Bioprocess Engineering

Departement of Chemical
Engineering
Universitas Indonesia

Presentation Report:
Assignment 2

PRODUCTION OF
CARRAGEENAN
FROM SEAWEED
Eucheuma cottonii IN
GROUP BIO 2
POWDER FORM Agustina Evania Dewi
Andrea Gilang Fauzi
(1606821923)
(1606906295)
Eldwin Maidiono (1606878884)
Muhamad Yusril Ihza M. (1606831142)
Shania Rosita A. S. (1606878745)
 SIZING &
SPECIFICATIONS
TABLE OF CONTENTS
MAIN PROCESS
01 EQUIPMENT

02 UTILITY EQUIPMENT

03 CONCLUSION

04 APPENDIX
Bioprocess Engineering
Departement of Chemical Engineering
Universitas Indonesia
MAIN PROCESS
EQUIPMENT

01
1. BELT
CONVEYOR Type & Function

Washing Conveyor
To transport raw seaweed
material in washing process

Elevator Conveyor
To transport refined
carrageenan from tray dryer
to miller
MAIN Equipment Specifications
Equipment Name Washing Belt Conveyor
PROCESS Equipment Code W-101
EQUIPMENT Function
Washing seaweed as raw
material
Number of Unit 1
Material Stainless Steel 304
WASHING BELT CONVEYOR Type Mesh Belt Conveyor
Mode of
Batch
Operation
Conveyor belts used in carrageenan production are divided Operation Data
into 2 parts. The first is the washing belt conveyor which is Temperature 25oC
Pressure 1.01 atm
used as a washing machine for seaweed. Mass Flow 1074.627 kg/h
Water 1432.841 L/h
Construction Data
Capacity 1000-1500 kg/h
Length 5m
Width 1.2 m
Height 1.3 m
Power 8.3 kW
Zhuzcheng Yazhong Food
Vendor
Machiner, Alibaba
MAIN Equipment Specifications
PROCESS Equipment Name Elevator Belt Conveyor
Equipment Code E-101
EQUIPMENT Function Tansport carrageenan from
tray drying into the miller
Number of Unit 1
Material Stainless Steel, Plastic
ELEVATOR BELT CONVEYOR Type Belt Conveyor
Equipment Specifications
Conveyor belts used in carrageenan production are divided Mode of Operation Batch
into 2 parts. The elevator belt conveyor which is used for Operation Data
Temperature 30oC
transportation of dried carrageenan to the milling machine. Pressure 101.325 kPa
Construction Data
Capacity 1000 kg/h
Length 5m
Width 750 mm
Height 3500 mm
Motor Power 0.75 kW
Vendor Shanghai Leadworld
Machinery
2. MIXING TANK
Type & Function

KOH Mixing Tank

To mix KOH in powder form
with water up to 0.2 M

IPA Mixing Tank

To mix IPA liquid with water
up to 95%
 Equipment Identification
Equipment Name KOH Mixing Tank
Equipment Code M-101
Number of unit 1

Function
To mix KOH and water
up to 0.2 M for alkaline KOH Mixing Tank
extraction process
Equipment Identification
Carrageenan extraction process needs
Mode of Operation Batch
alkaline solvent; which is KOH
Cylindrical tank with
Type dissolved in water (with the
ellipsoidal top and bottom
concentration of 0.2 M), thoroughly
Material Stainless Steel 316
mixed within 30 minutes and the
Material Composition
specifications of the mixing tank is
KOH 1.2%
written on the table.
Water 98.8%
Operating Condition
Capacity 25000 L
Mass Flow Rate 18047 kg/batch
Pressure 1.01 atm
Temperature 25oC
Mixture Density 1006.93 kg/m3
 Design Specification
Tank Volume 22.40 m3
Safety factor 20%
Tank Diameter
Tank Height
2.43 m
6.06 m
KOH Mixing Tank
Cylinder Height 4.85 m
Type of head Ellipsoidal
Head Height 0.43 m
Wall Thickeness 3.58 mm
Head Thickeness 3.57 mm
Stirrer Design
Impeller type Propeller with 6 leafs
Impeller diameter 0.81 m
Width of leaf
0.16 m
impeller
Impeller to
0.81 m
bottom
Baffle width 0.20 m
Impeller speed 15 rpm
Utilities
Motor Power 0.0272 kWh
 Equipment Identification
Equipment Name IPA Mixing Tank
Equipment Code M-102 IPA Mixing Tank
Number of unit 1
Mixing isopropyl
alcohol with water Isopropyl alcohol (IPA) that needed for
Function to make IPA 95% precipitation process is IPA 95%,
for Alcohol therefore before it is used for the
Precipitation precipitation process, pure IPA is first
Equipment Identification mixed with water in the mixing tank.
Mode of Operation Batch Mixing tank is a tank with impeller that
Cylindrical tank with has functions to mix IPA with water.
Type ellipsoidal top and Because the IPA solution tends to be
bottom corrosive, the tank used is made of
Material Stainless Steel 304 stainless steel material. The sizing and
Material Composition specification of IPA mixing tank is
Isopropyl Alcohol 95% explained in the table.
Water 5%
Operating Condition
Capacity 23,03 kg/batch
Pressure 1,01 atm
Temperature 25oC
 Design Specification
Tank Volume 463,45 L
Safety factor 20%
Height of Fluid
Pressure design
1.54 m
1.34 atm
IPA Mixing Tank
Tank Diameter 0.62 m
Tank Height 1.54 m
Cylinder Height 1.24 m
Type of head Ellipsoidal
Head Height 0.31 m
Wall Thickeness 2.36 mm
Head Thickeness 2.27 mm
Stirrer Design
Impeller type Vertical blade
Impeller diameter 0.206 m
Width of leaf
0.041 m
impeller
Impeller to
0.206 m
bottom
Baffle width 0.051 m
Impeller speed 155 rpm
Utilities
 Equipment Identification
Equipment Name Alkaline Extraction Tank
Equipment Code V-102
Number of unit 1
To extract carbohydrate
Function
from seaweed
3. Alkaline Extraction Tank Mode of Operation Batch
Material Composition (%)
In this process, a tank is used that KOH 0.840
contains the alkali solution that is Biomass 6.237
maintained at 80oC for 2 hours, the Proteins 2.348
seaweeds then were added to the Water 82.961
solvent into extractor. The speed of Carbohydrate 6.604
stirrer was set constant at 36 rpm and Fats 0.274
KOH 0.2 M used as solvent with ratio
Sodium 0.0049
of seaweed weight to solvent volume is
Potassium 0.033
1:3 maintained by adding hot water or
Ash 0.697
steam (Distantina, et al. 2011).
Operating Condition
Mass Flow Rate 24041.49 kg/batch
Pressure 1.184 atm
Temperature 80oC
Mixture Density 966.89 kg/m3
 Design Specification
Cylindrical tank with ellipsoidal
Type
top and bottom Utilities
Material Stainless Steel 316
Motor Power 0.5082 kWh
Capacity 30000 L
Jacket Design
Tank Volume 29.84 m3
Jacket Space 0.48 m
Safety factor 20%
Outside Radius
Tank Diameter 2.60 m 29.94 mm
of Jacket
Tank Height 6.06 m
Inside Radius of
Cylinder Height 5.20 m 0.00732 mm
Jacket
Ellipsoidal Height 0.43 m
Corner of Radius
Wall Thickeness 167.88 mm 1.96 m
Closure
Head Thickeness 89.79 mm
Thickness
Stirrer Design 0.65 m
Radius Closure
Impeller type Marine propeller with 3 blades
Length of Jacket 0.46 m
Impeller diameter 0.87 m
Area over which
Width of leaf 0.12 m2
0.17 m hot water passes
impeller
Impeller to
0.87 m
bottom
Baffle width 0.22 m
Impeller speed 36 rpm
Alkaline Extraction Tank

Figure 1.1. Design for Alkaline Extraction Tank

(Source: Walas, 1990)
 Equipment Specification
Equipment Name Coarse Filter
Equipment Code CF-101
4. Coarse Filter Number of unit 1
To separate solids seaweed
Function residue from the extracted
Coarse filter is used to separate carrageenan solution
suspended seaweed residues and Operation Mode Batch
remove solid from the extract slurry. Filter Screen Material Stainless Steel 316
Filtering Precision 25-6000 μm
Operating Temperature 0-68oC
Inlet and Outlet Pipe
25.4 cm
Diameter
Maximum Flow Rate 20 m3/h
Allowable Pressure Drop 14.8 atm
 Operation Data
Flow Rate 4.27 m3/h
Mixture Density 1001.59 kg/m3
Mixture Dynamic
1.18 cP
Viscosity
Temperature 25oC
Pressure Drop 10.86 atm
Equipment Dimension
Diameter of
1.02 m
cylinder
Height of cylinder 2.53 m
(Source: Kherad, 2019)

Figure 1.2. Design for Coarse Filter

(Source: Kherad, 2019)
5. Plate & Frame
Filter
Type of filtration unit which works based
on cake formation and it’s porosity on Type & Function
frame

•Filtering substances from

P&F 1 carrageenan solution

• Make sure the carrageenan

P&F 2 solution is free of fine
gelatinous particles.
 P&F Filtration 1 P&F Filtration 2
Equipment Specification Equipment Specification
Equipment Name Plate & Frame Filter 1 Equipment Name Plate & Frame Filter 2
Equipment Code PFF-101 Equipment Code PFF-102
Quantity 1 Quantity 1
Equipment type X G200/1245-U Equipment type X G200/1250-U
Equipment Vendor Dazhang filtration equipment Equipment Vendor Dazhang filtration equipment
Co., Ltd Co., Ltd
Operation Data Operation Data
Filter area 200 m2 Filter area 200 m2
Plate size 1250 x 1250 mm Plate size 1250 x 1250 mm
Cake thickness <40 mm Cake thickness <40 mm
Production capacity 3847 L Production capacity 3847 L
Number plate 73 Number plate 73
Working pressure 5.84 bar Working pressure 5.84 bar
Particle size 0.1-10 mm Particle size 15-600 microns
Construction Data Construction Data
Overall dimension 9980 mm x 2200 mm x 1900 Overall dimension 9980 mm x 2200 mm x 1900
mm mm
Power 7.5 kW Power 7.5 kW
Voltage 380 V Voltage 380 V
 Equipment Identification
Equipment Name Alcohol Precipitation Tank
Equipment Number PR-101
Number of unit 1
6. Alcohol
Function For precipitation process
Precipitation Mode of Operation Batch
Tank Type
Cylindrical tank with ellipsoidal
top and bottom
Material Stainless Steel 304
The carrageenan solution which has
Material Composition (%)
been through the filtration process
(filtrate) is then will be precipitated with KOH 0.474
isopropanol (IPA). Proteins 0.0167
Water 92.99
Carbohydrate 0.412
Fats 0.032
Sodium 0.0027
Potassium 0.0184
Potassium Sulfate 0.0021
Kappa Carrageenan 4.81
IPA 0.018
 Operating Condition Stirrer Design
Capacity 20247 kg/batch Agigator type Propeller with 6 leafs
Pressure 10 atm Stirrer Diameter 0.82 m
Temperature 25oC Width of leaf stirrer 0,16 m
Design Specification Distance to bottom 0,82
Tank Volume 23.27 L Baffle Diameter 0.20 m
Safety factor 20% Utilities
Height of Fluid 5.53 m Motor Power 0.0277 kWh
Pressure design 1,84 atm
Tank Diameter 2.46 m
Tank Height 6.14 m
Cylinder Height 4.91m
Type of head Ellipsoidal
Head Height 0.32 m
Wall Thickeness 3.30 mm
Head Thickeness 3.29 mm
 Equipment Specification
Equipment Name Tray Dryer
Equipment Code D-101
Quantity 1
Equipment Type Dehydrator
Equipment Vendor Guangdong IKE Industrial Co.,Ltd
Operation Data
Power supply 380V~3N / 50hz / 60hz
7. Tray Dryer Power input 17.0 kW
Running Current 30.0 A
Tray dryier used to drying carried Fast heating-up 6.0 kW
out after pure carrageenan is Maximum Power 24.0 kW
obtained from the previous Dehydration
45.0 kg/h
process. amount
Working
50~80 Degrees Celsius
temperature
Capacity 1000~1500kg/batch
Noise level ≤75db (A)
Operation Data
Wind volume 23500 m³/h
Construction Data
Overall Dimension 4000 mm x 2100 mm x 2100 mm
MAIN
PROCESS Equipment Specification
Equipment Name Miller
EQUIPMENT Equipment Code HG-101
Function Reduce the size of cake to
fulfill the next process
requirement
Quantity 1
8. Miller Equipment Type Hammer Mills
Equipment Vendor Yantai Lingyu Powder
The table belows shows the specifications of the Machinery, Alibaba
hammer mill used to homogenize the particle size of Operation Data
carrageenan solids to form powder. Flow Rate Input 1000 kg/h
Flow Rate Output 1000 kg/h
Pressure 101.325 kPa
Maximum feed size <100 mm
Output size range 0.177 mm
Construction Data
Overall Dimension 1100 mm x 3500 mm x
3500 mm
Motor Power 37 kW
MAIN Equipment Specification
PROCESS Equipment Name Powder Packing Machine
Equipment Code F-101
EQUIPMENT Function Fill the carrageenan powder
into papper bag
Quantity 1
Equipment Type Filling Machine
9. Filling Machine Equipment Vendor Zhengzhou DynNor
Industrial Machinery,
Alibaba
The table belows shows the specifications of the filling
Operation Data
machine used to fill the carrageenan powder into alumunium
Packaging Type Paper Bag with Alumunium
sack with 25 kg size.
foil in the inside
Packing weight 25 kg
Packing accuracy ±0.2%
Maximum feed size <100 mm
Air Consumption 0.6 m3/h
Construction Data
Overall Dimension 1000 mm x 800 mm x 2600
mm
Motor Power 3 kW
10. Storage
1. Seaweed Storage Warehouse

2. KOH Storage Warehouse

3. Refined Carrageenan Storage Warehouse

4. IPA Storage Tank

5. Silo Storage Tank

 Seaweed Storage
Warehouse
Warehouse Specification
Equipment Code WR-101
Seaweed used as raw material is
chopped dried seaweed that is Temperature 25oC
supplied from farmers and Humidity 55%
supplier. Seaweed that will be
used as raw material is stored in Mass of material storaged 168,000 kg
a well ventilated warehouse with
Safety factor 15%
the following sizes and
specifications: Capacity 503.25 m3
Warehouse Dimension
Length 9.90 m
Width 8.73 m
Height 5.82 m
KOH Storage Warehouse
Warehouse Specification
KOH pellets that uses to make Equipment Code WR-102
KOH 0,2 M solution is supplied
Temperature 25oC
from the supplier. Before the
KOH pellets used to make KOH Humidity 40%
0,2 M solution, KOH pellets are
Mass of material storaged 12,120 kg
stored in a cool, dry, well-
ventilated area away from Safety factor 15%
incompatible substance (strong Capacity 13.94 m3
acids, water, and metal)
warehouse with the following Warehouse Dimension
size and specification: Length 2.99 m
Width 2.64 m
Height 1.76 m
 Refined Carrageenan Storage
Warehouse
Warehouse Specification

The carrageenan produced is Equipment Code WR-103

packed in aluminum sacks with Temperature 25oC
amount of 25 kg/sack. The
Humidity 55%
carrageenan produced is
distributed by the distributor to Capacity 41.12 m3
be sold to the market every 15
days, before the carrageenan is Mass of material storaged 31,500 kg
distributed, the carrageenan is Safety factor 15%
stored in a well ventilated Warehouse Dimension
warehouse with the following Length 4.29 m
size and specifications.
Width 3.79 m
Height 2.53 m
 Equipment Identification
Equipment Name IPA Storage Tank
Equipment Code WR-103
Number of Unit 1
Store IPA anhydrous IPA Storage Tank
Function that will be used in
the process
Mode of Operation Batch IPA storage tank is used to
Cylindrical tank with store isopropyl alcohol
Type ellipsoidal head and anhydrous from the distributor
that will be used in
flat bottom
carrageenan production
Carbon Steel A285
Material process. The detail
Grade A
specification of IPA storage
Retention time 2 week tank that we use is shown in
Material Composition the table.
Isopropyl Alcohol 100%
Operating Condition
Capacity 9800 kg/batch
Pressure 1,01 atm
Temperature 25oC
 IPA Storage Tank
Design Specification
Tank Volume 12493,13 L
Safety factor 20%
IPA storage tank is used to
Height of Fluid 4,20 mstore isopropyl alcohol
Pressure design 1,20 atm
anhydrous from the distributor
Tank Diameter 1,94 mthat will be used in
Tank Height 4,21 mcarrageenan production
Cylinder Height 3,89 mprocess. The detail
Type of head Ellipsoidal
specification of IPA storage
Head Height 0,32 mtank that we use is shown in
Wall Thickeness the table.
31,56 mm
Head Thickeness 32,87 mm
MAIN
PROCESS
Silo Storage Tank
EQUIPMENT
Specification of the Equipment
This section explains the size and specifications for silo tank
Name Silo Storage Tank used as temporary shelters resulting from refining
Code ST-101 carrageenan into powder before being packed.
Storage tank for stores
Function carrageenan powder for Construction Data
distribution to filler Capacity 1418,367 L
Amount 1 Diameter of tank 0,941 m
Operation Batch Height of cylinder 1,882 m
Type Silo Thickness of cylinder 0,012 m
Material Stainless Steel 116 Head Type Ellipsoidal
Operation Data Height of head 0,157 m
Mass flow rate 1,062 kg/batch Head thickness 0,011 m
Mixture Density 0.881015 kg/m3 Total height of tank 2,039 m
Temperature 25oC Height of liquid in 1,733 m
Working volume 85% tank
Pressure design 2,877 atm
11. PUMP
•Adjust pressure drop from
Total 7 inlet and oultet area of liquid
Type & Function Pump streams which will be
transported

• For liquid flow, assume

pipeline pressure drop of 2
Heuristi psi/100 ft of pipe and a control
valve pressure drop of at least
c 38 10 psi. For each 10-ft rise in
elevation, assume pressure
drop of 4 psi.
 Pump 1 Pump 2 Pump 3
Pump Identification Pump Identification Pump Identification
Treated water for Seaweed Washer
Name Name Name IPA Mixing Pump
KOH Mixing Pump Pump
Code P-101 Code P-102 Code P-103
to help water flow to to help water flow to to help liquid flow to
Function Function Function
KOH Mixing tank belt washer IPA Mixing tank
Pump Identification Amount (unit) 1 Amount (unit) 1
Amount (unit) 1 Operating Condition Operating Condition
Operating Condition Flow rate 1404 Flow rate 61,20
Flow rate 3197 (kg/h) (kg/h)
(kg/h) Density 997,05 Density 786
Density 997,05 (kg/m3) (kg/m3)
(kg/m3) Temperature 25 Temperature 25
Temperature 25 (°C) (°C)
(°C) Efficiency 75% Efficiency 75%
Efficiency 75% ∆Pressure 1,03 ∆Pressure 1,03
∆Pressure 1,03 (Bar) (Bar)
(Bar) Specification Design Specification Design
Specification Design Type Centrifugal Type Centrifugal
Type Centrifugal Material Carbon steel Material Carbon steel
Material Carbon steel NPSH (m) 8,666 NPSH (m) 10,699
 Pump 4 Pump 5 Pump 6
Pump Identification Pump Identification Pump Identification
IPA Mixing Water IPA Pump for
Name Name IPA Mixing Pump Name
Pump Alkaline Extraction
Code P-104 Code P-105 Code P-106
to help water flow to to help liquid flow to help liquid flow to
Function Function
IPA mixing tank through flow splitter Function Alkaline Extraction
Amount (unit) 1 Amount (unit) 1 Tank
Operating Condition Operating Condition Amount (unit) 1
Flow rate 3,6 Flow rate 6,48 Operating Condition
(kg/h) (kg/h) Flow rate 32,4
Density 997,05 Density 796,5527656 (kg/h)
(kg/m3) (kg/m3) Density 796,55
Temperature 25 Temperature 25 (kg/m3)
(°C) (°C) Temperature 25
Efficiency 75% Efficiency 75% (°C)
Efficiency 75%
∆Pressure 1,03 ∆Pressure 1,03 ∆Pressure 1,03
(Bar) (Bar) (Bar)
Specification Design Specification Design Specification Design
Type Centrifugal Type Centrifugal Type Centrifugal
Material Carbon steel Material Carbon steel Material Carbon steel
NPSH (m) 8,666 NPSH (m) 12,296 NPSH (m) 12,006
 Pump 7
Pump Identification
Name IPA Pump for PFF
Code P-107
to help liquid flow to
Function
PFF
Amount (unit) 1
Operating Condition
Flow rate 32,4
(kg/h)
Density 796,55
(kg/m3)
Temperature 25
(°C)
Efficiency 75%

∆Pressure 1,03
(Bar)
Specification Design
Type Centrifugal
Material Carbon steel
NPSH (m) 12,006
 Equipment Specification
12. Cooler Equipment Name Cooler 1
Equipment Code C-101
Number of Unit 1
To cool down the stream after alkaline extraction
Function process before entering the coarse filtration
process
Mode of Operation Continuous
Approximation
20 year
Age
Material Stainless Steel 316
Operating Condition
Data Shell Side Tube Side
Type of Fluid Chilled Water Hot Mixture
Fluid Stream Cold Fluid Hot Fluid
Fluid Flow 6432 kg/h 4035 kg/h
Temperature in 5°C 80°C
Temperature out 10°C 25°C
Operating pressure 101 kPa 1200.165 kPa
No. of passes 1 4
Fouling factor 2
0.002 m °C/W 0.002 m2 °C/W
 Operating Condition
Heat Duty 64 kW
LMTD 40°C
Overall U 178 W/m2°C
Dimension
Type of Unit Fixed Tube
Heat Transfer Area 9.072 m2
Tube OD 19.050 mm
Tube Length 4.880 m
Shell ID 0.540 m
Tube Pitch 24 mm
Tube Thickness 0.710 mm
Number of tubes 8
Tube Arrangement Triangular
 Equipment Specification
Equipment Name Cooler 2
Equipment Code C-102
Number of Unit 1
To cool down the stream after tray drying process
Function
before entering the milling process
Mode of Operation Continuous
Approximation
20 year
Age
Material Stainless Steel 316
Operating Condition
Data Shell Side Tube Side
Type of Fluid Chilled Water Hot Mixture
Fluid Stream Cold Fluid Hot Fluid
Fluid Flow 1075 kg/h 190 kg/h
Temperature in 5°C 60°C
Temperature out 10°C 25°C
Operating pressure 101 kPa 401.325 kPa
No. of passes 1 2
Fouling factor 0.002 m2 °C/W 0.002 m2 °C/W
 Operating Condition
Heat Duty 12 kW
LMTD 38°C
Overall U 120 W/m2°C
Dimension
Type of Unit Fixed Tube
Heat Transfer Area 0.237 m2
Tube OD 19.05 mm
Tube Length 1.12 m
Shell ID 0.54 m
Tube Pitch 24 mm
Tube Thickness 0.71 mm
Number of tubes 2
Tube Arrangement Triangular
 Equipment Specification
13. IPA Condenser
Equipment Name IPA Condenser
Equipment Code X-101
Number of Unit 1
To condense evaporated IPA from tray drying
Function
process
Mode of Operation Continuous
Approximation
20 year
Age
Material Stainless Steel 316
Operating Condition
Data Shell Side Tube Side
Type of Fluid Cooled Water IPA Off Gases
Fluid Stream Cold Fluid Hot Fluid
Fluid Flow 1432 kg/h 137 kg/h
Temperature in 4°C 100°C
Temperature out 14°C 35°C
Operating pressure 101 kPa 401.325 kPa
No. of passes 1 6
Fouling factor 0.00009 m2 °C/W 0.00009 m2 °C/W
 Operating Condition
Heat Duty 34 kW
LMTD 53°C
Overall U 37 W/m2°C
Dimension
Type of Unit Fixed Tube
Heat Transfer Area 17.180 m2
Tube OD 19.050 mm
Tube Length 4.880 m
Shell ID 0.540 m
Tube Pitch 24 mm
Tube Thickness 0.710 mm
Number of tubes 10
Tube Arrangement Triangular
UTILITY
EQUIPMENT

02
 Equpment Specification Sand Filter Tank
Equpment
Sand Filter Tank
Name
Sand filter is used in water treatment to remove solid and
Equpment
V-101 biomass that contained in sea water feed. Sizing and
Number specifications of the sand filter tank used in sea water
Remove solid in seawater treatment section of the plant is explained in the table.
Function
feed
Material Carbon Steel SA285
Type Shallow Sand Filter
Filter Media Quartz sand
Operation Data
Temperature 25oC
Pressure 700 kPa
Filter Area 9,2 kg/m2
Capacity 15000 L/h
Construction Data
Inlet 50,8 mm
Outlet 50,8 mm
Filter Diameter 1240 mm
Height 2725 mm
 Equipment Identification
Equipment Name GAC Adsorption
Equipment Code GA-101
Number of unit 1
GAC Adsorption Function
To remove contaminants
include taste and
odor compounds
Tank Mode of Operation Batch
Carbon Steel A285
This section explains the specifications of Material Grade A
Reverse Osmosis Filter of production of Retention time 2 week
carrageenan. Material Composition
Granular Activated
≤ 2 nm micropore ≥90%
Carbon
Operating Condition
Surface Area 800 m2/g
Pressure 3,94 atm
Temperature 25oC
 Equipment Specification
Equipment Name Reverse Osmosis Filter
Equipment Code R-101
Function To remove dissolved solids
and impurities from water
Amount 4 Membranes
Operation Semi-Batch
REVERSE Type Semi-permeable RO
membrane
OSMOSIS Material Handled
Equipment
Water
Polymeric spiral semi-
permeable filter membrane
This section explains the specifications of Equipment vendor QT Enviro –Tech (Suzhou)
Reverse Osmosis Filter of production of Ltd., Alibaba
carrageenan. Operation Data
Mass Flow Rate 298.888 kg/h
Dimension Material Density 997.542 kg/m3
Capacity 2.3 m3/h Mixture Dynamic 0.89 cP
Length 6.096 m Viscosity
Widht 1.250 m Temperature 25oC
Height 1.750 m Pressure 4.95 atm
Reverse Osmosis Filter

Figure 2.1. Design for Reverse Osmosis Filter

(Source: Alibaba, 2019)
 Equipment Identification
Equipment Name Treated Water Storage Tank
Equipment Code
Number of unit
V-102
1
Treated Water
Function
To store water that has been
treated for main process
Storage Tank
Equipment Identification
Design Specification
Mode of Operation Batch
Cylindrical tank with ellipsoidal
Tank Volume 110.77 m3
Type Tank Diameter 4.02 m
head and flat bottom
Material Carbon Steel A285 Tank Height 8.71 m
Material Composition Cylinder Height 8.04 m
Water 100% Ellipsoidal Height 0.67 m
Operating Condition Wall Thickeness 141.81 mm
Mass Flow Rate 96.32 kg/h Head Thickeness 53.86 mm
Pressure 4.95 atm
Temperature 26.5oC
Mixture Density 996.653 kg/m3
Mixture Dynamic
0.859 cP
Viscosity
Allowance Factor 15%
MAIN
PROCESS Specification
EQUIPMENT Flow 3 m3/h

Cooling Tower Fan Diameter 300 mm

Theoretical wind 2200 m3/h
Cooling tower used to reduce water Inlet temperature 26.5oC
temperature from condenser by direct Specification
contact with air by convection using a fan. Outlet temperature 23oc
Motor Power kW 0.18
Dimension
Height 1200 mm
Max outer 650 mm
Voltage 220 V
Design pressure 0.6 Mpa
Power 1.5 kW
MAIN
PROCESS
EQUIPMENT Specification

Chiller Delta T 142.2oC

196.267 kg/h
Flowrate
Chiller in this process used to reduce the 0.86357 gmp
temperature of the water for water utility.
With used chiller sizing application, Energy 12430.5BTU/H
sizing of chiller that used is shown in
the table
Capacity 1.03588 tons

Ideal capacity 1.243 tons

MAIN
PROCESS
EQUIPMENT Specification
1250 x 3694 x
Chiller Dimension
1976 mm
R704C
Refrigeran
Chiller in this process used to reduce the R410A
temperature of the water for water utility.
With used chiller sizing application, Fan Heavy duty fan
sizing of chiller that used is shown in
the table
Capacity 105-1700 kg

Cooling capability 10-180 kw

MAIN
PROCESS 1
2
Standard example: QFiredHeater7
Box firebox, horizontal wall tubes + roof tubes. Process fluid: Bjac hydrocarbon

EQUIPMENT 3
4
Service of Unit:
Total absorbed duty
Our Reference:
kW 4596.9
5 PROCESS DESIGN
CONDITIONS
Steam 6 Heater section Firebox Bank 1 Bank 2 Bank 3 Bank 4

7 Heat absorption kW 4596.9

Generator 8 Fluid 1
9 Flow rate kg/h 29856
Boiler 10 Pressure drop, allowable kPa 2990

11 Pressure drop, calculated kPa 0

To know steam generator boiler 12 Avg. rad. sect. flux density, calc. kW/m² 6.9

specifications, the application 13 Max. rad. sect. flux density kW/m² 10.9
used is Hysis simulation. 14 Conv. sect. flux density (bare kW/m²
tube)
15 Process fluid mass velocity kg/s/m² 37.08

16 Max. calc. inside film temperature °C 166

17 Fouling factor (tube-side) m²-K/W 0

MAIN
18 INLET CONDITIONS:
PROCESS
19 Temperature °C 25

EQUIPMENT
20 Pressure kPa 3000

21 Vapor mass fraction - 0

22 Liquid flow kg/h 29856

23 Vapor flow kg/h 0

24 Liquid density kg/m³ 1008.2

25 Vapor density kg/m³

26 Liquid viscosity cp 0.8904

27 Vapor viscosity cp

28 Liquid specific heat kJ/(kg-K) 4.31

29 Vapor specific heat kJ/(kg-K)

30 Liquid thermal conductivity W/(m-K) 0.611

31 Vapor thermal conductivity W/(m-K)

MAIN
PROCESS
32 OUTLET CONDITIONS:

EQUIPMENT
33 Temperature °C 152

34 Pressure kPa 3000

35 Vapor mass fraction - 1

36 Liquid flow kg/h 0

37 Vapor flow kg/h 29856

38 Liquid density kg/m³ 0

39 Vapor density kg/m³ 905.59

40 Liquid viscosity cp 0

41 Vapor viscosity cp 0.0164

42 Liquid specific heat kJ/(kg-K) 0

43 Vapor specific heat kJ/(kg-K) 4.517

44 Liquid thermal conductivity W/(m-K) 0

45 Vapor thermal conductivity W/(m-K) 0.7008

MAIN
PROCESS
EQUIPMENT COMBUSTION DESIGN
CONDITIONS
1 Type of fuel Fuel Mix Fuel 1 Fuel 2 Fuel 3 Fuel 4
2 Fuel flowrate kg/h 355 355
3 Excess air, % 5
4 Calculated heat release (LHV) kW 4929.6
5 Calculated fuel efficiency (LHV), % 93.252
25
6 Flue gas temp leaving: Radiant °C 171
sect.
7 : Convection °C 171
8 : Air °C
preheater
9 Flue gas quantity (wet) kg/h 6126
10 Flue gas mass vel. (bank1- kg/s/m
bank5) ²
11 Flue gas mass vel. (bank6- kg/s/m
bank9) ²
12 Draft at arch Pa -80.1
13 Draft at burners Pa -172.3
14 Ambient air temp. (efficiency °C 20
calc.)
15 Ambient air temp. (stack design) °C 20
MAIN
PROCESS
16 FUEL CHARACTERISTICS:

EQUIPMENT
17 Type of fuel Fuel Mix Fuel 1 Fuel 2 Fuel 3 Fuel 4

18 Fuel lower calorific value (LHV) kJ/kg 50034.8 50034.8

19 Temperature @ burner °C 25

20 Composition (mass fraction)

21 Carbon - 0.7487 0.7487

22 Hydrogen - 0.2513 0.2513

23 Oxygen - 0 0

24 Nitrogen - 0 0

25 Sulphur - 0 0

26 Ash - 0 0

27 BURNER DATA:
28 Type natural draught, low NOX (API 560) Number 1

29 Heat release per burner kW 4929 Location bottom

.6
MAIN
PROCESS MECHANICAL DESIGN
CONDITIONS

EQUIPMENT
1 Heater section Firebox Bank
1
Bank
2
Bank
3
Bank
4
2 COIL DESIGN:
3 Max. calc. film temperature °C 166
4 Max. calc. tube metal °C 170
temperature
5 COIL ARRANGEMENT:
6 Tube orientation Horizontal
7 Tube material User
specified
8 Tube outside diameter mm 168.28
9 Tube wall thickness mm 7.11
10 Number of parallel flow streams 12

11 Number of tubes 84

12 Number of rows of tubes (conv.

sect.)
13 Number of tubes per path per row
(conv. sect.)
14 Effective tube length mm 15000

15 Bare tubes: Number 84

16 Total exposed surface m² 666.1

17 Extended surface tubes:

Number
18 Total exposed surface m²

19 Tube layout

20 Tube spacing (cent. to cen. mm 304.8

same row)
21 DESCRIPTION OF EXTENDED SURFACE:
22 Type
23 Material

24 Dimensions: Height mm

25 Thickness mm

26 Stud width mm

27 Spacing (fin frequency) #/m

28 Maximum tip temperature °C

(calculated)
29 Extension ratio (total area -
/ bare area)
 Equipment Specifications
Equipment Name Water Pump
Equipment Code P-101
Function Transporting water from

PUMP Sea to Granular Media

Filter Tank

This section explains the sizing and Type Centrifugal pumps

specifications for pumps used in the Operation Data
utility of production of carrageenan. Temperature 25℃
Density 997.542 kgΤm3
Pressure Inlet 101300 Pa
Pressure Outlet 401300 Pa
Flow Rate 0.00008667 m3 Τs
Efficiency 75%
Design Specification
Power 0,034 kW
 Equipment Specifications
Equipment Name Water Pump
Equipment Code P-102
Function Transporting water
3. PUMP (Cont.) from GAC Adsorption
to Reverse Osmosis
This section explains the sizing
Type Centrifugal pumps
and specifications for pumps used
in the utility of production of Operation Data
carrageenan. Temperature 25℃
Density 997.542 kgΤm3
Pressure Inlet 401300 Pa
Pressure Outlet 501300 Pa
Flow Rate 0.00008605 m3 Τs
Efficiency 75%
Design Specification
Power 0,012 kW
 Equipment Specifications
Equipment Name Water Pump
Equipment Code P-103
Function Transporting water from
3. PUMP (Cont.) Treated Water Tank to
Steam Generation
This section explains the sizing
Type Centrifugal pumps
and specifications for pumps used
in the utility of production of Operation Data
carrageenan. Temperature 25℃
Density 997.542 kgΤm3
Pressure Inlet 1001800 Pa
Pressure Outlet 1101800 Pa
Flow Rate 0.001395861 m3 Τs
Efficiency 75%
Design Specification
Power 0,192 kW
Type & Function

COMPRESSOR
Compressor •Filtering substances from carrageenan
solution
1
Compressor • Make sure the carrageenan solution
is free of fine gelatinous particles.
2

Adjust pressure drop from inlet and

oultet area of gas streams which will be
transported
 Compressor 1 Compressor 2
Compressor Identification Compressor Identification
Name Air Compressor 1 Name Air Compressor
Code C-101 Code C-102
Compress air for dry air Compress air for steam
Function Function generator to leaching
supply to tray dryer
Type Single-stage Reciprocal tank
Type Single-stage Centrifugal
Amount 1 unit
Amount 1 unit
Operating Condition
Operating Condition
Flow rate 12.5 kg/h
Flow rate 437.03 kg/h
Density 1.31 kg/m3
Density 1.31 kg/m3
Temperature 30°C Temperature 40°C
Pressure 100 kPa Pressure 110 bar
Specification Design Specification Design
Material Carbon Steel A285 Material Carbon Steel A285
Power Consumed 2.13 Kw Power Consumed 134.24 kW
Head 18144.6 m Head 18144.6 m
 Equipment Specification
Air Filter Equipment Name
Equipment Code
Air Filter
PI-101
Function To filter the air from dust and
This equipment is needed to filter the air impurity
from dust and impurities for producing hot Operation Mode Continuous
air (tray drying process) Type Pleated Panel Filter - Lattice
Filter Material Metal Facia Cap Scrap
Operation Data
Volumetric Rate 4.15 m3/h
Temperature 40oC
Pressure 5.93 atm
Filter Size Dimension
Widht 0.61 m
Height 0.61 m
Depth 0.03 m
 Equipment Data
Dust Particle 0.01-200 microns
Minimum Gross Media Area 0.55 m2
Air Flow Capacity 2000 m3/h
Filter Face Air Velocity 295 fpm
Maximum Initial Resistance 0.008 psi
Minimum Rated Final
0.036 psi
Resistance
Minimum Efficiency MERV 8:
Reporting Value (MERV) Efficiency 70-85%
(Source: Ashrae, 2017)

Figure 2.2. Design for Air Filter

(Source: Ashrae, 2017)
 Equipment Specification
Air Dryer Unit Equipment Name Air Dryer Unit
Equipment Code D-101
This equipment is needed to filterFunction
the air To dry the filtered air
Operation
from dust and impurities for producing hot Mode Continuous
Type Refrigerated Air Dryer
air (tray drying process)
Condenser Material Fin Copper
Operation Data
Volumetric Rate 0.69 m3/min
Temperature 40oC
Pressure 5.94 atm
Filter Size Dimension
Length 630 mm
Widht 450 mm
Height 640 mm
Equipment Data
Brand DENAIR
Type DAD-1HTF
Capacity 1.2 m3/min
Compressor Power 0.85 kW
Fan Power 90 W
Air Inlet/Outlet Pipe Diameter 2.54 cm
 Equipment Data
Maximum Inlet Temperature 60oC
Maximum Ambient Temperature 50oC
Working Pressure 14.80 atm
Refrigerant R410A
Weight 63 kg
(Source: Denair, 2018)

Figure 2.3. Design for Air Dryer Unit

(Source: Denair, 2018)
CONCLUSION

03
CONCLUSION

 The equipment that operating in the main process in the main process are belt conveyor, mixing tank, filter,
tray dryer, miller, and filling machine.
 Main process of carrageenan production need 2 types of Storage, which are solid storage and liquid storage.
Solid storage including seaweed warehouse, KOH warehouse, refined carrageenan silo, and refined
carrageenan finish product warehouse.
 There are two types of belt conveyor that used to transport solid material in the proposed plant which are
washing belt conveyor and elevator conveyor.
 Mixing tanks needed in the plant is 4 which are KOH mixing tank, isopropanol mixing tank for alcohol
precipitation tank, alkaline extraction tank (equipped with a heater jacket), and alcohol precipitation tank.

 The separation vessels required to be designed in our processes are leaching tank, coarse filtration, P&F
filtration, precipitation tank, and tray dryer.
CONCLUSION (2)
 There are 2 types of filter used in the plant which are coarse filtration and plate & frame filtration. The number
of coarse filter used in the plant is 1 and the number of plate & frame filter used in the plant is 2.

 There are 7 pumps and 2 types of heat exchanger that used in the main process. Heat exchanger that used in
main process are cooler and IPA condenser.

 The equipment that operating in the utility process devided into 5 category, which are sea water treatment,
heat exchanger, pump, compressor, and air utility equipment.

 Sea water treatment equpment including sand filter, granulated activated carbon filter, and reverse osmosis
system. sea water that have been treated is stored in the treated water storage tank

 Heat exchanger equipment in utility process including cooling tower, chiller, and steam generator boiler.

 There are 3 pumps and 2 compressor that used in the utility process.

 Air utility equipment including air filter and air dryer.

REFERENCES
 Battacharyya, D., Shaeiwitz, J.A., Turton, R., and Whiting, W.B. 2013. Diagrams for Understanding Chemical
Processes. [ONLINE] Available at: http://www.informit.com/articles/article.aspx?p=1915161&seqNum=3.
[Accessed 29 October 2019].
 B.S., Adesina, 2013. Effect of Milling Machines and Sieve Sizes on Cooked Cassava Flour Quality. Nigerian
Food Journal, 31, 115-119.
 J. A. Wesselingh, Soren Kiil, and Martin E. Vigild. 2007. Design and Development of Biological, Chemical,
Food, and Pharmaceutical Products. John Wiley &amp; Sons, Ltd.
 Liebermann, N.P., and Liebermann, E.T., 2008, A Working Guide to Process Equipment, 3ed, McGraw-Hill,
New York.
 Lin, K. H. 1968. Part 1, Applied Kinetics, Industrial and Engineering Chemistry, Vol. 60, No. 5, pp. 61–82.
 Perry, Robert H. 1999. Perry’s Chemical Engineers’ Handbook. McGraw-Hill Companies, Inc.
 Robin, Smith. Chemical Process Design and Integration. 2nd Edition. Centre of Process Integration,
University of Manchester, UK.
REFERENCES (2)

 Shuler, M.L. dan Kargi, F., 2002, Bioprocess Engineering, 2, Prentice Hall, New Jersey.
 Tarleton, E. S. and Wakeman, R.J., 2007, Solid/Liquid Separation: Equipment Selection and Process Design,
Elsevier Ltd., Burlington, Great Britain.
 Valvias. 2018. Diaphragm Valve. [ONLINE] Available at: http://www.valvias.com/type-diaphragm-
valve.php. [Accessed 3 November 2019].
 Walas, Stanley. 1990. Chemical Process Equipment: Selection and Design. North America: McGraw-Hill.
 Yang, K. H. and Hougen, O. A. 1950. Determination of Mechanism of Catalyzed Gaseous Reactions.
Chemical Engineering Process, p. 146.
APPENDIX

04
PUMP

There are several steps to sizing pump.

• Find out physical properties of the stream which will go into the pump and other information needed in
the calculation (mass flow, pressure inlet, pressure output, vapor pressure, temperature, density, static
head, pipe length after pump).
• By using these formula below, we get the information of Power, Head, and NPSHa of each pump:

•Assumptions:
•No velocity difference due to its small number
•Pump efficiency 75%
STORAGE TANK

1. Volume of Liquid
The volume of liquid that will stored in the storage tank is calculated by using this formula:
𝑘𝑔 𝑏𝑎𝑡𝑐ℎ
𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 × 𝑆𝑡𝑜𝑟𝑎𝑔𝑒 𝑡𝑖𝑚𝑒 𝑑𝑎𝑦 × 𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓
𝑏𝑎𝑡𝑐ℎ 𝑑𝑎𝑦
𝑉𝑙 =
𝑘𝑔
𝜌( 3 )
𝑚
Where the mass flowrate can be generated from simulation data.
𝑉𝑡 = 1 + 𝑠𝑎𝑓𝑒𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 × 𝑉𝑙
2. Volume of Tank
After calculating volume of liquid, The volume tank is calculated by the following equation:
𝑉𝑡 = 1 + 20% × 𝑉𝑙

The safety factor that will be used is assumed as 20 %. Hence the total tank volume is:
STORAGE TANK (Cont.)

3. Tank Dimension
For the tank dimension, the value that has to be specified are Diameter of tank, Height of
tank, and Height of head. To calculate the tank dimension, several assumptions are made
based on the the geometrical shape of the vessel; which assumed to be cylindrical flat
bottom tank with ellipsoidal head. The volume of cylindrical tank can be calculated by this
formula:
1
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 (𝑉𝑠 ) = × 𝜋 × 𝐷2 × 𝐻𝑠
4
Based on the rule of thumb of cylindrical tank, height and diameter ratio should be 2 – 5. So,
the assumption ratio of Hcyl : D used is 2:1, therefore Hcylinder = 2D, and the cylinder volume
modified into:
1
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 (𝑉𝑠 ) = × 𝜋 × 𝐷2 × 2𝐷
4
1
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 (𝑉𝑠 ) = × 𝜋 × 2𝐷3
4
STORAGE TANK (Cont.)

With tank total volume = cylinder volume + ellipsoidal head volume. The volume of the
ellipsoidal head is (ratio Height head : Diameter = 6 : 1):
1
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 ℎ𝑒𝑎𝑑 𝑒𝑙𝑙𝑖𝑝𝑠𝑜𝑖𝑑𝑎𝑙 (𝑉ℎ ) = 𝜋 × 𝐷2 × 𝐻ℎ
4
1 1
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 ℎ𝑒𝑎𝑑 𝑒𝑙𝑙𝑖𝑝𝑠𝑜𝑖𝑑𝑎𝑙 (𝑉ℎ ) = × 𝜋 × 𝐷2 × × 𝐷
4 6
1
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 ℎ𝑒𝑎𝑑 𝑒𝑙𝑙𝑖𝑝𝑠𝑜𝑖𝑑𝑎𝑙 (𝑉ℎ ) = × 𝜋 × 𝐷3
24
Hence, the total tank volume is:
1 1
𝑇𝑜𝑡𝑎𝑙 𝑉𝑜𝑙𝑢𝑚𝑒 (𝑉𝑇 ) = × 𝜋 × 2𝐷3 + × 𝜋 × 𝐷3
4 24
13
𝑇𝑜𝑡𝑎𝑙 𝑉𝑜𝑙𝑢𝑚𝑒 (𝑉𝑇 ) = × 𝜋 × 𝐷3
24
STORAGE TANK (Cont.)

The formula above can be used to calculate the diameter of tank:

3 24 × 𝑉𝑇
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑇𝑎𝑛𝑘 (𝐷𝑇 ) =
13 × 𝜋
For the height of tank, by using the all the assumption about the ratio of diameter tank,
height of tank, and height of head, height of tank can be calculate by using this formula:
𝐶𝑦𝑙𝑖𝑛𝑑𝑒𝑟 𝐻𝑒𝑖𝑔ℎ𝑡 (𝐻𝑠 ) = 2×𝐷
1
𝐻𝑒𝑎𝑑 𝐻𝑒𝑖𝑔ℎ𝑡 (𝐻ℎ ) = ×𝐷
6
𝑇𝑜𝑡𝑎𝑙 𝑇𝑎𝑛𝑘 𝐻𝑒𝑖𝑔ℎ𝑡 (𝐻𝑇 ) = 𝐻𝑠 + 𝐻ℎ
STORAGE TANK (Cont.)

4. Pressure Design
Pressure design is calculated with several steps below:
Calculate height of fluid in tank:
𝐿𝑖𝑞𝑢𝑖𝑑 𝑣𝑜𝑙𝑢𝑚𝑒 𝑖𝑛 𝑡𝑎𝑛𝑘 (𝑉𝑙 ) × 𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑡𝑎𝑛𝑘 (𝐻𝑇 )
𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑓𝑙𝑢𝑖𝑑 𝑖𝑛 𝑡𝑎𝑛𝑘 =
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡𝑎𝑛𝑘 (𝑉𝑇 )
Calculate Hydrostatic Pressure:
With gravity constant is determined to be 9,8 m/s2. Hydrostatic Pressure is calculated by using
the formula below:
𝐻𝑦𝑑𝑟𝑜𝑠𝑡𝑎𝑡𝑖𝑐 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 (𝑃ℎ ) = 𝜌 × 𝑔 × 𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑓𝑙𝑢𝑖𝑑 𝑖𝑛 𝑡𝑎𝑛𝑘
Calculate Pressure Design:
Pressure design are calculated by sum up hydrostatic pressure with operating pressure that
generated from the simulation. With safety factor is 20%; the pressure design is:
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = (100% + 20%)(𝑃𝑎𝑡𝑚 + 𝑃ℎ )
STORAGE TANK (Cont.)

5. Tank Wall and Head Thickeness

Wall and head thickness of reactor tank is influenced by several factors like corrosion factor
(C), maximum allowable stress (S), joint efficiency (E), and equipment age (A). Shell
thickeness and Head thickeness calculated based on type and shape of the shell and head.
The formula for calculate thickeness can be seen on table 18.13 on Walas (1990).
STORAGE TANK (Cont.)

5. Tank Wall and Head Thickeness

Wall and head thickness of reactor tank is influenced by several factors like corrosion factor
(C), maximum allowable stress (S), joint efficiency (E), and equipment age (A). Shell
thickeness and Head thickeness calculated based on type and shape of the shell and head.
The formula for calculate thickeness can be seen on table 18.13 on Walas (1990).
 Warehouse Storage
1. Mass of material storaged
Mass of material that will be storage in the warehouse can be calculated by using this formula
below:
𝑀𝑎𝑠𝑠 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑠𝑡𝑜𝑟𝑎𝑔𝑒𝑑

2. Volume of material storaged

Volume of material storaged can be calculated by devided the mass of material with the bulk
density of material.

𝑀𝑎𝑠𝑠 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 (𝑘𝑔)

𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 =
𝑘𝑔
𝑏𝑢𝑙𝑘 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 ( ൰
𝑚3
 Warehouse Storage
3. Storage Capacity
For safety reason, storage capacity is added 10% from the volume of material storage:
𝑆𝑡𝑜𝑟𝑎𝑔𝑒 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 1 + 20% × 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑠𝑡𝑜𝑟𝑎𝑔𝑒

4. Storage Dimension
Based on warehouse design rule of thumbs (https://www.logisticsbureau.com), building aspect
ratio for warehouse are 1.7 ; 1-2 ; 1. So, in this proposed plant, the bulding aspect ratio used is
1,7 ; 1,5 ; 1. By using this aspect ratio and volume, the actual dimension (Length, Width,
Height) of warehouse can be determined.
Pump Sizing ● There are several steps to sizing pump.
● Find out physical properties of the stream which will go into the pump and
other information needed in the calculation (mass flow, pressure inlet,
pressure output, vapor pressure, temperature, density, static head, pipe
length after pump).
● By using these formula below, we get the information of Power, Head, and
NPSHa of each pump:

● Assumptions:
● No velocity difference due to its small number
● Pump efficiency 75%
Cooler Sizing Determine The Properties of Cold Fluid and Hot
Fluid
Input the initial guess of U (Overall heat transfer
coefficient)
Calculate the LMTD, F, and A value of Heat
exchanger
● ∆𝑇1 = 𝑇1 − 𝑡2
● ∆𝑇2 = 𝑇2 − 𝑡1
∆𝑇1 −∆𝑇2
● ∆𝑇𝐿𝑀𝑇𝐷 = ∆𝑇1
𝑙𝑛 ൗ∆𝑇2
𝑇1 −𝑡2
● 𝑅=
𝑡2 −𝑡1
𝑡2 −𝑡1 𝐴𝑐𝑡𝑢𝑎𝑙 𝐻𝑒𝑎𝑡 𝑇𝑟𝑎𝑛𝑠𝑓𝑒𝑟
● 𝑃= =
𝑇1 −𝑡1 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑃𝑜𝑠𝑠𝑖𝑏𝑙𝑒 𝐻𝑒𝑎𝑡 𝑇𝑟𝑎𝑛𝑠𝑓𝑒𝑟

Correction Factor of Shell & Tube Heat Exchanger

(Source: Holman, 2008) ● The F factor and corrected LMTD are calculated
from the responding correlation graph below for
shell and tubes heat exchanger
Cooler Sizing Calculate The Tube Side Specification from
Determined Outer Diameter (OD), Thickness, And
Internal Diameter (ID)
● 𝐴𝑟𝑒𝑎 𝑝𝑒𝑟 𝑡𝑢𝑏𝑒 = 𝜋 ⋅ 𝑂𝐷 ⋅ 𝑡𝑢𝑏𝑒 𝑙𝑒𝑛𝑔𝑡ℎ
𝐴
● 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 =
𝐴𝑟𝑒𝑎 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠
● 𝑇𝑢𝑏𝑒 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 = 𝜋 ⋅ 0.25 ⋅ 𝐼𝐷2
● 𝐴𝑟𝑒𝑎 𝑝𝑒𝑟 𝑝𝑎𝑠𝑠 = 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 ⋅
𝑇𝑢𝑏𝑒 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎
𝑚𝑎𝑠𝑠
● 𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑙𝑜𝑤 =
𝜌
𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑙𝑜𝑤
● 𝑇𝑢𝑏𝑒 𝑠𝑖𝑑𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 (𝑢𝑡 ) =
𝐴𝑟𝑒𝑎 𝑝𝑒𝑟 𝑝𝑎𝑠𝑠
Constant of 𝐾1 and 𝑛1 of Each Pitch in Shell & Tube Heat Calculate shell side specification.
Exchangers
(Source: Walas, 2004) ● The important aspect top determine the shell side
specification is to define the tube bundle diameter
(𝐷𝑏 ) and finally volumetric flow rate and shell side
velocity. Data below are required to be determined
first. We use triangular pitch with 4 passes.
Cooler Sizing Calculate Shell and Tube Heat Transfer Coefficient
𝐷.𝑣.𝜌
● 𝑅𝑒 =
𝜇
𝑀𝑜𝑚𝑒𝑛𝑡𝑢𝑚 𝐷𝑖𝑓𝑓𝑢𝑠𝑖𝑣𝑖𝑡𝑦 𝐶𝑝 𝜇
● 𝑃𝑟 = =
𝑇ℎ𝑒𝑟𝑚𝑎𝑙 𝐷𝑖𝑓𝑓𝑢𝑠𝑖𝑣𝑖𝑡𝑦 𝑘
● 𝐿/𝐷 = 𝐿𝑡𝑢𝑏𝑒ൗ𝐼𝐷
● 𝑁𝑢 = 𝑗ℎ × 𝑅𝑒 × 𝑃𝑟 0.33
● Value of 𝑗ℎ for tube heat transfer can be determined by
figure on the next slide
𝑘𝑚𝑒𝑎𝑛 𝑐𝑜𝑙𝑑 𝑓𝑙𝑢𝑖𝑑
● ℎ𝑖 = 𝑁𝑢 ×
𝐼𝐷𝑡𝑢𝑏𝑒
𝑘𝑖𝑛𝑙𝑒𝑡 ℎ𝑜𝑡 𝑓𝑙𝑢𝑖𝑑
● ℎ𝑖 = 𝑗ℎ × 𝑅𝑒 × 𝑃𝑟 0.33 ×
𝑒𝑞𝑢𝑖𝑣 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟𝑠ℎ𝑒𝑙𝑙
Fouling Factor of Fluids
(Source: Holman, 2008)
1ൗ Calculate Overall Heat Transfer Coefficient
𝑈
1 𝑂𝐷𝑡𝑢𝑏𝑒 ● Determine the fouling factor of cold fluid (brine water)
= + 𝐹𝑜𝑢𝑙𝑖𝑛𝑔 𝑐𝑜𝑙𝑑 𝑓𝑙𝑢𝑖𝑑 × and hot fluid by table below
ℎ𝑖 𝐼𝐷𝑡𝑢𝑏𝑒
𝑂𝐷𝑡𝑢𝑏𝑒 ● From the table above, we determine the value of F hot
+ 𝑂𝐷𝑡𝑢𝑏𝑒 × 𝑙𝑛
𝐼𝐷𝑡𝑢𝑏𝑒 fluid by 0.00009 and F cold fluid by 0.0002, then
1 followed by U value calculation.
+ + 𝐹𝑜𝑢𝑙𝑖𝑛𝑔 𝐻𝑜𝑡 𝑓𝑙𝑢𝑖𝑑
ℎ𝑠
Cooler Sizing

Value of 𝑗ℎ for tube heat transfer Value of 𝑗ℎ for shell heat transfer
(Source: Walas, 2004) (Source: Walas, 2004)
 ● Define the inlet and outlet operating condition
Compressor ● Calculate the Compressor Head
𝑀𝑊𝑔𝑎𝑠
● 𝑆𝐺 =
𝑀𝑊𝑎𝑖𝑟
● 𝛾 = 1.3 − 0.31 𝑆𝐺 − 0.55
𝛾
𝑇1 𝑍𝛼 𝑅 𝑃2 𝛾−1
● Δℎ = 𝛾−1 −1
𝑀𝑊 𝑃1
𝛾
● Calculate the Compression Power
Conditions Inlet Outlet
𝑛−1 𝛾−1
Flow rate 12.5 kg/h 12.5 kg/h
● =
𝑛 𝛾⋅𝐸𝑝𝑜𝑙𝑦

Temperature 34 C 40 C 𝛾−1
𝑃2 𝛾
−1
𝑃!
1.01 ● 𝐸𝑖𝑠𝑒𝑛 = 𝑛−1
Pressure bar 6.013 bar 𝑃2 𝑛
3 −1
𝑃!

Number of 𝛾−1
1 - 1 - 𝑘𝑊 𝐴 𝛾 𝑃𝑠 𝑃2 𝛾
stage ● = 𝑞 𝑇𝑙 − 1 𝑍𝛼
𝑆𝑡𝑎𝑔𝑒 𝐸 𝛾−1 𝑇𝑠 𝑃1

𝑠𝑡𝑑 𝑚3 / 𝑑 𝑃𝑠 𝑇𝑙
● 𝑞= 𝑍𝛼 𝑚3 /𝑠
86400 𝑃𝑙 𝑇𝑠

𝑞
● 𝑑=
0.050 𝜇
 Define the inlet and outlet operating conditions
Compressor
● Calculate the velocity of inlet wind (u) by using 'goal
seek' function through the power required to value of
2.13 kW (dry air) and 135.24 kW (steam generator)
60 𝜇
● 𝑁=
𝑑𝜋
𝑁 2
● 𝑊𝐿 = 𝐹𝐿
1000
𝛾−1
𝑃2 𝛾
−1
𝑃1
● 𝑇𝐷 = 𝑇𝑙 1 +
𝐸𝑖𝑠𝑒𝑛

𝐴 𝑑 𝐻 0.25
● 𝑑𝑠 =
𝑞 0.5
𝐵 𝑁 𝑞 0.5
● 𝑁𝑠 =
𝐻 0.75
Parameters in Response to Type of Compressor
(Source: Walas, 1988) Determine the type of compressor needed for specific
process.
𝑍(𝑙𝑏/ℎ𝑟)𝑅𝑢 𝑇𝑠
● 𝐼𝐶𝐹𝑀 =
60 ×𝑀𝑊 ×𝑃𝑠
MAIN
PROCESS
EQUIPMENT General sizing formula based on chiller sizing application
Chiller Appendix
1. Calculate Temperature Differential = Incoming Temperatur
(F) – Requaired Chilled water = 28.8 C
2. Calculated BTU/hr. BTU/hr = Gallons per hr x 8.33 x T =
12430.50 BTU/hr
3. Calculate tons of cooling capacity = BTU/hr : 12.000 =
1.0358 tons
4. Oversize the chiller bby 20% ideal size in tons = Tons x 1.2
= 1.2430 tons
5. You have the ideal size for your needs.
MAIN
 Volume of fluid = 20.94 m3
PROCESS
EQUIPMENT  Volume of tank = 1+20% × 20.94 = 23.27 m3

Alcohol Precipitation Tank where 20% is a tank’s allowance factor.

Appendix
 Tank Diameter

so the diameter is written:

3 24 × 23.27
 = 2.46 m
13 ×3.14
MAIN
 Ellipsoidal and Cylindrical Height
PROCESS
EQUIPMENT Based on the previous rule of thumb, the tank height can
be obtained from diameter while from Walas (1990), the
Alcohol Precipitation Tank
Appendix ratio between height and diameter is 1:6 for the head,
hence Hh=1/6D and it is calculated below:

1
hh = × 2.46 m = 0.41 m
6

hs = 2 × 2.46 m = 4.92 m

• Height Tank, total

ht = hs + hh × 2 = 4.91 + 0.41 × 2 = 6.14 m

MAIN
PROCESS
EQUIPMENT • Thickness of Wall and Head
Wall and head thickness of reactor tank is influenced
Alcohol Precipitation Tank
Appendix by several factors like corrosion factor, maximum
allowable stress, joint efficiency, and equipment age.
Tank wall thickness is calculated by using the
equation:
MAIN From the table below with the C is corrosion factor for
PROCESS stainless steel 316 is 0.1 inch/year, allowable working stress
(S) is 20000 lb/inch2, efficiency of connection (E) is 85%,
EQUIPMENT and approximation age of equipment (A) is 20 years.
Alcohol Precipitation Tank
Appendix
MAIN
Stirrer Design
PROCESS
EQUIPMENT
Alcohol Precipitation Tank
Appendix
(Source: Kayode, 1998)

From tank diameter value which is 2.46 m, then the

stirrer design can be found:
Impeller diameter = 2.46 m
Impeller to bottom = 0.82 m
Baffle diameter = 0.20 m
Motor Power = 0.0277795 kW
MAIN To calculate motor power, it needs to calculate

PROCESS the Reynolds number first.

EQUIPMENT
Alcohol Precipitation TankThe Re is 81916,14.
Appendix
By the figure from the number power versus
Reynolds number below, it can be seen the
number power which is 5.

Then the motor power is amounted to 0.0277795 Kw.