UNIVERSITAS INDONESIA

PRELIMINARY DESIGN OF SODIUM CARBONATE PLANT

Darft Assignment 2

GROUP TK-15

GROUP PERSONNEL:
ARDINA AYU WULANDARI (1706104363)
BILQIS NUR FADHILAH (1606871341)
DAVID KRISTIANTO (1606908035)
MUHAMMAD DAFFA (1606907801)
YOHANES PANDU WICAKSONO (1606907814)

CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
UNIVERSITAS INDONESIA
NOVEMBER 2019
 EXECUTIVE SUMMARY

This sodium carbonate production plant consists several stages of process.

There are brine purification, lime section, solvay process, filtration, calcination of
sodium bicarbonate and recovery amonia. In order to produce sodium carbonate,
this plant need some equipment such as CSTR reactor, rotaty kiln, mixer tank,
rotary dryer, conveyor, bucket elevator, pump, heat exchanger, rotary drum filter,
vessel, storage tank, decanter and absorber column.
In this assignment, all of the equipments are being sized, where each
equipment dimension is determined through various formula and correlations.
Aside from manual calculation by means of formulas from several equipment
design books, various other types of tools had also been used to size the equipment.
These tools include excel spreadsheets of chemical engineering-related design
books, online tools to obtain diverse parameters, critical temperature and pressure,
Aspen Plus and Hysys Simulation, etc.
In brine purification section process, the main equipment is Brine reactor.
Based on the calculation, total volume of the CSTR reactor is 134.43 m3/h with
diameter of the reactor is 4.85 m and the height is 7.66 m. Beside CSTR reactor,
there are two pumps, brine pump and NaCl pump, two mixer tank, polyacrylamide
mixer tank and Na2CO3 mixer tank, two heaat exchanger, and decanter. The
exchanger is sized using Aspen Exchanger Design and Rating, while another
equipment is sized by manual calculated.
Solvay process is the main process of this plant which involves sodium
chloride to provide sodium ions, carbon dioxide and ammonia to provide carbonate
ions, and water. This process occurs in plug flow reactor and CSTR reactor. In plug
flow reactor, carbon dioxide, ammonia, and water are reacted to generate
ammonium bicarbonate which will react with sodium bicarbonate in CSTR reactor.
By using polymath software, the diameter and length for plug flow reactor are 1.1
m and 16 m. On the other hand, CSTR reactor sizing was done by using manual
calculation. The volume of the CSTR reactor is 517.21 m3 with diameter of the
reactor is 7.6 m and the height is 12 m.
 Lime section and calcination of sodium bicarbonate are mainly using rotary
kiln and rotary dryer to decompose the reactant. Both rotary kiln and rotary dryer
have the same principle in calculating the specification. Commonly, rotary kiln and
rotary dryer are followed by cyclone to remove all the dust as by product.
Besides the main process, all equipments in utility plant are also being
designed. The utilities such as cooling water, process water, sanitation water, air,
electricity, and fuel utilities. Aside from the utilities, there are waste treatment for
unwanted product. There are brine purification waste handling and by product
handling. Utility plant consists of tank, pump, vessel, mixer, and cooling tower
which all of them are sized manually.
The purpose of this assignment is getting the amount and specification of
all equipments which are involved in this plant. Furthermore, all of the specification
are used as the basis information to decide piping and instrumentation, safety
aspect, required land area, and economic analysis.
 LIST OF CONTENTS

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

LIST OF CONTENTS ......................................................................................... iv
LIST OF FIGURES ............................................................................................. vi
LIST OF TABLE ................................................................................................ vii
CHAPTER 1 PROCESS EQUIPMENT SIZING ............................................. 9
1.1 Brine Purification ................................................................................... 9
1.1.1. Brine Storage Tank (TK-200) ........................................................... 9
1.1.2. Polyacrylamide Storage Tank (TK-400) ......................................... 10
1.1.3. Brine Pump (P-200) ........................................................................ 11
1.1.4. Polyacrylamide Mixer Tank (M-200) ............................................. 11
1.1.5. Na2CO3 Storage Tank (TK-301) ..................................................... 12
1.1.6. Na2CO3 Mixer Tank (M-201).......................................................... 13
1.1.7. Na2CO3 Pump (P-201) .................................................................... 14
1.1.8. Brine Reactor (R-200) ..................................................................... 15
1.1.9. Brine Cooler (E-200)....................................................................... 16
1.1.10. Heat Exchanger (E-201) .............................................................. 18
1.1.11. Decanter (FL-200) ....................................................................... 20
1.1.12. NaCl Pump (P-202) ..................................................................... 21
1.2 Lime Section .......................................................................................... 21
1.2.1 Limestone Storage Tank (TK-100) ................................................. 21
1.2.2 Belt Conveyor (C-100).................................................................... 22
1.2.3 Rotary Kiln (DD-100) ..................................................................... 23
1.2.4 Grater Cooler (JJ-100)..................................................................... 23
1.2.5 Cyclone Rotary Kiln (FG-100) ....................................................... 23
1.2.6 Cyclone Greater Cooler (FG-101) .................................................. 23
1.2.7 Belt Conveyor (C-101).................................................................... 23
1.2.8 Bucket Conveyor (C-102) ............................................................... 24
1.2.9 Lime Slaker Tank (M-100) ............................................................. 24
1.2.10 Rotary Filter (F-100) ....................................................................... 25
1.2.11 Lime Milk Tank (V-100) ................................................................ 25
1.2.12 CO2 Cooler (E-101 A/B) ................................................................. 26
1.2.13 Heat Exchanger (E-102) .................................................................. 28
1.3 Solvay Process ....................................................................................... 30
1.3.1. R-201 ............................................................................................... 30
1.3.2. R-202 ............................................................................................... 30
1.4 Filtration of Sodium Bicarbonate ....................................................... 30
1.4.1. Rotary Drum Filter (F-101)..................................................................... 30
1.5 Calcination of Sodium Bicarbonate ................................................... 31
1.5.1. Rotary Dryer (E-300) ...................................................................... 31
1.5.2. Finfan Cooler (E-301) ..................................................................... 31
1.5.3. Cyclone Rotary Dryer (FG-300) ..................................................... 33
1.5.4. Belt Conveyor (C-300).................................................................... 33
1.5.5. Ball Mill (SR-300) .......................................................................... 33
1.5.6. Bucket Elevator (C-301) ................................................................. 34
1.5.7. Na2CO3 Vessel (V-300)................................................................... 34
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 1.5.8. Blower (JB-100) .............................................................................. 35
1.6 Recovery Ammonia .............................................................................. 36
1.6.1. Pre-Limer (R-100)........................................................................... 36
1.6.2. Pump Ca(OH)2 (P-100) ................................................................... 36
1.6.3. NH3 Make Up Tank (TK-401) ........................................................ 37
2 CHAPTER II UTILITIES AND WASTE TREATMENT EQUIPMENT
SIZING ................................................................................................................. 39
2.1. Utilities ................................................................................................... 39
2.1.1. Water Tank (TK-500)\ .................................................................... 39
2.1.2. Water Pump (P-500) ....................................................................... 40
2.1.3. Water Vessel (V-500) ..................................................................... 40
2.1.4. Water Sanitation Utillities ............................................................... 41
2.1.5. Cooling Water Utillities .................................................................. 45
2.1.6. Water Process Pump (P-506) .......................................................... 47
2.2. Waste Treatment ...................................... Error! Bookmark not defined.
2.2.1. Seprator Stage 1 (V-601) ................. Error! Bookmark not defined.
2.2.2. Compressor stage 1 (JC-601) ........... Error! Bookmark not defined.
2.2.3. Cooler CO2 (E-601).......................... Error! Bookmark not defined.
2.2.4. Separator Stage 2 (V-602)................ Error! Bookmark not defined.
2.2.5. Turbine Stage 1 (JC-602) ................. Error! Bookmark not defined.
2.2.6. Compressor Stage 2 (JC-603) .......... Error! Bookmark not defined.
2.2.7. Cooler 1 (E-602) .............................. Error! Bookmark not defined.
2.2.8. Cooler 2 (E-603) .............................. Error! Bookmark not defined.
2.2.9. Separator Stage 3 (V-603)................ Error! Bookmark not defined.
2.2.10. Turbin Stage 2 (JC-604) ............... Error! Bookmark not defined.
2.2.11. Compressor Stage 3 (JC-605)....... Error! Bookmark not defined.
2.2.12. Cooler 3 (E-604) ........................... Error! Bookmark not defined.
2.2.13. Cooler 4 (E-605) ........................... Error! Bookmark not defined.
3 CONCLUSION............................................................................................... xlix
REFERENCES .................................................................................................... 50

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 LIST OF FIGURES
Figure 1.1 Setting Plan Brine Cooler (E-200) ...................................................... 17
Figure 1. 2 Tube sheet Brine Cooler (E-200) ....................................................... 17
Figure 1. 3 Setting Plan Heat Exchanger (E-201) ................................................ 19
Figure 1. 4 Tubesheet Heat Exchanger (E-201) ................................................... 19
Figure 1. 5 Setting Plan CO2 Cooler..................................................................... 27
Figure 1. 6 Tubesheet CO2 Cooler........................................................................ 28
Figure 1. 7 Setting Plan Heat Exchanger (E-102) ................................................ 29
Figure 1. 8 Tubesheet Heat Exchanger (E-102) ................................................... 30
Figure 1. 9 Blower Ilustration .............................................................................. 35

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 LIST OF TABLE

Table 1.1 Brine Storage Tank (TK-200) Specification .......................................... 9

Table 1.2 Polyacrylamide Storage Tank (TK-400) Specification ........................ 10
Table 1.3 Brine Pump (P-200) Specification ....................................................... 11
Table 1.4 Polyacrylamide Mixer Tank (M-200) Specification ............................ 12
Table 1.5 Na2CO3 Mixer Tank (M-201) Specification ......................................... 12
Table 1.6 Na2CO3 Pump (P-201) Specification ................................................... 14
Table 1.7 Brine Reactor (R-200) Specification .................................................... 15
Table 1.8 Brine Cooler (E-200) Specification ...................................................... 16
Table 1.9 Heat Exchanger (E-201) Specification ................................................. 18
Table 1.10 NaCl Pump (P-202) ............................................................................ 21
Table 1.11 Limestone Storage Tank (TK-100) Specification .............................. 21
Table 1.12 Belt Conveyor (C-100) Specification ................................................. 22
Table 1.13 Rotary Kiln (DD-100) Specification .................................................. 23
Table 1.14 Grater Cooler (JJ-100) Specification .................................................. 23
Table 1.15 Cyclone Rotary Kiln (FG-100) Specification .................................... 23
Table 1.16 Cyclone Grater Cooler (FG-101) Specification ................................. 23
Table 1.17 Belt Conveyor (C-101) Specification ................................................. 23
Table 1.18 Bucket Conveyor (C-102) Specification ............................................ 24
Table 1.19 Lime Slaker Tank (M-100) Specification .......................................... 24
Table 1.20 Rotary Filter (F-100) Specification .................................................... 25
Table 1.21 Lime Milk Tank (v-100) Specification .............................................. 25
Table 1.22 CO2 Cooler (E-101 A/B) Specification .............................................. 26
Table 1.23 Heat Exchanger (E-102) Specification ............................................... 28
Table 1.25 (R-201) Specification ......................................................................... 30
Table 1.26 (R-202) Specification ......................................................................... 30
Table 1.27 Rotary Drum Filter (F-101) Specification .......................................... 30
Table 1.28 Rotary Dryer Specification ................................................................. 31
Table 1.29 Finfan Cooler (E-301) Specification .................................................. 31
Table 1.30 Cyclone Rotary Dryer (FG-300) Specification .................................. 33
Table 1.31 Belt Conveyor (C-300) ....................................................................... 33
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Table 1.32 Ball Mill (SR-300) Specification ....................................................... 34
Table 1. 33 Bucket Elevator (C-301) Specification ............................................ 34
Table 1. 34 Na2CO3 Vessel (V-300) ..................................................................... 34
Table 1. 35 Blower (JB-100) Specification ......................................................... 35
Table 1.36 Pre-Limer (R-100) Specification ........................................................ 36
Table 1. 37 Pump Specification (P-100) ............................................................. 36
Table 1.38 NH3 Make Up Tank (TK-401) Specification ..................................... 37

Table 2.1 Water Tank (TK-500) Specification..................................................... 39

Table 2.2 Water Pump (P-500) Specification....................................................... 40
Table 2.3 Water Vessel (V-500) Specifications ................................................... 40
Table 2.4 Disinfectant Tank (TK-501) Specification ........................................... 41
Table 2.5 Waters Disinfectant Pump Specification .............................................. 42
Table 2.6 Disinfectant Mixer (M-500) Specification ........................................... 43
Table 2.7 Pump (P-503) Specification ................................................................. 44
Table 2.8 Water Sanitation Pump (P-504) Specification ..................................... 45
Table 2.9 Pump (P-501) Specification ................................................................. 45
Table 2.10 Cooling Tower (CT-500) Specification ............................................. 46
Table 2. 11 Cooling Water Vessel (V-501) Specification .................................... 47
Table 2.12 Water Process Pump (P-506) Specification ....................................... 48

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 1 CHAPTER 1
PROCESS EQUIPMENT SIZING

1.1 Brine Purification

1.1.1. Brine Storage Tank (TK-200)
Brine storage tank is used for holding brine before being processing.
The brine storage tank specification is shown on table below.
Table 1.1 Brine Storage Tank (TK-200) Specification
Equipment Specification
Equipment Name Storage Tank
Equipment Code TK-200
Type of Fluid/ Solid Brine
Horizontal/ Vertical Vertical with Concrete Supports
Open/ Close Vessel Close Vessel
Vessel Head Type Torispherical Type
Material Type SA-283C
L/D 0.8
Operating Data
Data Units Value
Mass Flow Rate kg/h 143917.23
3
Density kg/m 1114.01
3
m /h 129.188454
Volume m3/week 21703.6603
3
m 23874.0264
Temperature C 30
kPa 100
Pressure
psig 14.5038
Design Specification
m 32.4630102
Diameter Vessel
in 1278.07127
Radius Vessel in 639.035634
m 25.9704082
Length Vessel
in 1022.45701
Crown Radius in 1279.79663
in 0.86267866
Thickness Shell m 0.07188989
mm 71.8898884
in 1.5279712
Thickness Head m 0.12733093
mm 127.330933

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1.1.2. Polyacrylamide Storage Tank (TK-400)

Polyacrylamide storage tank is used for holding polyacrylamide as
flocculant in brine purification process. The polyacrylamide storage tank
specification is shown on table below.
Table 1.2 Polyacrylamide Storage Tank (TK-400) Specification
Equipment Specification
Equipment Name Storage Tank
Equipment Code TK-400
Type of Fluid/ Solid Na2CO3
Horizontal/ Vertical Vertical with Supports
Open/ Close Vessel Close Vessel
Vessel Head Type Torispherical Type
Material Type SA-283C
L/D 0.8
Operating Data
Data Units Value
Mass Flow Rate kg/h 1.4
3
Density kg/m 1220
3
m /h 0.001148
3
Volume m /week 0.192787
m3 0.212066
Temperature C 30
kPa 100
Pressure
psig 14.5038
Design Specification
m 0.698889
Diameter Vessel
in 27.51533
Radius Vessel in 13.75767
m 0.559112
Length Vessel
in 22.01227
Crown Radius in 27.55248
in 0.018572
Thickness Shell m 0.001548
mm 1.547703
in 0.032895
Thickness Head m 0.002741
mm 2.741281

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1.1.3. Brine Pump (P-200)

Pump is used to convert energy of an electric motor or turbine into
velocity or kinetic energy and then into pressure energy of the fluid being
pumped. The pump is centrifugal pump. This pump is used to pump from brine
storage tank (TK-200) to brine purification reactor (R-200). The pump
specification is shown on table below
Table 1.3 Brine Pump (P-200) Specification
Equipment Specification
Equipment Name Pump
Equipment Code P-200
Type Centrifugal Pump
Operating Data
Data Units Value
Fluid Type Brine
3
Density kg/m 1114.01
Pressure Inlet Pa 101325
Pressure Outlet Pa 206250
Vapor Pressure Pa 20492
Pressure Atmosphere Pa 101325
Mass Flow Rate kg/s 39.99472
Volumetric Flow Rate m3/s 0.035902
Efficiency 0.75
Design Specification
Power W 5239.195
Head m 10.02529
NPSHa m 16.27087

1.1.4. Polyacrylamide Mixer Tank (M-200)

Polyacrylamide mixer tank is used to mix polyacrylamide with water
before being brought to the brine purification reactor. The mixer tank
specification is shown on the table 1.4.

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Table 1.4 Polyacrylamide Mixer Tank (M-200) Specification

Polyacrylamide Mixer Tank

Code M-200
Function Mixing Polyacrylamide
Operating Condition
Storage Time (days) 1.00
Flowrate (kg/day) 29616.00
3
Capacity (m ) 0.07
o
Temperature ( C) 30
Pressure (bar) 1.10
Specification Design
Type Vertical Cylinder Tank
Material SA-283 C
Inside Diameter (m) 0.35
Tank Height (m) 0.53
Head Type Torispherical Head
Head Height (m) 0.058
Total Height 0.584
Shell Thickness (m) 0.006
Head Thickness (m) 0.004
Agitator
Impeller Type Pitch Blade
Number 1
Diameter 0.12
Shaft Diameter 0.01
Distance from Tank Bottom 0.12
Rotation Speed (rpm) 120
Power (W) 5.56
1.1.5. Na2CO3 Storage Tank (TK-301)
Na2CO3 storage tank is used to holding Na2CO3 before brine purification
processing. The Na2CO3 storage tank specification is shown on table below.
Table 1.5 Na2CO3 Mixer Tank (M-201) Specification
Equipment Specification
Equipment Name Storage Tank
Equipment Code TK-301
Type of Fluid/ Solid Na2CO3
Horizontal/ Vertical Vertical with Concrete Supports
Open/ Close Vessel Close Vessel
Vessel Head Type Torispherical Type
Material Type SA-283C
L/D 0.8

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Table 1.5 Na2CO3 Mixer Tank (M-201) Specification (con’t)

Operating Data
Data Units Value
Mass Flow Rate kg/h 22923.562
Density kg/m3 2540
m3/h 9.0250244
Volume m3/week 1516.2041
m3 1667.8245
Temperature C 30
kPa 100
Pressure
psig 14.5038
Design Specification
m 13.489099
Diameter Vessel
in 531.06688
Radius Vessel in 265.53344
m 10.791279
Length Vessel
in 424.8535
Crown Radius in 531.7838
in 0.3584621
Thickness Shell m 0.0298718
mm 29.871839
in 0.6349058
Thickness Head m 0.0529088
mm 52.908819
1.1.6. Na2CO3 Mixer Tank (M-201)
Na2CO3 mixing tank is used to mix sodium carbonate with water for brine
purification process. The mixer tank specification is shown on the table below.

Table 1. 6 Na2CO3 Mixer Tank (M-201) Specification

Na2CO3 Mixer Tank

Code M-201
Function Mixing Na2CO3
Operating Condition
Storage Time (days) 1.00
Flowrate (kg/day) 255329.81
3
Capacity (m ) 1.33
o
Temperature ( C) 30
Pressure (bar) 1.10

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Table 1.6 Na2CO3 Mixer Tank (M-201) Specification (Cont’d)

Specification Design
Type Vertical Cylinder Tank
Material SA-283 C
Inside Diameter (m) 0.95
Tank Height (m) 1.42
Head Type Torispherical Head
Head Height (m) 0.158
Total Height 1.575
Shell Thickness (m) 0.011
Head Thickness (m) 0.007
Agitator
Impeller Type Pitch Blade
Number 1
Diameter 0.32
Shaft Diameter 0.04
Distance from Tank Bottom 0.32
Rotation Speed (rpm) 100
Power (W) 201.83
1.1.7. Na2CO3 Pump (P-201)
Pump that is used for Na2CO3 solution is centrifugal pump. This pump is
used to pump from Na2CO3 mixer (M-201) to brine purification reactor (R-200).
The pump specification is shown on table 1.7.

Table 1.7 Na2CO3 Pump (P-201) Specification

Equipment Specification
Equipment Name Pump
Equipment Code P-201
Type Centrifugal Pump
Operating Data
Data Units Value
Fluid Type Na2CO3 Solution
Density kg/m3 2540
Pressure Inlet Pa 101325
Pressure Outlet Pa 206250
Vapor Pressure Pa 1
Pressure Atmosphere Pa 101325
Mass Flow Rate kg/s 2.803806
3
Volumetric Flow Rate m /s 0.001104
Efficiency 0.75
L pipe m 10

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Table 1.7 Na2CO3 Pump (P-201) Specification (cont’d)

Design Specification
Power W 161.0887
Head m 4.396959
NPSHa m 7.95938

1.1.8. Brine Reactor (R-200)

Table 1.8 Brine Reactor (R-200) Specification

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1.1.9. Brine Cooler (E-200)

Table 1.8 shown the specification of Heat Exchanger (E-200) that designed
using Aspen Design and Rating
Table 1.9 Brine Cooler (E-200) Specification
1 Company:PT. Seminggo Pabrik
2 Location:
3 Service of Unit: E-200 Our Reference:
4 Item No.: Your Reference:
5 Date: Rev No.: Job No.:
6 Size : 432 - 3657.6 mm Type: BEM HorizontalConnected in: 1 parallel 1 series
7 Surf/unit(eff.) 49.7 m² Shells/unit 1 Surf/shell(eff.) 49.7 m²
8 PERFORMANCE OF ONE UNIT
9 Fluid allocation Shell Side Tube Side
10 Fluid name 11 Utility WATER
11 Fluid quantity, Total kg/s 42.9666 76.5298
12 Vapor (In/Out) kg/s 0 0 0 0
13 Liquid kg/s 42.9666 42.9666 76.5298 76.5298
14 Noncondensable kg/s 0 0 0 0
15
16 Temperature (In/Out) °C 88.36 59.97 30 43
17 Bubble / Dew point °C / / / /
18 Density Vapor/Liquid kg/m³ / 1116.15 / 1129.46 / 995.76 / 991.1
19 Viscosity mPa-s / 1.158 / 1.9187 / 0.7977 / 0.6182
20 Molecular wt, Vap
21 Molecular wt, NC
22 Specific heat kJ/(kg-K) / 3.512 / 3.372 / 4.173 / 4.173
23 Thermal conductivity W/(m-K) / 0.6192 / 0.6108 / 0.615 / 0.6342
24 Latent heat kJ/kg
25 Pressure (abs) bar 1.01325 0.90967 1.01325 0.86697
26 Velocity (Mean/Max) m/s 0.53 / 0.9 1.92 / 1.93
27 Pressure drop, allow./calc. bar 0.11013 0.10358 0.20684 0.14628
28 Fouling resistance (min) m²-K/W 0 0 0 Ao based
29 Heat exchanged 4151 kW MTD (corrected) 37.23 °C
30 Transfer rate, Service 2242.2 Dirty 2489.7 Clean 2489.7 W/(m²-K)
31 CONSTRUCTION OF ONE SHELL Sketc
32 Shell Side Tube Side
33 Design/Vacuum/test pressure bar 3.44738 / / 3.44738 / /
34 Design temperature / MDMT °C 126.67 / 126.67 / S1 T2

35 Number passes per shell 1 1

36 Corrosion allowance mm 3.18 3.18 T1 S2

37 Connections In mm 1 203.2 / - 1 254 /-

38 Size/Rating Out 1 254 / - 1 203.2 / -
39 Nominal Intermediate / - / -
40 Tube #: 232 OD: 19.05 Tks. Average 2.11 mm Length: 3657.6 mm Pitch: 23.81 mm Tube
pattern:30
41 Tube type: Plain Insert:None Fin#: #/m Material:Carbon Steel
42 Shell Carbon Steel ID 438.15 OD 457.2 mm Shell cover -
43 Channel or bonnet Carbon Steel Channel cover -
44 Tubesheet-stationary Carbon Steel - Tubesheet-floating -
45 Floating head cover - Impingement protection None
46 Baffle-cross Carbon Steel Type Single segmental Cut(%d) 40.59 Hori Spacing: c/c 596.9mm
47 Baffle-long - Seal Type Inlet 895.35 mm
48 Supports-tube U-bend 0 Type
49 Bypass seal Tube-tubesheet joint Expanded only (2 grooves)(App.A 'i')
50 Expansion joint - Type None
51 RhoV2-Inlet nozzle 1588 Bundle entrance 420 Bundle exit 415 kg/(m-s²)
52 Gaskets - Shell side - Tube side Flat Metal Jacket Fibe
53 Floating head -
54 Code requirements ASME Code Sec VIII Div 1 TEMA class R - refinery service
55 Weight/Shell 1579.6 Filled with water 2165.9 Bundle 866.7 kg

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Figure 1.1 Setting Plan Brine Cooler (E-200)

Figure 1. 2 Tube sheet Brine Cooler (E-200)

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1.1.10. Heat Exchanger (E-201)

Table 1.9 shown the specification of Heat Exchanger (E-201) that designed
using Aspen Design and Rating
Table 1.10 Heat Exchanger (E-201) Specification
1 Company: PT. Seminggo Pabrik
2 Location:
3 Service of Unit: E-201 Our Reference:
4 Item No.: Your Reference:
5 Date: Rev No.: Job No.:
6 Size : 533 - 1828.8 mm Type: BEM Horizontal Connected in: 1 parallel 1 series
7 Surf/unit(eff.) 28.2 m² Shells/unit 1 Surf/shell(eff.) 28.2 m²
8 PERFORMANCE OF ONE UNIT
9 Fluid allocation Shell Side Tube Side
10 Fluid name 19 Utility WATER
11 Fluid quantity, Total kg/s 11.275 14.0271
12 Vapor (In/Out) kg/s 11.275 11.275 0 0
13 Liquid kg/s 0 0 14.0271 14.0271
14 Noncondensable kg/s 0 0 0 0
16 Temperature (In/Out) °C 904.45 851.34 30 43
17 Bubble / Dew point °C / / / /
18 Density Vapor/Liquid kg/m³ 1.91 / 1.27 / / 995.76 / 991.1
19 Viscosity mPa-s 0.0446 / 0.0432 / / 0.7977 / 0.6182
20 Molecular wt, Vap 44.01 44.01
21 Molecular wt, NC
22 Specific heat kJ/(kg-K) 1.276 / 1.264 / / 4.173 / 4.173
23 Thermal conductivity W/(m-K) 0.0774 / 0.0748 / / 0.615 / 0.6342
24 Latent heat kJ/kg
25 Pressure (abs) bar 4.25298 2.69281 1.01325 0.98411
26 Velocity (Mean/Max) m/s 114.81 / 163.49 0.29 / 0.3
27 Pressure drop, allow./calc. bar 3.23972 1.56017 0.20684 0.02914
28 Fouling resistance (min) m²-K/W 0 0 0 Ao based
29 Heat exchanged 760.8 kW MTD (corrected) 841.18 °C
30 Transfer rate, Service 32.1 Dirty 749.5 Clean 749.5 W/(m²-K)
31 CONSTRUCTION OF ONE SHELL Sketch
32 Shell Side Tube Side
33 Design/Vacuum/test pressure bar 4.82633 / / 3.44738 / /
S1 T2

34 Design temperature / MDMT °C 943.33 / 943.33 /

35 Number passes per shell 1 1
36 Corrosion allowance mm 3.18 3.18
T1 S2

37 Connections In mm 1 406.4 / - 1 101.6 / -

38 Size/Rating Out 1 406.4 / - 1 88.9 / -
39 Nominal Intermediate / - / -
40 Tube #: 277 OD: 19.05 Tks. Average 2.11mm Length: 1828.8 mm Pitch: 23.81 mm Tube pattern:30
41 Tube type: Plain Insert:None Fin#: #/m Material:Carbon Steel
42 Shell Carbon Steel ID 533.4 OD 558.8 mm Shell cover -
43 Channel or bonnet Carbon Steel Channel cover -
44 Tubesheet-stationary Carbon Steel - Tubesheet-floating -
45 Floating head cover - Impingement protection None
46 Baffle-cross Carbon Steel Type Single segmental Cut(%d) 38.4 Hori Spacing: c/c 590.5 mm
47 Baffle-long - Seal Type Inlet 554.04 mm
48 Supports-tube U-bend 0 Type
49 Bypass seal Tube-tubesheet joint Expanded only (2 grooves)(App.A 'i')
50 Expansion joint - Type None
51 RhoV2-Inlet nozzle 4789 Bundle entrance 19222 Bundle exit 37418 kg/(m-s²)
52 Gaskets - Shell side - Tube side Flat Metal Jacket Fibe
53 Floating head -
54 Code requirements ASME Code Sec VIII Div 1 TEMA class R - refinery service
55 Weight/Shell 1367.5 Filled with water 1783.7 Bundle 702.7 kg

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Figure 1. 3 Setting Plan Heat Exchanger (E-201)

Figure 1. 4 Tubesheet Heat Exchanger (E-201)

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1.1.11. Decanter (FL-200)

Decanter is used to separating the NaCl from the solid after being
purified and added flocculant. The heavy phase will be bought to the waste water
treatment, and the NaCl will be bought to the next process.
Table 1. 11 Decanter (FL-200) Specification
Equipment Specification
Equipment Name Decanter
Equipment Code FL-200
Separating NaCl from sludge
Function
after brine purification
Operating Data
Data Unit Value
Pressure psig 14.5038
Temperature F 140
Heavy Phase Density lb/ft3 121633.6808
Light Phase Density lb/ft3 134.8443949
Heavy Phase Flowrate lb/hr 1738.267776
Light Phase Flowrate lb/hr 81745.202
Heavy Phase Volumetric Rate ft3/hr 2.52137E-06
Light Phase Volumetric Rate ft3/hr 0.1683941
Dispersed Velocity ft/s 0.450449779
Continuous Velocity ft/s 0.047591635
Design Specification
m 1.5748
Diameter
in 62
Radius in 31
Length Effective ft 10
ft 20
Length Seam to Seam m 6.096
in 240
Head and Shell
Material Type SA-283C
Type of Head Hemispherical
L/D 3.870967742
in 0.041849057
Shell Thickness m 0.003487421
mm 3.487421392
in 0.020910414
Head Thickness m 0.001742535
mm 1.742534512

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1.1.12. NaCl Pump (P-202)

Pump that is used for NaCl (purified brine) solution is centrifugal pump.
This pump is used to pump from decanter (FL-200) to the solvay process. The
pump specification is shown on table below.
Table 1.12 NaCl Pump (P-202)
Equipment Specification
Equipment Name Pump
Equipment Code P-202
Type Centrifugal Pump
Operating Data
Data Units Value
Fluid Type Brine (NaCl)
Density kg/m3 1194.43
Pressure Inlet Pa 101325
Pressure Outlet Pa 206250
Vapor Pressure Pa 20492
Pressure Atmosphere Pa 101325
Mass Flow Rate kg/s 42.23389
Volumetric Flow Rate m3/s 0.035359
Efficiency 0.75
L pipe m 10
Design Specification
Power W 5160.02
Head m 9.350298
NPSHa m 15.17536

1.2 Lime Section

1.2.1 Limestone Storage Tank (TK-100)
Limestone storage tank is used for holding limestone before limestone
is brought to the rotary kiln for decomposition
Table 1.13 Limestone Storage Tank (TK-100) Specification
Equipment Specification
Equipment Name Storage Tank
Equipment Code TK-100
Type of Fluid/ Solid Limestone
Horizontal/ Vertical Vertical with Concrete Supports
Open/ Close Vessel Close Vessel
Vessel Head Type Torispherical Type
Material Type SA-283C
L/D 0.8

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Table 1.13 Limestone Storage Tank (TK-100) Specification (cont’d)

Operating Data
Data Units Value
Mass Flow Rate kg/h 60000
Density kg/m3 2711
m3/h 22.132055
Volume m3/week 3718.1852
m3 4090.0037
Temperature C
30

kPa 100
Pressure
psig 14.5038
Design Specification
m 18.136026
Diameter Vessel
in 714.01679
Radius Vessel in 357.00839
m 14.508821
Length Vessel
in 571.21343
Crown Radius in 714.98069
in 0.4819505
Thickness Shell m 0.0401625
mm 40.162539
in 0.8536277
Thickness Head m 0.0711356
mm 71.135645

1.2.2 Belt Conveyor (C-100)

Belt conveyor is used for bringing limestone from limestone storage tank
to the rotary kiln for being decomposition. The belt conveyor specification is
shown on table below
Table 1.14 Belt Conveyor (C-100) Specification

Equipment Specification
Equipment Name Conveyor
Equipment Code C-100
Type of Solid Limestone
Belt Conveyor Type Flat
Belt Conveyor Grade M-24 Grade
Belt Width Size 30
Running Angle of Repose 5
Data from Table 13.51

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Table 1.14 Belt Conveyor (C-100) Specification (cont’d)

Design Specification
Data Unit Value
kg/hr 60000
Mass Flow Rate
ton/hr 60
ft/min 444.1155
Conveyor Speed
m/s 2.256107
Inclination 0
Rise m 0
Distance m 15
Conveyor Length m 15

1.2.3 Rotary Kiln (DD-100)

Table 1.15 Rotary Kiln (DD-100) Specification

1.2.4 Grater Cooler (JJ-100)

Table 1.16 Grater Cooler (JJ-100) Specification

1.2.5 Cyclone Rotary Kiln (FG-100)

Table 1.17 Cyclone Rotary Kiln (FG-100) Specification

1.2.6 Cyclone Greater Cooler (FG-101)

Table 1.18 Cyclone Grater Cooler (FG-101) Specification

1.2.7 Belt Conveyor (C-101)

Belt conveyor is used for bringing CaO from fin fan cooler after being
cooled down for being mix with water in lime milk mixing tank (M-100). The
belt conveyor specification is shown on table below.
Table 1.19 Belt Conveyor (C-101) Specification
Equipment Specification
Equipment Name Conveyor
Equipment Code C-101

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Type of Solid CaO

Belt Conveyor Type Flat
Belt Conveyor Grade M-24 Grade
Belt Width Size 24
Running Angle of Repose 5
Data from Table 9.57
Design Specification
Data Unit Value
kg/hr 35645.89
Mass Flow Rate
ton/hr 35.64589
ft/min 372.4753
Conveyor Speed
m/s 1.892175
Inclination 0
Rise m 0
Distance m 12
Conveyor Length m 12

1.2.8 Bucket Elevator (C-102)

Table 1.20 Bucket Conveyor (C-102) Specification

1.2.9 Lime Slaker Tank (M-100)

Lime slaker mixer tank is used for mixing CaO and H2O. The mixer
specification is shown on the table below.
Table 1.21 Lime Slaker Tank (M-100) Specification

Ca(OH)2 Mixer Tank

Code M-100
Function Mixing Ca(OH)2
Operating Condition
Storage Time (days) 1.00
Flowrate (kg/day) 1023573.60
3
Capacity (m ) 19.32
o
Temperature ( C) 30
Pressure (bar) 1.10
Specification Design
Type Vertical Cylinder Tank
Material SA-283 C
Inside Diameter (m) 2.31
Tank Height (m) 3.46
Head Type Torispherical Head

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Head Height (m) 0.385

Total Height 3.848
Shell Thickness (m) 0.020
Head Thickness (m) 0.011
Agitator
Impeller Type Pitch Blade
Number 1
Diameter 0.77
Shaft Diameter 0.10
Distance from Tank Bottom 0.77
Rotation Speed (rpm) 100
Power (W) 4827.28

1.2.10 Rotary Filter (F-100)

Table 1.22 Rotary Filter (F-100) Specification

1.2.11 Lime Milk Tank (V-100)

Lime milk (Ca(OH)2) tank vessel is used for holding the lime milk
before it is being brought to the pre-limer reactor for NH3 recovery process.
The vessel specification is shown on table below.
Table 1.23 Lime Milk Tank (v-100) Specification
Equipment Specification
Equipment Name Vessel
Equipment Code V-100
Type of Fluid/ Solid Ca(OH)2 Solution
Horizontal/ Vertical Vertical with Concrete Supports
Open/ Close Vessel Close Vessel
Vessel Head Type Torispherical Type
Material Type SA-283C
L/D 0.8
Operating Data
Data Units Value
Mass Flow Rate kg/h 40645.9
3
Density kg/m 2210
3
m /h 18.39181
3
Volume m /week 3089.824
m3 3398.806
Temperature C 45
kPa 100
Pressure
psig 14.5038
Design Specification

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m 17.06126
Diameter Vessel
in 671.7031
Radius Vessel in 335.8515
m 13.64901
Length Vessel
in 537.3624
Crown Radius in 672.6098
in 0.453389
Thickness Shell m 0.037782
mm 37.78245
in 0.80304
Thickness Head m 0.06692
mm 66.92004

1.2.12 CO2 Cooler (E-101 A/B)

Table 1.22 shown the specification of Heat Exchanger (E-101 A/B) that
designed using Aspen Design and Rating
Table 1.24 CO2 Cooler (E-101 A/B) Specification
1 Company: PT. Seminggo Pabrik
2 Location:
3 Service of Unit: E-101 B Our Reference:
4 Item No.: Your Reference:
5 Date: Rev No.: Job No.:
6 Size : 584 - 2438.4 mm Type: BEM Horizontal Connected in: 2 parallel 1 series
7 Surf/unit(eff.) 106.4 m² Shells/unit 2 Surf/shell(eff.) 53m²
8 PERFORMANCE OF ONE UNIT
9 Fluid allocation Shell Side Tube Side
10 Fluid name 35A 52B
11 Fluid quantity, Total kg/s 11.275 6.8121
12 Vapor (In/Out) kg/s 11.275 11.275 6.8121 6.8121
13 Liquid kg/s 0 0 0 0
14 Noncondensable kg/s 0 0 0 0
15
16 Temperature (In/Out) °C 952.4 904.44 30 129.95
17 Bubble / Dew point °C / / / /
18 Density Vapor/Liquid kg/m³ 1.84 / 1.8 / 1.16 / 0.77 /
19 Viscosity mPa-s 0.0458 / 0.0446 / 0.0185 / 0.0229 /
20 Molecular wt, Vap 44.01 44.01 28.77 28.77
21 Molecular wt, NC
22 Specific heat kJ/(kg-K) 1.287 / 1.276 / 1.014 / 1.023 /
23 Thermal conductivity W/(m-K) 0.0796 / 0.0774 / 0.026 / 0.033 /
24 Latent heat kJ/kg
25 Pressure (abs) bar 4.25298 4.00656 1.01325 0.89922
26 Velocity (Mean/Max) m/s 32.47 / 37.51 53.1 / 66.33
27 Pressure drop, allow./calc. bar 0.25855 0.24641 0.20684 0.11403
28 Fouling resistance (min) m²-K/W 0 0 0 Ao based
29 Heat exchanged 693 kW MTD (corrected) 848.06 °C
30 Transfer rate, Service 7.7 Dirty 64.8 Clean 64.8 W/(m²-K)
31 CONSTRUCTION OF ONE SHELL Sketch
32 Shell Side Tube Side ]

33 Design/Vacuum/test pressure bar 4.82633 / / 3.44738 / /

34 Design temperature / MDMT °C 987.78 / 987.78 /
35 Number passes per shell 1 1
36 Corrosion allowance mm 3.18 3.18

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37 Connections In mm 1 355.6 /- 1 254 /-

38 Size/Rating Out 1 355.6 /- 1 254 /-
39 Nominal Intermediate / - -
40 Tube #: 385 OD: 19.05 Tks. Average 2.11 mm Length: 2438.4 mm Pitch: 23.81 mm Tube pattern:30
41 Tube type: Plain Insert:None Fin#: #/m Material:Carbon Steel
42 Shell Carbon Steel ID 584.2 OD 609.6 mm Shell cover -
43 Channel or bonnet Carbon Steel Channel cover -
44 Tubesheet-stationary Carbon Steel - Tubesheet-floating -
45 Floating head cover - Impingement protection None
46 Baffle-cross Carbon Steel Type Single segmental Cut(%d) 39.41 Hori Spacing: c/c 590.55 mm
47 Baffle-long - Seal Type Inlet 858.84 mm
48 Supports-tube U-bend 0 Type
49 Bypass seal Tube-tubesheet joint Expanded only (2 grooves)(App.A 'i')
50 Expansion joint - Type None
51 RhoV2-Inlet nozzle 2186 Bundle entrance 1841 Bundle exit 2491kg/(m-s²)
52 Gaskets - Shell side - Tube side Flat Metal Jacket Fibe
53 Floating head -
54 Code requirements ASME Code Sec VIII Div 1 TEMA class R - refinery service
55 Weight/Shell 2065.4 Filled with water 2863.4 Bundle 1111.8 kg

Figure 1. 5 Setting Plan CO2 Cooler

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Figure 1. 6 Tubesheet CO2 Cooler

1.2.13 Heat Exchanger (E-102)

Table 1.23 shown the specification of Heat Exchanger (E-101) that designed
using Aspen Design and Rating
Table 1.25 Heat Exchanger (E-102) Specification
1 Company: PT Seminggo Pabrik
2 Location:
3 Service of Unit: E-102 Our Reference:
4 Item No.: Your Reference:
5 Date: Rev No.: Job No.:
6 Size : 533 - 1828.8 mm Type: BEM Horizontal Connected in: 1 parallel 1 series
7 Surf/unit(eff.) 28.2m² Shells/unit 1 Surf/shell(eff.) 28.2 m²
8 PERFORMANCE OF ONE UNIT
9 Fluid allocation Shell Side Tube
Side
10 Fluid name 19 Utility WATER
11 Fluid quantity, Total kg/s 11.275 14.0271
12 Vapor (In/Out) kg/s 11.275 11.275 0 0
13 Liquid kg/s 0 0 14.0271 14.0271
14 Noncondensable kg/s 0 0 0 0
15
16 Temperature (In/Out) °C 904.45 851.34 30 43
17 Bubble / Dew point °C / / / /
18 Density Vapor/Liquid kg/m³ 1.91 / 1.27 / / 995.76 / 991.1
19 Viscosity mPa-s 0.0446 / 0.0432 / / 0.7977 / 0.6182
20 Molecular wt, Vap 44.01 44.01
21 Molecular wt, NC
22 Specific heat kJ/(kg-K) 1.276 / 1.264 / / 4.173 / 4.173
23 Thermal conductivity W/(m-K) 0.0774 / 0.0748 / / 0.615 / 0.6342
24 Latent heat kJ/kg
25 Pressure (abs) bar 4.25298 2.69281 1.01325 0.98411
26 Velocity (Mean/Max) m/s 114.81 / 163.49 0.29 / 0.3
27 Pressure drop, allow./calc. bar 3.23972 1.56017 0.20684 0.02914
28 Fouling resistance (min) m²-K/W 0 0 0 Ao based
29 Heat exchanged 760.8 kW MTD (corrected) 841.18 °C
30 Transfer rate, Service 32.1 Dirty 749.5 Clean 749.5 W/(m²-K)
31 CONSTRUCTION OF ONE SHELL Sketch
32 Shell Side Tube Side

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33 Design/Vacuum/test pressure bar 4.82633 / / 3.44738 / /

34 Design temperature / MDMT °C 943.33 / 943.33 / S1 T2

35 Number passes per shell 1 1

36 Corrosion allowance mm 3.18 3.18
37 Connections In mm 1 406.4 / - 1 101.6 T1 S2

/ -
38 Size/Rating Out 1 406.4 / - 1 88.9
/ -
39 Nominal Intermediate / - / -
40 Tube #: 277 OD: 19.05 Tks. Average 2.11 mm Length: 1828.8 mm Pitch: 23.81 mm Tube pattern:30
41 Tube type: Plain Insert:None Fin#: #/m Material:Carbon Steel
42 Shell Carbon Steel ID 533.4 OD 558.8 mm Shell cover -
43 Channel or bonnet Carbon Steel Channel cover -
44 Tubesheet-stationary Carbon Steel - Tubesheet-floating -
45 Floating head cover - Impingement protection None
46 Baffle-cross Carbon Steel Type Single segmental Cut(%d) 38.4 Hori Spacing: c/c 590.55 mm
47 Baffle-long - Seal Type Inlet 554.04 mm
48 Supports-tube U-bend 0 Type
49 Bypass seal Tube-tubesheet joint Expanded only (2 grooves)(App.A 'i')
50 Expansion joint - Type None
51 RhoV2-Inlet nozzle 4789 Bundle entrance 19222 Bundle exit 37418 kg/(m-s²)
52 Gaskets - Shell side - Tube side Flat Metal Jacket Fibe
53 Floating head -
54 Code requirements ASME Code Sec VIII Div 1 TEMA class R - refinery service
55 Weight/Shell 1367.5 Filled with water 1783.7 Bundle 702.7 kg

Figure 1. 7 Setting Plan Heat Exchanger (E-102)

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Figure 1. 8 Tubesheet Heat Exchanger (E-102)

1.3 Solvay Process
1.3.1. R-201
Table 1. 26 (R-201) Specification

1.3.2. R-202
Table 1.27 (R-202) Specification

1.4 Filtration of Sodium Bicarbonate

1.4.1. Rotary Drum Filter (F-101)
Rotary drum filter is used to separate solid product from liquid product.
The solid product (sodium bicarbonate) is separated from liquid NH4Cl. Total
flow rate is 186,039 kg/hr with solid flow rate is 12,337 kg/hr and liquid flow
rate is 18,968 kg/hr. The volumetric flow rate is 261 m3/hr. Separated sodium
bicarbonate is then used for further process to produce soda ash. The
specification of rotary drum filter is shown in Table 1.27
Table 1.28 Rotary Drum Filter (F-101) Specification

Name Internally-fed Rotary Drum Filter

Series JVS-I
Material 304ss/316ss
Flows 289m3/h
Filter Media Wedgewire Drum/Perforated Drum
Slot opening size 0.25~2.5 / 0.05~0.5mm

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Operation Automatic
Drum rate 4~5rpm
Certification ISO9001/ISO14001
Dimensions 1027x350x805 (mm)

1.5 Calcination of Sodium Bicarbonate

1.5.1. Rotary Dryer (E-300)
Rotary dryer is used to decompose sodium bicarbonate becoming
sodium carbonate, carbon dioxide, and water. Rotary dryer is using dry heated
air as the heating agent. The specification of rotary dryer is shown from Table
1.28.
Table 1.29 Rotary Dryer Specification

Performance
Water Circulation Rate
(kg/h) 724509
Water Temp. In (oC) 40
Water Temp. Out (oC) 25
Fan HP (HP) 52,48
Construction Data
Counter-flow induced
Type draft
Tower height (m) 3,50
Area (ft2) 1280,00
Cooling Water Balance
Evaporation Losses (kg/h) 9237,49
Drift Losses (kg/h) 1449,02
Blowdown (kg/h) 3079,16
Make-Up Rate (kg/h) 13765,671

1.5.2. Finfan Cooler (E-301)

Finfan cooler is used to transfer heat from the solid phase to the atmosfer
by blewing them with air. The finfan cooler is similar with air cooled heat
exchanger which can be designed using Aspen Exchanger Design and Rating.
The specification of finfan cooler is shown from Table 1.28.

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Figure 1. 9 Finfan Cooler Illustration

Table 1.30 Finfan Cooler (E-301) Specification

Equipment Specification
Code E-301
Operating Condition
Unit Data Out Side Tube Side
Fluid Stream Air Na2CO3
Fluid Flow kg/h 804776 25471
Temperature in °C 30 165
Temperature out °C 34.98 35
Velocity m/s 5.53 0.71
Total Head Load kW 1117.7
Dimension - Tube
Material Carbon Steel
Length Tubes per
m 9.144 192
Actual Bundle
Transverse Surface
mm 60 0.84
Pitch Effectiveness
Longitudinal
mm 51.96 Pitch Angle 30
Pitch
Outlet
mm 25.4
Diameter
Inlet
mm 22.1
Diameter
Tube
Thermal W/(m.K) 60.2409
Conductivity
Dimension - Fin
Material Aluminum 1060

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Fin Type G-Finned

Fin Tip Diameter mm 57.15
Fin Thickness mm 0.28
Root Diameter mm 25.4
Dimension - Outside & Fan
Drive
Type Draft Induced 95%
Efficiency
Fans/bay 2 Fan Efficiency 65%
Fan Diameter m 3.048

1.5.3. Cyclone Rotary Dryer (FG-300)

Table 1.31 Cyclone Rotary Dryer (FG-300) Specification

1.5.4. Belt Conveyor (C-300)

This belt conveyor is used to bring sodium carbonate from rotary dryer
to ball mill. The belt conveyor specification is shown on table below
Table 1.32 Belt Conveyor (C-300)
Equipment Specification
Equipment Name Conveyor
Equipment Code C-300
Type of Solid Sodium Carbonate
Belt Conveyor Type Flat
Belt Conveyor Grade SHR (T-2) Grade
Belt Width Size 30
Running Angle of Repose 5
Data from Table 13.51
Design Specification
Data Unit Value
kg/hr 25470.61
Mass Flow Rate
ton/hr 25.47061
ft/min 188.5315
Conveyor Speed
m/s 0.95774
Inclination 10
Rise m 2.644905
Distance m 15
Conveyor Length m 15.2314
1.5.5. Ball Mill (SR-300)

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Ball mill is used to reduce and size of the sodium carbonate to the
standart size of sodium carbonate
Table 1.33 Ball Mill (SR-300) Specification

Type Continuous Ball Mills

Model 3200 x 4500
Capacity (Ton/D) 611,295
Power (hp) 186
Mill speed (rpm) 22,5
Ball charge (Ton) 13,10
Dimension
L (mm) 5600
W (mm) 1800
H (mm) 2100
Power (kW) 138,9915948

1.5.6. Bucket Elevator (C-301)

Table 1. 34 Bucket Elevator (C-301) Specification

1.5.7. Na2CO3 Vessel (V-300)

This vessel is used for holding Na2CO3 before being brought to the
Na2CO3 storage tank. The vessel specification is shown below
Table 1. 35 Na2CO3 Vessel (V-300)
Equipment Specification
Equipment Name Vessel
Equipment Code V-300
Type of Fluid/ Solid Na2CO3
Horizontal/ Vertical Vertical with Concrete Supports
Open/ Close Vessel Close Vessel
Vessel Head Type Torispherical Type
Material Type SA-283C
L/D 0.8
Operating Data
Data Units Value
Mass Flow Rate kg/h 25470.61
3
Density kg/m 2540
m3/h 10.0278
Volume m3/week 1684.67
3
m 1853.137
Temperature C 30
kPa 100
Pressure
psig 14.5038

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Design Specification
m 13.96635
Diameter Vessel
in 549.8561
Radius Vessel in 274.9281
m 11.17308
Length Vessel
in 439.8849
Crown Radius in 550.5984
in 0.371145
Thickness Shell m 0.030929
mm 30.92871
in 0.657369
Thickness Head m 0.054781
mm 54.78074

1.5.8. Blower (JB-100)

Sizing of blower to increase the velocity of air through the heat
exchangers as a cooling agent. The sizing method is done by benchmarking to a
vendor which has a similar air flow capacity. The specification of blower is
shown from Table 1.35.

Figure 1.10 Blower Ilustration

(Source: Shandong Mingtian Machinery Co., Ltd)

Table 1.36 Blower (JB-100) Specification

Equipment Specification
24523.7 kg/hr
Air Mass Flowrate
54065.503 lb/hr
1.164 kg/m3
Air Density
0.07269 lb/ft3
21068.47079 m3/hr
Volumetric Flowrate
351.1411798 m3/min

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Vendor Shandong Mingtian Machinery Co., Ltd

Type of Blower Roots Air Blower

Model MTRG450
Maximum Capcity 341.1 m3/minutes
Power 710-1000 kW
Rotary Speed 740 rpm
Maximum Pressure
58.8 kPa
Rise
Dimension
Outlet Size 450 mm
Width 2280 mm
Height 4100 mm
Outlet Flange Center
385 mm
Height

1.6 Recovery Ammonia

1.6.1. Pre-Limer (R-100)
Table 1.37 Pre-Limer (R-100) Specification

1.6.2. Pump Ca(OH)2 (P-100)

Pump that is used for Ca(OH)2 solution is centrifugal pump. This pump
is used to pump the fluid from vessel Ca(OH)2 (V-100) to the ammonia recovery
reactor/ pre-limer reactor (R-100). The pump specification is shown on table
below.
Table 1. 38 Pump Specification (P-100)
Equipment Specification
Equipment Name Pump
Equipment Code P-100
Type Centrifugal Pump
Operating Data
Data Units Value
Fluid Type Ca(OH)2 Solution
Density kg/m3 2210
Pressure Inlet Pa 101325
Pressure Outlet Pa 206250
Vapor Pressure Pa 8700
Pressure Atmosphere Pa 101325

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Mass Flow Rate kg/s 12.35869

Volumetric Flow Rate m3/s 0.005592
Efficiency 0.75
L pipe m 10
Design Specification
Power W 816.0773
Head m 5.053519
NPSHa m 8.746232

1.6.3. NH3 Make Up Tank (TK-401)

Ammonia make up tank is used for ammonia holding tank before used
in solvay process for making sodium bicarbonate. The NH3 make up storage
tank specification is shown on table below
Table 1.39 NH3 Make Up Tank (TK-401) Specification
Equipment Specification
Equipment Name Storage Tank
Equipment Code TK-401
Type of Fluid/ Solid NH3 Solution
Horizontal/ Vertical Vertical with Concrete Supports
Open/ Close Vessel Close Vessel
Vessel Head Type Torispherical Type
Material Type SA-283C
L/D 0.8
Operating Data
Data Units Value
Mass Flow Rate kg/h 11886.94
3
Density kg/m 880
3
m /h 13.50788
3
Volume m /week 2269.324
m3 2496.257
Temperature C 30
kPa 100
Pressure
psig 14.5038
Design Specification
m 15.40915
Diameter Vessel
in 606.6596
Radius Vessel in 303.3298
m 12.32732
Length Vessel
in 485.3276
Crown Radius in 607.4785
Thickness Shell in 0.409486

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m 0.034124
mm 34.12383
in 0.725279
Thickness Head m 0.06044
mm 60.43992

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 2 CHAPTER II
UTILITIES AND WASTE TREATMENT EQUIPMENT SIZING9

2.1. Utilities
2.1.1. Water Tank (TK-500)
Water tank is used for holding make up water tank for processing water for
cooling tower and sanitation process. The tank specification is shown below
Table 2.1 Water Tank (TK-500) Specification

Equipment Specification
Equipment Name Storage Tank
Equipment Code TK-500
Type of Fluid/ Solid Water
Horizontal/ Vertical Vertical with Concrete Supports
Open/ Close Vessel Close Vessel
Vessel Head Type Torispherical Type
Material Type SA-283C
L/D 0.8
Operating Data
Data Units Value
Mass Flow Rate kg/h 1107064.2
3
Density kg/m 1000
3
m /h 1107.0642
Volume m3/week 185986.78
3
m 204585.46
Temperature C 25
kPa 100
Pressure
psig 14.5038
Design Specification
m 65.957167
Diameter Vessel
in 2596.7388
Radius Vessel in 1298.3694
m 52.765733
Length Vessel
in 2077.3911
Crown Radius m 2600.2444
in 1.7527592
Thickness Shell m 0.1460633
mm 146.06327
in 3.1044764
Thickness Head m 0.2587064
mm 258.70637

39
 40

2.1.2. Water Pump (P-500)

Pump that is used for water is centrifugal pump. This pump is used to pump
from water tank (TK-500) to water vessel (V-500) before processing). The pump
specification is shown on table below.
Table 2.2 Water Pump (P-500) Specification
Equipment Specification
Equipment Name Pump
Equipment Code P-500
Type Centrifugal Pump
Operating Data
Data Units Value
Fluid Type Water
3
Density kg/m 1000
Pressure Inlet Pa 10.33929
Pressure Outlet Pa 206250
Vapor Pressure Pa 3169
Pressure Atmosphere Pa 101325
Mass Flow Rate kg/s 307.5178
3
Volumetric Flow Rate m /s 0.307518
Efficiency 0.75
L pipe m 10
Design Specification
Power W 86418.16
Head m 21.50651
NPSHa m 9.555329

2.1.3. Water Vessel (V-500)

Water vessel is used for holding water before it is being pumped to the
sanitation process and cooling tower. The vessel specification is shown below
Table 2.3 Water Vessel (V-500) Specifications
Equipment Specification
Equipment Name Vessel
Equipment Code V-500
Type of Fluid/ Solid Water
Horizontal/ Vertical Vertical with Concrete Supports
Open/ Close Vessel Close Vessel
Vessel Head Type Torispherical Type
Material Type SA-283C
L/D 0.8

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 41

Table 2.3 Water Vessel (V-500) Specifications (cont’d)

Operating Data
Data Units Value
Mass Flow Rate kg/h 1107064
3
Density kg/m 1000
3
m /h 1107.06
3
Volume m /week 185987
m3 204585
Temperature C 25
kPa 100
Pressure
psig 14.5038
Design Specification
m 65.9572
Diameter Vessel
in 2596.74
Radius Vessel in 1298.37
m 52.7657
Length Vessel
in 2077.39
Crown Radius m 2600.24
in 1.75276
Thickness Shell m 0.14606
mm 146.063
in 3.10448
Thickness Head m 0.25871
mm 258.706

2.1.4. Water Sanitation Utillities

1. Disinfectant Tank (TK-501)
Disinfectant tank is used for holding sodium hypochlorite solution for water
sanitation process. Disinfectant will be bought to the mixer disinfectant to mix
it with water before the water sanitation is being brought to the office for
consuming.
Table 2.4 Disinfectant Tank (TK-501) Specification
Equipment Specification
Equipment Name Storage Tank
Equipment Code TK-501
Type of Fluid/ Solid Sodium Hypochlorite Solution
Horizontal/ Vertical Vertical with Supports
Open/ Close Vessel Close Vessel
Vessel Head Type Torispherical Type
Material Type SA-283C
L/D 0.8

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 42

Table 2.4 Disinfectant Tank (TK-501) Specification (cont’d)

Operating Data
Data Units Value
Mass Flow Rate kg/h 10
Density kg/m3 1110
m3/h 0.009009009
Volume m3/week 1.513513514
m3 1.664864865
Temperature C 15
kPa 100
Pressure
psig 14.5038
Design Specification
m 1.379521215
Diameter Vessel
in 54.31185885
Radius Vessel in 27.15592943
m 1.103616972
Length Vessel
in 43.44948708
Crown Radius m 54.38517821
in 0.036659678
Thickness Shell m 0.003054973
mm 3.0549732
in 0.064931399
Thickness Head m 0.00541095
mm 5.410949949

2. Disinfectant Pump (P-502)

Pump that is used for sodium hypochlorite solution is centrifugal pump.
This pump is used to pump from disinfectant tank (TK-500) to disinfectant
mixer (M-500). The pump specification is shown on table below.
Table 2.5 Waters Disinfectant Pump Specification
Equipment Specification
Equipment Name Pump
Equipment Code P-502
Type Centrifugal Pump
Operating Data
Data Units Value
Fluid Type Sodium Hypochlorite Solution
Density kg/m3 1110
Pressure Inlet Pa 101325
Pressure Outlet Pa 206250
Vapor Pressure Pa 2500

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 43

Table 2.5 Waters Disinfectant Pump Specification (cont’d)

Pressure Atmosphere Pa 101325
Mass Flow Rate kg/s 0.002777778
Volumetric Flow Rate m3/s 2.5025E-06
Efficiency 0.75
L pipe m 10
Design Specification
Power W 0.365195576
Head m 10.06151077
NPSHa m 17.9836262

3. Disinfectant Mixer (M-500)

Disinfectant mixer tank is used for mixing disinfectant with water
for water sanitation processing. The mixer tank specification is shown on
the table below.
Table 2.6 Disinfectant Mixer (M-500) Specification
Disinfectant Mixer Tank
Code M-500
Function Mixing Disinfectant
Operating Condition
Storage Time (days) 1.00
Flowrate (kg/day) 2004.00
3
Capacity (m ) 0.07
o
Temperature ( C) 30
Pressure (bar) 1.10
Specification Design
Vertical Cylinder
Type
Tank
Material SA-283 C
Inside Diameter (m) 0.35
Tank Height (m) 0.52
Head Type Torispherical Head
Head Height (m) 0.058
Total Height 0.578
Shell Thickness (m) 0.004
Head Thickness (m) 0.004
Agitator
Impeller Type Pitch Blade
Number 1

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 44

Table 2.6 Disinfectant Mixer (M-500) Specification (cont’d)

Diameter 0.12
Shaft Diameter 0.01
Distance from Tank Bottom 0.12
Rotation Speed (rpm) 100
Power (W) 0.21

4. Pump (P-503)
Pump that is used for water before processing is centrifugal pump. This
pump is used to pump from water before processing vessel (V-500) to
disinfectant mixer (M-500). The pump specification is shown on table below.
Table 2.7 Pump (P-503) Specification

Equipment Specification
Equipment Name Pump
Equipment Code P-503
Type Centrifugal Pump
Operating Data
Data Units Value
Fluid Type Water
3
Density kg/m 1000
Pressure Inlet Pa 101325
Pressure Outlet Pa 206250
Vapor Pressure Pa 3169
Pressure Atmosphere Pa 101325
Mass Flow Rate kg/s 0.020417
3
Volumetric Flow Rate m /s 2.04E-05
Efficiency 0.75
L pipe m 10
Design Specification
Power W 2.979448
Head m 11.16828
NPSHa m 19.89356

5. Water Sanitation Pump (P-504)

Pump that is used for water sanitation is centrifugal pump. This pump is
used to pump from disinfectant mixer (M-500) to office for water sanitation.
The pump specification is shown on Table 2.8.

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 45

Table 2.8 Water Sanitation Pump (P-504) Specification

Equipment Specification
Equipment Name Pump
Equipment Code P-504
Type Centrifugal Pump
Operating Data
Data Units Value
Fluid Type Water
3
Density kg/m 1000
Pressure Inlet Pa 101325
Pressure Outlet Pa 206250
Vapor Pressure Pa 3169
Pressure Atmosphere Pa 101325
Mass Flow Rate kg/s 0.020417
3
Volumetric Flow Rate m /s 2.04E-05
Efficiency 0.75
L pipe m 10
Design Specification
Power W 2.979448
Head m 11.16828
NPSHa m 19.89356

2.1.5. Cooling Water Utillities

1. Pump (P-501)
Pump that is used for water before processing is centrifugal pump. This
pump is used to pump from water before processing vessel (V-500) to cooling
tower. The pump specification is shown on table below.
Table 2.9 Pump (P-501) Specification
Equipment Specification
Equipment Name Pump
Equipment Code P-501
Type Centrifugal Pump
Operating Data
Data Units Value
Fluid Type Water
3
Density kg/m 1000
Pressure Inlet Pa 101325

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 46

Table 2.9 Pump (P-501) Specification (cont’d)

Pressure Outlet Pa 206250
Vapor Pressure Pa 3169
Pressure Atmosphere Pa 101325
Mass Flow Rate kg/s 301.0492
Volumetric Flow Rate m3/s 0.301049
Efficiency 0.75
L pipe m 10
Design Specification
P W 43932.75
Head m 11.16828
NPSHa m 19.89356

2. Cooling Tower (CT-500)

The cooling tower is used to cool down cooling water that is used for heat
exchanger networking. Cooling tower is needed in the plant to produce 25°C water
Table 2.10 Cooling Tower (CT-500) Specification

Performance
Water Circulation Rate (kg/h) 724509
o
Water Temp. In ( C) 40
Water Temp. Out (oC) 25
Fan HP (HP) 52,48
Construction Data
Type Counter-flow induced draft
Tower height (m) 3,50
Area (ft2) 1280,00
Cooling Water Balance
Evaporation Losses (kg/h) 9237,49
Drift Losses (kg/h) 1449,02
Blowdown (kg/h) 3079,16
Make-Up Rate (kg/h) 13765,671

3. Cooling Water Vessel (V-501)

Cooling water vessel is used to holding water from cooling tower before
being pumped back to the main plant for processing. The vessel specification is
shown on Table 2.11.

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 47

Table 2. 11 Cooling Water Vessel (V-501) Specification

Equipment Specification
Equipment Name Vessel
Equipment Code V-501
Type of Fluid/ Solid Water
Horizontal/ Vertical Vertical with Concrete Supports
Open/ Close Vessel Close Vessel
Vessel Head Type Torispherical Type
Material Type SA-283C
L/D 0.8
Operating Data
Data Units Value
Mass Flow Rate kg/h 1083777
3
Density kg/m 1000
m3/h 1083.777
Volume m3/week 182074.5
m3 200282
Temperature C 25
kPa 100
Pressure
psig 14.5038
Design Specification
m 65.49606
Diameter Vessel
in 2578.585
Radius Vessel in 1289.292
m 52.39684
Length Vessel
in 2062.868
Crown Radius m 2582.066
in 1.740506
Thickness Shell m 0.145042
mm 145.0421
in 3.082773
Thickness Head m 0.256898
mm 256.8977

2.1.6. Water Process Pump (P-506)

Pump that is used for water before processing is centrifugal pump. This
pump is used to pump from vessel after cooling tower (V-501) back to the plant for
process. The pump specification is shown on Table 2.12.

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 48

Table 2.12 Water Process Pump (P-506) Specification

Equipment Specification
Equipment Name Pump
Equipment Code P-505
Type Centrifugal Pump
Operating Data
Data Units Value
Fluid Type Clean Brine
Density kg/m3 1000
Pressure Inlet Pa 101325
Pressure Outlet Pa 206250
Vapor Pressure Pa 3169
Pressure Atmosphere Pa 101325
Mass Flow Rate kg/s 301.0492
3
Volumetric Flow Rate m /s 0.301049
Efficiency 0.75
L pipe m 10
Design Specification
Power W 43932.75
Head m 11.16828
NPSHa m 19.89356

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3 CONCLUSION

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REFERENCES

50 Universitas Indonesia
 APPENDIX A
Heat Exchanger

Function : to incrase or decrease fluid temperature by indirect contact with another

fluid
Type : Shell and Tube
a. Step by Step Designing Heat Exchanger by using Aspen Design and Rating
Here are the step by step of designing heat exchanger by utilizing Aspen
Design and Rating software to achive both sizing and mechanical drawing
of heat exchanger.
1. Open the software and choose new and then choose the heat exchanger
type.

Figure A. 1 Homepage

2. Import the aspen plus or hysys file of the plant simulation, choose the
HE that want to design.

Figure A. 2 Choose Heat Exchanger Page

51 Universitas Indonesia
 52

3. Runnig the software, to see the result, kindly check the result summary

Figure A.3 Running Page

4. For knowing the mechanical drawing, check to the mechanical design.

Figure A.4 Mechanical Drawing Page

Universitas Indonesia
 APPENDIX B
Cooling Tower

Function : to reduce heat from cooling water return for cooling system from 40 0 C
to 250 C.
Type : Induced Draft Cooling Tower
Step by step calculating size of the cooling tower
1. Calculate water requirement to be cooled (W)
2. Define inlet temperatur (T1) and outlet temperature (T2) of cooling water
3. Define relative humdity to calclate dry bulb temperature (Tdb) and wet bulb
temperature (Twb) of air from psycrhomatric chart
4. Calculate temperature approach
temperature approach = T2-Twb
5. Calculate cooling range
cooling range = T1-T2
6. Define water concentration (Cw) from Figure 12.8c, Perry’s Handbook 8th
edition

Source: Perry. 2008. Chemical Engineering Handbook

7. Calculate tower area
𝑄
𝐴=
𝑐𝑤
8. Calculate tower dimension (Length/Width)
𝑃
=2
𝐿
9. Defie holding time to calculate basin dimension (height)

53 Universitas Indonesia
 54

𝑉 = 𝑊 𝑥 𝐻𝑜𝑙𝑑𝑖𝑛𝑔 𝑇𝑖𝑚𝑒
𝑉
𝐻=
𝑃𝑥𝐿
10. Calculation fan motor power
Fan power is defined from figure 12.8d, Perry’s Handbook 8th edition

Source: Perry. 2008. Chemical Engineering Handbook

ℎ𝑝
𝑇𝑜𝑡𝑎𝑙 𝑃𝑜𝑤𝑒𝑟 = 𝐴𝑟𝑒𝑎 𝑥 0,031
𝑓𝑡 2
𝑇𝑜𝑡𝑎𝑙 𝑃𝑜𝑤𝑒𝑟
𝐹𝑎𝑛 𝑝𝑜𝑤𝑒𝑟 =
𝑀𝑜𝑡𝑜𝑟 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
Define motor eficiency
𝑓𝑎𝑛 𝑝𝑜𝑤𝑒𝑟
𝑓𝑎𝑛 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
𝑀𝑜𝑡𝑜𝑟 𝑝𝑜𝑤𝑒𝑟 =
𝑚𝑜𝑡𝑜𝑟 𝑒𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

Universitas Indonesia
 APPENDIX C
Rotary Dryer Calculations

There are several steps to sizing rotary dryer:

1. Calculation of Heat Duty
The calculation is using ambient temperature at 30°C. From the
Psychometric chart, the humidity can be calculated. Humidity (H) = 0.03016 kg of
water per kg of dry air. Therefore, the humid of Air is:
𝐶𝑠 = 1.005 + 1.88𝐻
The amount of air needed:
𝑄
𝑚𝑎 =
𝐶𝑠 𝛥𝑇
Humidity of outlet air:
𝑚𝑣𝑎𝑝𝑜𝑟
𝐻= + 𝐻30°𝐶
𝑚𝑎𝑖𝑟
Relative humidity of outlet air:
𝑃𝐻2 𝑂
𝑅𝐻 =
𝑃°
If the relative humidity is less than 100% which means the outlet air does
not exceed the capacity of the air to carry vapor. Therefore, the air mass flowrate is
taken from simulation in Aspen Plus.
2. Calculation of Inside Diameter & Length
The diameter can be calculated by dividing mass flowrate with mass
velocity of the air. According to McCabe, Harriot, & Smith, 1993, mass velocity of
the air ranges from 2000 kg/hr-m2 up to 25000 kg/hr-m2. In this case, the mass
velocity of air is assumed 8000 kg/hr-m2. The area of dryer:
𝑚𝑎
𝐴=
𝐺
The diameter of dryer:

4𝐴
𝐷𝑖 = √
𝜋

Drying diameter ranges from 1 to 3 m (McCabe, Harriot, & Smith, 1993).

The length of the drier is done from heat transfer equation.
𝑄 = 𝑈𝑎 𝐴𝐿(∆𝑇)𝑙𝑚

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 56

𝑄
𝐿=
𝑈𝑎 𝐴(∆𝑇)𝑙𝑚
The following empirical equation is used to calculate the overall heat
transfer coefficient from Perry’s Handbook with the index n = 0.67. The k value
falls in the range 3.75 ≤ k ≤ 5.25 as suggested by AICHE for SI unit. Assuming k
=4.75.
𝑘𝐺 𝑛
𝑈𝑎 =
𝐷
For the calculation of wet bulb temperature, the most economical operation
of rotary dryer can be achieved for Nt is in general between 1.5 and 2.5 (Mujumdar,
2014). Assuming the value of Nt = 2, so wet bulb temperature can be calculated by
trial and error method.
𝑇𝐴𝑖𝑛 − 𝑇𝑤
𝑁𝑡 = ln ( )
𝑇𝐴𝑜𝑢𝑡 − 𝑇𝑤
3. Calculating the logarithmic mean temperature difference:
(𝑇𝐴𝑖𝑛 − 𝑇𝑤 ) − (𝑇𝐴𝑜𝑢𝑡 − 𝑇𝑤 )
(∆𝑇)𝑙𝑚 =
𝑇 −𝑇
ln (𝑇 𝐴𝑖𝑛 − 𝑇𝑤 )
𝐴𝑜𝑢𝑡 𝑤

After that, the L/D ratio should be checked, because L/D ratio is efficient
between 4 and 10 for industrial dryers (Mujumdar, 2014).
4. Calculation of RPM, Flight Design & Residence Time
Speed values ranges 0.1 to 0.5 m/s (van’t Land, 2012). Assuming the
peripheral speed of rotation to be 0.1 m/s.
𝑝𝑒𝑟𝑖𝑝ℎ𝑒𝑟𝑎𝑙 𝑠𝑝𝑒𝑒𝑑
𝑅𝑃𝑀 =
𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
Flight design:
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐹𝑙𝑖𝑔ℎ𝑡 = 3𝐷, (𝐷 𝑖𝑛 𝑓𝑒𝑒𝑡)
Flight depth:
𝐷
𝐹𝑑 =
8
Using the following empirical equation for the residence time (in minutes)
in dryer: (Residence time of rotary dryer typically ranges from 5 to 90 minutes).
𝐵 = 5𝑑𝑝 −0.5
0.23𝐿 2𝐵𝐿𝐺
𝜏= 0.9
+
𝑆𝑁 𝐷 𝐹

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 57

5. Calculation of Shell Dryer Thickness & Outer Diameter

Considering the material to be used is Carbon Steel (SA 285, Grade C)
because it can withstand up to 343.33°C. For operating pressure of 14.7 psia, the
design pressure is 24.7 psia of 170253.57 Pa (Hesse & Rushton, 1975).
𝑆𝑤 = 𝑆𝑢 × 𝐹𝑚 × 𝐹𝑎 × 𝐹𝑟 × 𝐹𝑠
Where,
Sw = working stress
Su = minimum specified tensile strength, 380 MPa (ASME SA285 Grade C)
Fm = material factor, 0.92 for Grade C material
Fa = radiographing factor, 1.00 since radiographing is not employed
Fr = stress relieving factor, 1.00 since relieving is not employed
Fs = factor of safety, 0.25 for temperature less than 315.56°C
Using the following equation to calculate shell thickness with a corrosion
allowance of 6.35 mm (Hesse & Rushton, 1975) and efficiency of the joint 0.70 for
double-welded butt joint since radiographing is not employed (Sinnot, 2005):
𝑃𝐷
𝑡𝑠 = +𝐶
2𝑆𝑤 𝑒 − 𝑃
The minimum shell thickness of equipment vessel with 1.0668 - 1.524-m
diameter is 8.128 mm (Couper, Penney, Fair, & Walas, 2005), therefore above
value can be accepted. To calculate the outer diameter of the dryer:
𝐷𝑜 = 𝐷𝑖 + 2𝑡𝑠
6. Calculation of The Insulation Thickness
To limit heat loss an insulation is to be given to the dryer. The chosen
insulating material is brick. From literature, its thermal conductivity equals to 0.72
W/m·K. Mild steel however has a thermal conductivity of 51.9220 W/m·K.
2𝜋𝐿(𝑇2 − 𝑇1 )
𝑄= 𝑟 𝑟 +𝑡
ln (𝑟2 ) ln ( 2 𝑟 𝑖 )
1 2
+
𝑘𝐴 𝑘𝐵
The value of ti will be calculated by trial and error method. Therefore, the
total diameter of the dryer:
𝐷𝑡 = 𝐷𝑜 + 2𝑡𝑖
7. Calculation of The Live Load & Rotating Load

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 58

To calculate the volume of shell material:

𝜋(𝐷𝑜2 − 𝐷𝑖2 )𝐿
𝑉𝑆𝑀 =
4
To calculate the volume of insulating material:
𝜋(𝐷𝑡2 − 𝐷𝑜2 )𝐿
𝑉𝐼𝑀 =
4
To calculate the weight of unloaded dryer using the density of mild steel
7850 kg/m3:
𝑊𝑑𝑟𝑦𝑒𝑟 = 𝑉𝑆𝑀 × 𝜌
To calculate the weight of insulating material using the density of brick
2165 kg/m3:
𝑊𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = 𝑉𝐼𝑀 × 𝜌
To calculate the weight of the material in the dryer:
𝑊𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 = 𝑚𝑁𝑎𝐻𝐶𝑂3 × 𝜏
Total weight of the loaded dryer:
𝑊𝑡𝑜𝑡𝑎𝑙 = 𝑊𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 + 𝑊𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 + 𝑊𝑑𝑟𝑦𝑒𝑟
Calculation of Blower Power, Motive Power, and Power to Drive a Driver
Using the equation in (van’t Land, 2012) for the calculation of motor power for
rotation for rotary dryers:
0.3𝜋𝐷𝑖2 𝐿
𝑃𝑚 =
4
To calculate the power requirement for blower:
𝑛𝑅𝑇
𝑄𝑖𝑛𝑙𝑒𝑡 𝑎𝑖𝑟 =
𝑃
Using the following equation proposed by CE Raymond Division,
Combustion Engineering Inc., to calculate the power to drive a dryer with flights
(Mujumdar, 2014):
𝑁(4.75𝐷𝑖 𝑊𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 + 0.1925𝐷′𝑊𝑡𝑜𝑡𝑎𝑙 + 0.33𝑊𝑡𝑜𝑡𝑎𝑙
𝑃𝐷 =
100000
Where,
N = in rpm
D’ = Di + 2

Universitas Indonesia
 APPENDIX D
Ball Mill

To calculate power required the ball mill used Bond’s Equation (Eq 14.5-6
;Geankoplis, 4th edition, pages 947)

P = Power Required (hp)

T = Feed Rate (ton/min)
Df = size of feed (ft)
Dp = sife of product (ft)
Ei = Work Index

Figure D. 1 Ball mill Ilustration

Source: Perry. 2008. Chemical Engineering Handbook

59 Universitas Indonesia
 APPENDIX E
Finfan Cooler

Finfan cooler sizing calculation is done by using Aspen Design and Rating
software. This software can calculate sizing calculation and resulting mechanical
drawing of finfan cooler. Here are the steps:
1. Open the software, choose new, and pick air cooled.

Figure E. 1 Homepage
2. Import the aspen plus file or hysys file of the plant simulation, and choose
which HE to be calculated.

Figure E. 2 Choose Heat Exchanger Page

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 61

3. Runnig the software, to see the result, kindly check the result summary

Figure E. 3 Running Page

4. For knowing the mechanical drawing, check to the mechanical design.

Figure E. 4 Mechanical Drawing Page

Universitas Indonesia
 APPENDIX F
PUMP

There are several steps to sizing pump. The first step is started with finding
out physical properties of the streams which will go into the pumps and other
information needed in the calculation (mass flow, pressure inlet, pressure output,
vapor pressure, temperature, density, static head, pipe length after pump). By using
these formula below, the information of Power, Head, and NPSHa of each pump
can be obtained. The pump sizing is based on the Heuristic 38 from Seider Book.
The equation for calculation power and NPSHa are shown below.
𝑑𝑊𝑎𝑜 𝑑𝑊𝑝𝑢𝑚𝑝 𝑃 𝑉2
− =− = ∆ ( + 𝑔𝑧 + ) + 𝐹
𝑑𝑚 𝑑𝑚 𝜌 2
𝑃1(𝑎𝑡𝑚) 𝑉22 𝐹 𝑃𝑣𝑎𝑝𝑜𝑟
𝑁𝑃𝑆𝐻𝑎 = (𝑧 )
− 2 − 𝑧1 − − −
𝜌𝑔 2𝑔 𝑔 𝜌𝑔
Assumptions :
 𝜂𝑝𝑢𝑚𝑝 = 75%
 The terms of velocity difference neglected due to its small number
 No fitting
The pump power requirement can be calculated by equation below.
𝐹𝐻𝑃 = 𝑊 = 𝑚̇ × 𝑔 × 𝐻
where 𝑚 is mass flow, g is gravity acceleration, and H is head.
The 𝑊𝑎𝑐𝑡 or BHP (brake horse power) is calculated by equation below.
𝑊𝑎𝑐𝑡 = 𝐵𝐻𝑃 = 𝐹𝐻𝑃 × 𝜂𝑝𝑢𝑚𝑝

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APPENDIX G
TANK AND VESSEL
The steps for calculating tank and vessel size are:
1. Determine Storage Capacity.
2. Choose Storage Tank Type: Vertical or Horizontal, in this part, determine
which type of storage tank based on plant storage capacity.
3. In this part, determine length and diameter ratio of storage based on vessel
function. Because the tanks used is using concrete plant so the L/D ratio
around 0.8-1. In this case, choose 0.8 ratio. Because the taller tank, will be
more troubled by wind.
4. Calculate Internal Diameter and Length, with 0.8 L/D ratio. So diameter
calculation equation is:
𝐷
𝑆𝑡𝑜𝑟𝑎𝑔𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 (𝑚3 ) = 𝜋𝐿( )2
2
4𝐷 𝐷
𝑆𝑡𝑜𝑟𝑎𝑔𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 (𝑚3 ) = 𝜋( )( )2
5 2
𝑆𝑡𝑜𝑟𝑎𝑔𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 1/3
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 (𝑚) = ( )
𝜋/5
𝐿𝑒𝑛𝑔𝑡ℎ (𝑚) = 0.8𝐷
5. Determine Material of Storage Tank.
Basic consideration of determining material is corrosion resistance. There
are no corrosive material/fluids used in this plan so Carbon Steel SA 283.
The table for material type is shown on figure below.

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Figure G.1 Maximum Allowable Stress

Source: Brownell et al. 1959. Process Equipment Design

6. Calculate Vessel Thickness , to calculate vessel thickness:

𝑃𝑅
𝑡𝑠 = +𝐶
𝑆𝐸 − 0.6𝑃
7. Determine Open or Closed Head. Head or roof would be chosen if liquid is
not volatile and closed head would be chosen if liquid is volatile.
The head thickness calculation is used from the figure below

Figure G.2 Head Thickness Equation

Source: Walas. 2005. Chemical Process Equipment

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 APPENDIX H
DECANTER

Decanter is the equipment that is used for liquid-liquid separation. The

steps on calculating the decanter size are:
1. Input the feed data such as: pressure, temperature, properties, volumetric
rate, and mass flow rate for the light and heavy phase in the decanter.
2. Calculate the density of mixture (because the inlet is consist of a mixture
both heavy and light phase), with the equation:
𝜌𝑙 𝑉𝑙 + 𝜌ℎ 𝑉ℎ
𝜌𝑚 =
𝑉𝑙 + 𝑉ℎ
3. Calculate the dispersed velocity. This velocity is required to know the
velocity of the heavy phase to drop. The dispersed velocity has to be
bigger than the continuous velocity (light phase velocity). Because the
heavy phase needed to be settle first before the light phase being settled.
The equation for calculating the dispersed velocity is:
𝑑𝑑2 𝑔(𝜌ℎ − 𝜌𝑙 )
𝑈𝑑 =
18𝜇𝑙
4. Assuming the continuous velocity is equal to dispersed velocity to find
the minimum required light phase area. The minimum light phase area
can be calculated with
𝑈min 𝑜𝑓 𝑙𝑖𝑔ℎ𝑡 𝑝ℎ𝑎𝑠𝑒
𝐴𝑚𝑖𝑛 =
𝑉𝑙
From this calculation it can be obtained the minimum light phase area
that is needed in the decanter.
5. Assuming diameter that can obtain the minimum light phase area, with
considering of the HHLL of the vessel.
6. Do the liquid level calculation. Liquid level calculation is required to
see if the assumption of the diameter is applicable with the minimum
required light phase area and the liquid level standard. The liquid level
calculation standard and retention time on each level are based on the
Process Design Criteria from ConocoPhillips.

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7. Assuming effective length to obtain the light phase residence time, and
seam to seam length for heavy phase travelling time. Because the heavy
phase travelling time is needed to be equal as the light phase residence
time, or at least the light phase residence time is bigger than the heavy
phase travelling time.
8. From the assumption of seam to seam length, see whether the L/D ratio
is between 3-5. If the ratio is around the 3-5, the diameter and the seam
to seam length is approvable.
The configuration of decanter is shown below.

Figure H.1 Decanter Configuration

Source: Perry. 2008. Chemical Engineering Handbook

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 APPENDIX I
BELT CONVEYOR

The standard for belt conveyor choosing is based on Walas book of

Chemical Process Equipment. The steps are:
1. Choose the belt conveyor type (whether it is flat belt or troughed belt).
2. Choose the belt width and running angle of repose from table. (Since in
this plant are using conveyor flat belt, therefore the table only showing the
conveyor flat belt).

Figure I. 1 Flat Belt Conveyor

Source: Walas. 2005. Chemical Process Equipment

3. Choose the belt conveyor grade depends on the material, and operating
condition of the material.
4. Calculate the conveyor speed on fps based with the equation:
𝑡𝑜𝑛
𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 ( )
𝑈𝑐𝑜𝑛𝑣𝑒𝑦𝑜𝑟 = ℎ𝑟 . 100
𝐷𝑎𝑡𝑎 𝑓𝑟𝑜𝑚 𝑡𝑎𝑏𝑙𝑒
5. Choose whether the belt has inclination or not. For the maximum
inclination is depends on the material (See Table 5.3 on Walas’ Book).
6. If there is an inclination calculate the rise of belt conveyor.
𝑅𝑖𝑠𝑒 𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 = 𝑖𝑛𝑐𝑙𝑖𝑎𝑛𝑡𝑖𝑜𝑛 . tan(𝑟𝑎𝑑 (𝑖𝑛𝑐𝑙𝑖𝑛𝑎𝑡𝑖𝑜𝑛))

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7. Calculate the distance of the each equipment.

8. Calculate the conveyor length with equation
𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒
𝐶𝑜𝑛𝑣𝑒𝑦𝑜𝑟 𝐿𝑒𝑛𝑔𝑡ℎ =
tan(𝑟𝑎𝑑 (𝑖𝑛𝑐𝑙𝑖𝑛𝑎𝑡𝑖𝑜𝑛))
If there is no inclination, the distance and the conveyor length are the
same.

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 APPENDIX J
MIXER
The steps for calculation mixer are shown below.
1. Input the operating data (pressure, temperature, mass flow rate, and
volumetric flow rate)
2. Input the viscosity and the density of the fluids.
3. Calculate the diameter, length, thickness of the vessel, and thickness of the
head (FOLLOW THE STEPS ON THE APPENDIX F)
4. Calculate the agitation size
1
𝐷𝑎 = 𝐷
3
5. Calculate the shaft size
1
𝑆ℎ𝑎𝑓𝑡 𝑆𝑖𝑧𝑒 = 𝐴𝑔𝑖𝑡𝑎𝑡𝑜𝑟 𝑆𝑖𝑧𝑒
8
6. Define the rotation of the impeller (N) and type of impeller
7. Calculate the Reynolds number
(𝐷𝑎2 . 𝑁. 𝜌)
𝑅𝑒𝑦𝑛𝑜𝑙𝑑𝑠 𝑁𝑢𝑚𝑏𝑒𝑟 =
𝜇
8. Specify the Power Number (Np) from the graphic below.

Figure J. 1 Power Number vs Reynolds Number

Source: Walas. 2005. Chemical Process Equipment
9. Calculate the impeller power with the equation:
𝐼𝑚𝑝𝑒𝑙𝑙𝑒𝑟 = 𝑁𝑝 . 𝜌. 𝑁 3 . 𝐷𝑎5

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