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

Transcription

1 PRELIMINARY DESIGN OF PRECIPITATED SILICA PLANT FROM SULPHURIC ACID AND SODIUM SILICATE WITH CAPACITY OF 40,000 TON/YEARS By: MR.ISMAAE YUSOH D Supervisor: Dr. Ir. Ahmad M. Fuadi, MT Kun Harismah Ph. D CHEMICAL ENGINEERING DEPARTMENT FACULTY OF ENGINEERING UNIVERSITAS MUHAMMADIYAH SURAKARTA 2015

2 APPROVAL CHEMICAL ENGINEERING DEPARTMENT ENGINEERING FACULTY UNIVERSITAS MUHAMMADIYAH SURAKARTA Name NIM Title : Mr. Ismaae Yusoh : D : 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 Approved by, Surakarta, July 2015 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

3 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

4 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 (มาม า), Kakak Bede (แบเดร ), Beheng (แบเฮง), Tetoh Dah (แตเตาะ), Besi (แบเซะ), Beding (แบด ง), 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

5 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, 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, and production costs Rp 182,861,209, 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

6 MOTTO Pray on time, surely GOD will always help us. Ibu Aminah Yusoh Just be a good person Mr.Dr. Muhammad Asmee Abubaka ความภ ม ใจส งส ดในช ว ต ค อ การประสบความสาเร จ ในส งท คนรอบข างเช อว าค ณไม ม ว นทาได (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."

7 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, Thanks for togetherness. Thanks for beautiful memories with you.

8 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 The Background of the Plant Selection of The Capacity of the Plant Design Literature Review The usefulness of products Properties of Physical and Chemical Raw Materials and Products The General Process Review... 9 CHAPTER II PROCESS DESCRIPTION The Specification of Raw Materials and Products The Process Concept The Thermodynamic Review The Flowchart The Process Stages The Flowchart of Material Balance and Heat Balance The Plant Layout and Equipment CHAPTER III THE SPESIFICATION OF THE EQUIPMENT Tank of Sodium Silicate (T-01) and Tank of H2SO4 (T-02) Mixer (M-01) Heat Exchanger (HE-01) Reactor 1 and Reactor Pump Bucket Elevator Belt Conveyor CHAPTER IV PROCESS SUPPORT UNIT AND LABORATORY Process Support Unit CHAPTER V MANAGEMENT Company Organizational Structure Employee Welfare Health and Safety Production Management Production Plan Production Control CHAPTER VI ECONOMICAL ANALYSIS Basic Calculation Cost Calculation... 72

9 6.3 General Expenses Feasibility Analysis The Result of Calculation CHAPTER VII CONCLUSION BIBLIOGRAPHY APENDIX... 87

10 LIST OF TABLE Table 1.1 The export data and import data precipitated silica... 2 Table 1.2 The existing capacity of precipitated silica plant... 3 Table 2.1 The data of reaction formation of precipitated silica Table 2.2 The component of material flow Table 2.3 The material balance mixer (M-01) Table 2.4 The material balance of reactor 1 (R-01) Table 2.5 The material balance of reactor 2 (R-02) Table 2.6 The material balance, rotary drum filter (RDF-01) Table 2.7 The material balance, rotary dryer (RD-01) Table 2.8 The total of material balance Table 2.9 The heat balance of mixer (M-01) Table 2.10 The heat balance of reactor (R-01) Table 2.11 The heat balance of reactor (R-02) Table 2.12 The heat balance of rotary drum filter (RDF-01) Table 2.13 The heat balance of rotary dryer (RD-01) Table 2.14 The heat balance around heat exchanger (HE-01) Table 2.15 Building precipitated silica Table 3.1 The needs of electricity for process Table 5.1 Schedule for each group Table 5.2 Positions and requirements Table 5.3 Data of the number of process employee Table 6.1 Cost index chemical plant year Table 6.2 Physical plant cost Table 6.3 Fixed capital cost Table 6.4 Working capital investment Table 6.5 Manufacturing cost Table 6.6 General expense Table 6.7 Fixed cost Table 6.8 Variable cost Table 6.9 Regulated cost... 79

11 LIST OF FIGURE Figure 2.1 Qualitative of flowchart Figure 2.2 Material balance of flowchart Figure 2.3 The layout of precipitated silica plant Figure 2.4 The layout of equipment layout of precipitated silica plant Figure 4.1 Diagram process of water treatment Figure 5.1 Organizational structure Figure 6.1 Relationship between years and cost index Figure 6.2 Graphic of parameters of economic analysis xiii