UNIVERSITY OF INDONESIA

PLANT DESIGN

PRELIMINARY DESIGN OF BIO LIQUIFIED PETROLEUM GAS
(LPG) FROM BIOMASS
ASSIGNMENT 2


GROUP 16

ALRISTO SANAL (1106070836)
ANANDA PUTRA SANGAJI (1106070703)
CAHYA TRI RAMA (1106070905)
GALIH MERY DAMAIATI (1206314610)
OLIVIA CESARAH TARIGAN (1106070754)



FACULTY OF ENGINEERING
UNIVERSITY OF INDONESIA
DEPOK
2014
CHAPTER IV
EQUIPMENT SIZING
4.1 Absorption Column
Equipment Specification
Name Absorption Column
Code V-101
Function To absorb CO
2
and H
2
S from
process gas
Material Carbon Steel
Operational Data
Temperature 30C
Pressure 10 bar
Mass flow in 0.7
Pressure Drop 30
Operational velocity 111.9
Dimensional Data
Type packed
Packing ring 1 in pall rings
Total height Carbon Steel
Diameter 1
Wall Thickness 939.8
Shell Thickness 2
Corossion Allowance Carbon Steel

Absorber has a function to absorbed the acid gas, especially H
2
S, that
contain in syngas gasification product before it enter to water gas shift reaction.
Solution used to absorbed acid gas is mixed amine (MEA and MDEA) with the
composition 0.35 MDEA, 0.06 MEA, and water. Steps to design absorber are:

State operation condition
- T = 45 C
- P = 1000 psia
- Sour gas composition:
Composition Mole Fractions
Methane 0,0003
H
2
S 0,0288
CO 0,3248
Nitrogen 0,3994
CO
2
0,0189
H
2
O 0,0009
Hydrogen 0,2269

- Feed sour gas = 2035 kgmole/h
- Mol fraction H
2
S in feed gas (y
N+1
) =0.0288
- Mol fraction H
2
S in top product (y
1
) = 0.01
Determine flow of amine solution that we need

= 0.2988

= 0.1240

TOTAL molar flow is 601.35 kgmole/hr

[(

) (

)]

Determine Mass (Molar) Liquid to Gas Ratio

Determine value of m

Determine Absorption Factor (A)

Determine Equilibrium Tray

Calculating Actual Tray

Calculating Height Absorber Column
For amine absorber, tray spacing that recommended is at least 2 ft or 61
cm (Campbell, 1992). Then, tray section will have a height:

Calculating Diameter Absorber Column
Calculating Shell and Head Thickness


4.2 Regeneration Column
Equipment Specification
Name Regeneration Column
Code V-102
Function To regenerate amine mixtures
from bottom outlet of
absorption column C
Material Carbon Steel
Operational Data
Temperature 70C
Pressure 5 bar
Mass flow in 0.7
Pressure Drop 30
Operational velocity 111.9
Dimensional Data
Type Flash Drum
Diameter 1
Total height Carbon Steel

Several step to design regeneration column is:
Determine Light Key and Heavy Key
Light Key is a componentthat almost coming out in the top of amine
stripper. Whereas, heavy key is a component that almost coming out in the bottom
of amine stripper. In this amine stripper, the light key (LK) is CO
2
and the heavy
key (HK) is H
2
O.


Determine T
dew
andT
bulb

To determine the dew and bubble temperatures, we need to know mole
fraction of each component first. The mole fraction of components is known by
the HYSYS Simulation. After we know the mole fraction, then we calculate the
vapor pressure of each component by the Antoine equation. After that, we
calculate the m by the equation of Psat/Ptotal and fraction mole of each
component in bottom. Known the P
total
in the system is 610.5 kPa. Here are the
results attached in table below:

4.3 Compressor
An air compressor is a device that converts power (usually from an electric
motor, a diesel engine or a gasoline engine) into kinetic energy by compressing
and pressurizing air, which, on command, can be released in quick bursts. There
are numerous methods of air compression, divided into either positive-
displacement or negative-displacement types. Types of air compressor:
a) Reciprocating Air Compressors
Reciprocating air compressors are positive displacement machines,
meaning that they increase the pressure of the air by reducing its volume. This
means they are taking in successive volumes of air which is confined within a
closed space and elevating this air to a higher pressure. The reciprocating air
compressor accomplishes this by a piston within a cylinder as the compressing
and displacing element.
Single-stage and two-stage reciprocating compressors are commercially available.
Single-stage compressors are generally used for pressures in the range of
70 psig to 100 psig.
Two-stage compressors are generally used for higher pressures in the
range of 100 psig to 250 psig.
1 HP ~ 4 CFM at 100 psi
and that 1 to 50 HP are typically for reciprocating units. Compressors 100 hp and
above are typically Rotary Screw or Centrifugal Compressors. The reciprocating
air compressor is single acting when the compressing is accomplished using only
one side of the piston. A compressor using both sides of the piston is considered
double acting.
Load reduction is achieved by unloading individual cylinders. Typically
this is accomplished by throttling the suction pressure to the cylinder or bypassing
air either within or outside the compressor. Capacity control is achieved by
varying speed in engine-driven units through fuel flow control.
Reciprocating air compressors are available either as air-cooled or water-
cooled in lubricated and non-lubricated configurations and provide a wide range
of pressure and capacity selections.
b) Rotary Screw Compressors
Rotary air compressors are positive displacement compressors. The most
common rotary air compressor is the single stage helical or spiral lobe oil flooded
screw air compressor. These compressors consist of two rotors within a casing
where the rotors compress the air internally. There are no valves. These units are
basically oil cooled (with air cooled or water cooled oil coolers) where the oil
seals the internal clearances.
Since the cooling takes place right inside the compressor, the working
parts never experience extreme operating temperatures. The rotary compressor,
therefore, is a continuous duty, air cooled or water cooled compressor package.
Rotary screw air compressors are easy to maintain and operate. Capacity
control for these compressors is accomplished by variable speed and variable
compressor displacement. For the latter control technique, a slide valve is
positioned in the casing. As the compressor capacity is reduced, the slide valve
opens, bypassing a portion of the compressed air back to the suction. Advantages
of the rotary screw compressor include smooth, pulse-free air output in a compact
size with high output volume over a long life.
The oil free rotary screw air compressor utilizes specially designed air
ends to compress air without oil in the compression chamber yielding true oil free
air. Oil free rotary screw air compressors are available air cooled and water cooled
and provide the same flexibility as oil flooded rotaries when oil free air is
required.

c) Rotary Screw Compressors
The centrifugal air compressor is a dynamic compressor which depends on
transfer of energy from a rotating impeller to the air.
Centrifugal compressors produce high-pressure discharge by converting
angular momentum imparted by the rotating impeller (dynamic displacement). In
order to do this efficiently, centrifugal compressors rotate at higher speeds than
the other types of compressors. These types of compressors are also designed for
higher capacity because flow through the compressor is continuous.
Adjusting the inlet guide vanes is the most common method to control
capacity of a centrifugal compressor. By closing the guide vanes, volumetric
flows and capacity are reduced. The centrifugal air compressor is an oil free
compressor by design. The oil lubricated running gear is separated from the air by
shaft seals and atmospheric vents.
Figure below is a general representation of the application range of most of
the compressor shown. Based on the inlet flow and discharge pressure of the
compressor, one is able to determine the compressor type.


Gambar 4.1 General Range of Application of Compressor
In our plant, we use 4 air compressors, all of them are reciprocating
compressor, labelled as C-201 (air compressor) and C-202(air compressor).


4.3.1 Operating Conditions Air Compressor C-201
Inlet : Air
Inlet Temperature

537 R
Inlet Pressure

0 psig
Outlet Pressure

249,8 psig
Molar Flow Rate 22,33 MMSCFD
Volumetric Flow Rate 0,365 ft
3
/s
Specific Gravity 1 -
Molecular Weight 28,92 lb/lbmole
Compressibility Factor

0,978 -
Compressor Efficiency 0,76 -
Stage number N 3 -

4.3.2 Operating Conditions Air Compressor C-202
Inlet : CO
2
to Sequestering
Inlet Temperature

779,4 R
Inlet Pressure

50 psig
Outlet Pressure

400 psig
Molar Flow Rate 16,42 MMSCFD
Volumetric Flow Rate 0,365 ft
3
/s
Specific Gravity 1 -
Molecular Weight 28,92 lb/lbmole
Compressibility Factor

1,010 -
Compressor Efficiency 0,79 -
Stage Number N 2 -


Reservoir CBM data:
Pressure: 400 psig with 500 meters depth.
4.3.3 Specification of Air Compressor
C-201
Operating conditions:
- Temperature at inlet (

) = 537
o
R
- Pressure at inlet (

) = 0 psig
- Pressure at outlet (

) = 249,8 psig
- Molar flow rate = 22,33 MMSCFD
- Volume flow rate () = 0,365 ft
3
/s
- Specific Gravity () = 1
- Molecular Weight = 28,92 lb
f
/lb mol
- Compressor efficiency () = 0,76
Calculated using: T in Kelvin,

using pressure ratio:

(

()

- Compressibility factor (

) = 0,9780

Calculated conditions:
- Compressor type : Reciprocating
- Stage number : 3
- Compression ratio per stage :
(

( ) ()(

) ()

( ) ()() ()

( )

( )

( )

( )

( ) ()(

) ()

( ) ()() ()

( )

( )

( )

( )

- Compressor head :
( )
( )

)(

)()
(

) ()
[(

()()()
(

) ()
[()

- Compressor power :
(

) (

) () (

) (

) [(

] (

)
(

) (

) () (

) () [()

] ()

- Discharge temperature :

[(

() [
[()

- Impeller diameter :

()

()



- Shaft speed :

()()
()


4.4 Pump
Centrifugal pumps are a sub-class of dynamic axisymmetric work-
absorbing turbomachinery. Centrifugal pumps are used to transport fluids by the
conversion of rotational kinetic energy to the hydrodynamic energy of the fluid
flow. The rotational energy typically comes from an engine or electric motor. The
fluid enters the pump impeller along or near to the rotating axis and is accelerated
by the impeller, flowing radially outward into a diffuser or volute chamber
(casing), from where it exits.
Common uses include water, sewage, petroleum and petrochemical
pumping. The reverse function of the centrifugal pump is a water turbine
converting potential energy of water pressure into mechanical rotational energy.

Centrifugal Pump

Like most pumps, a centrifugal pump converts mechanical energy from a
motor to energy of a moving fluid. A portion of the energy goes into kinetic
energy of the fluid motion, and some into potential energy, represented by fluid
pressure (Hydraulic head) or by lifting the fluid, against gravity, to a higher
altitude.
Advantages and Disadvantages of Centrifugal Pumps

Advantages

Disadvantages
Simpledesign
Compact
Lowcost
Wide rangeofcapacities
(2 2300m
3
/h)
Widerangeof liquids
(slurry, water,oil,
hazardous liquids,)
Smooth dischargeflow
Relatively quietoperation
Pumpwill not be damaged if
dischargelineis blocked.
Notsuitablefor viscousliquids
Theyarenotself-priming
Flowof liquid
bygravityisnotpreventedwhen
pump is stopped.
Poorly suitedtosmall capacities

The transfer of energy from the mechanical rotation of the impeller to the
motion and pressure of the fluid is usually described in terms of centrifugal force,
especially in older sources written before the modern concept of centrifugal force
as a fictitious force in a rotating reference frame was well articulated. The concept
of centrifugal force is not actually required to describe the action of the centrifugal
pump.
The outlet pressure is a reflection of the pressure that applies the
centripetal force that curves the path of the water to move circularly inside the
pump. On the other hand, the statement that the "outward force generated within
the wheel is to be understood as being produced entirely by the medium of
centrifugal force" is best understood in terms of centrifugal force as a fictional
force in the frame of reference of the rotating impeller; the actual forces on the
water are inward, or centripetal, since that is the direction of force need to make
the water move in circles. This force is supplied by a pressure gradient that is set
up by the rotation, where the pressure at the outside, at the wall of the volute, can
be taken as a reactive centrifugal force. This was typical of nineteenth and early
twentieth century writings, mixing the concepts of centrifugal force in informal
descriptions of effects, such as those in the centrifugal pump.
4.4.1 Principle of Operation
The impeller of such a pump is magnetically coupled with the motor,
across a separation wall which is resistant to the fluid pumped. The motor drives a
rotor carrying one or several pairs of permanent magnets, and these drag around a
second pair(s) of permanent magnets attached to the pump impeller.
4.4.2 Principal Characteristics of Pump
The nomenclature define below is used by engineers to describe the
operating characteristics of a pump.
a. Flowrate
Flowrate(or capacity) refers to the volumeof liquid passing through the
pump per unit of time.
Normal flowrate is the volume of fluid actually delivered perunit of time at
the stated operating condition sindicated in the material balance established
for the nominal operating conditions.
Design flowrate is equal to the normal capacity corresponding to the
nominal operating conditions increased by the overcapacity factor (or
pump design factor).
Overcapacity Factor Recomended for Pump
OvercapacityFactor
Recommended (%)

Type of Pump
0 Loading pump(toatanker)
10 Utilitypumps andotherprocess pumps
15 Exportpump
fromstoragetopipeline(continuousoperation)
20 Refluxpumpsand boiler feedwater pump
20 Boiler feedwater pumps

b. Head
The energy imparteed to a fluid by a pump consists of useful energy in the
form of pressure, velocity, or height above the datum point. The useful energy can
be expressed in terms of head in metres or feet.

Gambar 4.2 Illustration of Pump Head
The term head is also used to express changes of energy. For example, the
static head refers to the difference between the suction and final discharge static
levels in an open system and the total differential head is the total discharge head
minus the total suction head
c. Net Positive Suction Head (NPSH)
Two NPSH definitions areused in pumpingsystems:
Net Positive Suction Head required (NPSHR) is the head required by the
pump in order to prevent the liquid stagnation pressure dropping below
the vapor pressure and resulting in liquid boiling. Liquid boiling can lead
to cavitation. The NPSHR is a characteristic of the pump it self and is
generally determined experimentally by the pump manufacturer.
Net Positive Suction Head available (NPSHA) is the excess pressure of
the liquid in height absolute over its vapor pressure as it arrives at the
pump suction. It is a characteristic of the system in which the
pumpoperates.
d. Power
Two power definitions are used in pumping systems:
Hydraulic Power is the amount of power imparted to the liquid as it passes
through the pump.
Brake Power (or shaft power) is the amount of power delivered to the
pump (asopposed to the power used by the motor). The brake power
required will depend on the pump efficiency.
e. Efficiency
Pump efficiency is equal to the ratio between the hydraulic power
required and the brake power. It refers to the mechanical efficiency of the pump
and does not take into account the motor efficiency.
In our plant, centrifugal pump is labelled as P-201, P-202, and P-301 in
our plant PFD and it is used to pump water from water pond to heat steam
recovery generation, utility system, and for the heat exchanger system. The
specifications of our centrifugal pumps P-201, P-202, andP-301 are explained as
follow:
For pump sizing, the reference is used to determine the type of the pump
used, calculate the pump pressure drop, NPSHA, shut-off pressure, minimum
suction pressure, maximum discharge pressure, brake power needed and the pump
head, all calculated manually using Microsoft Excel. The formulas used are as
follows:
To calculate pressure loss due to piping and component friction is
calculated with the following equation (Metric):

Where

To calculate pump head the following formula is used (Metric):

Where

To calculate pump differential pressure the following formula is used:

To calculate brake pumping power the following formula is used:

The minimum suction pressure at rated capacity available at the centerline
of the pump suction flange is determined using the characteristics of the
suction section piping.

Where

The maximum discharge pressure at rated capacity available at the
centerline of the pump discharge flange is determined with the
characteristics of the discharge section piping.

Where

Net Positive Suction Head Available (NPSHA) is expressed by equation as
follows:

Where

4.5 Conveyor
4.5.1 Bucket Conveyor
This operating unit serves to bring the EFB from storage to shredder that is
located higher, using baskets contained in a series of rotating belt.
a. Type and Material of Bucket Elevator
- Type of elevator : supercapacity continous bucket
- Materials : melleable-iron (cheaper than steel bucket)
- Operational condition : 28
o
C, 1 atm
b. Capacity and Distribution Rate
Distribution rate of raw materials is 4875 kg/hour, based on the literature
Tabel 21.8 Perrys Chemical Engineering Handbook, than it must be provided
bucket spacing by 12%, so that the raw materials transported do not overload on
each bucket and fall. So that the space needed is:

Thus, the total rate of distributions obtained by:

c. Specification
For distribution rate of raw materials <14 tons/hour, specifications
determined by reference to the literature Table 21-8 Perrys Chemical
Engineering Handbook. Those specifications are:
- Height of elevator : 25 ft = 7.62 m
- Dimension of the bucket : (p x l x t) = (25.4 x 15.2 x 15.9) cm
- Space per bucket : 18 in = 45.72 cm
- Speed of the bucket : 1.32 m/s
- Rotational velocity of the head: 41 rpm
- Width of the belt : 13 in = 33,02 cm
d. Power Requirement
Power required by bucket elevators to operate (refer to the literature, the
Plant Design and Economics for Chemical Engineers, Peters and Timmerhaus) is
described as follows:

with:
P = Power needed (kW/s)
m = Mass distribution rate(kg/s), is 5460 kg/hour or 1.52 kg/s
z = Height of the elevator (m), is 25 ft or 7,62 m

(

e. Amount of buckets on the elevator
The number of buckets on elevator depends on the dimensions of the raw
materials that will be distributed. The following are the dimensions of the EFB
- Length : 23 cm
- Width : 27 cm
- Thickness : 2 cm
Thus, the estimated amount of EFB that can fit into each bucket on the
elevator, where the dimensions of the bucket is as precise as mentioned on the
specification. Thus, each bucket is only able to carry 1 piece EFB so that the
amount necessary to distribute the raw materials in accordance with the
distribution rate is as follows:
- Height of the elevator: 25 ft = 7.62 m (based on specification)
- Approximate length of the belt : 7.62 m x 2 = 15.24 m 16 m
- Space between bucket : 18 in = 45.72 cm = 0.457 m (based on
specification)
- Velocity of the elevator : 1.32 m/s = 4752 m/hour
Then, within an hour, each bucket elevators will rotates as much:









With a capacity of 5460 kg / hour and the average weight of EFB is 3,3 kg., then
the amount of EFB in each hour is:

4.5.2 Bucket Conveyor
Belt conveyor is used to carry raw material from the shredder to size
pulverizer unit.
a. Operation Condition
- Temperature : 28
o
C
- Pressure : 1 atm
b. Dimension and Type of Conveyor
- Belt type : horizontal wire mesh belt
- Material : stainless steel and polymer belt
- Raw material capacity : 4445 kg/hour
Referring to the literature, it should provide space to avoid overloading
which can lead to the fall of the material by 20% of the volume of material to be
distributed, which is equal to:

Then total mass flow rate to be distributed by conveyor is:

c. Belt Conveyor Specification
Based on Table 21.7 ofPerrys Chemical Engineering Handbook, for
capacity less than 32 ton/hour, the conveyor belt is used with the following
specifications:
- Widht of belt : 14 in = 35 cm
- Cross sectional area of load : 0.11 ft
2
= 0.010 m
2

- Normal belt speed : 200 ft/min = 61 m/min
- Maximum belt speed : 300 ft/min = 91 m/min
- Belt rotational speed during operation adjusted wih bucket elevator rate,
which is 1.32 m/s.
- Power: 0.44 hp = 0.33 kW
- Belt conveyor length estimation: 50 ft = 15.3 m

4.6 Fischer Tropsch Reactor
Equipment Spesification
Equipment name FT Reactor
Equipment code
Function to synthesis syngas into hydrocarbon
Catalyst Fe
Equipment type
Amount of equipment 1
Operation Data
Pressure (kPa)
Temperature (K)
Mass flow feed (kg/hr)
Superficial gas velocity (m/s)
Construction Data
Volume (m3)
Diamter (m)
Length (m)



4.6.1 Mechanism Of Fischer Tropsch Reactor
In the Fischer-Tropsch process, the synthesis gas (H
2
and CO) reacts in
presence of solid catalyst to produce a wide range hydrocarbon products, such as
olefins or paraffins. This selection of product will be based on operating condition
of the process. In this case, we want our product to be paraffins so use the
operating condition of LTFT (Low Temperature Fischer-Tropsch). The F-T
synthesis is a combination of oligomerization reaction which can be summarized
as follow:
( )

There is another reaction that is controlled by the type of catalyst used
may or may not be active to it such as:

There are three possible reaction mechanisms which are carbide
mechanism, enol mechanism, and CO-insertion mechanism. We focus our
mechanism at carbide mechanism because it is still favourite mechanism among
the research communities. In this mechanism, both CO and H2 are dissociatively
adsorbed on the catalyst surface. The adsorbed C and O are then hydrogenated
into CH2 and H2O. the CH2 adsorbed can be further hydrogenated into CH3
and/or insert itself into carbon metal bond of an adsorbed CnHm species allowing
the chain to grow.

Figure X.X. Carbide Mechanism of Fischer Tropsch
(Source: van Dijk, H.A.J., The Fischer-Tropsch synthesis: A mechanistic study using transient
isotopic tracing. Ph.D. Dissertation)

4.6.2 Operating Condition of Fischer Tropsch Reactor
In terms of operating condition, FTR can be divided into two types which
are LTFT (low temperature fischer tropsch) and HTFT (high temperature fischer
tropsch). The LTFT tends to make paraffins and HTFT tends to make olefins. In
this case, we use LTFT for our operating of condition:
T = 513 K
P = 2000 kPa

4.7 Hydrocraking Reactor
Equipment Spesification
Equipment name Hydrocracker
Equipment code
Function
To convert long chain HC into
short chain HC
Catalyst
Equipment type
Amount of equipment 1
Operation Data
Pressure (kPa)
Temperature (K)
Mass flow feed (kg/hr)
Construction Data
Volume (m3)
Diamter (m)
Length (m)

4.8 Fractionator
Fractionation is a separation process that is separating a certain quantity of
a mixture (gas, solid, liquid, suspension or isotope) which is divided during a
phase transition into a number of smaller quantities (fractions) in which the
composition varies according to a gradient. Fractions are collected based on
differences in a specific property of the individual components. A common trait in
fractionations is the need to find an optimum between the amount of fractions
collected and the desired purity in each fraction. Fractionation makes it possible to
isolate more than two components in a mixture in a single run. This property sets
it apart from other separation techniques.
Fractionators 1
Equipment Spesification
Equipment name Fractionators
Equipment code
Function to separate gas into product
Catalyst

Equipment type
Amount of equipment 1
Operation Data
Pressure (kPa)
Temperature (K)
Mass flow feed (kg/hr)
Superficial gas velocity (m/s)
Construction Data
Volume (m3)
Diamter (m)
Length (m)

Fractionation 1 is used to separate the desired product which are ethane
propane butane that contain in the stream. Distillation process is used to separate
several component from the stream. Several step to design distillation column is:
Minimum Number of Equilibrium Stages

*(

) (

)+
(

)

Minimum Reflux Ratio

Figure . Gilliland correlation for ordinary distillation
Fractionators 2
Equipment Spesification
Equipment name Vertical Separator
Equipment code
Function to separate gas into product
Catalyst

Equipment type Fractionators
Amount of equipment 1
Operation Data
Pressure (kPa)
Temperature (K)
Mass flow feed (kg/hr)
Superficial gas velocity (m/s)
Construction Data
Volume (m3)
Diamter (m)
Length (m)
Mesh pad

Volume Held Up


Fractionation 2 is used to separate gas from the liquid product. The top
product is gas and the bottom product is liquid. The gas will be processed back to
get more product. Several step to design vertical separator is:
Settling Velocity

Using demister pad

Vapour Volumetric Flowrate

Liquid Volumetric Flowrate

D
v

Volume Held Up

Liquid Depth (h
v
)

Separator surface area

Separator Height

Separator Thickness

Top Thickness

Separator Wight
Shell

Head and Bottom