Professional Documents
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}
GROUP 26
Amirah Amatullah
(1206262071)
Farisa Imansari
(1206212426)
Nurhayati
(1206246616)
Osvaldo Sahat
(1206247796)
Shella
(1206238721)
CHAPTER I
Background
Literature overview
Raw Material Analysis
Market and Production
Capacity Analysis
Plant Location Analysis
CHAPTER III
Mass Balance
Energy Balance
CHAPTER II
Process Selection
Process Description
Block Flow Diagram
Process Flow Diagram
CHAPTER IV
Conclusion
{
Indonesia is the largest producer
and exporter of palm oil worldwide.
Each processing of 1 ton fresh fruit
bunch will be generated 22-23% oil
palm empty fruit bunch
}
Oil palm empty fruit bunch usually
used by the CPO industry as fuel for
the boilers and burners, which
generating oil palm empty fruit
bunch ash.
}
Properties of potassium chloride
Chemical formula
KCl
Molar mass
74.5513 gmol1
Appearance
Odor
odorless
Density
1.984 g/cm3
Melting point
Boiling point
Solubility in water
(Source: various
Properties
Solubility
Acidity (pKa)
~7
The main raw material of potassium chloride plant is oil palm empty fruit bunch ash,
which often used as fertilizer. Oil palm empty fruit bunch ash has high potassium
levels. The chemical composition of oil palm empty fruit bunch ash is:
Availability and potential of oil palm empty fruit bunch ash can be seen from the
CPO plant production capacity data. Here is palm oil production data from 2007
until 2015:
Palm oil production and export
2007
2008
2009
2010
2011
2012
2013
2014
2015
Production
(million metric tons)
16.8
19.2
19.4
21.8
23.5
26.5
27.0
31.0
31.5
Export
(million metric tons)
n.a
14.2
15.5
15.6
16.5
18.1
21.2
20.0
19.5
n.a
15.6
10.0
16.4
20.2
21.6
19.0
18.4
Export
(in USD billion)
(Source : Food and Agriculture Organization of the United Nations, Indonesian Palm Oil Producers Association
(Gapki) and Indonesian Ministry of Agriculture, 2015)
The CPO industry will obtain oil palm fruit empty bunch waste around 1.2-1.4 tons for
each ton CPO production
7
Together, the U.S., Brazil, China and India represent about two-thirds of world potash
consumption
8
}
In this analysis we will
use the global
demand of
potassium chloride
data as our
reference to
determine the
capacity
Parameter
Global demand of potassium chloride in Southeast Asia, 2015
Global demand of potassium chloride for non-fertilizer
Global demand of potassium chloride for industrial
Market share
Production capacity for Southeast Asia
Production capacity of our plant (Just to meet the demand of
4 countries)
Production capacity / day
Quantity
6 million
540000
54000
2%
1080
Unit
Tons/year
Tons/year
Tons/year
%
Tons/year
Source
CRU
CRU
K+S Group
Assumption
Calculation
390
Tons/year
Calculation
1,2
Tons/day
Assumption: 330
work day
{
Primary
Factor
Secondary
Factor
Soil and climate conditions is one of the main factors in choosing a plant
location. We need to choose the area, which is not vulnerable to the
danger like landslides, earthquakes, and floods, as a location for our
plant.
10
}
(Source: Googlemaps.com, 2015)
We decided to built our plant beside PT Agronusa Investama in Sambas, West Kalimantan,
with the production capacity of up to 390 tons/year
Close from the source of raw material, which make it more efficient
and make the transportation costs is low
It is near the harbor (Sintete) which made us easier to deliver
potassium chloride to Singapore, Malaysia, and Brunei Darussalam.
This advantages can reduce the cost of exported the product
12
Process Selection
Neutralization
Material
Purification
Equipment
14
2. HCl + K+ KCl + H+
15
}
Ksp
HCl + K+ KCl + H+
Reactivity
Lattice
enthalpy
16
}
Parameter
Percentage
NaCl
HCl
Rating
Scoring
Rating
Scoring
15%
0.3
0.75
25%
1.25
0.75
Solubility
25%
0.75
1.25
10%
0.2
0.4
11
2.5
18
3.15
TOTAL
65%
17
Mixing boiling
boiling water
Mixing
water
Evaporation
Evaporation
18
Evaporation
19
}
Parameter
Percentage
Purity
Evaporator
Rating
Scoring
Rating
Scoring
25%
1.25
0.75
Energy
requirement
25%
1.25
0.75
25%
1.25
0.5
25%
1.25
0.75
TOTAL
25%
11
2.5
18
1.5
20
}
Main Raw Material: Ash from oil palm fruit empty fruit
bunches
Silo Tank: A vessel or a container which is specifically
functioned to safe raw materials in bulk.
Silo Tank
{
Leaching: an operation where the two
phases involved, solid and liquid, are in
intimate contact. The solutes are able to
diffuse from the solid to the liquid phase,
causing a separation of the components
originated in the solid.
Water leaching: construed as the removal
of water soluble and ion-exchangeable
inorganic constituents from solid substrate
with water. It is an inexpensive method to
decrease inorganic constituents in the
biomass content.
}
Except KCl, there would still be some other
constituents dissolved. Counter-current leaching
is applied in this leaching process to increase
the potassium chloride concentration in the
leaching liquor.
22
23
The liquid containing potassium that is generated from water leaching is transferred to
a batch reactor vessel where it is subjected with hydrochloric acid to form a
neutralization reaction.
Objective: to precipitate potassium chloride by
reacting potassium ion from the leached ashes with
hydrochloric acid.
The reaction between potassium and hydrochloric
acid has the lowest Ksp value compared to the
other compounds if reacted with said acid.
Since it has the lowest Ksp value, potassium chloride
is more likely to precipitate first before the other
precipitation that can occur (calcium chloride or
magnesium chloride).
25
Filtration: the process of separating suspended solid matter from a liquid, by causing the
latter to pass through the pores of some substance called a filter. The liquid that passes
through the filter is called the filtrated.
Objective: the removal of the residual liquid that wets the potassium chloride produced
after the neutralization process. The liquid from wet potassium chloride formed from the
neutralization process is full of Calcium and Magnesium ions which could affect the
purity of potassium chloride needed.
26
Time 30 minutes
Temperature 27oC
Pressure 1 bar
Membrane size 0.1 m
Feed Inlet 71.98427 tons/day
Filtrate 63.75 tons/day
Concentrate 8.24 tons/day
27
{
Falling film evaporator is constructed
with vertical shell-and-tube heat
exchanger, with a laterally or
concentrically arranged centrifugal
separator.
}
Objective: to produce a more moistureless final
product.
Evaporation: the process by which water changes
from a liquid to a gas or vapor.
Provides a higher product quality due to the gentle
evaporation and extremely short residence times in the
falling film evaporator.
Caters high energy efficiency, due to the multipleeffect arrangement or heating by thermal or
mechanical vapor recompressor.
Requires simple process control and automation.
Reacts quickly to changes in energy supply, vacuum,
feed quantities, concentrations, etc. (Important for a
uniform final concentrate).
28
Temperature 95oC
Time 30 minutes
Pressure 1 bar
Feed is heated in advance with a heater until it reaches 95oC.
Requires a steam generator
Feed inlet 8.246 tons/day
Gas out 7.071 tons/day
Solid out 1.165 tons/day
29
Temperature 18oC
Pressure 1 bar
Time 30 minutes
Feed inlet 1.165 tons/day
Solid Outlet 1.165 tons/day
Requires a chiller for the cooled water as cooling agent
Feed is cooled in advance with a cooler until it reaches 18oC.
31
{
EPOFB
Ashes
Storage
EPOFB
Ashes
Water
Leaching
}
Leached
Liquid
Leaching Residual
HCl
Neutralization
Mineral Residue
Steam
KCl (Wet)
Microfiltration
KCl Cake
Evaporation
KCl (Dry)
Crystallization
Residue
KCl
Packaging
32
33
35
Solid
In
Stream (Ton/day)
Liquid
Liquid
In
Out
Solid
Out
6.23
70
70
70
0.603
0.100
0.013
-70.72
0
0
0
0
-6.23
Stream (Ton/day)
Input
HCl 37%
Output
70
0.603
0.100
0.013
70.72
0.706
0.563
1.27
70.71
0
0.100
0.013
0
1.16
71.98
36
Stream (Ton/day)
Feed
Filtrate
Concentrate
Ash
(Biomass)
Water
70.71
63.63
7.070
K+
Ca2+
0.100
0.100
Mg2+
0.013
0.013
HCl
KCl
1.165
1.165
Total
71.98
63.75
8.236
Ash
(Biomass)
Water
K+
Ca2+
Mg2+
HCl
KCl
Total
Stream (Ton/day)
Feed
Vapor
Liquor
7.070
0
0
0
0
1.165
8.236
7.070
0
0
0
0
0
0
0
0
0
1.165
1.165
7.070
37
Ash
(Biomass)
Water
K+
Ca2+
Mg2+
HCl
KCl
Total
Stream (Ton/day)
Feed
Vapor Product
-
1.165
1.165
0
0
1.165
1.165
Ash
(Biomass)
Water
K+
Ca2+
Mg2+
HCl
KCl
Total
Stream (Ton/day)
Input
Output
-
1.165
1.165
1.165
1.165
38
205800
10265500
10471300
Output (kJ)
Ash
Water
K+
Ca2+
Mg2+
Total
184746.66
10265500
11391.03
2207.205
488.775
10464333.67
6966.33
7998918.532
8787.366
1702.701
377.055
47699.17794
8057484.832
Output (kJ)
Water
K+
Ca2+
Mg2+
HCl 37%
KCl
Total
7998918.532
1702.701
377.055
21709.96749
8022708.256
34776.58
39
Output (kJ)
Water
7998918.53
Ca2+
1702.701
Mg2+
377.055
KCl
21709.967
Total
Total
8022708.26
0.00
8022708.26
2814434
76386.92
2890821
Output (kJ)
Water
Vapor
KCl
Total
1266160
76386.92
1342547
1548275
40
2814434
76386.92
2890821
Output (kJ)
Water
Vapor
KCl
Total
1266160
76386.92
1342547
1548275
14473.31
Output (kJ)
KCl
14473.31
0
Total
14473.31
Total
14473.31
41
}
Raw Material Input (kJ)
Material
Energy
Ashes
205800
Total
205800
Energy
KCl
21709.967
Total
21709.967
42
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