Professional Documents
Culture Documents
Final Report
GROUP 13
GROUP PERSONNEL:
ABDI RIDHOLLOH FARRY (1406643053)
ABU BAKAR ASH SHIDDIQ (1306449302)
ADENIA GITA DIANTY (1306392960)
ANGGA KURNIAWAN SASONGKO (1306392916)
HANIF IBRAHIM (1306392973)
SHEILA NABILA PUTRI (1306392821)
ii Universitas Indonesia
PREFACE
Praise to God, The Cherisher and Sustainers of the worlds: God who has
been giving His blessing and mercy to the writer to complete this Final Report
entitled Preliminary Design of Copper Smelter Plant. This final report is
submitted to fulfill one of the requirements in Chemical Plant Design Class as
capstone course of Chemical Engineering Major in Universitas Indonesia. In
finishing this report, the writer really gives his regards and thanks for people who
has given guidance and help, they are:
1. Prof. Dr. Ir. Widodo Wahyu Purwanto, DEA., Dr. rer. Nat. Ir. Yuswan
Muharam, M.T., Dr. Ing. Ir. Misri Gozan M.Tech., Ir. Dijan Supramono,
M.Sc., Dr. Tania Surya Utami, S.T., M.T., and others lectures, who has
given their best guidance to the writer in writing a great quality report and
well developed chemical product.
2. Our Parents, who always give their supports, prayers, and blessing.
3. All of our friends from Chemical Engineering Department batch 2013 who
always give their supports.
Finally, the writer realizes there are unintended errors in writing this final
report. The writer really appreciates all readers giving their suggestion to improve
its content in order to be made as one of the good examples for the next report.
Writer Team
Indonesia is the top ten countries in the world which contribute around 4% copper
concentrate production in the world. Two largest company that provide copper
concentrate is PT. Freeport Indonesia and PT. Newmont. However not all copper
concentrate will be process in Indonesia, and mostly the copper mine (copper
concentrate) will be export overseas. The government regulation No. 4 in 2009 on
mineral and coal has pushed Indonesia to implement the advancement minerals
value-added in the country, particularly copper. Based on that background, we will
build copper smelter to reduce the export value of copper concentrate and
implement the government regulation.
The raw material in our plant are such as copper concentrates, limestone,
silica, and oxygen. The process will start when all the raw material burned on four
furnaces unit, then casting, and refinery electrolytic, which will be resulting in
copper cathode with high purity. In our plant, we also built oxygen plant to produce
oxygen-enriched air will help the combustion smelting process. PT. Smelco
Indonesia produce copper cathode (99,99% purity) and sulfuric acid (98.5% purity),
anode slime, slag, and gypsum as byproducts. PT. Smelco Indonesia is going to
produce copper cathode 320,000 tonnes/year and the copper concentrate needed to
produce our main product is 876 tonnes/day. To support the production, our plant
will be constructed in Gresik, East Java and the marketing target is exported to
China, and India as the most copper consumers from the worlds. PT. Smelco
Indonesia is divided into several areas, which are office area and process area. From
the plant layout, we could generate the total area needed to build the plant which
actually in total amounted 6.582 hectare of land area.
Equipment sizing has important role in increasing the standards of each
plants. The proper size of equipment helps to optimize the process in the plant
which is obtained by developing the Process Flow Diagram (PFD), Piping and
Instrumentation Diagram (P&ID), and sizing a static process equipment. From
P&ID could be generated controller and valve that we need for each process. P&ID
shows all of piping including the physical sequence of branches, reducers, valves,
equipment, instrumentation and control interlocks.
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To support its production process, we should determine the Health, Safety,
and Environment analysis, based on HAZID and HAZOP. To support the safety
aspect, we provide the personal protection equipment and the emergency
equipment, we also provide the evacuation procedure, firefighting and emergency
alarm, evacuation route, and the assembly or meeting point in case of emergency.
The waste of our production is grouped into three types, they are solid, liquid, and
gas. Solid waste is the largest waste produced from our plant which amounted about
27686.35 kg/hour. This waste is a byproduct which is beneficial to be processed.
Cost breakdown of our plant show that the material cost in our plant takes
about 75% of our total cost. The value of largest cost will be analyzed by sensitivity
analysis to see if the value change occurred in each variable will affect plant
economic significantly. Not only cost, the price of our product also may have its
value changing for a period of time. The analysis showed that NPV and IRR will
fall down if the cost increases and vice versa. Payback period will become longer
to reach if the cost of production is increased. The outstanding issues includes the
technical aspect and economic aspect of the plant. The technical aspects discuss the
advantages of out plant, whereas the economic aspects discuss the TCI of the
capacity of our plant compared with another plant.
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TABLE OF CONTENTS
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LIST OF TABLES
APPENDIX E: MSDS
APPENDIX F: ECONOMIC ANALYSIS
Table F.1 Total Equipment Cost ......................................................................... 228
Table F.2 Piping Cost of Copper Smelter Plant .................................................. 232
Table F.3 Piping Cost of Sulfuric Acid Plant ..................................................... 232
Table F.4 Piping Cost of Oxygen Plant .............................................................. 233
Table F.5 Piping Cost of Power Plant ................................................................. 234
Table F.6 Piping Cost of Water Utility ............................................................... 234
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Table F.7 Cost of Valve ...................................................................................... 234
Table F.8 Total Building Cost............................................................................. 235
Table F.9 Supporting Equipment Cost ................................................................ 235
Table F.10 Engineering and Supervision Cost .................................................... 236
Table F.11 Construction Expenses...................................................................... 236
Table F.12 Contingencies Cost ........................................................................... 236
Table F.13 Contractors Fee ................................................................................ 237
Table F.14 Royalties and Plant Start Up Cost..................................................... 237
Table F.15 Additional Cost ................................................................................. 237
Table F.16 Working Capital Cost ....................................................................... 237
Table F.17 Utility Cost ........................................................................................ 238
Table F.18 Waste Treatment Cost....................................................................... 238
Table F.19 Maintenance Cost ............................................................................. 238
Table F.20 Labor Need per Equipment ............................................................... 239
Table F.21 Direct Labor Cost.............................................................................. 239
Table F.22 Indirect Labor Cost ........................................................................... 239
Table F.23 Operating Overhead Cost.................................................................. 240
Table F.24 Taxes and Insurance Cost ................................................................. 240
Table F.25 Cash Flow ......................................................................................... 241
Figure F.1 FM factor for heat exchanger FOB cost ............................................ 227
Figure F.2 FL factor for heat exchanger FOB cost ............................................. 227
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CHAPTER I
BACKGROUND
1.1 Background
Indonesia is a green country with a lot of natural resources. One of natural
resources that has been commodity is mining and mineral. According the law
no.4/2009 it has been stated that mineral and coal in Indonesia miner area is
unrenewable natural resources that had a role to enrichen the society of Indonesian
therefore the management should be done in Indonesia. However, the usage is not
optimal, where still the commodity without maximum management is forced to be
export.
Based on data from ministry of energy and mineral (ESDM) production of
concentrate copper in Indonesia nearly 2,38 million Metrictonne (MT). From 100%
production, at least 70% of copper concentrate is exported as raw material and the
rest 30% is going to be process in Indonesia to become copper cathode. The
potential of copper is big with 4,925 million metric tonne ore with proven reserves
approximately 4,161 million tonne ore (Data from ministry ESDM, 2011). In fact,
according to International Copper Study Group (ICSG) report in 2014 the reserves
of copper in Indonesia contribute 4% from all over the world. The usage of coppes
is dominated from the sector of contruction, equipment, and manufacturing.
Considering the resources of copper in Indonesia still high and the usage of copper
is varied therefore improvement for sales value by doing process in Indonesia is a
must. At a recent, theres only one company to smelting copper it is PT. Smelting
Gresik. This company processing copper concentrate to become copper product
(main product) with 99,99% purity. To fullfiled the demand of copper cathode on
domestic and Asia, in 2009 the capacity of production is improve become 300.000
metric tonne per year where the copper concentrate is supplied by PT. Freeport
Indonesia. PT. Freeport Indonesia has reached 1 1,2 million metric tonne to
produce copper concentrate, however from 100% production, only 30% that can be
processes in PT. Smelting Gresik. The condition make PT. Freeport had to export
the rest of copper concentrate, while Indonesia is importing copper cathode. Based
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on Law no.4/2009 it was stated that mining product should be processed in
Indonesia and the usage is to enrich the society. Considering theres only one
company in smelting Industry and also Indonesia still doing import copper cathode
then the opportunity to build another smelting company should be done.
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In the smelting process, either hot calcine from the roaster or raw unroasted
concentrate is melted with siliceous flux in a smelting furnace to produce copper
matte. The required heat comes from partial oxidation of the sulfide charge and
from burning external fuel. Most of the iron and some of the impurities in the charge
oxidize with the fluxes to form a slag on top of the molten bath, which is
periodically removed and discarded. Copper matte remains in the furnace until
tapped.
Converting produces blister copper by eliminating the remaining iron and
sulfur present in the matte. Air, or oxygen-rich air, is blown through the molten
matte. Iron sulfide is oxidized to form iron oxide (FeO) and SO2. Blowing and slag
skimming continue until an adequate amount of relatively pure Cu2S, called "white
metal", accumulates in the bottom of the converter. A final air blast ("final blow")
oxidizes the copper sulfide to SO2, and blister copper forms, containing 98% to 99%
coppers. The blister copper is removed from the converter for subsequent refining.
The SO2 produced throughout the operation is vented to pollution control devices.
Fire refining and electrolytic refining are used to purify blister copper even
further. In fire refining, blister copper is usually mixed with flux and charged into
the furnace, which is maintained at 1100C (2010F). The impurities are removed
as slag. The remaining copper oxide is then subjected to a reducing atmosphere to
form purer copper. The fire-refined copper is then cast into anodes for even further
purification by electrolytic refining. Electrolytic refining separates copper from
impurities by electrolysis in a solution containing copper sulfate (Cu2SO4) and
sulfuric acid (H2SO4). The copper anode is dissolved and deposited at the cathode.
As the copper anode dissolves, metallic impurities precipitate and form a sludge.
Cathode copper, 99.95 to 99.96 percent pure, is then cast into bars, ingots, or slabs.
1. Pasokan Mineral
Produksi 879,696 N/A 281,718 1,168,897 1,816 1,375,466
Impor 295 3,588 66,067 610,992 6,306 48,688
2. Konsumsi Mineral
Dalam Negeri 227,811 3,588 217,615 610,992 6,306 48,688
Expor 652,180 N/A 130,170 1,168,897 1,816 1,375,466
(source: Report of Supply Demand Mineral ESDM, 2011)
The main product of our plant is refined copper (contains 99% of copper).
Based on the data from ministry energy and mineral (ESDM) the need in domestic
has been fullfiled so it will be better if we consider to export our product. We will
target our product in region asia such as China, and India. Our copper smelter plant
has acid sulphate (H2SO4), gypsum, copper slag, anode slime, and copper telluride
as byproduct and this also our opportunity to sell it to another industry. Acid
sulphate can be use for fertilizer, gypsum for cementing, copper slag for cement
and concrete, anode slime for gold, and copper telluride for semi conductor. If we
want to sells our acid sulphate we can sell to PT. Pupuk Sriwijaya (PUSRI) in West
Sumatera; PT. Pupuk Iskandar Muda Lhoksumawe Aceh; PT. Pupuk Kujang in
West Java; and PT. Pupuk Kaltim.
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1.5 Capacity Analysis
From the ESDM data on table 1.1, we can see that the demand of copper
cathode has been fullfiled. Although in Indonesia market for copper cathode is not
profitable but in overseas this commodity still has the market value. Based on the
Supply and Demand of World Refined Copper Data, we have around 2,131,000
deficit production. Then, we take 15% market share, so we get
2,131,000 15% = 320,000 tonne/year
Then we convert the demand of copper to be our market capacity product.
320,000 /
= 876 /
365 /
Coal is the most important energy source for Power Generation. Indonesia
is one of the largest coal producers and exporters in the world. Since 2005, when
production exceeded Australia, Indonesia became the leading exporter of thermal
coal. The three regions with the largest coal reserves in Indonesia are South
Sumatra, South Kalimantan and East Kalimantan.
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1.7 Plant Location Analysis
Plant site selection is one of the main factors that determine the success and
survival of a plant. The location we selected based on: the location near raw
material, the location near the buyer, the location has support facility (water,
electricity, transportation, and land availability) and also labor availability. From
the four criteria above, we selected that Gresik, Madura, and Timika has the
potential to be analyze
Based on the criteria that we selected, the next page contains the detail of
comparison from 3 locations:
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Table 1.4 Location Selection Result
Scoring
Priority Gresik Madura Timika
Criteria
Raw Material Analysis (Silica, Copper Consentrate,
5 5 25 3 5 5 25
Limestone)
Transportation 3 4 12 4 3 4 12
From the evaluated that has been done above, we selected Gresik is a
location for our Smelter plant. To be detailed our plant will be contruted in Manyar,
Gresik district. This location is selected because is only 20 Km away to PT.
Petrokimia, 43 Km away from PT. Semen Gresik, and 38 Km to international harbor
Tanjung Perak not only that the location is near with the coast, if we want to build
jetty for our plant the space still exists. Heres the detail of the location with the
coordinates 704'36.1"S and 11236'04.1"E.
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CHAPTER II
PROCESS SELECTION
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1. Higher oxygen utilization in concentrates smelting and matte conversion, by
virtue of the higher intensity reaction zone directly below the furnace lances.
2. Flexibility in treating a wide range and grade of concentrates and secondary
materials such as refinery anode scrap and scrap copper.
3. Furnace size are minimized since only short furnace retention times are
required.
4. Efficient capture of feed particles into the melt resulting in reduced carryover
or unsmelted dust to downstream equipment. Carryover from the smelting
furnace is typically 2 to 5% of the total solids fed to the furnace.
5. Slag from the smelting furnace typically contains 0.5 to 0.7% copper.
6. Continuous production of off-gases resulting in more stable operation of
downstream gas handling equipment and acid plant operation.
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+ H2O(l) H2SO4(aq) This process was a batch process and resulted in the
consumption of potassium nitrate.
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Table 2.2 Copper Smelter Technology Selection Result
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2.2.3 Sulfuric Acid Plant
The comparison of the alternative process in the sulfuric acid plant is shown
below. Based on the data that we got from the literature, we make the scoring based
on some criteria. The weight given represents our priority of choosing the process.
According to the total score below, the process chosen is double contact. Hence,
the method that will be applied in the sulfuric plant will have two absorbers.
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The Smelting (S) Furnace is the first stage of copper production in the
Mitsubishi Process. It is a continuous-operation furnace that produces a high-grade
copper sulfide matte as well as a silicate slag. Matte smelting process condition is
1250oC and 1 atm. The feed of smelting furnace is dried concentrates (containing
30% Cu, 25% Fe, 30% S, and moisture content about 0,5%) mixed with coal, silica
sand, and recycled slag from converter furnace. The mixed feed injected into
smelting furnace through vertical lances, together with oxygen enriched air. The
concentrates are bath-smelted instantly, producing a high-grade matte about 68%
copper and silicate slag. The oxidation raction occurs in smelting furnace are
2 CuFeS2 + O2 Cu2S + 2 FeS + SO2
2 FeS + 3 O2 2 FeO + 2 SO2
2 Cu2S + 3 O2 2 Cu2O + 2 SO2
FeO + SiO2 FeSiO3
Cu2O + FeS Cu2S + FeO
The electric slag-cleaning furnace (3600 kW) is elliptical with three or six
graphite electrodes arranged in two pairs of three. It is a process where molten matte
and slag containing metal that had been transferred from the smelting furnace
through a launder be heated by two sets of delta-type electrodes (2100 & 1500
KVA). Slag celaning furnace accepts matte and fayalite slag (2FeO SiO2) from the
smelting furnace and separates them into layers by the difference of specific gravity.
The process condition of slag cleaning furnace is 1250oC and 1 atm. Residence
times in the furnace are 1 to 2 hours. The purpose of the electrodes and electrical
power is to keep the slag hot and fluid. Heat is obtained by resistance to electric
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current flow between the graphite electrodes in the slag - selectively heating the
slag to 1250C. Only a tiny amount of offgas is generated in the electric furnace.
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o
possible. Converting furnaces process condition is 1250 C and 1 atm. The converter
reactions are:
Cu2S (matte) + O2 2 Cu (blister) + SO2
3 FeS (matte) + 5 O2 Fe3O4 (slag) + 3 SO2
CaCO3 (flux) CaO (slag) + CO2
In addition, some Cu2S is oxidized to Cu2O:
Cu2S (matte) + 2 O2 2 Cu2O (slag) + SO2
2 Cu2O + Cu2S 6 Cu + 5 O2
This process produces
1. blister copper (99% Cu and 0.5% S)
2. molten slag (mostlly as Cu2O, 14% Cu)
3. SO2 offgas (< 0.3 ppm SO2 or 25-30% vol SO2)
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This process aims to be produced copper refinery which will be ready in
casting the next process.
The final stage in the smelter is casting, uses technology called casting of
the English Hazelett Caster. This process takes place in two stages where the first
will be in the refined copper into copper continuous cast strip by a Hazelett Twin
Belt Caster. Then, continuous copper strips had to be cut into pieces by hydraulic
shearing machine anode.
Almost all copper is treated electrolytically during its production from ore.
It is electrorefined from impure copper anodes or electrowon from leach solvent
extraction solutions. Electrorefining entails:
1. Electrochemically dissolving copper from impure copper anodes into CuSO4-
H2SO4-H2O-electrolyte
2. Selectively electroplating pure copper from this electrolyte without the anode
impurities.
3. It produces copper essentially free of harmful impurities
4. Elimination of unwanted impurities; cathode copper typically has a purity >
99.9 % wt Cu, with < 0.005 % total metallic impurities;
Electrorefining produces the majority of cathode copper (ca. 95%). Overall
copper electrorefining is the sum of both reactions above would be
Cuimpure Cupure
The process for electrorefining copper is typical of those carried out in
aqueous solution. The electrolyte is copper sulfate (0.7 molar) and sulfuric acid (2
molar) and the way in which the purification of the copper occurs can be seen by
considering the metals likely to be found.
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CuFeS2 SiO2
SiO2 O2
O2 Cu
CaCO3 Fe2S3
FeO
FeSiO3
CaO
CaO-Fe2O4
SO2
CO2
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2.5.3 Sulfuric Acid Plant
The overall mass balance of the oxygen plant can be seen below.
= 100%
2
876 tonnes
= = 36.94 %
2385.5 tonnes
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2.7.2 Oxygen Plant
The efficiency of the oxygen plant is,
=
78
= = 93.9%
83
3
=
2
(0.4234 3800)
=
1792
= 99.2%
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Table 2.15 Sulfuric Acid Stream Classification
Cp
Stream Mass Flow Molar Flow Tin Tout Q
No. Stream In Type Q (kJ/hr) (kJ/kgmol
Out (tonne/day) (kgmol/hr) (oC) (oC) (MW/day)
oC)
1 1 1' 1860 1476 1200 1100 HOT 7216164 0.083 48.89
2 1' 2 1860 1476 1100 800 HOT 21165840 0.245 47.8
3 2 3 1860 1476 800 377 HOT 29100860.3 0.336 46.61
4 4 5 2560 2148 776 357 HOT 40239536.5 0.465 44.71
5 6 7 2560 2006 633 327 HOT 28340808.1 0.328 46.17
6 8 9 2560 1933 478.5 317 HOT 14694289.1 0.17 47.07
7 10 11 2560 1927 329 127 HOT 17123283.5 0.198 43.99
8 13 14 800 1850 26.85 115 COLD -12336813 -0.142 75.65
9 14 15 800 1850 115 293.5 COLD -25083891 -0.29 75.96
10 15 16 800 1850 293.5 305 COLD -1614134.3 -0.0187 75.87
11 18 19 700 1619 22.13 117 COLD -11690080 -0.135 76.11
12 19 20 700 1619 117 125 COLD -978135.04 -0.0113 75.52
13 20 21 700 1619 125 200 COLD -9214943.3 -0.107 75.89
14 21 21' 700 1619 200 218 COLD -2220620.4 -0.0258 76.2
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2.8.2 Heat Recovery Pinch Method
Linnhoff and Vredeveld has introduced the pinch term to design the heat
exchanger networks by the set of thermodynamically based on methods that
guarantee minimum energy. There are two methods that can be used to determine
the pinch from heat exchanger network, those are composite curve and problem
table cascade. The first step is determined the shifted temperature intervals (T*)
from actual supply and target temperatures. Hot streams are shifted down in
temperature by Tmin/2 and cold streams up by Tmin/2 as detailed in the table
below, in this case of our plant, Tmin that we used is 15.
Utility Q (MW)
Hot 0
Cold 23.258
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Figure 2.16 Cascade Table
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Table 2.19 Utility Requirement
Ti H Q
0
1185 14271444
14271444
1085 41804748
56076192
785 3956002.56
60032195
761 36815415.78
96847610
618 53833480.97
150681091
463.5 35366332.16
186047423
362 5592808.2
191640232
342 951364.26
192591596
320 768075.36
193359671
314 256025.12
193615696
312 -367956.61
193247740
308.5 228988.76
193476729
302 -12359629.8
181117099
233 -5435837.64
175681261
215 -22566754.5
153114507
140 423797.55
` 153538304
137 90218.8
153628523
132 716.28
153629239
130 2535914.52
156165154
112 1130179.83
157295334
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Table 2.19 Utility Requirement (contd)
109 -25006412.7
132288921
79 -16158466.3
116130455
71 -48475399
67655056
47 -809534.59
66845521
46 1563415.432
68408936
41.85 2438725.399
70847662
37.13 12881211.16
17
HOT COLD
1200
1000
800
T (oC)
600
400
200
0
0 10 20 30 40 50 60 70
H (MW/day)
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The premium approach temperature (Tmin) can be measured directly from
the T-H profiles as being the minimum vertical difference between the hot and cold
curves. This point of minimum temperature difference represents a bottleneck in
heat recovery and is commonly refer as the pinch. We are using temperature
difference about 10oC to get the pinch composition.
HOT COLD
1200
1000
800
T (oC)
600
400
200
0
0 10 20 30 40 50 60 70
H (MW/day)
Figure above shows that the pinch is being at 1100oC for cold fluid and
1090oC for hot fluid, as we use 10oC as the minimum temperature difference. The
hot end and overshoots indicate minimum hot utility requirement (QH min) and
minimum cold utility requirement (QCmin), as shown below.
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Figure 2.19 Pinch Design Method
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2.9 Utility Analysis
Utility plant is supporting facilities to running the process from the
beginning until the end of product. For our plant, we require several utilities.
They are electricity, water, and fuel. In this assignment.
2.9.1 Water
The water needed for our main process will be provided as the cooling agent
to reduce the temperature of the stream entering the heat reactor before going to the
next process. For example, in sulfuric acid plant the feed temperature reach 1200oC
as the outlet of the furnace. Hence, we need to cool down the temperature before it
enters the next equipment. The feed into this cooling water system is treated water
from the Bengawan Solo river.
Mass of Water
Plant Equipment Unit
(tonne/day)
Copper Smelter Anode Furnace F-104 53
Electrorefining P-101 8.8
E-201 6878
Oxygen Heat Exchanger
E-202 6734
E-304
E-305 800
E-302
Sulfuric Acid Heat Exchanger E-301
E-303
700
E-306
E-307
Total 15112
Total (tonne/hr) 629.67
The water needed for cooling in power plant is not included in the
calculation because we used the water from the oxygen plant.
After HEN calculation is done by cascade and composite curve method, the
total water consumption needed for this plant is shown below
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Table 2.22 Water Consumption After HEN
Q(MW) Q (Kj) M (kg) m (tonne/s) m (tonne/hr)
1.9 6840000 1636364 0.02513 90.4762
8 28800000 6889952 0.10582 380.952
11 39600000 9473684 0.1455 523.81
7.8 28080000 6717703 0.10317 371.429
4 14400000 3444976 0.05291 190.476
4.7 16920000 4047847 0.06217 223.81
Total 1780.95
The calculation of the water consumption after HEN is using the specific
heat of water, 4.19 kJ/kgoC, with the temperature difference (T) 15oC. The
temperature chosen based on the rule of thumb that states the cooling water could
cool down the hot stream about 15oC.
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The treated water has to fulfill the specification which needs certain process
from water source to be specified as the feed water of process. The description for
each process will be explained further
a. Screening
Screening stage is the initial stage of water treatment. The purpose of screening
is to maintain the structure of the flow in the utility of the large objects that may
damage the unit of utility facilities and facilitate the separation and remove solid
particles carried in large lake. At this stage, the particles will be filtered without the
added of chemicals.
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c. Sedimentation
The clumps sink to the bottom of the sedimentation basins, trapping larger
organic materials.
d. Filtration
Filtration in water purification is a common operation in order to get rid with
Suspended Solid (SS), including particulate BOD in water (Metcalf, 1984).
Materials used in the medium can vary: sand, anthracite (crushed anthracite coal),
carbon active granular, powdered active carbon and garnet stones. The most
commonly used in Africa and Asia are sand and gravel as a primary filter, consider
another type is quite expensive (Kawamura, 1991)
e. Demineralization
Far more resin is used for water purification than for any other purpose. It is
therefore appropriate to discuss water treatment examples when outlining the
application of the principles of ion exchange technology. Industrial ion exchange
units are produced in sizes ranging from a few litres up to vessels holding several
tonnes of resin. Service runs between regenerations usually range from 12 to 48
hours. The two major types of treatment applied to water are water softening - the
replacement of 'hard' ions such as Ca2+and Mg2+ by Na+ and demineralisation the
complete removal of dissolved minerals. Both of these treatments are outlined
below. Demineralisation virtually all the dissolved matter in natural water supplies
is in the form of charged ions. Complete deionization (i.e. demineralisation) can be
achieved by using two resins.
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The water is first passed through a bed of cation exchange resin contained
in a vessel similar to that described for softeners. This is in the hydrogen ion form
brought about by the use of a strong acid regenerant (either hydrochloric or
sulphuric). During service, cations in the water are taken up by the resin while
hydrogen ions are released. Thus, the effluent consists of a very weak mixture of
acids. The water now passes through a second vessel containing anion exchange
resin in the hydroxide form for which sodium hydroxide is used as the regenerant.
Here the anions are exchanged for hydroxide ions, which react with the hydrogen
ions to form water. Such twin bed units will reduce the total solids content to
approximately 1-2 mg L-1. With larger units, it is usual to pass water leaving the
cation unit through a degassing tower. This removes most of the carbonic acid
produced from carbon dioxide and bicarbonate in the feed water and reduces the
load on the anion unit. Without degassing the carbonic acid would be taken up by
the anion bed after conversion to carbonate.
f. De-aeration
De-aeration serves to heat the water that comes out of the ion exchanger and
condensate tool marks before it is sent as feed water. In this de-aerator, water is
heated to 100C so that the gases dissolved in the water such as O2 and CO2 can be
eliminated, because these gases can cause corrosion. The heating is done by using
a heating coil inside the de-aerator.
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2.9.2 Fuel
Fuel utility is used to determine how much fuel that must be prepared in a
period time. Fuel is used to burn copper concentrate, silica, limestone on the furnace
unit. The fuel that we use is coal, which is bituminous coal that fits for metallurgical
process. The coal is used in smelting furnace, converting furnace, and anode
furnace. Below is the calculation to determine fuel consumption. Assumption: we
use medium-volatile bituminous coal, with heating value of
Heating Value = 13840 Btu/lb = 32247 kJ/kg
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Q = QCaCO3 + Q Cu2 S
1523
Q = (m )CaCO3 + (m Cp dT)SiO2
1473
1523
tonnemole
Q Cu2 S = 0.27 (9.38 + 0.0312T + 20.97 T 2 )
h 1473
tonnemole MJ MJ
Q Cu2 S = 0.27 218660 = 59038
h tonnemole h
tonne MJ
QCaCO3 = (m )CaCO3 = 7.75 531.6
hr tonne
MJ
QCaCO3 = 4120
hr
MJ MJ MJ
Q = QCaCO3 + QCu2 S = 59038 + 4120 = 63158
h hr h
kJ MJ 103 kg MJ
Coal Heating Value = 32447 3 = 32247
kg 10 kJ tonne tonne
MJ
63158
Coal Mass = h = 1.96 tonne = 47 tonne
MJ h day
32247 tonne
= 0.472 [(5.45 . 103 . 4184)] /
= 0.472 23
= 10.86 /
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1523
Cu2S = (9.38 + 0.0312 + 20.9 2 )
1513
Cu2 S = 0.437 . [(2099.7 . 103 . 4184)] /
2 = 384 /
= 2 + 2 = 395 /
kJ MJ 103 kg MJ
Coal Heating Value = 32447 3 = 32247
kg 10 kJ tonne tonne
MJ
395 tonne tonne
Coal Mass = h = 0.02 = 0.48
MJ h d
32247 tonne
2.9.3 Air
Air is used in oxygen plant as a feed to adsorb the nitrogen, and produce
pure oxygen. Oxygen is consumed by copper smelter plant and sulfuric acid plant.
Oxygen is used in copper smelter plant for the combustion of coal to melt copper
concentrate, silica, and limestone. While oxygen in sulfuric acid plant is used to
oxidize sulfur dioxide into sulfur trioxide with the help of catalyst.
2.9.4 Electricity
In general, the electricity requirement in this plant can be divided as process,
utility unit, and another requirement. The electricity consumption of our main
process is listed on the table below
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Table 2.23 Electricity Consumption
Power
Plant Equipment Unit
(kW)
Slag Cleaning
F-102 3600
Furnace
C-201 11.54
C-202 5.59
Copper
Belt Conveyor C-203 3.15
Smelter
C-104 1.89
C-105 0.33
Hazelet Caster PM-101 100
Pump P-101 3.36
K-201 300
Oxygen Compressor
K-202 305
Sulfuric P-301 1.239
Pump
Acid P-302 1.083
Power
Pump P-401 117.9
Plant
Total 4451.082
Total (kWh/day) 106825.97
The electicity requirement in our plant would be supplied from the power
plant which use the steam produced from the main plant as the feed.
The copper smelter plant need such big power supply. Electricity supply
from PLN would not be a good idea due to the high cost of the copper smelter
operation plant. Hence, we decided to build the power plant that using steam turbine
as power supply to minimize the electricity requirement. Excess heat on copper
smelter plant, can be utilized to drive the steam turbine. Economizer is installed on
the furnace to utilized the heat from flue gas on the furnace to heat up the steam
from oxygen plant and finally it is used to drive the steam turbine. This power plant
uses a closed loop system. The PFD of the power plant is shown in the Appendix
B.
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CHAPTER III
EQUIPMENT SIZING
3.1 Furnace
3.1.1 Smelting Furnace
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Table 3.2 Slag Cleaning Furnace Specification Design (contd)
Electrodes
Material Graphite
Number 6
Diameter 0.4 m
Electricity
Min Voltage 90 V
Max Voltage 120 V
Min Current 5.5 kA
Max Current 12 kA
Power Rating 3600 kW
Applied Power 3000 kW
Operation
T 1250 C
P 2 atm
Residence Time 2 hour
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3.2 Electrolytic Cell
3.3 Caster
3.3.1 Hazelett Caster
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Table 3.5 Specification of Hazelett Caster (contd)
Dimension
Thickness of Cast Strip 0.045 m
Thickness of Lug 0.027 m
Casting Details
Casting rates 100 tones/day
Caster use 9 hours/day
Method of cutting Hydraulic sheer
Power consumption 100 kwh/tones
Equipment Specification
Name C-101
Material loaded CuFeS2
Parameters
Capacity 99.40 ton/h 27.610 kg/s
Speed 94.89 ft/min 0.482 m/s
Required mass flow 99.40 ton/h 27.610 kg/s
Maximum mass flow 125.70 ton/h 34.917 kg/s
Width 54 in 1.3716 m
Angle 1 0 0
Angle 2 5 5
Length 1 1200 ft 365.760 m
Length 2 60 ft 18.288 m
Height 10 ft 3.048 m
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Table 3.7 Specification of Belt Conveyor C-101 (contd)
Parameters
Power 16.92 Hp 12.448 kW
Belt material SL-516
Equipment Specification
Name C-103
Material loaded Coal
Capacity 0.60 ton/h 0.168 kg/s
Speed 5.37 ft/min 0.027 m/s
Required mass flow 0.60 ton/h 0.168 kg/s
Maximum mass flow 13.51 ton/h 3.753 kg/s
Width 30 in 0.762 m
Angle 1 0 0
Angle 2 5 5
Length 1 1200 ft 365.760 m
Length 2 60 ft 18.288 m
Height 10 ft 3.048 m
Power 1.10 Hp 0.807 kW
Belt material SL-516
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3.4.4 Belt Conveyor C-104
Equipment Specification
Name C-104
Material loaded CaCO3
Parameters
Capacity 7.75 ton/h 2.153 kg/s
Speed 68.84 ft/min 0.350 m/s
Required mass flow 7.75 ton/h 2.153 kg/s
Maximum mass flow 13.51 ton/h 3.753 kg/s
Width 30 in 0.762 m
Angle 1 0 0
Angle 2 5 5
Length 1 1200 ft 365.760 m
Length 2 60 ft 18.288 m
Height 10 ft 3.048 m
Power 4.61 Hp 3.392 kW
Belt material SL-516
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3.4.6 Belt Conveyor C-106
Equipment Specification
Name C-106
Material loaded Coal
Capacity 0.02 ton/h 0.006 kg/s
Speed 0.18 ft/min 0.001 m/s
Required mass flow 0.02 ton/h 0.006 kg/s
Maximum mass flow 13.51 ton/h 3.753 kg/s
Width 30 in 0.762 m
Angle 1 0 0
Angle 2 5 5
Length 1 1200 ft 365.760 m
Length 2 0 ft 0.000 m
Height 10 ft 3.048 m
Power 0.81 Hp 0.596 kW
Belt material SL-516
Equipment Specification
Name C-107
Material loaded Cu
Capacity 36.72 ton/h 10.200 kg/s
Speed 96.12 ft/min 0.488 m/s
Required mass flow 44.06 ton/h 12.240 kg/s
Maximum mass flow 45.84 ton/h 12.733 kg/s
Width 48 in 1.2192 m
Angle 1 0 0
Angle 2 0 0
Length 1 200 ft 60.960 m
Length 2 0 ft 0.000 m
Height 0 ft 0.000 m
Power 2.41 Hp 1.773 kW
Belt material SL-516
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3.4.7 Belt Conveyor C-108
Equipment Specification
Name C-108
Material loaded Cu
Capacity 36.50 ton/h 10.139 kg/s
Speed 95.55 ft/min 0.485 m/s
Required mass flow 36.50 ton/h 10.139 kg/s
Maximum mass flow 45.84 ton/h 12.733 kg/s
Width 48 in 1.2192 m
Angle 1 0 0
Angle 2 0 0
Length 1 200 ft 60.960 m
Length 2 0 ft 0.000 m
Height 0 ft 0.000 m
Power 2.60 Hp 1.915 kW
Belt material SL-516
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3.5.1 Adsorber Column R-202
Name R-202
Vessels
Number 1
Insulation type External Insulation
Diameter 2.029721 m
Height 6.089162 m
Adsorbent Bed
Type Ag-A Zeolit
Mass per vessel 6.892357 tonne
Density 700 kg/m3
Operation
Pressure 5 bar
o
Temperature 29 C
Duration 240 min
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Table 3.17 Specification of Absorber Column R-302 (contd)
Corrosion Allowance 3
Outer Diameter 3.15361374
Operating Condition
o
Input Gas, T 200 C
o
Input H2SO4, T 80 C
o
Output Gas,T 81 C
o
Output H2SO4, T 111 C
H2SO4 Production 0.98
Function
To absorb SO3 and produce H2SO4
Number of Unit 1
Material Carbon Steel
Type Packing
Packing Width and Height
Tower Diameter 3.09361374 m
Height of Packing 11.88847672 m
Permissible Tensile Stress kg/cm2
Mechanical Design
Working Pressure 101300 N/m2
Design Pressure 106365 N/m2
0.106365 N/mm2
Permissible Stress 950 N/mm2
Join Eff (j) 0.85
Corrosion Allowance 3
Outer Diameter 3.15361374
Operating Condition
o
Input Gas, T 200 C
o
Input H2SO4, T 80 C
o
Output Gas,T 81 C
o
Output H2SO4, T 111 C
H2SO4 Production 0.98
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3.7 Packed Bed Reactor
Equipment Specification
Code R-301
Function Oxidation of Sulfur Dioxide
Number of Units 1
Operation Continuous
Type Packed Bed Reactor
Operational Data
Inlet Temperature (oC) 439
o
Outlet Temperature ( C) 500
Pressure (bar) 2
Catalyst
Type V2O5
Weight (kg) 42165
Density (lb/ft3) 33.8
Diameter (mm) 8
Dimension
Number of Bed 4
Diameter (m) 3.133
Total Height (m) 12.5
Height of bed 1 3.510013
Height of bed 2 3.384656
Height of bed 3 3.13394
Height of bed 4 2.507152
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Table 3.20 Specification of Cyclone FG-301 (contd)
Dimension
Diameter Collecting Hopper (Dc) 12.95 cm
A 6.475 cm
W 1.67 cm
Do 6.475 cm
Hc 19.425 cm
H 32.375 cm
B 4.856 cm
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3.9.2 E-201
Table 3.22 Specification of E-201
3.9.3 E-202
Table 3 23 Specification of E-202
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3.9.4 E-203
Table 3.24 Specification of E-203
3.9.5 E-204
Table 3.25 Specification of E-204
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3.9.6 E-205
Table 3.26 Specification of E-205
Equipment Specification Construction - Each Shell
Equipment Code E-205 Shell Side Tube Side
Material carbon steel Design Pressure bar 8 5
o
Type Shell and Tube Design Temperature C 200 100
Performance of One Unit Passes per Shell 1 2
Shell Side Tube Side Shell Construction Information
Fluid Allocation Air Cooling Water ID m 1.283
Total Fluid Enter kg/hr 318800 280600 Length m 1.67
2
Vapor Phase In 1 0 Heat Transfer Area m 634.80
Vapor Phase Out 1 0 Baffle Information
o
Temperature In C 124 31 Baffle Spacing mm 641.62
o
Temperature Out C 80 43 Baffle Cut % 45.00
Viscosity Pa.s 0.00023 0.00780 Tube Information
Specific Heat kJ/kgK 1.01 4.23 Tubecount per Shell 270
Pressure bar 5 2 Inside Diameter mm 46.0
Velocity m/s 0.47 9.92 Outside Diameter mm 50
Pressure Drop bar 0.48 0.06 Pitch mm 67.5
Fouling Resistance m2K/W 0.000167 0.000125 Pitch Type triangular pitch
Heat Exchanged kW 3950.99
Overall Coeff. W/m2K 234.87 LMTD K 62
3.9.7 E-206
Table 3.27 Specification of E-206
3.9.9 E-301
Table 3.29 Specification of E-301
Equipment Specification Construction - Each Shell
Equipment Code E-301 Shell Side Tube Side
Material carbon steel Design Pressure bar 5 5
o
Type Shell and Tube Design Temperature C 1100 450
Performance of One Unit Passes per Shell 1 2
Shell Side Tube Side Shell Construction Information
Cooling
SO2 Gas m 0.710
Fluid Allocation Water ID
Total Fluid Enter kg/hr 77500 29170 Length m 2.50
2
Vapor Phase In 1 1 Heat Transfer Area m 25.03
Vapor Phase Out 1 1 Baffle Information
o
Temperature In C 1000 254 Baffle Spacing mm 354.85
o
Temperature Out C 900 370 Baffle Cut % 45.00
Viscosity Pa.s 0.00050 0.00039 Tube Information
Specific Heat kJ/kgK 0.88 2.00 Tubecount per Shell 64
Pressure bar 2 2 Inside Diameter mm 46.0
Velocity m/s 0.97 9.20 Outside Diameter mm 50
Pressure Drop bar 0.43 0.44 Pitch mm 67.5
Fouling Resistance m2K/W 0.000250 0.000125 Pitch Type triangular pitch
Heat Exchanged kW 2828.75
Overall Coeff. W/m2K 149.25 LMTD K 643
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3.9.10 E-302
Table 3.30 Specification of E-302
Equipment Specification Construction - Each Shell
Equipment Code E-302 Shell Side Tube Side
Material carbon steel Design Pressure bar 5 5
o
Type Shell and Tube Design Temperature C 1000 300
3.9.11 E-303
Table 3.31 Specification of E-303
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3.9.12 E-304
Table 3.32 Specification of E-304
Equipment Specification Construction - Each Shell
Equipment Code E-304 Shell Side Tube Side
Material carbon steel Design Pressure bar 5 5
o
Type Shell and Tube Design Temperature C 700 300
3.9.13 E-305
Table 3.33 Specification of E-305
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3.9.14 E-306
Table 3.34 Specification of E-306
Equipment Specification Construction - Each Shell
Equipment Code E-306 Shell Side Tube Side
Material carbon steel Design Pressure bar 5 5
o
Type Shell and Tube Design Temperature C 750 350
Performance of One Unit Passes per Shell 1 4
Shell Side Tube Side Shell Construction Information
Fluid Allocation SO3 Gas Cooling Water ID m 0.838
Total Fluid Enter kg/hr 106700 33330 Length m 2
Vapor Phase In 1 0.185 Heat Transfer Area m2 131.12
Vapor Phase Out 1 0.8343 Baffle Information
o
Temperature In C 633 115 Baffle Spacing mm 335.32
o
Temperature Out C 327 293.5 Baffle Cut % 45.00
Viscosity Pa.s 0.00040 0.00240 Tube Information
Specific Heat kJ/kgK 0.84 4.00 Tubecount per Shell 84
Pressure bar 2 2 Inside Diameter mm 46.0
Velocity m/s 2.25 30.47 Outside Diameter mm 50
Pressure Drop bar 4.17 0.30 Pitch mm 65
Fouling Resistance m2K/W 0.000250 0.000125 Pitch Type triangular pitch
Heat Exchanged kW 9142.06
Overall Coeff. W/m2K 200 LMTD K 342
3.9.15 E-307
Table 3.35 Specification of E-307
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3.9.16 E-308
Table 3.36 Specification of E-308
Equipment Specification Construction - Each Shell
Equipment Code E-308 Shell Side Tube Side
Material carbon steel Design Pressure bar 5 5
o
Type Shell and Tube Design Temperature C 500 250
3.9.17 E-401
Table 3.37 Specification of E-401
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3.9.18 E-402
Table 3.38 Specification of E-402
Equipment Specification Construction - Each Shell
Equipment Code E-402 Shell Side Tube Side
Material carbon steel Design Pressure bar 5 5
o
Type Shell and Tube Design Temperature C 450 350
Performance of One Unit Passes per Shell 1 2
Shell Side Tube Side Shell Construction Information
Fluid Allocation Steam Steam ID m 0.756
Total Fluid Enter kg/hr 41670 62500 Length m 2
2
Vapor Phase In 1 0.5 Heat Transfer Area m 23.35
Vapor Phase Out 0.9908 1 Baffle Information
o
Temperature In C 350 150 Baffle Spacing mm 378.08
o
Temperature Out C 276 280 Baffle Cut % 45.00
Viscosity Pa.s 0.00019 0.00019 Tube Information
Specific Heat kJ/kgK 2.40 4.90 Tubecount per Shell 75
Pressure bar 2 2 Inside Diameter mm 46.0
Velocity m/s 0.87 8.98 Outside Diameter mm 50
Pressure Drop bar 0.44 0.02 Pitch mm 67.5
Fouling Resistance m2K/W 0.000167 0.000125 Pitch Type triangular pitch
Heat Exchanged kW 2261.55
Overall Coeff. W/m2K 1790.00 LMTD K 74
3.9.19 E-403
Table 3.39 Specification of E-403
Equipment Specification Construction - Each Shell
Equipment Code E-403 Shell Side Tube Side
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3.9.20 E-404
Table 3.40 Specification of E-404
Equipment Specification Construction - Each Shell
Equipment Code E-404 Shell Side Tube Side
Material carbon steel Design Pressure bar 5 5
o
Type Shell and Tube Design Temperature C 650 500
Performance of One Unit Passes per Shell 1 4
Shell Side Tube Side Shell Construction Information
Fluid Allocation Steam Steam ID m 0.850
Total Fluid Enter kg/hr 62500 62500 Length m 1.5
Vapor Phase In 1 1 Heat Transfer Area m2 20.33
Vapor Phase Out 0.9908 1 Baffle Information
o
Temperature In C 580 320 Baffle Spacing mm 424.97
o
Temperature Out C 485 400 Baffle Cut % 45.00
Viscosity Pa.s 0.00032 0.00021 Tube Information
Specific Heat kJ/kgK 2.20 2.90 Tubecount per Shell 87
Pressure bar 2 2 Inside Diameter mm 46.0
Velocity m/s 36.35 0.11 Outside Diameter mm 50
Pressure Drop bar 1.86 0.00 Pitch mm 67.5
Fouling Resistance m2K/W 0.000167 0.000125 Pitch Type triangular pitch
Heat Exchanged kW 4354.60
Overall Coeff. W/m2K 1780.00 LMTD K 165
3.9.21 E-405
Table 3.41 Specification of E-405
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3.10 Storage Tank
3.10.1 Storage Tank T-201
Equipment Specification
Equipment Name Sulfuric Acid Tank
Equipment Code T-201
Storage Type Liquid Storage
Function Storage for H2SO4
Number of Unit 1
Material Carbon Steel SA 167
Type of Tank Cylinder Vertical Concrete Foundation
Type od Head Flat Head
Operation Data
Temperature (oC) 30
Pressure (bar) 2
Mass Flow (kg/h) 28437.5
Bulk Density (kg/m3) 1842
Dimension
Capacity (kg/h) 682500
3
Volume tank (m ) 407.5732899
3
Volume of Liquid in Tank (m ) 370.5211726
Tank Diameter (m) 6.377302582
Tank Height (m) 12.75460516
Height of Liquid in Tank (m) 11.47914465
Design Pressure (bar) 3.532994666
25.29
Hydrostatic Pressure (bar) 2.072169275
Shell Thickness (in) 0.212035665
Head Thickness (in) 0.742124829
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\
Table 3.43 Specification of Storage Tank for Demineralize Water (contd)
Equipment Specification
Material Carbon Steel SA 167
Cylinder Vertical
Type of Tank
Concrete Foundation
Type od Head Flat Head
Operation Data
Temperature (oC) 30
Pressure (bar) 2
Mass Flow (kg/h) 890475
3
Bulk Density (kg/m ) 1004
Dimension
Capacity (kg/h) 890475
Volume tank (m3) 975.6200199
3
Volume of Liquid in Tank (m ) 886.9272908
Tank Diameter (m) 8.530909854
Tank Height (m) 17.06181971
Height of Liquid in Tank (m) 15.35563774
Design Pressure (bar) 2.887502694
Hydrostatic pressure (bar) 1.510871908
Shell Thickness (in) 0.526092676
Head Thickness (in) 1.841324367
3.11 Warehouse
3.11.1 Warehouse TK-101
Table 3.44 Specification of Warehouse TK-101
Equipment Specification
Equipment Name Slag Warehouse
Equipment Code TK-101
Function store for slag
Number of Unit 1
Type Rectangle building with a triangular prism roofs
Operation Data
Temperature 30C
Pressure 1 atm
Bulk Density 3848.41 kg/ m3
Dimension
Capacity 31,987.5 tons
Length 37 m
Width 28 m
Height 10 m
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3.11.2 Warehouse TK-102
Equipment Specification
Equipment Name Coagulant Tank
Equipment Code T-501
Number of Vessel 4
Type Rigid Base Circular
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Table 3.47 Specification of Coagulant Tank (contd)
Number of Unit 4
Filter Specification
Filter Type Slow Sand Filter
Total Surface Area (m2) 267.1425
Max. Surface Per filter (m2) 50
Number of Filters 6
Surface Area per Filter (m2) 44.53
Dimension
Filtration Rate (m/h) 0.2
Required Tank Area (m2) 356.19
Long (m) 25
Width (m) 15
Height (m) 2.4
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Table 3.49 Specification of Demine Water Tank (contd)
Number of Unit 2
Operation Data
Cation Concentration 250 mq/L
Use degasifier (Yes/No) Yes
Anion Concentration 150.25 mq/L
Running time 15 h
Throughput Flow rate 19200 m3
Ionic Load
Cation Load 4800000 eq
Anion Load 2884800 eq
Operating Capacity
Cation regeneration with HCl 1 eq/L
Anion regeneration with NaOH 0.5 eq/L
Resin Volumes
SAC 4800000 L
SBA 5769600 L
Specific Flow Rate
SAC 5.1 h-1
SBA 4.72 h-1
3.16 Pump
3.16.1 P-301
Table 3.51 Specification of Pump P-301
Pump Identification
Name Pump
Code P-301
Function Transfer water into E-307
Amount (unit) 1
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Table 3.51 Specification of Pump P-301 (contd)
Pump Identification
Mode of Operation Continuous
Material Composition
Type Fluid Liquid
Operating Condisiton
Mass flow (kg/s) 8.102777778
Flow rate (m3/s) 0.008119444
Density (kg/m3) 997.3
Temperature (oC) 22.12
Specification Design
Type Centrifugal
Material CS A 285
NPSHa (m) 10.48853423
Head (m) 22.27529913
Utility
FHP (kW) 1.326614721
BHP (kW) 1.768819628
3.16.2 P-302
Table 3.52 Specification of Pump P-302
Pump Identification
Code P-302
Function Transfer water into E-305
Amount (unit) 1
Mode of Operation Continuous
Material Composition
Type of fluid Water
Operating Condition
Mass flow (kg/s) 9.166666667
Flow rate (m3/s) 0.009277778
Density (kg/m3) 996.1
Temperature (oC) 26.85
Specification Design
Type Centrifugal
Material CS A-285
NPSHa (m) 10.00451002
Head (m) 34.84116885
Utility
FHP (kW) 2.347423751
BHP (kW) 3.129898335
3.16.3 P-201
Table 3.53 Specification Pump P-201
Pump Identification
Name Pump
Code P-201
Function Transfer water into E-205
Amount (unit) 1
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Table 3.53 Specification Pump P-201 (contd)
Pump Identification
Mode of Operation Continuous
Material Composition
Type fluid Water
Operating Condisiton
Mass flow (kg/s) 79.44444444
Flow rate (m3/s) 0.079777778
Density (kg/m3) 994.6
Temperature (oC) 32
Specification Design
Type Centrifugal
Material CS A-285
NPSHa (m) 12.70941704
Head (m) 9.197232794
Utility
FHP (kW) 5.370417516
BHP (kW) 7.160556687
3.16.4 P-202
Table 3.54 Specification Pump P-202
Pump Identification
Name Pump
Code P-202
Function
Amount (unit) 1
Mode of Operation Continuous
Material Composition
Type Fluid Water
Operating Condisiton
Mass flow (kg/hr) 280600
Flow rate (m3/s) 0.078111111
Density (kg/m3) 994.9
Temperature (oC) 31
Specification Design
Type Centrifugal
Material CS A-285
NPSHa (m) 12.50132387
Head (m) 9.504604907
Utility
FHP (kW) 5.445108946
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3.16.5 P-101
Table 3.55 Specification Pump P-101
Pump Identification
Name Pump
Code P-101
Function Transfer H2SO4 into electrolytic cell
Amount (unit) 1
Mode of Operation Continuous
Operating Condiiton
Mass flow (kg/s) 52.77777778
Flow rate (m3/s) 0.028527778
Density (kg/m3) 1844
Temperature (oC) 26.85
Specification Design
Type Centrifugal
Material Metal
NPSHa (m) 14.66242959
Head (m) 17.05144771
Utility
FHP (kW) 0.661454076
BHP (kW) 0.881938767
3.16.5 P-101
Table 3.56 Specification Pump P-401
Pump Identification
Name Pump
Code P-401
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3.16.5 P-501
Table 3.57 Specification Pump P-501
Pump Identification
Name Pump
Code P-501
Function Take Water River
Amount (unit) 1
Mode of Operation Continuous
Material Composition
Type of Fluid Water River
Operating Condition
Mass flow (kg/s) 494.4444444
Flow rate (m3/s) 0.495555556
Density (kg/m3) 994.9
o
Temperature ( C) 31
Specification Design
Type Submerged Pump
Material Carbon Steel
NPSHa (m) 51.50248049
Head (m) 19.43797843
Utility
FHP (kW) 70.64085329
BHP (kW) 94.18780439
3.17 Compressor
3.17.1 K-100
Table 3.58 Specification Compressor K-100
Equipment Specification
Code of Project K-100
To transfer heating media into
Function
heat exchanger
No. Unit 1
Type Centrifugal
Material CRA (corrosion Resistant Alloy)
Operating Data
Compressor Power 474.375 kw
Efficiency (%) 75
Temperature Inlet (0C) 759.8
Temperature Outlet (0C) 776
Pressure Inlet (kPa) 154
Pressure Outlet (kPa) 165
Head (m) 1225
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3.17.2 K-101
Table 3.59 Specification Compressor K-101
Equipment Specification
Code of Project K-101
Function To transfer heating media into HE
No. Unit 1
Type Centrifugal
Material CRA (corrosion resistant Alloy)
Operating Data
Compressor Power 41.309 kw
Efficiency (%) 75
0
Temperature Inlet ( C) 632.5
0
Temperature Outlet ( C) 633.9
Pressure Inlet (kPa) 135
Pressure outlet (kPa) 136
Head (m) 106
3.17.3 K-102
Table 3.60 Specification Compressor K-102
Equipment Specification
Code of Project K-102
Function To transfer heating media into HE
No. Unit 1
Type Centrifugal
Material CRA (corrosion resistant alloy)
Operating Data
Compressor Power 161.636 kw
Efficiency (%) 75
0
Temperature Inlet ( C) 472.8
Temperature Outlet (0C) 478.5
Pressure inlet (kPa) 135
Pressure Outlet (kPa) 140
Head (m) 417
3.17.4 K-201
Table 3.61 Specification Compressor K-201
Equipment Specification
Code of Project K-201
Function To compress air atmosphere
No. Unit 1
Type Reciprocating
Material Carbon Steel
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Table 3.61 Specification Compressor K-201 (contd)
Operating Data
Compressor Power 10808.5 kw
Efficiency (%) 75
Temperature Inlet 31
(0C)
Temperature Outlet 152.6
(0C)
Pressure inlet (kPa) 100
Pressure Outlet (kPa) 250
Head (m) 9700
3.17.5 K-202
Table 3.62 Specification Compressor K-202
Equipment Specification
Code of Project K-202
Function To compress air from HE
No. Unit 1
Type Reciprocating
Material Carbon Steel
Operating Data
Compressor Power 8181 kw
Efficiency (%) 75
0
Temperature Inlet ( C) 32
Temperature Outlet (0C) 124.4
Pressure inlet (kPa) 245.2
Pressure Outlet (kPa) 500
Head (m) 7285
3.18 Piping
Table 3.63 Piping Specification of Copper Smelter Plant
ID OD
Stream In Nominal Size (inch) Wall thickness (inch)
(inch) (inch)
19 8 6.85130803 8.625 0.322
Pump to Electrolytic
8 6.85130803 8.625 0.322
Cell
2B 1.5 1.499949794 1.9 0.145
9B 1.25 1.097725931 1.66 0.14
13B 0.38 0.283463867 0.675 0.091
5B 1 1.032189433 1.315 0.133
10B 1 0.871887618 1.315 0.133
14B 0.38 0.246740468 0.675 0.091
1 1.25 1.264331402 1.66 0.14
2 0.75 0.73102575 1.05 0.113
3 10 9.992959225 10.75 9.271
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Universitas Indonesia
Table 3.65 Pipinng Specification of Oxygen Plant
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Table 3.67 Piping Specification of Water Pretreatment Plant
Nominal Size ID OD Wall Thickness
Stream
(inch) (Inch) (inch) (Inch)
Water from Bengawan
34 31.28069 34 0.75
Solo River
3.19 Valve
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Table 3.71 Valve Size of Power Plant
Flow Flow Valve Size
Stream SG Gf dP Cv, max
(tonne/day) (gpm) (in.)
C4, A, B, C,
1500 275.25 1 1 5 246.1911 5
D, E, F, G, H
6A, 7A, 8A 1001 183.6835 1 1 5 164.2915 4
3A, 4A, 5A 1500 275.25 1 1 5 246.1911 5
1A, 2A 6000 1101 1 1 5 984.7643 16
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CHAPTER IV
PROCESS CONTROL STRATEGY
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Table 4.2 Control Tabulation of Oxygen Plant
Final
Equipment Process Controller Manipulated
Unit Sensor Control Sequence of Instrumentation
Name Variable P/PI/PID Variable
Element
E-201 / E-202 / Thermocouple If the outlet temperature of the the heat exchanger not fit
Temperature
Heat E-203 / E-204 / & Proportional Cooling Water with the wanted condition, then the valve will adjust the
Temperature Control
Exchanger E-205 / E-206 / Temperature Integral TT Flow Rate flow of cooling water until the condition become
Valve TCV
E-207 Element normal again.
Flow
Flow Element Flow Cooling Water Indicator When the outlet pump flow is higher than design, the
Pump P-201 / P-202 Flow
& Flowmeter Control Flow Rate Controller valve will be closed.
FIC
Pressure
Pressure When the pressure of the adsorber is higher than the
Gauge & Pressure
Pressure Air Flow Rate Control design pressure, the pressure control valve will open to
Pressure Controller
Valve PCV reduce the pressure on the adsorber.
Element
Adsorber
R-201 / R-202
Column When the temperature of the of the adsorber is not fit
Thermocouple with the wanted condition, the TT will give an electric
Temperature
& Proportional signal to TIC and then transfer that signal into a
Temperature Air Flow Rate Control
Temperature Integral TT pneumatic signal to flow control valve at the cold fluid
Valve TCV
Element inlet (cooling water or steam) until the condition
become normal.
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Table 4.3 Control Tabulation of Sulfuric Acid Plant
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Table 4.4 Control Tabulation of Power Plant
Final
Equipment Process Controller Manipulated
Unit Sensor Control Sequence of Instrumentation
Name Variable P/PI/PID Variable
Element
Flow
Cooling When the outlet pump flow is higher than design,
Flow Element Flow Indicator
Pump P-401 Flow Water Flow the valve will be closed. But, if the outlet pump
& Flowmeter Control Controller
Rate flow is lower than design, the valve will be opened.
FIC
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Table 4.5 Control Tabulation of Water Utility
Final
Equipment Process Controller Manipulated
Unit Sensor Control Sequence of Instrumentation
Name Variable P/PI/PID Variable
Element
Coagulant
T-501
Tank
Filtration
V-501
Tank
Level
Reduce liquid level in column by opening the
Kation Mechanical Proportional Liquid Product Indicator
V-502 Level Level Control Valve on the bottom product of
Exchanger Float Integral LT Flow Rate Controller
the column.
LIC
Anion
V-503
Exchanger
Water
T-502
Tank
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CHAPTER V
PLANT LAYOUT
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Our plant is divided into two zone which each of them has certain functional
such as safety rule. The zone is red zone, and blue zone.
a. Red Zone
Red zone is a process zone which consist of process train, utilities, flare stacks
and storage and loading. The process train of our plant consist of copper smelting
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plant, oxygen plant, and sulfuric acid plant. The utilities consist of steam turbine
power plant, water pretreatment, and waste water treatment. The red zone is
dangerous, so the workers are suggested to wear minimum standard PPE (Personal
Protective Equipment) which consist of shoes, earplug, helmet, coverall, and
glasses. Considering the danger of this zone, all of worker are suggested to wear
minimum standard PPE (Personal Protective Equipment) which consist of shoes,
earplug, helm, and glasses. The red zone is necessary to design the layout
specifically due to the potential fire and explosion impact.
b. Blue Zone
Blue zone is the area of the plant which is not directly related to the process. It
consists of office area, clinic, laboratory, mosque, firefighting, and parking lot area.
This area is quite safe and does not need safety equipment or PPE (Personal
Protective Equipment). There is a rule of thumb of plant layout spacing based on
Center for Chemical Process AIChe Industry Technology Alliance. The figure
below is the zone that has been explained earlier.
N
GUEST CAR PARK (FOR SECURITY MOTORCYCLE PARKING
ADMISSION) SECURITY AREA
MAIN
W E
GATE
S
CHEMICAL ENGINEERING DEPARTMENT
FACULTY OF ENGINEERING
UNIVERSITAS INDONESIA
CAR PARKING AREA DEPOK
PROJECT
PRELIMINARY DESIGN OF COPPER
SMELTER PLANT
DRAWING
DATE
NO.
11/16/2016
2
ASSEMBLY
POINT
BLUE ZONE
GROUP
PAR13
OFFICE BUILDING
MOSQUE
CLINIC
FIRE STATION
K3 BUILDING
LAB
MECHANICAL AND
ASSEMBLY POINT ELECTRICAL
BUILDING
CANAL CANAL
CENTRAL
CONTROL
POWER PLANT ROOM
WATER UTILITY
ASSEMBLY POINT
SULFURIC
ACID PLANT
OXYGEN PLANT
RED ZONE
RAW MATERIAL
STORAGE
ASSEMBLY POINT
LOADING AND
PRODUCT STORAGE UNLOADING
FLARE
25 m 40 m N
MOTORCYCLE PARKING
20 m
GUEST CAR PARK (FOR SECURITY
ADMISSION) SECURITY AREA
MAIN 40 m
W E
GATE 65 m
S
CHEMICAL ENGINEERING DEPARTMENT
45 m
FACULTY OF ENGINEERING
55 m
UNIVERSITAS INDONESIA
CAR PARKING AREA DEPOK
E-101/201/202/203/204/205/206/207/301/302/
303/304/305/306/307/308
25 m /401/402/404/405 : Heat Exchangers
R-301 : Packed Bed Reactor
R-302/303 : Absorber
R-201/202 : Adsorber
60 m ASSEMBLY K-201/202 : Kompresor
30 m
T-401 : Turbine
POINT F-101/102/103 : Furnace
F-/104/105 : Furnace
25 m PM-101/102 : Hazelette Caster
45 m
OFFICE BUILDING P-101/102/103/ : Electrorefining
P-104/105/106 : Electrorefining
20 m
MOSQUE P-501/502 : Pump
T-501/502/503/504 : Coagulant Tank
25 m
V-501 : Filtration Tank
30 m 35 m
V-502/503 : Ion Exchanger
V-504 : Cooling Tower
10 m
20 m
FIRE STATION
PROJECT
45 m
30 m
LAB PRELIMINARY DESIGN OF COPPER
20 m
ASSEMBLY POINT
20 m
ELECTRICAL DRAWING
DATE
NO.
10 m
BUILDING 5
11/16/2016
65 m 25 m
GROUP
PAR13
5m
5m
CANAL CANAL
5m
80 m
5m
35 m
5m
5m
2500 mm
Evaporator
5000 mm
1800 mm
HE
2500 mm
HE
5000 mm
2300 mm
2300 mm
3000 mm
8400 mm
CENTRAL
1500 mm
P-501
5000 mm
5000 mm
40 m
800 mm 900 mm
CONTROL
1800 mm
T-501
5000 mm
2500 mm
30000 mm
Condenser
2300 mm
ROOM
(E-404)
(E-405)
(P-401)
1900 mm
Pump
HE
5000 mm
5000 mm
55 m
5000 m
5000 m 6800 mm
5000 mm
65 m
15000 mm
Cooling Tower
V-502 V-503 (V-504)
V-501
3000 m 5000 m
30000 mm
25000 mm
5000 mm
35 m
2000 mm
5000 mm
Turbine
(T-401)
5500 mm
T-505 5000 m
T-504 T-503 T-502
15 m
ASSEMBLY POINT
8350 mm
8350 mm 8350 mm
8350 mm
5000 mm
3000 mm
5000 mm
1500 mm
2400 mm
P-502
2200 mm
E-308
2800 m
E-305
E-306
3000 mm
4000 mm
1200 mm
1100 mm
1100 mm
4000 mm
6000 mm 50 m
1500 mm
R-301
4000 mm
1500 mm
FILTER
5000 mm 5000 mm
1500 mm
950 mm
1150 mm
2100 mm 2500 mm
2500 mm
5000 mm
2400 mm 2000 mm
30 m
15000 mm
10000 mm
1000 mm
E-204 E-203
8000 mm
5000 mm
5000 mm
10000 mm
40 m
1250 mm
1500 mm
3000 mm
E-307
2500 mm
1500 mm
K-202
2200 mm 2200 mm
3000 mm
2000 mm
5000 mm
E-303
3000 mm
E-302
R-302
2000 mm
1000 mm
2200 mm
2200 mm
R-201
6000 mm
2000 mm
1000 mm
R-202
1500 mm
800 mm
2500 mm
2500 mm
3000 mm
1500 mm 1500 mm
2100 mm
1900 mm
2200 mm 2400 mm
E-304
3000 mm
E-301
8000 mm
E-207 E-206 E-205
3000 mm
R-303
1500 mm
1100 mm
1100 mm
1000 mm 10000 mm
1500 mm
1000 mm
3000 mm
35 m
75 m
1000 mm
4000 mm
10100 mm
RAW MATERIAL
65 m
E-101
6000 mm
10400 mm
12500 mm
4000 mm
STORAGE
10100 mm
6000 mm
9000 mm
6300 mm
40 m
12500 mm
1200 mm
P-101
5000 mm 6000 mm
1m
6300 mm 4000 mm
1200 mm
2000 mm
3150 mm
6300 mm
1200 mm
P-103
2500 mm
5000 mm
6300 mm
1200 mm
P-104 12500 mm
6000 mm
25 m 5000 mm
1m
6300 mm 4000 mm
3150 mm
2000 mm
1200 mm
6300 mm
1200 mm
P-106
2000 mm
10 m
155 m
ASSEMBLY POINT 80 m
LOADING AND
10 m
PRODUCT STORAGE
15 m
UNLOADING
FLARE
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CHAPTER VI
HEALTH, SAFETY, AND ENVIRONMENTAL MANAGEMENT
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Table 6.2 HAZID List
Potential Hazard
Location Causes Frequency Prevention
Hazard Effect
Copper Smelter Plant
Power motor
The Velocity of
Conveyor which used is Control/ monitoring
conveyor is to Minor Most
System higher than it periodically
high
should be
Routine check on the Slag
High
Smelting Cleaning Furnace
Fire & Temperature and
Furnace Severe Likely condition. Placing a
Explosion Pressure Inside
Unit temperature and pressure
the Furnace
contro
Barriers and other
protecting covering,
Electrolytic cells including the mobile
Electrolitic Electrical may emit large shields should be used or
Severe Most
Cells Hazard quantities of set up to protect workers
dusts against the splashes of
molten metal and
electromagnetic radiation
Application of explosion
High protection system.
Slag
Temperature Cascade control which
Cleaning Explosion Severe Likely
Inside the operates automatically
Furnace
Furnace responds temperature and
product moisture change
Routine check on the Slag
High
Cleaning Furnace
Converter Fire & Temperature &
Severe Likely condition. Placing a
Furnace Explosion Pressure Inside
temperature and pressure
the Furnace
control
Application of explosion
High protection system.
Anode Temperature Cascade control which
Explosion Severe Likely
Furnace Inside the operates automatically
Furnace responds temperature and
product moisture change
Routine check on the Slag
High
Cleaning Furnace
Melting Fire & Temperature &
Severe Likely condition. Placing a
Furnace Explosion Pressure Inside
temperature and pressure
the Furnace
control
Charging a
furnace with Barriers and other
coming in
impure or moist protecting covering,
contact with
scrap metal and including the mobile
metal splashes
Casting alloys, Molten shields should be used or
or be exposed Severe Most
System metal also emits set up to protect workers
to
electromagnetic against the splashes of
electromagnetic
radiation in the molten metal and
radiation
furnace and electromagnetic radiation
pouring areas
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Table 6.2 HAZID List (contd)
Potential Hazard
Location Causes Frequency Prevention
Hazard Effect
Oxygen Plant
Air
Compressor Safety ear plug
Compressor Noise Pollution Major Most
Sound provisioning
Unit
Protect the piping
Piping Damage and Corrosion,
Major Likely network and control
Network leakage of pipe failure
periodically
Defficiency on Make sure the Drum is
Leaking, Crack
the welded joint, properly design, Do a
Drum and material Major Likely
Exposure to the routine maintenance and
exposure
wind, Corrosion weld inspection
Adsorber Overpressure in Control and monitoring
Explosion Severe Likely
Unit the adsorber unit the pressure
Sulfuric Acid Plant
Loud operation
Safety ear plug
Water Pump Noise Pollution noise Major Most
provisioning
Protect the piping
Piping Damage and Corrosion,
Major Likely network and control
Network leakage of pipe failure
periodically
Outout will not
Heat have Cold water flow
Control/monitoring
Exchanger temperature as is too low, feed Major Likely
periodically
Unit specified inlet is to high
before
Overflow
High capacity of
Water which release
cooling water Minor Most Control the flow capacity
Utility Unit to the
which produce
environment
Overpressure in Control and monitoring
Absorber Explosion Severe Unlikely
the absorber unit the pressure
The reaction
The reaction Control/monitoring
Converter will not run Major Likely
uncontrolled periodically
optimally
There is a leak
in the storage
Acid Routine Inspection.
tank, so that the
Storage Corrosion Severe Unlikely Protect the storage tank
acid released
Tank with cathodic protection
into the
environment
Water Utility System
Water flooding Minor Likely Checking tank/vessel
Tank/Vessel Overcapacity
Leakage Minor Likely level periodically
Surfacing tools that
Loud operation
Pump Noise pollution Minor Most generate the noise and
noise
oblige the use of earplug
Protect the piping
Piping Leakage and Corrosion,
Major Likely network and control
Network damage of pipe Failure
periodically
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Table 6.2 HAZID List (contd)
Potential Hazard
Location Causes Frequency Prevention
Hazard Effect
Water Utility System
Ion
Checking level
Exchange Water flooding Overcapacity Minor Likely
periodically
Unit
Power Plant
Outout will not Cold water
Heat have temperature flow is too low, Control/monitoring
Major Likely
Exchanger as specified feed inlet is to periodically
before high
Over speed in
There should be
steam turbine
Steam Boiler in valves to release the
which will make Major Most
Turbine HRSG too hot pressure and prevent
rotor failure in
over speed
steam turbine
Surfacing tools that
Loud operation generate the noise
Pump Noise pollution Minor Most
noise and oblige the use of
earplug
6.1.2 HAZOP
Hazard and Operability Studies (HAZOP) was first developed by ICI, a
British chemical company. Hence, HAZOP is more often implemented in the
chemical industry. But along with the increasing need for hazard analysis
techniques, several other industries, such as food industry, pharmaceutical, and
mining (including oil and gas drilling offshore), also began to implement many
HAZOP. The main purpose of HAZOP is to identify:
a. The dangers (hazards) are a potential (especially that endanger human health
and the environment)
b. All sorts of problems operational capability (operability) on each process as a
result of irregularities against the design goals (design intent) processes in plants
as well as plants that have new activity or will be operated.
For HAZOP, there are a few parameters that we use in, meaning for each
parameter can be seen in table below. For each unit, there is deviation that are not
write because we consider that deviations have probability very low.
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Table 6.3 HAZOP Parameter
Guide Word Meaning
No or not Complete negation of the design intent
More Quantitative increase
Less Quantitative decrease
As well as Qualitative modification/increase
Part of Qualitative modification/decrease
Reverse Logical opposite of the design intent
Other than Complete substitution
Early Relative to the clock time
Late Relative to the clock time
Before Relative to order or sequence
After Relative to order or sequence
(source: Geoff Wells, 1996)
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Table 6.4 HAZOP List (contd)
Guide
Location Parameter Possible Cause Consequences Action Required
Words
Oxygen Plant
Low input
Less flowrate, FIC Compressor Failure Install flow indicator
Compresso failure
Flow
r
Process fluid valve
More Over-pressure Install flow indicator
failure
Close the pressure
output valve so that
Gas pressure is too Pressure deficiency in
the pressure could
low, defect on the column operation,
Less reach the specified
compressor mass transfer is not
pressure in the column
function effective
operation, Install the
pressure control
Adsorber Pressure
Open the pressure
Gas pressure is too output valve so that
high, valve before Overpressure in the the pressure inside the
More entering adsorber column operation, mass column will not
is inadvertently transfer is not effective accumulated to
opened prevent damages in
the column
The defection of Explosion or drum
valve on the leakage, the harm
Drum Pressure More pipeline before exhaust gas will be Install Valve
reentering the damage the
drum environment
Sulfuric Acid Plant
Failure of inlet Process fluid Install high
No cooling water temperature is not temperature alarm
vapor lowered accordingly TAH
Process fluid
Less Pipe leakage Install flow meter
Pump Flow temperature too low
Install low
Inlet valve failed Output of process fluid temperature alarm
More
open temperature TAL before and after
the process
Less flow carried
Less conversion and Install flow and
upstream due to
Less SO3 Release hazard temperature indicator
pressure drop Gas
gases as above as above.
pipe leakage
Install flow and
More flow carried
Heat Flow Equilibrium conversion temperature indicator
More upstream Increase
Exchanger Temperature in may not reached as above. Regular test
in pressure
on catalyst.
Install thermocouples
Too much heat Higher conversion if
as above and regular
Less removed by heat enough catalyst is
check on boiler
exchangers available.
efficiency
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Table 6.4 HAZOP List (contd)
Guide
Location Parameter Possible Cause Consequences Action Required
Words
Sulfuric Acid Plant
Heat exchangers Inefficiency in heat Install thermocouples as
Heat Flow
More fail to remove exchanger also affects above and regular check
Exchanger Temperature
specified heat other beds temperature on boiler efficiency
Less inlet gases Less production of Instal flow indicator and
Less
carried upstream H2SO4 controller
Increased load on
Flow downstream
More More inlet gas equipment Control the inlet gases
More H2SO4 needed
for absorption
Reaction rate not
reach Install thermocouples as
Insufficient conversion
equilibrium, less above and gas bypass to
to meet environmental.
Less conversion control gas temperatures.
Requirement. Less
Too much Check catalyst activity
production of H2SO4
cooling in heat and plug of catalyst.
Catalyst
Temperature exchanger
Converter
Higher
temperature
Install thermocouples as
carried from Failure in heat
More above and gas bypass to
previous bed. exchanger
control gas temperatures.
Insufficient
cooling
Install pressure relief
Outlet gas pipe Increase pressure
Pressure More valve Shut down and
partial blockage downstream
clear pipes.
Breakage of
Damage to
As catalyst and
downstream Install layers of porous
Catalyst Well chips carried
equipment and loss of silica.
As downstream by
catalysts
gases
Ensure liquid feeds to
the absorber and other
process units shutdown
Flow stopped
No absorption in Install low flow alarm
upstream Line
column Pressure build onto the FIC. Install
Intermediet blockage or the
Flow No up in pipe Gasess kick-back on steam on
Absorber isolation valve
escape into the upstream pumps and
shut in error Line
surrounding ensure pressure relief
fracture
system is tolerable. Plant
emergency shutdown
procedure
Sulfuric Acid Plant
High liquid flow Accumulation of
Intermediet at loading point. liquid in the column Regular patrolling of
Temperature Less
Absorber Leaking inlet No absorption in feed transfer lines
flange column
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Table 6.4 HAZOP List (contd)
Guide
Location Parameter Possible Cause Consequences Action Required
Words
Sulfuric Acid Plant
Pump at
maximum
Possible reduction in Ratio control on liquid feed
discharge or
More absorption efficiency streams. Install high level
pump
May cause flooding alarm on the FIC
malfunction
Intermediet Increased feed
Temperature
Absorber Increased dissolved Ensure accurate
Less Over cooling gases in acid temperature control on the
(impurities) internal cooling circuit
Ensure accurate
Insufficient Decreased absorption,
More temperature control on the
cooling higher pollution
internal cooling circuit
No Line blockage Line rupture Regular inspection
Decrease in H2SO4 Install suitable alarms to
production 2. Health column to indicate low
Less Pipe/ line leakage
Flow and safety hazard flow. Install low level
because it is toxic alarm
Level control Increase pressure in
More Install low level alarm
valve pails open tank
Acid
Storage LCV fails shut or
Increase pressure in Covered by control and
Tank Pressure More isolation valve
tank alarms
closed in error
Lower inlet
stream
temperatures or Install high level alarm
Temperature Less Insufficient drying
over capacity ontic on H2SO4 outlet.
from cooling
circuit
Water Ulitity System
Failure of inlet
Process fluid is Install high temperature
No cooling water
stopped alarm TAH
vapor
Pump Flow Less Pipe leakage Process fluid is lower Install flow meter
Install low temperature
Inlet valve failed purifying process in
More alarm TAL before and after
open not maximal
the process
Input flow rate is Close the inlet valve to
too large reduce the flowrate
High Flooding
Output flow rate
Ion Open the output valve
Level is too small
Exchanger
Material damage and
Input flow rate is Open the inlet valve to
Low process is not running
too small increase flowrate
optimum
Input flow rate is Close the inlet valve to
Tank Level High Flooding
too large reduce the flowrate
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Table 6.4 HAZOP List (contd)
Guide
Location Parameter Possible Cause Consequences Action Required
Words
Water Ulitity System
Output flow rate
High Flooding Open the output valve
is too small
Tank Level Material damage and
Input flow rate is Open the inlet valve to
Low process is not running
too small increase flowrate
optimum
Power Plant
Rechecking
Rpm of The rpm of motor The power generated inspection/maintenance
Turbine Less
motor is too low is low regime will be suitable
toward the specification
Less flow carried
upstream due to Heat transfer is not
Less
pressure drop Gas maximal
pipe leakage
Flow Install flow control
More flow carried
upstream Increase Heat transfer is not
More
Heat in pressure drop maximal
Exchanger Gas pipe leakage
Too much heat
less removed by heat product is offspec
install flow control, and
exchangers
Temperature checking the temperature
Heat exchangers
Can be harmful for the periodically
more fail to remove
next process
specified heat
Low input
Storage
Level Less flowrate, high Flowrate decreases Install Level Indicator
Tank
output flow rate
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a. Smelting System
During initial stages of the plant commissioning and operation, concentrate
feed rates were maintained at between 80 t/h and 100 t/h, after which a step-wise
increase in production to design capacity was achieved following construction of
the new oxygen and acid plants. Matte and slag grades have been well controlled
since start-up and are currently achieving the design target of 55 wt. % Cu in matte
and less than 0.75 wt.% Cu in slag. Cold commissioning teams finalize construction
and cold commission the furnace, lance service, feed system, product handling
system and Mitsubishi designed and supplied process control system. For our
system, the schematic procedures are:
Checking for oxygen and silica supply.
Pre-treating the solid raw material
Input raw material to primary furnace manually. Generating steam as the
pre-heater of air to make auto ignition in the primary furnace firebox.
After combustion process happened for several times, synchronizing the gas pre-
heater (between flue gas as the hot fluid and air from blower as the cold fluid) and
stop running the steam generator and start running the scrubber to absorb flue gas.
Collecting copper from primary furnace bottom product while slag will flow
into slag recovery furnace continuously.
Preparing to start up slag recovery furnace for the next 12 hours by applying
step three to five then emptying and cleaning the primary furnace.
Collecting tin from slag recovery furnace bottom product while hardhead
will flow into hardhead recovery furnace continuously.
b. Electro-Refining System
The principal technical objective of the refinery is to produce high purity
cathode copper. Other important objectives are to produce this pure copper rapidly
and with a minimum of energy. For electro-refining system, the start-up procedures
are:
Making sure that the arrangement of the anodes and cathodes in the
electrolytic cells are right.
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Installing anode and cathode in parallel system.
Pumping the electrolyte to electro-refining tank. Check chemical
conditions, particularly electrolyte composition, temperature, and
circulation rate.
Test and verifying the output voltage.
Connecting electricity and turning AC into DC by using rectifier.
Check electrical conditions, particularly current density.
2. Shut Down Procedure
Shut down procedures of this plant include two ways too, smelting system
and electro-refining system. The procedures are:
a. Smelting System
For smelting unit system, there are two kind of shut down procedures. They are
normal shut down and emergency shutdown. Normal shutdown process is done by
turning off air blower by closing the input valve. Emergency shutdown process is a
force shut down process, the blower is turned off without reducing speed process
and flue gas valve is opened fully to make sure all gas left the furnace. The
emergency shutdown process is used for the emergency situation such as if the
system is brake out and need maintenance immediately.
b. Electro-Refining System
For the electro-refining system, the shutdown process is simple. The shutdown
process will be done by turning off the connection of current from the electrical
circuit.
6.2.1.2 Oxygen Plant
1. Start-Up Procedure
The successful long term performance of the Pressure Swing Adsorbed
depends on operation and maintenance of the system. This includes the initial plant
start-up and operational start-ups and shut-downs. Preventing the problems not only
a matter of system design but also a matter of proper commissioning and operation.
Before beginning to start-up the upstream process facilities, should be
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commissioned and ready for operation. Start up and commissioning of air
separation plant is taken up after following activities:
a. Make a visual inspection of the machine and make sure all parts are properly
attached.
b. Connect the oxygen outlet to the application
c. Connect the unit into an electrical outlet and verify that power supply switch
the power switch to On. Set the mode switch to the generate position.
d. Open the inlet air valve. Check all upstream and downstream fittings thoroughly
e. Turn on the compressed air supply. Follow air compressor manufacturers start-
up instructions. Check the air pressure. Listen for the sound of the compressor
to start operating. The storage tank pressure gauge should indicate a pressure
increase after approximately 15 minutes.
2. Shut Down Procedure
The safety shutdown systems based on the following procedures:
a. Emergency Shutdown
In case of an emergency, simply turn the Main Power Switch to OFF. This will
stop all generator functions immediately. Oxygen supply can be shut off manually
closing the Oxygen product ball valve located on the optional product receiver tank.
b. Normal Shutdown
Switch the PSA Mode switch to the "DESORB" mode and allow 2 minutes
for the PSA tower to safely depressurize. When the PSA tower is completely
desorbed, the tower pressure gauge will read zero.
Turn the power switch to the off position and unplug generator from its
power.
Close the (customer installed) shutoff valve on the inlet air line. Turn the
(customer installed) inlet air (pressure-relieving) pressure regulator down
until the pressure in the air line is zero.
Close the valves at the inlet and outlet of the oxygen receiver tank. The
receiver tank pressure gauge should read zero. (Note: The receiver tank is
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pressurized with high purity oxygen even though the receiver tank pressure
gauge reads zero.)
Empty the receiver tank by opening 2-way valve beneath the receiver tank
Check to confirm that the inlet pressure regulator gauge, PSA tower pressure
gauge, oxygen receiver gauge, oxygen outlet pressure gauge all read zero
before attempting any maintenance.
6.2.1.3 Sulfuric Acid Plant
1. Start-Up Procedure
The start-up procedure for sulfuric acid plant are:
a. During start-up, the initial heating of the converter should be carried out using
dry air to minimize the water condensation on the catalyst. MECS recommends
a single dry blow, but some clients continue dry blows until all passes are
between 100oC and 170oC (212 and 340oF). Using only a single dry blow reduces
the heat-up time by approximately 24 hours.
b. Acid should be circulating through all of the towers. With the acid circulating,
the drying tower will dry the ambient air and the absorbing towers will absorb
any SO3 that is formed during the converter heat-up.
c. As the converter is heating, the vent gases in the start-up vents (at the
economizers) may become cloudy as SO3 gas is evolved from the catalyst when
it reaches approximately 300oC (570oF). If these emissions are not acceptable,
shut down the main compressor and change the blinds so that the combustion
gases flow through the final tower to the stack. In some plants a start-up bypass
duct is provided to bypass the interpass tower. Restart the main compressor to
continue the heating process.
d. After the catalyst, has reached the specified temperatures, the plant is ready to
start with. Shut off the fuel supply, and shut down the main compressor.
e. Initiate SO2 supply 30% to 40% of full rate. It is recommended that this be done
using approximately 7% to 8% SO2 gas feed at a reduced blower rate.
f. A gradual temperature rise will be observed in the first pass within a few minutes
of sulfur dioxide admission. For the initial start-up with new catalyst, this
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temperature rise (measured at the first pass outlet) should peak within forty-five
minutes at a maximum of 20 oC to 50oC (35 oC to 90oF) above the expected outlet
operating temperatures for the given gas strength. This temperature maximum
will begin to drop after approximately thirty minutes to eventually line out at the
expected operating temperature for the given SO2 strength gas stream. There will
not be a tremendous temperature rise during the initial start-up with new catalyst
since the catalyst is almost completely sulfated prior to operation.
g. Slowly increase the sulfur flow Hold this outlet temperature until the inlet
temperatures to each pass of catalyst are near the design temperatures. The pass
1 outlet temperature should not exceed 630oC (1160oF) to prevent damage to the
catalyst.
h. The plant should be stabilized before attempting to increase the plant rate. The
plant rate can slowly be increased by adjusting the main compressor pressure.
The rate of feed adjustment should be dictated by the emissions and the bed inlet
temperatures. Raising the rate slowly minimizes process upsets and helps to keep
everything under control. The feed rate increase will not generate a large
temperature rise during the initial start-up with new catalyst since the catalyst is
almost completely sulfated prior to operation.
2. Shut Down Procedure
Condensed moisture or acid may cause weakening and partial disintegration
of the catalyst, leading tohigh pressure drop and a possible permanent decrease in
conversion efficiency. The catalyst ishygroscopic (attracts moisture), especially if
SO2 or SO3 gas is left in contact with the catalyst. Therefore, during a plant
shutdown, moist air must be precluded, to the maximum possible extent, from the
catalyst and the converter / heat exchanger system.
a. Short Term Shutdown
Adjust heat exchanger bypasses to raise the temperatures in the converter
by 28C (50F) in each pass. Shut down the sulfur feed flow and the main
compressor.
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b. Long Term Shutdown
If any shutdown is to be of such length that the catalyst temperatures will
fall below the dew point ofsulfuric acid (i.e. the point where moisture or acid would
condense), the converter system should firstbe purged with dry air to remove the
SO2 and SO3 prior to shutdown.
Shut off the sulfur feed and decrease the main compressor volume to
approximately 50%. Purge the converter / heat exchanger system with dry air until
all the equipment is cooled down and the SO2 and SO3 are purged from the catalyst
passes (approximately four hours).
After purging the system, care should be taken so that moist air does not
subsequently reach thecatalyst. Natural draft will bring in moist air through the
plant stack and the air inlet. Valves can beshut and blanks installed to prevent moist
air intrusion. If maintenance work is performed on theconverter, the length of time
that the man ways are open should be minimized.
If the shutdown plans require the plant to be held down for long periods, in
excess of several months, and sulfuric acid will not be circulated through the towers
on a regular basis, it will be very difficult tomaintain a dry environment for the
catalyst. In this case, it is recommended that the catalyst isremoved from the
converter and stored in moisture resistant packages in a dry warehouse until theplant
is ready to start up again. The packages should be labeled with the catalyst converter
location so that the catalyst can be replaced in the same location later.
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and vapor contaminants), mechanical filter respirator (dust, mists, metal fumes,
acids) and a cartridge or canister respirator (mixed gas/vapor to solid particles
equipped with a filter).
2. Protection Equipment for Hands
Hand Gloves is equipment used for hazardous work hand in case of contact
between the hand with heat, chemicals or other dangerous hands. Usually this type
of hand gloves hanging from its use in the existing conditions in the work, namely:
a. Asbestos gloves made of leather, PVC should be used if the heat generated in
the factory work, such as welding gloves to be used must pass through the
wrist.
b. Rubber gloves, made of synthetic material, vinyl as well as natural, to protect
hands from chemicals caustic acids, alkalis and various types of other
solvents.
c. Gloves canvas/leather, wear gloves of canvas or heavy cotton is typically used
when the main danger is very high heat caused by friction.
d. Gloves with chrome leather or PVC material with special design, to reduce
the hazard when in contact with sharp objects.
e. Glove fabric type is used to work under normal conditions.
3. Protection Equipment for Legs
Safety shoes is a safety shoes are used to protect workers against accidents
caused by heavy items falling to the feet, protruding nails, liquid metal, and so on.
Standard for leg protection is ANSI Z41.
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Ear protective devices commonly used in the area located the tools that can
cause noise. For protection against ear every employee who dealt with the process
equipment required to use earplugs. Earmuffs are divided into two types:
a. Thermal earmuffs are earmuffs used in cold environments to keep one's ears to
keep warm.
b. Acoustic earmuffs, also known as ear defenders. This tool is coated with sound
dampening materials, such as thermal earmuffs and headphones in appearance,
which is used as hearing protection from noisy sound.
6. Protection Equipment for Head
This protection equipment for head or safety helmet is a protective device that
is used to protect the head from impact by hard objects while working in the field,
whether it's due to hit by accident or because of a fall or stumble. Standard for safety
helmet is ANSI Z89.1
6.2.3 MSDS
A Material Safety Data Sheet (MSDS) is a document that contains
information on the potential hazards (health, fire, reactivity and environmental) and
how to work safely with the chemical product. It is an essential starting point for
the development of a complete health and safety program. It also contains
information on the use, storage, handling and emergency procedures all related to
the hazards of the material. The MSDS contains much more information about the
material than the label. MSDSs are prepared by the supplier or manufacturer of the
material. It is intended to tell what the hazards of the product are, how to use the
product safely, what to expect if the recommendations are not followed, what to do
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if accidents occur, how to recognize symptoms of overexposure, and what to do if
such incidents occur. The key to the hazards associated with the numerical ratings
is provided below.
Table 6.5 Explanation of HMIS
For our plant, we are going to summarize the main material in our plant.
There are copper concentrate, limestone, silica sand, suluic acid, copper cathode
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and oxygen. In this section, we will describe each criteria for health and safety of
each components. Below, we are going to summarize each raw materials of our
product.
1. Copper Concetrate
Formula : CuFeS2
Appearance : Solid, copper colored, odorless
Based on MSDS we get, this material score for health =1, fire = 2, and
reactivity = 1. Copper concentrate is finely ground material that is not flammable
or combustible under normal conditions of transport and storage. However, when
heated strongly in air for a sufficient time it will burn, releasing toxic and irritating
sulphur dioxide gas as well as possible copper and iron oxide fumes. Contact with
strong acids will generate flammable and highly toxic hydrogen sulphide gas.
Inhalation or ingestion of copper concentrate dust or copper oxide fume may
produce irritation of the upper airways. Possible cancer hazard due to the silica
content. Protective clothing are required for fire emergency response personnel due
to the potential for release of high concentrations of sulphur dioxide from burning
concentrate. The metals content in this product have low direct bioavailability and
pose little immediate ecological risk. To store this material must provide well-
ventilated area away from sources of combustion, acids and strong oxidizers
2. Limestone
Chemical Name : Calcium Carbonate
Formula : CaCO3
Appearance : White, odorless, granular solid
Based on MSDS rating, limestone shows that they give hazard rating of
health=2, fire=0, reactivity = 0, and personal protection = E. from this hazard rating,
we can conclude that limestone can cause temporary or minor injury. It will not
burn and it is stable. Limestone potentially cause acute health effect if its dust
contact with our eyes or inhaled by human because it can cause irritation. It is
slightly hazardous in case of skin contact because it can irritate our skin and slightly
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hazardous in case of ingestion and inhalation. Limestone potentially cause chronic
health effect such as toxic to kidneys and repeated or prolonged exposure to the
substance can produce target organ damage. There is no special effect in fire hazard
unless it contacts with fluorine. Limestone will ignite and burn fiercely. Personal
protection used are safety glasses, gloves, and dust respirator.
3. Silica Sand
Chemical Name : Silicon Dioxide
Formula : Si-O2
Appearance : Solid, white, odorless
From MSDS silica sand it shows that they give hazard rating of health =1,
fire = 0, reactivity = 0 and personal protection=E. For health, the rating is 1 which
means that its slightly dangerous. For fire the rating is 0 which means that it will
not burn ignite if theres a fire. For reactivity, the rating is 0 which means that it is
stable and it will not react with water. This material is slightly hazardous in case of
skin contact (irritant), of eye contact (irritant), of ingestion, of inhalation. So, the
workers must use personal protection such as Safety glasses, Lab coat, and Dust
respirator. To store this material the container must provide well ventilation to keep
exposure to airborne contaminants below the exposure limit.
4. Sulfuric Acid
Chemical Name : Hydrogen Sulfate
Formula : H2-SO4
Appearance : Colorless, odorless
From MSDS sulfuric acid it shows that they give hazard rating of health =3,
fire = 0, reactivity = 2, For health the rating is 3 which means that its extremely
danger. For fire the rating is 0 which means that it will not burn ignite if theres a
fire. For reactivity, the rating is 2 which means that it is violent chemical change.
Eventough the material is non-flammable. However, products of decompostion
include fumes of oxides of sulfur. Will react with water or steam to produce toxic
and corrosive fumes. Reacts with carbonates to generate carbon dioxide gas. Reacts
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with cyanides and sulfides to form poisonous hydrogen cyanide and hydrogen
sulfide respectively. A place that store this material should provide well ventilated
area and should be store with coated fiberboard drum using a strong polyethylene
inner package. Since this product quite danger, a worker should use personal
protection such as Face shield with Full suit, and Vapor respirator.
5. Copper Cathode
Chemical Name : Copper Cathode
Formula : Cu (99,9%)
Appearance : Solid with Reddish color
Copper cathode is a Metallic product which poses little or no immediate
hazard in solid form. However, this product still also has hazardous if this material
repeatedly exposure to human can discolor skin and hair and irritate the skin; may
cause mild dermatitis, runny nose, and irritation of the mucous membranes.
Repeated ingestion may damage the liver and kidneys. In order to minimize the
hazard, worker should use gloves to handle our product this is because most
Particulate may enter the body through cuts, abrasions or other wounds on the
surface of the skin. Since our operation may generate dust, fume or mist, the use
ventilation is a must to keep exposure to airborne copper below the TLV. If
ventilation alone cannot so control exposures, use approved respirators selected
according to local regulations
6. Oxygen
Product Name : Oxygen
Formula : O2
Appearance odor and state : Odorless and colorless
Based on MSDS, oxygen shows that they give hazard rating of health=0,
fire=0, and reactivity = 0. From this hazard rating, we can conclude that oxygen has
no significant risk to health. It will not burn and it is stable material. Breathing 80%
or more oxygen at atmospheric pressure for more than a few hours may cause nasal
stuffiness, cough, sore throat, chest pain and breathing difficulty. Breathing oxygen
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at higher pressure increases the likelihood of adverse effects within a shorter time
period. Breathing pure oxygen under pressure may cause lung damage and also
central nervous system effects resulting in dizziness, poor coordination, tingling
sensation, visual and hearing disturbances, muscular twitching, unconsciousness
and convulsions. Breathing oxygen under pressure may cause prolongation of
adaptation to darkness and reduced peripheral vision. Oxygen is nonflammable but
will support combustion. Use extinguishing media appropriate for surrounding fire.
A place with high oxygen concentration should provide ventilation and/or local
exhaust to prevent accumulation of high concentrations of gas (greater than 23%).
There is no special personal protection needed but safety shoes and work gloves are
recommended when handling cylinders. Clothing exposed to high concentrations
may retain oxygen 30 minutes or longer and become a potential fire hazard. Stay
away from ignition sources.
7. Sulfur dioxide
Chemical Name : Sulfurdioxide
Formula : SO2
Appearance : Gas, colorless, odor
Based on MSDS, sulfur dioxide has been giving rating for health=3, fire=0
and reactivity=0. This means that sulfur dioxide could cause serious temporary or
residual injury even though prompt medical attention was given. This material is
poisonous by inhalation and may irritate the eyes, nose, throat, and sinuses,
resulting in choking, coughing, and sometimes bronchoconstriction. Eventough the
material is extremely dangerous, but this material is stable and will not burn in order
to prevent risk, the worker should wear a self-contained breathing apparatus and
appropriate personal protective equipment (PPE). To store this material Store only
where temperature will not exceed 125F (52C). Firmly secure containers upright
to keep them from falling or being knocked over. Install valve protection cap, if
provided, firmly in place by hand. Store full and empty containers separately. Use
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a first-in, first-out inventory system to prevent storing full containers for long
periods.
8. Sulfur Trioxide
Chemical Name : Sulfurtrioxide
Formula : SO3
Appearance : clear, odorless
Based on MSDS, sulfur trioxide has been giving rating for health=3, fire=0
and reactivity=2. This material is categorized as extremely dangerous where
Inhalation of the spray mist may produce severe irritation of respiratory tract,
characterized by coughing, choking, or shortness of breath. Severe over-exposure
can result in death. Inflammation of the eye is characterized by redness, watering,
and itching. Skin inflammation is characterized by itching, scaling, reddening, or,
occasionally, blistering. This material also reactive with oxidizing agents, metals,
alkalis, moisture. The product may undergo hazardous decomposition,
condensation or polymerization, it may react violently with water to emit toxic
gases or it may become self-reactive under conditions of shock or increase in
temperature or pressure. the workers who handled this material should use gloves,
full suit, vapor respirator and be sure to use an approved/certified respirator or
equivalent. Wear appropriate respirator when ventilation is inadequate and also face
shield.
9. Coal
Product Name : Bituminous Coal
Formula : C
Appearance : Black Powder
Based on HMIS rating, coal shows that they give hazard rating of health=1,
fire=3, reactivity = 0, and personal protection = E. From this hazard rating, we can
conclude that coal can cause temporary or minor injury. Coal is stable material. The
principal health hazard associated with coal occurs during its mining and transport.
Coal workers pneumoconiosis (CWP) can occur in miners after as little as 15 years
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of excessive inhalation of respirable coalmine dust. Respirable quartz particles and
free silica may be co-implicated. Coal dust is deposited in the lungs where its site
of action is the lung parenchyma, lymph nodes and hila. The severity of the disease
is directly related to the amount of coal dust in the lungs. In the simple stages, the
disease is detectable by x-ray as round, irregular "macules" of 1-5 mm. This stage
typically does not change lung function or shorten life. The chronic stage of CWP,
however, involves massive pulmonary fibrosis that does impair pulmonary function
and shorten life. Chronic Bronchitis (lung inflammation, coughing attacks, difficult
breathing, etc.) and emphysema can result from excessive coal dust inhalation.
Rheumatoid arthritis can be exacerbated by pneumonias leading to rapidly
developing lung damage (Caplans Syndrome). Fire will be occur when coal is
exposed to flame of temperature in excess of 127oC. It is highly combustible and/or
explosive when in dust or powder form. Coal dust may react slowly with oxygen at
room temperature. Heat accelerates the process, which could lead to spontaneous
ignition in piles of coal dust. Personal protection are used in the management of this
material are respiratory protection, safety glasses, and gloves.
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b. All primary emergency escape routes and designated meeting locations shall
be provided to each employee by departmental managers as part of the
emergency planning process. These primary route and designated meeting
locations must be approved by the plant manager.
c. An orderly evacuation shall be supervised by departmental managers, line
supervisors, and designated wardens who will check all rooms/enclosed
spaces and report any problems via telephone or radio to plant security.
d. Each local manager or supervisor shall provide for the specialized
evacuation of any handicapped employees.
6.3.2 Firefighting
A firefighting strategy should consider:
Appointment of fire wardens, with subsequent training;
Location plans of safety shower, fire hoses, extinguishers, and water
sources.
Access for emergency services;
Provision of firewater lagoons.
There are several important aspects in fire fighting equipments, which are:
a. Fire Extinguisher
Fire extinguisher is the equipment that is used to extinguish the fire in small
scale. This equipment usually in tubular form and used to extinguish the fire in the
emergency situation. Fire extinguisher which will be used in our plant is class B
fire extinguisher. This type usually used for flammable liquids and gases. We chose
this type because some raw materials that we use are flammable.
b. Fire Hydrant
Fire hydrant is a permanent system that is used to extinguish the fire. It uses
pressurized water which flowed through pipes and fire hose to extinguish the fire.
In our plant, there are class 2 of building hydrant system. This type has 1,5 inch
diameter of a hose. This type usually used for untrained people.
c. Safety shower and eyewash station
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Safety showers and eye wash stations are the emergency facilities which
shoud be available in every chemical laboratory. They are used by laboratory
workers in case of splash of toxic or corrosive chemicals or fire. This equipment
should also provide a drainage system for the excess water and should not come
into contact with any electrical equipment that may become a hazard when wet, and
should be protected from freezing when installing emergency equipment outdoors.
Whereas, an emergency blangket should be available near the shower to prevent
from shock and cover the place for removal of clothes.
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N
GUEST CAR PARK (FOR SECURITY MOTORCYCLE PARKING
ADMISSION) SECURITY AREA
MAIN
W E
GATE
S
CHEMICAL ENGINEERING DEPARTMENT
FACULTY OF ENGINEERING
UNIVERSITAS INDONESIA
CAR PARKING AREA DEPOK
PROJECT
PRELIMINARY DESIGN OF COPPER
SMELTER PLANT
DRAWING
DATE
NO.
11/16/2016
2
ASSEMBLY
POINT GROUP
PAR13
OFFICE BUILDING
MOSQUE
CLINIC
FIRE STATION
K3 BUILDING
LAB
MECHANICAL AND
ASSEMBLY POINT ELECTRICAL
BUILDING
CANAL CANAL
CENTRAL
CONTROL
POWER PLANT ROOM
WATER UTILITY
ASSEMBLY POINT
SULFURIC
ACID PLANT
OXYGEN PLANT
RAW MATERIAL
STORAGE
ASSEMBLY POINT
LOADING AND
PRODUCT STORAGE UNLOADING
FLARE
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CHAPTER VII
CAPITAL ESTIMATE
In this chapter, there will be explained about several calculation and analysis
needed to be done to estimate the economic analysis for this plant. The calculation
need several assumptions as shown below
1. Plant lifetime is 20 year; start from 2020 (including the equipment purchase
and based on the benchmarking).
2. The main plant, copper smelter has a total production of 320,000
tonnes/year copper cathode that is done in continuous production.
In estimating equipment cost, we use index value to estimating price at
present time, the equation is shown below.
= ( ) (6.1)
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7.3 Site Development Cost
In our plant site development cost consist of site preparation cost and land
cost. The wide area of our plant is
Table 7.2 Building Plant Cost
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engineering, supervision, and construction. We use 10% of Total Direct Permanent
Investment Cost. The calculation shown in table below.
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7.12 Calculation of Total Capital Investment
Table 7.3 Total Capital Investment
Total Permanent Investment CTPI 139,525,587 (CTPI = CTDC + Croyal + Cstart up)
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CHAPTER VIII
OPERATING COSTS
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anything about technical aspect. This includes administrative cost that can also
contributes in calculation of general expenses cost. The indirect labor cost can be
seen on Appendix F.
8.9 Depreciation
Depreciation is the reduction in value of an asset. The assets of our plant
come from equipment and building cost. The method used to depreciate an asset is
a way to account for decreasing value of the asset to the owner and to represent the
diminishing value (amount) of the capital funds invested in it.
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that we have calculated is shown below:
General expenses (GE) refer to activities that are conducted by the central
operations of a company, perhaps at the corporate headquarters, and are financed
from profits made by thecompany from their operating plants (Seider, 2003). This
expenses are mostly related with distribution of product, administrative of
employee (indirect labor), and other general possible expense beside costs that we
have obtained before.
TOTAL GE 357,037,488
OPEX Breakdown
18%
Raw Material Cost
2% 0% 1%
Direct Operating Labor
1% 0%
0% Utiliy Cost
Indirect Labor
Maintenance Cost
Safety and Environmental Cost
Insurance Cost
78% General Expenses
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CHAPTER IX
ECONOMIC EVALUATION
Capacity
Product Product Price [USD/ton] Total [USD/year]
[tonnes/year]
Copper 321565 6.700,00 2.154.485.500,00
H2SO4 265000 250,00 66.250.000,00
Slime 70000 3.510,00 245.700.000,00
Slag 387265 150,00 58.089.750,00
CaSO4 64000 1.100,00 70.400.000,00
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The reasons why we brave to sell it 100% from the first year because our product
is cheap and the consumer is determined and only one. The graph below on
Appendix F cash flow diagram of our plant.
For after tax cash flow, this cash flow is calculated with tax. The income tax
we assume is 30% after depreciation according to Direktorat Jenderal Pajak,
2013.Because it is after tax, the cash flow will have the lower cumulative income;
this after tax cash flow is used for calculating the profitability analysis such as,IRR
and Payback Period. The calculations of after tax and before tax cash flow are
shown in the appendix.
With the value of r is the IRR. Calculating cash flow by using Microsoft excel, we
obtain IRR of 35,17 % from our copper smelter plant. If we compare the IRR with
MARR (35,17% (IRR) > 23,46% (MARR)), the difference is quite high (11,71%).
According to the definition of IRR Itself, It means that IRR will be used to compare
the working capital as project with minimum probability. Comparing IRR of our
plant to other competitors, the value is below other bigger plants that have IRR
value about 35,17%. Its almost equal with our plant. Those facts give us a good
impact, so that our plant and product may be compared with other plant and also
visible to be built.
9.2.2 NPV
Net Present Value (NPV) shows the net benefits received by a project over
the life of the project at a certain interest rate. NPV can also be interpreted as the
present value of the cash flows generated by the investment. In calculating the NPV
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is necessary to determine the relevant interest rate. In this calculation, the interest
rate used is the interest rate on the bank loan for start-up capital, average amounting
to 11,7%.
A project can be counted as feasible if the NPV>0, which means the project
is profitable or provide benefits if implemented. If NPV<0, the project is not
eligible to run because it does not generate profit. Cash flow in year-n drawn into
present value with a reasonable interest rate by using the following formula:
,0 = (9.2)
(1 + )
MARR value for our product is 23,46% based on average WACC. By MARR
23,46%, we obtained NPV $ 2.164.107.388,44. The rule of thumb of NPV is the
NPV should be positive with high interest (higher than 10%). If the NPV is negative
the project will be stopped. Our NPV is positive and high. It means that the project
can be implemented. Analysis for negative NPV will be explained in sensitivity
analysis.
If the payback period is less than a pre-determined period, the project is acceptable.
If the payback period exceeds the predetermined period, the project is rejected. The
payback period for this plant is 4,39 years, after calculate use Microsoft Excel.
Our payback period is matched with the rule of thumb. The rule of thumb
said that the tolerable payback period is about 10 years and should be done after all
the loan are fully paid. Figure below shows the cumulative cash flow
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12,000
Millions
10,000
Cummulative Cash flow(USD)
8,000
6,000
4,000
2,000
-
0 5 10 15 20 25 30
(2,000)
Years
164.121.246
= = 32728 (9.6)
($5010/)
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9.3 Cost Breakdown
Cost breakdown is consisted of cost breakdown for capital cost and
operational cost. Cost Breakdown is used to map out the contribution of the details
for capital and operating costs. Capital cost breakdown consisted of direct cost
breakdown, indirect cost breakdown, total capital cost breakdown.
15%
Direct Cost
9%
Indirect Cost
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60.00%
50.00%
40.00%
Raw Material Price
30.00% Product Price
20.00%
10.00%
0.00%
-15% -10% -5% 0% 5% 10% 15%
$5,000,000,000.00
$4,000,000,000.00
$3,000,000,000.00
Raw Material
$2,000,000,000.00
Product Price
$1,000,000,000.00
$0.00
-15% -10% -5% 0% 5% 10% 15%
-$1,000,000,000.00
-$2,000,000,000.00
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9.4.3 Payback Period Sensitivity Analysis
Were going to analysis the payback period based on price product
fluctuation, raw material. We see that the impact price fluctuation of product and
raw material is giving effect for payback period. When the change of price is higher
than normal price, then payback period is being faster. When the raw material is
being higher then payback period is being longer.
4 Raw Material
Product Price
3
0
-15% -10% -5% 0% 5% 10% 15%
Product price is the most significant parameter that affected our plant. In
order to maintain this parameter, we have to find out which from all our product
that play the biggest role. Based on our calculation in revenue section, it is known
that copper cathode is the biggest parameter that play affected the product price. It
is because copper cathode is the most expensive from our product,and also the the
biggest product that we sell.
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CHAPTER X
OUTSTANDING ISSUES
Universitas Indonesia
CHAPTER XI
CONCLUSION
1. Raw material for our plant is natural gas, silica, copper concentrate,
limestone and coal
2. PT. Smelco Indonesia has the capacity 320,000 tonnes/year to produce
copper cathode, and the needs for copper concentrate is 876 tonnes/year.
3. PT. Smelco Indonesia main product will be focused to sell overseas, since
domestic market is not profitable.
4. PT. Smelco Indonesia is divided into several areas, which is office area and
process area. Office area (blue zone) includes parking area, mosque,
laboratory, firefighting, clinic, and mechanical and electrical building.
While process area (red zone) includes all of the process, from utility to side
process plant, and main process plant, storage area, and unloading and
loading dock. Our plant will be built in 6.582 ha land construction in Gresik,
Jawa Timur.
5. Copper smelter method we use is Mitsubishi process, oxygen plant method
we use pressure swing adsorption process, and for sulfur acid plant is double
contact process.
6. Mass efficiency for copper smelter is 37%, for oxygen plant is 95,33%, and
for sulfuric acid plant is 99,2%
7. Utility system in our plant consist of water, air, electricity, and fuel. Total
water consumption of our plant as the cooling feed is 1780.95 tonne/hr
which source is treated water from Bengawan Solo River. Fuel needed in
our plant is 62 tonne/day of bituminous coal which is used for combution
process of the furnace in our copper smelter plant. Air utility used to produce
pure oxygen for sulfuric acid plant and copper smelter plant requirement is
527 tonne/day.
8. Total electricity needed in PT. Smelco Indonesia is 106852.97 kWh/day
which will be consumed as the power source of our main equipment in
Universitas Indonesia
REFERENCES
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st
The Mitsubishi Process, Copper Smelting for the 21 Century.
The World Copper Fsctbook. 2014. International Copper Study Group (ICSG).
Ziaeee, M. and M. Naser Zare. 2015. Combination Mutual Pressure Swing
Adsorption and Cryogenic Distillation to Optimize Separation Unit.
Universitas Indonesia
APPENDIX
APPENDIX A:
Mass and Energy Balances
3. Converting Furnace
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Table A.3 Converting Mass Balance
Component In (tonne/day) Out (tonne/day)
6B 8B 9B 2 10B 11B 12B
CuFeSs - - - - - - -
SiO2 - - - - - - -
O2 - - 600 - 71.36 - -
CaCO3 - 186 - - - - -
Cu2S 1033.5 - - - - - 103.35
Cu - - - - - - 749.3
Fe2S3 537.4 - - - - 25.04 -
FeO 16.54 - - - - 16.54 -
FeSiO3 - - - - - - -
Fe3O4 - - - - - - -
CaO - - - - - 25.4 -
CaO.Fe3O4 - - - - - 488.6 -
SO2 - - - - 848 - -
CO2 - - - - - - -
Coal - - - 47 - - -
Total 1587.44 186 600 47 71.36 537.4 852.65
4. Anode Furnace
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5. Casting
Table A.5 Casting Machine Mass Balance
Component In (tonne/day) Out (tonne/day)
15B 16B
CuFeSs - -
SiO2 - -
O2 - -
CaCO3 - -
Cu2S - -
Cu 881.25 881.25
Fe2S3 - -
FeO - -
FeSiO3 - -
Fe3O4 - -
CaO - -
CaO.Fe3O4 - -
SO2 - -
CO2 - -
Total 881.25 881.25
6. Electrolytic Cell
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A.2 Mass Balance of Oxygen Plant
in out
Component
4 1 5
O2 (tonnemole/day) 82 82 0.000
N2 (tonnemole/day) 357 357 0.000
Dust 0.001 0.001 0.001
Total 440 440 0.001
P [atm] 1 1 1
T [K] 300 300 300
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Table A.12 Heat Exchanger Mass Balance E-207
E-207
Component in out
2b 13a 2c 15
m (tonne/day) 7652 6734 7652 6734
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2. Converter
Table A.18 Bed Converter Mass Balance
1st Converter 2nd Converter 3rd Converter 4th Converter
Stream In Out In Out In Out In Out
3 22 4 5 6 7 8 9 10
m(tonne/day) 1860 700 2560 2560 2560 2560 2560 2560 2560
3. Absorber
Table A.19 Absorber Mass Balance
In Out
Stream
11 23 25 26
m (tonne/day) 2560 2100 100 1000
Stream 24 26 27 28
m (tonne/day) 4560 1000 100 5560
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nd
2. 2 Compressor
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3. Absorber
Table A.28 Absorber Energy Balance
Intermediete Final
Stream In Out In Out
11 23 25 26 24 26 27 28
o 127 30 130 130 27 130 130 130
T[ C]
P[bar] 1.1 1.2 1.1 1.1 1.5 1.1 1.2 1.2
Heat Flow (MW) -10 -3 -5.2 -5.2 -3.5 -5.2 -6.4 -6.4
4. Pump
P-301 P-302
Stream In Out In Out
13 13 18 18
T[K] 27 27 22 22
P [atm] 1 2 1 2
Universitas Indonesia
APPENDIX B:
BFD and PFD
O2 To Copper Smelter
O2 O2 O2 O2 O2
Air Filter Compressor Drum Adsorber Drum Plant & Sulfuric
N2 N2 N2 N2 Acid Plant
N2 To Copper Smelter
Drum Plant
O2
SO3
To Flare Stack
Heat Heat
SO2 Reactor Adsorber
Exchanger SO3 Exchanger SO3
+ Vanadium
to H2SO4
catalyst Storage
H2SO4
From
16B
Casting
C-108
17B Cu
C-109
P-101
TK-103
P-101
Anode Slime
TK-102
16 B 17 B 18 B 19 B
P (a tm) 1 1 1 1
Compone nt (tonne / da y)
CuFe S s - - - -
S iO 2 - 876 - -
O2 - - - -
Ca CO 3 - - - -
Cu2 S - - - -
Cu 881.3 - - -
Fe 2 S 3 - - - -
Fe O - - - -
7
CV-210
Power Plant, O2
CV-203 CV-208
Water Utility
D-201
Power Plant,
Water Utility CV-205
Air C4
C2
4
2
V-202
2a E-202 R-202
R-201
1
1a E-201
V-201 1b
CV-204
FG-201
CV-201 CV-206
5 C3
K-201
C1 CV-202 CV-207
K-202
6 N2
CV-209
Water
Utility D-202
P-201
Dust To Flare
DEPARTEMEN TEKNIK KIMIA NAME SIGNATURE DATE
FAKULTAS TEKNIK
NAME Group 13
UNIVERSITAS INDONESIA
Stream 4 5 1 1a 1b 2a 2 6 7 C1 C2 C3 C4 CORRECTED BY
T (K) 302 302 300 425 305 397 302 302 302 305 337 304 329
PFD
PICTURE NO. PFD 002/2016
P (atm) 1 1 1 2.5 2.45 5 5 5 5 1.5 0.98 1.5 0.98
Mass Flow
7652 0 7652 7652 7652 7652 7652 7652 7652 6878 6878 6734 6734
PRELIMINARY DESIGN OF
(tonne/day) WITHOUT SCALE
COPPER SMELTER
H2SO4
Storage
To Flare
25
Stack
11
23
E-307
9 10
O2
22 19 To Flare
Storage 27
Stack
20 R-302
24
8
Economizer, E-306 26
Copper Smelter Plant 21'
6
7
R-303
4
5
18
Water E-305
17
Utility 14
3 28
R-301
P-301
15 TT-301
E-304
SO2 1 1' 2
13
12
Water
E-301 E-302 E-303 Utility
16 21 Economizer,
Copper Smelter Plant P-302
CV-210
To Oxygen
Plant 7
O2
CV-203 CV-208
D-201
To Sulfuric
Acid Plant CV-205
13a
C2
19 14a C4
Air
4
2a 2 2b 2c
1b 1c 1d
V-202 E-205 E-206 E-207
1 E-201 E-202 E-203 E-204 1e R-201 R-202
FG-201
V-201 1a
CV-204
5 13
C1
16 C3 CV-206
18 14 CV-201
15
K-202
K-201
CV-202 CV-207
6 N2
Water CV-209
Utility
P-201 D-202
To Sulfuric
Acid Plant
From Sulfuric
Acid Plant
Dust To Flare
DEPARTEMEN TEKNIK KIMIA NAME SIGNATURE DATE
FAKULTAS TEKNIK
NAME Group 13
Stream 4 5 1 1a 1b 2a 2 6 7 C1 C2 C3 C4 UNIVERSITAS INDONESIA
T (K) 303 303 303 415 303 424 303 303 303 305 337 304 329 CORRECTED BY
P (atm) 1 1 1 2.5 2.45 5 5 5 5 1.5 0.98 1.5 0.98 PFD
Mass Flow PICTURE NO. PFD 002/2016
7652 0 7652 7652 7652 7652 7652 7652 7652 6878 6878 6734 6734
(tonne/day)
PRELIMINARY DESIGN OF COPPER
WITHOUT SCALE
SMELTER
H2SO4
Storage
To Flare
25
Stack
11
23
E-308
9 10
O2
22 19 To Flare
Storage 27
Stack
20 R-302
24
8
Economizer, E-307 26
Copper Smelter Plant 21'
6
7
R-303
4
5
18
Water E-306
17
Utility 14
3 28
R-301
From P-301
C1
O2 Plant TT-301
15
E-305
SO2 1 1' 2 2'
13
12
Water
E-301 E-302 E-303 E-304 To O2
C2 Utility
16 21 Plant
Economizer, P-302
Copper Smelter Plant
From Economizer,
6A From Economizer,
Copper Smelter Plant 3A
Copper Smelter Plant
5A
6A
A B C D E
4A
7A
Z
P-401
Electricity F
T-401
H
2A
From Oxygen
C4 G
Plant
E-405
Stream C4 A B C D E F G H 1A 2A 3A 4A 5A 6A 7A 8A
P (Kpa) 98 5000 5000 5000 5000 5000 50 45 45 90 85 133 120 110 120 110 90
T (celcius) 56 79 264 280 320 400 81 78 78 70 78 400 485 320 300 276 132 From Oxygen
1A
Mass Flow Plant
1500 1500 1500 1500 1500 1500 1500 1500 1500 6000 1500 1500 1500 1500 1500 1500 1500
(tonne/d)
C-101 / C-102 / C-103 / F-102 F-103 F-104 E-101 PM-101 C-107 TK-101
F-101
C-104 / C-105 / C-106 Slag Cleaning Converting Furnace Anode Furnace Economizer Casting Machine Belt Conveyor Storage
Smelting Furnace
Belt Conveyor Furnace
TRC
TT
TAL TAH
TI PI TE
Steam to TI PI
3
Power Plant 10" Sch 40 CS
1 SO2 to Acid Plant
TE TE 5" Sch 40 CS
1.25" Sch 40 CS
TT TT
TCV TCV
TAH TAH
TRC
5"
TRC TY
5"
TY
TAL TAL
TRC TAH
14B PI
TI
TAL TAH
TRC
TY Steam from Sulfuric
TCV
TY 2
TCV TAL
Acid Plant
0.75" Sch 40 CS
5B 3" E-101
4"
Oxygen- 9B
10B 1.5" Sch 40 CS
Oxygen- TI Enriched Air
2B 3" Sch 40 CS
Enriched Air 4" Sch 40 CS
TCV
CuFeS2 1B
C-101
1 1/2"
MCC ST
M TE TAH
TT TY
SIC
PI 4B TI
TRC
SiO2 3B TI TY
MCC ST
C-102 TI
M TAL
TCV
PI
SIC
5" Sch 40 CS
F-101 1"
Coal 1 Oxygen-Enriched
6B TT TE
MCC ST C-103 F-102 Air
M 1" Sch 40 CS
PI
SIC
8B TI TI
11B
CaCO3 PI
C-104 TI PI
MCC ST
M 7B TT TE
13B
SIC
F-103 TI PI
15B 16B
Coal 2 12B MCC ST C-107
TI M
MCC ST
M
C-105 PM-101 SIC
SIC
3 F-104
Coal
ST C-106 Slag
MCC
M
SIC
TI PI
1B 2B 3B 4B 5B 6B 7B 8B 9B 10 B 11B 12 B 13 B 14 B 15 B 16 B 1 2 3 TK-101
T (K) 299 299 299 1523 1473 1523 1523 299 299 1473 1523 1523 299 1473 1523 1523 303 303 303
P (a tm) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Compone nt (tonne / da y)
CuFe S s 2386 - - - - - - - - - - - - - - - - - -
S iO 2 - - 516 62 - - 62 - - - - - - - - - - - -
Ca CO 3 - - - - - - - 186 - - - - - - - - - - -
From
16B
Casting
MCC ST
M C-107 PI
SIC
FAH
TI PI TI
FRC
FT
FAL
19B
17B Cu
FY
PI TI FE
FCV ST C-108
MCC
M
SIC
P-101
8" TK-103
H2SO4 & 8" Sch 40 CS
18B
CuSO4
8" Sch 40 CS
P-101
PI TI
Anode Slime
TK-102
16 B 17 B 18 B 19 B
P (a tm) 1 1 1 1
Compone nt (tonne / da y)
CuFe S s - - - -
S iO 2 - 876 - -
O2 - - - -
Ca CO 3 - - - -
Cu2 S - - - -
Cu 881.3 - - -
Fe 2 S 3 - - - -
Fe O - - - -
Dust To Flare 7 O2
1" Sch 40 CS
TCV TCV
5 PRC PRC
1"
1"
PY PY
PAH PAL
To Oxygen
0.5" Sch 40 CS
FI
Plant 1" Sch 40 CS
PAH PAL
TI
TI
FI To Sulfuric PE PT
16" Sch 40 CS
TAH PT PE
Acid Plant
16" Sch 40 CS
TY TRC
TAL
PI
TAH
3" Sch 40 CS
TI TCV
TI
TRC
PSV TI
PSV TY
FI TAL TI
TI TCV
FI PI
4"
5" 5" Sch 40 CS
5" 5" Sch 40 CS
4"
4" Sch 40 CS
C4 13a
TI FI TT TI
C2 4" Sch 40 CS PC PT FI
FI 19 TI FI 14a TI
PC TI TT
TI PI PT PT TE
R-202
TE R-201
5" Sch 40 CS 5" Sch 40 CS 2a 2 2b 2c
1b 1c 1d 5" Sch 40 CS 5" Sch 40 CSTE
6 N2
Air 4 E-205 5" Sch 40 CS TE 1"
5" Sch 40 CS 5" Sch 40 CS TE 5" Sch 40 CS E-206 E-207 1" Sch 40 CS
PT E-201 TE E-202 E-203 TE
E-204 5" Sch 40 CS
5" Sch 40 CS 1 TI TT TT
C1 TT TT FI
TT
FG-201 18 14 TAH TAL 13 TAH TAL
FI C3
TAH TAL TAH TAL 1e
5" Sch 40 CS 1a TAH TAL
TCV
FAH 16 TCV
15
TCV TCV TCV
4"
16"
TY
M TY
16"
4"
3"
TY TY TY
FRC
K-202
K-201
FAL
FCV FY
4" Sch 40 CS
TI
5" Sch 40 CS
FT FE TI TI
TI
16" TI
Water
4" Sch 40 CS
4" Sch 40 CS
Utility
16" Sch 40 CS TI
P-201
PI TI
3" Sch 40 CS
FI
4" Sch 40 CS
To Sulfuric
Acid Plant
FAH
From Sulfuric
Acid Plant
FRC 16" Sch 40 CS
FAL
FT
From Sulfuric From Sulfuric
FCV FY To Sulfuric
Acid Plant Acid Plant
TI PI
Acid Plant
FE
16"
Water
Utility
TRC
3"
H2SO4 TAL
PSV
To Flare
TI TAH 25 Stack
1" Sch 40 CS 0.75" Sch 40 CS
3/4"
6" Sch 40 CS
TI TE
5"
11
TE 1" Sch 40 CS
FAH E-308 TE TI
TT
TI TI
PI PI PSV
FRC
TI 23
1" Sch 40 CS LE To Flare
9 10 27
TI PI Stack
0.75" Sch 40 CS
FAL TI
LT 3/4"
4" Sch 40 CS
TRC
4" Sch 40 CS
FCV
FY O2 TAH TAL LAH
22
Storage
LAL
H2SO4 24
3"
TY 3/4"
TAH TAL
LIC
TCV TY
3" TI 1.5" Sch 40 CS TI TCV R-302
20 TRC TT
Water PI
17 1/2" 26
Utility TT TE TI
4" Sch 40 CS TE
19 TI TI
Economizer, TAH
1" Sch 40 CS TY
TRC
TAL
Copper Smelter Plant E-307 TAL TI
5"
TI TCV
LT
TY
FE PI LAH
4" Sch 40 CS 4
E-306 5
PI
TI LY 3/4"
P-301 TI
1" Sch 40 CS
TY LCV
PI 14 PI
TCV TI
TI TI
5" Sch 40 CS
3 PI
TCV TI 5"
16" 8" Sch 40 CS
From R-301
4"
TY
TAH TAL TI
O2 Plant TCV 8" Sch 40 CS 5"
LE
16" Sch 40 CS 1.5" Sch 40 CS TAH TAL
TI
4"
3"
T-301
4" Sch 40 CS
TAH TY LCV
C1 TRC LY
TY TI
TRC TAH TAL
TAL TCV
TE LT
FAH
TI TRC 1.5" Sch 40 CS FRC
E-305 TT
LIC
4"
15 LAH LAL
5" Sch 40 CS
PI TI TI
TI TI 13 FT
FAL
FY
FCV
1.25" Sch 40 CS
5" Sch 40 CS
1.25" Sch 40 CS
1.25" Sch 40 CS
SO2 1 1' 2 2'
FE
1.25" Sch 40 CS 1.25" Sch 40 CS TE TE TE
TE
E-302 E-303 E-304
E-301 TAH
TRC 4"
TT
TI TT TT
4"
TY TRC TT 21
TCV
16 C2 Water
TAL
12
TI 5" Sch 40 CS Utility
PI TI
3" P-302
4" Sch 40 CS
TI PI
DEPARTEMEN TEKNIK KIMIA NAME SIGNATURE DATE
Economizer,
5" Sch 40 CS
Copper Smelter Plant FAKULTAS TEKNIK NAME Group 13
16" Sch 40 CS
UNIVERSITAS INDONESIA
CORRECTED BY
1 1' 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 21' 23 24 25 26 27
T (K) 1473 1373 1073 650 1049 630 906 600 751 590 602 400 298 500 388 566.5 297 295 390 398 473 491 303 403 403 403 403
P (atm) 2 1.85 1.7 1.6 1.6 1.3 1.3 1.3 1.3 1.2 1.2 0.97 1 2 1.8 1.6 1 2 1.7 1.7 2 2 1.2 1.2 1.1 1.2 1.2 To O2
Component (tonne/day)
Plant P&ID PICTURE NO. P&ID 003/2016
O2 - - - - - - - - - - - - - - - - - - - - - - - - - - -
PRELIMINARY DESIGN OF
SO2 1860 1860 700 700 2560 2560 2560 2560 2560 2560 2560 - - - - - - - - - - - - - - - -
PI TI
H2O - - - - - - - - - - - - 800 800 800 800 700 700 700 700 700 700 - - 100 - 100
SO3 - - - - - - - - - - - 2560 - - - - - - - - - - - - - -
WITHOUT SCALE
COPPER SMELTER
H2SO4 - - - - - - - - - - - - - - - - - - - - - - 3120 2120 - 4560 -
TAH
TY TRC
TAH
TAL From Economizer,
TI TCV
5A TY
TRC
Copper Smelter Plant
TAL
TI TCV
4"
From Economizer,
Copper Smelter Plant 4" Sch 40 CS 5"
PSV
5" Sch 40 CS
5" Sch 40 CS
3A
5" 5" Sch 40 CS
TT
8A 6A
4" Sch 40 CS TE
TI TI TI
TI TT
TE
5" Sch 40 CS
B C D E PC TI
5" Sch 40 CS PT
5" Sch 40 CS 5" Sch 40 CS TAH TE
5" Sch 40 CS
FAH TAH TE
PT
FE TCV
1a 5" Sch 40 CS
FAL
4" 5"
FCV A 7A 4A
FY
5" Sch 40 CS
4" Sch 40 CS
PI PI
5"
PI
Z
TI P-401
FI Electricity
F
T-401
H
5" Sch 40 CS
2A
TI
TY
TAL
TT E-405
TCV
FY FCV FE 1A
FAL 16"
From Oxygen
Plant
FRC FT 16" Sch 40 CS
FAH
PI
LIC
LIC
LT LAL LAH
FT
LAL LAH
LY
FE LCV
LY
TI
Water from FAH
LCV
TI PI TI
Bengawan Solo LT
LIC
2"
To Copper
LE
River 16"
FRC
C D V-501 LE
LAL LAH
2" Sch 40 CS
Smelter Plant
A 16" Sch 40 CS 16" Sch 40 CS
FAL PI TI
LY
PI LCV
H
B LIC
FY LT
FCV T-501 V-502
E 16" LAL LAH
LE
16" Sch 40 CS
16" LT
LIC
LY LIC
LCV LT
LAL
PI TI LAH
LAL LAH
F
LE
16" Sch 40 CS 16"
V-503 LY
P-501 16" Sch 40 CS LY LCV
LCV TI
PI TI LE
16"
G 16" I
To Sulfuric Acid
16" Sch 40 CS Plant
16" Sch 40 CS 16" Sch 40 CS
LE
PI TI
T-502 LT
LIC
LAL LAH
LY
LCV
TI
16" To Oxygen
16" Sch 40 CS Plant
1. Required Speed
mass flow
= 100
maximum mass flow
99.4
= 100
119.3
= 94.89 ft/min
2. Conveyor length
distance distance
Conveyor length = +
cos cos
1200 60
Conveyor length = + = 1260.23 ft
cos0 cos5
3. Rise (H)
= 2 = 60 5 = 5.24
4. Power
L W uc
Power = ( 0.4 + )( ) + 0.001 HW +
300 100 100
1260 99.4 8.5
= ( 0.4 + 300
) ( 100 ) + 0.001x5.24x99.4 + 94.89 100
= 16.92 hp
D.2 Absorber Column
Table D.1 Component of Absorption Column
= 55.335 /
2. Density of gas mixture calculation
= 1270
( )
=
22.4 ( )
= 1.686 /3
2 98% = 3 3
= 42869.866
- Calculating Weight of 98% acid needed for the absorption in the tower (W)
( 0.02 80)
3 =
18
0.02 80
100% = + = 1.0889
18
3 = 1.12167 = 0.2157
0.2157 = 42869.866
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176
= 97.95 /
Thus, liquid flowrate is given as
= 97.966 /
= 1850 /3
= 29.6 /
= 1.686 /3
4. Column Section
In this case of absorber, there are two kind of column, tray column and packing
column. We have chosen packing column for the reason below:
The gas material which enter to the absorber column is an acid liquid, the
corrosive one.
From the economic side, packing column is cheaper than tray column especially
for corrosive liquid
The result of pressure drop in packing column is lower than tray column. The
gas and liquid contact in packing column is better to the higher area contact.
5. Material Selection
The packing that chosen is Rasching ring packing. The specification of the
packing chosen is seen on the table given from Richardson abd Coulson as below
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Table D.3 Packing Specification
6. Diameter Calculation
Table D.4 Industrial Absorber Specification
0.5
= ( ) {( )}
= 0.099
Then we have to get K4 from the graph below by plotting the FLV at the flooding
line. K4 at flooding line based on the number of the FLV is 3.6
( )
= [ 4 . ]
0.1
13.1 ( )
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= /2
Designing for a pressure drop of 42 mm water per m of packing
4 = 1.2
Then,
1.2 0.5
% = { } 100%
3.6
% = 57.73 %
And G* is get as below
= % ( )
100
= 3.94
2
Cross section area required
=
= 7.51 2
Diameter required
4 0.5
=( )
= 3.0936
Hence. the diameter which is calculated from this approach is 3.09 meter.
7. Number of Stage
8. Height of Packing Calculation
Volumetric flowrate of the entering gas is given by
=
= 17.563 /
Gas velocity at the bottom of tower
=
= 2.33 /
Mass flowrate at the top of tower
(2824 1015.04 )(50.99)
=
3600
= 16.55 /
Volumetric flowrate at the top of tower
=
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= 9.82 3/
Gas velocity at the top of tower
=
= 1.3 /
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0.5 0.25
( ) ( )( ) = 0.04 ( )
With
=1
so we get that
= 0.239
Surface area packing (A)
= = 518.38
The mean driving force given 0.09 atm
SO3 absorbed
67984.56
3 = = 1871.82 /
(80 . 0.454)
Area of packing (AP)
3
=
0.31 ( )
= 6167.79 2
Height of packing require
=
= 11.88
Therefore, the height of packing required is 11.88 m.
9. Thickness Calculation
Table D.5 Data for Shale Thickness Calculation
Fa
Component Symbol X
(Kmol/h)
SO2 A 1476 0.615256
O2 B 830.7 0.346269
SO3 C 0 0
N2 D 92.3 0.038474
Total 2399 1
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b. Material Balance
c. Energy Balance
d. Momentum Balance
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With:
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d1 = Mean diameter of particle separated at the standard condition=30
d2 = Mean diameter of the particle separated in the proposed design=50
Dc1 = Diameter of the standard cyclone=8 inchs
Dc2 = Diameter of proposed cyclone,mm
Q1 = Standard flow rate, which amount is
- For high efficiency design = 223 m3/h
- For high throughput design = 669 m3/h
Q2 = Proposed flow rate, m3/h = 362.5
1 = Solid fluid density difference in standard design = 2000 kg/m 3
2 3 1 1 2 1/2
2 = 1 [( ) ]
1 2 2 1
2 = 0.5326 = 53.26
Dc = 0.1295 m
A = 0.5Dc = 0.06475 m
W = 0.5 Dc x 0.2 Dc = 0.01677 m
D0 = 0.5 Dc = 0.06475 m
Hc = 1.5 Dc = 0.19425 m
H = 2.5 Dc = 0.323 m
B = 0.375 Dc = 0.04585 m
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= 4,313 2
Where is gas density, for air is 0.0765 lbm/ft3 and V is gas velocity,
which assumed 150 ft/s.
150 2
= 4.313 0.0765 ( ) = 0.742
100
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- Number of tube
=
- Tube cross sectional area
= . (2 )
4
- Area per pass
= .
- Tube side superfacial velocity
1
= .
3600
- Tube side velocity
, =
Tube side velocity about 5-15 m/s for high pressure gas and 1-4 m/s for
liquid
8. Calculate the diameter of shell
- Diameter bundle, Db
1
1
= ( )
1
The value of K1 dan n1 are obtained from table 12.4 in Chemical
Engineering Design vol 6, 2005
- Diameter shell Ds
= +
The value of shell bundle clearance is obtained from figure 12.10 in
Chemical Engineering Design vol 6, 2005
9. Estimate tube side heat transfer coefficient
- Reynlods Number, Prandtl Number, and L/D
=
=
=
- Tube side heat transfer coefficient, hi
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= . . (Pr)0.33 ( )
The value of jH is obtainable from figure 2.23 in Chemical Engineering
Design vol 6, 2005
10. Estimate shell side heat transfer coefficient
- Baffle spacing dan tube pitch
Baffle Spacing, lB = baffle spacing coefficient x inside diameter shell
Tube pitch, pt = tube pitch coefficient x outside diameter tube
The value of baffle spacing coefficient is 0.2 0.5 while tube pitch
coefficient is 1.25 1.35
- Shell Cross Flow Area
= . .
- Equivalent Diameter, de
1.10
For triangular pitch: = (2 0.9172 )
1.27
For square pitch: = (2 0.7852 )
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The value of jH is obtainable from figure 2.29 in Chemical Engineering Design
vol 6, 2005
11. Calculate the overall heat transfer coefficient, Uo
1 1 () ln 1
= ( + ) + +
2
+
Where K is thermal conductivity for heat exchanger material. For carbon steel
K = 45 Wm-1 oC-1
12. Calculate pressure drop in shell side and tube side
- Pressure drop in tube
2
= [8 ( ) + 2.5]
2
The value of jF is obtainable from figure 2.24 in Chemical Engineering
Design vol 6, 2005
- Pressure drop in shell
2
= 8 . . .
2
Pressure drop must be below 0.5 bar. If the pressure drop above 0.5 bar, we
must change the value of Uc in step 3.
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2. Assume tank space to determine tank volume
a. The volume of the tank space is 10%
b. Height ratio cylinder with a diameter of the cylinder is 2:1
c. Close the top and bottom cap shaped dished head (flat).
= 1.1
1 2
= ( )
2
1
= 2 2
4
= (2)1/3
Therefore,
= 2 8.53 = 17.062
=
= 1004 /3 9.8 / 2 15.355
= 151087 = 1.51
With a safety margin of 15%, then
= 1.15 (1 + 1.51) = 2.88 = 41.87
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5. Determine Shell and Head Thickness
Used construction material made of stainless steel with specifications
type 304, grade 3 (SA-167) (App. D, Brownell, p: 342)
fallowable = 18,750.00
Corrosion factor (CA) = 0.042
Connection for welding selected type double welded butt joint
Welding efficiency. (E) = 0.80 (Table 13.2, Brownell)
To calculate the shell thickness (ts) we use the equation from Brownell, page 254
[ + ]
=
[2 ( 0.6 )]
41.86 336.11 + 0.0042
( ) = = 0.52
2 (16750 0.8 0.6 41.86 )
( ) = 3.5 = 3.5 0.52 = 1.84
Basic Planning
The stocks will be available for 30 days of productions, which is
= 1066.25 30 = 31987.5
= 31987.5 3848.41 /3 = 8311.88 3
To ensure that the Warehouse is safe and not overloaded, we decided to make the
Warehouse is 90% filled. So the Warehouse volume would be
= 8311.88 3 90% = 9235.43 3
=
= 4 3 1
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D.8.2 Warehouse TK-102
The Warehouse is used to stocking the Anode Slime. The Anode Slime are
stocked for 30 days. The Warehouse is a rectangle building with a triangular prism
roofs. Some specifications that should be known are
Bulk density for Anode Slime is 5000 kg/m3
The processs will be done with feed flow rate is 5.25 tonne/day
Basic Planning
The stocks will be available for 30 days of productions, which is
= 5.25 30 = 157.5
Raw material Volume
= 157.5 5000 3 = 31.5 3
To ensure that the Warehouse is safe and not overloaded, we decided to make the
90% .
31.5 3
= = 35 3
90%
=
= 4 3 1
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= 4 3 1
D.9 Coagulant Tank
267.14 2
= = 5.34 6
50 2
D.11 Ion Exchanger
1. Examine water analysis
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7. Calculate the ionic load per cycle in eq (concentration in meq/L times
throughput in m3):
o [] = = 250 . 19200 = 4800000
o [] = = 150.25 . 19200 = 2884800
10. At the end of this calculation, we must make sure that the specific flow rate
of both resin columns is compatible with the general recommendations of
the resin producer.
D.12 Pump
To size a pump, firstly things that must be defined:
The flow rate of liquid the pump is required to deliver
The total differential head the pump must generate to deliver the required flow
rate
Other key considerations for pump sizing are the net positive suction head
available (NPSH) and the power required to drive the pump
Heres the algorithm to find the parameter that we state above:
1. Calculate Head
2. Calculate WHP
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3. Calculate BHP
4. Calculate NPSHa
D.12 Compressor
Compressor Power
With
A = Conversion Factor
Za =Compresibility factor
R = Universal Gas Constat
T1 =Inlet Temperature
Ps =Standart Pressure
E =Overall efficiency
q =gas flow rate
P2 =Pressure Outlet
P1 =Pressure Inlet
= Heat capacity ratio
(). ()
=
(). () 1.99
Discharge Temperature
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Compressor Head
with
= Head
1 = Suction temperature
= Compesibility Factor
= Universal gas law
= Molecular weight
= Heat capacity ratio
P2 = Pressure Outlet
P1 = Pressure Inlet
1) Curtis Turbine.
Curtis turbine is used to power generated up to 4000 kW.
2) Reaction Turbine.
Same with Curtis turbine, reaction turbine is used for low output power and
therere chemical reaction in the process.
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3) Rateau Turbine.
Rateau turbine is used to power generated from 4000 kW up to above 30,000
kW
Based on international design standard, the turbine with output power 11680
kW, can be operated with speeds up to 4000 rpm, and usually used 3600 rpm. Based
on Rataeu turbine, can be known the enthalpy change per stage is 25 kJ/kg. So the
number of stage which needed for this turbine is
121
= = = 4,84 5
25
2. Other Data
Another data that we used is Flow rate Q (m3/h) where it can be seen from
the simulation.
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3. Calculation
Find the surface area of pipe
=
Calculate the inside diameter (ID)
4
=
3.14
,max = 2
5. After we got the value of Cv,max then we can know the valve size with this
table.
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APPENDIX E:
MSDS
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E.2 Limestone
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E.4 Sulfuric Acid
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E.5 Copper Cathode
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E.6 Oxygen
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E.7 SO2
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E.8 SO3
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E.9 Coal
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APPENDIX F:
ECONOMIC ANALYSIS
F.1 Purchase Equipment Cost
a. Conveyor
The copper smelter plant has a solid raw material and product. Hence, this plant
is needed conveyor to distribute the material and product. There are eight belt
conveyors being used. The calculation is based on Product and Process Design
Principle by Sieder. The equation to calculate the cost of conveyor belt is shown
below
= 16.9
W = Width (in)
L = Length (ft)
D = Diameter (in)
b. Filter
In our plant, there are one filter used in oxygen plant to filter the natural gas
before it is processed further. The calculation is based on Product and Process
Design Principle by Sieder. The equation is shown below.
= exp{11.432 0.1905[ln()] + 0.0554[ln()]2 }
Where:
A = Filtering area (ft2)
c. Reactor
Packed bed reactor is needed in the sulfuric acid plant to process the
byproduct from copper smelter plant, SO2. We only need one reactor and will be
calculated based on Product and Process Design Principle by Sieder.
= CS n
Where,
S = Characteristic size, volue (ft3)
C = Cost constant (Reactor =15000)
n = Index for equipment type (Reactor = 0.6)
d. Compressor
There are five compressors in our plant that is used in our plant. The
calculation is based on Product and Process Design Principle by Sieder. The price
= exp{7.2223 + (0.8[()]}
=
Where:
PC = Power (hp)
FM = Compressor Material (SS =2.5)
FT = Compressor type
e. Pump
There are seven pumps used in our plant and utility. These equipments are
calculated based on equation in Product and Process Design Principle by Sieder.
The calculation required some data such as flow rate, Q, and head of pump, H. The
equation is shown below
= exp{9.2951 0.6019[ln()] + 0.0519[ln()]2 } (1.7)
= (1.8)
Where,
FM = Pump Material
FT = Pump type
f. Tank
The tank that will be calculated in this section including tank, filtration, and ion
exchanger tank. The calculation is based on the equation in Sieder as shown below.
The S for tank calculation is the capacity of the tank.
= CS n
Where,
S = Characteristic size, volume (ft3)
C = Cost constant (Tank = 2900)
n = Index for equipment type (Reactor = 0.6)
g. Heat Exchanger
The total heat exchanger used in our plant is 21. For calculating heat its FOB
price we use Seider, Seider, and Lewis book (2004). The equation is shown below
=
Where CB is calculated based on the type of heat exchanger used. The formula as
seen below
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We use fixed head for all of our heat exchanger in our plant. As for FM is material
factor for combination of tube and shell material as given in table below
(1.15)
The bare module factor that is used is the one for the shell and tube exchanger which
amounted 3.17 (SSL, 2004).
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F.2 Equipment Cost
Table F.1 Total Equipment Cost
Bare Module
Equipment Price/Unit Total Price Bare Module
No Qty. Year Basis Cost in 2020
Code (USD) (USD) Factor
(USD)
Compressor
1 K-100 1 954,510 954,510 2000 2.15 3,992,370
2 K-101 1 195,360 195,360 2000 2.15 817,120
3 K-102 1 581,990 581,990 2000 2.15 2,434,250
4 K-201 1 3,273,110 3,273,110 2000 2.15 13,690,220
5 K-202 1 2,366,400 2,366,400 2000 2.15 9,897,780
Pump
1 P-301 1 2,050 2,050 2000 3.3 13,161
2 P-302 1 4,130 4,130 2000 3.3 26,514
3 P-201 1 3,080 3,080 2000 3.3 19,774
4 P-202 1 3,070 3,070 2000 3.3 19,709
5 P-101 1 2,530 2,530 2000 3.3 16,243
6 P-401 1 3,700 3,700 2000 3.3 23,754
7 P-501 1 7,970 7,970 2000 3.3 51,167
Furnace
1 F-101 1 406,553 406,553 2000 1.86 1,774,670
2 F-102 1 397,803 397,803 2000 1.86 1,736,477
3 F-103 1 246,960 246,960 2000 1.86 1,078,022
4 F-104 2 370,812 741,623 2000 1.86 3,237,306
Bare Module
Equipment Price/Unit Total Price Bare Module
No Qty. Year Basis Cost in 2020
Code (USD) (USD) Factor
(USD)
Conveyor
1 C-101 1 269,400 269,400 2000 1.61 843,810
2 C-102 1 186,250 186,250 2000 1.61 583,370
3 C-103 1 149,670 149,670 2000 1.61 468,790
4 C-104 1 133,040 133,040 2000 1.61 416,710
5 C-105 1 166,300 166,300 2000 1.61 520,890
6 C-106 1 149,670 149,670 2000 1.61 468,790
7 C-107 1 106,430 106,430 2000 1.61 333,360
8 C-108 1 106,500 106,500 2000 1.61 333,580
Filter
1 F-101 1 78,380 78,380 2000 2.32 360,000
Reactor
1 R-301 1 93,160 93,160 2004 4.16 621,210
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Table F.3 Piping Cost of Sulfuric Acid Plant (contd)
Nominal Price/L Total Cost
Stream L (ft) OD (inc)
Size (inc) (USD) (USD)
16 10.02 5 5.563 32.26 324
17 8.769 4 4.5 24.77 218
18 8.769 4 4.5 24.77 218
19 8.769 4 4.5 24.77 218
20 8.769 4 4.5 24.77 218
21 8.769 4 4.5 24.77 218
21' 8.769 4 4.5 24.77 218
23 21.072 6 6.625 40.85 861
25 1.2525 0.5 0.84 2.54 4
24 14.319 2.5 2.875 12.45 179
26 30.81 8 8.625 66.7 2056
27 1.2525 1.5 1.9 6.21 8
Total 6345
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Table F.5 Piping Cost of Power Plant
Nominal Price/L Total Cost
Stream L (ft) OD (inc)
Size (inc) (USD) (USD)
Pump to E-401 2.4 4 4.5 24.77 59.448
E-401 2.4 4 4.5 24.77 59.448
E-402 2.4 4 4.5 24.77 59.448
E-403 2.4 4 4.5 24.77 59.448
E-404 2.4 4 4.5 24.77 59.448
T-401 7.5 4 4.5 24.77 185.775
HE to HE 2.4 4 4.5 24.77 59.448
HE to HE 2.4 4 4.5 24.77 59.448
from Economizer 45 4 4.5 24.77 1114.65
from Economizer 45 4 4.5 24.77 1114.65
Total 2831.21
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F.4 Building Cost
Table F.8 Total Building Cost
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Table F.9 Supporting Equipment Cost (contd)
Price per
Supporting Equipment Quantity Price (USD)
Piece (USD)
White Board 25 4 100
Generator 10 11 110
Office Car 25 17,000 425,000
Distribution Car 15 45,000 675,000
Television 15 200 3,000
Office Equipment 20 310 6,200
Canteen Chair 100 150 15,000
Canteen Desk 40 4 160
Pantry Utensils 8 300 2,400
Printer 15 100 1,500
Neon Lamp 2000 5 10,000
Photocopy Mechine 15 550 8,250
CCTV 35 100 3,500
Total Supporting Equipment Cost 1,252,500
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Table F.13 Contractors Fee
Based Cost
No Type of Cost N Cost (USD)
(USD)
1 Contractors Fee 3% 59,940,828 2,747,870
Total 2,747,870
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F.7 Utility, Maintenance,Waste Treatment Cost
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F.8 Direct Labor Cost
Table F.20 Labor Need per Equipment
Equipment Quantity Factor Total Labor/ shift
Compressor 5 0.15 0.75
Turbine 2 1 2
Reactor 6 1 6
Storage 9 0.1 0.9
HE 21 1 21
Pump 7 0.5 3.5
Filter 1 1 1
Conveyor 8 0.5 4
Caster 2 4 8
Furnace 5 3 15
Electrolytic Cell 6 4 24
Total labor/ shift 85
Total labor/ day 344
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Table F.22 Indirect Labor Cost (contd)
Number of Monthly Salary Yearly Salary
Job Title
Employees [USD/month] [USD/year]
R&D Officer 1 1,000 14,000
Utility Officer 4 1,000 56,000
Machine Officer 5 1,000 70,000
Electrical Employee 5 1,000 70,000
Instrument officer 1 1,000 14,000
Safety Officer 1 1,000 14,000
Accounting Officer 1 1,000 14,000
Administration Officer 1 1,000 14,000
Human Resource Officer 1 1,000 14,000
Public Relation Officer 1 1,000 14,000
Security Officer 1 1,000 14,000
Marketing Officer 1 1,000 14,000
Production Employee 70 417 408,333
Technical Employee 10 417 58,333
Finance & Accounting
20 417 116,667
Employee
Marketing Employee 15 417 87,500
Doctor 3 1,250 52,500
Nurse 8 400 44,800
Security 15 250 52,500
Cleaning Service 15 250 52,500
Driver 5 250 17,500
TOTAL
TOTAL 195 1,479,333
[USD/year]
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F.11 Cash Flow
Table F.25 Cash Flow
Kapasitas Depreciation Cash expanese
Tahun opex (USD) Revenue (USD) All expansese (USD) Gross Profit (USD) NPBT (USD) NPAT (USD) Cash Flow (USD) CCF (USD)
Penjualan f=10% (USD)
2016 (164.121.246) (172.327.308)
2017 0,5 (2.001.583.912) (15.997.838) 1.297.462.625 (2.001.583.912) (2.017.581.750) (704.121.287) (720.119.125) (504.083.387) (497.684.252) (670.011.560)
2018 0,7 (2.001.583.912) (12.798.270) 1.816.447.675 (2.001.583.912) (2.014.382.182) (185.136.237) (197.934.507) (138.554.155) (133.434.847) (803.446.407)
2019 0,9 (2.001.583.912) (10.238.658) 2.335.432.725 (2.001.583.912) (2.011.822.570) 333.848.813 323.610.155 226.527.109 230.622.572 (572.823.835)
2020 1 (2.001.583.912) (8.190.908) 2.594.925.250 (2.001.583.912) (2.009.774.820) 593.341.338 585.150.430 409.605.301 412.881.664 (159.942.171)
2021 1 (2.001.583.912) (6.552.721) 2.594.925.250 (2.001.583.912) (2.008.136.632) 593.341.338 586.788.618 410.752.032 413.373.121 253.430.950
2022 1 (2.001.583.912) (5.242.148) 2.594.925.250 (2.001.583.912) (2.006.826.060) 593.341.338 588.099.190 411.669.433 413.766.292 667.197.242
2023 1 (2.001.583.912) (4.193.755) 2.594.925.250 (2.001.583.912) (2.005.777.667) 593.341.338 589.147.583 412.403.308 414.080.810 1.081.278.052
2024 1 (2.001.583.912) (3.355.004) 2.594.925.250 (2.001.583.912) (2.004.938.916) 593.341.338 589.986.334 412.990.434 414.332.436 1.495.610.487
2025 1 (2.001.583.912) (2.684.021) 2.594.925.250 (2.001.583.912) (2.004.267.933) 593.341.338 590.657.317 413.460.122 414.533.730 1.910.144.218
2026 1 (2.001.583.912) (2.147.209) 2.594.925.250 (2.001.583.912) (2.003.731.120) 593.341.338 591.194.130 413.835.891 414.694.774 2.324.838.992
2027 1 (2.001.583.912) (1.717.747) 2.594.925.250 (2.001.583.912) (2.003.301.659) 593.341.338 591.623.591 414.136.514 414.823.613 2.739.662.604
2028 1 (2.001.583.912) (1.374.166) 2.594.925.250 (2.001.583.912) (2.002.958.078) 593.341.338 591.967.172 414.377.020 414.926.687 3.154.589.291
2029 1 (2.001.583.912) (1.099.437) 2.594.925.250 (2.001.583.912) (2.002.683.349) 593.341.338 592.241.901 414.569.331 415.009.106 3.569.598.397
2030 1 (2.001.583.912) (879.432) 2.594.925.250 (2.001.583.912) (2.002.463.344) 593.341.338 592.461.906 414.723.334 415.075.107 3.984.673.504
2031 1 (2.001.583.912) (703.579) 2.594.925.250 (2.001.583.912) (2.002.287.490) 593.341.338 592.637.760 414.846.432 415.127.863 4.399.801.367
2032 1 (2.001.583.912) (562.853) 2.594.925.250 (2.001.583.912) (2.002.146.765) 593.341.338 592.778.485 414.944.939 415.170.081 4.814.971.448
2033 1 (2.001.583.912) (450.381) 2.594.925.250 (2.001.583.912) (2.002.034.292) 593.341.338 592.890.958 415.023.670 415.203.823 5.230.175.270
2034 1 (2.001.583.912) (360.223) 2.594.925.250 (2.001.583.912) (2.001.944.135) 593.341.338 592.981.115 415.086.781 415.230.870 5.645.406.140
2035 1 (2.001.583.912) (288.128) 2.594.925.250 (2.001.583.912) (2.001.872.039) 593.341.338 593.053.211 415.137.247 415.252.498 6.060.658.638
2036 1 (2.001.583.912) (230.578) 2.594.925.250 (2.001.583.912) (2.001.814.490) 593.341.338 593.110.760 415.177.532 415.269.763 6.475.928.402
2037 1 (2.001.583.912) (184.417) 2.594.925.250 (2.001.583.912) (2.001.768.329) 593.341.338 593.156.921 415.209.845 415.283.612 6.891.212.013
2038 1 (2.001.583.912) (147.606) 2.594.925.250 (2.001.583.912) (2.001.731.517) 593.341.338 593.193.733 415.235.613 415.294.655 7.306.506.668
2039 1 (2.001.583.912) (118.034) 2.594.925.250 (2.001.583.912) (2.001.701.945) 593.341.338 593.223.305 415.256.313 415.303.527 7.721.810.195
2040 1 (2.001.583.912) (94.473) 2.594.925.250 (2.001.583.912) (2.001.678.385) 593.341.338 593.246.865 415.272.805 415.310.595 8.137.120.790
2041 1 (2.001.583.912) (75.476) 2.594.925.250 (2.001.583.912) (2.001.659.388) 593.341.338 593.265.862 415.286.104 415.316.294 8.552.437.084
2042 1 (2.001.583.912) (60.447) 2.594.925.250 (2.001.583.912) (2.001.644.359) 593.341.338 593.280.891 415.296.624 415.320.803 8.967.757.886
2043 1 (2.001.583.912) (48.367) 2.594.925.250 (2.001.583.912) (2.001.632.278) 593.341.338 593.292.972 415.305.080 415.324.427 9.383.082.313
2044 1 (2.001.583.912) (38.651) 2.594.925.250 (2.001.583.912) (2.001.622.562) 593.341.338 593.302.688 415.311.881 415.327.342 9.798.409.654
2045 1 (2.001.583.912) (30.940) 2.594.925.250 (2.001.583.912) (2.001.614.852) 593.341.338 593.310.398 415.317.279 415.329.655 10.213.739.309
2046 1 (2.001.583.912) (24.789) 2.594.925.250 (2.001.583.912) (2.001.608.701) 593.341.338 593.316.549 415.321.584 415.331.500 10.629.070.809
1000 mm
6000 mm
ECONOMIZER
10100 mm
10400 mm
10,1 m
12500 mm
4000 mm 4000 mm
10100 mm
F-103
9000 mm
6000 mm
F-101 F-102
2000 m
6000 mm
6300 mm
40 m
1200 mm
P-101
12500 mm
6000 mm
1000 m
6300 mm
5000 mm 4000 mm
1200 mm
2000 mm
3150 mm
P-102 PM-101 F-104
1000 m
6300 mm
1200 mm
P-103
5000 mm
2500 mm
6300 mm
1200 mm
P-104
12500 mm
6000 mm
1000 m
6300 mm
5000 mm 4000 mm
2000 mm
1200 mm
3150 mm
P-105 PM-102 F-104
1000 m
6300 mm
1200 mm
P-106
2000 mm
1500 mm
6000 mm
1500 mm
FILTER
5000 mm
5000 mm 1500 mm
2100 mm 2500 mm
COMPRESSOR
2500 mm
1150 mm
950 mm
1500 mm
1500 mm
2400 mm 2000 mm
1000 mm
1250 mm
E-204 E-203
15000 mm
5000 mm
5000 mm
10000 mm
40 m
COMPRESSOR
2500 mm
K-201
2200 mm 2200 mm
ADSORBER
2200 mm
2200 mm
ADSORBER
6000 mm
(R-202) (R-201)
8000 mm
1500 mm 1500 mm
2500 mm
1100 mm
1500 mm
1100 mm
3000 mm 2000 mm
800 mm
E-301 E-302
1m
1500 mm
2000 mm
1,5 m
1900 mm 2000 mm
1000 mm
1000 mm
2200 mm
E-304 E-303
8000 mm 4000 mm
1100 mm
4000 mm
E-308
3m
3000 mm
4000 mm
1000 mm
E-307
5000 mm
2800 m
4000 mm
10000 mm
1100 mm
(R-301) 4000 mm
E-306
3000 mm
5m
4000 mm
35 m
2400 mm
1200 mm
3000 mm
E-305
3000 mm
10000 mm
3000 mm
AbSORBER
3000 mm
AbSORBER
(R-303)
(R-303)
2500 mm
80 m
3000 mm
8400 mm
Pump
1500 mm
(P-501)
Coagulant Tank
(T-501)
5000 mm
5000 m
6800 mm
5000 m 5000 m
30000 mm
Cooling
Ion Exchanger Ion Exchanger Tower
Filtration Tank
15000 mm
25000 mm
5000 mm
3000 mm
Pump
1500 mm
(P-502)
Universitas Indonesia
244
58 m
1800 mm 1900 mm
5000 mm
700 mm
HE HE
900 mm
(E-403) (E-404)
5500 mm
5000 mm 5000 mm
2300 mm
2300 mm
Turbine
2000 mm
(T-401)
5000 mm
30000 mm
30 m
Condenser
800 mm
800 mm
Evaporator
(E-405)
(E-402)
5000 mm
5000 mm
2500 mm
2300 mm
5000 mm
1800 mm
900 mm
HE Pump
(E-401) (P-401)
Universitas Indonesia
25 m 40 m N
MOTORCYCLE PARKING
20 m
GUEST CAR PARK (FOR SECURITY
ADMISSION) SECURITY AREA
MAIN 40 m
W E
GATE 65 m
S
CHEMICAL ENGINEERING DEPARTMENT
45 m
FACULTY OF ENGINEERING
55 m
UNIVERSITAS INDONESIA
CAR PARKING AREA DEPOK
E-101/201/202/203/204/205/206/207/301/302/
303/304/305/306/307/308
25 m /401/402/404/405 : Heat Exchangers
R-301 : Packed Bed Reactor
R-302/303 : Absorber
R-201/202 : Adsorber
60 m ASSEMBLY K-201/202 : Kompresor
30 m
T-401 : Turbine
POINT F-101/102/103 : Furnace
F-/104/105 : Furnace
25 m PM-101/102 : Hazelette Caster
45 m
OFFICE BUILDING P-101/102/103/ : Electrorefining
P-104/105/106 : Electrorefining
20 m
MOSQUE P-501/502 : Pump
T-501/502/503/504 : Coagulant Tank
25 m
V-501 : Filtration Tank
30 m 35 m
V-502/503 : Ion Exchanger
V-504 : Cooling Tower
10 m
10 m
CLINIC T-503/504/502 : Water Tank
20 m
FIRE STATION
PROJECT
45 m
30 m
LAB PRELIMINARY DESIGN OF COPPER
20 m
K3 BUILDING SMELTER PLANT
MECHANICAL AND
10 m
ASSEMBLY POINT
20 m
ELECTRICAL DRAWING
DATE
NO.
10 m
BUILDING 5
11/16/2016
65 m 25 m
GROUP
PAR13
5m
5m
CANAL CANAL
5m
80 m
5m
35 m
5m
5m
2500 mm
Evaporator
5000 mm
1800 mm
HE
2500 mm
HE
5000 mm
2300 mm
2300 mm
3000 mm
8400 mm
CENTRAL
1500 mm
P-501
5000 mm
5000 mm
40 m
800 mm 900 mm
CONTROL
1800 mm
T-501
5000 mm
2500 mm
30000 mm
Condenser
2300 mm
ROOM
(E-404)
(E-405)
(P-401)
1900 mm
Pump
HE
5000 mm
5000 mm
55 m
5000 m
5000 m 6800 mm
5000 mm
65 m
15000 mm
Cooling Tower
V-502 V-503 (V-504)
V-501
3000 m 5000 m
30000 mm
25000 mm
5000 mm
35 m
2000 mm
5000 mm
Turbine
(T-401)
5500 mm
T-505 5000 m
T-504 T-503 T-502
15 m
ASSEMBLY POINT
8350 mm
8350 mm 8350 mm
8350 mm
5000 mm
3000 mm
5000 mm
1500 mm
2400 mm
P-502
2200 mm
E-308
2800 m
E-305
E-306
3000 mm
4000 mm
1200 mm
1100 mm
1100 mm
4000 mm
6000 mm 50 m
1500 mm
R-301
4000 mm
1500 mm
FILTER
5000 mm 5000 mm
1500 mm
950 mm
1150 mm
2100 mm 2500 mm
2500 mm
5000 mm
2400 mm 2000 mm
30 m
15000 mm
10000 mm
1000 mm
E-204 E-203
8000 mm
5000 mm
5000 mm
10000 mm
40 m
1250 mm
1500 mm
3000 mm
E-307
2500 mm
1500 mm
K-202
2200 mm 2200 mm
3000 mm
2000 mm
5000 mm
E-303
3000 mm
E-302
R-302
2000 mm
1000 mm
2200 mm
2200 mm
R-201
6000 mm
2000 mm
1000 mm
R-202
1500 mm
800 mm
2500 mm
2500 mm
3000 mm
1500 mm 1500 mm
2100 mm
1900 mm
2200 mm 2400 mm
E-304
3000 mm
E-301
8000 mm
E-207 E-206 E-205
3000 mm
R-303
1500 mm
1100 mm
1100 mm
1000 mm 10000 mm
1500 mm
1000 mm
3000 mm
35 m
75 m
1000 mm
4000 mm
10100 mm
RAW MATERIAL
65 m
E-101
6000 mm
10400 mm
12500 mm
4000 mm
STORAGE
10100 mm
6000 mm
9000 mm
6300 mm
40 m
12500 mm
1200 mm
P-101
5000 mm 6000 mm
1m
6300 mm 4000 mm
1200 mm
2000 mm
3150 mm
6300 mm
1200 mm
P-103
2500 mm
5000 mm
6300 mm
1200 mm
P-104 12500 mm
6000 mm
25 m 5000 mm
1m
6300 mm 4000 mm
3150 mm
2000 mm
1200 mm
6300 mm
1200 mm
P-106
2000 mm
10 m
155 m
ASSEMBLY POINT 80 m
LOADING AND
10 m
PRODUCT STORAGE
15 m
UNLOADING
FLARE