TK01 - Report - Final
TK01 - Report - Final
Final Report
GROUP 1
GROUP PERSONNEL:
Billi (1506724575)
Natasya Mareta Mualim (1506673385)
Nico Nathanael (1506737016)
Salma Amaliani Putri (1506673334)
1. Name : Billi
NPM : 1506724575
DOB : Palembang, 25th September 1997
Address : Merbau Street No. 1326 Palembang
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.
iv Universitas Indonesia
EXECUTIVE SUMMARY
v Universitas Indonesia
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.
vi Universitas Indonesia
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.
ix Universitas Indonesia
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
x Universitas Indonesia
LIST OF TABLES
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
1 Universitas Indonesia
2
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.
Universitas Indonesia
3
Universitas Indonesia
4
Universitas Indonesia
5
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
Universitas Indonesia
6
Universitas Indonesia
7
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.
Universitas Indonesia
8
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).
Universitas Indonesia
10
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
Universitas Indonesia
11
Universitas Indonesia
12
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.
Universitas Indonesia
13
Universitas Indonesia
15
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
Universitas Indonesia
16
Universitas Indonesia
17
CHAPTER 2
PROCESS SYNTHESIS
Universitas Indonesia
18
Universitas Indonesia
19
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
Universitas Indonesia
20
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
Universitas Indonesia
21
Universitas Indonesia
Table 2.2. Scoring criteria for process route selection
23 Universitas Indonesia
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.
24 Universitas Indonesia
25
Universitas Indonesia
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)
26 Universitas Indonesia
27
Universitas Indonesia
28
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.
Universitas Indonesia
29
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
Universitas Indonesia
30
Universitas Indonesia
31
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
Universitas Indonesia
32
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)
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.
Universitas Indonesia
34
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).
Universitas Indonesia
35
Universitas Indonesia
36
Universitas Indonesia
37
Universitas Indonesia
38
Universitas Indonesia
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.
39 Universitas Indonesia
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
40 Universitas Indonesia
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
41 Universitas Indonesia
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
42 Universitas Indonesia
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
43 Universitas Indonesia
In each shifted temperature interval, a simple energy balance is calculated.
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.
44 Universitas Indonesia
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
45 Universitas Indonesia
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
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
47 Universitas Indonesia
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
49 Universitas Indonesia
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
50 Universitas Indonesia
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
51 Universitas Indonesia
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.
52 Universitas Indonesia
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.
53 Universitas Indonesia
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
54 Universitas Indonesia
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
56 Universitas Indonesia
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.
57 Universitas Indonesia
2.6. Block Flow Diagram
58 Universitas Indonesia
59
CHAPTER 3
EQUIPMENT SIZING
Universitas Indonesia
60
Universitas Indonesia
61
Universitas Indonesia
63
Universitas Indonesia
65
Universitas Indonesia
66
Universitas Indonesia
67
Universitas Indonesia
68
Universitas Indonesia
69
Universitas Indonesia
70
Universitas Indonesia
71
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
Universitas Indonesia
72
Universitas Indonesia
79
Universitas Indonesia
80
Universitas Indonesia
81
Universitas Indonesia
82
Universitas Indonesia
83
5,58 m
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.
Universitas Indonesia
85
Universitas Indonesia
86
Universitas Indonesia
87
Universitas Indonesia
88
CHAPTER 4
PROCESS CONTROL AND P&ID
88 Universitas Indonesia
89
89 Universitas Indonesia
90
90 Universitas Indonesia
91
95 Universitas Indonesia
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
98 Universitas Indonesia
CHAPTER 5
HEALTH, SAFETY, AND ENVIRONMENTAL PROTECTION
99 Universitas Indonesia
100
Universitas Indonesia
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
Universitas Indonesia
106
Universitas Indonesia
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
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
Universitas Indonesia
117
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
Universitas Indonesia
118
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.
Universitas Indonesia
119
Universitas Indonesia
121
Earplugs or
Hearing Excessive noise
earmuffs
Universitas Indonesia
123
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.
Universitas Indonesia
125
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.
Universitas Indonesia
126
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
Universitas Indonesia
127
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.
Universitas Indonesia
128
Universitas Indonesia
129
Universitas Indonesia
130
Universitas Indonesia
131
Universitas Indonesia
132
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.
Universitas Indonesia
133
Universitas Indonesia
134
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
Universitas Indonesia
135
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
Universitas Indonesia
136
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.
Universitas Indonesia
137
CHAPTER 6
PLANT LAYOUT
Universitas Indonesia
138
Universitas Indonesia
139
Universitas Indonesia
140
Universitas Indonesia
141
Universitas Indonesia
142
Universitas Indonesia
CHAPTER 7
ECONOMIC ANALYSIS
500
450
400
350
1995
1997
1999
2001
2003
2005
2007
2009
2011
2013
2015
2017
Year
Universitas Indonesia
145
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
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
Universitas Indonesia
147
Universitas Indonesia
148
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)
Universitas Indonesia
150
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
Universitas Indonesia
151
Universitas Indonesia
152
Universitas Indonesia
153
Universitas Indonesia
154
Universitas Indonesia
155
Universitas Indonesia
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
Universitas Indonesia
161
Universitas Indonesia
163
Universitas Indonesia
164
Universitas Indonesia
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
Universitas Indonesia
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
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
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
Universitas Indonesia
171
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
Universitas Indonesia
172
Utility
36%
Raw Material
Labour 1%
Salary Catalyst
1% 0%
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
Universitas Indonesia
174
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
Universitas Indonesia
175
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
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:
Universitas Indonesia
176
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.
Universitas Indonesia
177
Universitas Indonesia
178
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
Deviation vs NPV
20,000,000.00
0.00 Gasoline
NPV
Universitas Indonesia
179
PBP
10 Gasoline
0 Oxygen
-100% -50% 0% 50% Maintenance
Deviation
Universitas Indonesia
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,
180 Universitas Indonesia
181
Universitas Indonesia
REFERENCES
Universitas Indonesia
186
Universitas Indonesia
187
Universitas Indonesia
188
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
Universitas Indonesia
189
Universitas Indonesia
190
Universitas Indonesia
191
Universitas Indonesia
APPENDIX B. PROCESS FLOW DIAGRAM
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
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
Universitas Indonesia
207
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
Universitas Indonesia
208
Universitas Indonesia
209
Universitas Indonesia
210
Universitas Indonesia
211
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
Universitas Indonesia
212
Universitas Indonesia
213
Universitas Indonesia
214
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
ℎ
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
Universitas Indonesia
215
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
Universitas Indonesia
217
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
Universitas Indonesia
218
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
Universitas Indonesia
219
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.
Universitas Indonesia
220
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
Universitas Indonesia
221
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
Universitas Indonesia
222
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
Universitas Indonesia
223
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
Universitas Indonesia
224
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.
Universitas Indonesia
227
𝑇2 − 𝑇1
𝑃=
𝑡2 − 𝑡1
Universitas Indonesia
228
𝐷𝐺
𝑅𝑒 =
𝜇
Determine 𝑗ℎ using Re data and L/D, baffle cut using figures below.
(Source: J.P.Holman,1959)
Universitas Indonesia
229
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.
Universitas Indonesia
230
Universitas Indonesia
231
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:
Universitas Indonesia
232
- 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
Universitas Indonesia
233
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:
Universitas Indonesia
234
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
Universitas Indonesia
235
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.
Universitas Indonesia
236
Universitas Indonesia
237
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
D.10. ELECTROLYZER
Electrolyzer
Universitas Indonesia
238
Universitas Indonesia
239
Universitas Indonesia
240
APPENDIX E. MSDS
Hydrogen MSDS
Oxygen MSDS
Universitas Indonesia
241
Universitas Indonesia
242
Methanol MSDS
Universitas Indonesia
243
Isobutane MSDS
Gasoline MSDS
Universitas Indonesia
244
Universitas Indonesia
245
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
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
Universitas Indonesia
246
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
Universitas Indonesia
247
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
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
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.
Universitas Indonesia
APPENDIX G. CASH FLOW