Lamp - Perht.Neraca Massa

LAMPIRAN A
PERHITUNGAN NERACA MASSA
Komponen
UREA
BIURET
WATER
MELAMIN
AMONIA
CARBONDIOKSIDA
Kode
U
B
W
M
A
C
Basis perhitungan
: 1 jam operasi
Waktu produksi
: 330 hari kerja /tahun
1 hari
: 24 jam
Kapasitas produksi
: 25.000 ton/tahun
Berat Molekul (gr/mol)

60.06
103.09
18
126.144
17.031
44.01
: 25.000 ton/th x 103 kg/ton x 1 th/330 hari x 1 hari/24 jam

: 3.156,6 kg/jam
Komposisi produk
M
: 99,9%
: 0,05%
: 0,05%
Komposisi bahan baku urea prill

U
: 99,3%
: 0,57%
PRARANCANGAN PABRIK MELAMIN

PROSES BASF KAPASITAS 25.000 ton/tahun
LAMPIRAN A
: 0,13%
Komposisi urea melt

U
: 99,43%
: 0,57%
Konversi reaksi
: 95%
Yield
: 95%
( Ullman Vol A 16 )
Gambar. Diagram Alir Neraca Massa
NERACA MASSA DI MASING MASING ALAT

1. Neraca Massa di Sekitar Cyclone

LAMPIRAN A
Dirancang 99% Melamin terpisah sebagai produk pada cyclone, dengan

kemurnian produk 99,9%.
(Ullman Vol. A.16)
Neraca massa total
F8 = F9 + F10
F9 = Fproduk = 3.156,6 kg/jam
Neraca massa komponen

Urea (U)
U8
= U9 + U10
U9
= 0,05% x F9
= 0,05% x 3.156,6 kg/jam
U10
= U8 U9
U10
= U8 1,6
= 1,6 kg/jam
Biuret (B)
B8
= B9 + B10
B9
= 0,05% x F9
= 0,05% x 3.156,6 kg/jam
B10
= B8 B9
B10
= B8 1,6
= 1,6 kg/jam

LAMPIRAN A
Melamin (M)
M8
= M9+ M10
M9
= 99,9% x F9
= 99,9% x 3.156,6 kg/jam
M9
= 99% x M8
M8
= M9/99%
= 3.153,4 kg/jam / 0,99
M10
= 3.153,4 kg/jam
= 3.185,2 kg/jam
= M8 M9
= 3.185,2 3.153,4
= 31,8 kg/jam
Amonia (A)
A8
= A9 + A10
A9
= 0 kg/jam
A10
= A8 A9
A10
= A8 0
= A8
Carbondioksida (C)
C8
= C9 + C10
C9
= 0 kg/jam
C10
= C8 C9
= C8 0
Komponen
U
B
= C8
Input
Arus 8
U8
B8

Output
Arus 9
1,6
1,6
Arus 10
U8 1,6
B8 1,6
LAMPIRAN A
M
A
C
Total
3.185,2
A8 = A10
C8=C10
3.153,4
0
0
3.156,6
2. Neraca Massa di Sekitar Scrubber dan Tangki
Asumsi :
Arus 4,5,6 merupakan arus siklus
Komposisi arus 4,5,6 adalah sama
Off gas arus 14 bebas dari melamin,urea dan biuret
Neraca massa total
F3 + F12 = F5+ F14

Urea(U)
Yield = 95%

31,8
A8 = A10
C8 = C10
LAMPIRAN A
= (mol M9 / mol U3) x 6

Mol U3=( Mol M9 x 6 ) / Yield
= (( M9 / BM M ) x 6 ) / Yield
= ((3.153,4 / 126,144) x 6 ) / 0,95
= 157,88
U3
= Mol U3 xBM U
= 157,88 x 60,06
= 9482,6 kg / jam
U14
=0
U12
= U5 + U14 U3
= U5 + 0 9.482,6
= U5 9.482,6
Biuret (B)
Arus 3 hanya terdiri dari urea dan biuret
F3
= U3 + B3
B3
= F3 U3
U3
= 99,43% x F3
F3
= ( 9.536,9 / 0,9943 )
B3
= F3 U 3
= 9.536,9 9.482,6
B14
=0
B5
= B3
B14
= 0 kg/jam
= 9.536,9 kg/jam
= 54,3 kg/jam
= 54,3 kg/jam

LAMPIRAN A
B3 + B12
= B5 + B 14
54,3 + B12
= 54,3 + 0
B12
=0
Melamin (M)
M3
= 0 kg/jam
M14
= 0 kg/jam
M3 + M12
= M5 + M14
0 + M12
M12
= M5 + 0
= M5
Amonia (A)
A3
= 0 kg/jam
A5
= 0 kg/jam
A3 + A12
= A5 + A14
0+ A12
= 0 + A14
A12
= A14
Carbondioksida (C)
C3
= 0 kg/jam
C5
= 0 kg/jam
C3 + C12
= C5 + C14
0 + C12
= 0 + C14
C12
= C14
Komponen
Input
Arus 3
Arus 12

Output
Arus 5
Arus 14
LAMPIRAN A
U
B
M
A
C
Total
9.482,6
54,3
0
0
0
9.536,9
U5 9.482,6
0
M12=M5
A12=A14
C12=C14
U5
54,3
M12=M5
0
0
0
0
0
A12=A14
C12=C14
3. Neraca Massa di Sekitar Melter
Asumsi :
Arus 1 hanya terdiri dari urea, biuret dan air
Air menguap semua
Biuret tidak ada yang menguap
Urea tidak ada yang menguap, komposisi lelehan urea 99,43% dan biuret
0,57%
Neraca massa total
F1 = F2 + F3

Urea (U)
U1
= U2 + U3
U2
= 0
U1
= U3
= 9.482,6 kg/jam

LAMPIRAN A
Biuret (B)
B1
= B2 + B3
B2
= 0
B1
= B3
= 54,3 kg/jam
Melamin (M)
M1
= M2 + M3
M1
= M2 = M3
= 0 kg/jam
Amonia (A)
A1
= A2 + A3
A1
= A2 = A3
= 0 kg/jam
Carbondioksida (C)
C1
= C2 + C3
C1
= C2 = C3
= 0 kg/jam
Air (W)
F1
= U1+B1+W1
= 9.482,6 + 54,3 + W1
U1 + B1
= 99,87% F1
F1
= ( U1 + B1 ) / 0,9987
= 9.536,9 / 0,9987
W1
=9.549,3 kg/jam
= F1 U1 B1
= 9.549,3 9.482,6 54,3
= 12,4 kg/jam
W2
= W1 W3

LAMPIRAN A
= 12,4 0
= 12,4 kg/jam
Komponen
U
B
W
M
A
C
Sub Total
Total
Input
Arus 1
9.482,6
54,3
12,4
0
0
0
9.549,3
Output
Arus 2
0
0
12,4
0
0
0
12,4
Arus 3
9.482,6
54,3
0
0
0
0
9.536,9
9.549,3
4. Neraca Massa di Sekitar Arus Purging
Neraca massa overall

F1
= F2 + F9 + F11
F11
= F1 F2 - F9
F1- F2 = F3
F11
= F3 - F9
F3
= U3 + B3
F11
= 9.482,6 + 54,3
= 9.536,9 kg/jam
= 9.536,9 3.156,6
= 6.380,3 kg/jam
Neraca massa total

F10
= F11 + F12

LAMPIRAN A

Urea (U)
Urea yang dipurging = 5% dari urea fresh urea pada produk
U11
= 5% x U3 U9
= 5% x 9.482,6 1,6
U12
= 472,5 kg/jam
= U 10 U 11
= U 10 472,5
Biuret (B)
B11
= B3 B9
= 54,3 1,6
B10
= B11
B12
= B10 B11
= 52,7 52,7
= 52,7 kg/jam
= 0 kg/jam
Amonia (A)
Pada keadaan steady state diharapkan semua amonia dipurging
Mol A11
= 95% x mol U3
= 95% x ( U3 / BM U )
= 0,95 x ( 9.482,6/60,06 )
A11
= mol A11 x BM A
= 150 x 17,031
A12
= 150
= A10 A11
= A10 2.554,5

= 2.554,5 kg/jam
LAMPIRAN A
Karbondioksida (C)
Pada keadaan steady state diharapkan semua karbondioksida dipurging
Mol C11
= ( 3/6 ) x 95% x mol U3

= ( 3/6 ) x 0,95 x ( 9.482,6/60,06 )
C11
= 74,959
= mol C11 x BM C
=74,959 x 44,01
C12
= 3.300,5 kg/jam
= C10 C11
= C8 3.300,5
Melamin (M)
M11
= F11 U11 B11 A11 C11

= 6.380,3 472,6 52,7 2.554,5 3.300,5
M12
= 0 kg/jam
= M10 M11
= 31,8 0
Komponen
U
B
M
A
C
Total
= 31,8 kg/jam
Input
Arus 10
U10
B10
31,8
A10
C10

Output
Arus11
472,6
52,7
0
2.554,5
3.300,5
6.380,3
Arus 12
U10 472,6
0
31,8
A10 2.554,5
C10 3.300,5
LAMPIRAN A
5. Neraca Massa di Sekitar Reaktor
Reaksi pembentukan melamin :

6U M + 6A + 3C
Keterangan : U : Urea
M : Melamin
A : Amonia
C : Carbondioksida
Konversi =
U yang bereaksi
U dalam feed
Neraca massa total

F5 + F 16
= F7
M7
= M5 + M hasil reaksi
M hasil reaksi = M7 M5

LAMPIRAN A
M7
= M8
M hasil reaksi = M7 M5
= 3.185,2 31,8
= 3.153,4 kg/jam
Berdasarkan stoikiometri :
Mol A hasil reaksi
= 6 x mol M hasil reaksi

= 6 x ( 3.153,4 kg/jam / 126,144 )
= 149,990
A hasil reaksi
= mol A hasil reaksi x BM A

= 149,990 x 17,031
= 2.554,5 kg/jam
Mol C hasil reaksi

= 3 x ( 3.153,4 kg/jam / 126,144 )
= 74,995
C hasil reaksi
= mol C hasil reaksi x BM C

= 74,995 x 44,01
= 3.300,5 kg/jam
Mol U yg bereaksi

= 6 x ( 3.153,4 kg/jam /126,144 )
= 149,990 kg/jam
U yang bereaksi
= mol U yang bereaksi x BM U

= 149,99 x 60,06
= 9.008,4 kg/jam

LAMPIRAN A
U yg dibthkan
= U bereaksi / konversi
= 9.008,4 kg/jam / 0,95
= 9.482,6 kg/jam
= 1, 65 Nm3/kg U x U yg dibutuhkan
Fluidizing gas
= 1, 65 Nm3/kg U x 9.482,6 kg/jam

= 15.646,2 Nm3/jam
Untuk campuran gas perbandingan mol = perbandingan volume
A:C=2:1
Arus 16
U16
= 0 kg/jam
B16
= 0 kg/jam
M16
= 0 kg/jam
A16
= 2/3 x fluidizing gas x A

= 2/3 x 15.646,2 Nm3/jam x 0,77088 kg/m3
= 8.040,9 kg/jam
C16
= 1/2 x (A16/BM A) x BM C
= 1/2 x (8.040,9 kg/jam / 17,031) x 44,01
= 10.389,3 kg/jam
Arus 5
U5
= U yg dibutuhkan
= 9.482,6 kg/jam
B5
= 54,3 kg/jam

(USPTO, 2.152.505)
LAMPIRAN A
M5
= 31,8 kg/jam
A5
= 0 kg/jam
C5
= 0 kg/jam
Arus 7
U7
= U yang tidak bereaksi

= U yang dibutuhkan U yang bereaksi
= 9.482,6 kg/jam 9.008,4 kg/jam
= 474,2 kg/jam
B7
= B5 + B16
= 54,3 + 0
= 54,3 kg/jam
M7
= M8
= 3.185,2 kg/jam
A7
= A5 + A 16 + A hasil reaksi
= 0 + 8.040,9 + 2.554,5
= 10,595,4 kg/jam
C7
= C5 + C16 + C hasil reaksi

= 0 + 10.389.3 + 3.300.5
= 13.689,8 kg/jam

LAMPIRAN A
Komponen
U
B
M
A
C
Subtotal
Total
Input
Arus 5
9.482,6
54,3
31,8
0
0
9.568,7
Arus 16
0
0
0
8.040,9
10.389,3
18.430,2
27.998,9
6. Neraca Massa di Sekitar Desublimer
Neraca massa total

F8
= F15 + F7

Massa arus 15 diperoleh dari trial dengan neraca panas
Arus 15 hanya terdiri dari A dan C

Output
Arus 7
474,2
54,3
3.185,2
10.595,4
13.689,8
27.998,9
LAMPIRAN A
Urea (U)
U7
= 474,2 kg/jam
U15
= 0 kg/jam
U8
= U7 + U15
= 474,2 + 0
= 474,2 kg/jam
Biuret (B)
B7
= 54,3 kg/jam
B15
= 0 kg/jam
B8
= B7 + B15
= 54,3 + 0
= 54,3 kg/jam
Melamin (M)
M7
= 3185,2 kg/jam
M15
= 0 kg/jam
M8
= M7 + M15
= 3185,2 + 0
= 3185,2 kg/jam
Massa Amonia dan Carbondioksida pada arus 15 diperoleh dari trial neraca panas
di desublimer.
Arus 15 = 3,407 x Arus 16
Amonia (A)
A7
= 10.595,4 kg/jam
A15
= 1608,55 kmol/jam x 17,031 kg/kmol
A8
= A7 + A15
= (10.595,4 + 27.395,2) kg/jam

= 27.395,2 kg/jam
= 37.990,6 kg/jam
LAMPIRAN A
Carbondioksida (C)
C7
= 13.689,8 kg/jam
C15
C8
= C7 + C15
= 35.396,80 kg/jam
= (13.689,8 +35.396,80) kg/jam
Komponen
U
B
M
A
C
Sub total
Total
= 49.086,6 kg/jam
Input
Arus 7
474,2
54,3
3.185,2
10.595,4
13.689,8
27.998,9
Arus 15
0
0
0
27.395,2
35.396,8
62.792,0
90.790,9
7. Neraca Massa di Sekitar Arus Percabangan

Output
Arus 8
474,2
54,3
3.185,2
37.990,6
49.086,6
90.790,9
LAMPIRAN A
Neraca massa total

F14
= F15 + F16

Urea (U)
U15
= 0 kg/jam
U16
= 0 kg/jam
U14
= U15 + U16
U14
=0+0
= 0 kg/jam
Biuret (B)
B15
= 0 kg/jam
B16
= 0 kg/jam
B14
= B15 + B16
B14
=0+0
= 0 kg/jam
Melamin (M)
M15
= 0 kg/jam
M16
= 0 kg/jam
M14
= M15 + M16
M14
=0 + 0
Amonia (A)
A15
= 27.395,2 kg/jam
A16
= 8.040,9 kg/jam

= 0 kg/jam
LAMPIRAN A
A14
= A15 + A16
A14
= 27.395,2 + 8.040,9
= 35.436,1 kg/jam
Carbondioksida (C)
C15
= 35.396,8 kg/jam
C16
= 10.389,3 kg/jam
C14
= C15 + C16
C14
= 35.396,8 + 10.389,3
Komponen
U
B
M
A
C
Sub Total
Total
Input
Arus 14
0
0
0
35.436,1
45.786,1
81.222,2
8. Neraca Massa di Sekitar Scrubber

= 45.786,1 kg/jam
Output
Arus 15
0
0
0
27.395,2
35.396,8
62.791,98
Arus 16
0
0
0
8.040,9
10.389,3
18.430,2
81.222,2
LAMPIRAN A
Neraca massa total

F6 + F12
= F13 + F14

Urea (U)
U6 + U12 = U13 + U14
U6 + 0
= U13 + 0
U6 = U13
Biuret (B)
B6 + B12 = B13 + B14
B6 + 0
= B13 + 0
B6 = B13
Melamin (M)
M6 + M12 = M13 + M14
M6 + 31,8 = M13 + 0
M6 + 31,8 = M13
Amonia (A)
A6 + A12
= A13 + A14
A6 + 35.436,1
= A13 + 35.436,1
A6
= A13
Carbondioksida (C)
C6 + C12
= C13 + C14

LAMPIRAN A
C6 + 45.786,1
C6
= C13 + 45.786,1
= C13
Arus 6 diperoleh dari trial neraca panas di sekitar scrubber.

Arus 6
= 0,85 x arus 5
Urea (U)
U5
= 157,88 kmol/jam
U6
= 0,85 x U5
U13
= 0,85 x 157,88 kmol/jam
= 134,198 kmol/jam
= 8.059,93 kg/jam
= U6
= 8.059,93 kg/jam
Biuret (B)
B5
= 0,53 kmol/jam
B6
= 0,85 x 0,53 kmol/jam
= 0,4505 kmol/jam
= 46,4 kg/jam
= B6
= 46,4 kg/jam
B13
Melamin (M)
M5
= 0,25 kmol/jam
M6
= 0,85 x 0,25 kmol/jam
= 0,2125 kmol/jam
= 26,8 kg/jam
M6 + 31,8
= M13
M13
= 26,8 + 31,8
Amonia (A)
A6
= 0,85 x A5

= 58,6 kg/jam
LAMPIRAN A
A13
= 0,85 x 0
= 0 kg/jam
= A6
= 0 kg/jam
Carbondioksida (C)
C6
= 0,85 x C5
C13
= 0,85 x 0
= 0 kg/jam
= C6
= 0 kg/jam
Komponen
U
B
M
A
C
Sub total
Total
Input
Arus 6
Arus 12
8.059,9
0
46,4
0
26,8
31,8
0
35.436,1
0
45.786,1
8.133,1
81.254,0
89.387,1
9. Neraca Massa di Sekitar Tangki
Neraca massa total

F4
= F3 + F13

Urea (U)

Output
Arus 13
Arus 14
8.059,9
0
46,4
0
58,6
0
0
35.436,1
0
45.786,1
8.164,9
81.222,2
89.387,1
LAMPIRAN A
U3
= 9.482,3 kg/jam
U13
= 8.059,9 kg/jam
U4
= U3 + U13
U4
= 9.482,6 + 8.059,9
= 17.542,5 kg/jam
Biuret (B)
B3
= 54,3 kg/jam
B13
= 46,4 kg/jam
B4
= B3 + B13
B4
= 54,3 + 46,4
= 100,7 kg/jam
Melamin (M)
M3
= 0 kg/jam
M13
= 58,6 kg/jam
M4
= M3 + M13
M4
= 0 + 58,6
= 58,6 kg/jam
Amonia (A)
A3
= 0 kg/jam
A13
= 0 kg/jam
A4
= A3 + A13
=0+0
= 0 kg/jam
=0+0
= 0 kg/jam
Carbondioksida (C)
C3
= 0 kg/jam
C13
= 0 kg/jam
C4
= C3 + C13

LAMPIRAN A
Komponen
U
B
M
A
C
Sub total
Total
Input
Arus 3
9.482,6
54,3
0
0
0
9.536,9
Output
Arus 4
17.542,5
100,7
58,6
0
0
Arus 13
8.059,9
46,4
58,6
0
0
8.164,9
17.701,8
17.701,8
NERACA MASSA OVERALL

Komponen
Urea
Biuret
Melamine
Amonia
CO2
Input
Arus 1
9.482,6
54,3
0
0
0
Water
Sub total
Total
12,4
9.549,3
9.549,3
Arus 2
0
0
0
0
0
12,4
12,4

Output
Arus 9
1,6
1,6
3.153,4
0
0
0
3.156,6
9.549,3
Arus 11
472,6
52,7
2.544,5
3.300,5
0
0
6.380,3

Lamp - Perht.Neraca Massa

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Lamp - Perht.Neraca Massa

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LAMPIRAN A

PERHITUNGAN NERACA MASSA

PERHITUNGAN NERACA MASSA

: 330 hari kerja /tahun

Berat Molekul (gr/mol)

: 25.000 ton/th x 103 kg/ton x 1 th/330 hari x 1 hari/24 jam

Komposisi bahan baku urea prill

PRARANCANGAN PABRIK MELAMIN

Komposisi urea melt

Gambar. Diagram Alir Neraca Massa

NERACA MASSA DI MASING MASING ALAT

PRARANCANGAN PABRIK MELAMIN

Dirancang 99% Melamin terpisah sebagai produk pada cyclone, dengan

Neraca massa komponen

PRARANCANGAN PABRIK MELAMIN

PRARANCANGAN PABRIK MELAMIN

2. Neraca Massa di Sekitar Scrubber dan Tangki

Neraca massa komponen

PRARANCANGAN PABRIK MELAMIN

= (mol M9 / mol U3) x 6

PRARANCANGAN PABRIK MELAMIN

PRARANCANGAN PABRIK MELAMIN

3. Neraca Massa di Sekitar Melter

Neraca massa komponen

PRARANCANGAN PABRIK MELAMIN

PRARANCANGAN PABRIK MELAMIN

4. Neraca Massa di Sekitar Arus Purging

Neraca massa overall

Neraca massa total

PRARANCANGAN PABRIK MELAMIN

Neraca massa komponen

Pada keadaan steady state diharapkan semua amonia dipurging

PRARANCANGAN PABRIK MELAMIN

= ( 3/6 ) x 95% x mol U3

= F11 U11 B11 A11 C11

PRARANCANGAN PABRIK MELAMIN

5. Neraca Massa di Sekitar Reaktor

Reaksi pembentukan melamin :

Neraca massa total

PRARANCANGAN PABRIK MELAMIN

= 6 x mol M hasil reaksi

= mol A hasil reaksi x BM A

Mol C hasil reaksi

= 3 x mol M hasil reaksi

= mol C hasil reaksi x BM C

= 6 x mol M hasil reaksi

= mol U yang bereaksi x BM U

PRARANCANGAN PABRIK MELAMIN

= 1, 65 Nm3/kg U x 9.482,6 kg/jam

= 2/3 x fluidizing gas x A

PRARANCANGAN PABRIK MELAMIN

= U yang tidak bereaksi

= C5 + C16 + C hasil reaksi

PRARANCANGAN PABRIK MELAMIN

6. Neraca Massa di Sekitar Desublimer

Neraca massa total

Neraca massa komponen

PRARANCANGAN PABRIK MELAMIN

= 1608,55 kmol/jam x 17,031 kg/kmol

PRARANCANGAN PABRIK MELAMIN

= 804,29 kmol/jam x 44,01 kg/kmol

= (13.689,8 +35.396,80) kg/jam

7. Neraca Massa di Sekitar Arus Percabangan