
Methanol 0.00 0.00 0.00
H2O 0.08 0.08 0.00
Hydrogen 0.00 0.00 0.00
diM-Ether 43.81 43.81 0.00
Methane 0.00 0.00 0.00
Ethane 0.00 0.00 0.00
Ethylene 0.00 0.00 0.00
Propane 0.02 0.02 0.00
i-Butane 636.92 633.81 3.11
i-Pentane 554.07 0.86 553.22
2M-1-butene 401.29 0.30 400.99
2-Mpentane 950.08 0.00 950.08
2M1C5= 213.44 0.00 213.44
223-Mbutane 5,502.96 0.00 5,502.96
n-Heptane 1,879.89 0.00 1,879.89
2-Mhexane 391.08 0.00 391.08
2233-Mbutane 1,293.38 0.00 1,293.38
244M1pentene 332.99 0.00 332.99
224M3Epentane 6,461.13 0.00 6,461.13
n-Nonane 294.85 0.00 294.85
Hex-M-Benz 98.36 0.00 98.36
TOTAL 19,054.36 19,054.36

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APPENDIX B. PROCESS FLOW DIAGRAM

Figure B.1. Area 100


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Figure B.2. Area 200

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Figure B.3. Area 300

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Figure B.4. Area 400
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Figure B.5. Area 500

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Figure B.6. Area 600

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Figure B.7. Area 700

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APPENDIX C. PIPING AND INSTRUMENTATION DIAGRAM

Figure C.1. Area 100

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Figure C.2. Area 200

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Figure C.3. Area 300

Figure C.4. Area 400

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Figure C.5. Area 500

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Figure C.6. Area 600

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Figure C.7. Area 700

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APPENDIX D. EQUIPMENT SIZING PROCEDURE

D.1. REACTOR
 Methanol Synthesis Reactor (R-201)
The sizing method follows the design of a plug flow reactor, in terms of molar flow rate.
1. Reaction and design equation
There are three reactions which occur simultaneously. Each species is then re-symbolized
as follow for calculation convenience.
CO + 2H2 ↔ CH3OH
CO2 + H2 ↔ CO + H2O
CO2 + 3H2 ↔ CH3OH + H2O
The design equation for packed-bed reactor is illustrated as follow. Since there are five
species, there are five design equations.
𝑑𝐹𝑥
= 𝑟𝑥
𝑑𝑊
2. Rate law
(R1) CO + 2H2 ↔ CH3OH
A + 2C ↔ D
𝑃𝑑
𝑘1 𝐾𝑎 (𝑃𝑎 𝑃𝑐 1.5 − )
𝐾𝑒𝑞1 𝑃𝑐 0.5
𝑟1 =
(1 + 𝐾𝑎 𝑃𝑎 + 𝐾𝑏 𝑃𝑏 )(𝑃𝑐 0.5 + 𝐾𝑐 𝑃𝑒 )
10.99.104
𝑘1 = 2.96.107 exp(− )
𝑅𝑇
5139
−12.621
𝐾𝑒𝑞1 = 10 𝑇

(R2) CO2 + H2 ↔ CO + H2O


B+C↔A+E
𝑃𝑑 𝑃𝑎
𝑘2 𝐾𝑏 (𝑃𝑏 𝑃𝑐 − )
𝐾𝑒𝑞2
𝑟2 =
(1 + 𝐾𝑎 𝑃𝑎 + 𝐾𝑏 𝑃𝑏 )(𝑃𝑐 0.5 + 𝐾𝑐 𝑃𝑒 )
12.34.104
𝑘2 = 7.31.108 exp(− )
𝑅𝑇
2073
𝐾𝑒𝑞2 = 10− 𝑇
+2.029

(R3) CO2 + 3H2 ↔ CH3OH + H2O


B + 3C ↔ D + E
𝑃𝑑 𝑃𝑒
𝑘3 𝐾𝑏 (𝑃𝑏 𝑃𝑐 1.5 − )
𝑃𝑐 1.5 𝐾𝑒𝑞3
𝑟3 =
(1 + 𝐾𝑎 𝑃𝑎 + 𝐾𝑏 𝑃𝑏 )(𝑃𝑐 0.5 + 𝐾𝑐 𝑃𝑒 )
6.52.104
𝑘3 = 4.36.102 exp(− )
𝑅𝑇
3066
−14.650
𝐾𝑒𝑞3 = 10 𝑇

5.81.104
𝐾𝑎 = 7.99.10−7 exp ( )
𝑅𝑇
6.74.104
𝐾𝑏 = 1.20.10−7 exp ( )
𝑅𝑇
10.45.104
𝐾𝑐 = 4.13.10−11 exp(− )
𝑅𝑇
3. Relative rate law

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The relative rate law is determined through the stoichiometric coefficient balance of each
species in reaction. After that, the reaction rate for each species can be determined as follow.
𝑟𝑎 = −𝑟1 + 𝑟2
𝑟𝑏 = −𝑟2 − 𝑟3
𝑟𝑐 = −2𝑟1 − 𝑟2 − 3𝑟3
𝑟𝑑 = 𝑟1 + 𝑟3
𝑟𝑒 = 𝑟2 + 𝑟3
4. Stoichiometry
𝐹𝑎 𝑇0 𝑃
𝑐𝑎 = 𝑐𝑡0
𝐹𝑡 𝑇 𝑃0
𝐹𝑏 𝑇0 𝑃
𝑐𝑏 = 𝑐𝑡0
𝐹𝑡 𝑇 𝑃0
𝐹𝑐 𝑇0 𝑃
𝑐𝑐 = 𝑐𝑡0
𝐹𝑡 𝑇 𝑃0
𝐹𝑑 𝑇0 𝑃
𝑐𝑑 = 𝑐𝑡0
𝐹𝑡 𝑇 𝑃0
𝐹𝑒 𝑇0 𝑃
𝑐𝑒 = 𝑐𝑡0
𝐹𝑡 𝑇 𝑃0
𝑃0
𝑐𝑡0 =
𝑅𝑇0
𝐹𝑡 = 𝐹𝑎 + 𝐹𝑏 + 𝐹𝑐 + 𝐹𝑑 + 𝐹𝑒
P0 = 60 bar
T0 = 411.65 K
5. Energy balance
𝑑𝑇 −𝑟1 ∆𝐻1 − 𝑟2 ∆𝐻2 − 𝑟3 ∆𝐻3
=
𝑑𝑊 𝐹𝑎 𝑐𝑝𝑎 + 𝐹𝑏 𝑐𝑝𝑏 + 𝐹𝑐 𝑐𝑝𝑐 + 𝐹𝑑 𝑐𝑝𝑑 + 𝐹𝑒 𝑐𝑝𝑒
The value of cp and ΔH is obtained through process simulator.
∆H1 = −90700kJ/kmol
∆H2 = 41200kJ/kmol
∆H3 = −49500kJ/kmol
cpa = 31.02kJ/kmolK
cpb = 49.87kJ/kmolK
cpc = 48.74kJ/kmolK
cpd = 120.9kJ/kmolK
cpe = 75.07kJ/kmolK
6. Pressure drop
Pressure drop calculation is conducted with modified Ergun equation. The parameter 𝛼 is
used for additional differential equation relating to pressure drop.
𝑑𝑃 𝛼 𝑃02 𝑇 𝐹𝑡
=−
𝑑𝑊 2 𝑃 𝑇0 𝐹𝑡0
2𝛽𝑜
𝛼=
𝐴𝑐 (1 − ∅)𝜌𝑐 𝑃𝑜
𝐺(1 − ∅) 150(1 − ∅)𝜇
𝛽𝑜 = ( + 1.75𝐺)
𝜌𝑜 𝑔𝑐 𝐷𝑝 ∅3 𝐷𝑝
The calculation of parameter alpha is tabulated in the following table.
Table D1.1. Pressure Drop Parameter Calculation for R-201
Variable Value Unit Note
Dr 0.8 m Trial
dp 0.006 m Input

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ρc 1920 kg/m3 Input


ρ0 19.99 kg/m3 Input
P0 60 bar Input
m 10.058 kg/s Input
Ac 0.502 m2 Calculated
G 20.021 kg/s.m2 Calculated
dp/Dr 0.0075 Calculated
∅ 0.400 Calculated
𝜇 1.01.10-9 bar.s Input
𝛽𝑜 0.569876 bar/m Calculated
𝛼 3.28.10 -5
kg -1 Calculated
7. Conversion
𝐹𝑎0 − 𝐹𝑎
𝑋=( ) . 100%
𝐹𝑎
8. Dimension calculation
The equation system is simultaneously solved by Polymath.

Figure D1. 1. Polymath Listing for R-201

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Figure D1.2. Polymath Calculation Result for R-201

Figure D1. 3. Conversion versus Catalyst Weight for R-201


Through the calculation from Polymath, it is inferred that to reach optimum conversion of
30.50%, the catalyst weight needed is 3210 kg. Hence, catalyst volume and reactor volume can be
calculated.
𝑚𝑐𝑎𝑡 3210 𝑘𝑔
𝑉𝑐𝑎𝑡 = = = 1.672 𝑚3
𝜌𝑐𝑎𝑡 1920 𝑘𝑔/𝑚3
𝑉𝑐𝑎𝑡 1.672𝑚3
𝑉𝑟 = = = 2.788𝑚3
1−∅ 1 − 0.4
From the assumed diameter and area, the length of the reactor is calculated as follow.
𝑉𝑟 2.788 𝑚3
𝐿= = = 5.550 𝑚
𝐴𝑐 0.502𝑚2
After that, the space time is calculated to make sure that the calculation is proceeded
correctly.
𝑉
𝑠𝑝𝑎𝑐𝑒 𝑡𝑖𝑚𝑒 = = 3.323 𝑠
𝑣0
The range of space time predicted by Atsonios (2015) gives value of 0.5 to 20 s. Since the
space time obtained from the calculation is on the range, the calculation is confirmed to be likely
correct.
9. Material and head type selection

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Figure D1. 4. Material Selection Chart


For low to moderate temperature, the material selected is carbon steel, preferably SA-516.
For pressure higher than 400 psig, the type of head chosen is hemispherical head.
10. Shell and head thickness
Shell thickness is calculated through the higher value of longitudinal stress and
circumferential stress shell thickness.
𝑃𝑅
𝑡 (𝑙𝑜𝑛𝑔𝑖𝑡𝑢𝑑𝑖𝑛𝑎𝑙) = +𝐶
𝑆𝐸 − 0.6𝑃
𝑃𝑅
𝑡 (𝑐𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑡𝑖𝑎𝑙) = +𝐶
2𝑆𝐸 + 0.4𝑃
Head thickness for hemispherical is calculated as follow.
𝑃𝑅
𝑡= +𝐶
2𝑆𝐸 − 0.2𝑃
Table D1. 2. Head and Shell Thickness Calculation for R-201
Variable Value Unit
P 870 psia
R 400 mm
S 20000 psia
E 0.85
C 3 mm
t (longitudinal joint) 27.119 mm
t (circumferential joint) 16.132 mm
Shell Thickness 27.119 mm
Head Thickness 16.288 mm
 DME Synthesis Reactor
1. Reaction and design equation
There is a single reaction in the reactor. Each species is then re-symbolized for calculation
convenience.
2𝐶𝐻3 𝑂𝐻 ↔ 𝐶𝐻3 𝑂𝐶𝐻3 + 𝐻2 𝑂
2A ↔ B + C
The design equation is for packed-bed reactor in terms of conversion, which is represented
by species A.
𝑑𝑋 −𝑟𝑎
=
𝑑𝑊 𝐹𝑎0
2. Rate law
𝑃𝑏 𝑃𝑐 −𝐾 𝑃 𝑛 −𝐾 𝑃 𝑚 −𝐾 𝑃 𝑞
−𝑟𝑎 = 𝑘 (𝑃𝑎 2 − )𝑒 𝑐 𝑐 𝑒 𝑎 𝑎 𝑒 𝑏 𝑏
𝐾
𝐸𝑎 1 1
𝑘 = 𝑘𝑟 exp(− ( − ))
𝑅 𝑇 𝑇𝑟

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3.20.103 6.05.103
𝐾 = exp(−9.76 + + 1.07 log 𝑇 − 6.57.10−4 𝑇 + 4.90.10−8 𝑇 2 + )
𝑇 𝑇2
Table D1. 3. Parameter values for DME synthesis kinetic model
Kinetic Parameters Value Unit

Kr 2.64.10-7 mol.gcat-1h-1Pa-2
Ea 263.6 kJ.mol-1
Kc 0.171 Pa-0.36
ΔHc 3.60 kJ.mol-1
Ka 1.68.10-9 Pa-0.86
ΔHa 2.01 kJ.mol-1
Kb 3.47.10-4 Pa-0.86
ΔHb 7.20 kJ.mol-1
N 0.36
M 1.86
Q 0.86
3. Stoichiometry
𝑇0
𝑐𝑎 = 𝑐𝑎0 (1 − 𝑋) 𝑦
𝑇
𝑇0
𝑐𝑏 = 𝑐𝑏0 + 0.5𝑐𝑎0 𝑋 𝑦
𝑇
𝑇0
𝑐𝑏 = 𝑐𝑐0 + 0.5𝑐𝑎0 𝑋 𝑦
𝑇
𝑐𝑎0 = 239.0363𝑚𝑜𝑙/𝑚3
𝑐𝑏0 = 0
𝑐𝑐0 = 2.4152 𝑚𝑜𝑙/𝑚3
4. Energy balance
For adiabatic packed bed reactor with Δcp almost equals zero and pure reactant enters
reactor, the equation for energy balance is illustrated below.
𝑋(−∆𝐻𝑟 )
𝑇 = 𝑇0 +
𝑐𝑝𝑎
The value of cp and ΔH is obtained through process simulator.
∆H𝑟 = −1.2.104 kJ/kmol
cpa = 62.57kJ/kmolK
5. Pressure drop
Pressure drop calculation is conducted with modified Ergun equation. The parameter 𝛼 is
used for additional differential equation relating to pressure drop.
𝑑𝑦 𝛼 𝑇
= − (1 − 𝑒𝑋)
𝑑𝑊 2 𝑇0
2𝛽𝑜
𝛼=
𝐴𝑐 (1 − ∅)𝜌𝑐 𝑃𝑜
𝐺(1 − ∅) 150(1 − ∅)𝜇
𝛽𝑜 = ( + 1.75𝐺)
𝜌𝑜 𝑔𝑐 𝐷𝑝 ∅3 𝐷𝑝
Table D1. 4. Pressure Drop Parameter Calculation for R-301
Variable Value Unit Note
Dr 1.2 m Trial
dp 0.007 m Input
ρc 960 kg/m3 Input
ρ0 8.096 kg/m3 Input

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P0 9.997 bar Input


m 0.923 kg/s Input
Ac 1.130 m2 Calculated
G 0.816 kg/s.m2 Calculated
dp/Dr 0.005833 Calculated
∅ 0.400 Calculated
𝜇 1.01E-09 bar.s Input
𝛽𝑜 0.003671 bar/m Calculated
𝛼 1.13E-06 kg-1 Calculated
6. Dimension calculation
The differential and algebraic equations are simultaneously solved by Polymath as follow.

Figure D1. 5. Polymath Listing for R-301

Figure D1. 6. Polymath Calculation Result for R-301

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Figure D1. 7. Conversion versus Catalyst Weight for R-301


Through the calculation from Polymath, it is inferred that to reach optimum conversion of
72%, the catalyst weight needed is 4850 kg. Hence, catalyst volume and reactor volume can be
calculated.
𝑚𝑐𝑎𝑡 4850 𝑘𝑔
𝑉𝑐𝑎𝑡 = = = 5.052 𝑚3
𝜌𝑐𝑎𝑡 960 𝑘𝑔/𝑚3
𝑉𝑐𝑎𝑡 5.052𝑚3
𝑉𝑟 = = = 8.424𝑚3
1−∅ 1 − 0.4
From the assumed diameter and area, the length of the reactor is calculated as follow.
𝑉𝑟 8.424 𝑚3
𝐿= = = 7.453 𝑚
𝐴𝑐 1.130𝑚2
After that, the space time and DME productivity per catalyst weight is calculated to make
sure that the calculation is proceeded correctly.
𝑉
𝑠𝑝𝑎𝑐𝑒 𝑡𝑖𝑚𝑒 = = 44.325 𝑠
𝑣0
𝑘𝑔
𝐷𝑀𝐸 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑝𝑒𝑟 𝑐𝑎𝑡𝑎𝑙𝑦𝑠𝑡 𝑤𝑒𝑖𝑔ℎ𝑡 = 0.45 /𝑘𝑔𝑐𝑎𝑡

The optimum DME productivity provided by Tan (2015) is 0.39 kg/h/kgcat, which is not
far different with the calculated space time. This clarifies that the calculation is likely to be true.
7. Material and head type selection
Stainless steel is preferred for high temperature operation, which is supported through
material selection chart. The material selected is stainless steel SS-304. For pressure lower than 200
psig, the type of head chosen is torispherical head.
8. Shell and head thickness
Shell thickness is calculated through the higher value of longitudinal stress and
circumferential stress shell thickness.
𝑃𝑅
𝑡 (𝑙𝑜𝑛𝑔𝑖𝑡𝑢𝑑𝑖𝑛𝑎𝑙) = +𝐶
𝑆𝐸 − 0.6𝑃
𝑃𝑅
𝑡 (𝑐𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑡𝑖𝑎𝑙) = +𝐶
2𝑆𝐸 + 0.4𝑃
Head thickness for torispherical is calculated as follow.
0.885𝑃𝐿
𝑡= +𝐶
𝑆𝐸 − 0.1𝑃
The calculation for shell and head thickness is tabulated as follow.
Table D1. 5. Head and Shell Thickness Calculation for R-201
Variable Value Unit
P 144.96 Psia
R 600 Mm
S 18000 Psia
E 0.85

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C 3 mm
t (longitudinal joint) 11.717 mm
t (circumferential joint) 8.837 mm
Shell Thickness 11.717 mm
Head Thickness 8.845 mm
 Gasoline Synthesis Reactor (R-302)
Due to the abundant simultaneous multiple reactions occurring, the kinetic data for gasoline
synthesis reaction is not provided. Sizing of this reactor is then proceeded with optimum space
velocity provided by Tan (2015).
1. Feed volumetric flowrate
Inlet mass flow rate (mt0) and mass density (𝜌0 ) is obtained through simulator.
𝑚𝑡0 7968 𝑘𝑔/ℎ
𝑣0 = = = 817.65 𝑚3 /ℎ
𝜌0 9.745 𝑘𝑔/𝑚3
2. Reactor dimension
The space velocity provided by Tan (2015) is 0.69 m3/h.kgcat. Catalyst weight can then be
calculated.
𝑚3
𝑣0 817
𝑊= = ℎ = 1185 𝑘𝑔
𝑠𝑝𝑎𝑐𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑚3
0.69 /𝑘𝑔𝑐𝑎𝑡

Catalyst volume and reactor volume can then be calculated as follow.
𝑚𝑐𝑎𝑡 1185 𝑘𝑔
𝑉𝑐𝑎𝑡 = = = 0.617 𝑚3
𝜌𝑐𝑎𝑡 1920 𝑘𝑔/𝑚3
𝑉𝑐𝑎𝑡 0.617𝑚3
𝑉𝑟 = = = 1.029𝑚3
1−∅ 1 − 0.4
The assumed diameter is taken to be 0.8 m, with area of 0.502 m2. The length of the reactor
is calculated as follow.
𝑉𝑟 1.029 𝑚3
𝐿= = = 2.047 𝑚
𝐴𝑐 0.052𝑚2
After that, the space time and DME productivity per catalyst weight is calculated to make
sure that the calculation is proceeded correctly.
𝑉
𝑠𝑝𝑎𝑐𝑒 𝑡𝑖𝑚𝑒 = = 2.717 𝑠
𝑣0
3. Material and head type selection
For low to moderate temperature, the material selected is carbon steel, preferably SA-516.
For pressure lower than 200 psig, the type of head chosen is torispherical head.
4. Shell and head thickness
Shell thickness is calculated through the higher value of longitudinal stress and
circumferential stress shell thickness.
𝑃𝑅
𝑡 (𝑙𝑜𝑛𝑔𝑖𝑡𝑢𝑑𝑖𝑛𝑎𝑙) = +𝐶
𝑆𝐸 − 0.6𝑃
𝑃𝑅
𝑡 (𝑐𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑡𝑖𝑎𝑙) = +𝐶
2𝑆𝐸 + 0.4𝑃
Head thickness for torispherical is calculated as follow.
0.885𝑃𝐿
𝑡= +𝐶
𝑆𝐸 − 0.1𝑃
The calculation for shell and head thickness is tabulated as follow.
Table D1. 6. Head and Shell Thickness Calculation for R-201
Variable Value Unit
P 129.96 psia

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R 400 mm
S 18000 psia
E 0.85
C 3 mm
t (longitudinal joint) 9.415 mm
t (circumferential joint) 7.696 mm
Shell Thickness 9.415 mm
Head Thickness 7.700 mm

D.2. DISTILLATION COLUMN


 Methanol Purification Column (T-201)
1. Basic Operating and Design Data
The following basic operating and design data is obtained through process simulator.
Table D2. 1. Basic Operating and Design Data of T-201
Variable Value Unit
Feed rate 230.2798 kgmol/h
Distillate rate 104.1092 kgmol/h
Bottom rate 126.1705 kgmol/h
Reflux ratio 3
Minimum reflux ratio 1.245
Minimum tray 5.804
Actual tray 8.537
Optimum feed stage 4.785
2. Liquid and Vapor Rate
The liquid and vapor rate in rectifying and stripping section is obtained through process
simulator.
Table D2. 2. Liquid and Vapor Rate of T-201
Variable Rectifying Stripping Unit
Vm 426 235.2 kmol/h
Lm 319.5 359 kmol/h
3. Properties Data
The properties in stripping and rectifying section is obtained through process simulator and
is tabulated below.
Table D2. 3. Properties Data of T-201
Properties Rectifying Strippping Unit
Pressure 1.1 1.1 bar
Temperature 65.1 102.3 oC
Density Vap 1.261 0.642 kg/m3
Density Liq 744.04 954.28 kg/m3
Surface Tension 0.0260 0.0581 N/m
Molecular Weight 31.839 18.039 kg/kgmol
Viscosity Vap 7.12E-06 9.20E-06 Ns/m2
Viscosity Liq 3.43E-04 2.66E-04 Ns/m2
4. Column Diameter
The column diameter is estimated through the calculation of flooding velocity by K factor
obtained from the curve below.
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Figure D2. 1. Correlation of Flv, Plate Spacing, and K


(Source: Sinnott, 2010)
Initial calculation proceeds to get Flv value in order to get K factor from the chart.
𝑉𝑚 𝜌𝑣
𝐹𝐿𝑉 = ×√
𝐿𝑚 𝜌𝐿
The value of K is corrected with surface tension through the following equation.
𝜎 0.2
𝐾 ′ = 𝐾( )
0.02
Then flooding velocity is calculated as follow.
𝜌𝐿 − 𝜌𝑣
𝑢𝑓 = 𝐾 × √
𝜌𝐿
The actual velocity taken is 85% of the flooding velocity. After that, net area is calculated
through the division of gas volumetric flowrate to the corrected velocity.
𝑄𝑣
𝐴𝑛𝑒𝑡 =
0.85𝑢𝑓
The net area must be added by a factor of 12% for downcomer to provide a total minimum
area for distillation plate, and diameter is calculated from that area.
𝐴𝑛𝑒𝑡
√4 1 − 12%
𝐷=
𝜋
Table D2. 3. Diameter Calculation of T-201
Variable Rectifying Stripping Unit
Vm/Lm 1.333 0.655
Flv 0.055 0.017
K 0.110 0.105
K’ 0.116 0.130
Uf 2.813 5.010 m/s
85%uf 2.391 4.259 m/s
Net area 1.250 0.431 m2
Total area (+downcomer) 1.420 0.490 m2
Diameter 1.345 0.790 m
5. Plate Efficiency and Column Height
Calculation of plate efficiency is based on O’Connell’s efficiency.
𝐸0 = 51 − 32.5 log(𝜇𝑎 𝛼𝑎 )
The liquid viscosity and relative volatility is measured on the feed stream at the average
temperature of the distillation column. The efficiency is needed to calculate the number of actual
tray. The column height is then calculated by multiplying the tray spacing and actual tray.
Table D2. 4. Plate Efficiency and Column Height of T-201
Variable Value Unit

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o
Ta 83.70 C
𝜇𝑎 0.3152 mNs/m2
K light key 2.555
K heavy key 0.559
𝛼𝑎 4.570
E0 65.85 %
N actual 13
Plate spacing 0.6 m
Column net height 7.60 m
Top + bottom space 0.50 m
Column height 8.30 m
6. Material and Head Type
The selection of material is based on the following table. The operating temperature is on
the range of 65oC to 102oC. Since the handled fluid is not corrosive, carbon steel is chosen,
particularly SA-516.
Table D2. 5. Material Selection Guide based on Temperature

(Source: Bednar, 1961)


For pressure range of less than 200 psig, torispherical head is chosen.
7. Shell and Head Thickness
Shell thickness is calculated through the higher value of longitudinal stress and
circumferential stress shell thickness.
𝑃𝑅
𝑡 (𝑙𝑜𝑛𝑔𝑖𝑡𝑢𝑑𝑖𝑛𝑎𝑙) = +𝐶
𝑆𝐸 − 0.6𝑃
𝑃𝑅
𝑡 (𝑐𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑡𝑖𝑎𝑙) = +𝐶
2𝑆𝐸 + 0.4𝑃
Head thickness for torispherical is calculated as follow.
0.885𝑃𝐿
𝑡= +𝐶
𝑆𝐸 − 0.1𝑃
The calculation for shell and head thickness is tabulated as follow.
Table D2. 6. Head and Shell Thickness of T-201
Variable Value Unit
P 16.17 Psia
R 672.5 Mm
S 20000 Psia
E 0.85

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C 3 mm
t (longitudinal joint) 3.640 mm
t (circumferential joint) 3.320 mm
Shell Thickness 3.640 mm
Head Thickness 6.494 mm

 Deethanizer Column (T-401)


1. Basic Operating and Design Data
The following basic operating and design data is obtained through process simulator.
Table D2. 7. Basic Operating and Design Data of T-401
Variable Value Unit
Feed rate 33.577 kgmol/h
Distillate rate 9.668 kgmol/h
Bottom rate 23.909 kgmol/h
Reflux ratio 4.5
Minimum reflux ratio 2.747
Minimum tray 10.026
Actual tray 17.879
Optimum feed stage 9.102
2. Liquid and Vapor Rate
The liquid and vapor rate in rectifying and stripping section is obtained through process
simulator.
Table D2. 8. Liquid and Vapor Rate of T-401
Variable Rectifying Stripping Unit
Vm 57.79 55.11 kmol/h
Lm 47.29 78.18 kmol/h
3. Properties Data
The properties in stripping and rectifying section is obtained through process simulator and
is tabulated below.
Table D2. 9. Properties Data of T-401
Properties Rectifying Strippping Unit
Pressure 21.53 21.53 bar
Temperature 53.69 191.4 oC
Density Vap 28.558 42.389 kg/m3
Density Liq 534.38 521.3 kg/m3
Surface Tension 0.0086 0.0050 N/m
Molecular Weight 46.263 89.659 kg/kgmol
Viscosity Vap 1.02E-05 1.16E-05 Ns/m2
Viscosity Liq 8.08E-05 1.08E-04 Ns/m2
4. Column Diameter
The column diameter is estimated through the calculation of flooding velocity by K factor,
with the steps provided in the previous section (T-201).
Table D2. 10. Diameter Calculation of T-401
Variable Rectifying Stripping Unit
Vm/Lm 1.333 0.655
Flv 0.055 0.017

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K 0.110 0.105
K’ 0.116 0.130
uf 2.813 5.010 m/s
85%uf 2.391 4.259 m/s
Net area 1.250 0.431 m2
Total area (+downcomer) 1.420 0.490 m2
Diameter 1.345 0.790 m
5. Plate Efficiency and Column Height
Calculation of plate efficiency is based on O’Connell’s efficiency.
𝐸0 = 51 − 32.5 log(𝜇𝑎 𝛼𝑎 )
The liquid viscosity and relative volatility is measured on the feed stream at the average
temperature of the distillation column. The efficiency is needed to calculate the number of actual
tray. The column height is then calculated by multiplying the tray spacing and actual tray.

Table D2. 11. Plate Efficiency and Column Height of T-401


Variable Value Unit
o
Ta 122.55 C
𝜇𝑎 0.1346 mNs/m2
K light key 1.961
K heavy key 1.457
𝛼𝑎 1.346
E0 75.11 %
N actual 24
Plate spacing 0.30 m
Column net height 7.20 m
Top + bottom space 0.30 m
Column height 7.50 m
6. Material and Head Type
The selection of material is based on material selection guide table. The operating
temperature is on the range of 54oC to 191oC. Since the handled fluid is not corrosive, carbon steel
is chosen, particularly SA-516.
For pressure range of 200 psig to 400 psig, ellipsoidal head is chosen.
7. Shell and Head Thickness
Shell thickness is calculated through the higher value of longitudinal stress and
circumferential stress shell thickness.
𝑃𝑅
𝑡 (𝑙𝑜𝑛𝑔𝑖𝑡𝑢𝑑𝑖𝑛𝑎𝑙) = +𝐶
𝑆𝐸 − 0.6𝑃
𝑃𝑅
𝑡 (𝑐𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑡𝑖𝑎𝑙) = +𝐶
2𝑆𝐸 + 0.4𝑃
Head thickness for ellipsoidal is calculated as follow.
𝑃𝐷
𝑡= +𝐶
2𝑆𝐸 − 0.2𝑃
The calculation for shell and head thickness is tabulated as follow.
Table D2. 11. Head and Shell Thickness of T-401
Variable Value Unit
P 316.49 Psia
R 263.03 Mm
S 20000 Psia
E 0.85

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C 3 mm
t (longitudinal joint) 10.952 mm
t (circumferential joint) 8.439 mm
Shell Thickness 10.952 mm
Head Thickness 10.906 mm
 Debutanizer Column (T-402)
1. Basic Operating and Design Data
The following basic operating and design data is obtained through process simulator.
Table D2. 12. Basic Operating and Design Data of T-402
Variable Value Unit
Feed rate 23.9088 kgmol/h
Distillate rate 2.8604 kgmol/h
Bottom rate 1.0000 kgmol/h
Reflux ratio 5
Minimum reflux ratio 3.687
Minimum tray 8.738
Actual tray 12.986
Optimum feed stage 6.535
2. Liquid and Vapor Rate
The liquid and vapor rate in rectifying and stripping section is obtained through process
simulator.
Table D2. 13. Liquid and Vapor Rate of T-402
Variable Rectifying Stripping Unit
Vm 17.16 21.54 kmol/h
Lm 14.13 42.59 kmol/h
3. Properties Data
The properties in stripping and rectifying section is obtained through process simulator and
is tabulated below.
Table D2. 14. Properties Data of T-402
Properties Rectifying Strippping Unit
Pressure 13.79 13.79 bar
Temperature 121.6 203.8 oC
Density Vap 34.887 48.676 kg/m3
Density Liq 508.89 481.8 kg/m3
Surface Tension 0.0051 0.0032 N/m
Molecular Weight 65.987 102.41 kg/kgmol
Viscosity Vap 1.07E-05 1.15E-03 Ns/m2
Viscosity Liq 9.97E-05 8.74E-05 Ns/m2
4. Column Diameter
The column diameter is estimated through the calculation of flooding velocity by K factor,
with the steps provided in the previous section (T-201).
Table D2. 15. Diameter Calculation of T-402
Variable Rectifying Stripping Unit
Vm/Lm 1.214 0.506
Flv 0.318 0.161
K 0.042 0.050

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K’ 0.032 0.035
uf 0.118 0.103 m/s
85%uf 0.100 0.088 m/s
Net area 0.090 0.143 m2
Total area (+downcomer) 0.102 0.163 m2
Diameter 0.361 0.456 m
5. Plate Efficiency and Column Height
Calculation of plate efficiency is based on O’Connell’s efficiency.
𝐸0 = 51 − 32.5 log(𝜇𝑎 𝛼𝑎 )
The liquid viscosity and relative volatility is measured on the feed stream at the average
temperature of the distillation column. The efficiency is needed to calculate the number of actual
tray. The column height is then calculated by multiplying the tray spacing and actual tray.
Table D2. 16. Plate Efficiency and Column Height of T-402
Variable Value Unit
o
Ta 162.70 C
𝜇𝑎 0.1174 mNs/m2
K light key 3.321
K heavy key 1.184
𝛼𝑎 2.806
E0 66.67 %
N actual 20
Plate spacing 0.30 m
Column net height 6.00 m
Top + bottom space 0.30 m
Column height 6.30 m
6. Material and Head Type
The selection of material is based on material selection guide table. The operating
temperature is on the range of 121oC to 204oC. Since the handled fluid is not corrosive, carbon steel
is chosen, particularly SA-516.
For pressure range of 200 psig to 400 psig, ellipsoidal head is chosen.
7. Shell and Head Thickness
Shell thickness is calculated through the higher value of longitudinal stress and
circumferential stress shell thickness.
𝑃𝑅
𝑡 (𝑙𝑜𝑛𝑔𝑖𝑡𝑢𝑑𝑖𝑛𝑎𝑙) = +𝐶
𝑆𝐸 − 0.6𝑃
𝑃𝑅
𝑡 (𝑐𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑡𝑖𝑎𝑙) = +𝐶
2𝑆𝐸 + 0.4𝑃
Head thickness for ellipsoidal is calculated as follow.
𝑃𝐷
𝑡= +𝐶
2𝑆𝐸 − 0.2𝑃
The calculation for shell and head thickness is tabulated as follow.
Table D2. 17. Head and Shell Thickness of T-402
Variable Value Unit
P 202.71 Psia
R 180.45 Mm
S 20000 Psia
E 0.85
C 3 mm
t (longitudinal joint) 8.167 mm
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t (circumferential joint) 7.073 mm


Shell Thickness 8.167 mm
Head Thickness 8.154 mm

D.3. SEPARATOR
 Two-Phase Separator
Vertical two-phase separator is designed through calculating settling velocity (ut). Towler
and Sinnott (2012) provides general calculation for settling velocity as follow.
𝜌𝐿 − 𝜌𝑣 1/2
𝑢𝑡 = 0.07 ( )
𝜌𝑣
In the absence of demister, the actual gas velocity is calculated by multiplying settling
velocity with a factor of 0.15. Area is then calculated by dividing gas volumetric flow rate to actual
gas velocity.
𝑉𝑣
𝐴=
𝑢𝑠
Liquid level is calculated for 10-minutes holdup and added by a factor of 0.3 m for level
controller.
𝐻𝑙 = 𝑉𝑙 . (10 𝑚𝑖𝑛𝑢𝑡𝑒𝑠) + 0.3 𝑚
Inlet height is the sum of liquid height and 0.5 diameter. The separator height is the sum of
inlet height and diameter.
𝐻𝑖 = 𝐻𝑙 + 0.5𝐷
𝐻 = 𝐻𝑖 + 𝐷
The vessel thickness is determined by the higher value of longitudinal joint and
circumferential joint vessel thickness calculation.
𝑃𝑅
𝑡 (𝑙𝑜𝑛𝑔𝑖𝑡𝑢𝑑𝑖𝑛𝑎𝑙) = +𝐶
𝑆𝐸 − 0.6𝑃
𝑃𝑅
𝑡 (𝑐𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑡𝑖𝑎𝑙) = +𝐶
2𝑆𝐸 + 0.4𝑃
The head thickness is calculated by the equations below.
0.885𝑃𝐿
Torispherical :𝑡= +𝐶
𝑆𝐸−0.1𝑃
𝑃𝐷
Ellipsoidal :𝑡= +𝐶
2𝑆𝐸−0.2𝑃
𝑃𝑅
Hemispherical :𝑡= +𝐶
2𝑆𝐸−0.2𝑃
There are three two-phase separators operating in the plant. The calculation for each
separator is tabulated below.
Table D3. 1. Design Calculation of First Stage Methanol Separator
Variable Value Unit
m liquid 6070 kg/h
m vapor 30140 kg/h
ρ liquid 844.50 kg/m3
ρ vapor 24.85 kg/m3
V liquid 0.0020 m3/s
V vapor 0.3369 m3/s
ut (settling velocity) 0.402 m/s
us (actual gas velocity) 0.201 m/s
A 1.676 m2
D 1.461 M
Hl (liquid depth) 1.015 M
Hi (inlet height) 1.745 M

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H 3.207 M
P 870 psia
R 730.605 mm
S 20000 psia
E 0.85
C 3 mm
t (longitudinal) 41.574 mm
t (circumferential) 21.505 mm
Shell thickness 41.574 mm
Bottom head type Flat
Bottom head thickness 13.498 mm
Top head type Hemispherical
Top head thickness 21.791 mm

Table D3. 2. Design Calculation of Second Stage Methanol Separator


Variable Value Unit
m liquid 5621 kg/h
m vapor 449.2 kg/h
ρ liquid 859.70 kg/m3
ρ vapor 0.25 kg/m3
V liquid 0.0018 m3/s
V vapor 0.5046 m3/s
ut (settling velocity) 4.127 m/s
us (actual gas velocity) 0.619 m/s
A 0.815 m2
D 1.019 M
Hl (liquid depth) 1.637 M
Hi (inlet height) 2.146 M
H 3.165 M
P 2.9 psia
R 509.504 mm
S 20000 psia
E 0.85
C 3 mm
t (longitudinal) 6.319 mm
t (circumferential) 6.043 mm
Shell thickness 6.319 mm
Bottom head type Flat
Bottom head thickness 5.206 mm
Top head type Torispherical
Top head thickness 6.102 mm

Table D3. 3. Design Calculation of DME Reactor Effluent Separator


Variable Value Unit
m liquid 608.8 kg/h
m vapor 2713 kg/h
ρ liquid 899.50 kg/m3
ρ vapor 11.80 kg/m3

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V liquid 0.0002 m3/s


V vapor 0.0639 m3/s
ut (settling velocity) 0.607 m/s
us (actual gas velocity) 0.091 m/s
A 0.701 m2
D 0.945 M
Hl (liquid depth) 0.461 M
Hi (inlet height) 0.933 M
H 1.879 M
P 140 psia
R 472.582 mm
S 20000 psia
E 0.85
C 3 mm
t (longitudinal) 9.911 mm
t (circumferential) 7.943 mm
Shell thickness 9.911 mm
Bottom head type Flat
Top head thickness 7.005 Mm
Top head type Hemispherical
Top head thickness 6.014 mm
 Three-Phase Separator
The three-phase separator design calculation is based on method by Hussein et al. (2005).
The principle is to calculate drag coefficient and minimum diameter for water droplet settling, with
liquid and gas capacity constraint.
𝜌0 − 𝜌𝑔 𝑑𝑚 1
𝑢 = 0.01186(( ) )2
𝜌𝑔 𝐶𝑑
𝜌𝑔 𝑑𝑚 𝑢
𝑅𝑒 = 0.0049
𝜇𝑔
3 24
𝐶𝑑 = 0.34 + 0.5 +
𝑅𝑒 𝑅𝑒
The liquid and gas capacity constraint is illustrated below.
𝑇𝑍𝑄𝑔 𝜌𝑔 𝐶𝑑
𝐷𝐿 = 420( )( )0.5
𝑃 𝑑𝑚 (𝜌0 − 𝜌𝑔 )
𝐷2 𝐿 = 1.429𝑄0 𝑡0 + 𝑄0 𝑡𝑤
1. Input parameters
Table D3. 4. Input Parameter of S-401 Calculation
Variable Value Unit Note
Qg 2.439 mmscfd Gas rate
Qo 662.2 bbl/d Oil rate
Qw 48.98 bbl/d Water rate
ρ'o 77 o
API Oil density
µo 0.2358 cP Oil viscosity
γw 0.9978 Water specific gravity
Γ 0.54 Gas specific gravity
Z 0.89 Gas compressibility
P 105 psia Operating pressure
o
T' 173 F Operating temperature
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tw 5 minutes Water retention time


to 5 minutes Oil retention time
µg 0.01059 cP Gas viscosity
dm,w 500 Micron Smallest water droplet size removed
dm,o 100 Micron Smallest oil droplet size removed
NLL 50% Normal liquid level due to oil and water

2. Drag coefficient and water droplet diameter


Table D3. 5. Drag Coefficient and Water Droplet Diameter Calculation for S-401
Variable Value Unit
Cd assumed 3.80
U 0.76 ft/s
Re 10
Cd calculated 3.83
Error 0.00
H0/D 0.350
DL 86 in.ft
2
DL 5081.381 in2.ft
3. Dimension
As per GPSA, typical horizontal L/D ratios are normally in the range of 2.5 to 5, and the
slenderness ratio (SR) is typically 3 to 5. For SR = 3, the diameter and length is calculated.
L = 1.707 m
D = 0.762 m
L/D = 2.24
4. Material, shell and head thickness
From the perspective of temperature, the chosen material is SA-516. For low pressure
operation, the type of head chosen is torispherical. The calculation of shell and head thickness is
similar to the previous sections.
Table D3. 6. Shell and Head Thickness of S-401
Variable Value Unit
P 105 Psia
R 381 Mm
S 20000 Psia
E 0.85
C 3 Mm
t (longitudinal) 8.362 Mm
t (circumferential) 7.175 Mm
Shell thickness 8.362 Mm
Head thickness 6.000 Mm

D.4. HEAT EXCHANGER


There are two main types of heat exchanger, such as shell and tube heat exchanger and
plate and frame heat exchanger.
 Shell and Tube Heat Exchanger
This type of heat exchanger is covering almost all heat exchanger in this plant due to its
capacity and ability in handling large pressure and temperature different. The exchangers which fall
into this category in this plant are majority of heat exchangers, condensers and reboilers. Reboiler
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use a little bit different type of shell and tube heat exchanger which is kettle shell and tube that has
an extra room for vapor to go back to distillation column. The steps in designing this type of heat
exchanger is listed below.
1. Determine heat flow which is exchanged, the mass flow and physical properties of each
fluid passing the heat exchanger. Physical properties needed are pressure, temperature, heat
capacity (Cp), conductivity (k), density (ρ) and viscosity (μ).
2. Assume the value of overall heat transfer coefficient for the first guess. The first assumption
can be made by using the table below.

Table D4. 1. Typical Overall Coefficicents

(Source : Brownell and Young, 1959)


3. Calculate the Log Mean Temperature Different (LMTD)
∆𝑇1 = (𝑇2 − 𝑡1 )
∆𝑇1 = (𝑇1 − 𝑡2 )
∆𝑇1 − ∆𝑇2
∆𝑇𝐿𝑀𝑇𝐷 =
∆𝑇
ln ( 1 )
∆𝑇2
After, that determine the correction factor 𝐹𝑇 to calculate corrected LMTD using the value
of R and P, then determine the 𝐹𝑇 using the figure below.
𝑡1 − 𝑡2
𝑅=
𝑇2 − 𝑇1

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𝑇2 − 𝑇1
𝑃=
𝑡2 − 𝑡1

Figure D4. 1. Correction Factor Correlation


(Source: J.P.Holman,1959)
4. Determine the tube and shell properties. The properties used in this plant is almost the same
for each exchanger, the typical value from heuristic is used. The value is shown in Table
I.2 and I.3. The difference is located at the number of tube passes in shell which can be
manipulated between 1 until 8.
Table D4. 2. Typical Tube Properties
Use 3/4 intube, 1.6 mm thickness, 4.88 m long
Outer Diameter 19.05 Mm
Thickness 1.6 Mm
Inner Diameter 15.85 Mm
Tube length 4.88 M
Area per tube 0.292 m2
Number of tubes 14 tubes
Tube cross sectional area 0.00020 m2
Area per pass 0.00279 m2
Volumetric flow 0.00033 m3/s
Tube side velocity, ut 0.11987 m/s

Table D4. 3. Typical Shell Properties


Tube pitch, Pt 23.8125 mm
ID shell 21.25 In
Pitch Type Triangle
Number of Tube Passes in Shell 2
K1 249.000
n1 2.207
Tube bundle diameter, Db 5.2 mm
Num of tubes in center, Nr 0 tubes
Shell diameter 539.75 mm
Trial baffle spacing 107.95 mm
Cross flow area, As 11653.20 mm2
Equivalent diameter, de 13.53 mm
Volumetric flow rate 0.01 m3/s
Shell side velocity 1.05 m/s
5. Calculate Heat Transfer Coefficient in Tube and Shell

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𝐷𝐺
𝑅𝑒 =
𝜇
Determine 𝑗ℎ using Re data and L/D, baffle cut using figures below.

Table D4. 1. Tube-side Heat Transfer Factor


(Source: J.P.Holman,1959)

Figure D4. 2. Shell-side Heat Transfer Factor


(Source: J.P.Holman,1959)
1
𝑘 𝑐𝜇 3
ℎ𝑜 = 𝑗𝐻
𝑑𝑒 𝑘
1
𝑘 𝑐𝜇 3
ℎ𝑖 = 𝑗𝐻
𝑑𝑒 𝑘
𝐼𝐷
ℎ𝑖𝑜 = ℎ𝑖 ( )
𝑂𝐷
6. Calculate Heat Transfer Coefficient in Tube and Shell
Fouling factor of the both fluid is determined using table below for known fluids.
Table D. 3. Typical Fouling Factor

(Source: J.P.Holman,1959)
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ℎ𝑖𝑜 ℎ𝑜
𝑈𝑐 =
ℎ𝑖𝑜 + ℎ𝑜
7. Using newton-raphson method, change assumed U until 𝑈 = 𝑈𝑐 .
When using HTRI application to calculate and draw the heat exchangers, the steps that this
plant to do are listed below.
1. Choose Shell and Tube Exchanger.
2. Choose “Design” and fill the red box with typical data and simulation data. Property
worksheet in Hot Fluid Properties and Cold Fluid Properties must be filled as well.

Figure D4. 3. HTRI Input Summary

Figure D4. 4. HTRI Input Process

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Figure D4. 5. HTRI Input Hot Fluid Properties

Figure D4. 5. HTRI Input Cold Fluid Properties


3. TEMA type in Input Summary should be defined as well based on literature.
TEMA Designs Available:
a. Straight Tube and Fixed Tube Sheet: Types BEM, AEM, NEN, etc
This design is the simplest design and most economical in most cases. The tube sheet is
welded to the shell and heads are bolts to the tube sheet.
Advantages:
- Less costly than removable bundle designs
- Capable of multiple pass designs
Limitations:
- Shell side can only be cleaned by a chemical solution
- No ability to absorb thermal expansion between the outer shell and tube bundle
b. Removable Bundle and Externally Sealed Floating Tube sheet: Type AEW, BEW

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This design allows for the tube bundle to be removed for inspection and cleaning. With
Basco’s OP design, the head can be removed for inspection of the interior of the tubes, without
releasing the pressure on the shell side process.
Advantages:
- Floating tube sheet allows for Thermal Expansion
- Shell side can be inspected and mechanical cleaned
- Tube bundle can be replaced or repaired without breaking the piping on the shell side.
- Maximum surface area for specified shell diameter for a removable bundle
Limitations:
- Tube side passes are limited to one or two passes
- Packing material limits operational pressure and temperature
c. Removable Bundle, Outside Packed Head: Type BEP, AEP, etc.
This design allows for the easy removal, inspection and cleaning of the shell side circuit
and shell interior without removing the floating head cover. Special floating tube sheet prevents
intermixing of fluids. In most cases, straight tube removable bundles are a more costly design that
U-tube designs.
Advantages:
- Floating tube sheet allows for differential thermal expansion between the shell and tube
bundle
- The tube bundle can be repaired or replaced without disturbing shell piping
- Tubes can be serviced without disturbing the tube side piping on AEP designs
- Less costly than TEMA BES and BET designs
d. Removable Bundle, Internal Split Ring Floating Head: Type AES, BES, Etc.
These designs are best for applications when frequent tube bundle removal is necessary.
More favorable to thermal shock than AEW or BEW designs. This design is suitable for volatile or
toxic fluids.
Advantages:
- Floating head design allows for thermal expansion
- Maximum surface area for specified shell diameter than a “pull through” designs like AET
or BET
- Available to multiple passes on tube side
Limitations:
- Shell cover, split ring and floating head cover must be removed to remove the tube bundle,
results in higher maintenance costs
e. Removable Bundle, Pull Through Floating Head: Type AET, BET etc.
These designs are best for applications when frequent tube bundle removal is necessary as
the floating head is bolted directly to the floating tube sheet. This allows the bundle to be pulled
complete, with the head.
Advantages:
- Floating head allows for thermal expansion
- Shell side can be inspected or mechanically cleaned
- Provide a large shell side nozzle entrance area for proper distribution over the bundle
- Multiple tube side passes available
- Suitable for volatile or toxic fluids
f. Removable Bundle, U-tube: Type BEU, AEU etc.
This design is best suited for maximum thermal expansion applications. Each tube has the
ability to expand and contract independently. This design is suitable for high thermal shock
applications. U-tube bundles are very economical.
Advantages:

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- The U-tube design not only allows for differential thermal expansion between the shell and
tube bundle, but also each tube individually.
- Shell side can be inspected and cleaned
- Least costly design for removable bundles
- Multiple tube side passes are available
- Capable of handling high thermal shock applications
- Bundle can be removed from one end for cleaning or replacement

D.5. STORAGE TANK


 Tank Sizing
1. Determine Storage Capacity.
2. Choose Storage Tank Type: Vertical or Horizontal, in this part, determine which type of
storage tank based on plant storage capacity.
3. In this part, determine length and diameter ratio of storage based on vessel function.
Because the tanks used is using concrete plant so the L/D ratio around 0.8-1. In this case,
choose 0.8 ratio. Because the taller tank, will be more troubled by wind.
4. Calculate Internal Diameter and Length, with 0.8 L/D ratio. So diameter calculation
equation is:
𝐷
𝑆𝑡𝑜𝑟𝑎𝑔𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 (𝑚3 ) = 𝜋𝐿( )2
2
3
4𝐷 𝐷 2
𝑆𝑡𝑜𝑟𝑎𝑔𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 (𝑚 ) = 𝜋( )( )
5 2
𝑆𝑡𝑜𝑟𝑎𝑔𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 1/3
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 (𝑚) = ( )
𝜋/5
𝐿𝑒𝑛𝑔𝑡ℎ (𝑚) = 0.8𝐷
5. Determine Material of Storage Tank.
Basic consideration of determining material is corrosion resistance. There are no corrosive
material/fluids used in this plan so Carbon Steel SA 283. Tanks in utility use the material
HDPE.
6. Calculate Vessel Thickness , to calculate vessel thickness:
𝑃𝑅
𝑡𝑠 = +𝐶
𝑆𝐸 − 0.6𝑃
7. Determine Open or Closed Head. Head or roof would be chosen if liquid is not volatile and
closed head would be chosen if liquid is volatile.
 Deaerator
Here is the step for determining Deaerator column size by DOW:
1. Calculate Tank Capacity
Water for aeration = 81400.78 kg/h = 81.4 m3/h
Residance time = 15 second = 0.25 h
Safety factor = 20% (Peter and Timmerhouse, 1991, hal. 37)
Volume of water = 81.4 m3/h x 0.25 h = 0.3695 m3
Volume of tank = 1.2 x 0.3695 m3 = 0.4434 m3
2. Determine Tank Dimension
Top volume is Torispherical Flanged and Dished Head
Vd = 0.1039
1
𝑉𝑡𝑎𝑛𝑘 = 𝜋𝐷3 𝐻 + 0.1039𝐷3 + 0.1039𝐷3 = 4.1348𝐷 3
4
Vtank = 4.1348𝐷3
0.4434 m3 = 4.1348 x D3
D = 0.9144 m
 D < D standard so we use standard diameter = 0.9144 m = 3 ft = 36 in

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H/D = 5
H/0.9144 m = 5
H = 2.393 m
 H < H standard so it use standard height = 4.5721 m = 15 ft = 180 in
3. Calculate Tank Capacity
𝑃𝑎𝑏𝑠 = 𝑃𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛 + 𝑃ℎ𝑖𝑑𝑟𝑜𝑠𝑡𝑎𝑡𝑖𝑠
𝜌(ℎ − 1)
𝑃𝑎𝑏𝑠 = 73.47𝑝𝑠𝑖 +
144
62.4 𝑙𝑏/𝑓𝑡 3 (15 − 1)
𝑃𝑎𝑏𝑠 = 73.47𝑝𝑠𝑖 +
144
𝑃𝑎𝑏𝑠 = 153.01 𝑝𝑠𝑖
Design pressure 5-10% above absolute pressure (Coulson, 1988 hal. 637)
Design pressure chosen is 10% above.
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = 1.1 𝑥𝑃𝑎𝑏𝑠 = 1.1 𝑥 153.01 𝑝𝑠𝑖 = 168.31 𝑝𝑠𝑖
4. Determine Shell Thickness
𝑃𝑑
𝑡𝑠 = +𝐶
2(𝑓𝐸 − 0.6𝑃)
(Brownell & Young 1959 page 256), where :
ts = shell thickness, in
P = Pressure design , psi
F = Allowable stress, psi
d = shell diameter, in
E = efficiency
C = corrosion factor, in
Material recommended is Stainless Steel 316
f = 15,600 psi (Peters & Timmerhause, 1991, Table 4, page 538)
E = 80% (Brownell & Young, 1959, table 13.2)
C = 0.125 in
ri = 18 in
168.31 𝑝𝑠𝑖 𝑥 18 𝑖𝑛
𝑡𝑠 = + 0.125 𝑖𝑛
2(15600 𝑝𝑠𝑖 𝑥 0.8 − 0.6 𝑥 168.31 𝑝𝑠𝑖)
ts = 0.2648 in = 6.72592 mm
OD = ID + (2ts)
OD = 36 in + (2 x 0.2648 in)
OD = 36.494 in (use OD standard  38 in)
5. Determine Head Thickness
OD = 38 in
Rc = 36 in
0.885𝑃𝑟𝑐
𝑡ℎ = +𝐶
𝑓𝜀 − 0.1𝑃
0.885 𝑥 168.31 𝑝𝑠𝑖 𝑥 36 𝑖𝑛
𝑡ℎ = + 0.125 𝑖𝑛
15600 𝑥 0.85 − 0.1 𝑥 168.31 𝑝𝑠𝑖
th = 0.5299 in = 13.45946 mm
 Clarifier
1. Assume that the clarifier height is 5 meter and the ratio of D2/D1 is 0.4
𝐷2
= 𝑦(𝑦 + ℎ)
𝐷1
0.4 = 𝑦/(𝑦 + 5)
y= 3.33 meters
2. Find the clarifier volume, using:

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1 𝑦+ℎ 1 𝑦+ℎ
𝐶𝑙𝑎𝑟𝑖𝑓𝑖𝑒𝑟 𝑣𝑜𝑙𝑢𝑚𝑒 = 𝜋𝐷 2 ( ) − 𝜋𝐷2 2 ( )
4 1 3 4 3

D.6. PIPE
1. To calculate the size of the pipe, off-grid plant need to volumetric rate of fluid which goes
through it and also the velocity of the fluid. Assume that the velocity of water is 3 m/s and non-
water is 1 m/s.
𝑚̇
𝑄=
𝜌
𝑄
𝐴=
𝑣
4𝐴
𝐼𝐷 = √
𝜋
2. After getting the minimum internal diameter, use the table to find the appropriate size from
vendor. Using schedule 20 for low pressure, schedule 40 for medium pressure, and schedule 80
for high pressure.
Table D6. 1. Thickness of Shell

3. Determining the pressure drop of the pipe.

D.7. COMPRESSOR AND PUMP


 Compressor
1. The compressor’s capacity, discharge temperature, and power is calculated using
Honeywell’s UNISIM.
2. Compressor head is the compressor ability to reach maximum height of other unit to
transport gas. The equation is to calculate compressor head in compressor is:
Σ(𝑦𝑖)(𝐶𝑝𝑖)
𝑦=
Σ(𝑦𝑖)(𝐶𝑝𝑖) − 1.99
𝑇1 𝑍𝑎 𝑅 𝑃2 𝑦−1
∆ℎ = [ ) 𝑦 − 1]
𝑦−1
( ) (𝑀𝑊) 𝑃1
𝑦
 Pump
There are several steps to sizing pump. The first step is started with finding out physical
properties of the streams which will go into the pumps and other information needed in the
calculation (mass flow, pressure inlet, pressure output, vapor pressure, temperature, density, static
head, pipe length after pump). By using these formula below, the information of Power, Head, and
NPSHa of each pump can be obtained.
𝑑𝑊𝑎𝑜 𝑑𝑊𝑝𝑢𝑚𝑝 𝑃 𝑉2
− =− = ∆ ( + 𝑔𝑧 + ) + 𝐹
𝑑𝑚 𝑑𝑚 𝜌 2

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𝑃1(𝑎𝑡𝑚) 𝑉22 𝐹 𝑃𝑣𝑎𝑝𝑜𝑟


𝑁𝑃𝑆𝐻𝑎 = − (𝑧2 − 𝑧1 ) − − −
𝜌𝑔 2𝑔 𝑔 𝜌𝑔
Assumptions :
 𝜂𝑝𝑢𝑚𝑝 = 75%
 The terms of velocity difference neglected due to its small number
 No fitting
The pump power requirement can be calculated by equation below.
𝐹𝐻𝑃 = 𝑊 = 𝑚̇ × 𝑔 × 𝐻
where 𝑚 is mass flow, g is gravity acceleration, and H is head.
The 𝑊𝑎𝑐𝑡 or BHP (brake horse power) is calculated by equation below.
𝑊𝑎𝑐𝑡 = 𝐵𝐻𝑃 = 𝐹𝐻𝑃 × 𝜂𝑝𝑢𝑚𝑝

D.8. BOILER
The aim of boiler design is calculating the furnace width and depth. This boiler uses natural
gas as fuel to generate steam. The steps for determining the sizing parameter are illustrated below.

Figure D8. 1. Boiler Design


(Source: Brownell & Young, 1959)
1. Volume of the furnace
The volume is calculated through the value of qv, from the equation below.
𝑚𝑐 𝐿𝐻𝑉 𝑘𝑊
𝑞𝑣 = [ 3]
𝑉 𝑚
mc is the design fuel consumption rate. The value of qv can be determined through the rule
of thumb as follow. It is taken to be 0.35 MW/m3.
Table D8. 1. Lower Limit of Furnace

2. Furnace height (Hfu + Hb) and heat transfer area (Fgrate)


𝑚𝑐 𝐿𝐻𝑉 𝑘𝑊
𝑞𝐹 = [ ]
𝐹𝑔𝑟𝑎𝑡𝑒 𝑚2
The value of qf can be determined through the following table. It is taken to be 2.130
MW/m2.
Table D8. 2. Upper Limit of Furnace

3. Furnace length and width (a and b)


𝑚𝑐 𝐿𝐻𝑉 𝑘𝑊
𝑞𝑏 = [ 2]
2(𝑎 + 𝑏)𝐻𝑏 𝑚
Table D8. 3. Calculation for Boiler Sizing
Variable Value

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Heat Release Rate per Unit Volume


ṁc (kg/h) 542
ṁc (kg/s) 0.151
LHV (kJ/kg) 47141
qv (kW/m3) 530
V (m3) 13.401
Heat Release Rate per Unit Cross Sectional Area
ṁc (kg/h) 542.401
ṁc (kg/s) 0.151
qf (kW/m3) 2130.0
Fgrate (m2) 3.335
Hfu+Hb 4.019
Heat Release Rate per Unit Wall Area of Burner
qb (kW/m3) 1400
b (m) 1.741
Hb (m) 0.694
Hfu (m) 3.325
a (m) 1.915
Power produced (kW) 81400.3
Determination of Furnace Size
α 30
β 45
Γ 50
E (m) 0.8
d (m) 0.173

D.9. REVERSE OSMOSIS


The sizing steps are based on vendor product (DOW) are:
1. Consider feed source, feed quality, feed/product flow, and required product quality.
2. Select the flow configuration and number of passes.
The standard flow configuration for water desalination is plug flow, where the feed volume is
passed once through the system. The selected configuration is plug flow and number of passes
is 1.
3. Select membrane element type.
The membrane type chosen is using DOW seawater reverse osmosis product which is
recommended based on the permeate flow and feed water source. Table I. 1. show the DOW
reverse osmosis product. Based on Table 1.2, SW30XLE is chosen.
Table D9. 1. Reverse Osmosis Element Type

(Source: FILMTEC, 2017)

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The effective membrane area is chosen for SW element based on DOW. Based on Table I. 2,
400 ft2 membrane area is chosen.
Table D9. 2. Maximum Feed Flowrate Reverse Osmosis

(Source: FILMTEC, 2017)


4. Select average membrane flux.
Average membrane flux is determined using typical data for seawater open intake source based
on Table I. 3. is 19 gfd.
Table D9. 3. Design Guidelines

(Source: FILMTEC, 2017)


5. Calculate the number of elements needed.
Divide the design permeate flowrate QP by the design flux f and by the membrane surface area
of the selected element SE (ft2 or m2) to obtain the number of elements NE.
𝑄𝑃
𝑁𝐸 =
𝑓𝑆𝐸
6. Calculate number of pressure vessels needed.
Divide the number of elements NE by the number of elements per pressure vessel, NEpV, to obtain
the number of pressure vessels, Nv round up to the nearest integer. For large systems, 6-element
vessels are standard but vessels with up to 8 elements are available. For smaller and/or compact
systems, shorter vessels may be selected.
𝑁𝐸
𝑁𝑉 =
𝑁𝐸𝑝𝑉
7. Select the number of stages.
The number of stages defines how many pressure vessels in series the feed will pass through
until it exits the system and is discharged as concentrate. Every stage consists of a certain
number of pressure vessels in parallel. The number of stages is a function of the planned system
recovery, the number of elements per vessel, and the feed water quality. The higher the system
recovery and the lower the feed water quality, the longer the system will be with more elements
in series. The selected stages for 6 element vessels is 3 stage based on Table I.4.
Table D9. 4. Design Number of Stage

(Source: FILMTEC, 2017)


8. Select the staging ratio.
Selected staging ratio is 4:3:2

D.10. ELECTROLYZER
 Electrolyzer
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There are several steps to sizing pump.


1. Find Out G and E
∆𝐺 = ∆𝐻 − 𝑇. ∆𝑆
∆𝐺
∆𝐸 = −
𝑛𝐹
2. Find Out Q
𝑄 = 𝑒. 𝐹
𝐹
𝑄 𝑎𝑐𝑡 = 𝑒.
𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
3. Find Out Power
𝑃𝑜𝑤𝑒𝑟 = ∆𝐸. 𝑄
4. Calculate the Area of Electroda
𝑇𝑜𝑡𝑎𝑙 𝑃𝑜𝑡𝑒𝑛𝑡𝑖𝑎𝑙 (𝑉) = ∆𝐸 + 𝑂𝑣𝑒𝑟 𝑃𝑜𝑡𝑒𝑛𝑡𝑖𝑎𝑙
𝑃/𝑉
𝐴=
𝑖
Where i is current density which is depends on the material
 Photovoltaic
There are several steps to calculate the energy of photovoltaic:
1. Define the voltage.
Voltage = 4800 Volt
2. Find out the number of panel.
𝑉
𝑁 𝑝𝑎𝑛𝑒𝑙 = = 400 𝑝𝑎𝑛𝑒𝑙
12
3. Find out the number of cells
1 module = 36 cells
𝑁 𝑐𝑒𝑙𝑙𝑠 = 𝑁 𝑝𝑎𝑛𝑒𝑙 𝑥 36 𝑐𝑒𝑙𝑙𝑠
4. Calculate the Energy
𝐸 = 𝐴 𝑥 𝑟 𝑥 𝐻 𝑥 𝑃𝑅
𝑘𝑊ℎ
𝐸 = 1000 𝑚2 𝑥 15% 𝑥 1668.78 2 . 𝑎𝑛 = 187624 𝑘𝑊ℎ/𝑎𝑛
𝑚
Where :
E = Energy (kWh)
A = Total solar panel area (m2)
r = solar panel yield (%)
H = Annual average irradiation on titled panels (shading not included)
PR = Performance ratio, coefficient for losses (range between 0.9 and 0.5, default value =
0.75)
 Battery Bank
There are several steps to calculate the bank capacity:
1. Define the energy.
Energy = 514038 Wh/days
2. Find out the DOD.
𝐷𝑂𝐷 = 𝐸𝑛𝑒𝑟𝑔𝑦 𝑥 130% = 668249 𝑊ℎ
3. Find out the number of battery.
Voltage = 12 Volt = 55687.4 Ah
Current = 100 A
𝑣𝑜𝑙𝑡𝑎𝑔𝑒
𝑁 𝑏𝑎𝑡𝑡𝑒𝑟𝑦 = = 557
𝑐𝑢𝑟𝑟𝑒𝑛𝑡

D.11. COOLING TOWER


Calculation of makeup water is shown below.

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1. Assumed that Tin of cooling water is 25oC and Tout 45oC.


2. The water loss from evaporation:
𝑊𝑒 = 0.00085𝑊𝑐 (∆𝑇)
where,
𝑊𝑐 = inlet water to cooling tower
𝑊𝑒 = water loss from evaporation
∆𝑇 = temperature difference between inlet and outlet water
3. The water loss from drift loss is usually 0.1-0.2% from the total inlet cooling water.
Assumed 0.2% drift loss.
𝑊𝑑 = % 𝑑𝑟𝑖𝑓𝑡 𝑙𝑜𝑠𝑠 × 𝑊𝑒
4. Water losses from blow down depend on the amount of cooling water cycle, usually
between 3-5 cycles. Assumed 4 cycles.
𝑊𝑒
𝑊𝑏 =
𝐶−1
where,
𝑊𝑏 = water losses from blow down
𝐶 = number of cycle
5. The total make up cooling water required can then be calculated :
Makeup Cooling Water = We + Wd + Wb
Table D11.1. Total Makeup Cooling Water
Cp water Mass flow
Equipment T in (oC) T out (oC) Q (kJ/h)
(KJ/kg.K) (kg/h)
E-205 25.00 45.00 162,344.71 4.18 1,941.92
E-207 25.00 45.00 131,750.00 4.18 1,575.96
E-208 25.00 45.00 15,287,500.00 4.18 182,864.83
E-402 25.00 45.00 570,939.49 4.18 6,829.42
E-404 25.00 45.00 1,074,600.00 4.18 12,854.07
E-406 25.00 45.00 159,345.00 4.18 1,906.04
Total (kg/h) 207,972.24
Water loss from evaporation (We) 3,535.53
Drift loss (0.1-0.2%) (Wd) 0.002 415.94
Blowdown (amount of cooling water cycle 3-5) (Wb) 4.00 69,324.08
Total Makeup Cooling Water (kg/h) 73,275.55

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APPENDIX E. MSDS
Hydrogen MSDS

Oxygen MSDS

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Carbon Dioxide MSDS

Carbon Monoxide MSDS

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Methanol MSDS

Dimethyl Ether MSDS

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Isobutane MSDS

Gasoline MSDS

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APPENDIX F. EQUIPMENT PURCHASE COST PROCEDURE

F.1. Reactors and Separators


Reactor and separator purchase cost is calculated by the following equation.
𝐶𝑝 = 𝐹𝑀 𝐶𝑉 + 𝐶𝑃𝐿
For horizontal vessels with 1,000 lb < W < 920,000 lb, 3 ft < Di< 12 ft
𝐶𝑉 = exp[8.717 − 0.2330 ln 𝑊 + 0.04333 (ln 𝑊) 2
For vertical vessels with 4,200 lb < W < 1,000,000 lb, 3 ft < Di < 21 ft, 12 ft < L< 40 ft,
𝐶𝑉 = exp[6.775 + 0.18255 ln 𝑊 + 0.02297 (ln 𝑊) 2
𝐶𝑃𝐿 = 285.1 (𝐷𝑖 )0.73960 (𝐿)0.70684
where
FM = material factor (cast iron = 1, stainless steel 316 = 2.1)
W = weight in pounds of the shell and the two heads
𝐷𝑖 = vessel inner diameter in ft
L = vessel length in ft
The vessel weight is calculated through the following equation.
𝑊 = π(𝐷𝑖 + 𝑡𝑠 )(𝐿 + 0.8𝐷𝑖 )𝑡𝑠 𝜌
where ts refers to shell thickness and 𝜌 refers to material density.
F.2. Distillation Column
Distillation column’s purchase cost is estimated with respect to tower structure which
includes distillation column, absorber and stripper. The equation for calculation is shown below.
𝐶𝑝 = 𝐹𝑀 𝐶𝑉 + 𝐶𝑃𝐿
𝐶𝑉 = exp[7.0374 + 0.18255 ln 𝑊 + 0.00297 (ln 𝑊) 2
𝐶𝑃𝐿 = 237.1 (𝐷𝑖 )0.63316 (𝐿)0.80161
F.3. Compressor
The equation for compressor purchase cost estimation is shown below.
𝐶𝐵 = exp{7.2223 + (0.8[ln 𝑃𝑐]}
𝐶𝑝 = 𝐹𝑇 𝐹𝑀 𝐶𝐵
where
PC = power (hp)
FM = compressor Material (SS =2.5, CS = 1.5)
FT = compressor type factor
F.4. Pump
The equation for compressor purchase cost estimation is shown below.
𝐶𝑝 = 𝐹𝑇 𝐹𝑀 𝐶𝐵
𝐶𝐵 = exp{9.2951 − 0.6019[𝑙𝑛(𝑆)] + 0.0519[𝑙𝑛(𝑆)]2 }
𝑆 = 𝑄 (𝐻)0.5
where
Q = volumetric flowrate (gpm)
H = head (ft)
FM = material factor
F.5. Heat Exchangers
For calculating heat exchanger FOB’s price Seider is used, Seider, and Lewis book (2004)
and use equation as below
𝐶𝑝 = 𝐹𝑝 𝐹𝑀 𝐹𝐿 𝐶𝐵
Where CB calculated based on the kind of exchanger used with formula as seen below
Table F.1. Formula of any kinds of heat exchanger

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Floating head is used for all of our heat exchanger in our plant. As for FM is material factor
for combination of tube and shell material as given in table below.
Table F.2. FM factor for heat exchanger FOB cost

(Source: SSL, 2004)


Carbon steel/stainless steel material are used for heat exchanger in our plant. So FM can be
calculated from equation as below.
𝐴 𝑏
𝐹𝑀 = 𝑎 + ( )
100
For FL is factor for tube length correction in table below.
Table F.3. Tube length correction

(Source: SSL, 2004)


And the last, FP which is pressure factor base on shell side pressure and given by this
following equation.

For bare module price, bare module for shell and tube exchanger which is 2.91 used (SSL,
2004).
F.6. Filtration Unit
This plant has two filtration units. They are multimedia filter and catridge filter. The
calculation for those filtration units is based on Product and Process Design Principle by Seider. The
equation is shown below. The step is:
1. Determine type and filtering area. The multimedia filter is the type of plate and frame
filtration unit, while the catridge filter is the type of rotary pan filtration unit.
2. Material construction is carbon steel. Therefore the value of Cp can be calculated using
equations that are listed in table below.
Table F.4. Equations of any kinds of filtration units

F.7. Reverse Osmosis


In this plant there are 12 reserve osmosis units. The calculation is based on Product and
Process Design Principle by Seider. The equation is shown below. The step is:
1. Determine flow rate.

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2. The type is reserve osmosis seawater, so a value of CBM can be calculate below.
𝐶𝐵𝑀 = exp[0.8020[ln(𝑄)] − 0.01775[ln(𝑄)]2 ]
Table F.5. Equations of any kinds of reverse osmosis

F.8. Electrolyzer
Because there is not equation for electrolyzer provided in book, we use vendor price as
purchase price and calculate by the correction factor. The assumption of bare module factor is 1
because there is no information about FBM for electrolyzer in Seider.
𝐶𝑎𝑝𝑎𝑐. 𝑜𝑓 𝑒𝑞𝑢𝑖𝑝. 𝑎 0.6
𝐶𝑜𝑠𝑡 𝑜𝑓 𝑒𝑞𝑢𝑖𝑝. 𝑎 = 𝐶𝑜𝑠𝑡 𝑜𝑓 𝑒𝑞𝑢𝑖𝑝. 𝑏 ( )
𝐶𝑎𝑝𝑎𝑐. 𝑜𝑓 𝑒𝑞𝑢𝑖𝑝. 𝑏
Data from Vendor (Alibaba.com, 2018):
1 kg/h H2 = 9 kg/h water  Need of Power = 50 kW  Cost = 770000 USD / 2 MW
So, cost of electrolyzer that we use is
21000 𝑘𝑊 0.6
𝐶𝑜𝑠𝑡 𝑜𝑓 𝑒𝑙𝑒𝑐𝑡𝑟𝑜𝑙𝑦𝑧𝑒𝑟 = 770000 ( ) = 3,156,489.18 𝑈𝑆𝐷
2000 𝑘𝑊
F.9. Cooling Tower
In calculating the bare module cost of cooling tower, it used a graph from literature. The
graph shows the relation between water rate in gallons/minutes and equipment cost.
Figure A.1. Cooling tower purchased equipment cost

From the graph above, the linear equation can be obtained


y = 16.301x + 1695.7
where x is the water rate (gal/min) and y is the cost (USD).
F.10. Deaerator
In this plant there are 5 deaerators. The calculation is based on Product and Process Design
Principle by Seider. The equation is shown below. The step is:
1. Determine volume (gal)
2. Deaerator’s form is spherical with pressure 30-200 psig, and material construction is carbon
steel, so a value of Cp can calculate by equation below.
𝐶𝑝 = 37 𝑉 0.78
Where: V = Volume (gal)
Table F.6. Equations of any kinds of deaerator

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F.11. Boiler
For calculating Boiler FOB’s price we use Seider, Seader, and Lewin book (2004) and
use equation as below.
1. First, determine type of fire heater foe specific purposes.
2. Calculate Cp. Because in this plant, fire heater for specific purposes, so used formula for
Cp:
𝐶𝑝 = 0.289 𝑄0.77

Table F.7. Equations of any kinds of boiler

F.12. Clarifier
In this plant there are two clarifiers. The calculation is based on Product and Process Design
Principle by Seider. The equation is shown below. The step is:
1. Determine settling area.
2. Material construction is carbon steel, the type is clarifier steel, so a value of Cp can
calculate by equation below.
𝐶𝑝 = 2400 𝐴0.58

Table F.8. Equations of any kinds of clarifier

F.13. Storage Tank


In this plant there are four storage tanks, which are aeration tank, sludge tank, fuel storage
tank, and DME storage tank. The calculation is based on Product and Process Design Principle by
Seider. The equation is shown below.

Table F.9. Equations of any kinds of storage tanks

In this plant, we use open storage tank for aeration tank and sludge tank with fiberglass for
the material construction, so a value of Cp can calculate by equation below.
𝐶𝑝 = 14 𝑉 0.72
Then, for the Fuel storage tank we use spherical storage tank with pressure 0-30 psig, and
material construction is carbon steel so a value of Cp can calculate by equation below.
𝐶𝑝 = 47 𝑉 0.72
But, we use spherical storage tank with pressure 30-200 psig for DME storage tank, so a
value of Cp can calculate by equation below.
𝐶𝑝 = 37 𝑉 0.78
Where: V = Volume (gal)
F.14. Photovoltaics Unit
The calculation of PV cost includes the cost of its panel which includes battery and
component structures in USD/Watt and the cost of the inverter, also in USD/Watt. It is simply
multiplied by 1.3 USD/W for panel and multiplied by 0.23 USD/W for the inverter. Therefore, the
total PV systems cost is an addition of panel cost and inverter cost.

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APPENDIX G. CASH FLOW

Table G.1. Cash flow


Year % Capacity Revenue OPEX Maintenance Cost Depreciation Cash Expenses All Expenses
0 2020 0 0 0 0 0 0 0
1 2021 70% 18,659,058 13,901,093 2,748,764 7,148,648 16,649,857 23,798,505
2 2022 90% 23,990,218 16,968,062 2,748,764 11,482,821 19,716,826 31,199,646
3 2023 100% 26,655,798 18,064,220 2,748,764 6,978,894 20,812,984 27,791,879
4 2024 100% 26,655,798 17,453,226 2,748,764 4,275,193 20,201,990 24,477,183
5 2025 100% 26,655,798 16,485,858 2,748,764 4,269,206 19,234,622 23,503,828
6 2026 100% 26,655,798 15,696,677 2,748,764 2,247,720 18,445,441 20,693,160
7 2027 100% 26,655,798 15,085,683 2,748,764 226,267 17,834,447 18,060,714
8 2028 100% 26,655,798 14,118,314 2,748,764 218,749 16,867,078 17,085,828
9 2029 100% 26,655,798 13,329,133 2,748,764 211,249 16,077,897 16,289,146
10 2030 100% 26,655,798 12,718,139 2,748,764 211,249 15,466,903 15,678,152
11 2031 100% 26,655,798 11,750,771 2,748,764 211,249 14,499,535 14,710,783
12 2032 100% 26,655,798 11,750,771 2,748,764 211,249 14,499,535 14,710,783
13 2033 100% 26,655,798 11,928,958 2,748,764 211,249 14,677,722 14,888,970
14 2034 100% 26,655,798 11,750,771 2,748,764 211,249 14,499,535 14,710,783
15 2035 100% 26,655,798 11,750,771 2,748,764 211,249 14,499,535 14,710,783
16 2036 100% 26,655,798 11,928,958 2,748,764 211,249 14,677,722 14,888,970
17 2037 100% 26,655,798 11,750,771 2,748,764 211,249 14,499,535 14,710,783
18 2038 100% 26,655,798 11,928,958 2,748,764 211,249 14,677,722 14,888,970
19 2039 90% 23,990,218 10,575,694 2,748,764 211,249 13,324,458 13,535,706
20 2040 70% 18,659,058 9,330,393 2,748,764 105,624 12,079,157 12,184,781

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Table G.1. Cash flow (cont’d)
Before Tax Cash
Year Net Profit Before Tax Income Tax Net Profit After Tax After Tax Cash Flow Cummulative Cash Flow
Flow
0 2020 -79,115,914 -79,115,914 0 -79,115,914 -79,115,914 -79,115,914
1 2021 2,009,201 -5,139,447 0 -5,139,447 2,009,201 -77,106,713
2 2022 4,273,392 -7,209,428 0 -7,209,428 4,273,392 -72,833,321
3 2023 5,842,813 -1,136,081 0 -1,136,081 5,842,813 -66,990,508
4 2024 6,453,807 2,178,614 0 2,178,614 6,453,807 -60,536,700
5 2025 7,421,176 3,151,970 0 3,151,970 7,421,176 -53,115,525
6 2026 8,210,357 5,962,637 1,490,659 4,471,978 6,719,697 -46,395,827
7 2027 8,821,351 8,595,084 2,148,771 6,446,313 6,672,580 -39,723,247
8 2028 9,788,719 9,569,970 2,392,492 7,177,477 7,396,227 -32,327,020
9 2029 10,577,900 10,366,652 2,591,663 7,774,989 7,986,238 -24,340,783
10 2030 11,188,895 10,977,646 2,744,411 8,233,234 8,444,483 -15,896,300
11 2031 12,156,263 11,945,014 2,986,254 8,958,761 9,170,009 -6,726,290
12 2032 12,156,263 11,945,014 2,986,254 8,958,761 9,170,009 2,443,719
13 2033 11,978,076 11,766,827 2,941,707 8,825,120 9,036,369 11,480,088
14 2034 12,156,263 11,945,014 2,986,254 8,958,761 9,170,009 20,650,098
15 2035 12,156,263 11,945,014 2,986,254 8,958,761 9,170,009 29,820,107
16 2036 11,978,076 11,766,827 2,941,707 8,825,120 9,036,369 38,856,476
17 2037 12,156,263 11,945,014 2,986,254 8,958,761 9,170,009 48,026,486
18 2038 11,978,076 11,766,827 2,941,707 8,825,120 9,036,369 57,062,855
19 2039 10,665,760 10,454,512 2,613,628 7,840,884 8,052,132 65,114,987
20 2040 13,868,875 6,474,277 1,618,569 4,855,708 12,250,306 70,076,319

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