TYPE OF UTILITY

Created by :
1. Erfina Febrianti

(1215041016)

2. Dera Seta Saputri

(1215401010)

3. Nyayu Fathia Zahra

(1215041035)

4. Sebastian Djoni Syukur

(1215041044)

Program Study of Chemical Engineering

Faculty of Engineering Universitas Lampung
Bandar Lampung
2012

A plant has two main process systems, ie systems reacting and systems separation
and purification processes. Both systems require the operating conditions of
temperature and pressure. In plants, the heat usually 'stored' in the fluid is
maintained at a certain temperature and pressure. The most commonly used fluid
is hot water and steam for reasons of inexpensive and has a high heat capacity.
Another commonly used fluid for heat exchange conditions at temperatures above
100 C at atmospheric pressure. Water or water vapor pressure (called steam or
steam) is getting heat from boilers (boilers).
Heat removal system is responsible for providing heat and absorbs heat. For
example, absorbs heat from the process that generates energy as the system
processes involve exothermic reaction or absorb heat so that the condition of the
system under room temperature or ambient temperature. For a heat sink for
temperature below room temperature using a refrigerant plant typically, the same
material with which to work on the fridge. The use of water as the cooling
medium is also limited its physical properties, which is the boiling point and
freezing point. Cooling water temperature needs to be returned to the ambient
temperature or the temperature of the space to be used again As with cooling.
Processing system that does this is the cooling tower.
Cooling towers, boilers and furnaces are system-processor system to system
providers summer heat and exhaust systems. Both systems this process together
with the compressed air supply system, the system provider of electricity and
water for production is an ongoing support system called the primary process
system utility system. Needs of the utility system and its performance depends on
how well the system utility is able to 'serve' the needs of the system and the main
process depends on the efficient use of raw materials and fuel.
The factory does not have to have a processing system utilities sendiri.Listrik
example, plants can be bought from the local power company PLN if capacity is
insufficient or the purchase of the plant neighbors. Similarly to a waste treatment
facility, water vapor and provider unit cooling water and compressed air supply
unit

UTILITY
Utility Unit is a support unit for other units in a plant or supporting facilities to
run a factory from the initial stage to the final product. Utilities Unit include:
1. Unit water intake.
2. Water treatment units.
3. Unit water supply
4. Steam generating unit (steam).
5. Power generation unit.
6. Instruments and air conditioning unit manufacturer.
7. Air separation unit (ASP).
8. The unit of measurement of gas (gas metering station).
9. Wastewater treatment unit.
1. Unit Water Intake
The water source for the plant, office and housing for example PT. Iskandar Muda
fertilizer taken from the river Peusangan (Bireuen District), located about 25 km
from the plant site. Broad Watershed Peusangan is 2260 km2 and are located
mostly dikabupaten Central Aceh. Water is pumped to the normal flow rate of 700
to 800 tons / hour at a pressure of minimum 2 kg/cm2G.
In all there are three water intake pump unit, where each pump has a capacity of
1250 tons / hour and dilangkapi with:
Water Intake Channel, is an insulated pool so shaped channel (channel), and
equipped with a bar screen that serves to filter coarse floating objects that may be
in place, especially in the building tapping tapping the river, so as not to interfere
with subsequent water treatment processes .
Intake Pond, a pond with a size of 27 900 x 7600 m2, which serves to hold water
that has been extracted from the source and is used as a raw material. Water is
poured into Settling Basin (bath deposition) using a pump.
Settling Basin, serve to precipitate coarse particles by gravity and set the flow to
be transmitted, the basin is divided into limachannel and alternately
sebuahchannel cleaned and taken mud.
Water from Water Intake facility then flowed into the water treatment plant with a
flow rate of 1650 tons / hour.
2. Water Treatment Unit
The need for water in the plant required for raw materials and auxiliary processes
in the form of Water and Demin Water Filters or Water Polish, besides it also
produced

2.1 Clarifier
Clarifier (63-FD-1001) serves as the first stage of the water treatment process
water purification to remove solids in suspension by the neutralization,
sedimentation, coagulation, and filtration. Clarifier has a capacity of 1330 tons /
hour, while the needs of incoming raw water clarifier is 600 to 800 tons / hour
(normal). In the clarifier inlet injected chemicals are alum sulphate, chlorine,
caustic soda, while the coagulant aid is added to the clarifier.
The function of these chemicals are:
a. Alum Sulfate (Al2 (SO4) 3)
Serves to form clumps of particles suspended in water. When alum is contacted
with water, there will be a result of hydrolysis of aluminum hydroxide (Al2 (SO4)
3) and sulfuric acid. The reaction is as follows:
Al2 (SO4) 3. 18 H2O + 6 H2O -----> 2 Al (OH) 3 + H2O + 18 3H2SO4
Clumps of Al (OH) 3 in the form of colloids will settle with the other impurities
entrained into the water and H2SO4 will lead to acidic water. The addition of
alum depends on turbiditi and raw feed water flow rate.

b. Caustic Soda (NaOH)

Serves to neutralize the water due to the addition of alum so the pH range from 6
to 8. The reaction is as follows:
NaOH + H2SO4 -----> Na2SO4 + 3 H2O
c. Chlorine (Cl2)
The main objective is the addition of chlorine to kill microorganisms in the water,
but it is also to prevent the growth of moss on the wall clarifier and will interfere
with the next process.
d. Coagulant Aid (Polymer)
Serve to accelerate the deposition process, due to the addition of this material will
form a floc-floc larger so it will be easier and faster buildup.
Clarifier is equipped with an agitator and a rake that serves as a stirrer, both
worked continuously. Agitator serves to accelerate the floc-floc and work with
speed 1.05 to 4.2 rpm. While the rake function prevents the floc-floc (clumps of
mud) is not concentrated at the bottom
clarifier and works with the speed of 0.033 rpm. Impurities that settle with mud
(sludge) removed from bawahclarifier as blow down, while the crystal clear water
dariclar ifier out the over flow
2.2 Sand Filter (Gravity Sand Filter)
Clear water flows from the Clarifier Gravity Sand Filter (63-FD-1002) by gravity.
Gravity sand filters consist of 5 (five) empats er vice-units and one standby unit
(stand by). The main component of the sand filter is the sand of different sizes.

Sand filter works continuously, if dirt or mud clot that was too thick in the filter, it
will be back wash regularly.
2.3 Filter Water Reservoir
Water from sand filter housed in Filter Water Reservoir (63-FB-1006), then
divided by three tanks are:
potable water tank (63-FB-1002) is used to distribute water that meets drinking
water to residential, offices, boats, and emergency shower.
Filter Water Tank (63-FB-1008) Used as fire water, make up Cooling Water and
back wash.
Recycle Water Tank (63-FB-1008) is used as feed water demin. The water is
processed again to produce mineral free water and will be used as a water
umpanBoiler.
2.4 Activated Carbon filter (Activated Carbon Filter)
Water from the Recycle Water Tank (63-FB-1008) is applied to dalamActivated
Carbon Filter (63-FB-1003) to absorb CO2 dissolved in water and organic
substances that exist dalamfilter water, and residual chlorine from the water before
it goes into the system Deionization (Demineralizer).
2.5 Demineralizer
This unit serves to release water from the elements silica, sulfate, chloride and
carbonate using resin, this unit consists of:
a. Cation Tower (63-DA-1001)
This process aims to eliminate the metallic elements that form positive ions
contained in water filter using R-SO3H cation resin (Dowex type Upcore Mono
A-500). This process is done by passing the water through the bottom, which will
be binding the metals by the resin. Resin R-SO3H is strongly acid, because it is
called a strong acid cation exchanger resin
The reaction is:
CaCl2 + 2R - SO3H -----> (R - SO3) 2Ca + 2 HCl
MgCl2 + 2R - SO3H -----> (R - SO3) + 2 HCl 2mg
NaCl2 + 2R - SO3H -----> (R - SO3) 2Na + 2 HCl
CaSO4 + 2R - SO3H -----> (R - SO3) 2Ca + 2 HSO4
MgSO4 + 2R - SO3H -----> (R - SO3) 2w + 2 HSO4
NaSO4 + 2R - SO3H -----> (R - SO3) 2Na + 2 HSO4
Na2SiO4 + 2R - SO3H -----> (R - SO3) 2Na + 2 HSiO4
CaCO3 + 2R - SO3H -----> (R - SO3) 2Ca + 2 HCO3
b. Degasifier (63-DA-1002)
Degasifier for removing CO2 from carbonic acid formed in the previous process,
with the following reaction:
H2CO3 -----> CO2 + H2O
Degasifier process takes place at a pressure of 740 mmHg with
menggunakansteam vacuum ejector, is contained in the tank ring netting to extend

the contact area between the water entering the low-pressure steam is injected.
While outletsteam ejector is condensed by water injection from the top and then
stored in the seal pot as bait Recovery Tank.
c. Anion Tower (63-DA-1003)
Serves to absorb or bind negative ions contained in the water that comes out dariD
Egas ifier. Anion exchanger resin is R = NOH (Type Dowex Upcore Mono C600). The reaction is:
H2SO4 + 2 R = N - OH -----> (R = N) 2SO4 + 2 H2O
HCl + R = N - OH -----> R = N - Cl + H 2 O
H2SiO3 + 2 R = N - OH -----> (R = N) 2SiO3 + 2 H2O
H2CO3 + R = N - OH -----> R = N - CO3 + H2O
HNO3 + R = N - OH -----> R = N - NO3 + H2O
This reaction produces H2O, therefore demin water is always neutral. Air out the
tank has a pH of 7.5 to 8.5 conductivity less than 3
d. Mix Bed Polisher (63-DA-1004)
Serves to eliminate the remnants of metal or acid from the previous process, so
expect water coming out of the mix bed polisher has been cleared of cations and
anions. In the mixed bed polisher used two kinds of resins are cation resin and
anion resin which also serves to remove residual both cations and anions,
especially sodium and residual acid as silica compound with the following
reaction:
Cation Reactions:
Na2SiO3 + 2 R - SO3H -----> 2 RSO3Na + H2SiO3
Anion Reactions:
Na2SiO3 + 2 R = N - OH -----> 2 RSO3Na + H2SiO3
Free mineral water that has been incorporated into the Polish Water Tank (53-FB1004) and used to water umpanboiler
3. Water Procurement Unit
3.1 Water Cooling
Cooling water used is obtained from sea water sea not far from the location of the
factory. The reason for the use of sea water as a cooling medium is due to the
following factors:
a. Sea water can be obtained in large quantities at low cost.
b. Easy to setup and processing.
c. Can absorb some heat per unit volume is high.
d. Not decompose.
e. Cooling tower is not needed, because the sea water directly discharged sea
again.
Cooling water is used as coolant in the condenser, cooler and reactors. Things
that need to be considered in the treatment of sea water as a coolant are:
a. Large particles / makroba (living sea creatures and other constituents)
b. Small particles / marine microbes (algae and marine microorganisms) that can
cause fouling on heat exchanger equipment.

3.2. Public Consumption of Water and Sanitation

The source of water for consumption and sanitation comes from groundwater
sources. This water is used for drinking water needs, laboratory, office, residential
and landscaping. Water consumption and sanitation must meet several
requirements, which include physical requirements, chemical requirements, and
bacteriological terms.
Physical Conditions:
a. temperature below the outside air temperature
b. clear color
c. has no taste and no smell.
Chemical terms:
a. does not contain any organic or anorgaik
b. not toxic
Terms bacteriological:
It contains no bacteria, particularly pathogenic bacteria.
Processing seawater
To avoid fouling that occurs in the heat exchanger tools we need to hold the sea
water treatment. Processing is done physically and chemically. Processing is
physically and chemically screening is the addition of chlorine. Stages are as
follows:
The sea water is sucked from the pond located directly on the seafront with the
pump, the operation used six pumps, and the remaining three standby service.
Before entering the pump, the water is passed on the traveling screens to filter the
particles with a large size. Washing is done continuously. Having pumped then
passed through sieve strainer that has a 0.4 mm stainless steel and undergo
periodic back washing. The sea water then flows to the plant. Sodium
hypochlorite is injected in the pool to maintain a minimum chlorine content of 1
ppm. In this design as much as 1 ppm chlorine injected. Sodium hypochlorite is
made in Chloropac with raw sea water by means of electrolysis. Chlorine is
injected continuously in the pool and in the intermittent drainage pipe.
Processing water for consumption and sanitation.
Waste water for consumption and sanitation is a separate unit at the factory. The
processing is done the process of aeration, filtration, and chlorination. Aeration
aims to remove dissolved gases and oxidize ferrous ion content to be converted
into ferric ions to form ferric hydroxide is not soluble in water. Ferric hydroxide
precipitate was removed by blowdown, and the rest are not terendapkan screened
in iron removal filter. Into the water filtration products further injected a solution
of calcium hypochlorite to kill biological content of water. The concentration of
calcium hypochlorite is kept around 0.8 to 1.0 ppm. To maintain a minimum pH
of water, plus a solution of Ca (OH) 2 so that the pH is around 6.8 to 7.0. Besides
the addition of the above compounds are also added flouride.
Ground water treatment schemes for consumption and sanitation can be seen in
figure 4.3 next page.
4. Steam Generating Units

In the Utilities Unit, the source of the steam generator is used for the operation is
the Package Boiler (63-BF-4001). Water from the Polish Water Tank (63-FB1004) inserted into the deaerator (63-EG-4001) to remove dissolved CO2 and O2
gases that cause corrosion. In deaerator also injected hydrazine (N2H4) to bind
O2 gas contained in water. The reaction is as follows:
N2 H4 + O2 -----> 2H2O + N2
In the deaerator outlet also serves injected ammonia to adjust the pH of the boiler
feed water. Package boilers with a capacity of 120 tons / hour, pressure and
temperature of 385oC 41 kg/jam2G uses heat from gas pembakaranfuel. The
operating system is the water from the deaerator into Economizer (63-EC-4001)
and then applied to the steam drum, the drum steam injected Na3PO4 to bind
components to increase the hardness and pH airboiler. Circulation between the
steam-coil heating coil drumdan occur naturally due to differences in specific
gravity of the water in the pipes. Steam generated by the Package Boilers are used
in utility plant, urea plant, while the ammonia plant at the given moment.

5. Power Unit
Electricity demand in the plant can be met by electricity and generator plant, it is
intended that the power supply can take place continuously even if there are
disruptions in supply from PLN. Generator is used alternating current generator
with the following considerations:
1. Electric power generated considerable.
2. The voltage can be increased or decreased as needed with transformers.
This plant's electricity needs, include:
1. Electricity for the process and utility
2. Electricity for lighting
3. Power to AC
4. Electricity for laboratory and instrumentation.
To meet the demand for electricity, as the power source of energy that can be
classified as follows:
a. Main Generator (63-EG-7001)
These generators are the main source of electric power generators at the utility
plant powered by natural gas-fired turbines, its function is to supply power to the
entire plant and housing.
Power: 20 MW
Voltage: 13.8 KV
b. Main Generator (53-GI-7001)
These generators are the main source of electric power generators at the utility
plant powered by natural gas-fired turbines, together with the main function
generator (EG-63-7001) and the only one playing generators are operating.
Power: 15 MW

Voltage: 13.8 KV
c. Standby Generator (53-GI-7002)
Is a companion generator, operated in case of disturbances in the main generator.
Fuel can be diesel or natural gas.
Power: 1.5 MW
Voltage: 2.4 KV
d. Emergency Generator (53-GH-7001)
Is a backup generator, which is used in circumstances when a sudden disturbance
in the main generator and during the transition to a standby generator.
Power: 350 KW
Voltage: 480 V
6. Air and Air Unit Instrument Factory
Plant air requirements at the beginning and at the factory operated emergency,
with Air Compressor (63-GB-5001), after the plant was taken from the air
operation Air Compressors Ammonia (51-101-J) with a pressure of 35 kg/cm2G.
The air is still dry or pure padadryer then dried to remove the water content using
Alumina Silica Gel (silicagel).
The function of the air instrument include:
- Moving Pneumatic Control Valve.
- Purging diBoiler.
- Flushing at Turbine.
The function of the air plant, among others:
- Flushing the pipeline.
- Mixing urea tank is chemical packing.
- Burning Burning in the pit.
7. Air Separation Unit
In principle, an air separation unit (N2 and O2) works by melting point. Raw air
filtered through a filter and then compressed by an air compressor to pressure
41oC to separate moisture (water content) of the air, cooling was continued until
the temperature in Unit Precooler 5oC. The air that condenses released through
the drain separator and enters the MS adsorbent to absorb CO2 and H2O, then the
air is passed into the cool box. In the cool box N2 and O2 are separated by three
different methods:
- Method I is the production of N2 gas, a maximum of 300 Nm3/hr.
- Method II is the production of liquid N2, maximum 50 Nm3/hr
- Method III is the production of O2 gas, a maximum of 75 Nm3/hr.
8. Gas Measurement Units
Function to measure the amount of natural gas consumed by the plant, which is
used by the utility plant (to produce steam and fuel generator), and the number of

natural gas used by the ammonia plant (for process and fuel). Indication of
measuring the flow rate of natural gas contained in the field and control the room
is a measure of flow rate, pressure, temperature, and density.
9. Waste Water Treatment Unit
To avoid environmental pollution, the waste from the production process are
treated before disposal. Waste water collection unit consists of a Waste Water
Pond (WWP) and Outdoor Storage and Waste Control (KPPL).
8.1 Basin Waste (WWP)
Wastewater pond is a waste containment unit derived from:
a. Neutralization tank on demineralizer unit.
b. Fend slurry in water treatment unit.
c. Ammonia plant.
d. The urea plant.
The waste water is neutralized with menambahacid ataucaus tic until reaching pH
6 to 8, then shipped by transfer pumps. Once the wastewater pH neutral, waste
water discharged into the sea.
8.2 Outdoor Storage and Waste Control
Outdoor Storage and Waste Control (KPPL) has a capacity of 5250 m3. The
function of KPPL is to regulate the composition of waste water and exhaust
velocity, to reduce the amount of dissolved solids by precipitation and holds waste
(waste water) when the plant was in operation and release of dissolved ammonia
in wastewater.

COMPRESSED AIR SYSTEM

Industrial plants use compressed air for the entire operation of production,
generated by compressed air units range from 5 horsepower (hp) to over 50,000
hp. DepartemenEnergi U.S. 364 (2003) reported that 70 to 90 percent of
compressed air is lost in the form of heat that can not be used, friction, misuse and
noise. Thus, compressors and compressed air into areas important to improve
energy efficiency at industrial plants.
Is a valuable record of the cost of running a compressed air system is much higher
than the compressor itself (see Figure 5-11). Energy savings from system
improvements can range from 20 to 50 percent or more of the electricity,
generating thousands and even hundreds of thousands dollars. Compressed air
systems are managed correctly can save energy, reduce maintenance, lower
operating stoppage time, increase production, and improve quality.
Compressed air systems consist of a supply, which includes compressors and air
treatment, and the demand, which consists of distribution and storage systems and
end-use equipment. A supply side managed properly will result in cleaner air, dry,
stable, sent on the pressure required in a cost effective manner.
Part requests are managed properly to minimize waste and the use of 365 air
compressed air for applications tepat.Perbaikan maintaining peak compressed air
system performance requires parts of the supply and demand system and the
interactions between them.
Main Components of Compressed Air Systems
Compressed air systems consist of the following major components: filter
incoming air, inter-stage coolers, after-coolers, dehumidifiers, moisture traps
spending, receivers, piping networks, filter, regulator and lubrication (see Figure
5-12).
1. Intake Air Filters: Prevent dust from entering the compressor; Dust causes
sticky valve / faucet, damaged cylinder and excessive consumption.
2. Cooling between stages: menurunan air temperature before it goes into the next
stage to reduce the work of compression and increase efficiency. Usually used
water cooling.
3. After-Coolers: The aim is to remove the moisture present in the air with a drop
in temperature in a water-cooled heat exchanger.
4. Air Dryer: The remains of the water content after the after-cooler removed
using air dryers, as for instrument air and pneumatic equipment must be free of

moisture. The water content is removed by using adsorbents such as silica gel /
activated carbon, or refrigerant dryer, or heat from the air compressor itself.
5. Spending Moisture Traps: Trap expenditure moisture diguakan to remove
moisture present in the compressed air. Trap resembles steam traps. Different
types of traps used are spending manual faucets, valves or automatic spending
based on time and other.
6. Receiver: The receiver of air provided as storage and smoothing the air output
pulse - reducing the pressure variation of the compressor