PRELIMINARY DESIGN OF PRECIPITATED SILICA PLANT FROM SULPHURIC ACID AND SODIUM SILICATE Preliminary of Precipitated Silica Plant from Sulphuric Acid and Sodium Silicate with Capacity of 40,000 ton/years.

PRELIMINARY DESIGN OF PRECIPITATED SILICA PLANT FROM
SULPHURIC ACID AND SODIUM SILICATE
WITH CAPACITY OF 40,000 TON/YEARS

By:
MR.ISMAAE YUSOH
D500112010

Supervisor:
Dr. Ir. Ahmad M. Fuadi, MT
Kun Harismah Ph. D

CHEMICAL ENGINEERING DEPARTMENT
FACULTY OF ENGINEERING
UNIVERSITAS MUHAMMADIYAH SURAKARTA
2015

APPROVAL
CHEMICAL ENGINEERING DEPARTMENT
ENGINEERING FACULTY
UNIVERSITAS MUHAMMADIYAH SURAKARTA

Name

: Mr. Ismaae Yusoh

NIM

: D500112010

Title

: Preliminary of Precipitated Silica Plant from Sulphuric
Acid and Sodium Silicate with Capacity of 40,000
ton/years

Advisor

: 1. Dr.Ir.Ahmad M. Fuadi, MT
2. Kun Harismah, Ph. D
Surakarta, July 2015

Approved by,
Supervisor I

Supervisor II

Dr.Ir.Ahmad M. Fuadi, MT
NIK.618

Kun Harismah, Ph. D
NIK.402

Knowed by,
Dean,

Head of Chemical Engineering,

Ir. Sri Sunarjono.,MT.,Ph. D
NIK.682

Rois Fatoni, ST, M.Sc, Ph. D

NIK.892

STATEMENT LETTER
I declare that this final report is original. There are no previous researches
that have been submitted in order to get bachelor degree. As I know, there are no
statements from other researchers, except the statements that are listed in the
bibliography.
In the future, if there is a lie on my statements then I will be fully
responsible.

Surakarta, July 2015

Mr.Ismaae Yusoh
D 500 112 010

ACKNOWLEDGEMENT

The author says thank to Allah SWT who gives His blessing, so the author
has been able finish the final a project “Preliminary of Precipitated Silica Plant
from Sulphuric Acid and Sodium Silicate with Capacity of 40,000 ton/years”.

In arranging the report, the author have get supports from several parties.
Because of that, the author wants to say thank to:
1. Allah SWT who has given me His mercy and His blessing.
2. Baba (บาบอ), Mama (มาม่า), Kakak Bede (แบเดร์ ), Beheng (แบเฮง), Tetoh Dah
(แตเตาะ), Besi’ (แบเซะ), Beding (แบดิง), Bema’ (แบมะ) and brother Hanan (ฮา
นาน) who always gives a support to the writer.
3. Mr. Dr. Ir. Ahmad M Fuadi, MT as supervisor I.
4. Mrs. Kun Harismah Ph.D as supervisor II.
5. Linda Fatmawati as a partner of Our Final Project
6. Nurdeeyah Thank you for all the support.
7. Arbideen and Masoleah thank you for standing by me.
Finally, the writer hopes that this final project report will give benefit for
all researchers, writers, and reader. Aamiin
Surakarata,

June 2015

Author

ABSTRACT

In Indonesia, precipitated silica plant is an industry that can provide a good
opportunity for the country. Indonesia has not been able to meet the needs
of precipitated silica, so that Indonesia imports from other countries. From
2005 to 2012 Indonesia has exported 89,801.806 tons of precipitated silica,
and the capacity for imports are 111,362.3 tons, so the precipitated silica
plant is designing of 40,000 tons/year. Precipitated silica (SiO2) is the
oxidation of non-metallic compounds. it has a solid powder form, white,
odorless, insoluble in water, and has a crystalline structure. The process of
manufacturing of precipitated silica using silicate acidification uses CSTR
reactor (continuous stirrer tank reactor). It operates at a temperature of 90°C
and at a pressure of 1 atm. This reactor proceeds in the liquid phase,
irreversible, and non-adiabatic. The product of the reactor are separated in
rotary vacuum filter, and then the result is a cake of SiO2. It is dried with
dryer.
Utility units of the plant consists of the units of the water provider, the unit
of steam supply, electricity and fuel supply unit, and laboratories to maintain
the quality of materials and products to conform to the standards. This
company is a Limited Incorporation with a system of organizational
structure and staff. As a plan, the company is built in Karawang, District
Ciampel, and West Java Province. The establishment of the plant requires a

total investment (capital investment) amounting to Rp 274,988,392,478.30
and production costs Rp 182,861,209,437.49. Economic analysis obtained
BEP 54.8%, SDP 30.6%, 24.31% ROI before tax, ROI after tax (Inc, Ltd)
14.59%. Profit after tax earned Rp 28,550,485,320

MOTTO

Pray on time, surely GOD will always help us.
Ibu Aminah Yusoh
Just be a good person
Mr.Dr. Muhammad Asmee Abubaka
ความภูมิใจสู งสุดในชี วิต คือ การประสบความสาเร็ จ ในสิ่ งที่คนรอบข้ างเชื่ อว่ าคุณไม่ มีวันทาได้
(A great pleasure in life is doing what people say you cannot do.)
Hamidah Yusoh
Always thing that time is important thing that will make us get better and
successful
We thing when we dream, and we try to do it, Insya allah it will become true
Muhammad Yusoh
"Don't limit yourself. Many people
Limit themselves to what they

Think they can do. You can go as far
As your mind lets you.
What you believe, remember, you can archive."
Zeal is a volcano, the peak of which the grass of indecisiveness does not grow.
(The spirit is a volcano that on it, the doubts grass never grows)
"Be you. Find you.
Be happy with that."

DEDICATION

This work is dedicated for:
My mom is the one who give a spirit for me, advise me, and also give me a
direction so that I can finish this final report.
(I LOVE YOU MOM)

Baba is my idol. Even he is hard but I know that he did for me.
(I LOVE YOU BABA)

For my baba and mama. Thank you for your praying. Thanks for your money. I
will replace it later.

My partner Linda Fatmawati. When I am down, you are the one who always
give me a spirit. Thanks

For my friends, chemical engineering, 2011. Thanks for togetherness. Thanks for
beautiful memories with you.

TABLE OF CONTENTS
TITLE .................................................................................................................. i
APPROVAL ...................................................................................................... iii
ACKNOWLEDGEMENT .................................................................................. iv
ABSTRACT ........................................................................................................ v
MOTTO .............................................................................................................. vi
TABLE OF CONTENTS .................................................................................... viii
LIST OF TABLE ................................................................................................ xi
LIST OF FIGURE ............................................................................................... xiii
CHAPTER I INTRODUCTION ......................................................................... 1
1.1 The Background of the Plant ................................................................ 1
1.2 Selection of The Capacity of the Plant Design ..................................... 2
1.3 Literature Review.................................................................................. 5
1.4 The usefulness of products.................................................................... 6

1.5 Properties of Physical and Chemical Raw Materials and Products ...... 6
1.6 The General Process Review ................................................................ 9
CHAPTER II PROCESS DESCRIPTION ......................................................... 10
2.1 The Specification of Raw Materials and Products…............................ 10
2.2 The Process Concept ............................................................................. 10
2.3 The Thermodynamic Review ................................................................ 11
2.4 The Flowchart ....................................................................................... 12
2.5 The Process Stages ................................................................................ 12
2.6 The Flowchart of Material Balance and Heat Balance ......................... 14
2.7 The Plant Layout and Equipment ......................................................... 18
CHAPTER III THE SPESIFICATION OF THE EQUIPMENT ........................ 23
3.1 Tank of Sodium Silicate (T-01) and Tank of H2SO4 (T-02) ................. 23
3.2 Mixer (M-01) ........................................................................................ 23
3.3 Heat Exchanger (HE-01)....................................................................... 24
3.4 Reactor 1 and Reactor 2 ........................................................................ 25
3.5 Pump ..................................................................................................... 26
3.6 Bucket Elevator ..................................................................................... 30
3.7 Belt Conveyor ....................................................................................... 31
CHAPTER IV PROCESS SUPPORT UNIT AND LABORATORY ................ 32
4.1 Process Support Unit............................................................................. 32

CHAPTER V MANAGEMENT ......................................................................... 56
5.1 Company ............................................................................................... 56
5.2 Organizational Structure ....................................................................... 57
5.3 Employee Welfare ................................................................................ 65
5.4 Health and Safety .................................................................................. 65
5.5 Production Management ....................................................................... 66
5.6 Production Plan ..................................................................................... 64
5.7 Production Control ................................................................................ 67
CHAPTER VI ECONOMICAL ANALYSIS ..................................................... 70
6.1 Basic Calculation .................................................................................. 70
6.2 Cost Calculation .................................................................................... 72

6.3 General Expenses ..................................................................................
6.4 Feasibility Analysis ...............................................................................
6.5 The Result of Calculation .....................................................................
CHAPTER VII CONCLUSION .........................................................................
BIBLIOGRAPHY ...............................................................................................
APENDIX ...........................................................................................................

74

74
76
81
82
87

LIST OF TABLE
Table 1.1
Table 1.2
Table 2.1
Table 2.2
Table 2.3
Table 2.4
Table 2.5
Table 2.6
Table 2.7
Table 2.8
Table 2.9
Table 2.10
Table 2.11
Table 2.12
Table 2.13
Table 2.14
Table 2.15
Table 3.1
Table 5.1
Table 5.2
Table 5.3
Table 6.1
Table 6.2
Table 6.3
Table 6.4
Table 6.5
Table 6.6
Table 6.7
Table 6.8
Table 6.9

The export data and import data precipitated silica..................
The existing capacity of precipitated silica plant......................
The data of reaction formation of precipitated silica................
The component of material flow...............................................
The material balance mixer (M-01)..........................................
The material balance of reactor 1 (R-01)..................................
The material balance of reactor 2 (R-02)..................................
The material balance, rotary drum filter (RDF-01)...................
The material balance, rotary dryer (RD-01)..............................
The total of material balance.....................................................
The heat balance of mixer (M-01)............................................
The heat balance of reactor (R-01)...........................................
The heat balance of reactor (R-02)...........................................
The heat balance of rotary drum filter (RDF-01).....................
The heat balance of rotary dryer (RD-01)................................
The heat balance around heat exchanger (HE-01)...................
Building precipitated silica.......................................................
The needs of electricity for process..........................................
Schedule for each group...........................................................
Positions and requirements.......................................................
Data of the number of process employee.................................
Cost index chemical plant year 1990-2010..............................
Physical plant cost....................................................................
Fixed capital cost......................................................................
Working capital investment......................................................
Manufacturing cost...................................................................
General expense........................................................................
Fixed cost..................................................................................
Variable cost.............................................................................
Regulated cost..........................................................................

2
3
11
14
15
15
15
15
16
16
16
17
17
17
17
17
20
50
63
63
64
71
76
77
77
77
78
79
79
79

LIST OF FIGURE

Figure 2.1
Figure 2.2
Figure 2.3
Figure 2.4
Figure 4.1
Figure 5.1
Figure 6.1
Figure 6.2

Qualitative of flowchart.............................................................
Material balance of flowchart....................................................
The layout of precipitated silica plant.......................................
The layout of equipment layout of precipitated silica plant.....
Diagram process of water treatment.........................................
Organizational structure..........................................................
Relationship between years and cost index............................
Graphic of parameters of economic analysis..........................

xiii

11
14
20
22
37
69
71
80