Assgn 2 Has+muto+fdel+anto+irvi+rays

THIS IS YOUR
PRESENTATION TITLE
1
MAIN
EQUIPMENT
SIZING
2
Conveyor
3
Belt
Conveyor
Belt Width, Angle & Maximum Capacity of Power Requirement
Conveyor (tonnes/hr) at 100 ft/min
4
Belt
Conveyor
Equipment Specification
Equipment Name Belt Conveyors
Equipment Code B-101, B-102
Type Flat
Design Specification
Inclination Degree 30°
Width (inches) 48
Length (ft) 1000
Power (hp) 7.44
Required Speed (ft/min) 83.33
Recommended Speed (ft/min) 100
Maximum Capacity (tonnes/hr) 300
Material of Belt Rubber
5
Heat Exchanger
6
HTRI (Heat
Transfer Research
Incorporation)
• Input Geometri
heat exchanger type, shell diameter
and orientation, hot and cold fluid
placement in shell and tube, tube
type, tube diameter and wall
thickness, tube pitch and pitch ratio,
number of tube and tube pass, tube
material, baffle spacing and baffle
cut, baffle orientation, etc.
7
HTRI (Heat
Transfer
Research
Incorporation)
• Process Input: Process Data

include fluid phase, flow rate,
inlet and outlet temperature,
inlet pressure, maximum
pressure drop allowed, and
fouling factor.
• Hot and cold fluid property
Input
• Input Design, for sizing used
design mode.
8
HTRI (Heat
Transfer The Fouling Resistance table
Research
Incorporation)
• The heuristics for allowable

pressure drop are 1.5 psi for boiling
and condensing, 3 psi for a gas, 5
psi for a low-viscosity liquid, 7-9 psi
for a high-viscosity liquid, and 20 psi
for a process fluid passing through a
furnace.
9
E-104
TEMA type BEM

Shell diameter 2400 mm
Tube length 4,3 m
Dry weight 77603 kg/shell
Wet weight 124865 kg/shell
Bundle weight 33761 kg/shell
2400
mm
4,3
m
307,087 mm TEMA type BEM

Shell diameter 2400,00 mm
Outer tube limit 2301,68 mm
Height under inlet nozzle 76,050 mm
Height under outlet nozzle 76,050 mm
Tube type Plain
Tube diameter 25,400 mm
Tube pitch 31,750 mm
Tube layout angle 90
Number of tubes (specified) 4029
Number of tubes (calculated) 4029
Number of tie rods 12
Number of seal strip pairs 8
Number of passes 1
Baffle cut % diameter 20
TUBEPASS DETAILS
Pass Rows Tubes Plugged
1 71 4041 0
SYMBOL LEGEND
Tube
Plugged tube
Tie rod
Impingement rod
Dummy tube
Seal rod
Seal strip/Skid bar
258,877 mm
10
E-105
TEMA ty pe BEM
Tube length 4,877 m
1500
mm
4,877
m

Tube type Plain
Number of passes 1
TUBEPASS DETAILS
1 43 1481 0
SYMBOL LEGEND
Tube
Plugged tube
Tie rod
Impingement rod
Dummy tube
Seal rod
Seal strip/Skid bar
258,877 mm
11
E-106
TEMA type BEM

Tube length 4,267 m
1500
mm
4,267
m

Tube type Plain
Number of passes 1
TUBEPASS DETAILS
1 43 1481 0
SYMBOL LEGEND
Tube
Plugged tube
Tie rod
Impingement rod
Dummy tube
Seal rod
Seal strip/Skid bar
258,877 mm
12
E-107
TEMA type BEM

Tube length 3,048 m
1500
mm
3,048
m

Tube type Plain
Number of passes 1
TUBEPASS DETAILS
1 43 1481 0
SYMBOL LEGEND
Tube
Plugged tube
Tie rod
Impingement rod
Dummy tube
Seal rod
Seal strip/Skid bar
258,877 mm
13
E-108
TEMA type BEM

Tube length 2,438 m
600
mm
2,438
m

Tube type Plain
Number of passes 1
TUBEPASS DETAILS
1 10 130 0
SYMBOL LEGEND
Tube
Plugged tube
Tie rod
Impingement rod
Dummy tube
Seal rod
Seal strip/Skid bar
540,000 mm
14
E-201
TEMA type BEM

Tube length 3,048 m
1500
mm
3,048
m

Tube type Plain
Number of passes 1
Perpendicular passlane width 22,225 mm
TUBEPASS DETAILS
1 66 3047 0
SYMBOL LEGEND
Tube
Plugged tube
Tie rod
Impingement rod
Dummy tube
Seal rod
Seal strip/Skid bar
52,5527 mm
15
E-202
TEMA type BEM

Tube length 4,877 m
2000
mm
4,877
m

Tube type Plain
Number of passes 1
Perpendicular passlane width 22,225 mm
TUBEPASS DETAILS
1 90 5645 0
SYMBOL LEGEND
Tube
Plugged tube
Tie rod
Impingement rod
Dummy tube
Seal rod
Seal strip/Skid bar
154,051 mm
16
Aspen EDR
⊡ Determine heat flow, which is exchanged, the mass flow and physical properties of
each fluid passing the heat exchanger. The Aspen Exchanger Design and Rating are
connected to the Aspen Plus Simulator, therefore the physical properties of each
flow are calculated automatically.
⊡ Determine the placement of hot streams entering at the inlet of the exchangers,
which is shell or tube. Based on the heuristics, tube side is for corrosive, fouling,
scaling, and, high pressure fluids. Aspen EDR will automatically calculate the
optimum design for the specified value of shell and tube properties.
⊡ Determine the Allowable Pressure Drop. The heuristics are 1.5 psi for boiling and
condensing, 3 psi for a gas, 5 psi for a low-viscosity liquid, 7-9 psi for a high-
viscosity liquid, and 20 psi for a process fluid passing through a furnace.
17
⊡ Determine the
Fouling Resistance.
18
⊡ Select the Exchanger material construction. Carbon steel are
typically used due to cheap price material. However, Stainless
steel are better at handling corrosive fluids such as H2S and CO2.
Aspen EDR will automatically calculate the optimum design for
the specified value of shell and tube properties.
⊡ Apply those steps for all exchangers, then set the Exchanger
Simulation Option to Rating. Aspen EDR will calculated the
possible errors and warnings. Follow the steps on the manual if
errors and warnings are occurred, make sure the Exchanger
Summary are all feasible.
19
20
21
E-101
22
23
17 in
16 in
24
E-301
25
Equipment Name Heat Exchanger
Type Shell and Tube
Condenser for Distillation Column 1
Operating Condition
Data Shell Side Tube Side
Fluid Flow (kg/h) 24157 10980
Temperature in (oC) 25 120
Temperature out (oC) 70 105
Operating pressure (kPa) 101 130
No. of passes 1 2
Fouling factor (m2 oC/W) 0.00009 0.00009
Heat Duty (MW) 15.276
∆T LMTD ( C)o
62.964
Overall U (W/m2 oC) 4008.802
Type of unit Fixed tube
Material SS-316 atau SA-240
Heat Transfer Area (m2) 341.610
Tube OD (mm) 19.050
Tube Length (m) 4.880
Shell ID (m) 0.540
Tube Pitch (mm) 24
Tube Thickness (mm) 0.710
Number of tubes 585
26
Equipment Code E107
Type Shell and Tube
Condenser for Distillation Column 2
Operating Condition
Fluid Stream Inlet 1 2-2'

Fluid Stream Outlet 2 2
Temperature out ( C) o
70 308
Operating pressure (kPa) 101 130
No. of passes 1 2

∆T LMTD (oC) 261.732
Tube OD (mm) 19.050

Shell ID (m) 0.540
27 Tube Pitch (mm) 24

reboiler for Distillation Column 1 Equipment Code E107
Type Shell and Tube
Operating Condition
Fluid Stream Inlet 1 7

Temperature out (oC) 343 135
Operating pressure (kPa) 150 1317.225
No. of passes 1 2

∆T LMTD (oC) 115.209
Tube OD (mm) 19.050

Shell ID (m) 0.540
Tube Pitch (mm) 24
28
reboiler for Distillation Column 2 Equipment Code E107
Type Shell and Tube
Operating Condition
Fluid Stream Inlet 1 7

Temperature out ( C)
o
404 135
Operating pressure (kPa) 150 1317.225
No. of passes 1 2

∆T LMTD ( C)o
213.816
Tube OD (mm) 19.050

Shell ID (m) 0.540
Tube Pitch (mm) 24
29
Roll Mill
30
Roll Mill
Equipment Name Roll Mill
Equipment Code G-101
Case size (m) 1.5x1
Number of roll 4
Rolls nominal diameter (cm) 32
Length of the roll face (cm) 40
Case material Fabricated steel
Operation Data
Nominal torque/roll (kNm) 20
Roller pressure (MPa) 40
Rolling temperature (oC) 600
Water consumption (l/h) 400
Roll position Horizontal
Rotational speed (rpm) 30
Shaft angle (deg) +/- 12
Roll space (cm) 30
Hydraulic pressure (MPa) 0.6
31
Fluidized Bed
Reactor
32
Fluidized Bed Reactor
33
Fluidized Bed Reactor
Name Gasification Reactor
Equipment Code R-101
Equipment Type Fluidized Bed Reactor
Operating Condition
Temperature (oC) 730
Pressure (atm) 1
Material Stainless Steel SA-240-347H
Feeding Point (m) 0,5
Bed Section Internal Diameter (m) 7,1255

Dynamic Bed Height (m) 1,9533
Freeboard Internal Diameter (m) 7,1255
Freeboard Height (m) 1,3028
Disengaging Zone Diameter (m) 10,6883
Disengaging Zone Height (m) 1,9977
Total Height (m) 5,7538
34
FT Reactor
(Slurry Bed)
35
FISCHER TROPSCH REACTOR
• Calculation Procedure
⊡ Determine hydrogen rate of reaction using Power Law approach as follows. The
rate of reaction can be determined by evaluating hydrogen gas concentration.
⊡ Calculating the mole consumption of hydrogen gas. The mass of hydrogen gas
consumption can be calculated from mass flow difference of hydrogen in input and
output stream of FT reactor.
36
⊡ Calculating volume of catalyst needed and by using cobalt catalyst density data of
850 kg/m3, calculation of catalyst mass can be done.
⊡ By assuming mass fraction of catalyst to catalyst solvent is equal to 0.35,

calculating mass of catalyst solvent and calculating volume of solvent with solvent
density of 700 kg/m3.
37
⊡ The solvent is located outside of the pores of catalyst, thus the actual volume of
solvent must be calculated by substracting pore volume.
⊡ Calculating volume of solvent-catalyst slurry
⊡ By guessing diameter of reactor, calculating the gas volumetric flowrate and

determine gas hold up.
38
⊡ Calculating volume of reactor using this following equation, and

caompare volume obtain by using reactor L/D rule of thumb,
achieving minimum different using Ms. Excel Goalseek by changing
the value of reactor dimeter guess.
⊡ After obtaining value of D and L, calculating actual height by adding

10% height to anticipate leak when bubbling happen.
39
Equipment Name Fischer-Tropsch Reactor
Equipment Code R-301
Function To convert syngas to syncrude
Operating Data
Type Slurry Bed Reactor
Catalyst Co/MgO/SiO2
Pressure (bar) 35
Temperature ( C)
o
220
Catalyst Volume (m )
3
8.13
Catalyst Weight (kg) 4,282
Reactor Volume (m )3
15.10
Construction Data
Material SA-515
Diameter (m) 0.8
Height (m) 8.27
Lcoil (m) 127.73
Ncoil 49
Head Type Torispherical
Head Thickness (mm) 10.85 40
Cyclone
41
Cyclone
Inlet velocities should be in the range 100-150

ft/sec, the higher the better, but may be limited
by the occurrence of reentrainment and
unacceptable pressure drop. Correlated studies
have been made chiefly for the design with a
rectangular inlet whose width is D/4 (one-
fourth of the vessel diameter) and whose height
is 2-3 times the width and Do is DB/3. A key
concept is a critical particle diameter which is
the one that is removed to the extent of 50%.
Figure. Typical dimension ratios of a cyclone separator (figure is scalable)
42
Cyclone
Equation for the critical particle diameter is :
D : diameter of the vessel

V : inlet linear velocity (ft/s)
¿
The quantity N : number of turns made by the gas in the vessel.
A graphical correlation given by Zenz (1982) can be represented by the equation :

𝑁𝑡 = [0.1079 − 0.0077𝑉 + 1.924(10−6)𝑉2]𝑉
a height of opening equal to 2.5 times the width, the volumetric rate is :
2.5 𝐷2 𝑉
𝑄= 𝐴𝑉 =
16
43
Cyclone
The data known are listed below:

• Air volumetric rate = 7528 cuft.s
• Density of air = 0.075 lb/cuft
• Particle density = 99.88 lb/cuft
• Inlet velocity range of 50-150 ft/sec (50 ft/sec)
• Particle size = 140-180 micron (average = 160 micron)
Equation for the critical particle diameter becomes :

𝐷
=¿
𝑁𝑡𝑉
Where N, is given by Equation for volumetric rate. The number of vessel in parallel is :
𝑄
𝑛=
𝐴𝑉
44
Cyclone
Figure. Percent removal of particles in a cyclone as a function of

their diameters relative to the critical diameter
(Source: Walas, 1988)
45
Cyclone
Equipment Name Cyclone
Equipment Code V-101
Function Capture particle from dedusting process
Material Stainless steel 316
Quantity 1
Operation Data
Temperature 730 (°C)
Pressure 1.013 bar
Inlet Velocity 50 ft/sec
Average Particle Size 160 micron
Air volumetric rate 7528 cuft/sec
Particle Density 99.88 lb/cuft
Critical Particle Size 14.72 micron
46
Cyclone
Cylindrical with
Type of Tank
conical bottom
Design Pressure 1.4 bar
Thickness 70 mm
Total Height 7.36 m
Internal Diameter 3.35 m
Height of Conical Part 3.68 m
Solid Outlet Diameter 0.64 m
Gas Outlet Diameter 1.12 m
Rectangular Inlet Width 0.84 m
Height of Rectangular Inlet 2.09 m
47
Compressor
48
Compressor
Compressors are used in the process industries to compress gases and vapors so that both may be used in a
system that requires a higher pressure.
There are several steps to sizing compressor.

1. Determine physical properties of the stream
2. Determine information needed in the calculation (pressure inlet, temperature inlet,
compression ratio, flow rate, molecular weight and tip speed)
3. Determine the type of the compressor, use “general range of application of compressor”
in table
49
Compressor
4. Calculate the specific gravity and

isentropic heat capacity ratio :
5. Calculate the compressor speed :
Figure. Comparative Guidlines to Selection of Compressors
6. Calculate efficiency isentropic 7. Calculate the actual flowrate
( )
𝛾 −1
𝑃2 𝛾 𝑚3
−1 𝑠𝑡𝑑
( )( )
𝑃1 𝑑 𝑃𝑠 𝑇1
𝐸 𝑖𝑠𝑒𝑛 = 𝑞= 𝑍𝑎
( )
𝑃2 𝑛 −1 86400 𝑃 1 𝑇𝑠
𝑛
−1
𝑃1
50
Compressor
8. Calculate compression power (kW/stage) :
( )( ) ( ) [( ) ]
𝛾 −1
𝐴 𝛾 𝑃 𝑃2
𝑘𝑊 = (𝑞 ) 𝑠 ( 𝑇1) 𝛾
−1 ( 𝑍 𝑎 )
𝐸 𝛾−1 𝑇𝑠 𝑃1
9. Calculate diameter of impeller and compressor speed :
11. Calculate Mechanical Losses :
( )
2
𝑁
𝑊 𝐿 =𝐹 𝐿
1000
10. Determine Loss Factor from figure below. 12. Calculate Total Power :
Total Compressor Power
= kW + Mechanical Losses (WL)
51
Compressor
Table. Compressor Specification (C-101) Table. Compressor Specification (C-102)
Equipment Specification Equipment Specification

Equipment Name Compressor Equipment Name Compressor
Equipment Code C-101 Equipment Code C-102
Type Centrifugal Compressor Type Centrifugal Compressor
Material Carbon Steel Material Carbon Steel
Operation Data
Operation Data
Inlet Temperature 373.15 K
Oulet Temperature 538.853 K Inlet Temperature 423.15 K
Inlet Pressure 101.325 kPa Oulet Temperature 600.453 K
Outlet Pressure 300 KPa Inlet Pressure 300 kPa

Discharge Temperature 507.2 K Outlet Pressure 900 KPa
Discharge Temperature 577.3 K
Flow Rate 284920 m3/h
Design Specification Flow Rate 108967 m3/h
Compressor Head 18942.6 m Design Specification
Compression Ratio 2.96 Compressor Head 21771.5 m
Efficiency 0.688 Compression Ratio 3.00
Power 19433.75 kW Efficiency 0.688
Power 15748.48 kW
52
Compressor
Table. Compressor Specification (C-103) Table. Compressor Specification (C-104)
Equipment Specification Equipment Specification

Equipment Name Compressor Equipment Name Compressor
Equipment Code C-103 Equipment Code C-104
Type Centrifugal Compressor Type Centrifugal Compressor
Material Carbon Steel Material Carbon Steel
Operation Data Operation Data
Inlet Temperature 423.15 K Inlet Temperature 473.15 K

Oulet Temperature 600.688 K Oulet Temperature 521.146 K
Inlet Pressure 2700 kPa Inlet Pressure 2700 kPa
Outlet Pressure 3618 KPa Outlet Pressure 3618 KPa

Discharge Temperature 577.3 K Discharge Temperature 514 K
Flow Rate 36094 m3/h Flow Rate 13349 m3/h

Design Specification Design Specification
Compressor Head 21771.5 m Compressor Head (m) 5963 m
Compression Ratio 3.00 Compression Ratio 1.34
Efficiency 0.688 Efficiency 0.712
Power 15716.81 kW Power 4263.93 kW
53
Boiler
54
Boiler
The volume is calculated through the value of qv, from the equation below.
Height (Hfu + Hb) and heat transfer area (Fgrate)
Length and width (a and b)

Boiler
Equipment Name Boiler
Equipment Code E-102
Operating Data
Type of Fuel Diesel
Fuel Consumption (kg/h) 396
LHV (kJ/kg) 47,141
qv (kW/m3) 530
qf (kW/m2) 2,130
qb (kW/m2) 1,400
Construction Data
V (m )
3
9.78
b (m) 1.49
Hb (m) 0.59
Hfu (m) 3.43
a (m) 1.64
α 30
β 45
γ 50
E (m) 0.8
d (m) 0.148
Case Material Stainless Steel, SS-316
Dryer
57
Dryer
Steps for calculating dryer specification:

1. Calculation of heat duty
Output: Amount of air needed
2. Calculation of inside diameter and length
Output: L/D is most efficient between 4 and 10
3. Calculation of RPM, Flight, and Residence time
Output:
- The revolution of a drier varies between 2-5 rpm,
- Residence time of rotary dryer typically ranges at 5-90
minutes (Couper, Penney, Fair, & Walas, 2005)
3. Calculation of shell dryer thickness and outer diameter
4. Calculation of the load
5. Calculation of power
Equipment Name Dryer
Type Rotary
Operation Data
Operating Temperature (℃) 132.2 Dryer Classification Criteria
Drying Capacity (tonnes/hr) 83,333 - Type: direct-heat
Air Required (kg/hr) 335841.05 - Operation: continous
Air Velocity (kg/hr-m2) 25000
- Heating System: steam heated air
- Gas flow in dryer: co-current
Peripheral Speed (m/s) 0.3
RPM 4.3532
Residence time (min) 33.2572
Inclination 5 degrees
Power (kW) 98.2069
Area of Dryer (m2) 13.4336
Diameter inlet (mm) 4135
Diameter outlet (mm) 4159
Length (mm) 18051
Number of Flight 41
Weight (tonnes) 68.5579
Carbon steel (SA 285,
Material
Absorber
60
Absorber
1. Calculating NOG
Partial pressure CO2 Feed = 146.83 kPa
Partial pressure CO2 out = 2.58 kPa
With mGm/Lm = 0.7, NOG from the figure is 10.
61
Absorber
2. Calculate Column Diameter
mL = mass flowrate liquid = 55,160 lbm/hr = 15.32 lbm/s
mg = mass flowrate gas = 9,518 lbm/hr = 3.47 lbm/s
ρl = mass density liquid = 66.59 lbm/ft3
ρg = mass density gas = 3.6 lbm/ft3

μ = 2.754 cp = 2.588 centistokes
62
Absorber
4. Calculating Column Thickness

3. Calculating Column Height
P design = 3850 kPa = 558.4 psia
T design = 141.8 oF
Packing Size HETP

2.54 cm [1 in.] 0.46 m [18 in]
3.81 cm [1.5 in.] 0.66 m [26 in]
Double welded butt joint efficiency 90%.
5.08 cm [2 in.] 0.89 m [1 in.]

Absorber
Equipment Name Boiler
Operating Data
Type of Fuel Diesel
Fuel Consumption (kg/h) 396
LHV (kJ/kg) 47,141
qv (kW/m3) 530
qf (kW/m2) 2,130
qb (kW/m2) 1,400
Construction Data
V (m3) 9.78
b (m) 1.49
Hb (m) 0.59
Hfu (m) 3.43
a (m) 1.64
α 30
β 45
γ 50
E (m) 0.8
d (m) 0.148
Case Material Stainless Steel, SS-316
64
Mixer
65
Mixer
Equipment Name Mixer
Equipment Code M-201
Type Mixing Tank without Impeller
Operating and Dimension Data
Flowrate (m3/s) Stream MDEA 7.53
Stream from HE 98.76
Density (kg/m3) Stream MDEA 1047.21
Stream from HE 1046.81
Residence Time (s) 5
Volume (m )3
0.18
L/D 1.5
Diameter (m) 0.50
Height (m) 0.75
Material and Thickness
Material Carbon Steel SA-516
Pressure (psi) 507.63
Allowable Stress (psi) 20000
Head Top Flat
Bottom Hemispherical
Thickness (mm) Shell 10.62
Head 6.72
66
Pump
67
Pump
Assumptions:
• =75%
By using these formulas below, the
• The terms of velocity difference
information of Power, Head, and NPSHa
neglected due to its small number
of each pump can be obtained.
• No fitting
The pump power requirement can be
calculated by equation below.
where 𝑚 is mass flow, g is gravity

acceleration, and H is head.
The or BHP (brake horse power) is
68
PUMP
Name P-201
Name P-201 ṁ 217.21 kg/s
P in 260,000.00 Pa Flow 0.21 m3/s
P out 3,600,000.00 Pa η 0.75
ΔP 3,340,000.00 Pa W theo 697,846.56 Watt
Δh - m W act 930,462.08 Watt
ρ 1,040.00 kg/m3 Head 327.84 m
g 9.80 m/s2 Type Centrifugal
L pipe 3.00 m P atm 101,325 Pa
F 1.31 m2/s2 P vap 58,870 Pa
NPSHa 4.03 m
69
Regenerator
Column
70
Regenerator
Column
Regenerator Column
Identification Item Regenerator Column ⊡ Regenerator is used to
Item No R-202
capture acid gas that
Function To regenerate a-MDEA from absorber
Operation Continous
contaminate the
Design Data absorbent. Absorbent that
Type Packed Column is regenerated is a
Tower Material Stainless Steel
Packing type Rasching ring packing
mixture of amine, namely
Inside diameter 0.0975 m MDEA
Cross-sectional Area 0.0074 m2 (Methyldiethanolamine).
Column height 2.8415 m
Column Thickness 5,08 cm
Max flooding 70 %
Temperature 86,59 C
o
Pressure 205 kPa
71
Regenerator
Column
⊡ Solvent mass flowrate (L) = 391 58 kg/h = 863.285lb/h

⊡ Density =1,007.22 kg/m3 = 62.878 lb/ft3
⊡ Viscosity = 3.577 cP = 0.00357 kg/m.s
⊡ Gas flowrate (Gy) = 42.76 kg/h = 94.27 lb/h
⊡ Gas density = = 1.77 kg/m3= 0.1105 lb/ft3
⊡ Determining packing type
⊡ Packing will be used is rasching ring packing with specificatio:
⊡ Naminal size = 1.5 𝜀 = 0.76 Fp = 52
⊡ ΔP = 0.115 – Fp0.7 = 0.115 – 520.7 = 1.83 in. H2O/packing
72
Regenerator
Column
⊡ Determining superficial gas velocity using graphics
⊡ is 0,05
⊡ G’ = 0.434 lb/s.ft2
⊡ at flooding
73
Regenerator
Column
⊡ Calculate superficial gas velocity at operating condition

⊡ G’ operating = eficiency x G’ flooding
⊡ = 75% x 0.434 lb/s.ft2
⊡ = 0.3259 lb/s.ft2
⊡ Calculate the cross sectional area of the packed tower
⊡ A = Gy/G’operating
⊡ = 94.27 lb/h /(0.3259 lb/s.ft2 x 3600hr/s)
⊡ = 0.0803 ft2
⊡ Calculate the tower diameter
⊡ = 0.3198 ft= 0.09747504 m
74
Regenerator
Column
⊡ Calculate column height

⊡ Column height =HETP x Nt
⊡ HETP = Dt0,3 = (0.09747504 m) 0,3
⊡ = 0.7103
⊡ Yb(CO2+H2S) = 0.0603%mol
⊡ Y emisi = = 0.002474%mol
⊡ Nt = =
⊡ = 3.194 =4
⊡ Column height = 0.7103 x 4
⊡ = 2.8415
75
Membrane
76
Membrane
Equipment Name Membrane Gas Separation

Equipment Code F-201
Membrane Module Type Hollow Fiber
Membrane Material Polymide
Cartridge Shell 6061-T6 Aluminium
CO2 Permeability (GPU) 14.7
CH4 Permeability (GPU) 0.24
Selectivity (%) 59.6
Number of Stages 2
Operation Data
Pressure (barg) 38
CO2 Partial Pressure Limit (barg) 33
Temperature Maximum (℃) 65.5
Diameter (mm) 184.1
Height (mm) 1629.2
Weight (kg) 24.4
77
Steam Super Heater
78
Steam Super Heater
Equipment Name Steam Super Heater
Type Convection
Operating Condition
Maximum Temperature (℃) 537.78
Maximum Pressure (bar) 82.73
Heat to be Supplied to Super
1961700
Heater (kCal/hr)
Overall Heat Transfer Coefficient
809.8496
(kCal/m2h0c)
Area considered (m2) 96.89
Tube Outside Diameter (m) 0.615
Tube Inlet Diameter (m) 0.461
Length of Tube Consider (m) 30.848
79
Biomass Storage
Tank
80
Storage Tank
• Determine storage capacity

determined by the mass flow rate that flows in to the next process
• Choose storage tank type
Volume <3.8 m3 Vertical with legs
3.8 < volume < 38

Storage Horizontal
m3
Vertical concrete
Volume > 38 m3
Horizontal/vertical
Function foundation
3- phase (gas-gas-
Horizontal
liq or gas-liq-liq)
Separator
2-phase or many
Vertical
solid
Limited Vertical
Plant Size
Wide Horizontal
81
Storage Tank
• Choose storage tank type: slim or fat

L/D for solids commonly used is 3.
• Calculate internal diameter and length
82
Storage Tank
• Determine material of storage tank basic

• Determine open or closed head
• Calculate vessel thickness
• Determine top and bottom head

• Calculate head thickness
To calculate flat head:
To calculate conical head:
83
BIOMASS
STORAGE TANK
Equipment Specification Vessel Head Specification
Material Stored Empty Fruit Bunch Type Flat Head
Operating Conditions C (edge support) 0.1
Mass flow (kg/h) 91,666.70
Head Thickness (in) 1.06
Density (kg/m )
3
1,264.46
Temperature (°C) 39.027 Head Thickness (mm) 26.99
Pressure (kPa) 101.325 Vessel Bottom Specification
Volumetric flow Type Conical
72.49 Thickness (in) 0.46
(m3/h)
Residence Time Thickness (mm) 11.89
7
(days)
Volume (m3) 13,397.03
Amount of tank 3.00
Volume per tank (m )3
4,465.68
Horizontal/vertical Vertical with Support
L/D 0.800
Diameter (m) 18.670
Length (m) 14.936
Open/close vessel Close
Material type Carbon steel SA-516
Thickness (in) 0.27
Thickness (mm) 6.81
84
Flash Separator
85
Flash Separator
This plant will be operated under condition:

• Density vapor in : 1.67 kg/m3
• Density liquid in : 889.3 kg/m3
• Vapor mass flow in : 0.37 kg/s
• Liquid mass flow in : 7.82 kg/s
There are several steps to sizing separator such as:

Separator Diameter and Height
Rule of thumb L/D = 2,
86
Flash Separator
Corrosion Rate : 0.625 inch,
The vessel thickness is determined by the higher value of longitudinal joint and circumferential
joint vessel thickness calculation.
The head thickness is calculated by the equations below.
87
Flash Separator
Table Flash Separator Specification (V-202)
Equipment Name Separator
Type Vertical Separator
Shell Unit Dimension
A min 1.38 m2
D min 1.33 m
L 2.65 m
L/D 2.00 Dimensionless
P 14.7 Psi
S 20000 Psi
R 26.1 m
Efficiency (E) 0.85
Separator Thickness 1.65 cm
Head Thickness & Type 0.3 cm & torisphericall
88
Flash Tank
89
Flash Tank
This plant will be operated under condition:

• Density vapor in : 39 kg/m3
• Density liquid in : 203.30 kg/m3
• Vapor mass flow in : 1.0 kg/s
• Liquid mass flow in : 11.11 kg/s
There are several steps to sizing separator such as:

Separator Diameter and Height
Rule of thumb L/D = 2,
90
Flash Tank
Corrosion Rate : 0.625 inch,
The vessel thickness is determined by the higher value of longitudinal joint and
circumferential joint vessel thickness calculation.
The head thickness is calculated by the equations below.
91
Flash Tank
Table Flash Tank Specification (V-301)
Equipment Name Flash Tank
Type Vertical Separator
Shell Unit Dimension
A min 6.26 m2
D min 2.82 m
L 5.65 m
L/D 2.00 Dimensionless
P 30 Psi
S 20000 Psi
R 55.57 m
Efficiency (E) 0.85
Separator Thickness 1.71 cm
Head Thickness & Type 0.3 cm & torisphericall
92
Knock Out Drum
93
Knock Out Drum
Knock out drum is designed through calculating settling velocity (u t).
Area is then calculated by dividing gas volumetric flow rate to actual gas
velocity.
Liquid level is calculated for 10-minutes holdup and added by a factor of 0.3
m for level controller.
94
Knock Out Drum
Inlet height is the sum of liquid height and

0.5 diameter. The separator height is the sum
The head thickness is calculated by the
of inlet height and diameter.
equations below.
Torispherical :
Ellipsoidal :
The vessel thickness is determined by the
Hemispherical :
higher value of longitudinal joint and
circumferential joint vessel thickness
calculation.
95
Knock Out Drum
Specification Value
m liquid 54320.00 kg/h Specification Value
m vapor 132900.00 kg/h T 37.78 o

C
ρ liquid 998.90 kg/m3 P 524.7 psia
ρ vapor 30.09 kg/m3 R 1402.643 mm
V liquid 0.0151 m3/s S 20000 psia
V vapor 1.2269 m3/s E 0.85

C 3 mm
ut (settling velocity) 0.397 m/s
t (longitudinal joint) 47.109 mm
us (actual gas
m/s t (circumferential joint) 24.513 mm
velocity) 0.199
Bottom Flat
A 6.178 m2
Thickness 20.125 mm
D 2.805 m
Top Hemispherical
Hl (liquid depth) 1.767 m
Thickness 24.713 mm
Hi (inlet height) 3.170 m
H 5.975 m
Material Carbon Steel SA-516
96
KNOCK OUT DRUM
Equipment Design Specification

Equipment Name Knock Out Drum Area 6.18 m
Equipment Code V-203 Diameter 2.81 m
Separate liquid from Liquid Depth 1.77 m
Function
gas Inlet Height 3.17 m
Operating Conditions
Height 5.98 m
Temperature 37.78 C
o
Carbon Steel
Pressure 524.70 psia Material
SA-516
Design Parameters
Thickness (mm) 47.11 mm
Liquid Mass Flow Rate 54320.00 kg/h
Vapor Mass Flow Rate 132900.00 kg/h Head Specification
Liquid Density 998.90 kg/m3 Bottom Flat
Vapor Density 30.09 kg/m3 Thickness (mm) 20.13 mm
Liquid Volumetric Flow Top Hemispherical
0.02 m3/s
Rate Thickness (mm) 24.71 mm
Vapor Volumetric Flow
1.23 m3/s
Rate
Hold-up Time 10.00 minutes
Settling velocity 0.40 m/s
Actual gas velocity 0.20 m/s
97
Decanter
98
Decanter
1. Basic Operating and Design Data
99
Decanter
2. Determining the separation time

Separation time is calculated using this equation:
where,
= separation time, h
= density of heavy liquid, kg/m3
= density of light liquid, kg/m3
= viscosity of light liquid, cP
After calculation it is determined that the separation time is 0.19 hour or 11.40
minutes.
100
Decanter
3. Calculating the design specification for decanter
In design practice, the tank volume is 10 to 25% greater than the required holdup
volume. In this calculation the tank volume is 1.2 times the holdup volume. Then, the
length and diameter of the tank can be calculated, with an L/D ratio of between 3-5. In
this calculation, 5 is used.
By assuming that the two liquids interface midway between the vessel bottom and the
liquid surface, the height of heavy liquid, heavy liquid overflow, and liquid depth in
tank can be calculated based on this equation.
101
DECANTER
Equipment Specification Design Specification
Name Decanter Holdup Volume 8.46 m3
Equipment Code V-302 Tank Volume 10.15 m3
Separate Diameter 1.37 m
Function water from
Length 6.86 m
syncrude
Liquid Depth in Tank 5.72 m
Operating Conditions
Temperature 35 o
C Height of Heavy Liquid 2.86 m
Pressure (bar) 35 bar Height of Heavy Liquid
0.88 m
Light Liquid Syncrude Overflow
Heavy Liquid Water Shell Thickness 22.45 mm
Light Liquid Flow Rate 18082.87 kg/hr Vessel Head Specification
Light Liquid Density 405.04 kg/m3 Type Hemispherical
Light Liquid Viscosity 1.1 cP Head Thickness 22.14 mm
Heavy Liquid Flow Rate 21917.68 kg/hr
Heavy Liquid Density 984.1864 kg/m3
Separation Time 0.19 hr
11.40 min
Light Liquid Volumetric
44.64 m3/hr
Flow Rate
Heavy Liquid Volumetric
22.27 m3/hr
Flow Rate
102
Distillation Column
103
DISTILLATION COLUMN 1
Equipment Name Distillation Column 1
To separate light (C1-
Function C13) and heavy
(C13+) hydrocarbons
Operating Data
Material SA-516
Feed Flow Rate (kgmol/h) 482.17
Column Height (m) 11.9
Minimum Reflux Ratio 1.03
Column Diameter (m) 4.231
Actual Reflux Ratio 1.27
Plate Type Sieve
Number of Actual Tray 15.63
Shell Thickness (mm) 4.379
Feed Stage 10.18
Condenser Temperature
106.8 Head Thickness (mm) 9.375
(oC)
Condenser Pressure (bar) 1.3
Reboiler Temperature ( C)
o
342.2
Reboiler Pressure (bar) 1.5
Stage Efficiency (%) 82.94
104
DISTILLATION COLUMN 2
Equipment Name Distillation Column 2
To separate diesel
Function
and wax
Operating Data Design Specification
24.33 Material SA-516
Feed Flow Rate (kgmol/h)
2.41 Column Height (m) 19.1
Minimum Reflux Ratio
2.80 Column Diameter (m) 1.14
Actual Reflux Ratio
29.95 Plate Type Sieve
Number of Actual Tray
15.31 Shell Thickness (mm) 3.60
Feed Stage
Condenser Temperature
307.7 Head Thickness (mm) 13.23
(oC)
Condenser Pressure (bar) 1.3
Reboiler Temperature (oC) 404.4
Reboiler Pressure (bar) 1.5
Stage Efficiency (%) 96.80
105
Distillation Column
1. Basic Operating and Design Data
106
Distillation Column
2. Liquid and Vapor Rate
107
Distillation Column
3. Properties Data
108
Distillation Column
4. Column Diameter
The column diameter is estimated
through the calculation of flooding
velocity by K factor obtained from the
curve below.
Initial calculation proceeds to get Flv
value in order to get K factor from the
chart.
The value of K is corrected with

surface tension through the following
equation.
109
Distillation Column
4. Column Diameter
Then flooding velocity is calculated as follow.
The actual velocity taken is 85% of the flooding velocity. After that, net area is
calculated through the division of gas volumetric flowrate to the corrected velocity.
The net area must be added by a factor of 12% for downcomer to provide a total
minimum area for distillation plate, and diameter is calculated from that area.
110
Distillation Column
4. Column Diameter
111
Distillation Column
5. Plate Efficiency and Column Height

Calculation of plate efficiency is based on O’Connell’s efficiency.
112
Distillation Column
6. Material and Head Type
113
Distillation Column
7. Shell and Head Thickness
114
2
UTILITY
EQUIPMENT
SIZING
115
Pump
Assumptions:
• =75%
By using these formulas below, the
• The terms of velocity difference
information of Power, Head, and NPSHa
neglected due to its small number
of each pump can be obtained.
• No fitting
The pump power requirement can be
where 𝑚 is mass flow, g is gravity

acceleration, and H is head.
The or BHP (brake horse power) is
116
Water Pump
Equipment Specification Equipment Specification Equipment Specification

Equipment Name Pump Equipment Name Pump Equipment Name Pump
Equipment Code P-501 Equipment Code P-502 Equipment Code P-503
Type Centrifugal pump Type Centrifugal pump Type Centrifugal pump
Operation Data Operation Data Operation Data
Temperature (K) 303 Temperature (K) 303 Temperature (K) 303
Density ( 998 Density ( 998 Density ( 998
Pressure inlet (Pa) 100,000 Pressure inlet (Pa) 230,000 Pressure inlet (Pa) 230,000
Pressure outlet (Pa) 230,000 Pressure outlet (Pa) 365,000 Pressure outlet (Pa) 365,000
Mass Flow (kg/s) 16.952 Mass Flow (kg/s) 13.889 Mass Flow (kg/s) 1.4874
Efficiency (%) 75 Efficiency (%) 75 Efficiency (%) 75
Fluid Water Fluid Water Fluid Water
Design Specification Design Specification Design Specification
Power (W) 3046.74 Power (W) 2588.96 Power (W) 277.26
Head (m) 13.75 Head (m) 14.27 Head (m) 14.27
NPSHa (m) 9.897 NPSHa (m) 9.897 NPSHa (m) 9.897
117
Water Tank
Equipment Name V-501 Equipment Name V-503

Type of fluid Water Type of fluid Water
Mass flow (kg/h) 61,028 Mass flow (kg/h) 61,028
Density (kg/m3) 1,000 Density (kg/m3) 1,000
Volume (m3/h) 61.028 Volume (m3/h) 61.028
Temperature (°C) 25 Temperature (°C) 25
Pressure (kPa) 100 Pressure (kPa) 100
Horizontal/vertical Vertical with legs Horizontal/vertical Vertical with legs
L/D 0.8 L/D 0.8
D (m) 4.527911533 D (m) 4.527911533
L (m) 3.622329226 L (m) 3.622329226
Thickness (mm) 7 Thickness (mm) 7
Open/close vessel Close Open/close vessel Close
Vessel head type Dished head Vessel head type Dished head
Material type HDPE Material type HDPE
118
Clarifier
Equipment Name V-503
Flocculation time 20 Min
Settling time 1 Hr
Surface loading 2 m/hr
Weir loading 7.3 m3/hr ⊡ Many clarifier designs have
been established. Almost a
Upflow velocity 8 mm/min
Flowrate 61028 kg/hr
lot of vendors use the

Volume with solid 2.7321 m3/hr
Slurry circulation rate 52.04 kg/hr
G 30 1/s
common specification to
Max mixer tip speed 1.8 m/s
produce the clarifier. In this
Free board approximate 0.6 m
design, we will use
Water depth 1.2 m
Clarifier shape Rectangular basin

Kawamura design as the
Tank head Open head
basic of parameter
Height
Length x width
1.500
1.821
m
m2
specifications
Length 1.820 m
Width 1.001 m
Blade type Disc turbine
Amount of blade 6
Shaft 12 rpm
119
Demineralizer
This process is used to remove any ion and mineral to make the water free
of it. Regarding to ion exchanger vendor such as AES Arabia, the
specification of ion exchanger from vendor can be determined with the flow
rate parameter. Our flowrate of water is 269.26 gpm. Based on the table
above, we need TBA-72 model with 114 cuft for cation bed vessel and 114
cuft for anion bed vessel. Both of two tanks have 72 inch diameter with 4
inch pipe size.
120
Filter
We need water filter (F-501) to filter the

micro solid particle and make the water
into demineralize water. The vendor of
this filter come from Harmsco. The
specification of the filter from Harmsco
can be determined based on water
flowrate. Based on our flowrate, 269.26
gpm, we need water filter with HIF-75
model number. The service height
clerance for this filter is 70 feet, the
dimension is (42x20) feet, and the
weight is 129lbs.
121
O2 Purifier
122
Air Filter
Specification
⊡ In order, to know the Product Name Outer Alumunium frame H13 HEPA Air
sizing of air filter that we Filter with Clapboard
used, first we should Model No Compact Hepa filter

Type Air Filter
know the air requirement Efficiency can filter 99,99% contaminants up to 0,3
or air flow rate. We use μm size)
the specification of air Medium Material Fiberglass
filter from vendor that is Inspection 100%inspection before shipment

Frame Alumunium
Compressed Air System, Dimension W*H*D: 610mm*610mm*292mm
Inc. Here’s the
specification of air filter Capacity 4250 m3
cost US 25-90
that we used. Trademark Jowell
123Origin Dongguan, China
Air Filter (Cont’d)
124
Nitrogen receiver
⊡ The size of a tank is based on:

System size, Compressor output,
Nitrogen demand cycles
⊡ Know the nitrogen flowrate, so the
capacity and size of nitrogen
receiver can be choosen.
125
Nitrogen Receiver
• A commonly formula to find a receiver size is:
Where:
V= volume of the receiver tank (cu ft)
t = time for the receiver to go from upper to lower pressure limit (min)
C= air needed (scfm)
Pa= atmosphere pressure (14.7 psia)
P1= minimum tank pressure (psia), shown in the table xx above
P2 = maximum tank pressure (psia), shown in the table xx above
The calculation to sizing nitrogen receiver is:
126
⊡ After that, choose the
compressor power
based on receiver
volume.
127
N2 Flowrate 2.874 m3/min
From the calculation, Nitrogen flowrate is 81.377 scfm = 81 galon, so the capacity
and size of nitrogen receiver can be choosen
P1 16 psig
P2 125 psig
V 120 gal
V 19,26525 cu ft
t 10,93417 minute
128
Compressor Power:
hp 30
kW 22,4
129
Kesimpulan
From the sizing calculations in the previous chapters, some important points can be taken :
• Every equipment has been sized and specified in order to give information for fabrication or
choosing vendor.
• Utility’s equipment in our plant are boiler, pumps, compressors, water filter, and pipe.
• Standard used for sizing the equipments are TEMA (Tubular Exchanger Manufacturers
Association), API (American Petroleum Institute), and ASME (American Society of
Mechanical Engineering).
• The material selected for each equipment is based on corrosion chart that give information
about materials resistance.
130
Reference
• Branan, Carl. 2002. Rules of Thumb for Chemical Engineers. Houston: El- Sevier.
• Broughton, J. Process Utility Systems: Introduction to Design, Operation and
Maintenance Institution of Chemical Engineers: Rugby, Warwickshire, UK, 1994.
• Blank & Tarquin. 5th edition. Ch.16 Authored by Dr. Don Smith, Texas A&M University
• Branan, Carl. 2002. Rules of Thumb For Chemical Engineers. Houston : ElSevier.
• Brownell, Lloyd E and Edwin H. Young. 1959. Process Equipment Design. John Wiley & Sons,
inc.
• Chen, David et all. 2016. Utility System, [ONLINE], Available at:
https://processdesign.mccormick.northwestern.edu/index.php/Utility_systems#Steam.
[Accessed at 6 October 2018].
• Cheremisinoff , Nicholas P. 2000. Handbook of Chemical Processing Equipment. Butterworth-
Heinemann.
131
Reference
• Coulson & Richardson. 1983. Chemical Engineering Design. Oxford : El-Sevier. Chemical And
Process Design Handbook. New York : McGraw-Hill.
• Couper, J.R. 2003. Process engineering economics. Florida: CRC Press.
• Deng, Y., Zhang, T., Wang, Q., 2017. Biochar Adsorption Treatment for Typical Pollutants
Removal in Livestock Wastewater: A Review. Engineering Applications of Biochar, 71-82.
• Eckenfelder, W. Wesley. 2000. Industrial Water Pollution Control. New York, USA: McGraw
Hill Companies, Inc.
• Ganapathy, V. 2015. Steam Generators and Waste Heat Boilers for Process and Plant
Engineers, USA: Taylor & Francis Group, LLC.
• Himmelblau, D. and Riggs, J. (2009). Basic principles and calculations in chemical
engineering. 7th ed. Upper Saddle River, NJ: Prentice-Hall PTR.
132
Reference
• Himmelblau, D. and Riggs, J. (n.d.). Basic principles and calculations in chemical engineering.
• Manyuchi, M.M., Mbohwa, C., Muzenda, E., 2018. Potential to Use Municipal Waste Bio Char
in Wastewater Treatment for Nutrients Recovery. Physics and Chemistry of the Earth.
• Perry, Robert H. 1999. Perry’s Chemical Engineers’ Handbook. McGraw-Hill Companies, Inc.
• Seider, Seader, Lewin, Widagdo. 2009. Plant Design and Economics for Chemical Engineers,
5th Edition. Hoboken: Wiley.
• Sinnott, R. K. 2005. Chemical Engineering Design 4th edition. Elsevier.
• Smith, Robin. 2005. Chemical Process Design and Integration, 2nd edition. Centre of Process
Integration, University of Manchester, UK.
133
Reference
• Tan, X., Liu, Y., Zeng, G., Wang, X., Hu, X., Gu, Y., Yang, Z., 2015. Application of Biochar for
the Removal of Pollutants from Aqueous Solutions. Chemosphere 125, 70–85.
• Vilbrandt, F. C. 1959. Chemical Engineering Plant Design. United State: McGraw-Hill Inc.
• Wallas, Stanley M. 1988. Chemical Process Equipment Selection and Design. Butterworth-
Heinemann.
134

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• Process Input: Process Data

• The heuristics for allowable

TEMA type BEM

307,087 mm TEMA type BEM

307,087 mm TEMA type BEM

TEMA type BEM

307,087 mm TEMA type BEM

TEMA type BEM

307,087 mm TEMA type BEM

TEMA type BEM

540,000 mm TEMA type BEM

TEMA type BEM

52,5527 mm TEMA type BEM

TEMA type BEM

154,051 mm TEMA type BEM

Data Shell Side Tube Side

Fluid Stream Inlet 1 2-2'

Operating pressure (kPa) 101 130

Fouling factor (m2 oC/W) 0.00009 0.00009

Heat Duty (MW) 0.485

Material SS-316 atau SA-240

Heat Transfer Area (m2) 2.449

Tube OD (mm) 19.050

27 Tube Pitch (mm) 24

Data Shell Side Tube Side

Fluid Stream Inlet 1 7

Operating pressure (kPa) 150 1317.225

Fouling factor (m2 oC/W) 0.00009 0.00009

Heat Duty (MW) 6.350

Material SS-316 atau SA-240

Heat Transfer Area (m2) 61.243

Tube OD (mm) 19.050

Data Shell Side Tube Side

Fluid Stream Inlet 1 7

Operating pressure (kPa) 150 1317.225

Fouling factor (m2 oC/W) 0.00009 0.00009

Heat Duty (MW) 0.840

Material SS-316 atau SA-240

Heat Transfer Area (m2) 4.908

Tube OD (mm) 19.050

Bed Section Internal Diameter (m) 7,1255

⊡ By assuming mass fraction of catalyst to catalyst solvent is equal to 0.35,

⊡ Calculating volume of solvent-catalyst slurry

⊡ By guessing diameter of reactor, calculating the gas volumetric flowrate and

⊡ Calculating volume of reactor using this following equation, and

⊡ After obtaining value of D and L, calculating actual height by adding

Inlet velocities should be in the range 100-150

Figure. Typical dimension ratios of a cyclone separator (figure is scalable)

Equation for the critical particle diameter is :

D : diameter of the vessel

A graphical correlation given by Zenz (1982) can be represented by the equation :

The data known are listed below:

Equation for the critical particle diameter becomes :

Figure. Percent removal of particles in a cyclone as a function of

Design Pressure 1.4 bar

Total Height 7.36 m

Internal Diameter 3.35 m

Height of Conical Part 3.68 m

Solid Outlet Diameter 0.64 m

Gas Outlet Diameter 1.12 m

Rectangular Inlet Width 0.84 m

Height of Rectangular Inlet 2.09 m