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UNIVERSITAS INDONESIA
Final Report
GROUP 1
GROUP PERSONNEL:
ALFIANI GUNTARI MAHADEWI (1306370871)
AYU GAYATRI (1306447663)
DYAH PARAMAWIDYA (1306447846)
EGA ADI SURYA (1306412174)
TRISIANA CHRYSANTHI SANDRALINTANG (1306371054)
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LIST OF GROUP MEMBERS
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PREFACE
Praise to God, The cherisher and sustainers of the worlds; God who has
been giving His blessing and mercy to the writer to complete this Final Report
entitled Preliminary Design Of Di-Ethanolamide Plant From Crude Palm Oil
(CPO)
This Final report is submitted to fulfill one of the requirements in
Chemical Plant Design Class as capstone course of Chemical Engineering Major
in Universitas Indonesia.
In finishing this report, the writer really gives his regards and thanks for
people who has given guidance and help, they are :
1. Prof. Dr. Ir. Widodo Wahyu Purwanto, DEA. , Dr. rer. nat. Ir. Yuswan
Muharam M.T. , Prof. Dr. Ing. Ir. Misri Gozan M.Tech., Dr. Tania Surya
Utami, S.T,.M.T and others lecturers, who has given their best guidance to
the writer in writing a great quality report and well developed chemical
product.
2. The informant of our questionnaire that helps indirectly to begin this
report
3. Our Parents, who always give their supports, prayers, and blessing.
4. All friends in Chemical Engineering Department who always give their
supports.
Finally, the writer realizes there are unintended errors in writing this final
report. The writer really appreciates all readers giving their suggestion to improve
its content in order to be made as one of the good examples for the next report.
One of Indonesias most developing sector and commodity in agriculture and fast-
moving consumer goods (FMCG) products is palm oil. Indonesia is considered as
one of the worlds largest palm oil and palm fruit producers, and to its extent, the
global demand of palm oil derivate products has also increased in the past years.
Derivate products of palm oil include; biodiesel, variety of food, as well as
cosmetic and personal hygiene care. In this preliminary plant design, our
application of palm oil focuses on cosmetic and personal hygiene care products,
where emulsifiers and surfactants plays a critical role in the products stability.
Solution to reduce the import number of surfactans, such as Alkyl Benzene
Sulfonate, is by making a di-ethanolamide from indonesian natural resource, that
is Crude Palm Oil (CPO), has same function as surfactant for cosmetic product
such as soap and shampoo. Di-Ethanolamide plant will be built in Jalan Pulau
Sumatera near Kawasan Industri Dumai with production capacity is 10,000
tons/year. The overall production process that will go through selection is divided
into three parts which are CPO refinery, di-ethanol amide formation, and
purification. Based on economic analysis calculation, the payback period for our
plant is 4.35 years of operation (10 years life time) with 19 % of IRR, 43,476.59
ton of BEP and US$ 699,706.68 of NPV costs.
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Executive Summary
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Sizing the equipment and instruments is critical because this information
will help us decide and estimate the piping, pump, and control systems. Not only
that, sizing the equipment will enable us to plan and layout our plant. To show
specific details on the production process, a P&ID of all the equipment are
necessary, where it shows piping sequence, controlling elements and parameters,
and even control interlocks. Our plant consists of 41 equipment, which includes 9
vessels/ tanks, 15 pumps, 3 filters, 2 reactors, 1 flash column, 1 mixers, 5 heat
exchangers, 1 decanter, 1 heater, and 3 coolers.
Analyzing health, safety, and environment (HSE) aspect of our plant is
also important. By doing so, we can establish a protocol for handling accidents,
emergencies, as well as firefighting. Our plants HSE analysis also includes plant
process safety management, where it is based on OSHA and Peraturan
Kementrian Ketenagakerjaa. Another crucial decision for our plant is plant
layout. This will not only impact the operation in the long term, but also the
quality of work environment for the employees as well as HSE aspect. Another
consideration that is important for a plant layout is the spacing which includes
spacing between instruments, people, and constructions. Our plant has a total area
of 14,703.96 m2, which consists of a production, utility, waste water treatment,
administration, supporting as well as evacuation and emergency area. The
production area of our plant is both indoors and outdoors because some equipment
is not quite applicable for an indoor situation. We also have a warehouse,
laboratory, and control room to support our production process.
To find out whether our plant feasible to set or not, it is necessary
economic analysis calculations. The plant will be built in 2017 and the duration
estimated for plant completion is 1 year. The total capital investment for our plant
is $2,467,568.97 USD , operational cost of our company is $13,740,262.14 USD,
and the price of Cocomide DEA is $1,500 USD/ton. To fulfil the need of starting
capital, were loan from two different sources, banks debt from Mandiri (40%)
and investors equity (60%). Based on economic analysis calculation, the payback
period for our plant is 4.35 years of operation (10 years life time) with 19 % of
IRR, 43,476.59 ton of BEP and US$ 699,706.68 of NPV costs.
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Table of Contents
TITLE ....................................................................................................................... i
LIST OF GROUP MEMBERS ............................................................................... ii
PREFACE .............................................................................................................. iii
ABSTRACT ........................................................................................................... iv
Executive Summary ................................................................................................ v
Table of Contents .................................................................................................. vii
List of Tables........................................................................................................... x
List of Figures ....................................................................................................... xii
CHAPTER 1 ........................................................................................................... 1
INTRODUCTION .................................................................................................. 1
1.1. Background .......................................................................................................1
1.2. Literature Riview ..........................................................................................1
1.2.1. Crude Palm Oil (CPO) ...........................................................................1
1.2.1.1. Free Fatty Acids (FFA) ................................................................... 2
1.2.1.2. Moisture of CPO ............................................................................. 3
1.2.1.3. Heavy Metal Contents ..................................................................... 3
1.2.1.4. Deterioration of Bleachability Index (DOBI) ................................. 3
1.2.1.5. Oxidized Products ........................................................................... 4
1.2.1.6. Minor Constituents .......................................................................... 4
1.2.2. Refined Bleached Deodorized Palm Oil (RBDPO) ...............................4
1.2.3. Diethanolamine (DEA) ..........................................................................5
1.2.4 Cocamide DEA .......................................................................................6
1.3. Market and Capacity Analysis ......................................................................7
1.4. Plant Location Analysis ................................................................................9
1.4.1. Raw Material Availability ......................................................................9
1.4.2. Product Distribution ...............................................................................9
1.4.3. Water Accessibility ..............................................................................10
1.4.4. Labor Availability ................................................................................10
1.4.5. Infrastructure ........................................................................................10
CHAPTER 2 ..........................................................................................................12
PROCESS SYNTHESIS ........................................................................................12
2.1. Alternative Processes and Selection...........................................................12
2.1.1. CPO Refinery .....................................................................................12
2.1.1.1. Physical Refinery ...........................................................................12
2.1.1.2. Chemical Refinery .........................................................................13
2.1.1.3. Physical Refinery with Membrane Technology.............................13
2.1.1.4. Process Selection............................................................................13
2.1.2. Cocamide DEA Formation...................................................................17
2.1.2.1. Cocamide DEA Formation without catalyst ..................................17
2.1.2.2. Cocamide DEA Formation with Sulphuric Acid Catalyst .............17
2.1.2.3. Cocamide DEA Formation with Acetic Anhydrade Catalyst ........18
2.1.2.4. Cocamide DEA Process Scoring ....................................................18
2.2. Process Description .....................................................................................21
2.2.1. CPO Refinery .......................................................................................21
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List of Tables
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Table 6.4. Waste Identification ............................................................................ 90
Table 6.5. Wastewater Parameter ......................................................................... 91
Table 7. 1. Process Equipment Cost ..................................................................... 96
Table 7. 2. Piping Cost ......................................................................................... 97
Table 7. 3. Piping Elbow Cost .............................................................................. 97
Table 7. 4. Piping Valve Cost............................................................................... 98
Table 7. 5. Offsite facilities cost ........................................................................... 98
Table 7. 6. Total Cost of Land and Building ........................................................ 99
Table 7. 7. Total Capital Expenditure .................................................................. 99
Table 7. 8. Raw Material Cost of Cocamide DEA Plant .................................... 100
Table 7. 9. Insurance Cost .................................................................................. 105
Table 7. 10. OPEX Breakdown .......................................................................... 107
Table 7. 11. Producer Price ................................................................................ 108
Table 7. 12. Total Depreciation .......................................................................... 109
Table 7. 13. Selling Price Analysis .................................................................... 112
Table 7. 14. Raw Material Analysis ................................................................... 113
Table 7. 15. Labor Cost Analysis ....................................................................... 114
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List of Figures
1.1. Background
As the demand of cosmetic and personal care products increases
nowadays, the development of surfactants is indeed crucial. The most important
property from surfactants is their amphiphilic ability, which means that one part of
the molecule is lipophilic and the other is lipophobic. A number of synthetic or
petroleum based surfactants and emulsifiers are known to be toxic to animals,
ecosystem, and humans; and can increase the diffusion of the other environmental
contaminants (Emmanuel et al., 2005; Metcalfe et al., 2008). Hence, the need to
produce low cost and ecofriendly surfactants from renewable and biodegradable
sources is necessary.
Cocamide DEA (CDEA) or cocamide diethanolamide is a diethanolamide
derived from a mixture of fatty acids from palm oil with diethanolamine. This
viscous substance is mostly used as a non-ionic surfactant, foaming agent, and
emulsifiers in products such as hair shampoos, hand soap, aqueous-based cleanser,
and numerous cosmetic products. The usage of crude palm oil as the fatty acid
base is due to the fact that Indonesia is one of the largest producers of palm fruit
and oil, with 32 MT palm oil produced in 2016 according to Indonesias
Investment. However, Indonesia has not produced its own CDEA. In order to
fulfill the consumers increasing needs of cosmetic and personal care sector, a
plant design for dietahnolamide, specifically from palm oil is needed.
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refined oil with minimal possible oil loss and damage to the oil. Compositions of
crude palm oil is summarized in the table 1.1.
The quality of crude palm oil depends on the contents of the free fatty
acids, moisture, heavy metal, DOBI, oxidized products, and minor constituents;
where these factors will differ crude palm oil and the derivative products.
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chemical and physical reactions as well as its process variables (moisture levels,
temperature, contact time, oil quality).
The third process to refine CPO into RBDPO is deodorization.
Deodorization is a stripping process that uses a stripping agent (commonly steam)
to release volatile components of oil through a low pressure operation condition.
CPOs quality that has been deodorized is evaluated by parameters such as low
residual FFA content, a high oxidative stability, a light color and a bland odor and
taste. Specifications of RBDPO and CPO can be compared from the Table 1.2.
below.
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Figure 1.2. Reaction scheme of the synthesization. R1, R2, R3 are the alkyl chains with or without
epoxide(s) functionality
(Source : www.researchgate.net)
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plant with big city in Sumatera. This road also give us access to major harbour in
Sumatra Island that help us distribute our products such as Pelabuhan Penumpang
Dumai that connect us with Malaysia and Singapore, and Pelabuhan Bakauheni in
Lampung that connect us with Java Island. This will help us increase our profit by
expanding our market and reduce product distribution cost.
1.4.5. Infrastructure
The location that we choose is passed by Sumatera Island main road,
which is Jalan Pulau Sumatera. Our plant also located near Kawasan Industri
Dumai, which give us good electricity and telecommunication infrastructure.
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(Source: maps.google.com)
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CHAPTER 2
PROCESS SYNTHESIS
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phospholipids thus making them easy to separate from the oil. The acid will then
be carried along to the bleaching and deodorization stage where it will be removed
using high pressure steam with high temperature.
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comparison, the physical process with membrane technology does not use any
acid at all. Therefore, it is scored the highest in terms of process with less toxicity.
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Table 2.1. Scoring for CPO refinery alternative
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160 C (International
Journal of
Operating 110C ( Journal of
Innovative
1 Condition 80C (US 5108661 A) American oil
Research in
Sustainability Chemistry Society)
Science, Engineering
and
Technology)
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Based on table 2.3., we can see that the scoring number is different. Score
of cocamide DEA formation using Sodium Methylate Catalyst is higher than
using sulphuric acid catalyst or without enzyme. Based on table 2.3., yield product
of cocamide DEA formation using Sodium Methylate Catalyst is higher than
using sulphuric acid catalyst and without catalyst. The use of catalyst is not cheap
so it can increase capex and opex, because it should add to the operating units
such as catalyst storage tank and separation tank to separate the catalyst with
impurity cocamide DEA, and also increase cost for purchasing catalyst. Based on
research from Ir. Renita et al (2013), synthetis of diethanolamide by using
sulphuric acid catalyst and without catalyst need high temperature, so it can
increase energy for heating and impact on the increase in operating costs. Based
on above explanation, so we choose process of cocamide DEA formation using
sodium methylate catalyst.
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2.2.1.2. Bleaching
The second step in CPO refinery is called bleaching. This process remove
the colour-producing substances and further purify the palm oil. A bleaching
agent is used in the removal of colour and impurities in this process. A bleaching
agent is a substance, in this chase is called bleaching earth, which have the
capability to adsorb pigment-type molecules because of their affinity towards it.
This removal process will produced a cleaner, more clear oils without demaging
the oil.
The bleaching agent used in this procedure is acid activated bleaching
earth. Bleaching earth itself is a decolourising agent, which will change the tint of
any coloured oil to a lighter shade by changing the basic colour units in oil,
without altering the chemical properties of the oil. This bleaching earth are
produced from high-purity montmorillonite clay which is treated with mineral
acid. It is said that the optimum ratio of bleaching earth to oil used in the process
are by range of 0,5-2,0% wt/wt (Rohani, 2006). In this process, we used a ratio of
1% wt/wt of bleaching earth, as recomended by Rohani in her research report.
2.2.1.3. Deodorization
The last step of CPO refinery are deodorization. Deodorization is the
removal of odor producing substance that may reduced palm oil purity and
quality. The odor substances are represented by free fatty acid (FFA). The filtered
oil (DBPO/Degummed Bleached Palm Oil) is channelled into the deodorizer that
will remove FFA in the oil mixture. The deodorized palm oil also passed through
a filter press before moving to the storage tank to make sure there is no suspended
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impurities carried by RBDPO. During this process, FFA will be removed at the
upper section of deodorizer. The FFA will be carried away by the steam and
separated in the form of palm fatty acid distillate (PFAD). Apart from FFA,
carotenoids pigments, primary, and secondary oxidation products are also being
removed.
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R1 represent the fatty acid in the triglyceride from palm oil and RdOH represent
the ethanol inside the amine.
Based on this reaction, 1 mol of triglyceride can be converted into 3 mol
of cocamide DEA, by reacting it with 3 mol diethanolamine, producing glycerol
as its by product. Sodium methoxide is used as catalyst to lower the energy
needed in reaction. The temperature needed to perform this reaction without any
catalyst is ranging from 130-200oC (EP 2321389 B1, 2015). However, in the
presence of sodium methoxide as methylation agent, the operation condition can
be lowered to as low as 80oC under vacuum condition. This reaction can achive
95% conversion.
The second reaction occur in a stirred tank reactor using acetic anhydride
as catalyst. The reaction occured in vacuum condition at 40o-45oC, and said to
give 99,5% conversion. The vacuum condition is between 300-400 torr, or 0,3-0,4
bar. 50 kg of acetic anhydrade is use for every 1000 kg diethanolamide produced.
Thus, the ratio of acetic anhydrade used is 5% from the product mass. The
residence time in this reactor is set to be 1 hour.
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sedimentation/decanting tank. This method will also separate some water which
occur on the heavy phase. The product from this process is gathered from the light
phase and will contaion cocamide DEA and water.
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Figure 2.2 Block Flow Diagram
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CHAPTER 3
EQUIPMENT SIZING AND SPECIFICATIONS
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For each pump specification are shown in appendix B, either about utility
specification process and calculation each equipment are shown at appendix C.
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CHAPTER 4
PROCESS CONTROL STRATEGY
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Level transmiter
will send the
Alarm reading about the
operator if level status of
the liquid the storage using
level in the electric signal to
Level storage is the level
Acetic Outlet
indicator low to indicator in the
Anhydride Liquid level stream flow Low
transmitter prevent control room,
Storage valve
(PI) production alarm will ring
shut down when the level is
caused by the low and operator
lack of will decrease the
catalyst outlet flow and
refill the storage
tank
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Temperature
indicator
transmiter will
read the exit
Make sure temperature of
that the the flow, the
cooler can be reading is sent to
Cooling
used to the cooling water
Outlet stream water flow Flow
Cooler - achieve the flow control
temperature control control (PI)
desired which will sent
valve
temperature pneumatic
for next unit control to the
operation control valve that
will reduce or
increase the
volumetric flow
rate
Level transmiter
Inlet stream
will notice if the
flow control Preventing
liquid level
valve the reactor
inside the reactor
from higher
Flow is too high or too
High; or lower
CSTR 2 Liquid level control low, giving
low level other
Catalyst (PID) signal to flow
than the
flow control control of inlet
design
valve stream and
parameter
catalyst to reduce
or increase the
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CHAPTER 5
PLANT LAYOUT
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cost and quality of the work environment, customer contacts and company image.
An effective layout can help achieve the strategy that supports the differentiation,
low cost, or a quick response. Destination layout strategy is to build an
economical layout that meets the needs of enterprise competition (Heizer and
Render; 2009:532). By Fred E Mayer in his book "Plant Layout and material
handling '(1993: 1) states that: Plant layout is the organization of the companys
physical facilities to promote the efficiently use of equipment, material, people,
and energy.
Another factor that must be considered for plant layout is the safety,
health, and environmental objectives of the layout to minimize the potential for
injuries, overall property and environmental damage, and related business
interruption. The magnitude of a potential incident may be reduced by:
Minimizing the potential quantity of hazardous materials that can be
released:
Quantities can be reduced by siting more, smaller tanks, reducing and
integrating storage and day tanks, or minimizing inventories in pipe ways.
Containing the release:
Providing containment by using dikes, utilizing changes in elevation, and
installing remote collection tanks and lined ponds.
Minimizing inventory in piping and equipment:
Locating units and equipment that interconnect to minimize running piping
lengths and piping traversing through unrelated units.
Appropriate drainage and grading:
Locating large inventories of hazardous liquids to drain away from process
units and occupied structures. Design drainage to minimize water treatment
needs and collection of liquids under vessels.
The impact of a potential incident may also be addressed by the following,
among others:
Providing adequate separation distances
Segregating different risks
Minimizing potential for and impact of explosion
Minimizing potential for and exposure to toxic release
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Figure 5. 2. Typical Flammable and Combustible liquid and liquefied Flammable Gases Tank
(Source: Assessment Methodology for Equipment Layout, 2015)
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Figure 5. 3. Typical Spacing requirement for On-site buildings for Fire Consequences
(Source: Assessment Methodology for Equipment Layout, 2015)
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CHAPTER 6
HEALTH, SAFETY, AND ENVIRONMENT
The consequence of the risk examine on how severely the risk could hurt
someone, while likelihood examine the frequency or how likely a risk may occur.
The HAZID analysis for our Cocamide DEA plant can be seen on Table 1.2.
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Table 6.2 Hazard Identification Analysis
Location/ Description Potential Causes Hazard Likelihood Prevention
Unit/Equipment Hazard Effect
CPO Storage To store liquid Leakage Over capacity Minor Possible Control and check
Unit crude palm oil storage level periodically
Ultrafiltration To separate Membrane Over flow Moderate Unlikely Control the flow and
Unit CPO and its filter pressure of CPO
retentate damage periodically
Mixing Unit To mix Leakage Over flow Moderate Possible Control the water flow
bleaching earth and the bleaching earth
and water size to prevent clogging
Clogging Clogging from
the pipes the solid
bleaching earth
Bleaching Unit To remove Major Unlikely Control the flow of the
color and CPO inlet as well as the
impurity in Leakage Over flow bleaching earth mixture.
CPO Moderate Possible Control both temperature
inlet.
Deodorizing To remove Fire and/or Over heating Major Unlikely Flow and temperature of
Unit odor and explosion the BPO must be checked
remaining regularly.
Leakage Over flow Moderate Possible
impurities from Medium pressure steam
BPO injection must be
Fire and/or Steam leakage Catastrophic Possible controlled thoroughly.
explosion
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Table 6.2. Hazard Identification Analysis (contd)
Location/ Description Potential Causes Hazard Likelihood Prevention
Unit/Equipment Hazard Effect
Plate and Frame To separate Plate and Over flow Moderate Unlikely Control the flow and pressure
Unit RBDPO from frame of RBDPO periodically
impurities damage
component
RBDPO Storage To store Leakage Over capacity Minor Possible Control and check storage
RBDPO level periodically
Methanol & Sodium To store Leakage Over capacity Moderate Possible Control and check storage
Methoxide Storage methanol and level periodically, as well as
Unit sodium Fire and/or Exposure to fire Major Unlikely keeping a distance from fire
methoxide explosion sources
DEA Storage Unit To store DEA Leakage Over capacity Moderate Possible Control and check storage
prior to usage level periodically, as well as
keeping a distance from fire
sources
Fire and/or Exposure to fire Major Unlikely
explosion
CSTR 1 Unit For Cocamide Leakage Over capacity Moderate Unlikely Flow and temperature of the
DEA inlet liquid must be checked
formation regularly. Vacuum pump must
be controlled frequently to
Fire and/or High temperature Major Possible maintain pressure allowable in
explosion operation the reactor. Reaction and
mixing rate must be checked
Explode Pressure exceeds the Catastrophic Possible
limit
Fire Thermal Runaway Major Unlikely
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Table 6.2. Hazard Identification Analysis (contd)
Location/ Description Potential Causes Hazard Likelihood Prevention
Unit/Equipment Hazard Effect
Acetic To store Acetic Leakage Over capacity Moderate Possible Control and check storage level
Anhydrate Anhydrate prior to periodically; keeping a distance
Storage Unit usage from fire sources and other
Fire and/or Exposure to fire Major Unlikely reactive substances
explosion
CSTR 2 Unit For Cocamide DEA Leakage Over capacity Moderate Unlikely Flow of the inlet liquid must be
formation checked regularly. Vacuum pump
Implode Pressure exceeds the limit Major Possible
must be controlled frequently to
Fire Thermal Runaway Major Unlikely maintain pressure allowable in the
reactor. Reaction and mixing rate
must be checked
Vacuum Pump To create a vacuum Implode Blockage in the exhaust Major Possible The pipeline of the vacuum pump
Unit operating condition in system exhaustion must be checked and
the CSTRs cleared out regularly from any
dust with exhaust scrubber
Decanting Unit To separate product Leakage Over flow Minor Possible Flow of the inlet liquid must be
from its by-product and controlled to ensure product and
impurities based on by-product separation
density
Flash Evaporator To separate methanol Fire and/or High temperature and Major Unlikely Temperature inlet of the fluid must
Unit and acetic anhydrate explosion pressure operation be controlled regularly. Vapor
from Cocamide DEA respirator must be provided for
workers to minimize serious
inhalation effects.
Air Methanol and acetic Major Possible
pollution anhydrate leakage
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Table 6.2. Hazard Identification Analysis (contd)
Location/ Description Potential Causes Hazard Likelihood Prevention
Unit/Equipment Hazard Effect
Cocamide DEA To store the final Leakage Over capacity Minor Possible Control and check storage
Storage Unit product of level periodically; keeping
Cocamide DEA a distance from fire sources
formation and other reactive
substances
Heat Exchangers For heating and Fire and/or High Major Possible Temperature, pressure, and
cooling process explosion temperature flow of the fluids must be
throughout the during operation checked regularly. Fire
production process extinguishers equipment
must be nearby.
Pumps To transport Leakage Overflow Moderate Possible Flow and pressure of the
fluids/substances Implode Over Catastrophic Unlikely fluid must be controlled.
pressurized Pump should be equipped
Noise pollution High decibel Major Certain to with a pump seal to prevent
operation occur leakage. Using a silencer or
a sound insulation and
provide workers with ear
plugs/muff
Piping System and To distribute fluid Damage of the Corrosion Major Possible Piping system, which also
Network throughout the piping system Piping system involves controls and
production process and leakage of failure valves, must be maintained
the fluid regularly to avoid any
hazards
Cation-Anion To demineralize Leakage Over flow Moderate Possible Flow of the water inlet
Exchanger Unit water for utility Low Resin saturation Moderate Unlikely must be controlled. Resin
and process demineralize bed must be checked and
requirements water quality maintained periodically
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Table 6.2. Hazard Identification Analysis (contd)
Location/ Description Potential Causes Hazard Effect Likelihood Prevention
Unit/Equipment Hazard
Deaerator Unit To remove Corrosion Build-up of Major Possible Demineralized water
dissolved oxygen dissolved gas quality must be checked
and CO2 in Block flow Major Unlikely regularly in order to
demineralized minimize build-up of
water dissolved gas
Leakage Moderate Very likely
Boiler Unit To generate steam Fire/explosion, Pressure exceeds Catastrophic Unlikely Keep all joints and pipes
for processes in damage of boiler limit tight. Warn personnel of
the plant parts hazards of invisibility of
Severe burns Steam leakage Catastrophic Rare superheated steam leaks.
Color code piping.
Implode, Steam build-up Catastrophic Unlikely Adequate ventilation.
fire/explosion Regular checking must
Fire/explosion Gas line leakage Major Possible be done
Diesel Generator To generate Fire Spark of Major Possible Installation must be done
Unit electricity for the combustible gas thoroughly. Generator
plant leakage should be kept a distance
Electrocution, Exposed wiring Major Unlikely from any substance that
fire triggers fire and
Electrocution Water Major Possible electrocution. Generator
exposure/splash should be maintained
Fire Burden of cords Major Very likely periodically
attached to
generator
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Table 6.2. Hazard Identification Analysis (contd)
Location/ Description Potential Causes Hazard Likelihood Prevention
Unit/Equipment Hazard Effect
Waste Treatment Unit to treat and Environment Overflow of the Moderate Possible Level of the pond must
Unit manage plant contamination treating pond be controlled to avoid
waste Poisoning/ Leakage Moderate Possible spilling. Workers must
infecting workers be equipped with the
Exposure of Moderate Possible proper personal
chemicals to protection when
workers handling plant waste
Laboratory For research & Slips and falls Chemical Minor Very likely Workers must be well
development, and substance spill aware of the
Exposure of Moderate Very likely
quality control substances at hand and
chemicals to
also equipped with the
workers
proper personal
Fire Major Unlikely
protection
Control Room To control System shut- Errors and Major Unlikely Operators and workers
operation down system3 failure must be master the
throughout the entire process in the
plant plant. A regular
briefing and
coordination between
operators and
supervisors must be
done
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Table 6.3. Hazard and Operability Study Analysis (contd)
Equipment/
Equipment
No Operation Parameter Guideword Possible Cause Consequences Action Required Safeguards
Code
Unit
Cavitation may occur
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Table 6.3. Hazard and Operability Study Analysis (contd)
Equipment/
Equipment Action
No Operation Parameter Guideword Possible Cause Consequences Safeguards
Code Required
Unit
Increase steam flowrate Check flow
More Valve opens too wide
H-102; CX- and steam temperature control
Heater and Flow Control
107; CX-108; Flow Decrease steam and maintain the
Cooler (FC)
CX-109 Less Valve opens too small flowrate and steam controller
temperature periodically
Decrease hot
Hot stream flowrate is
fluid flow to heat
too much
the reboiler
High
Increase cold
Cool stream flowrate is
fluid flow to heat
too low
the reboiler
Heat transfer may not Temperature
Temperature
effectively Increase hot fluid Control (TC)
HE-101; HE- Hot fluid flowrate
flow to heat the
102; HE-103; is too low
reboiler
Heat HE-104; HE- Low
4
Exchanger 105; HE-106; Cold fluid Decrease cold
HE-107; HE- flowrate is too fluid flow to heat
108; much the reboiler
HE-109; HE-
Check flow
110;
control and
HE-111
High Valve opens too wide maintain the
Final temperature controller Flow Control
Flow
will not be achieved periodically (FC)
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Table 6.3. Hazard and Operability Study Analysis (contd)
Equipment/
Equipment
No Operation Parameter Guideword Possible Cause Consequences Action Required Safeguards
Code
Unit
Flooding, leaking in
Inlet flowrate is too decanter and Decrease inlet
high separation process will flowrate
not run appropriately
High
Flooding, leaking in
decanter and
Outlet flowrate is separation process will Increase outlet
too low not run appropriately flowrate
Level
5 Decanter V-109 Level Control
(LC)
Inlet flowrate is too Separation process will Increase inlet
low not run appropriately flowrate
Low Increase inlet flowrate
Separation process
Outlet flowrate is too
will not run Decrease outlet
high
appropriately flowrate
Pressure
Filter was clogged by Clean the filter Control
Low Product supply decreases
UF-101; PFF- the dirt (PC)
6 Filtration 101; Pressure When the fluid flow is too
PFF-102 The driving force of Pressure
fast, the pump will run
High the pump is too Pump power Control
out of fluid that can cause
strong (PC)
heat and fires at the pump
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Table 6.3. Hazard and Operability Study Analysis (contd)
Equipment/
Equipment Action
No Operation Parameter Guideword Possible Cause Consequences Safeguards
Code Required
Unit
Production
Input flowrate is too small Clean the filter
process at next
to make process
Low process doesnt
with plate filter
Output flowrate is too low enough to
flowrate faster
achive target Level Control
Level
(LC)
Input flowrate is too large Using the valve
Deodorizing
and pump to
High process isnt
decrease
Output flowrate is too small maximum
flowrate
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Table 6.3. Hazard and Operability Study Analysis (contd)
Equipment/
Equipment Action
No Operation Parameter Guideword Possible Cause Consequences Safeguards
Code Required
Unit
Increase the
Steam flowrate is too
Low heater
low Bleaching process
8 Bleaching V-103 temperature Temperature
Temperature will not run
Tank Decrease the Control (TC)
Steam flowrate is too appropriately
High heater
high
temperature
Input flowrate is too Production process at
small next process doesnt
Level Low
Output flowrate is too enough to achive Clean the filter
low target to make process
Level Control
Input flowrate with
(LC)
is too large Using the valve and ultrafiltration
Bleaching process
High Output pump to decrease flowrate faster
doesnt maximum
flowrate is too flowrate
small
Driving force from
pump it to weak The fluid is taken
Increase pump
Less Input flow rate is too along with vacuum
power
low (hydrostatic pump
pressure) Pressure Control
CSTR Pressure
(PC)
Vacuum pump is Close valve 24
9 R-101; broke (integrated with
R-102 High Tank implodes
A leak in the reactor vacuum pump)
causing the air in and repair
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Table 6.3. Hazard and Operability Study Analysis (contd)
Equipment/
Equipment Action
No Operation Parameter Guideword Possible Cause Consequences Safeguards
Code Required
Unit
Inlet not enough
space
The speed of agitator Decrease agitator
More of The heat is increase
is too fast speed
and disturbing the
Agitator Speed normal process Speedometer
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Table 6.3. Hazard and Operability Study Analysis (contd)
Equipment/ Equipment
No Parameter Guideword Possible Cause Consequences Action Required Safeguards
Operation Unit Code
Inlet can't enough
space
The speed of agitator is Decrease agitator
More of The heat is increase
too fast speed
and disturbing the
10 Mixer MX-101 Agitator Speed Speedometer
normal process
The speed of agitator is The mixing process Increase agitator
Less of too slow doesnt occur speed
The inlet is too viscose maximum Viscosity check
Decrease inlet
Too much inlet
Liquid in the mixer flowrate
High
can be spilled Decrease agitator
Agigator speed is to fast Level Control
Level speed
(LC)
The agitator can't
Increase the inlet
Low Flowrate inlet is too low reach the fluid to be
flowrate
mix
Close all valve
A leak in the tank integrated to tank, Pressure
Pressure High Bubbling, foaming
causing the air in shut off the Control (PC)
process and repair
Liquid flow into column Decrease the inlet
High Flooding
is too high flow into column Level Control
Level
Liquid flow into column Mass transfer is not Increase the inlet (LC)
F-101 Low
is too low efficient flow into column
11 Flash Evaporator Inlet temperature from Equilibrium phase Increase hot fluid
Low
decanter-HE is too low may not occur and flowrate into HE
Temperature
Temperature there still another Increase cold
Inlet temperature from Control (TC)
High component in outlet fluid flowrate into
decanter-HE is too high
flow HE
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Table 6.3. Hazard and Operability Study Analysis (contd)
Regeneration
Resin is The water will
High with high acid or
saturated contain mineral Flow Control
Concentration base
(FC)
the purity process
Low Resin is too low Add resin
doesnt optimal
Demineralization
12 UDM-115 Flowrate inlet is Decrease inlet
Tank High Flooding
too high flowrate
The utility water for Flow Control
Level
Flowrate inlet is process doesnt Increase inlet (FC)
Low
too low enough to achieve flowrate
target
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The wastes identified above will be grouped based on their phases. In the
management, reduction of waste will firstly be attempted in the form of reduce,
reuse, and recycle (3R) wherever possible. The rest of the wastes will be treated
and discarded according to the regulation applied by the Indonesian government.
They will be separated and receive different treatments.
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converted into fertilizer. Meanwhile, the bleaching earth slurry from our bleaching
process mainly consists of activated carbon. To maximize its usage, this spent
activated carbon can be sold to other companies to be reused as fuels to fire up
equipment such as cement kilns. Otherwise, the non-hazardous activated carbon
can be disposed in an industrial landfill.
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to water bodies. All our liquid waste will be put together to undergo this
treatment. The figure below shows an alternative of industrial wastewater
treatment process.
The wastewater treatment for this plant will follow the path below:
a. Filtration: The wastewater is firstly filtered out to remove any solids that
are present in the wastewater and are large enough in size to be removable
using a filter screen. The solid components will mostly be disposed in
landfill if they are non-hazardous or reused as compost due to the presence
of organic nutrients in them. This is important to ensure that these large
solids do not interfere and lower the efficiency of the following biological
treatment.
b. Equalization: The different flows of wastewater which may vary in terms
of concentration, flow rate, pH, and other properties are combined into one
large equalization tank. Equalization is important to make all the different
flows become uniform before they enter the following treatment.
c. Neutralization: The wastewater which contains oil components, mostly
FFA, will be acidic in nature and requires neutralization. Neutralization
can be done by adding basic chemicals such as NaOH or Na2CO3 in order
to help increase the pH of the mixture. This is important so that the pH of
the mixture will not be too low for the microorganism in biological
treatment to handle.
d. Skimming: The wastewater may still contain oil components, such as FFA,
triglyceride, and others from miscellaneous spillages, which need to be
separated from the mixture. This is done by putting the wastewater into an
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oil separator that allows oil and fat in the wastewater to separate from the
others according to their difference in density. The oil and fat will float
upwards and will be skimmed away from the wastewater and can be sold
to be reused as a low-grade fatty acid raw material in mixture with the
higher-grade ones.
e. Anaerobic treatment: After all the previous processes, have lowered the
chemical oxygen demand (COD) of the wastewater, now microorganisms
are utilized to biologically degrade the wastewater and lower their
biological oxygen demand (BOD). The microorganisms used are the ones
that do not require oxygen and therefore perform anaerobic digestion.
Anaerobic treatment is very commonly used in industrial wastewater
treatment and produces biogas in the form of methane which can be sold to
be reused as one of the sources of bioenergy.
f. Aerobic treatment: This treatment is used as a follow-up treatment to the
anaerobic treatment. The microorganisms require oxygen to digest the
organic waste and therefore will require a maintained aeration. The
product of aerobic treatment will be carbon dioxide and water.
6.3.3. Gas Waste
The gas wastes emitted from our plant are mostly from heating processes
such as off gas from the bleaching process and flue gas from the natural gas
combustion process to produce electricity. The gas will be filtered through screens
using chimneys in the factory. This ensures that the gas released to the atmosphere
is not toxic and safe enough for humans and the surrounding environment. Our
gas emission should meet the standards regarding the quality of waste gas
emissions from non-moving sources set by Peraturan Menteri Lingkungan Hidup
Republik Indonesia Nomor 13 Tahun 1995 and our pollution control should meet
the requirements set by Peraturan Pemerintah Republik Indonesia Nomor 41
Tahun 1999 regarding the control of air pollution.
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CHAPTER 7
ECONOMIC CALCULATIONS & ANALYSIS
Thus, by considering all of the factors above, we can achieve the Total
Capital Investment (TCI). TCI is broken down into two parts, which are Fixed
Capital and Working Capital. Each part has specific calculations for Cocamide
DEA production, such as the cost of site, buildings, facilities etc. By achieving an
estimation from TCI calculation, we then can obtain a number that indicates if this
entire production is profitable or not. Total Capital Investment can be calculated
by:
where
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other additional costs necessary before operation. Fixed capital investment does
not directly affect the production capacity or cost; thus, it is only required for
construction and for all plant components. The mentioned factors and aspects
above will be calculated using the Peter-Timmerhaus Method. To achieve the
actual cost of all equipment, we must use an index as a reference to find the real
cost of the equipment according to the year we target this production plant, which
can be calculated by:
( )
where:
I = index value at the time of purchase
Ibase = index value at year x of the known price
The equipment cost and calculations are listed in the table below.
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7.2.2. Utility Cost and Water Waste Treatment Cost (Offsite Facilities)
The utility required in our plant are diesel generator, boiler, cooling tower,
and water treatment as well as waste treatment. The table below shows the total
cost required for the utility.
Table 7. 6. Offsite facilities cost
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a total volume of 4,390.70 m3. The total price of the building and land cost is US
$506,598.74. The full calculations can be seen on Appendix Table F.2
On the other hand, our land which will be in Kawasan Industri at Dumai,
Riau, will cost $53.85/m2. With a total land area of 14,703.96 m2, the total cost of
land as well as building that is required is shown in the table below.
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Total Order
Unit Order per Unit Price
Material Supplier Location Cost/year
Order year Price (USD)
(USD)
Ruko Villa
Pamulang
Blok C 1
No. 2 - 3
PT.
Pondok
Bleaching Insoclay USD/
Benda kg 156,961.54 33.85 212,513.25
Earth Acidatama 25kg
Tangerang
Indonesia
Selatan,
Tangerang
Banten ,
Indonesia
Henan
CXH
Purity Henan,
Acetic USD/
Industrial China ton 436.52 500.00 218,257.65
Anhydrad ton
and (Mainland)
Trading
Co.,Ltd
PT.
Sodium
Insoclay Tangerang, USD/
Hypochl- litre 237,600.00 0.67 158,729.22
Acidatama Banten Liter
orite (L)
Indonesia
PT.
Insoclay Tangerang, USD/
Nitrite (L) kg 237,600.00 0.64 13,241.90
Acidatama Banten 25kg
Indonesia
PT. USD/
Diesel (L) indonesia litre 469,251.80 0.94 442,361.78
Pertamina Liter
PT.
USD/
Natural Pratama Sidoarjo, mmB 3,654.10
mmB 6.00 21,924.59
Gas Energi Jawa Timur TU
TU
Mandiri
TOTAL 11,904,225.93
From the tables above, the total cost for the raw material is US$
11,904,225.93 per year. This cost is already including the shipping the materials
to our plant. As we can see the total cost of raw materials is so high, which means
that our production is really depends on this variable.
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(DW&B) of operators and direct salaries & benefit (DS&B) of supervisors and
engineering personnel. The DW&B and DS&B can be calculated from an hourly
rate for the labors of a proposed plant. The direct operating labor requirements
will be estimated by the basis of plant with 10-100 ton/day of product as seen in
Figure below.
The estimated number of technician is for per shift and to account for three
shift daily. For this plant, since the continuous operation covered the production
process for every day, the technician should cover the full 24 hour, 4 shifts must be
covered. There are 9 workers for each shift. Using the data on figure above, this
estimation is shown Appendix Table F.5 and gives a total of 39 workers.
When considering the amount of wages for each operator, we should
follow the standard regulation of the minimum regional wages (Upah Minimum
Regional/UMR) in the plant location, Dumai. For 2016, the minimum regional
wages in Dumai, Riau is Rp2,514,000 per month or US$186.65. The total direct
labor operation cost is given by US$ 169,952.49 annually. For the indirect labor,
the total salary per year is US$ 297,304.63. Hence, the total salary for direct and
indirect labor will be US$ 467,257.13. This value hasnt included insurance costs
which will be added every month to the salary. The full calculation of direct and
indirect labor can be seen on Appendix Table F.5 and F.6
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7.3.3. Utility
Utility costs are costs that used to finance the main necessities of the
production such as water, electricity, and plant infrastructure. Those utilities are
such as electricity and fuel for the generator.
For the electricity usage, our plant requires 126,583.8 kWh per year or
US$14,233.87 annually. The full breakdown of each equipment and supporting
equipment and its power requirements can be seen on Appendix Table F.7 and
F.8
As for water consumption, domestic usage will not be treated as it is
provided by PDAM of Dumai City. However, the water for process and other
instrumental needs will be from Kemeli River and will be given a treatment to
avoid piping and instrumental damage in the production process. Domestic water
usage is obtained from PDAM, which costs Rp. 1,440/m3. The water usage per
year is 1,009,800 liters/year, hence the total cost is Rp 504,000.00/year or US$
38.77.
As for fuel consumption, fuel is needed for steam generation process in
boiler unit and electricity generation in generator. We chose natural gas as the fuel
for steam generation process in boiler unit because it is usually readily available,
burn cleanly, and is typically less expensive than oil or electricity. For the steam
generation process, we already determined the Quantity of steam needed in the
overall process. The generated steam for this process produced by boiling water in
boiler. Water in ambient temperature (37oC, 1 atm) will be heated to saturated
point and convert to steam. Our Cocamide DEA production process needs steam
at temperature 220oC. With the diesel price of Rp 7,600/liters and the required
fuel is 58.56 liters/hour, so we achieve Rp 3,524,758,875 or US $271,135.30 for
the cost of electricity using diesel per year.
Based on all the utility calculation, the total utility cost is US $285,407.93.
Full calculations of electricity and fuel consumption can be seen on Appendix
Table F.9.
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From Figure 7.2., the largest portion of our operating cost is utility and
raw material. This is because our production process requires high electricity and
water supply.
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Price
No Company Country
(USD/ton)
Guangzhou Hangsheng Chemical
1 1,500 - 1,800 China
Industry Co.
2 Anhui Leafchem Co., Ltd. 1,400 - 1,800 China
3 Zhengzhou Sino Chemical Co., Ltd. 1,100 - 1,700 China
4 Briture Co., Ltd. 1,200 - 1,600 China
Yibo Foundation Hebei International,
5 2,080 China
Ltd.
6 Anglo Chemical, Ltd. 500 South Africa
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7.11.1. WACC
For this project, we plan to get our capital from two different sources,
banks debt and investors equity. We loan from Mandiri Bank as our debt
sources, in which they give 10.5% interest for corporate loan. We loan 40% of our
capital expenses from them and the rest 60% from investor. Based on calculations
seen on Appendix Table F.12, our WACC value is 13.93%.
7.11.2. Depreciation
Depreciation is the reduction of value in assets. This reduction of value is
calculated to be able to determine the diminishing value of capital investment
spent on the assets in the first place as well as the salvage value left of the assets
by the end of the operational period of our plant. Our calculation for depreciation
incorporates the single declining balance method with the rate of depreciation of
0.1 per year for equipment and 0.03 for land and building. The total depreciation
is shown below and the detailed calculation is attached in our appendix.
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yearly depreciation. We constructed to types of cash flow, one before taking tax
into account and the other one after. We have also calculated the cumulative cash
flow as shown below.
2.000.000
1.000.000
-
2024
2017
2018
2019
2020
2021
2022
2023
2025
2026
2027
-1.000.000
USD
Cash Flow
-2.000.000
-3.000.000 Discounted
Cash Flow
-4.000.000
-5.000.000
Year
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to the amount of cash flow spent for the initial investment. Based on the
cumulative cash flow, the payback period for our plant is 4.35 years.
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and direct labor and raw material cost as free variable is because those two have
contributed a lot in operational cost. The reason we choose selling price is
because, generally the selling price itself is the most contributed variable that
affect the cash flow. Parameters used in the sensitivity analysis are NPV, IRR,
Payback Period, and BEP, in which those parameters because those parameters
have biggest probability to fluctuate in reality.
As we can see from the table above. the selling price of Cocamide DEA is
very sensitive. The fluctuation by 4.5% higher or lower really impact the IRR and
NPV. This is very unacceptable from the investor side
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lower. This mean that the returns would be lower. It is also evident from the
payback period is the longer the payback. The factory is said to be visible because
it is not easily swayed by these changes despite the cost breakdown can be seen
that most influence the production process is the cost of raw materials.
From the table above, we can see the sensitivity of raw material. If the raw
material cost is increase about 1.5%, the effect are IRR and NPV will become
lower and PP longer. The difference is clearly visible. It means that raw material
is very sensitive.
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Labor Fluctuation
Labor Price
Deviation IRR NPV (USD) PP (years) BEP (%)
(USD)
-4.5% 441,557.99 19.53% $788,194.25 4.2572904 42,572.90
-3.0% 453,239.42 19.25% $747,972.63 4.2978967 42,978.97
-1.5% 460,248.27 19.08% $723,839.65 4.3226345 43,226.34
0.0% 467,257.13 19% $699,706.68 4.35 43,476.59
1.5% 474,265.99 18.75% $675,573.71 4.3729743 43,729.74
3.0% 481,274.84 18.58% $651,440.74 4.3985864 43,985.86
4.5% 488,283.70 18.42% $627,307.76 4.4245004 44,245.00
From the table above, we can see that an increase or decrease in labor cost
will not significantly impact the operational cost, hence also the NPV, payback
period, IRR, and BEP. We can say from this analysis that this aspect of the
production activity is not sensitive towards fluctuation compared to raw material
and selling price.
IRR Chart
40%
35%
30%
IRR Rate
25%
20% Selling Price
15% Raw Material
10%
Labor
5%
0%
-4,5% -3,0% -1,5% 0,0% 1,5% 3,0% 4,5%
Deviation
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From the graph above, we can see that both selling price and raw material
affects the IRR significantly. Price changes for raw material and selling price
should be considered because it may cause the IRR value to be high or low. When
the IRR rate is lower than the MARR, which is 13.93%, this means that our
Cocamide DEA plant is not suited to meet the investors interest. Labor cost
changes show minor affect towards the IRR value.
NPV Chart
$4.000.000,00
$3.000.000,00
$2.000.000,00
NPV (USD)
Selling Price
$1.000.000,00
Raw Material
$0,00 Labor
-4,5% -3,0% -1,5% 0,0% 1,5% 3,0% 4,5%
-$1.000.000,00
-$2.000.000,00
Deviation
Figure 7.6. shows the impact of selling price, raw material purchases, and
labor cost towards NPV. We can see that both raw material and selling price
affects the business when each price is increased and the plant can no longer be
profitable, or in other words NPV value is negative. When raw material prices are
increase, this will cause an increase in the selling price as well; where raw
material cost play an important role in the entire production. Labor cost does not
affect the NPV value significantly.
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Figure 7.7. shows that raw material and selling price impacts the payback
period significantly. High selling prices can influence the demand of our product
in the market. Hence, a competitive and good price, which also brings profit to the
business must be put into consideration. On the other hand, raw material prices
also affect the payback period because an increase in the main materials can
contribute a fluctuation to the selling price and the even the payback period. Labor
cost is steady, which means that it causes minor influence to the payback period.
80000,00
60000,00 Selling Price
40000,00 Raw Material
20000,00
Labor
0,00
-4,5% -3,0% -1,5% 0,0% 1,5% 3,0% 4,5%
Deviation
From the graph above, we can see that the BEP is mostly affected from
selling price and raw material cost. When the selling prices is reduced, we can
expect an increase in the volume or unit sold in the market, whereas when the
price is increase, we can see a lower BEP value which indicates lower purchase of
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Cocamide DEA. The opposite occurs to raw material. Labor cost is a minor affect
towards the BEP value.
7.13.5. Strategy
According to the sensitivity calculations, the most sensitive is selling price
of Cocamide DEA. The Labor cost is not that sensitive because the portion of our
operating cost is almost the same for each component. Selling price of cocamide
DEA and raw material cost are very sensitive because it can affect the IRR below
the MARR, which means not attractive to investors and will be not profitable. The
strategies to overcome the sensitivities is; maintaining the selling price 15%
higher than its original price because our company will be the first Cocamide
DEA producer in Indonesia (market monopoly). We might decrease our selling
price if unpredicted things occur, such as inflation, and reduce the production
capacity so our plant is still profitable. The strategies to the sensitivity of raw
material is to find a supplier for raw materials with a lower price with good
quality. By doing so, the cost of raw materials can be reduced as well as the
operational costs.
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CHAPTER 8
OUTSTANDING ISSUE
containing this substance. However, FDA (US Food and Drug Agency) have not
issued any prohibition on the use of this chemical.
Another issue is about the market of our product in Indonesia.
Currently, according to the BPS, on average, Indonesias demand on cocamide
DEA are only 2,500 ton/year. This indicate that we need to widened our market
by influencing other industry to switch from other surfactant to this product. We
targeted that on 2018, when we start producing our product, we have already
influencing 2.5% of the market to switch their commonly use surfactant into
cocamide DEA, which will add 7,500 ton product resulting in overall production
capacity of 10,000 ton/year. This strategy will give us PBP in 4.35 years, with
IRR value of 19% and NPV of USD 699,706.68.
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CHAPTER 9
CONCLUSION
The total requirement for fuel utilities after implementing HEN is 59.25
L/h of diesel
This sizing is including the dimension and material construction. There are
41 equipment.
We have been sizing equipment for Cocamide DEA production plant,
including 1 unit CPO Storage tank, 15 unit pump, 9 unit heat exchanger, 1
unit ultrafilter, 1 unit Bleaching Earth storage, 2 unit Blending Tank, 2 unit
Plate and Frame Filtration, 1 unit RBDPO Storage, 1 unit Methanol +
NaOCH3 Storage, 1 unit DEA Storage, 2 unit CSTR, 1 unit Acetic
Anhydrade Storage, 2 unit Decanter, 1 unit Flashing Column, 1 unit
Dehydration Column, and 1 unit Product Storage. The types of equipment
are tank, pump, decanter, filter, mixer, and heat exchanger.
There are several utility and supporting equipment specification such as
pump, heat exchanger, and valve. Our plant utility are water utility, and
fuel utility. Equipment for water utility, that are NaOCl injection, rotary
filter with micro mesh, nitrate injection, mixed bed polisher, deaerator.
Equipment for fuel utiliy, that are package boiler, and diesel generator.
Controlled variable in pipeline and instrumentation diagram are
temperature, pressure, liquid level, flow rate, composition, filtrated
concentration and certain physical properties whose magnitudes may be
influenced by some of the other variables, for instance, viscosity, etc.
HAZID and HAZOP analysis can be used to help analyze any potential
risks and hazards at our facility.
Based on MSDS, some of our materials need special handling because its
corrosiveness, easily flamable, and volatile & toxic characteristic.
Personal protective equipment (PPE) is mandatory for employee and guest
inside the facility to prevent any injury cause by plant potential hazard.
It is important to have safety training, fire extinguisher, and evacuation
route to help employee in case of emergency.
The effluent waste can be grouped into four types, which are solid, liquid,
gas, and noise.
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Most of our waste are organic matters with high nutritional content, which
can be used as fertilizer.
Most of our waste have high BOD content which can be use as substrate
for biological waste treatment (anaerobic and aerobic digester).
Our plant has a total area of 14,703.96 m2
There are several area inside our facility, which are production area, office
area, utility area, waste treatment area, storage area, and supporting area.
Most of our process equipment is placed inside the plant building to help
maintain its operating condition.
The plant will be built in 2017 with duration estimate for plant completion
is 1 year, therefore the production can begin at approximately in the end of
2018.
The total capital investment (CAPEX) for our plant is $2,467,568.97 USD.
It is being used for land and building administration, buying equipment for
plant.
Operational cost of our company is $13,740,262.14 USD
The price of Cocomide DEA is $1,500 USD/ton we get the price by using
method the trend line from eksisting producen.
To fulfil the need of starting capital, were loan from two different
sources, banks debt from Mandiri (40%) and investors equity (60%).
Our plant is 10 years life time
The payback period of our company is 4.35 year. It is indeed fast payback
period.
The BEP of our company is 43,476.59 tons of Cocomide DEA until we
have profit.
NPV, or Net Present value of our product with MARR 13.93% the
calculation result is $699,706.68 USD.
The cash flow most sensitive for the value from selling price and raw
material cost
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REFERANCES
Badan Pusat Statistik, 2015. Badan Pusat Statistik Kota Dumai. [Online]
Available at: https://dumaikota.bps.go.id/linkTableDinamis/view/id/29
[Diakses 7 September 2016].
Balai Besar Penelitian dan Pengembangan Sumberdaya Lahan Pertanian, 2008.
Tersedia Luas, Lahan untuk Pengembangan Jarak Pagar. Dalam: Warta
Penelitian dan Pengembangan Penelitian. Bogor: Kementerian Pertanian
Republik Indonesia, pp. 5-7.
Boiteux, J.-P., Brancq, B., Lecocu, N. & Frederic, L., 1992. Process for the
preparation of purified fatty alkyldiethanolamides products obtained
according to said process and their use. United State of America, Paten No.
US 5108661 A.
Cereals & Oils Machinery, t.thn. Crude Palm Oil Refining Methods Introduction
and Advantages. [Online]
Available at: http://www.palmoilmills.org/industry-news/crude-palm-oil-
refining-methods-introduction-and-advantages.html
[Diakses 8 September 2016].
Cereals & Oils Machinery, t.thn. Palm Oil Refinery. [Online]
Available at: http://www.palmoilmills.org/products/palm-oil-refining-
plant/palm-oil-refinery.html
[Diakses 8 September 2016].
de Oliveira, J. S. et al., 2008453. Characteristics and composition of Jatropha
gossypiifolia and Jatropha curcas L. oils and application for biodiesel
production. Biomass & Bioenergy, 33(1), pp. 449-453.
Hidayu, B. O. N. et al., 2014. A process for degumming of crude palm oil.
Malaysia, Paten No. WO 2014058294 A1.
Jung, A. K., Voelkel, L., Crema, S. & Andrea, M., 2015. Composition and method
to improve the fuel economy of hydrocarbon fueled internal combustion
engines. Germany, Paten No. EP 2321389 B1.
Kurniasih, E., 2008. Pemanfaatan Asam Lemak Sawit Distilat Sebagai Bahan
Baku Diethanolamida Menggunakan Lipase (Rhizomucor meihei), Medan:
Sekolah Pascasarjana Universitas Sumatera Utara.
Lee, C. S., Ooi, L. T., Chuah, C. H. & Ahmad, S., 2007. Synthesis of Palm Oil-
Based Diethanolamides. Journal of the American Oil Chemists' Society,
Volume 84, pp. 945-952.
Manurung, R., Sinaga, R. A. & Simatupang, R. T., 2013. Kinetics of Amidation
for the Synthesis of Diethanolamide from Methyl Ester and Diethanolamine
by Using Sulphuric Acid Catalyst. International Journal of Innovative
Research in Science, Engineering and Technology, 2(9), pp. 4205-4210.
Moser, B. R., 2009. Biodiesel production, properties, and feedstocks. The Society
for In Vitro Biology, 45(3), pp. 229-266.
Parchem, t.thn. Lauric Diethanolamide. [Online]
Available at: http://www.parchem.com/chemical-supplier-distributor/Lauric-
Diethanolamide-008322.aspx
[Diakses 13 September 2016].
Rohani, 2006. Process Design in Degumming and Bleaching of Palm Oil, Johor:
Centre of Lipid Engineering and Applied Research.
Boiteux, J.-P., Brancq, B., Lecocu, N. & Frederic, L., 1992. Process for the
preparation of purified fatty alkyldiethanolamides products obtained
according to said process and their use. United State of America, Paten No.
US 5108661 A.
Chapman, F. S. and F. A. Holland. Liquid Mixing and Processing in Stirred
Tanks, 1966.
Kern, Donald Q. Process heat transfer. New Delhi: Tate McGraw-Hill Publishing
Company, 1997.
Rohani, 2006. Process Design in Degumming and Bleaching of Palm Oil, Johor:
Centre of Lipid Engineering and Applied Research.
Walas, Stanley M. Chemical process equipment. Boston: Butterworth-
Heinemann, 1990.
Eckenfelder, W. Wesley. 2000. Industrial Water Pollution Control. New York,
USA: McGraw Hill Companies, Inc.
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Edwards. NA. Vacuum Pump and Vaccum System Safety. Available at:
https://www.edwardsvacuum.com/uploadedFiles/Content/Pages/About_Us
/Edwards_Vacuum_Safety_Booklet.pdf (Accessed on 8 November 2016)
Science Lab. Crude Palm Oil MSDS. [Online]. Available at:
http://www.sciencelab.com/msds.php?msdsId=9926383 (Accessed on 8
November 2016)
Science Lab. Diethanolamine MSDS. [Online]. Available at:
http://www.sciencelab.com/msds.php?msdsId=9923743 (Accessed on 8
November 2016)
Science Lab. Sodium Methoxide in Methanol MSDS. [Online]. Available at:
http://www.sciencelab.com/msds.php?msdsId=9925010 (Accessed on 8
November 2016)
Science Lab. Sodium Methoxide in Methanol MSDS. [Online]. Available at:
http://www.sciencelab.com/msds.php?msdsId=9925010 (Accessed on 8
November 2016)
Science Lab. Acetic Andhydrate MSDS. [Online]. Available at:
http://www.sciencelab.com/msds.php?msdsId=9927061 (Accessed on 8
November 2016)
Science Lab. Acetic Andhydrate MSDS. [Online]. Available at:
http://www.sciencelab.com/msds.php?msdsId=9927061 (Accessed on 8
November 2016)
Lincoln Inc. Cocamide DEA MSDS. [Online]. Available at:
http://www.lincolnfineingredients.com/pdfs/product/65/Linamide_C_msds
.pdf (Accessed on 8 November 2016)
Science Lab. Water MSDS. [Online]. Available at:
http://www.sciencelab.com/msds.php?msdsId=9927321 (Accessed on 8
November 2016)
Science Lab. Sodium Hypochlorite MSDS. [Online]. Available at:
http://www.sciencelab.com/msds.php?msdsId=9925000 (Accessed on 8
November 2016)
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APPENDICES
(Source: pertanian.go.id)
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1. Storage Tanks
Sizing for tanks is first done on the CPO storage tank. This tank is as a
storage for crude palm oil before it is inserted into the ultrafiltration to fulfill the
requirement for bleaching process. The material selection for this tank is will be
carbon steel SA 167, grade 3, type 304. This selection is because CPO is a crude
liquid and non corrosive. This is according to ASME BPVC Section II, EN
13445-2. Based on API 620 and API 650, the type of tank for water is a vertical
tank.
Operating conditions
Temperature = 25oC
Pressure = 1 atm = 14.7 psi
Volume of tank
Solution = 887.5 kg/m3
CPO Mass = 184348.9 kg/week
CPO Volume = m/ = 207.7 m3/week
With the empty space in tank about 10%, the volume of tank will be:
Vtank = Vliquid*100/90 = 230.79 m3
Assumptions:
1. The volume of the tank space is 10%
2. Height ratio cylinder with a diameter of the cylinder is 1.4:1
3. Close the top and bottom cap shaped thorispherical head.
Therefore,
( )
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Longitudinal Stress
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We use a same tank sizing calculation algorithm for all the tank. The algorithm
can be seen below.
Assume Tank
Determine
Estimate Liquid Space To
Operating
Volume In Tank Determine Tank
Condition
Volume
The table below shows the summary of sizing results for all storage tanks in the
plant.
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2. Pumps
A positive displacement pump (PD Pump) is used as our plant fluid
transporter. It is due to high viscosity of our fluid and low flow rate, which a
centrifugal pump can not handle. We calculate the pump based on its total head,
resulting in NPSHa and the predicted BHP. The total head is the sum of pipe
friction head loss, fitting friction head loss, equipment friction head loss, check
valve head loss, total static head, velocity head difference, and tank pressure head
difference.
Pipe friction head loss
H L
H FP FP
L TABEL 100
Fitting friction head loss
The pump we choose must have NPSHr value smaller than NPSHa we have. The
NPSHr data is given by the pump manufacturer. We can also predict our pump
power (Brake Horse Power, BHP), using equation:
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Table below are shown specification of each pump using in this plan:
Pump (PM-101)
Table B.2 PM-101 Specification
Equipment Specification
Equipment Code PM-101
Type Positive Displacement Pump
Function To Pump CPO From Tank to Ultrafiltration
Operation Continuous
Quantity 1
Material Carbon Steel
Operation Data
Flow rate 1.5337 m3/h
Total Head Loss 72.01 ft fluid
NPSH 4.72 m
Efficiency 25 %
Break Horse Power 135 W
Pump (PM-102)
Table B.3 PM-102 Specification
Equipment Specification
Equipment code PM-102
Type Positive Displacement Pump
Function To pump from ultrafiltration to blending tank
Operation Continuous
Quantity 1
Material Carbon Steel
Operation Data
Flow rate 1.497 m3/h
Total Head Loss 133.89 ft fluid
NPSH 3.19 m
Efficiency 23 %
Break Horse Power 229 W
Pump (PM-103)
Table B.4 PM-103 Specification
Equipment Specification
Equipment Code PM-103
Type Positive Displacement Pump
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Pump (PM-104)
Table B.5 PM-104 Specification
Equipment Specification
Equipment Code PM-104
Type Positive Displacement Pump
Function To pump filtered fluid from plate and
frame filtration 1 to deodorizing tank
Equipment Specification
Operation Continuous
Quantity 1
Material Stainless Steel
Operation Data
Flow rate 1032.53 kg/h
Total Head Loss 12.58 ft fluid
Efficiency 30%
NPSH 0.24 m
Break Horse Power 47.13 W
Pump (PM-105)
Table B.6 PM-105 Specification
Equipment Specification
Equipment Code PM-105
Type Positive Displacement Pump
Function To pump deodorized palm oil from
deodorizing tank to plate and frame
filtration 2
Operation Continuous
Quantity 1
Material Stainless Steel
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Operation Data
Flow rate 1103.601 kg/h
Total Head Loss 24.23 ft fluid
Efficiency 30%
NPSH 0.2 m
Break Horse Power 97.01 W
Pump (PM-106)
Table B.7 PM-106 Specification
Equipment Specification
Equipment Code PM-106
Type Positive Displacement Pump
Function Transports RBDPO to CSTR 1
Operation Continuous
Quantity 1
Material Carbon Steel
Operation Data
Flow rate 1.09 m3/h
Total Head Loss 13.56 ft fluid
NPSH 3.877 m
Efficiency 25%
Break Horse Power 58.96 W
Pump (PM-107)
Table B.8 PM-107 Specification
Equipment Specification
Equipment Code PM-107
Type Positive Displacement Pump
Function To pump filtered palm oil plate and
frame filtration 2 to RBDPO Storage
Operation Continuous
Quantity 1
Material Stainless Steel
Operation Data
Flow rate 978.135 kg/h
Total Head Loss 12.35 ft fluid
Efficiency 25%
NPSH 0.17 m
Break Horse Power 52.59 W
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Pump (PM-108)
Table B.9 PM-108 Specification
Equipment Specification
Equipment code PM-108
Type Positive Displacement Pump
Function To pump from RBPDO to heat exchanger
Operation Continuous
Quantity 1
Material Carbon Steel
Operation Data
Flow rate 1.47 m3/h
Total Head Loss 144.36 ft fluid
NPSH 6.5 m
Efficiency 15 %
Break Horse Power 353 W
Pump (PM-109)
Table B.102 PM-109 Specification
Equipment Specification
Equipment Code PM-109
Type Positive Displacement Pump
Transports methanol and sodium methoxide to CSTR
Function
1
Operation Continuous
Quantity 1
Material Carbon Steel
Operating Condition
Flow rate 0.081 m3/h
Total Head Loss 10.34 ft fluid
NPSH 2.85 m
Efficiency 10%
Break Horse Power 8.18 W
Pump (PM-110)
Table B.11 PM-110 Specification
Equipment Specification
Equipment Code PM-110
Type Positive Displacement Pump
Transport fluid from acetic anhydride storage tank to
Function
CSTR 1
Equipment Specification
Operation Continuous
Quantity 1
Material Carbon Steel
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Pump (PM-111)
Table B.12 PM-111 Specification
Equipment Specification
Equipment Code PM-111
Type Positive Displacement Pump
Function Transports fluid from CSTR 1 to CSTR 2
Operation Continuous
Quantity 1
Material Carbon Steel
Operating Conditon
Flow rate 1.35 m3/h
Total Head Loss 11.44 ft fluid
NPSH 0.954 m
Break Horse Power 118.8 W
Pump (PM-112)
Table B.13 PM-112 Specification
Equipment Specification
Equipment Code PM-112
Type Positive Displacement Pump
Transports fluid from acetic anhydride storage tank to
Function
CSTR 1
Operation Continuous
Quantity 1
Material Carbon Steel
Operating Condition
Flow rate 0.0463 m3/h
Total Head Loss 38.40 ft fluid
NPSH 9.476 m
Break Horse Power 20.9 W
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Pump (PM-113)
Table B.14 PM-113 Specification
Equipment Specification
Equipment Code PM-113
Type Positive Displacement Pump
Function Transport fluid from CSTR 2 to decanter
Operation Continuous
Quantity 1
Material Carbon Steel
Operating Condition
Flow rate 1.35 m3/h
NPSH 4.69 m
Total Head Loss 25.06 ft fluid
Break Horse Power 260.2 W
Decanter (V-109)
Table B.15 V-109 Specification
Equipment Specification
Equipment Name Decanter
Equipment Code V-109
Separating product (cocamide DEA) from its by-
Function
product (Glycerol) and impurities based on its density
Operating Condition
Pressure 172.68 kPa
Temperature 45C
Settling Time 7.93 hours
Residence Time 8 hours
Vessel Design
Materials Carbon Steel
Tank Type Horizontal Two Phase Separator
Head Type Thorispherical
Capacity 13 m3
Tank Diameter 1.38 m
Tank Length 6.92 m
Shell Thickness 0.03 m
Straight Flange 0.72 m
Head Thickness 0.0043 m
Pump (PM-114)
Table B.16 PM-114 Specification
Equipment Specification
Equipment Code PM-114
Type Positive Displacement Pump
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Equipment Specification
Function Transport product to product storage
Operation Continuous
Quantity 1
Material Carbon Steel
Operating Condition
Flow rate 1.26 m3/h
NPSH 1.539 m
Total Head Loss 15.18 ft fluid
Break Horse Power 240 W
Equipment Specification
Equipment Name Vacuum Pump
Equipment Code VP-101
Function Creating vacuum operating condition in CSTR 1
Quantity (unit) 1
Mode of Operation Continuous
Operating Condition
Pressure 400 torr
Temperature 80C
Specification Design
Type Positive Displacement, Reciprocating
Material Steel
Free Air Displacement 40.5 L/min
Ultimate Vacuum 0.375 torr
BHP 200 W
Equipment Specification
Equipment Name Vacuum Pump
Equipment Code VP-102
Function Creating vacuum operating condition in CSTR 2
Quantity (unit) 1
Mode of Operation Continuous
Operating Conditon
Pressure 400 torr
Temperature 80C
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Specification Design
Type Positive Displacement, Reciprocating
Material Steel
Free Air Displacement 40.5 L/min
Ultimate Vacuum 0.375 torr
BHP 200 W
The table below shows the summary of sizing results for all pumps in the plant.
3. Heat Exchangers
Heat Exchanger calculation starts from HX-102, designed to increase heat
for bleaching process. Before calculating the design of heat exchanger, we have to
understand the detail information from the cold and hot stream to design shell and
tube heat exchanger. Below is Hot and Cold fluid data
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To be able to see the difference in temperature between the two fluids is neede FT
correction factor, the value of R and S follows:
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With use value of R and S, we get FT (LMTD correction) value that see in Figure
18, Kern.
FT = 1
So,
= = 1x257.95 = 257.95
Heat Transfer Srea
Based on Kern 1983, table 8 appendix for heaters with steam as hot fluid and
heavy organic as cold fluid told that range for UD 6-60. So it is assumed that UD
= 15. Place the small stream in the shell
A=
A = 45.58 Ft2
a see in table 10, Kern)
ac = 0.196
so,
Number of Tube =
Nmber of Tube = 19
Based on calculation number of tube , we get number of tube actual, Shell ID and
Shell Pass (Table 9, kern), as follows:
Number of tube actual = 20, Shell ID = 8 in, and 4-Passes
Below is calculation of correction Flow area and UD with the same equation, as
follows:
= "= 47.11 ft2
UD = 14.51
B ID / 5
as ID C ' B / 144 PT
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Where,
as = flow area shell
at = flow area tube
C = the distance between the tube with another tube in the shell
ID = inner diameter shell
B = distance between baffle
Nt = number of tube
= flow area per tube
n= number of passes tube
so,
as = 0.067 ft2
at = 0.0093 ft2
Mass Velocities calculation
Mass velocity to the shell as follows
W
Ga
as
Where De is given from fig.28 based on its pitch type and size, D is given from
table 10 based on tube size, and a is given from fig 18, below is the result
calculation;
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Table B.24. Heat Transfer Factor and Heat Transfer Coefficient (contd)
Heat Transfer Coefficient
ho 146.11 Btu/(hr)(ft2)(oF) hi 181.09 Btu/(hr)(ft2)(oF)
Fig.25
hio 141.005 Btu/(hr)(ft2)(oF)
Based on Reynold number finds value tube side friction factor (f) based on figure
29 and finally calculating pressure drop
=( 2
)/(5.221010 )
Number
of crosses 30
Ga 3968,320719
De 0,666666667
1
Ps 3,80107E-09
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The table below shows the summary of sizing results for our heat exchangers.
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4. Mixer
This tank is as a mixing tank for bleaching earth and water before it is
inserted into the bleanding tank fulfill the requirement for bleaching process. The
material selection for this tank is will be carbon steel SA 167, grade 3, type 304.
This selection is because both water and bleaching earth are non corrosive. This is
according to ASME BPVC Section II, EN 13445-2. Based on API 620 and API
650, the type of tank for water is a vertical tank.
Operating conditions
Temperature = 25oC
Pressure = 1 atm = 14.7 psi
Volume of tank
Solution = 1550 kg/m3
Mass = 237.816 kg/day
Volume = m/ = 0.17 m3
With the empty space in tank about 10%, the volume of tank will be:
Vtank = Vliquid*100/90 = 0.8 m3
Assumptions:
1. The volume of the tank space is 10%
2. Height ratio cylinder with a diameter of the cylinder is 0.7
3. Close the top and bottom cap shaped thorispherical head.
Therefore,
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( )
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Longitudinal Stress
Agitator Calculation
Diameter Impeller (Di)
Define N Value
With normal method to define power requirement we must define viscosity
first. But in suspended liquid, its hard to define it. So the way is using figure
10.8 at Walas book than define HP each point of d/D base on settling velocity
factor. Than we define the average of HP than found it and extrapolation with
tabel 10.4 on Walas Book. There is the way to fine HP or N value.
a. Volume vector = 1 (Figure 10.8a, Walas )
b.Z/T Vector = 1 (Figure 10.8b, Walas )
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We define HP each point of d/D at point 12 (Suspension factor), the table are
bellow :
Table B.29. d/D and HP Value
d/D HP Value
0.1 2.75
0.2 4
0.3 15
0.4 20
0.6 50
Average 18.35
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Than from the table 10.4 on Walace we define the HP witch similar with
18.35 value.
Figure B.30. Velocity and HP/rpm value
Then extrapolation with HP value as x and rpm value as y, than we get rpm
value when HP was at 18.35
Table B.31. Extrapolation for RPM
Superficial
HP RPM
Liquid velocity
25 125
20 100
0.8
15 68
10 45
Extrapolation 18.35 89.124
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5. Blending Tanks
The calculation of blending tank, is shown below
Determination of fluid characteristics
Mass rate feed : 1061.694 kg/h
Table B.32. Bleacher Mass Balance
OUT
IN (kg/h)
(kg/h)
Compound
Stream- Stream-
110 DBPO
B-Carotene 0.515 0.515
FFA 19.297 19.297
Impurities 20.412 20.412
Phosphorus 0.302 0.302
triglyceride 990.919 990.919
water 20.34 20.34
Bleaching Earth 9.909 9.909
TOTAL 1061.694 1061.694
Volume Total
Flowrate massa 1.062 kg/h
897,84 kg.m-3
Residence time 30 min
Volume 0,59 m3
Volume of work (90%) 0,656943331 m3
Actual Volume 1 m3
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- D cylinder = = 0.93 m
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Corrosion factor (C) for carbon steel = 3.175 mm/year = 0.003175 m/year
Allowable working stress (S)
Allowable working stress (S) for carbon steel at 220C = 88,942.37 kPa
Efficiency of connection (E)
Efficiency of connection (E) = 1
Approximate age of equipment = 10 year
Below is equation for calculate cylinder thickness
Cylinder thickness (d) = + (CxA) = 0.0323 m = 3.23 cm
Head Thickness
Below is data for calculation of head thickness;
Pressure design (P)
Pressure design (P) = 101.325 kPa
Allowable working stress (S)
Allowable working stress (S) for carbon steel at 220C = 88,942.37 kPa
Efficiency of connection (E)
Efficiency of connection (E) = 1
h
h = D/4 = 0.24
K
K = [( ) ] = 0.98
Impeller Design
One of important thing for blending tank for bleaching process is agitator.
Size, type, and Quantity of impeller should be defined and sizing. First, we should
define type of impeller that will be used in liming tank. Election impeller based on
fluid viscocity. Viscosity of RBPO (Refined Bleaced Pam Oil) is 23.25 cp, so we
choose turbine 6 blade because this impeller cause turbulency more fastly than
other impeller type and appropriate to viscosity of the fluid. After we defined type
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First step, we should find out Np (Number Power), data used to search for Np
such as type of impeller and Reynold number,
Reynold number = 3710.35, type of impeller is (11) turbine impeller, six blades,
four baffles, so based on above chart our power number is 2. To calculate power,
we use equation, as follows;
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6. Filter
Plate and frame Filtration (PFF) I is used to separate RBPO component with
bleaching earth and impurities component. The operation conditions are:
Temperature : 100C
Operating Pressure : 1 atm
Below is data for calculation of Plate and Frame Filter I, we get from SuperPro
Simulator:
Feed flowrate : 1061.69 kg/h
Filtrate flowrate (Ft) : 1032.53 kg/h
Cake flowrate (Fc) : 29.17 kg/h
Filtrate volumetric flow (Vt) : 1534.99 L/h = 1.53 m3/h
Cake volumetric flow (Vc) : 28.054 L/h = 0.028 m3/h
Below is calculation steps of Plate and Frame Filter I:
Filtrate density (
Cake density ( )
Where,
L : Cake thickness in frame = 0.05 m (based on assumption)
A : effective filter area (m2)
: cake density (kg/m3) = 1039.67 kg/m3
: filtrate density (kg/m3) = 672.66 kg/m3
V : filtrate volume (m3/h) = 1.53 m3/h
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:W=
So,
0.62 m2
The same calculation is used for the second plate and frame filter and ultrafilter.
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In which Fj is molar flow of the reactant. This value can also expressed in term of
volumetric flow rate and consentration.
Solving those problem, we can get , which is the space time of the stream inside
the reactor. Therefore, we can calculate the volume of the CSTR based on the
space time and the volumetric flowrate. Based on this calculation, we can get
reactor volume of 7 m3. With assumption that the working volume of the CSTR
will no greater than 90%, the actual volume of the tank is 8m3.
We can calculate the dimension of the tank based on the volume and ideal
ratio of CSTRs length and diameter. With assumption that 80% of the fluid will
be at the shell, we can calculate the volume of the silinder as 7,2 m3.
From this calculation, we got the reactors inside diameter as 1,83 m and 2,75 m
high.
Our reactor will be operating at vacuum condition, therefore, the head
must be able to operate under low pressure. Therefore a thorispherical head is
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used, as it can operate at low pressure and have the lowest price rather then other
head type. The torispherical head can be calculated using equation:
We got SF as 0.11 m.
Head and Shell Thickness
The minimum thickness of head and shell of the reactor can be calculated
based on its circumferential and longitudinal strain. This calculation considering
the operating preassure, allowable stress of the material, wielding efficiency, and
internal radius of the wall.
PR
t
SE 0.6 P
The tank operate in vacuum condition, which is 400-500 torr, equal to 53.329 kPa.
Allowable stress of the material use, stainless steel 316, is 126,366.978 kPa with
wielding efficiency 100%. From this calculation, we got the minimum shell
thickness is 0.04 cm.
The minimum head thickness is calculated based on the same parameter,
but using another factor called factor formula of ellipsoidal head, K.
From the calculation, we got the minimum head thickness at 0.34 cm.
The actual shell thickness will be greater than the minimum shell
thickness. Factors such as wind pressure, dead weight of the vessels,
instrumentation can increase the stress of the wall. The calculation to determine
the actual thickness is conducted using trial and error method. The dead weight of
the vessel can be calculated from the wall thickness itself, and the weight of its
internal fitting.
Typical Cw value for vessels with only few internal fitting is 1.08, and the
diameter (Dm) is the outside diameter of the vessels.
( )
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( )
( )
From this calculation, we know that the maximum compressive stress is 150.29
N/mm2 and the critical buckling stress of stainless steel 316 at thickness of 2.5 cm
is 240.58 N/mm2, well above the maximum compressive stress. So we decide the
shell thickness is 2.5 cm.
Agitator
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The power of the agitator is than determined using power number based on its
reynold value. The Reynold number is calculated as:
Using Figure B.4., we can determine the power number of our impaller. The
reynold calculated based on the equation is 1,281.58 and the power number (Np)
is 2.35 based on the graph. The power used is calculated using equation:
From the calculation, we get that the power needed by flat-blade turbines is 0.158
kW. This calculation also conducted for the second CSTR reactor.
8. Decanter
Decanter is a two phase liquid-liquid separator which separate liquid based on its
density using gravitational force. To make sure that the two liquid separated, we
need to make sure that each particle get the needed time to separate. The time for
the two particle to separate is called residence time.
Decanter Residence Time and Volume Calculation
The volume of our decanting tank can be calculated based on a continuous
flow vessel equation.
In a decanting process, the residence time must be the same or greater than the
time needed for the two immiscible liquid to separate. The time needin for the two
liquid to separate can be calculated based on its viscosity and density.
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Based on the viscosity of the mixture at 45oC, and its corresponding density, we
calculate the residence time at
With assumption that the working volume is 90%, we get the actual volume of our
reactor to be 13 m3.
We can calculate the dimension of the tank based on the volume and ideal
ratio of decanters length and diameter. With assumption that 80% of the fluid
will be at the shell, we can calculate the volume of the silinder as 7,2 m3.
From this calculation, we got the reactors inside diameter as 1.38 m and 7 m
long.
Our decanter operate at normal atmospheric pressure, Therefore a
thorispherical head is used, as it can operate at low pressure and have the lowest
price rather then other head type. The torispherical head can be calculated using
equation:
We got SF as 0.72 m.
Head and Shell Thickness
The minimum thickness of head and shell of the reactor can be calculated
based on its circumferential and longitudinal strain. This calculation considering
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the operating preassure, allowable stress of the material, wielding efficiency, and
internal radius of the wall.
PR
t
SE 0.6 P
The tank operate in atmospheric condition, which is 172.68 kPa. Allowable stress
of the material use, carbon steel, is 88,942.369 kPa with wielding efficiency
100%. From this calculation, we got the minimum shell thickness is 0.13 cm.
The minimum head thickness is calculated based on the same parameter,
but using another factor called factor formula of ellipsoidal head, K.
From the calculation, we got the minimum head thickness at 0.43 cm.
The actual shell thickness will be greater than the minimum shell
thickness. Factors such as wind pressure, dead weight of the vessels,
instrumentation can increase the stress of the wall. The calculation to determine
the actual thickness is conducted using trial and error method. The dead weight of
the vessel can be calculated from the wall thickness itself, and the weight of its
internal fitting.
Typical Cw value for vessels with only few internal fitting is 1.08, and the
diameter (Dm) is the outside diameter of the vessels.
( )
The pressure due to wind is called wind loading. It is calculated based on
its dynamic wind pressure and the vessels diameter.
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( )
( )
From this calculation, we know that the maximum compressive stress is 312.52
N/mm2 and the critical buckling stress of carbon steel at thickness of 3.5 cm is
423.34 N/mm2, well above the maximum compressive stress. So we decide the
shell thickness is 3.5 cm.
9. Flashing Column
The use of a flash column in our plant is to increase the purity of
Cocamide DEA product by removing the remaining methanol and acetic
anhydrate. Before entering the flash column, the semi-product of Cocamide DEA
passes through a decanter and two heat exchangers, where it results in a two-phase
equilibrium of vapor and liquid.
The data required to calculate the flash column are; operating and final
temperature, flowrate, density, molecular mass, and the mole fraction of each
component. Calculations are based on Wankat (2007).
a. Calculating Liquid Density
The operating temperature of flash column is at 95C, where the final temperature
is 35C. Then, we also need to calculate the mole fraction of each component by
dividing each components flow rate by the total flow rate. Next, molecular
weight of each component is required as well as the density. We can calculate the
average liquid density with:
Which gives us 0.339 kg/mole.
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We then can obtain the specific volume of the pure components, which is the sum
of mole fractions multiplied by the pure component using the following equation.
Thus, we can obtain the liquid density with the equation below.
The liquid density is 988.89 kg/m3.
b. Determining the Vapor Density
For this part, we use the ideal gas rule, where
P is the operation pressure for this equipment which is 1.013 bar; the gas constant
is 8.314 J/mole. K, and the temperature is 95C. to calculate the average
molecular weight, we must remember to calculate using the subtracted fraction to
achieve the vapor fraction. The average molecular weight is 0.306 kg/mole. This
gives the vapor density 0.219 kg/m3.
c. Determining the Flow parameter
This calculation is to define the liquid and vapor rates which then can be used to
calculate the Kdrum value. The equation of flow parameter is
WL and Wv is the liquid and vapor flow rates in weight units per hour. To obtain
these values, we multiply the vapor and liquid flow rate to their average molecular
weight respectively. By inputting the data, we obtain FLv with a value of 0.0357
kg/hour.
d. Determining Kdrum Value
The Kdrum value is an empirical constant that describes the type of drum. Flash
columns can be either vertical or horizontal, where the two requires a different
design configuration, especially for the demisters. Using the Blackwell (1984)
equation, we can obtain Kdrum value with:
[ ]
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and/or heat capacities of the liquid and vapors, and the overall heat-transfer
coefficients.
Where,
Y = Water fraction in solution
T = Temperature (oC)
P = Pressure (atm)
F = Feed Mass flow rate (kg/hr)
S = Steam Mass flow rate (kg/hr)
V = Vapor mass flow rate (kg/hr)
L = Liquid mass flow rate (kg/hr)
Data known:
- Steam pressure to first effect (TS1) : 5 atm, 220C
- Final pressure in vapor : 1 atm
- Physical properties : Cp solution = 4,2Y + 1,6 (1-Y) kJ/kg/oC.
According to book Transport Processes and Unit Operations 3rd edition by
Geankoplis (1993), typical value of overall heat transfer (U) for agitated film,
forced circulation is around 680- 2300W/(m2.K).
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Where,
Kd = Boiling point elevation constant of water (oC/m)
m = molalitas (m)
i = Vant Hoff factor
mass flow in kg/hr
From these equation, we can get the value of BPR, with Kd water is 0,512C/m.
= ( )= .
( )=0.5120.00017=0.000052
1=200+0.0042=200.0042
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STEP 2: Making an overall and a solids balance to calculate the total amount
vaporized and L1
Overall mass balance
= 1+V1
1033 / = 1+V1
Total solid mass balance
(1)= 1(11)+( 1)(0)
1033(13,86%)= 1(11,9%)+( 1)(0)
993.13= 0.981 1
1=1012.36 /
The total amount vaporized
= 3+( 1)
1033= 1012.36+( 1)
1 = 20.64 /
Solid mass balance
(1)= 1 1
1033(13.86%)= 1012.36 1
1=98.10%
y1=1.9%
From equation about BPR above, we can calculate BPR. The calculation
procedure is same with BPR1 calculation. So, we get
1= . =0.000052
= 1 1( )+( 1)
=220200.0042+(0.000052)=19.996
1= [ ]
1=19.996
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The values of the enthalpy (H for vapor, h for liquid) of the various vapor streams
relative to water at 0C as a datum are obtained from the steam table as follows:
H1 = Hs2 (saturation enthalpy at Ts2) + 1.88 (BPR1)
= 2516.1 + 1.88 (0.000052)
= 2516.1 kJ/kg
s1 = Hs1 (vapor saturation enthalpy) - hS1 (liquid enthalpy at TS1)
= 2801.28 943.91
= 1857.37 kJ/kg
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( )
Where, A1 = 1.269 m2
So,
DT = = 1.27 m
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First step, we should find out Np (Number Power), data used to search for Np
such as type of impeller and Reynold number,
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Appendix C. Utility Sizing And Specifications
1. Water Treatment
1.1. Process
To avoid piping and instrumental damage in the production process, the
water that will flow to each component must be given a treatment. However,
water for domestic usage will not be treated as it is provided by PDAM of Dumai
City. The following explanation will focus on water treatment for steam, cooling
water, and process water usage. The overall water treatment process is shown
below.
River Water
Intake
Disinfection
(NaOCl Injection)
Filtration
Disinfection
(Nitrite Injection)
Deaeration
Boiler Feed
Water
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SPECIFICATION VALUE
Physical Analysis
Odor -
Temperature 28.5C
Chemical Analysis
pH 6.9 - 7.6
DO 3.46 mg/l
BOD 18.10 mg/l
COD 57.53 mg/l
TSS 36.89 mg/l
PO4P 0.07 mg/l
Fecal Coliform 7681 mg/l
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As seen above, the water from the intake is injected with sodium
hypochlorite. Then it passes through the rotary filter to separate the dirt, rocks,
and other particles. Lastly, it is injected with nitrite to counter balance the sodium
hypochlorite and is pumped to the next stage of water treatment.
1.1.2 Demineralization Process
In this process, minerals from the river water will be reduced, hence the
water outcome from this process will be used as the boiler feed water to produce
steam. In order to produce steam, minerals and impurities must be kept to a
minimum value in favor to avoid corrosion within the instruments and quality of
the steam itself. Besides that, condensate and process condensate that has been
circulating in the system is also pumped into this stage so that it will be
reprocessed.
Condensate and process condensate are firstly treated using a condensate
stripper. This is done in advance before the next stage because condensates
contain a high level of CO2 and also small traces of crude palm oil. To remove the
CO2 and traces of crude palm oil, the condensates are reacted with Low Pressure
steam that is pumped from the opposite direction. By doing so, CO2 will exit
along with the steam from the top part of the stripper to the atmosphere. On the
other hand, the final condensate will be pumped to the mixed bed polisher.
The river water and final condensate are pumped simultaneously into a
mixed bed polisher. The function of this unit is to exchange the ions from the
water with the resin in the polisher. The reaction of ion exchange between feed
water and resins are:
(cation resin exchange)
(anion resin exchange)
The outcome of this process is obtaining water that is free from ions as
well as minimum content of Na+, K+, Fe, Cl- and Cu2+. These minerals may cause
scaling in the equipment and piping system and also will impact the temperature
of steam production. Apart from that, the resins that are in the mixed bed polisher
can be regenerated using a high dose of strong acids or bases. The indication when
resin regeneration is needed is when the demineralized water has a high level of
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minerals. In other words, the resin is saturated and the ability to bind to ions has
decreased. The table below shows the specification of a demineralized water.
Table C.1 Demineralized Water Specification
Specification Value
pH 6.2 6.5
Conductivity (max.) 0.2 s/cm
Na+ dan K+ 0.01 ppm
Chlorine (Cl-) 0.02 ppm
Total Fe 0.02 ppm
Total Cu 0.003 ppm
Total SiO2 0.02 ppm
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Fe2O3 and Fe(OH)3. Dissolved gas removal is done by a physical process that
involves low pressure steam.
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Table C.4 Cooling Water Requirements After and Before Heat Exchanger Network
Before After
Specification Unit
Value Value
Q 177.68 75.77 kj/s
T 23 23 C
Cp 4.2 4.2 kj/kg.K
1.84 0.78 kg/s
Mass Flowrate
6621.58 2823.81 kg/h
Total Cooling Water
6621.58 2823.81 kg/h
Required
Table C.5 Make-Up Water Requirements After and Before Heat Exchanger Network
Before After
Specification Unit
Value Value
Cooling and Steam
6858.868186 2943.911181 kg/h
Mass Flowrate
10% Water Loss 685.8868186 294.3911181 kg/h
Table C.6 Total Water Requirements After and Before Heat Exchanger Network
Before After
Specification Unit
Value Value
Steam Requirements 237.2868195 120.1002865 kg/h
Cooling Water
6621.581366 2823.810894 kg/h
Requirements
Process Water 23.6 23.6 kg/h
Make-Up Water
685.8868186 294.3911181 kg/h
Requirements
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Table C.7 Total Water Requirements After and Before Heat Exchanger Network (contd)
7568.355005 3261.902299 kg/h
Total Water Mass 181640.5201 78285.65518 kg/day
Flowrate 181.6405201 78.28565518 tonnes/day
181.6405201 78.28565518 m3/day
It can be seen that HEN optimizes the heat recovery that we have after
applying heat exchanger network. This reduce our heating duty by almost 50%
and reduced the cooling duty by more than 50%. As explained before, some steam
can not be reduce and replace by the process stream, leaving the steam
consumption after HEN a little bit high and the reduction is bellow 50%.
However, this result in the reduction of total water consumption of our plant to
only 78.29 m3/day. There are no energy wasted in our process after we use HEN
in our process design, making it more efficient in term of energy usage.
1.3. Water Treatment Equipment Sizing
1.3.1. Sodium Hypochlorite Injection
Table C.8 Sodium Hypochlorite Injection Specification
Equipment Specification
Pump Type Dosing pump
Function To pump NaOCl to water treatment with dosing concentration
Operation Continuous
Quantity 1
Material Carbon Steel
Operation Data
Flow rate 30 L/h
Operation Data
Pressure 16 bar
Power supply 240 volt
Control option Manual in L/h or gph, pulse in ml/pulse, analog 0/4-20mA
(Source: http://www.kruger.dk/krugeras/ressources/documents/3/38962,Grundfos_dmh.pdf)
1.3.2. Rotary Filter with Micro Mesh
Table C.9 Rotary Filter with Micro Mesh Specification
Equipment Specification
Equipment Name Rotary Filter with Micro Mesh
Filter dirt and impurities in the water before
Function
demineralization process
Equipment Design
Type Gravity flow filtration system
Disc Diameter 2230 mm
Throughput Capacity 2000 m3/h
Filter Discs 35 discs/unit
Mesh Size 2-100 m
(Source: http://pdf.directindustry.com/pdf/huber-technology/rodisc-rotary-mesh-screen/69228-
484753.html)
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1.3.5. Deaerator
Deaerator is used for remove dissolved oxygen and CO2 in demineralized
water before it is pumped into the boiler for steam production. Dissolved gas
removal is done by a physical process that involves low pressure steam. Deaerator
effluent water is used for the manufacture of cocamide DEA. The water
requirement for the process that is 115.18 kg/h, so that the output of the deaerator
should be 115.18 kg/h. Based on the needs of the water, which is 115.18 kg/h, and
the quality of output water is shown in the table below.
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Therefore, we will be using the type of deaerator that compatible with that
specification. The deaerator from Tianjin Talents International Trade Co., Ltd.
shown below.
Based on the above specifications, the deaerator that will used with model
T10 with the following details:
Tank volume : 5 L
Work pressure and temperature: 0.02Mpa 104C
Soft water pressure and temperature: 0.2Mpa >20C
Steam pressure and temperature: 0.33Mpa 145C
Normal pumping oxygen levels: 0.04~0.1mg/L
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2. Electricity
2.1. Process
Our Cocamide DEA plant utilizes a diesel generator to supply electricity
throughout the production process. Therefore, we find that it would be best to find
a diesel generator that can accommodate the production process as well as other
minor electrical installations in the plant. This diesel generator will provide
enough electricity for our equipments that require it such as pumps, reactors, and
others.
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3. Fuel
3.1. Process
In our Cocamide DEA plant, fuel is needed for steam generation process in
boiler unit and electricity generation in generator. We chose natural gas as the fuel
for steam generation process in boiler unit because it is usually readily available,
burn cleanly, and is typically less expensive than oil or electricity. For the steam
generation process, we already determined the Quantity of steam needed in the
overall process. The generated steam for this process produced by boiling water in
boiler. Water in ambient temperature (37 oC, 1 atm) will be heated to saturated
point and convert to steam. Then the steam will be heated until the temperature
needed is reached.
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2. Mass of fuel
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Note:
An orderly evacuation shall be supervised by departmental managers, line
supervisors, and designated wardens who will check all rooms/enclosed
spaces and report any problems via telephone or radio to plant security.
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Lab coat.
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2. Diethanolamine
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Eye Contact:
Check for and remove any contact lenses. Immediately flush eyes with running
water for at least 15 minutes, keeping eyelids open. Cold water may be used. Do
not use an eye ointment. Seek medical attention.
Skin Contact:
After contact with skin, wash immediately with plenty of water. Gently and
thoroughly wash the contaminated skin with running water and non-abrasive soap.
Be particularly careful to clean folds, crevices, creases and groin. Cold water may
be used. Cover the irritated skin with an emollient. If irritation persists, seek
medical attention. Wash contaminated clothing before reusing.
Serious Skin Contact:
Wash with a disinfectant soap and cover the contaminated skin with an anti-
bacterial cream. Seek medical attention.
Inhalation:
Allow the victim to rest in a well-ventilated area. Seek immediate medical
attention.
Serious Inhalation: Evacuate the victim to a safe area as soon as possible.
Loosen tight clothing such as a collar, tie, belt or waistband. If breathing is
difficult, administer oxygen. If the victim is not breathing, perform mouth-to-
mouth resuscitation. Seek medical attention.
Ingestion:
Do not induce vomiting. Loosen tight clothing such as a collar, tie, belt or
waistband. If the victim is not breathing, perform mouth-to-mouth resuscitation.
Seek immediate medical attention.
Serious Ingestion: Not available.
Section 5: Fire and Explosion Data
Flammability of the Product: Flammable.
Auto-Ignition Temperature: The lowest known value is 463.89C (867F)
(Methyl alcohol).
Flash Points: The lowest known value is CLOSED CUP: 12C (53.6F). (Methyl
alcohol)
Flammable Limits: The greatest known range is LOWER: 6% UPPER: 36.5%
(Methyl alcohol)
Products of Combustion: These products are carbon oxides (CO, CO2).
Fire Hazards in Presence of Various Substances:
Highly flammable in presence of open flames and sparks, of heat, of combustible
materials. Flammable in presence of moisture.
Explosion Hazards in Presence of Various Substances:
Risks of explosion of the product in presence of mechanical impact: Not available.
Risks of explosion of the product in presence of static discharge: Not available.
Fire Fighting Media and Instructions:
Flammable liquid, soluble or dispersed in water. SMALL FIRE: Use DRY
chemical powder. LARGE FIRE: Use alcohol foam, water spray or fog.
Special Remarks on Fire Hazards:
Explosive in the form of vapor when exposed to heat or flame. Vapor may travel
considerable distance to source of ignition and flash back. When heated to
decomposition, it emits acrid smoke and irritating fumes. CAUTION: MAY
BURN WITH NEAR INVISIBLE FLAME (Methyl alcohol)
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4. Bleaching Earth
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5. Acetic Anhydrate
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least 15 minutes. Get medical attention such as a collar, tie, belt or waistband.
immediately. If
Skin Contact: breathing is difficult, administer
In case of contact, immediately flush oxygen. If the victim is not breathing,
skin with plenty of water for at least 15 perform mouth-to-mouth resuscitation.
minutes while removing contaminated WARNING: It may be hazardous to the
clothing and shoes. Cover the irritated person providing aid to give mouth-to-
skin with an emollient. Wash clothing mouth resuscitation when the inhaled
before reuse. Thoroughly clean shoes material is toxic, infectious or
before reuse. Get medical attention corrosive. Seek immediate medical
immediately. attention.
Serious Skin Contact: Ingestion:
Wash with a disinfectant soap and Do NOT induce vomiting unless
cover the contaminated skin with an directed to do so by medical personnel.
anti-bacterial cream. Seek immediate Never give anything by mouth to an
medical attention. unconscious person. If large quantities
Inhalation: of this material are swallowed, call a
If inhaled, remove to fresh air. If not physician immediately. Loosen tight
breathing, give artificial respiration. If clothing such as a collar, tie, belt or
breathing is difficult, give oxygen. waistband.
Serious Ingestion: Not available.
Section 5: Fire and Explosion Data
Flammability of the Product: Flammable.
Auto-Ignition Temperature: 316C (600.8F)
Flash Points: CLOSED CUP: 49C (120.2F). OPEN CUP: 51C (123.8F).
Flammable Limits: LOWER: 2.7% UPPER: 10.3%
Products of Combustion: These products are carbon oxides (CO, CO2).
Fire Hazards in Presence of Various Substances: Flammable in presence of
heat
Explosion Hazards in Presence of Various Substances:
Risks of explosion of the product in presence of mechanical impact: Not available.
Risks of explosion of the product in presence of static discharge: Not available.
Fire Fighting Media and Instructions: Flammable liquid. SMALL FIRE: Use
DRY chemical powder. LARGE FIRE: Use alcohol foam, water spray or fog.
Cool containing vessels with water jet in order to prevent pressure build-up,
autoignition or explosion.
Special Remarks on Fire Hazards: Not available.
Special Remarks on Explosion Hazards: Not available.
Section 6: Accidental Release Measures
Small Spill: Absorb with an inert material and put the spilled material in an
appropriate waste disposal.
Large Spill: Flammable liquid. Corrosive liquid. Keep away from heat. Keep
away from sources of ignition. Stop leak if without risk. Absorb with DRY earth,
sand or other non-combustible material. Do not get water inside container. Do not
touch spilled material. Use water spray curtain to divert vapor drift. Prevent entry
into sewers, basements or confined areas; dike if needed. Call for assistance on
disposal. Be careful that the product is not present at a concentration level above
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6. Cocamide DEA
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7. Water
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Possibly hazardous short term degradation products are not likely. However, long
term degradation products may arise.
Toxicity of the Products of Biodegradation: The product itself and its products
of degradation are not toxic.
Special Remarks on the Products of Biodegradation: Not available.
Section 13: Disposal Considerations
Waste Disposal:
Waste must be disposed of in accordance with federal, state and local
environmental control regulations
Section 14: Transport Information
DOT Classification: Not a DOT controlled material (United States).
Identification: Not applicable.
Special Provisions for Transport: Not app
(Source: www.sciencelab.com)
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permanent damage.
IF ON SKIN: Corrosive-May cause moderate to severe irritation, burns.
IF SWALLOWED: Gastrointestinal irritation, nausea, vomiting. Harmful or fatal
if swallowed.
IF INHALED: Irritation to upper respiratory tract, headache nausea.
EMERGENCY AND FIRST AID PROCEDURES
IF IN EYES: Flush eyes and under eyelids with plenty of cool water for at least 15
minutes. Obtain medical attention.
IF ON SKIN: Flush area with water while removing contaminated clothing.
Continue flushing for at least 15 minutes. Launder clothing
separately before re-use. If irritation persists, obtain medical attention.
IF SWALLOWED: Contact physician or poison control center immediately.
Rinse
mouth with water and give affected person 1 to 2 glasses of water. Do not induce
vomiting unless instructed by a physician of poison control center. Never give
anything to an unconscious person.
IF INHALED: Remove person to fresh air. If breathing has stopped, perform
artificial respiration. If breathing is difficult, administer oxygen. Obtain medical
attention.
Section 4: Fire and Explosion Data
FLASH POINT (F): 154 (TEST METHOD): Closed cup
FLAMMABLE LIMITS IN AIR (VOLUME %) UPPER: N/D LOWER: N/D
EXTINGUISHING MEDIA: Water, foam, carbon dioxide, dry chemical.
SPECIAL FIRE FIGHTING PROCEDURES: Cool fire exposed containers with
water fog. Firefighters should be equipped with full protective gear including self-
contained breathing apparatus.
UNUSUAL FIRE AND EXPLOSION HAZARD: None
Section 5: Physical and Chemical Properties
BOILING POINT (F): N/D SPECIFIC GRAVITY (WATER = 1):
VAPOR PRESSURE (mm Hg): N/D 0.99
VAPOR DENSITY (AIR = 1): N/D VOC CONTENT (% by weight): N/D
SOLUBILITY IN WATER: Soluble EVAPORATION RATE (WATER =
APPEARANCE AND ODOR: Clear, 1): N/D
colorless liquid; amine odor pH: 11.25-12.25
Section 6: Reactivity Data
STABILITY: Stable
INCOMPATIBILITY: Strong oxidizers and acids.
CONDITIONS TO AVOID: Excess heat and open flame.
HAZARDOUS DECOMPOSITION PRODUCTS: Thermal decomposition may
produce oxides of carbon and nitrogen.
HAZARDOUS POLYMERIZATION: Will not occur.
CONDITIONS TO AVOID: None
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9. Sodium Hypochlorite
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may produce chronic eye irritation and severe skin irritation. Repeated or
prolonged exposure to spray mist may produce respiratory tract irritation leading
to frequent attacks of bronchial infection.
Section 4: First Aid Measures
Eye Contact: Inhalation:
Check for and remove any contact If inhaled, remove to fresh air. If not
lenses. In case of contact, immediately breathing, give artificial respiration. If
flush eyes with plenty of water for at breathing is difficult, give oxygen. Get
least 15 minutes. Cold water may be medical attention immediately.
used. Get medical attention Serious Inhalation:
immediately. Evacuate the victim to a safe area as
Skin Contact: soon as possible. Loosen tight clothing
In case of contact, immediately flush such as a collar, tie, belt or waistband.
skin with plenty of water for at least 15 If
minutes while removing contaminated breathing is difficult, administer
clothing and shoes. Cover the irritated oxygen. If the victim is not breathing,
skin with an emollient. Cold water may perform mouth-to-mouth resuscitation.
be used. Wash clothing before reuse. Seek medical attention.
Thoroughly clean shoes before reuse. Ingestion:
Get medical attention immediately. Do NOT induce vomiting unless
Serious Skin Contact: directed to do so by medical personnel.
Wash with a disinfectant soap and Never give anything by mouth to an
cover the contaminated skin with an unconscious person. Loosen tight
anti-bacterial cream. Seek medical clothing such as a collar, tie, belt or
attention. waistband. Get medical attention if
symptoms appear.
Serious Ingestion: Not available.
Section 5: Fire and Explosion Data
Flammability of the Product: Non-flammable.
Auto-Ignition Temperature: Not applicable.
Flash Points: Not applicable.
Flammable Limits: Not applicable.
Products of Combustion: Not available.
Fire Hazards in Presence of Various Substances: combustible materials,
metals, organic materials
Explosion Hazards in Presence of Various Substances:
Slightly explosive in presence of open flames and sparks. Non-explosive in
presence of shocks.
Fire Fighting Media and Instructions: Not applicable.
Special Remarks on Fire Hazards:
Releases chlorine when heated above 35 deg. C. The substance itself is non-
combustible and does not burn. However, when heated to decomposition it emits
corrosive and/or toxic fumes. May ignite combustibles. Fire risk in contact with
organic materials. Contact with metals may evolve flammable hydrogen gas.
Section 6: Accidental Release Measures
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Small Spill:
Dilute with water and mop up, or absorb with an inert dry material and place in an
appropriate waste disposal container.
Large Spill:
Corrosive liquid. Oxidizing material. Stop leak if without risk. Absorb with DRY
earth, sand or other non-combustible material. Do not get water inside container.
Avoid contact with a combustible material (wood, paper, oil, clothing...). Keep
substance damp using water spray. Do not touch spilled material. Use water spray
curtain to divert vapor drift. Prevent entry into sewers, basements or confined
areas; dike if needed. Call for assistance on disposal. Be careful that the product is
not present at a concentration level above TLV. Check TLV on the MSDS and
with local authorities
Section 7: Handling and Storage
Precautions:
Keep locked up. Keep container dry. Keep away from heat. Keep away from
sources of ignition. Keep away from combustible material. Do not ingest. Do not
breathe gas/fumes/ vapor/spray. Never add water to this product. In case of
insufficient ventilation, wear suitable respiratory equipment. If ingested, seek
medical advice immediately and show the container or the label. Avoid contact
with skin and eyes. Keep away from incompatibles such as reducing agents,
combustible materials, organic materials, metals, acids.
Storage:
Keep container tightly closed. Keep container in a cool, well-ventilated area.
Separate from acids, alkalies, reducing agents and combustibles. See NFPA 43A,
Code for the Storage of Liquid and Solid Oxidizers. Air Sensitive to light. Store in
light-resistant containers.
Section 8: Exposure Controls/Personal Protection
Engineering Controls:
Provide exhaust ventilation or other engineering controls to keep the airborne
concentrations of vapors below their respective threshold limit value.
Personal Protection:
Face shield. Full suit. Vapor respirator. Be sure to use an approved/certified
respirator or equivalent. Gloves. Boots.
Personal Protection in Case of a Large Spill:
Splash goggles. Full suit. Vapor respirator. Boots. Gloves. A self-contained
breathing apparatus should be used to avoid inhalation of the product. Suggested
Table A.9. Sodium Hypochlorite MSDS (contd)
protective clothing might not be sufficient; consult a specialist BEFORE handling
this product.
Exposure Limits:
Sodium hypochlorite TWA: 1 CEIL: 1 (ppm as Cl2) STEL: 1 (ppm as Cl2) from
ACGIH (TLV) [United States] Sodium hydroxide
STEL: 2 (mg/m3) from ACGIH (TLV) [United States] TWA: 2 CEIL: 2 (mg/m3)
from OSHA (PEL) [United States] CEIL: 2 (mg/
m3) from NIOSH Consult local authorities for acceptable exposure limits.
Section 9: Physical and Chemical Properties
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10. Nitrite
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1-281-441-4400
Section 2: Composition and Information on Ingredients
Composition:
Name CAS # % by Weight
Sodium nitrite 7632-00-0 100
Section 3: Hazards Identification
Potential Acute Health Effects:
Very hazardous in case of eye contact (irritant), of ingestion, of inhalation.
Hazardous in case of skin contact (irritant). Slightly hazardous in case of skin
contact (permeator). Prolonged exposure may result in skin burns and ulcerations.
Overexposure by inhalation may cause respiratory irritation. Severe over-exposure
can result in death. Inflammation of the eye is characterized by redness, watering,
and itching.
Potential Chronic Health Effects:
CARCINOGENIC EFFECTS: Not available. MUTAGENIC EFFECTS:
Mutagenic for mammalian somatic cells. Mutagenic for bacteria and/or yeast.
TERATOGENIC EFFECTS: Classified POSSIBLE for human.
DEVELOPMENTAL TOXICITY: Classified Reproductive system/toxin/female,
Reproductive system/toxin/male [POSSIBLE]. The substance may be toxic to
blood, cardiovascular system, Smooth Muscle. Repeated or prolonged exposure to
the substance can produce target organs damage. Repeated exposure to a highly
toxic material may produce general deterioration of health by an accumulation in
one or many human organs.
Section 4: First Aid Measures
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Small Spill: Use appropriate tools to put the spilled solid in a convenient waste
disposal container.
Large Spill:
Oxidizing material. Poisonous solid. Stop leak if without risk. Do not get water
inside container. Avoid contact with a combustible material (wood, paper, oil,
clothing...). Keep substance damp using water spray. Do not touch spilled
material.
Use water spray to reduce vapors. Prevent entry into sewers, basements or
confined areas; dike if needed. Call for assistance on disposal.
Section 7: Handling and Storage
Precautions:
Keep locked up. Keep away from heat. Keep away from sources of ignition. Keep
away from combustible material. Do not ingest. Do not breathe dust. In case of
insufficient ventilation, wear suitable respiratory equipment. If ingested, seek
medical advice immediately and show the container or the label. Avoid contact
with skin and eyes. Keep away from incompatibles such as reducing agents,
combustible materials, organic materials, metals, acids.
Storage:
Oxidizer. Hygroscopic. Air sensitive. Keep container tightly closed. Keep
container in a cool, well-ventilated area. Separate from acids, alkalies, reducing
agents and combustibles. See NFPA 43A, Code for the Storage of Liquid and
Solid Oxidizers. Do not store above 23C (73.4F).
Section 8: Exposure Controls/Personal Protection
Engineering Controls:
Use process enclosures, local exhaust ventilation, or other engineering controls to
keep airborne levels below recommended exposure limits. If user operations
generate dust, fume or mist, use ventilation to keep exposure to airborne
contaminants below the exposure limit.
Personal Protection: Safety glasses. Synthetic apron. Gloves (impervious).
Personal Protection in Case of a Large Spill:
Splash goggles. Full suit. Boots. Gloves. Suggested protective clothing might not
be sufficient; consult a specialist BEFORE
handling this product.
Exposure Limits: Not available.
Section 9: Physical and Chemical Properties
Physical state and appearance: Solid. Vapor Density: Not available.
(Powdered solid.) Volatility: Not available.
Odor: Odorless. Odor Threshold: Not available.
Taste: Saline. (Slight.) Water/Oil Dist. Coeff.: Not available.
Molecular Weight: 69 g/mole Ionicity (in Water): Not available.
Color: White to slightly yellowish. Dispersion Properties: See solubility
pH (1% soln/water): 9 [Basic.] in water, methanol.
Boiling Point: 320C (608F) Solubility:
Melting Point: 271C (519.8F) Easily soluble in hot water. Soluble in
Critical Temperature: Not available. cold water. Partially soluble in
Specific Gravity: 2.2 (Water = 1) methanol. Very slightly soluble in
Vapor Pressure: Not applicable. diethyl ether.
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Table F.6 Total Indirect Labor Estimation of Cocamide DEA Plant (contd)
HUMAN RESOURCES
Supervisor of
Industrial Relationship 1 593.82 7,125.89 7,125.89
Supervisor of Health
Safety Environment 1 593.82 7,125.89 7,125.89
Health Safety
Environment Staff 2 296.91 3,562.95 7,125.89
Supervisor of Human
Resource Information
System 1 593.82 7,125.89 7,125.89
Supervisor of Public
Relation & Total
Quality Management 1 593.82 7,125.89 7,125.89
Public Relation &
Total Quality
Managment staff 2 296.91 3,562.95 7,125.89
Recruitment &
Trainning staff 2 371.14 4,453.68 8,907.36
Administration staff 1 371.14 4,453.68 4,453.68
OPERATIONAL
Operational Director 1 1,113.42 13,361.05 13,361.05
Engineering Manager 1 742.28 8,907.36 8,907.36
Processing Manager 1 742.28 8,907.36 8,907.36
Research &
Development Manager 1 742.28 8,907.36 8,907.36
Research &
Development Staff 2 371.14 4,453.68 8,907.36
Supply Chain
Management (SCM)
Manager 1 742.28 8,907.36 8,907.36
Warehouse Staff 2 371.14 4,453.68 8,907.36
Quality Control
Manager 1 371.14 4,453.68 4,453.68
Quality Control staff 2 222.68 2,672.21 5,344.42
SALES AND MARKETING DEPARTMENT
Marketing Manager 1 593.82 7,125.89 7,125.89
Marketing Staff 2 296.91 3,562.95 7,125.89
GENERAL SUPPORT AND SERVICE DEPARTMENT
Security 4 186.65 2,239.76 8,959.03
Receptionist 2 186.65 2,239.76 4,479.51
Cleaning Service 4 186.65 2,239.76 8,959.03
56,00 Fixed Cost of Indirect Labor 247,753.86
Variable Cost of Indirect Labor = 20% TDL 49,550.77
Total Indirect Labor 297,304.63
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Power
No Equipment Qty Power (kW) Required/day
(kWh)
1 Positive displacement pump (PM-101) 1 0.135 3.24
2 Positive displacement pump (PM-102) 1 0.229 5.496
3 Positive displacement pump (PM-103) 1 0.115 2.76
4 Positive displacement pump (PM-104) 1 0.05 1.2
5 Positive displacement pump (PM-105) 1 0.098 2.352
6 Positive displacement pump (PM-106) 1 0.059 1.416
7 Positive displacement pump (PM-107) 1 0.053 1.272
8 Positive displacement pump (PM-108) 1 0.353 8.472
9 Positive displacement pump (PM-109) 1 0.01 0.24
10 Positive displacement pump (PM-110) 1 0.021 0.504
11 Positive displacement pump (PM-111) 1 0.119 2.856
12 Positive displacement pump (PM-112) 1 0.021 0.504
13 Positive displacement pump (PM-113) 1 0.261 6.264
14 Positive displacement pump (PM-114) 1 0.24 5.76
15 Vacum pump (VP-101) 1 0.2 4.8
16 Vacum pump (VP-102) 1 0.2 4.8
17 Mixer (MX-101) 1 0.2 4.8
18 Heater (H-102) 1 0.12 2.88
19 Cooler (CX-107) 1 0.21 5.04
20 Cooler (CX-108) 1 0.2 4.8
21 Cooler (CX-109) 1 0.16 3.84
22 CSTR (R-101) 1 0.158 3.792
23 CSTR (R-102) 1 0.023 0.552
TOTAL 77.088
Total Power
No Supporting Equipment Qty Power (kW) per Day
(kWh)
1 Computers 7 0.6 100.8
2 Facsimiles machine 2 0.018 0.432
3 Photocopy, scanner, and printer machine 3 0.5 36
4 CCTV 10 0.0084 2.016
5 Dispenser 2 0.5 24
6 Air Conditioner 2 PK 10 0.8 96
7 Television 3 0.11 3.96
8 Outdor Lamp 50 0.0045 2.7
9 Process, utility and storage lamp 66 0.006 9.504
10 Office Lamp 188 0.003 6.768
11 LCD 2 0.6 2.4
TOTAL 284.58
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Fuel Consumption
The data needed for calculation of the mass of the fuel used in the boiler is
as follows:
BTO (Boiler Thermal Output) = Energy needed in steam generation process
Basis operation = 1 hour
Boiler efficiency = 75% (based rule of thumb)
Fuel used is natural gas with Net Heating Value (NHV) = 22000 btu/lb =
51172 kJ/kg
Cp water = 4.179 kJ/kgoC (assumed constant in every temperature)
Mass Fuel
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Fuel need = 78.9 L/h for 320 kW = 58.56 L/h for 237.5 kW
Fuel need/day = 58.56 L x 24 = 1.405.41 L
Fuel need/year = 1.405.41 L x 330 = 463,783.98 L
Cost of electricity
Cost of electricity/ h = fuel need x diesel price
= 58.56 L/h x 7,600 IDR = 445,045.31 IDR
Cost of electricity/year
Cost of electricity/year = cost of electricity/h x 24 x 330
= 445,045.313 IDR x 24 x 330
= 3,524,758,875 IDR
= USD 271,135.30
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