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Heater (E-213)
Fungsi : Memanaskan asam fosfat dari suhu 30C
sampai 76C
Type : Double pipe heat exchanger
Bahan : Carbon Steel SA 212 Grade A
Jumlah : 1 buah
1) Heat transfer
Q = 2657479 kkal/hari
= 110728 kkal/jam
= 439405.47 btu/jam
W steam = 5339 kg/hari
= 222 kg/jam
= 490.44312 lb/jam
W asam fosfat = 98530 kg/hari
= 49265 kg/jam
= 108610.28 lb/jam
2) LMTD
Steam : T1 = 320 F t1 = T1 - t1
T2 = 320 F = 234 F
Asam fosfat : t1 = 86 F t2 = T2 - t2
t2 = 169 F = 151 F
t2 - t1
LMTD =
2,3 log (t2/t1)
-83
=
-0.436227
= 190 F
3) Caloric temperature
TAV = 1/2 ( T1 + T2 )
= 320 F
tAV = 1/2 ( t1 + t2 )
= 127.4 F
Trial ukuran DPHE 3 x 2
Untuk anulus :
D2 = 3 in = 0.25 ft
D1 = 2 in = 0.17 ft
Untuk inner pipe
D = 2 in = 0.17 ft
a" = 0.622 ft2/ft
= 0.0273 ft2
De = (D22 - D12)/D1
= 0.2083 ft
5a) Mass velocity
Ga = W/aa
= 17993.33 lb/(hr)(ft2)
6a) Reynolds number
Pada suhu 320 oF,
= 0.0145 cP (fig. 15 Kern)
= 0.0351 lb/ft.hr
karena <1 maka = 1
Rea De . Ga
=
= 106828.44
7a) jH = 280 (fig. 24 Kern)
8a) Pada suhu 320 oF,
c = 0.8 btu/lb.oF (fig.3 Kern)
k = 0.398 btu/hr(ft2)(oF/ft) (Tabel 5 Kern)
= 0.4131713
9a) ho
=
= 221 btu/hr(ft2)(oF)
= 0.38
9b) hi
=
= 284 btu/hr(ft2)(oF)
10b) hio = hi x D
D1
= 284 x 0.17
###
= ### btu/hr(ft2)(oF)
ho Summary hi
221 h outside 284
Uc #NAME?
UD #NAME?
UD = Q = 439405.47
A . t 24.9 x 190
= 93 btu/hr(ft2)(oF)
Rd = Uc - UD = ### - 93
Uc . UD ### x 93
= #NAME? (hr)(ft2)(oF)/btu
Pressure drop
1) Untuk Re = 106828.4 ,
f = 0.0013 ft2/in2
s = 1.83
2) No. Of crosses, N + 1 = 12 L/B
12 x 40
=
1. Heater (E-213)
Fungsi : Memanaskan asam fosfat dari suhu 30C
sampai 76C
Type : Shell and tube exchanger
Bahan : Carbon Steel SA 212 Grade A
Jumlah : 1 buah
1) Heat transfer
Q = 2657479 kkal/hari
= 110728 kkal/jam
= 439405.47 btu/jam
W steam = 5339 kg/hari
= 222 kg/jam
= 490.44312 lb/jam
W asam fosfat = 98530 kg/hari
= 49265 kg/jam
= 108610.28 lb/jam
2) LMTD
Steam : T1 = 320 F t1 = T1 - t1
F T2 = 320 F = 234 F
Asam fosfat : t1 = 86 F t2 = T2 - t2
F t2 = 169 F = 151 F
t2 - t1
LMTD =
2,3 log (t2/t1)
-83
=
-0.436227
= 190 F
3) Caloric temperature
TAV = 1/2 ( T1 + T2 )
= 320 F
tAV = 1/2 ( t1 + t2 )
= 127 F
Dari Tabel 6.2 hal 110 Kern didapatkan data flow area
dan annulus
aa = 2.93 in2 = 0.24417 ft2
ap = 3.35 in2 = 0.27917 ft2
De = 1.57 in = 0.13083 (annulus)
De' = 0.69 in = 0.0575 ft
ID = 2.07 in = 0.17225 ft
9. k c. 9. k c.
ho = jH ( ) hi = jH ( )
ho = jH ( ) hi = jH ( )
De k De k
hi x ID
hio =
OD
1417.16 x 0.17
=
0.20
= 1230.79 btu/jam.ft2.oF
Uc - UD 18.38 - 15.91
Rd = =
Uc x UD 18.38 x 15.91
= 0.00845 (hr)(ft2)(oF)/btu
Pressure drop
1. Rea = 6787.116881 2. Rep = 880380.816
4f Ga L
2
Fa =
2g De
2
= 1934838.2
0.0108982
3. Heater (E-213)
Fungsi : Memanaskan asam fosfat dari suhu 30C
sampai 76C
Type : Shell and tube exchanger
Bahan : Carbon Steel SA 212 Grade A
Jumlah : 1 buah
1) Heat transfer
Q = 3519528 kkal/hari
= 146647 kkal/jam
= 581942.44 btu/jam
W steam = 5339 kg/hari
= 222 kg/jam
= 490.44312 lb/jam
W asam fosfat = 98530 kg/hari
= 49265 kg/jam
= 108610.28 lb/jam
2) LMTD
Steam : T1 = 320 F t1 = T1 - t1
T2 = 320 F = 234 F
Asam fosfat : t1 = 86 F t2 = T2 - t2
t2 = 169 F = 151 F
t2 - t1
LMTD =
2,3 log (t2/t1)
-83
=
-0.436227
= 190 F
T1 - T2 t2 - t1
R = R =
t2 - t1 T1 - t1
0 82.8
R = = 0 R = = 0.35385
R = = 0 R = = 0.35385
82.8 234
Dari Fig. 18 Kern didapatkan FT = 1, maka T = LMTD
T = 190 F
7) Mengkoreksi harga UD
Menghitung harga A terkoreksi
A terkoreksi = N x L x a"
= 32.9868 ft2
Q
UD koreksi =
A terkoreksi x T
= 92.94 Btu /jam.ft2.oF
as = ID x C' x B
144 Ps
8 x 0.25 x 6
=
144 x 1.25
= 0.06667 ft2
De x Gs D x Gt
Res = Ret =
0.06 x 7356.65 0.07 x 1364022
= =
0.03509 33.88
= 12579.048 = 2784.6778
1/3
c.
( ) = 3.87
k
1/3
1/3
17. Condensation of steam Jh k c s
17. hio =
ho = 1500 btu/jamft2oF Dk
hi 0.21
= 10 x 3.87
t 0.07
hi
= btu/jam.ft2.oF
t 118
t = 1
hio = 118 btu/jamft2oF
UD = Q 581942.44
=
A.t 32.99 x 190
= 92.94 btu/jam.ft2.oF
Ringkasan
1500 h outside 117.579
Uc = 109.033
UD = 92.94
Rd = 0.00159
Pressure drop
1. Res = 12579.048 1. Ret = 2784.6778
Dari Fig.29 Kern : Dari Fig.26 Kern :
f = 0.002 ft2/in2 f = 0.0004 ft2/in2
ID
Ds =
12
= 8
12
= 0.67 ft
3. f Gs2 Ds (N+1)
Ps =
5,22 1010 De s t
865924.0274
=
5025988861
= 0.0002 psi
Dimana :
Ns = Jumlah putaran efektif dalam cyclone
= 4
Vmax = Kecepatan maksimal gas masuk cyclone
= 20 m/s
0.000004 9 x 0.078 x Bc
=
x 4 x 20 x ( 996.21 - 0.9 )
0.000004 0.702 Bc
=
250021.872
0.702 Bc = 1.000087
Bc = 1.42 m
Dc
De =
2
= 2.85 m
Dc
Hc =
2
= 2.85 m
Lc = 2 x Dc
= 11.40 m
Dc
Sc =
8
= 0.71 m
Zc = 2 x Dc
= 11.40 m
Dc
Jc =
4
= 1.42 m
Spesifikasi cyclone
Fungsi : Untuk menangkap padatan yang terikut udara panas
dari rotary dryer
Kecepatan gas masuk = 20 m/s
Dimensi cyclone
Bc = 1.42 m
Dc = 5.70 m
De = 2.85 m
Hc = 2.85 m
Lc = 11.40 m
Sc = 0.71 m
Zc = 11.40 m
Jc = 1.42 m
5. Blower (G-325)
Fungsi = Mengalirkan udara luar ke cooler drum
(E-326)
Jenis = sentrifugal
Massa udara masuk = 808275.06 kg/hari
= 33678.128 kg/jam
Jumlah blower = 1 buah
Efisiensi, = 80 %
Suhu udara = 33 C
= 306 K
Tekanan, P = 1 atm
Densitas udara = 1.164 kg/m
(Sumber: Geankoplis, tabel A.3-3)
F
Laju alir volumetrik udara, Q =
33678.128 kg/jam
=
1.164 kg/m
= 28933.099 m/jam
= 17029.386 ft/menit
Dasar perencanaan :
= #REF! lb/jam
Jenis = Double-deck vibrating screen
Sehinga
FOA = 100 x 0.2152
0.215 + 0.297
= 18
A = 223.76 ft2
0,4 x Ct
A =
Cu x Foa x Fs
Dimana,
A = luas screen
Ct = laju alir massa
Cu = kapasitas unit, fig19-21= 0.4 ton/jam.ft
Foa = faktor open-area, fig 19-22
Fs = faktor slotted-area, tabel 19-7 =1
0,4 x Ct
A =
A =
Cu x Foa x Fs
Dimana,
A = luas screen
Ct = laju alir massa
Cu = kapasitas unit, fig19-21= 0.4 ton/jam.ft
Foa = faktor open-area, fig 19-22
Fs = faktor slotted-area, tabel 19-7 =1
2) LMTD
Air : T1 = 104 F t1 = t1 - T1
T2 = 86 F = 99 F
MA : t1 = 203 F t2 = t2 - T2
t2 = 149 F = 63 F
t2 - t1
LMTD = 2,3 log (t /t )
2 1
-36
=
-0.451478
= 80 F
3) Caloric temperature
TAV = 1/2 ( T1 + T2 )
= 95 F
tAV = 1/2 ( t1 + t2 )
= 176 F
Trial ukuran DPHE 3 x 2
Untuk anulus :
D2 = 3 in = 0.25 ft
D1 = 2 in = 0.17 ft
Untuk inner pipe
D = 2 in = 0.17 ft
a" = 0.62 ft2/ft
Re De . Ga
=
= 702460.4503
7a) jH = 380 (fig. 24 Kern)
8a) Pada suhu 104 oF,
c = 1.2 btu/lb.oF (fig.3 Kern)
k = 0.38 btu/hr(ft2)(oF/ft) (Tabel 5 Kern)
= 0.46274
9a) ho
=
= 322 btu/hr(ft2)(oF)
9b) hi
=
= 2268 btu/hr(ft2)(oF)
10b) hio = hi x D
D1
= 2268 x 0.17
0.17
= 2268 btu/hr(ft2)(oF)
ho Summary hi
322 h outsie 2268
Uc 281.64
UD 180.16
APPENDIKS C
SPESIFIKASI ALAT
C-52
Appendiks C
2. Pompa (L-211)
Fungsi : Memompa asam sulfat dari tangki (F-130) ke tangki pencampuran (M-210)
Jenis : Pompa sentrifugal
Jumlah : 1 unit
Bahan konstruksi : commercial steel
Kondisi operasi :
Tekanan = 1 atm
Temperatur = 30 C
Laju alir massa = 147794.76 kg/hari
= 6158.12 kg/jam
= 3.77 lb/detik
H2SO4 = 1823.11 kg/m3
= 113.81 lb/ft3
H2SO4 = 18 cP (Sumber: Fig. A.3-4 Geankoplis)
= 43.54 lb/ft.jam
= 0.018 kg/m.detik
massa
Laju alir volumetrik, Q =
6158.12 kg/jam
=
1823.11 kg/m3
= 3.378 m3/jam
= 0.0009 m3/s
= 0.033 ft3/s
C-53
Appendiks C
Jenis Aliran
Q 0.033 ft3/s
v = = = 0.9974 ft/s
Ai 0.03322 ft2
= 0.30401 m/s
x v x ID
NRe =
1823.11 x 0.30401 x 0.06271
=
0.018
= 1930.98
Karena Nre <2100, maka asumsi aliran laminar benar
Ukuran pipa keluar dipilih = 2,5 in Sch 40
C-54
Appendiks C
4f x L x v2
Ff = (Sumber: Geankoplis, pers. 2.10-5)
Dx2
4 x 0.026 x 36.9 x 0.30401
=
0.0627126 x 2
= 9.3015919 J/kg
b. Sudden contraction
Friksi yang terjadi karena adanya perpindahan dari luas
penampang besar ke luas penampang kecil
Untuk aliran turbulen, = 0.5 (Sumber:Geankoplis, hal 93)
K
hc = c x v
2
2
A2
Kc = 0.55 ( 1 -
A1)
Karena A2 jauh lebih kecil dari A1, maka A2/A1 dianggap
0, sehingga harga Kc = 0.55 , maka hc :
0,02912
hc = 0.55 x
2 x 0.5
= 0.05083 J/kg
C-55
Appendiks C
Kex x v2
hex =
2
A1
Kex = (
1 -
A2 )
Karena A2 jauh lebih kecil dari A1, maka A1/A2 dianggap
0, sehingga harga Kex = 1 , maka hex :
0,02912
hex = 1 x
2 x 0.5
= 0.00085 J/kg
4. Daya Pompa
Persamaan Bernoulli
(P2-P1) v22 - v12
-Ws = + (Z2-Z1) x g + + F
2
(Sumber: Pers. 2.7-28 Geankoplis)
Dimana :
Tekanan keluar tangki (P1)
P1 = 1 atm = 101325 Pa
Tekanan masuk tangki pencampur (P2)
P2 = 1 atm = 101325 Pa
P = 0 Pa
Z = 10 m
v22 - v12 = 0 m/s
Ws = - x Wp
(Sumber: Pers. 2.7-30 Geankoplis)
-107.37 = -0.018 x Wp
-107.37
Wp =
-0.018
= 5964.82 J/kg
C-56
Appendiks C
5. Power pompa
Laju alir massa = 147794.76 kg/hari
= 6158.12 kg/jam
= 1.71 kg/detik
Wp = 5964.8 J/kg
P = Q x Wp
= 1.71 kg/detik x 5964.8 J/kg
= 10203.347 W
= 10.2033 kW
= 13.6829 hp
C-57
Appendiks C
[( 4D ) L+12D ]
2 3
Vtangki =
C-58
Appendiks C
P.ri
ts = + c
f.E - 0.6 P
Dimana:
ts = tebal shell (in)
P = tekanan internal (psi)
ri = jari-jari dalam (in)
f = tekanan maks. Yang diijinkan (psia)
E = efisiensi pengelasan
c = faktor korosi
P.ri
ts = + c
f.E - 0.6 P
= 17.64 x 88.9061
+ 0.13
12650 x 0.85 - 0.6 x 17.64
= 0.271 in
Maka digunakan tebal shell standar 0,31 in atau 5
in
16
Karena icr > 6% dari rc, maka digunakan persamaan 7.76 &
7.77 hal. 138 Brownell (1959),
0,5
1
W = 3+
4
rc
icr ( ( )) ..... Pers.7.76
P.rc.W
th = + c ...... Pers 7.77
2.f.E - 0,2.P
= 17.64 x 170 x 1.733
+ 0.13
( 2 x 12650 x 0.85 ) - ( 0.2 x 17.6 )
= 0.3667 in
C-59
Appendiks C
BC = rc - icr
= 170 - 11
= 159 in
ID
AB = - icr
2
= 177.81
- 11
2
= 77.91 in
AC = (BC2-AB2)0.5
= 138.61 in
b = rc - AC
= 170 - 138.61
= 31.39
Bedasarkan tabel 5.6 hal. 88 Brownell (1959), untuk tebal head
3/8 in diperoleh harga sf = 1 - 3. Dipilih sf = 3, maka :
Hh = th + b + sf
= 0.3667 + 31.39 + 3
= 34.76 in
C-60
Appendiks C
2 x 0.52532
= 161.561
0,5
1
W = 3+
4
L
( ())
rk
dalam hal ini : W = faktor intensifikasi stress
W = 1.83993
P.L.W
tk = + c
(2 . f . E) - 0,2 . P
= 17.6 x 161.561 x 1.83993
+ 0.125
( 2 x 12650 x 0.85 ) - 0.2 x 17.6
= 0.369 in
Dimana,
Dt = diameter tangki
Da = diameter impeller
E = tinggi turbin dari dasar tangki
C-61
Appendiks C
Berdasarkan laju massa ton/hari, dari Tabel 20-16 Perry ed. 7 didapatkan :
Kapasitas = 315 ton (97% lolos ukuran 200 mesh)
Ukuran = 9x7 ft
Ball charge = 30 ton
Power = 350 hp
Kecepatan = 20 rpm
C-62
Appendiks C
Spesifikasi Keterangan
Kode alat = C-110
Fungsi = Menghaluskan batuan fosfat hingga berukuran 200 mesh
Tipe = Marcy Ball Mill
Bahan konstruksi = Carbon Steel SA-283 Grade C
Kapasitas = 315.00 ton/hari
Panjang = 9 ft
Diameter = 7 ft
Kecepatan putar = 20 rpm
Power = 350 hp
C-63
6. Granulator (S-310)
Fungsi : Mengubah ukuran dan bentuk pupuk fosfat
menjadi butiran
Tipe : Rotary drum
Bahan : Carbon Steel SA-283 C
Asumsi : Kapasitas granulator 10% lebih besar
Vtangki =
[( )
D2
4
L+
D3
12 ]
Berdasarkan Tabel 4.18 hal.248 Ulrich (1984), rasio L/D = 2
sehingga,
a. Diameter (D) = 4.52 m
= 177.81 in
b. Tinggi (L) = 9.03 m
P.ri
ts = + c
f.E - 0.6 P
= 17.64 x 88.9061
+ 0.13
12650 x 0.85 - 0.6 x 17.64
= 0.271 in
Maka digunakan tebal shell standar 0,31 in atau 5
in
16
Karena icr > 6% dari rc, maka digunakan persamaan 7.76 &
7.77 hal. 138 Brownell (1959),
0,5
W=
1
4( ( ))
3+
rc
icr
..... Pers.7.76
P.rc.W
th = + c ...... Pers 7.77
2.f.E - 0,2.P
= 17.64 x 170 x 1.733
+ 0.13
( 2 x 12650 x 0.85 ) - ( 0.2 x 17.6 )
= 0.3667 in
BC = rc - icr
= 170 - 11
= 159 in
ID
AB = - icr
2
= 177.81
- 11
2
= 77.91 in
AC = (BC2-AB2)0.5
= 138.61 in
b = rc - AC
= 170 - 138.61
= 31.39
d1 = ID -2rk (1 - cos )
= 177.81 - (2 8.5 (1 - 0,5253))
= 169.743
d1
L =
2 cos
= 169.74
2 x 0.52532
= 161.561
0,5
W=
1
4 ( ())
3+
L
rk
dalam hal ini : W = faktor intensifikasi stress
W = 1.83993
P.L.W
tk = + c
(2 . f . E) - 0,2 . P
= 17.6 x 161.561 x 1.83993
+ 0.125
( 2 x 12650 x 0.85 ) - 0.2 x 17.6
= 0.369 in
Dimana,
Dt = diameter tangki
Da = diameter impeller
E = tinggi turbin dari dasar tangki
L = panjang blade turbin
W = lebar blade turbin
J = lebar baffle
in standar yaitu :
Keterangan
Diketahui :
Jumlah nozzle = 6
Diameter nozzle = 1/2 in
Jumlah dust deflector = 3 in
Diameter dust deflector = 4 in
Diameter atas cone = 24 in
Diameter bawah cone = 4 in
Panjang cone reaktor = 26 in
e reaktor dengan
G = 92944.736 kg/hari
= 3872.6973 kg/jam
= ( 3872.6973 kg/jam / 2470.04 kg/m3 )
= 1.568 m3/jam
= 0.923 ft3/menit
= 0.015 ft3/detik
1.49312 gal/menit
Rasio liquid/gas (R) =
0.92281 ft3/menit
= 1.61801 gpm/acfm
Data Operasi dan Desain
Laju alir volumetrik gas = 1.568 m3/jam
Average particle size, dp = 1.75 in
= 0.146 ft
Johnstone scrubber coefficient, k = 0.14
Required collection efficiency, E = 100%
Cunningham correction factor, C = 1
Viskositas gas, = 0.015 cP
= 0.0000101 lb/ft.s
Mencari parameter impaksi inersial,
= 195.2
G
Luas throat =
v
0.015 ft3/detik
=
595.64 ft/s
= 0.000026 ft2
do = (16400/v) + 1,45R1,5
16400
= + (1, 45 x 1,168^1,5)
595.64
= 29 m
12544.292 kg/jam
Volume hopper =
2470.04 kg/m3
= 5.079 m3
x v x ID
NRe =
1823.11 x 0.30401 x 0.06271
=
0.018
= 1930.98
Karena Nre <2100, maka asumsi aliran laminar benar
Ukuran pipa keluar dipilih = 2,5 in Sch 40
b. Sudden contraction
Friksi yang terjadi karena adanya perpindahan dari luas
penampang besar ke luas penampang kecil
Untuk aliran turbulen, = 0.5 (Sumber:Geankoplis, hal 93)
K
hc = c x v
2
2
A2
Kc = 0.55 ( 1 -
A1)
Karena A2 jauh lebih kecil dari A1, maka A2/A1 dianggap
0, sehingga harga Kc = 0.55 , maka hc :
hc = 0.55 x 0,02912
2 x 0.5
= 0.05083 J/kg
c. Friksi pada elbow :
Digunakan 3 buah elbow 90
Kf = 1.08 (Sumber : Tabel 2.10-2 Geankoplis)
hf = Kf x v2
(Sumber: Pers 2.10-17 Geankoplis)
2
0,02912
= 3 x 1.08 x
2 x 0.5
= 0.0027437 J/kg
d. Friksi pada valve
Digunakan 1 buah globe valve
Kf = 12.7 (Sumber : Tabel 2.10-2 Geankoplis)
hf = Kf x v2
(Sumber: Pers 2.10-17 Geankoplis)
2
0,02912
= 1 x 12.7 x
2 x 0.5
= 0.0107545 J/kg
e. Sudden enlargement losses
Friksi yang terjadi karena adanya perpindahan dari luas
penampang kecil ke luas penampang besar
Untuk aliran turbulen, = 0.5 (Sumber:Geankoplis, hal 93)
K
hex = ex x v
2
2
A1
Kex = ( 1 -
A2)
Karena A2 jauh lebih kecil dari A1, maka A1/A2 dianggap
0, sehingga harga Kex = 1 , maka hex :
hex = 1 x 0,02912
2 x 0.5
= 0.00085 J/kg
f. Friksi total pada pompa
F = Ff + hc + hf (elbow+valve) + hex
= 9.30159 + 0.05083 + 0.0135 + 0.00085
= 9.36677 J/kg
4. Daya Pompa
Persamaan Bernoulli
(P2-P1) v 2 - v12
-Ws = + (Z2-Z1) x g + 2 + F
2
(Sumber: Pers. 2.7-28 Geankoplis)
Dimana :
Tekanan keluar tangki (P1)
P1 = 1 atm = 101325 Pa
Tekanan masuk tangki pencampur (P2)
P2 = 1 atm = 101325 Pa
P = 0 Pa
Z = 10 m
v22 - v12 = 0 m/s
Ws = - x Wp
(Sumber: Pers. 2.7-30 Geankoplis)
-107.37 = -0.018 x Wp
-107.37
Wp =
-0.018
= 5964.82 J/kg
5. Power pompa
Laju alir massa = 147794.76 kg/hari
= 6158.12 kg/jam
= 1.71 kg/detik
Wp = 5964.8 J/kg
P = Q x Wp
= 1.71 kg/detik x 5964.8 J/kg
= 10203.347 W
= 10.2033 kW
= 13.6829 Hp
Maka dipilih pompa dengan daya motor 14 Hp