Pra-Rancangan Pabrik Melamin dari Urea dengan Proses Chemie Linz dengan Kapasitas 40.000 ton/tahun

  LAMPIRAN A PERHITUNGAN NERACA MASSA

  Basis perhitungan : 1 jam operasi Satuan operasi : kg/jam Waktu operasi per tahun : 330 hari Kapasitas produksi : 40.000 ton/tahun Sehingga kapasitas produksi tiap jam = 40.000 ton/tahun

  ton 1 tahun 1 hari 1000 kg = = 4 .000 x x x 5050,505 kg/jam tahun 330 hari 24jam 1 ton

  Untuk mendapatkan melamin sebesar 5050,505 kg/jam, digunakan perhitungan dengan menggunakan alur maju. Basis perhitungan yang digunakan adalah alur 1 (urea) sebesar 15309,633 kg/jam.

  Tabel L.A Berat molekul dari bahan baku dan produk Berat Molekul

  Komponen Kode (gr/mol) Urea U 60,06

  Biuret B 103,09 Water W

  18 Melamin M 126,144 Amonia A 17,031

  Karbondioksida C 44,01 Asam isosianyc

  I

  43 Ammonium karbamat AK

  78 Bahan baku : Urea Produk akhir : Melamin (99,9%) Missal F = laju alir massa (kg/jam)

  W= fraksi massa N = laju alir mol (kgmol/jam) X = fraksi mol

   Komposisi produk M : 99,9% U : 0,05% B : 0,05%

   Komposisi bahan baku urea prill U : 99,3% B : 0,57% W : 0,13%

   Komposisi urea melt U : 99,43% B : 0,57% Konversi reaksi : 95% Yield : 95% ( Ullman Vol. A 16 )

  LA.1 Neraca Massa disekitar Melter (M-01)

  1 F

  3 U

  1 F

  B

  1 W

  3 W

  1

  2 _L

  F _ML-01 U

  2 B

  2

1 F = 15309,633 kg/jam

  U = 99,3%

  1 B 1 = 0,57%

  W = 0,13%

  1 U 2 = 99,43%

  B

  2 = 0,57%

• Neraca Massa Total

  1

  2

3 F = F + F

• Neraca Massa Komponen

  1

2 Urea : F U = F U

  1

  2

  1

  2 Biuret: F B 1 = F B

  2

  1

  3 Water: F W 1 = F W

  3

  2 Menghitung Laju alir massa (F )

  1

  2 F U 1 = F U

  2

  2 F1U1

  F

  = U2

  2 15202,466 kg/jam

  F =

  99,43%

  2 F = 15289,731 kg/jam

  1

  2

  3 F = F + F

  3

  1

  2 F = F - F

  3 F = 15309,633 kg/jam - 15289,731 kg/jam

  3 F = W 3 = 19,903 kg/jam

  1 U 1 = 99,3% x F

  U = 99,3% x 15309,633 kg/jam

  1 U 1 = 15202,466 kg/jam

  1 B 1 = 0,57% x F

  B = 0,57% x 15309,633 kg/jam

1 B = 87,265 kg/jam

  1

  1 W 1 = 0,13% x F

  W = 0,13% x 15309,633 kg/jam

1 W = 19,903 kg/jam

  1

  2 U 2 = 99,43% x F

  U

  2 = 99,43% x 15289,731 kg/jam

  U = 15202,466 kg/jam

  2

  2 B 2 = 0,57% x F

  B

  2 = 0,57% x 15289,731 kg/jam

  B = 87,206 kg/jam

  2 Tabel L.A.1 Neraca Massa (M-01)

  Alur Masuk Alur Keluar Komponen (kg/jam) (kg/jam)

  Alur 1 Alur 2 Alur 3 U 15.202,466 15.202,466

  B 87,265 87,265 W 19,903 19,903

  15.309,633 15289,731 19,903 Total 15.309,633 15.309,633

  L.A.2 Neraca Massa disekitar Reaktor (R-01)

  5 F

  U

  5 _E-72

  B

  5 _R-01

  I

  

5

A

  5

  4 F

2 F

  _F-01 A

  4 U

  2 _{P-03 TC}

  B

2 Fuel + Air

  Konversi reaksi := 95% Reaksi:

  6(NH ) CO

  2 2 → 6NH=C=O + 6NH

  

3

  6U → 6I + 6A

  Neraca massa total

  2

  4

  5 F + F = F

  5

  4 F – F = 15289,731 kg/jam U bereaksi

  Konversi reaksi =

  U umpan

  U umpan = U

  2 = 15289,617 kg/jam

  U bereaksi = konversi reaksi x U umpan U bereaksi = 95% x 15289,731 kg/jam U bereaksi = 14442,343 kg/jam U sisa = U = U umpan - U bereaksi

  5

  = 15289,731 kg/jam - 14442,343 kg/jam = 760,123 kg/jam

  Mol U bereaksi = U bereaksi/BM U

  14442,343 kg/jam

  =

  60,061 kg/kmol

  = 240,461 kmol/jam Mol I hasil reaksi = Mol U bereaksi

  = 240,461 kmol/jam I hasil reaksi (I

  5 ) = Mol I hasil reaksi x BM I

  = (760,123 + 87,265 + 10347,047 + 4095,295) kg/jam = 20927,011 kg/jam

  = B

  5

  5 + B 5 + I 5 + A

  = U

  5

  = 87,265 kg/jam F

  2

  5

  4

  B

  ) = Mol A hasil reaksi x BM A = 240,461 kmol/jam x 17,031 kg/kmol = 4095,295 kg/jam

  5

  A hasil reaksi (A

  Mol A hasil reaksi = Mol U bereaksi = 240,461 kmol/jam

  = 240,461 kmol/jam x 43 kg/kmol = 10347,047 kg/jam

  5

2 F

  F

  = F

• – F

  4

  = A

  4 = F

  5

• 15289,731 kg/jam = 20927,011 kg/jam - 15289,617 kg/jam = 5637,394 kg/jam

  Tabel L.A.2 Neraca Massa (R-01) Alur Masuk

  (kg/jam) Alur Keluar

  Komponen (kg/jam)

  Alur 2 Alur 4 Alur 5 U 15.202,466 760,123 B 87,265 87,265

  I 10.347,047

  A 5637,394 9.732,690 15289,731 5637,394 20.927,011

  Total 20.927,011 20.927,011

  L.A.3 Neraca Massa disekitar Reaktor (R-02) _{4 V-62 F}

  6 _R-02

  U

  6 B

  6 M

  6 A

  6 C

  6

  5 F

  U

  5 B

  5 I

  5 A

  5 Reaksi :

  6NH=C=O

  3 N 3 (NH 2 ) 3 + 3CO

  

2

  → C

  6I → M + 3C

  Asam Isosianyc (I) habis bereaksi Mol I bereaksi = I bereaksi/ BM I

  10347,047 kg/jam

  =

  43 kg/kmol

  = 240,461 kmol/jam

  1 Mol M hasil reaksi = x mol I bereaksi

  6

  1

  = x 240,461 kmol/jam

  6

  = 40,077 kmol/jam M hasil reaksi = M = Mol M hasil reaksi x BM M

  6

  = 40,077 kmol/jam x 126 kg/kmol = 5055,698 kg/jam

  3 Mol C hasil reaksi = x mol I bereaksi

  6

  3

  = 240,461

  x kmol/jam

  6

  = 120,231 kmol/jam C hasil reaksi = C

  6 = Mol C hasil reaksi x BM C

  = 120,231 kmol/jam x 44 kg/kmol = 5291,350 kg/jam Neraca total

  5

6 F = F = 20.927,011kg/jam

  U

  5 = U 6 = 760,123 kg/jam

  B = B = 87,265 kg/jam

  5

  6 A 5 = A 6 = 9.732,690 kg/jam

  Tabel L.A.3 Neraca Massa (R-02) Alur Masuk Alur Keluar

  Komponen (kg/jam) (kg/jam) Alur 5 Alur 6

  U 760,123 760,123 B 87,265 87,265

  I 10.347,047 M 5.055,698

  A 9.732,690 9.732,690 C 5.291,350

  Total 20.927,011 20.927,011

  L.A.4 Neraca Massa disekitar Quencher (Q-01)

  6

  8 F F

  U A

  6

  8 B

  6 C

  8 M

  6 W

  8 A

  6

  7 F

  C

6 Q-01

  W

  7

  

9

F

  U

  

9

B

  

9

M

  9 W

  9 Perbandingan bahan yang masuk dengan bahan peng-quenching

  Bahan masuk : bahan peng-quenching = 1 : 0,8 Air menguap = 5% (Patent application, 2011)

  Neraca massa total

  6

  7

  8

9 F + F = F + F

  Neraca massa komponen

  6

  6

  9

  9 Urea : F U = F U

  6

  6

  9

  9 Biuret : F B = F B

  6

  6

  9

  9 Melamin : F M = F M

  6

  6

  8

  8 Ammonia : F A = F A

  6

  6

  8

  8 Karbondioksida: F C = F C

  7

  7

  8

  8

  9

  9 Water : F W = F W + F W

  U

  6 = U 9 = 760,123 kg/jam

  B

  6 = B 9 = 87,265 kg/jam

  M = M = 5.055,698 kg/jam

  6

  9 A 6 = A 8 = 9.732,690 kg/jam

  C

  6 = C 8 = 5.291,350 kg/jam

  7

  6 F = W 7 = 0,8 x F

  = 0,8 x 20.927,011 kg/jam = 16741,610 kg/jam

  W = 0,05 x W

  8

  7

  = 0,05 x 16741,610 kg/jam = 837,080 kg/jam

  8 F = A 8 + C 8 + W

  8

  = (9.732,690 + 5.291,350 + 837,080)kg/jam = 15861,680 kg/jam

  W

  9 = W 7 – W

  8

  = 16741,610 kg/jam - 837,080 kg/jam = 15904,53 kg/jam

  Tabel L.A.4 Neraca Massa (Q-01) Alur Masuk Alur Keluar

  Komponen (kg/jam) (kg/jam) Alur 6 Alur 7 Alur 8 Alur 9

  U 760,123 760,123

  B 87,265 87,265

  M 5.055,698 5.055,698

  A 9.732,690 9.732,690 C 5.291,350 5.291,350

  W 16.741,610 837,080 15.904,530 20.927,011 16.741,610 15.861,681 21.806,939

  Total 37668,620 37668,620

  L.A.5 Neraca Massa disekitar Sentrifuse (ST-01)

  9 F

  U

  9 ST-01

  B

  9

  10 M

  9 F

  W

  9 U

  10 B

  10

  11 F M

  10 W

  W

  10

  11 Neraca massa total

  9

  10

11 F = F + F

  Neraca massa komponen

  9

  10 Urea : F U 9 = F U

  10

  9

  10 Biuret : F B 9 = F B

  10

  9

10 Melamin : F M = F M

  9

  10

  9

  10

  11 Water : F W 9 = F W 10 + F W

  11 W 10 = 1,3% dari umpan (Ullman Vol. A 16)

  = 1,3% x 15904,530 kg/jam = 206,759 kg/jam

  W

  11 = F 11 = W 9 – W

  10

  = 15904,530 kg/jam - 206,759 kg/jam = 15697,7694 kg/jam

  U

  9 = U 10 = 760,123 kg/jam

  B

  9 = B 10 = 87,265 kg/jam

  M = M = 5055,137 kg/jam

  9

  10

  10 F = (U 10 + B 10 + M 10 + W 10 )

10 F = (760,123 + 87,265 + 5055,137 + 206,759)kg/jam

  = 6109,170 kg/jam Tabel L.A.5 Neraca Massa (ST-01)

  Alur Masuk Alur Keluar

  Komponen (kg/jam) (kg/jam) Alur 9 Alur 10 Alur 11

  U 760,123 760,123 B 87,265 87,265

  M 5055,137 5055,137 W 15904,528 206,759 15697,7694

  21806,939 6109,170 15697,7694 Total 21806,939 21806,939

  L.A.6 Neraca Massa disekitar Tangki Mother Liquor (ML-01)

UT

  F W

  UT

  11

  7 F F

  W

  11 W _ML-01

  7 Neraca massa total

  11 UT

  7 F + F = F

  Neraca massa komponen

  11 UT

  7 F W + F W = F W

  11 UT

  7 UT

  7

  11 F = F – F UT

  F = W = 16741,609 kg/jam – 15697,769 kg/jam

  UT UT

  F = W = 1043,839 kg/jam

  UT

  Tabel L.A.6 Neraca Massa (ML-01) Alur Masuk Alur Keluar

  Komponen (kg/jam) (kg/jam) Alur 11 Alur UT Alur 7

  W 15697,769 1043,839 16741,609 Total 16741,609 16741,609

  10 B

  13 B

  10 M

  10 W

  10 F

  12 U

  12 B

  12 M

  12 F

  13 U

  13 M

  10 U

  13 W

  13

  = F

  10

  Neraca massa total F

  Komposisi produk M : 99,9% U : 0,05% B : 0,05% ( Ullman Vol. A 16 )

  TC

  L.A.7 Neraca Massa disekitar Dryer (DR-01) RD-01

  13

12 Neraca massa komponen

• F
• F

  12 U

  = F

  Urea : F

  10 U

  10

  = F

  13 U

  13

  12 U

  12 Biuret : F

  10 B

  13 B

• F

  10

  F

  13

  ) F

  12

  12

  12

  = (M

  12

  = 0,05% x 760,123 kg/jam = 0,380 kg/jam

  12 Melamin : F

  10

  10 M 10 = F

  13 M 13 + F

  12 U

  12 Water : F

  10 W 10 = F

  13 W

  13 M

  12

  = 99,9%xM

  = 99,9% x 5055,137 kg/jam = 5050,081 kg/jam

  B

  12

  = 0,05%xB

  10

  = 0,05% x 87,265 kg/jam = 0,154 kg/jam

  U

  12

  = 0,05%xU

  10

• B
• U

  = (5050,081 + 0,154 + 0,370) kg/jam = 5050,505 kg/jam

  F

  13 = F 10 – F

  12

  = 6109,170 kg/jam - 5050,505 kg/jam = 1058,665 kg/jam

  U

  13 = U 10 – U

  12

  = 760,123 kg/jam - 0,370 kg/jam = 759,743 kg/jam

  B

  13 = B 10 – B

  12

  = 87,265 kg/jam - 0,154 kg/jam = 87,107 kg/jam

  M

  13 = M 10 – M

  12

  = 5055,137 kg/jam – 5050,081 kg/jam = 5,055 kg/jam

  W

  13 = W

  10

  = 206,759 kg/jam Tabel L.A.7 Neraca Massa (DR-01)

  Alur Masuk Alur Keluar

  Komponen (kg/jam) (kg/jam) Alur 10 Alur 13 Alur 12

  U 760,123 759,743 0,370 B 87,265 87,107 0,154

  M 5055,137 5,055 5050,081 W 206,759 206,759

  6109,170 1058,664 5050,505 Total 6109,170 6109,170

  L.A.8 Neraca Massa disekitar Absorbsi (ABS-01)

  16 F

  14 F

  A

  16 A

  14 ABS-01

  8 F

  A

  8

  15 C

  8 F

  W

  8 AK

  15 W

  15

  2 NH

  3 + CO 2 → NH

  2 CO ONH 4 (Ammonium Karbamat)

  CO

  2 habis bereaksi

  Bahan masuk : bahan peng-absorbsi = 1 : 0,35 (Patent application, 2011) Mol CO bereaksi = massa CO yang masuk (C )/ BM CO

  2

  2

  8

  2 5291,911 /

  =

  44,01 /

  = 120,231 kmol/jam Mol NH

  3 bereaksi = 2 x Mol CO

2 bereaksi

  = 2 x 120,231 kmol/jam = 240,461 kmol/jam

  NH bereaksi = Mol NH bereaksi x BM NH

  3

  3

  3

  = 240,461 kmol/jam x 17,031kg/kmol = 4095,295 kg/jam

  Mol NH COONH hasil reaksi = Mol CO bereaksi

  2

  4

  

2

  = 120,231 kmol/jam NH

  2 COONH 4 hasil reaksi = 120,231 kmol/jam x 78 kg/kmol

  = 9377,988 kg/jam

  14

8 F = A = 0,35 x F

  14

  = 0,35 x 15861,681 kg/jam = 5551,588 kg/jam

  W = W

  8

  17

  = 837,080 kg/jam

  15 F = AK 15 + W

  15

  = 9377,988 kg/jam + 837,080 kg/jam = 10215,069 kg/jam

  16

  14

  8

  15 F = A 16 = F + F – F

  = 5551,588 kg/jam + 15861,681 kg/jam - 10215,069 kg/jam = 11198,2 kg/jam

  Tabel L.A.8 Neraca Massa (ABS-01) Alur Masuk Alur Keluar

  Komponen (kg/jam) (kg/jam) Alur 8 Alur 14 Alur 16 Alur 15

  A 9732,690 5551,588 11198,2 C 5291,911

  W 837,080 837,080

  AK 9377,988

  15861,681 5551,588 11198,2 10215,069 Total 21413,269 21413,269

  L.A.9 Neraca Massa disekitar Vaporizer (V-01)

17 F TC

  A

  1

18 F

  A

  1

8 V-01

  Neraca total F18 = F17 Neraca komponen F18A18 = F17A17 F18 = A18 = 11188,982 kg/jam F18 = F17 = 11188,982 kg/jam Tabel L.A.9 Neraca Massa (PA-01)

  Alur Masuk Alur Keluar Komponen (kg/jam) (kg/jam)

  Alur 18 Alur 17 A 11188,982 11188,982

  Total 11188,982 11188,982

  L.A.10 Neraca Massa disekitar Percabangan Ammonia (PA-01)

  17

  14 F

  F A

17 A

  14

  4 F

  A

  4 Total

  17 F = F 4 + F

14 Neraca Komponen

  17

  4

  14 F A 17 = F A 4 + F A

  14 Tabel L.A.10 Neraca Massa (PA-01)

  Alur Masuk Alur Keluar Komponen (kg/jam) (kg/jam)

  Alur 17 Alur 4 Alur 14 A

  11188,982 5637,394 5551,588 Total 11188,982 11188,982

  LAMPIRAN B PERHITUNGAN NERACA PANAS

  Basis Perhitungan : 1 jam operasi Satuan : kJ/jam Temperatur : 25 C = 298 K

  Persamaan-persamaan termodinamika yang dipergunakan dalam perhitungan neraca energy atau panas ini adalah sebagai berikut:

• Panas masuk dan keluar

  ∫

  Q = H = ................................ (Smith, dkk.2005) . .

  298

• Panas penguapan

  Q = n.H ...................................................... (Smith, dkk.2005)

  VL B.1 Kapasitas Panas B.1.1 Kapasitas Panas Gas

  2

3 Cp= A+ BT + CT + DT

  Dalam hubungan ini: Cp = kapasitas panas cairan, kJ/kmol K T = suhu, K A,B,C,D = konstanta

  Tabel LB. 1 Kapasitas panas gas

  Komponen A B C D

  Urea 9,3626 0,0355 -2,72E-06 -1,01E-08 Biuret 9,107 0,0787 -5,03E-05 -2,14E-08 Melamin 27,7929 3,26E-02 2,81E-05 -2,92E-08 Amonia 27,315 2,38E-02 1,71E-05 -1,18E-08 Karbondioksida 19,774 7,34E-02 -5,60E-05 2,81E-09 Air 32,1902 1,837E-03 1,504E-05 -3,59E-09

  120,57

• Am. Karbamat Nitrogen 29,4119 -3,07E-03 5,45E-06 5,13E-09

  29,6632 Oksigen -0,0113842 4,33779E-05 -3,70062E-08

  Sumber : Yaws, Handbook, 2003)

  (

  B.1.2 Kapasitas Panas Cairan

2 Cp= A+ BT + CT

  Dalam hubungan ini: Cp = kapasitas panas cairan, kJ/kmol K T = suhu, K A,B,C = konstanta

  Tabel LB. 2 Kapasitas panas cairan

  D Komponen A B C

• Urea 104,4582 -
• Biuret 266,7676
• Air 72,356 0,0104 -1,496E-06 Ammonia 20,1494

  0,845765 -0,00406745 6,60687E-06

  ( Sumber : Yaws, Handbook, 2003) B.1.3 Kapasitas Panas Padat

  Tabel LB. 3 Kapasitas panas padat Komponen Cp ( kJ/kmol K)

  Urea 38,43 Biuret 215,2282 Melamin 216,9436

  Komponen Panas Pelelehan Panas Penguapan Panas Desublimasi ( kJ/kmol K) ( kJ/kmol K) ( kJ/kmol K)

  Urea 15.063,048 62.207,93 - 14.658,148 - Biuret 71.350,726

  121.000 - - Melamin Water 40616,6 - -

• Ammonia 23,3

  ( Sumber : Yaws, Handbook, 2003)

  PERHITUNGAN NERACA PANAS B.1 Neraca Panas di Sekitar Melter (M-01) T :140 C

3 T : 30 C T : 140 C

  2

  1 Q Q OUT

  IN Panas Masuk

  Panas yang dibawa umpan masuk melter.T1:30 C:303 K (fase padat) Alur 1

• Urea

  303

  Q = n( ) ∫

  298 303

  Cp.dT = 38,43]dT ∫ [

  298

  = [(38,43) x (303-298)] = 192,15 Kj/Kmol

  Q = n.Cp.dT = 253,121312 Kmol x 192,15 Kj/Kmol = 48637,2601 Kj = 11.616,81 Kkal

• Biuret

  303

  Cp.dT = 215,2282]dT

  ∫ [

  298

  = [(215,2282) x (303-298)] = 1076,141 Kj/Kmol

  Q = n.Cp.dT = 0,846493 Kmol x 1076,141 Kj/Kmol = 910,94527 Kj = 217,5755 Kkal

• Water

  303

  Cp.dT = dT ∫ [ ]

  298

0,0104

  2

  2

  = 72,356(303 (303 )

  − 298) + − 298

  

2

−6

  1,5x10

  3

  3

  (303 )) − − 298

  3 = 377,406 Kj/Kmol

  Q = n.Cp.dT = 1,105696 Kmol x 377,406 Kj/Kmol = 417,29621 Kj = 99,66949 Kkal

  Q alur 1 = Q urea + Q biuret + Q water = (11616,81 + 217,5755 + 99,66949) Kkal = 11934,05503 Kkal

  Panas Keluar

  Alur 2

• Urea

  413

  Cp.dT = 104,4582]dT ∫ [

  298

  = [(104,4582) x (413-298)] = 12012,693 Kj/Kmol

  Q = n.Cp.dT = 253,121312 Kmol x 12012,693 Kj/Kmol = 3040668,613 Kj = 726251,2212 Kkal

• Biuret

  413

  Cp.dT = 266,7676]dT ∫ [

  298

  = [(266,7676) x (413-298)] = 30678,274 Kj/Kmol

  Q = n.Cp.dT = 0,8464925 Kmol x 30678,274 Kj/Kmol = 25968,9285 Kj = 6202,572 Kkal

  Q alur 2 = Q urea + Q biuret = 726251,2212 Kkal + 6202,572 Kkal = 732453,7932 Kkal

  Alur 3

• Water

  413

  Cp.dT = Cp]dT

  ∫ [

  298

0,0104

  2

  2 Cp.dT = 72,356(413

  (413 ) − 298) + − 298

  

2

−6

  1,5x10

  3

  3

  (413 )) − − 298

  3 = 3978,433745 Kj/Kmol

  Q = n.Cp.dT = 1,11203 Kmol x 3978,433745 Kj/Kmol = 4424,15496 Kj = 1056,6913 Kkal

  Panas penguapan dan pelelehan (Qp) Tabel B. 1 Panas penguapan dan pelelehan (Qp)

  Komponen n (kmol) Q (kJ) Q (kkal) λ

  Urea 253.121312 15063,05 3812778,47 910666,493 Biuret 0.846492488 14658,15 12408,0122 2963,602791

  Water 1.105695748 40616,6 44909,6019 10726,47414 Total 3870096,09 924356,5699

  Q yang dibutuhkan = Q masuk – Q keluar = Q – (Q + Q + Qp)

  alur 1 alur 2 alur 3

  =(11934,055–(732453,793+1056,691 +924356,569))Kkal = -1645932,999 Kkal

  Tsteam masuk melter = 455 C = 728 K Tsteam keluar melter = 390 C = 663 K

  C (5 bar) = 3389,5 Kj/Kg = 809,568 Kkal/Kg ΔH steam 455

  C = 3251,2 Kj/Kg = 776,536 Kkal/Kg (Reklaitis, 1983)

  (5 bar)

  ΔH steam 390 Kebutuhan steam = Q yang dibutuhkan /

  ΔH = -1645932,999 Kkal/(776,536 – 809,568) Kkal/Kg = 49827,855 Kg

  3

  11934,055 T2:140 C

  (Kkal) Q

  2

  (Kkal) Q

  1

  Input Output Q

  (Kkal) Qp

  Tabel B. 2 Neraca Panas disekitar Melter (M-01)

  (Kkal) Urea 11616,810 726251,221 - 910666,493

  Biuret 217,576 6202,572 - 2963,603 Water 99,669 - 1056,691 10726,474

  Sub total 11934,055 732453,793 1056,691 -1645932,999 924356,569 Total 11934,055

  Q salt out Q salt in

  (Kkal) Qsteam

  = 6 x ∆Hf NH

  T4:360 C T5: 350 C

  Reaktor

  ∆Hf Urea = -324,5 kJ/mol ( Ullman , Vol A 16 )

  ∆Hf as. isocyanic = -101,67 kJ/mol

  3 = -46,150 kJ/mol ( Smith Vannes, 1996)

  6 NH=C=O + 6 NH3 ∆Hf NH

  2 )

  Reaksi: 6 (NH

  B.2 Neraca Panas di Sekitar Reaktor-01

2 CO →

• 6 x

  Panas Masuk Komponen

  reaksi x Mol reaksi

  ∆Hf

  Mol reaksi = 240,46525 mol Q reaksi =

  ∆Hf as. isocyanic – 6 x ∆Hf Urea = 6x(-46,150 kJ/mol )+ 6x(-101,67 kJ/mol) – 6x(-324,5 kJ/mol) = 1060,08 kJ/mol

  3

  reaksi

  ∆Hf

  = 1060,08 kJ/mol x 240,46525 mol = 254912,3984 Kj = 60884,78036 Kkal

  2 413

  Panas masuk alur 2 = senyawa [ ∑n

  ∫ . ]

  298

  Tabel B. 3 Panas masuk alur 2 Komponen n (kmol) Q (kJ) Q (kkal)

  ∫Cp dT Urea 253,1213 12012,693 3040668,613 726251,221

  Biuret 0,84649 30678,274 25968,9285 6202,572 Total 3066637,542 732453,793

  4 633

  Panas masuk alur 4 = senyawa [ ∑n

  ∫ . ]

  298

  Tabel B. 4 Panas masuk alur 4 Komponen n (kmol) Q (kJ) Q (kkal)

  ∫Cp dT Amonia 331,0078 13706,47671 4536950,903 1083632,106

  Total 4536950,903 1083632,106 Panas Keluar

  5 623

  Panas keluar alur 5 = senyawa [ ∑n

  ∫ . ]

  298

  Cp as.isocyanic 350 C = 14116,4 Kj/Kmol.K (Geankoplis, 2003) Tabel B. 5 Panas keluar alur 5

  Komponen n (kmol) Q (kJ) Q (kkal) ∫Cp dT

  Urea 12,65607 7800,157573 98719,30591 23578,70113 Biuret 0,845386 10363,91162 8761,503079 2092,649059

  As.isosianic 240,461243 14116,4 3394447,085 810749,7577 Amonia 571,46906 13245,64891 7569478,494 1807938,878

  Total 11071406,39 2644359,986 Panas penguapan (Qv) Tabel B. 6 Panas penguapan

  Komponen n (kmol) Qv (kJ) Qv (kkal) λ

  Urea 253,121312 62207,93 15746152,86 3760903,998 Biuret 0,846493 71350,726 60397,85355 14425,77948

  Total 15806550,71 3775329,778 Menghitung Qsalt Qsalt = Q alur 5 + Q v +Q - Q alur 4 – Q alur 2

  reaksi

  = (2644359,986+3775329,778+60884,780 -1083632,106-732453,793) Kkal

  = 4.664.488,644 Kkal Cp salt = 1, 57 kJ/kg.K = 0,3678 kkal/kg.K ( Ullman , Vol A 16 ) Tsalt masuk reaktor = 390 C = 663 K Tsalt keluar reaktor = 360 C = 633 K

  = 30 K ΔT Kebutuhan salt = Q salt/ Cp.ΔT

  4.664.488,644

  =

  0,3678

  

30

.

  = 371.737,533 Kg Tabel B. 7 Neraca Panas disekitar Reaktor-01

  INPUT OUTPUT Komponen Q ^{2 Q}

^{4 Qsalt Q}

^{5 Q V Q Reaksi} (kkal/jam) (kkal/jam) (kkal/jam) (kkal/jam) (kkal/jam) (kkal/jam)

• Urea 726251,221 23578,701 3760903,998 - -
>

-

- - Biuret 6202,572 2092,649 14425,779
• Amonia 1083632
• 1807938,878 810749,758 - - - As.Isocyanic
• 732453,793 1083632,106 4664488,644 2644359,986 3775329,778 60884,780 Total 6480574,544 6480574,544

  B.3 Neraca Panas di Sekitar Furnace T4a :135 C

  T4b : 360 C Furnace

  Q salt Q salt

Q fuel

  Panas Masuk

  4a 408

  Panas masuk alur 4a = senyawa [ ∑n . ]

  ∫

  298

  Tabel B. 8 Panas masuk alur 4a Komponen n (kmol) Q (kJ) Q (kkal)

  ∫ Cp dT Amonia 331,008 4106,609 1359319,694 324667,931

  Total 1359319,694 324667,931 Panas Keluar

  4b 633

  Panas keluar alur 4b = senyawa [ ∑n

  ∫ . ]

  298

  Tabel B. 9 Panas keluar alur 4b Komponen n (kmol) ∫ Cp dT Q (kJ) Q (kkal)

  Amonia 331,008 13706,47671 4536950,903 1083632,106 Total 4536950,903 1083632,106

  Menghitung Q Fuel Q fuel = Q salt + Q4b - Q4a

  = (4665054,284+ 1083632,106- 324667,931) Kkal = 5423452,819 Kkal

  Menghitung kebutuhan fuel Efisiensi furnace = 70% Kebutuhan panas (Qbb) =

  

5423452,819

  =

  

70%

  = 7747789,742 Kkal = 30725689,01 Btu

  Bahan bakar yang digunakan solar, dengan nilai panas = 19.440 Btu / lb

3 Densitas = 54,26 lb/ft

  30725689,01

  Kebutuhan bahan bakar =

  19440 /

  = 1580,5396 lb

  

3

  = 29,129 ft Tabel B.10 Neraca Panas disekitar Furnace

  INPUT OUTPUT Komponen

  Q (kkal/jam) Qfuel(kkal/jam) Q (kkal/jam) Qsalt(kkal/jam)

  4a 4b

• Urea
• Biur
• Melamin - Amonia 324667,931 1083632,106 -

  324667,931 5423452,819 1083632,106 4665054,284 Total 5748120,751 5748120,751

  B.4 Neraca Panas di Sekitar Vaporizer

  T

  17 : 135 C

  T

  18 : -5.5 C

  Qsteam (455

  C) Panas Masuk

  18 267,5

  Panas masuk alur 18 = senyawa [ ∑n . ]

  ∫

  298

  Tabel B. 11 Panas masuk alur 18 Komponen n (kmol) Q (kJ) Q (kkal)

  ∫Cp dT Amonia 656,9774 2549,047 1674666,438 399987,207

  Total 1674666,438 399987,207 Panas Keluar

  17 408

  Panas keluar alur 17 = [

  senyawa

  ∑n ∫ . ]

  298

  Tabel B. 12 Panas keluar alur 17 Komponen n (kmol) Q (kJ) Q (kkal)

  ∫Cp dT Amonia 656,9774 4106,609071 2697949,406 644394,1449

  Total 2697949,406 644394,1449 Menghitung panas penguapan (Q v)

  Komponen n (kmol) Qv (kJ) Qv (kkal) λ

  Amonia 656,977 23,3 15307,5737 3656,1512 Total 15307,5737 3656,1512

  Q yang dibutuhkan = Qmasuk + Q

  V – Q keluar

  = 399987,207 kkal + 3656,1512 kkal - 644394,1449 kkal = -240750,7868 kkal

  C = 3389,5 Kj/Kg

  (5 bar)

  ΔH steam 455 = 809,568 Kkal/Kg

  C = 3251,2 Kj/Kg (Reklaitis, 1983)

  (5 bar)

  ΔH steam 390 = 776,536 Kkal/Kg

  Tsteam masuk = 455 C = 728 K Tsteam keluar = 390 C = 663 K Kebutuhan steam = Q yang dibutuhkan /

  ΔH

  −240750,7868

  =

  ( 776,536−809,568)

  = 7288,325 Kg Tabel B.13 Neraca Panas disekitar Vaporizer

  INPUT OUTPUT Komponen

  Q

  18 (kkal/jam) QV (kkal/jam) Q 17 (kkal/jam) Qsteam (kkal/jam)

  Amonia 399987,2069 644394,1449 399987,2069 3656,1512 644394,1449 -240750,7868

  Total 403643,3581 403643,3581

  B.5 Neraca Panas di Sekitar Reaktor-02

  Q : 455 C

  steam

  T : 450 C _R-02

  6 T : 350 C

  5 Panas Masuk 5 623

  Panas masuk alur 5 = senyawa [ ∑n . ]

  ∫

  298

  Cp as.isocyanic 350 C = 14116,4 Kj/Kmol.K (Geankoplis, 2003) Tabel B. 14 Panas masuk alur 5 n Q Q

  5

  5 Komponen

  ∫Cp dT (kmol) (kJ) (kkal)

  Urea 12,656 7800,158 98719,306 23578,701 Biuret 0,845 10363,912 8761,503 2092,649

  As.isocyanic 240,461 14116,400 3394447,085 810749,758 Amonia 571,469 13245,649 7569478,494 1807938,878

  Total 11071406,390 2644359,986 Panas Keluar

  6 723

  Panas keluar alur 6 = senyawa [ ∑n

  ∫ . ]

  298

  Tabel B. 15 Panas keluar alur 6 Komponen n (kmol) Q

  6 (kJ) Q 6 (kkal)

  ∫Cp dT Urea 12,656 10692,576 135325,937 32322,045

  Biuret 0,845 13632,779 11524,957 2752,689 Melamin 40,074 20239,933 811101,812 193728,339

  Amonia 571,469 17993,148 10282527,390 2455939,474 CO

  

2 120,243 17954,649 2158927,501 515650,975

  Total 13399407,600 3200393,521 Reaksi:

  6 NH=C=O C N (NH ) + 3 CO →

  3

  

3

  2

  3

  2 2 = -393,509 kJ/mol

  ∆Hf CO = -101,67 kJ/mol ( Smith Vannes, 1996)

  ∆Hf as. isocyanic = -71,72 kJ/mol ( Ullman , Vol A 16 )

  ∆Hf melamin = 3 x

• reaksi

  2

  ∆Hf ∆Hf CO ∆Hf melamin – 6 x ∆Hf as.isosianic

  = (3 x (-393,509) + (-71,72 ) – 6 x (-101,67)) kJ/mol = -642,23 kJ/mol

  Mol reaksi = 80,15375 mol Q reaksi = x Mol reaksi

  reaksi

  ∆Hf = (-642,23 kJ/mol) x 80,15375 mol = -51477,14128 kJ = -12295,10397 Kkal

  (455

  C, 5 bar) = 3389,5 kJ/Kg

  ΔH = 809,568 Kkal/Kg

  (390

  C, 5 bar) = 3251,2 kJ/Kg

  ΔH = 776,536 Kkal/Kg (Reklaitis, 1983)

  Q yang dibutuhkan = Q

  5 – (Q 6 + Q reaksi )

  = (2644359,986– (3200393,521+ (-12295,10397)) Kkal = -543738,4318 Kkal

  T steam masuk = 455 C = 728 K T steam keluar = 390 C = 663 K

  Kebutuhan steam = Q yang dibutuhkan / Cp ΔT

  −543738,4318

  =

  ( 776,536−809,568)

  = 16460,767 Kg Tabel B.16 Neraca Panas disekitar Reaktor-02

  INPUT OUTPUT Komponen

  Q Q Qsteam Qreaksi

  5

  6

  (kkal/jam) (kkal/jam) (kkal/jam) (kkal/jam) Urea 23578,701 32322,045 Biuret 2092,649 2752,689

• As.Isocyanic 810749,758
• Melamin 193728,339
• CO 515650,975

2 Ammonia 1807938,878 2455939,474

  2644359,986 3200393,521 -543738,4318 -12295,10397 Total 2644359,986 2644359,986

  B.6 Neraca Panas di Sekitar Quenching (Q-01)

  T : 450 C T : 221,92 C

  6

  8 T 7 : 30 C Q-01

  T

  9 : 221,92 C

  Panas Masuk

  6 723

  Panas masuk alur 6 = senyawa [ ∑n . ]

  ∫

  298

  Tabel B. 17 Panas masuk alur 6 Komponen n (kmol) Q (kJ) Q (kkal)

  6

  6

  ∫Cp dT Urea 12,656 10692,576 135325,937 32322,045

  Biuret 0,845 13632,779 11524,957 2752,689 Melamin 40,074 20239,933 811101,812 193728,339

  Amonia 571,469 17993,148 10282527,390 2455939,474

  CO

  Komponen

  ∫Cp dT Q

  8

  (kJ) Q

  8

  (kkal) Ammonia 571,469 7623,355 4356553,201 1040544,856

  CO

  2

  120,243 7891,930 948961,308 226655,514 Water 46,505 6910,600 321376,766 76759,522

  Total 5626891,275 1343959,892 Tabel B.21 Neraca Panas disekitar Quenching (Q-01)

  INPUT OUTPUT Q

  494,919 298

  6

  (kkal/jam) Q

  7

  (kkal/jam) Q

  9

  (kkal/jam) Q

  8

  (kkal/jam) Urea 32322,045 - 62180,048 - Biuret 2752,689 - 10607,128 - Melamin 193728,339 - 408905,485 - Ammonia 2455939,474 - - 1040544,856 CO

  2 515650,975 - - 226655,514

  Water - 83689,947 1458430,916 76759,522 3200393,521 83689,947 1940123,577 1343959,892

  Tabel B. 20 Panas keluar alur 8 Komponen n (kmol)

  ∫ . ]

  

2 120,243 17954,649 2158927,501 515650,975

  ∫ . ]

  Total 13399407,600 3200393,521 Panas masuk alur 7 =

  ∑n

  7 senyawa [

  ∫ . ]

  303 298

  Tabel B. 18 Panas masuk alur 7 Komponen n (kmol)

  ∫ Cp dT Q (kJ) Q (kkal)

  Water 930,0893733 376,7305385 350393,0705 83689,9471 Total 350393,0705 83689,9471

  Panas keluar alur 9 = ∑n

  9 senyawa [

  494,919 298

  8 senyawa [

  Panas Keluar Tabel B. 19 Panas keluar alur 9

  Komponen n (kmol) ∫Cp dT

  Q

  9

  (kJ) Q

  9

  (kkal) Urea 12,656 20569,829 260335,427 62180,048

  Biuret 0,845 52531,672 44409,923 10607,128 Melamin 40,074 42720,368 1712005,485 408905,485

  Water 883,585 6910,600 6106158,559 1458430,916 Total 8122909,393 1940123,577

  Panas keluar alur 8 = ∑n

  Total 3284083,469 3284083,469

  B.7 Neraca Panas di Sekitar HE -01 T 8a : 221.92 C

  HE-01

Qcw

T 8b : 120 C

  Panas Masuk

  8a 494,92

  Panas masuk alur 8a = senyawa [ ∑n

  ∫ . ]

  298

  Tabel B. 22 Panas masuk alur 8a Komponen n (kmol) Q8a(kJ) Q8a (kkal)

  ∫ Cp dT Ammonia 571,469 7623,355 4356553,201 1040544,856 CO

  2 120,243 7891,930 948961,308 226655,514

  Water 46,505 6910,600 321376,766 76759,522 Total 5626891,275 1343959,892

  Panas Keluar

  8b 393

  Panas keluar alur 8b = senyawa [ ∑n

  . ] ∫

  298

  Tabel B. 23 Panas keluar alur 8b Komponen n (kmol) Q 8b (kJ) Q 8b (kkal)

  ∫ Cp dT Ammonia 571,469 3524,133 2013932,745 481019,572 CO 120,243 3659,869 440074,916 105110,088

2 Water 46,505 3275,663 152332,974 36384,106

  Total 2606340,635 622513,766 Q Cooling water = Q 8a – Q 8b

  = 1343959,892Kkal - 622513,766 Kkal = 721446,126 Kkal

  Cp Cooling water = 1,008 kkal/kg.K (Geankoplis, 2003) Tcw masuk HE = 30 C = 303 K Tcw keluar HE = 50 C = 323 K

  = 20 K Δ T Kebutuhan cooling water

  = Qcooling water / Cp ΔT

  721446,126

  =

  1,008

  20

  = 35786,018 kg Tabel B.24 Neraca Panas disekitar HE-01

  Panas Masuk Tabel B. 24 Panas masuk alur 9a

  Total 4188007,534 894936,049 Q Cooling water = Q 9a – Q 9b

  Q9b (kJ) Q9b (kkal) Urea 12,656 2113,650 26750,493 6389,246 Biuret 0,845 11837,551 10007,297 2390,202 Melamin 40,074 11931,898 478162,843 8854,868 Water 883,585 4157,028 3673086,901 877301,734

  Komponen n (kmol) ∫Cp dT

  Panas Keluar Tabel B. 25 Panas keluar alur 9b

  323 298

  ∫ . ]

  9b senyawa [

  ∑n

  Total 8122909,393 1940123,577 Panas keluar alur 9b =

  Q9a (kJ) Q9a (kkal) Urea 12,656 20570,012 260335,427 62180,048 Biuret 0,845 52532,141 44409,923 10607,128 Melamin 40,074 42720,749 1712005,485 408905,485 Water 883,585 6910,664 6106158,559 1458430,916

  Komponen n (kmol) ∫Cp dT

  494,92 298

  Komponen

  ∫ . ]

  9a senyawa [

  Panas masuk alur 9a = ∑n

  B.8 Neraca Panas di Sekitar HE -02

  1343959,892 622513,766 721446,126 Total 1343959,892 1343959,892

  226655,514 105110,088 Water 76759,522 36384,106

  2

  (kkal/jam) Qcw(kkal/jam) Ammonia 1040544,856 481019,572 CO

  8b

  (kkal/jam) Q

  8a

  INPUT OUTPUT Q

  = 1940123,577 kkal - 894936,049 kkal ^{HE-02 T 9b : 80 C T 9a : 221.92 C Qcw}

  = 1045187,528 kkal Cp cooling water = 1,008 kkal/kg.K (Geankoplis, 2003) Tcw masuk HE = 30 C = 303K Tcw keluar HE = 50 C = 323K

  = 20 K Δ T Kebutuhan cooling water = Qcooling water /

  Cp ΔT

  

1045187,528

  =

  1,008

  20

  = 51844,61946 kg Tabel B.26 Neraca Panas disekitar HE-02

  INPUT OUTPUT Komponen

  Q9a(kkal/jam) Q9b(kkal/jam) Qcw(kkal/jam)

• Urea 62180,048 6389,246
• Biuret 10607,128 2390,202 Melamin 408905,485 - 8854,868
• Water 1458430,916 877301,734 1940123,577 894936,049 1045187,528

  1940123,577 Total 1940123,577

  B.9 Neraca Panas di Sekitar Dryer (DR-01)

  T

  10 : 80 C RD-01

  T

  13 : 120 C

  Q h : 180 C _TC T

  12 : 120 C

  Panas Masuk

  10 323

  Panas masuk alur 10 = senyawa [ ∑n

  . ] ∫

  298

  Tabel B. 27 Panas masuk alur 10 Komponen n (kmol) Q

  10 (kJ) Q 10 (kkal)

  ∫Cp dT Urea 12,656 2113,650 26750,493 6389,246 Biuret 0,845 11837,551 10007,297 2390,202 Melamin 40,074 11931,898 478162,843 114207,233 Water 11,487 4157,028 47750,129 11404,923

  Total 562670,763 134391,603 Panas keluar alur 13 =

  ∫Cp dT Q

  = 134391,603 kkal – (35102,381 + 197077,354) kkal = -97788,13208 kkal

  10 – (Q 13 + Q 14 )

  = 0,221601568 kkal/kg Qudara = Q

  = 0,228324735 kkal/kg Cp Oksigen 85 C = 0,927801444 kJ/kg

  = 0,248758431 kkal/kg (Geankoplis, 2003) Cp Oksigen 180 C = 0,95595 kJ/kg

  = 0,250185583 kkal/kg Cp Nitrogen 85 C = 1,0415018 kJ/kg

  Total 825123,466 197077,354 Cp Nitrogen 180 C = 1,047477 kJ/kg

  (kkal) Urea 0,0063 3650,850 23,103 5,518 Biuret 0,0004 20446,679 8,643 2,064 Melamin 40,0343 20609,642 825091,721 197069,772

  12

  (kJ) Q

  12

  Tabel B. 29 Panas keluar alur 12 Komponen n (kmol)

  ∑n

  393 298

  . ]

  [ ∫

  12 senyawa

  ∑n

  Total 146966,648 35102,381 Panas keluar alur 12 =

  Komponen n (kmol) ∫ Cp dT Q13 (kJ) Q13 (kkal) Urea 12,649 3650,850 46182,294 11030,452 Biuret 0,845 20446,679 17276,688 4126,466 Melamin 0,041 20609,642 825,918 197,267 Water 11,487 7198,102 82681,748 19748,196

  Panas Keluar Tabel B. 28 Panas keluar alur 13

  393 298

  [ ∫ . ]

  13 senyawa

  Tudara masuk = 180 C = 453 K

  Tudara keluar = 85 C = 358 K = 95 K

  ΔT Kebutuhan udara

  = Qudara / Cp ΔT

  −97788,13208

  =

  ( 0,24876+0,2216)−(0,250186+0,228325)

  95

  = 126295,5163 kg Tabel B.30 Neraca Panas disekitar Dryer (D-01)

  IN OUT Komponen

  Q (kkal) Q (kkal) Q (kkal) Qudara (kkal)

  10

  13

  14

• Urea 6389,246 11030,452 5,518
• Biuret 2390,202 4126,466 2,064 Melamin 197,267 - 114207,233 197069,772
• Water 11404,923 19748,196 134391,603 35102,381 197077,354 -97788,132

  134391,603 Total 134391,603