PAR13_FINALREPORT

UNIVERSITAS INDONESIA

PRELIMINARY DESIGN OF COPPER SMELTER PLANT

Final Report

GROUP 13 GROUP PERSONNEL: ABDI RIDHOLLOH FARRY

(1406643053)

ABU BAKAR ASH SHIDDIQ

(1306449302)

ADENIA GITA DIANTY

(1306392960)

ANGGA KURNIAWAN SASONGKO

(1306392916)

HANIF IBRAHIM

(1306392973)

SHEILA NABILA PUTRI

(1306392821)

CHEMICAL ENGINEERING DEPARTMENT ENGINEERING FACULTY, UNIVERSITAS INDONESIA DEPOK 2016

LIST OF GROUP MEMBERS

1. Name

: Abdi Ridholloh Farry

NPM

: 1406643053

BOP

: Jakarta, October 27th 1991

Address

: Jl. H. Japat No. 75 Sukamaja, Depok 16417

2. Name

: Abu Bakar Ash Shiddiq

NPM

: 1306449302

BOP

: Jakarta, April 15th 1995

Address

: Jl Kalibaru Timur Gg, VI No. 2 Senen, South Jakarta

3. Name

: Adenia Gita Dianty

NPM

: 1306392960

BOP

: Jakarta, August 2nd 1995

Address

: Pancoran Barat IV, No. 2 RT 011/RW 01, South Jakarta

4. Name

: Angga Kurniawan Sasongko

NPM

: 1306392916

BOP

: Jakarta, March 14th 1995

Address

: Jl. Pinang Emas 1 UT 19, Pondok Indah, South Jakarta

5. Name

: Hanif Ibrahim

NPM

: 1306392973

BOP

: Bekasi, September 18th 1995

Address

: Jl. Pertanian 2 No 118 Lebak Bulus, South Jakarta

6. Name

: Sheila Nabila Putri

NPM

: 1306392821

BOP

: Jakarta, December 22nd 1995

Address

: Kavling Setiabudi No. 7, Cipadu, Larangan, Tangerang

ii

Universitas Indonesia

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 Copper Smelter Plant”. 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., Dr. Ing. Ir. Misri Gozan M.Tech., Ir. Dijan Supramono, M.Sc., Dr. Tania Surya Utami, S.T., M.T., and others lectures, who has given their best guidance to the writer in writing a great quality report and well developed chemical product. 2. Our Parents, who always give their supports, prayers, and blessing. 3. All of our friends from Chemical Engineering Department batch 2013 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.

Depok, December 15th 2016

Writer Team

iii


EXECUTIVE SUMMARY

Indonesia is the top ten countries in the world which contribute around 4% copper concentrate production in the world. Two largest company that provide copper concentrate is PT. Freeport Indonesia and PT. Newmont. However not all copper concentrate will be process in Indonesia, and mostly the copper mine (copper concentrate) will be export overseas. The government regulation No. 4 in 2009 on mineral and coal has pushed Indonesia to implement the advancement mineral’s value-added in the country, particularly copper. Based on that background, we will build copper smelter to reduce the export value of copper concentrate and implement the government regulation. The raw material in our plant are such as copper concentrates, limestone, silica, and oxygen. The process will start when all the raw material burned on four furnaces unit, then casting, and refinery electrolytic, which will be resulting in copper cathode with high purity. purit y. In our plant, we also built oxygen plant to produce oxygen-enriched air will help the combustion smelting process. PT. Smelco Indonesia produce copper cathode (99,99% (99 ,99% purity) and sulfuric acid (98.5% purity), anode slime, slag, and gypsum as byproducts. PT. Smelco Indonesia is going to produce copper cathode cath ode 320,000 tonnes/year to nnes/year and the copper concentrate needed n eeded to produce our ou r main product is 876 tonnes/day. To support the production, prod uction, our plant will be constructed in Gresik, East Java and the marketing target is exported to China, and India as the most copper consumers from the worlds. PT. Smelco Indonesia is divided into several areas, which are office area and process area. From the plant layout, we could generate the total area needed to build the plant which actually in total amounted 6.582 hectare of land area. Equipment sizing has important role in increasing the standards of each plants. The proper size of equipment helps to optimize the process in the plant which is obtained by developing the Process Flow Diagram (PFD), Piping and Instrumentation Diagram (P&ID), and sizing a static process equipment. From P&ID could be generated controller and valve that we need for each process. P&ID shows all of piping including the physical sequence of branches, reducers, valves, equipment, instrumentation and control interlocks. iv


To support its production process, we should determine the Health, Safety, and Environment analysis, based on HAZID and HAZOP. To support the safety aspect, we provide the personal protection equipment and the emergency equipment, we also provide the evacuation procedure, firefighting and emergency alarm, evacuation route, and the assembly or meeting point in case of emergency. The waste of our production is grouped into three types, they are solid, liquid, and gas. Solid waste is the largest waste produced from our plant which amounted about 27686.35 kg/hour. This waste is a byproduct which is beneficial to be processed. In plant design, we have to determine economic analysis to make sure the profitable of our plant. The total CAPEX for our plant is USD 164,225,587. After we calculate the CAPEX, we have to calculate OPEX (Operational Cost), from the operational cost breakdown, the biggest cost for operational is raw material. The total operating cost is USD 1,999,971,434 per year. Based on the production of copper cathode before, the price for our copper cathode is USD 6,700/tonne. Capital cost of our plant will be obtained by loan some money from investors and banks. The money we loaned form investors is 60% of total capital cost and from the bank is 40% of total capital cost. cost . The WACC that we got from calculation is 20.43% and the percentage of MARR is 23.46%. After we make the Before Tax Cash Flow and After Tax Cash Flow, we calculate the profitability analysis. Payback Period is 4.4 years, IRR is 35.7%. The BEP for copper cathode is 24495 tonne and 32728 tonne for the byproduct. Cost breakdown of our plant show that the material cost in our plant takes about 75% of our total cost. The value of largest cost will be analyzed by sensitivity analysis to see if the value change occurred in each variable will affect plant economic significantly. Not only cost, the price of our product also may have its value changing for a period of time. The analysis showed that NPV and IRR will fall down if the cost increases and vice versa. Payback period will become longer to reach if the cost of production is increased. The outstanding issues includes the technical aspect and economic aspect of the plant. The technical aspects discuss the advantages of out plant, whereas the economic aspects discuss the TCI of the capacity of our plant compared with another plant. v


TABLE OF CONTENTS LIST OF GROUP MEMBERS ............................................................................ ii PREFACE ............................................................................................................. iii EXECUTIVE SUMMARY .................................................................................. iv TABLE OF CONTENTS..................................................................................... vi LIST OF FIGURES ............................................................................................. ix LIST OF TABLES ................................................................................................ x LIST OF APPENDICES ................................................................................... xiii CHAPTER I BACKGROUND ............................................................................ 1 1.1 Background ................................................................................................... 1 1.2 Project Objective .......................................................................................... 2 1.3. Basic Theory ................................................................................................. 2 1.4 Market Analysis ............................................................................................ 3 1.5 Capacity Analysis ......................................................................................... 6 1.6 Raw Material Analysis ................................................................................. 6 1.7 Plant Location Analysis ................................................................................ 7 CHAPTER II PROCESS SELECTION ............................................................. 9 2.1 Process Selection Alternative ....................................................................... 9 2.2 Process Selection ........................................................................................ 17 2.3 Process Description .................................................................................... 19 2.4 BFD and PFD ............................................................................................. 25 2.5 Mass Balance .............................................................................................. 25 2.6 Energy Balance ........................................................................................... 27 2.7 Mass Efficiency .......................................................................................... 28 2.8 Heat Exchanger Network (HEN) Network ................................................. 29 2.8.1 Heat Exchanger Information ...................................................................... 29 2.8.2 Heat Recovery Pinch Method ..................................................................... 31 2.8.3 Pinch Design Method ................................................................................. 36 2.9 Utility Analysis ........................................................................................... 38 2.9.1 Water .......................................................................................................... 38 2.9.2 Fuel ............................................................................................................. 43 2.9.3 Air ............................................................................................................... 45 2.9.4 Electricity.................................................................................................... 45 CHAPTER III EQUIPMENT SIZING ............................................................. 47 3.1 Furnace ....................................................................................................... 47 3.2 Electrolytic Cell .......................................................................................... 49 3.3 Caster .......................................................................................................... 49 3.4 Belt Conveyor ............................................................................................. 50 3.5 Adsorber Column ....................................................................................... 54 3.6 Absorber Column ....................................................................................... 55 3.7 Packed Bed Reactor .................................................................................... 57 3.8 Filter Equipment ......................................................................................... 57 3.9 Heat Exchanger ........................................................................................... 58 3.10 Storage Tank ............................................................................................... 69 3.11 Warehouse .................................................................................................. 70 3.12 Coagulant Tank........................................................................................... 71

vi


3.13 Filtration Tank ............................................................................................ 72 3.14 Ion Exchanger Tank .................................................................................... 72 3.15 High Pressure Turbine ................................................................................ 73 3.16 Pump ........................................................................................................... 73 3.17 Compressor ................................................................................................. 77 3.18 Piping .......................................................................................................... 79 3.19 Valve ........................................................................................................... 82 CHAPTER IV PROCESS CONTROL STRATEGY ...................................... 84 4.1 Plant Control Tabulation ............................................................................ 84 4.2 Piping and Instrumentation Diagram .......................................................... 88 CHAPTER V PLANT LAYOUT....................................................................... 89 5.1 Area Plant Layout ....................................................................................... 89 5.2 Equipment Plant Layout ............................................................................. 92 5.2.1 2D Picture ................................................................................................... 92 CHAPTER VI HEALTH, SAFETY, AND ENVIRONMENTAL MANAGEMENT ...................................................................................... 93 6.1 HSE Aspect................................................................................................. 93 6.1.1 HAZID........................................................................................................ 93 6.1.2 HAZOP ....................................................................................................... 96 6.2 HSE Management ..................................................................................... 101 6.2.1 Operational Details ................................................................................... 101 6.2.2 Personal Protection Equipment (PPE) ...................................................... 107 6.2.3 MSDS ....................................................................................................... 109 6.3 Emergency Action Plant ........................................................................... 116 6.3.1 Emergency Operating Procedures or Training ......................................... 116 6.3.2 Firefighting ............................................................................................... 119 6.3.3 Evacuation Area ....................................................................................... 120 6.4 Waste Management .................................................................................. 121 6.4.1 Solid Waste ............................................................................................... 121 6.4.2 Liquid Waste............................................................................................. 122 6.4.3 Gas Waste ................................................................................................. 122 6.4.4 Sound Pollution ........................................................................................ 123 CHAPTER VII CAPITAL ESTIMATE ......................................................... 124 7.1 Total Equipment Cost ............................................................................... 124 7.2 Total Bulk Material Cost .......................................................................... 124 7.3 Site Development Cost ............................................................................. 125 7.4 Building Cost ............................................................................................ 125 7.5 Supporting Equipment Cost...................................................................... 125 7.6 Engineering and Supervision Cost ........................................................... 125 7.7 Construction Expenses ............................................................................. 125 7.8 Contingencies Cost ................................................................................... 126 7.9 Contractor’s Fee ....................................................................................... 126 7.10 Additional Cost ......................................................................................... 126 7.11 Working Capital ....................................................................................... 126 7.12 Calculation of Total Capital Investment ................................................... 127 CHAPTER VIII OPERATING COSTS ......................................................... 128 8.1 Equity........................................................................................................ 128 8.2 Raw Material Cost .................................................................................... 128 vii


8.3 Utility Cost ............................................................................................... 129 8.4 Waste Treatment Cost .............................................................................. 129 8.5 Labor Cost ................................................................................................ 129 8.5.1 Direct Labor Cost ..................................................................................... 129 8.5.2 Indirect Labor Cost ................................................................................... 129 8.6 Maintenance Cost ..................................................................................... 130 8.7 Operating Overhead Cost ......................................................................... 130 8.8 Local Taxes and Insurance Cost ............................................................... 130 8.9 Depreciation.............................................................................................. 130 8.10 Cost of Manufacture ................................................................................. 130 8.11 Operating Cost (OPEX) Breakdown ........................................................ 131 CHAPTER IX ECONOMIC EVALUATION ................................................ 133 9.1 Investment Feasibility Analysis................................................................ 133 9.1.1 Income ...................................................................................................... 133 9.1.2 Cash Flow ................................................................................................. 133 9.2 Profitability Analysis ................................................................................ 134 9.2.1 IRR............................................................................................................ 134 9.2.2 NPV .......................................................................................................... 134 9.2.3 Payback Period ......................................................................................... 135 9.2.4 Break Event Point (BEP) .......................................................................... 136 9.3 Cost Breakdown ....................................................................................... 137 9.4.1 IRR Sensitivity Analysis .......................................................................... 138 9.4.2 NPV Sensitivity Analysis ......................................................................... 139 9.4.3 Payback Period Sensitivity Analysis ........................................................ 140 CHAPTER X OUTSTANDING ISSUES ........................................................ 141 10.1 Technical Aspect ...................................................................................... 141 10.2 Economical Aspect ................................................................................... 142 CHAPTER XI CONCLUSION........................................................................ 143 REFERENCES.................................................................................................. 145 APPENDIX ........................................................................................................ 148 APPENDIX A: Mass and Energy Balances ........................................................ 148 APPENDIX B: BFD and PFD ............................................................................ 157 APPENDIX C: PIPING AND INSTRUMENTATION ..................................... 168 APPENDIX D: SIZING CALCULATION ALGORITHM ............................... 174 APPENDIX E: MSDS ........................................................................................ 203 APPENDIX F: ECONOMIC ANALYSIS.......................................................... 225 APPENDIX G: PLANT LAYOUT..................................................................... 242

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LIST OF FIGURES

Figure 1.1 World Copper Forecast .......................................................................... 5 Figure 1.2 Smelter Plant Location .......................................................................... 8 Figure 2.1 Isasmelt Furnace .................................................................................. 11 Figure 2.2 Mount Isa Copper Isasmelt Plant ......................................................... 11 Figure 2.3 Hydrometallurgical Extraction Process ............................................... 12 Figure 2.4 Copper Solvent Extraction Process ..................................................... 12 Figure 2.5 Flash Smelting Process ........................................................................ 13 Figure 2.6 Schematic of a Pressure Swing Adsorption Unit ................................. 13 Figure 2.7 Schematic of a Conventional Cryogenic Air Separation Unit ............. 14 Figure 2.8 Schematic of a Conventional Membrane Air Separation Unit ............ 15 Figure 2.9 The Single Contact Process ................................................................. 16 Figure 2.10 Double Contact Process ..................................................................... 17 Figure 2.11 Mitsubishi Copper Smelting Diagram and Equipment ...................... 20 Figure 2.12 Smelting Furnace ............................................................................... 21 Figure 2.13 Slag Cleaning Furnace ....................................................................... 21 Figure 2.14 Composition of Converter Product from Smelting Copper Scrap ..... 22 Figure 2.15 Overall Mass Balance of Copper Smelter ......................................... 26 Figure 2.16 Cascade Table .................................................................................... 33 Figure 2.17 Combined Composite Curves ............................................................ 35 Figure 2.18 Combined Composite Curves After Pinch ........................................ 36 Figure 2.19 Pinch Design Method ........................................................................ 37 Figure 2.20 BFD of Water Treatment Process ...................................................... 39 Figure 2.21 Raw Water Screening ........................................................................ 40 Figure 2.22 Coagulation and Flocculation Process ............................................... 40 Figure 2.23 Filtration Unit .................................................................................... 41 Figure 2.24 Ion Exchange Unit ............................................................................. 42 Figure 5.1 Typical Spacing for Plant Equipment .................................................. 90 Figure 5.2 Typical Spacing for Plant Equipment .................................................. 90 Figure 5.3 Red and Blue Zone .............................................................................. 91 Figure 5.4 Total 2D Plant Layout ......................................................................... 92 Figure 6.1 Evacuation Route Map ...................................................................... 121 Table 7.1 Total Bulk Material Cost..................................................................... 124 Table 7.2 Building Plant Cost ............................................................................. 125 Table 7.3 Total Capital Investment ..................................................................... 127 Figure 8.1 OPEX Breakdown Diagram .............................................................. 132 Figure 9.1 Profile of Cummulative Cash Flow ................................................... 136 Figure 9.2 Capital Cost Breakdown .................................................................... 137 Figure 9.3 IRR Sensitivity Analysis ................................................................... 139 Figure 9.4 NPV sensitivity Analysis ................................................................... 139 Figure 9.5 Payback Period Sensitivity Analysis ................................................. 140

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LIST OF TABLES

Table 1.1 Supply and Demand Balance .................................................................. 4 Table 1.2 World Refined Copper Usage and Demand ............................................ 4 Table 1.3 Location Comparison .............................................................................. 7 Table 1.4 Location Selection Result ....................................................................... 8 Table 2.1 Copper Smelter Technology Selection ................................................. 17 Table 2.2 Copper Smelter Technology Selection Result ...................................... 18 Table 2.3 Oxygen Purification Method Selection ................................................. 18 Table 2.4 Oxygen Purification Method Selection ................................................. 18 Table 2.5 Sulfuric Acid Plant Technology Selection ............................................ 19 Table 2.6 Sulfuric Acid Plant Method Selection Result ....................................... 19 Table 2.7 Overall Mass Balance of Copper Smelter ............................................. 26 Table 2.8 Overall Mass Balance of Oxygen Plant ................................................ 26 Table 2.9 Overall Mass Balance of Sulfuric Acid Plant ....................................... 27 Table 2.10 Energy Requirement for Each Equipment .......................................... 27 Table 2.11 Overall Energy Balance of Copper Smelter ........................................ 27 Table 2.12 Overall Energy Balance of Oxygen Plant ........................................... 28 Table 2.13 Overall Energy Balance of Sulfuric Acid Plant .................................. 28 Table 2.14 Oxygen Plant Stream Classifications .................................................. 29 Table 2.15 Sulfuric Acid Stream Classification .................................................... 30 Table 2.16 Shifted Temperatures in Oxygen Plant ............................................... 31 Table 2.17 Shifted Temperature in Sulfuric Acid ................................................. 31 Table 2.18 Minimum Utility Requirements .......................................................... 32 Table 2.19 Utility Requirement............................................................................. 34 Table 2.20 Minimum Utility Requirement After Pinch ........................................ 36 Table 2.21 Water Consumption Before HEN ....................................................... 38 Table 2.22 Water Consumption After HEN .......................................................... 39 Table 2.23 Electricity Consumption ..................................................................... 46 Table 3.1 Specification of Smelting Furnace ........................................................ 47 Table 3.2 Slag Cleaning Furnace Specification Design ........................................ 47 Table 3.3 Specification of Anode Furnace ............................................................ 48 Table 3.4 Specification of Electrolyic Cell ........................................................... 49 Table 3.5 Specification of Hazelett Caster ............................................................ 49 Table 3.6 Specification of Hazelett Caster ............................................................ 50 Table 3.7 Specification of Belt Conveyor C-101 .................................................. 50 Table 3.8 Specification of Belt Conveyor C-102 .................................................. 51 Table 3.9 Specification of Belt Conveyor C-103 .................................................. 51 Table 3.10 Specification of Belt Conveyor C-104 ................................................ 52 Table 3.11 Specification of Belt Conveyor C-105 ................................................ 52 Table 3.12 Specification of Belt Conveyor C-106 ................................................ 53 Table 3.13 Specification of Belt Conveyor C-107 ................................................ 53 Table 3.14 Specification of Belt Conveyor C-108 ................................................ 54 Table 3.15 Specification of Adsorber Column R-201 .......................................... 54 Table 3.16 Specification of Adsorber Column R-202 .......................................... 55 Table 3.17 Specification of Absorber Column R-302 .......................................... 55 Table 3.18 Specification of Absorber Column R-303 .......................................... 56 x


Table 3.19 Specification of Packed Bed Reactor R-301 ....................................... 57 Table 3.20 Specification of Cyclone FG-301 ....................................................... 57 Table 3.21 Specification of E-101 ........................................................................ 58 Table 3.22 Specification of E-201 ........................................................................ 59 Table 3 23 Specification of E-202 ........................................................................ 59 Table 3.24 Specification of E-203 ........................................................................ 60 Table 3.25 Specification of E-204 ........................................................................ 60 Table 3.26 Specification of E-205 ........................................................................ 61 Table 3.27 Specification of E-206 ........................................................................ 61 Table 3.28 Specification of E-207 ........................................................................ 62 Table 3.29 Specification of E-301 ........................................................................ 62 Table 3.30 Specification of E-302 ........................................................................ 63 Table 3.31 Specification of E-303 ........................................................................ 63 Table 3.32 Specification of E-304 ........................................................................ 64 Table 3.33 Specification of E-305 ........................................................................ 64 Table 3.34 Specification of E-306 ........................................................................ 65 Table 3.35 Specification of E-307 ........................................................................ 65 Table 3.36 Specification of E-308 ........................................................................ 66 Table 3.37 Specification of E-401 ........................................................................ 66 Table 3.38 Specification of E-402 ........................................................................ 67 Table 3.39 Specification of E-403 ........................................................................ 67 Table 3.40 Specification of E-404 ........................................................................ 68 Table 3.41 Specification of E-405 ........................................................................ 68 Table 3.42 Specificatin of Storage Tank for Sulfuric Acid .................................. 69 Table 3.43 Specification of Storage Tank for Demineralize Water ...................... 69 Table 3.44 Specification of Warehouse TK-101................................................... 70 Table 3.45 Specification of Warehouse TK-102................................................... 71 Table 3.46 Specification of Warehouse TK-103................................................... 71 Table 3.47 Specification of Coagulant Tank......................................................... 71 Table 3.48 Specification of Filtration Tank .......................................................... 72 Table 3.49 Specification of Demine Water Tank.................................................. 72 Table 3.50 Specification of Turbine T-401 ........................................................... 73 Table 3.51 Specification of Pump P-301 .............................................................. 73 Table 3.52 Specification of Pump P-302 .............................................................. 74 Table 3.53 Specification Pump P-201 ................................................................... 74 Table 3.54 Specification Pump P-202 ................................................................... 75 Table 3.55 Specification Pump P-101 ................................................................... 76 Table 3.56 Specification Pump P-401 ................................................................... 76 Table 3.57 Specification Pump P-501 ................................................................... 77 Table 3.58 Specification Compressor K-100 ........................................................ 77 Table 3.59 Specification Compressor K-101 ........................................................ 78 Table 3.60 Specification Compressor K-102 ........................................................ 78 Table 3.61 Specification Compressor K-201 ........................................................ 78 Table 3.62 Specification Compressor K-202 ........................................................ 79 Table 3.63 Piping Specification of Copper Smelter Plant .................................... 79 Table 3.64 Piping Specification of Sulfuric Acid Plant ........................................ 80 Table 3.65 Pipinng Specification of Oxygen Plant ............................................... 81 Table 3.66 Pipinng Specification of Power Plant ................................................. 81 xi


Table 3.67 Piping Specification of Water Pretreatment Plant .............................. 82 Table 3.68 Valve Size of Copper Smelter Plant ................................................... 82 Table 3.69 Valve Size of Oxygen Plant ................................................................ 82 Table 3.70 Valve Size of Sulfuric Acid Plant ....................................................... 82 Table 3.71 Valve Size of Power Plant .................................................................. 83 Table 3.72 Valve Size of Water Utility ................................................................. 83 Table 4.1 Control Tabulation of Copper Smelter Plant ........................................ 84 Table 4.2 Control Tabulation of Oxygen Plant ..................................................... 85 Table 4.3 Control Tabulation of Sulfuric Acid Plant ............................................ 86 Table 4.4 Control Tabulation of Power Plant ....................................................... 87 Table 4.5 Control Tabulation of Water Utility...................................................... 88 Table 6.1 HAZID Parameters (Hazard Effect) ..................................................... 93 Table 6.2 HAZID List ........................................................................................... 94 Table 6.3 HAZOP Parameter ................................................................................ 97 Table 6.4 HAZOP List .......................................................................................... 97 Table 6.5 Explanation of HMIS .......................................................................... 110 Table 6.6 HMIS Protective Equipment Code ..................................................... 110 Table 7.1 Total Bulk Material Cost..................................................................... 124 Table 7.2 Building Plant Cost ............................................................................. 125 Table 7.3 Total Capital Investment ..................................................................... 127 Table 8.1 Financial Interest ................................................................................. 128 Table 8.2 Raw Material Cost .............................................................................. 129 Table 8.3 Cost of Manufacture............................................................................ 131 Table 8.4 OPEX Breakdown ............................................................................... 132 Table 9.1 Income of The Plant ............................................................................ 133 Table 9.2 Raw Material Price Flutuation ............................................................ 138 Table 9.3 Product Price Fluctuation .................................................................... 138

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LIST OF APPENDICES

APPENDIX A: Mass and Energy Balances

Figure A.1 Smelting Furnace Equipment............................................................ 148 Figure A.2 Slag Cleaning Furnace Equipment ................................................... 149 Figure A.3 Converting Furnace Equipment ........................................................ 149 Figure A.4 Anode Furnace Equipment ............................................................... 150 Figure A.5 Electrolytic Cell Equipment ............................................................. 151 Table A.1 Smelting Furnace Mass Balance ........................................................ 148 Table A.2 Slag Cleaning Furnace Mass Balance ................................................ 149 Table A.3 Converting Mass Balance .................................................................. 150 Table A.4 Anode Furnace Mass Balance ............................................................ 150 Table A.5 Casting Machine Mass Balance ......................................................... 151 Table A.6 Electrolytic Cell Mass Balance .......................................................... 151 Table A.7 Mass Balance ..................................................................................... 152 Table A.8 Compressor Mass Balance ................................................................. 152 Table A.9 Heat Exchanger Mass Balance E-201 and E-202 .............................. 152 Table A.10 Heat Exchanger Mass Balance E-201 and E-202 ............................ 152 Table A.11 Heat Exchanger Mass Balance E-205 and E-206 ............................ 152 Table A.12 Heat Exchanger Mass Balance E-207 .............................................. 153 Table A.13 Adsorber Mass Balance.................................................................... 153 Table A.14 Heat Exchanger E-301 and E-302 Mass Balance ............................. 153 Table A.15 Heat Exchanger E-303 and E-304 Mass Balance ............................. 153 Table A.16 Heat Exchanger E-305 and E-306 Mass Balance ............................. 153 Table A.17 Heat Exchanger E-307 and E-308 Mass Balance ............................. 153 Table A.18 Bed Converter Mass Balance ........................................................... 154 Table A.19 Absorber Mass Balance.................................................................... 154 Table A.20 Total Energy Requirements of Copper Smelter Plant ...................... 154 Table A.21 Energy Requirements of 1st Compressor .......................................... 154 Table A.22 Energy Requirements of 2nd Compressor ......................................... 155 Table A.23 Heat Exchanger E-301 and E-302 Energy Balance .......................... 155 Table A.24 Heat Exchanger E-303 and E-304 Energy Balance .......................... 155 Table A.25 Heat Exchanger E-305 and E-306 Energy Balance .......................... 155 Table A.26 Heat Exchanger E-307 and E-308 Energy Balance .......................... 156 Table A.27 Bed Converter Energy Balance ........................................................ 156 Table A.28 Absorber Energy Balance ................................................................ 156 Table A 29 Pump Energy Balance ...................................................................... 156 APPENDIX B: BFD and PFD

Figure B.1 BFD of Copper Smelter Plant ........................................................... 157 Figure B.2 BFD of Oxygen Plant ........................................................................ 158 Figure B.3 BFD of Sulfuric Acid Plant ............................................................... 159 Figure B.4 PFD Before HEN Copper Smelter I .................................................. 160 Figure B.5 PFD Before HEN Copper Smelter II ................................................ 161 Figure B.6 PFD Before HEN Oxygen Plant ....................................................... 162 xiii


Figure B.7 PFD Before HEN Sulfuric Acid Plant .............................................. 163 Figure B.8 PFD After HEN Oxygen Plant .......................................................... 164 Figure B.9 PFD After HEN Sulfuric Acid Plant ................................................. 165 Figure B.10 PFD of Pre-Water Treatment .......................................................... 166 Figure B.11 PFD of Power Plant......................................................................... 167 APPENDIX C: PIPING AND INSTRUMENTATION

Figure C.1 Figure C.2 Figure C.3 Figure C.4 Figure C.5 Figure C.6

P&ID of Copper Smelter Plant ......................................................... 168 P&ID of Copper Smelter Plant ......................................................... 169 P&ID of Oxygen Plant ...................................................................... 170 P&ID of Sulfuric Acid Plant ............................................................. 171 P&ID of Power Plant ........................................................................ 172 P&ID of Water Utility ...................................................................... 173

APPENDIX D: SIZING CALCULATION ALGORITHM

Table D.1 Component of Absorption Column .................................................... 174 Table D.2 Properties of Absorber Feed .............................................................. 175 Table D.3 Packing Specification ......................................................................... 177 Table D.4 Industrial Absorber Specification ...................................................... 177 Table D.5 Data for Shale Thickness Calculation ................................................ 180 Table D.6 Flow Information of Reactor .............................................................. 182 Table D.7 The Result of Storage Tank Sizing .................................................... 192 Table D.8 Rigid Base Material Data Sheet ......................................................... 194 Table D.9 Design Criteria For SSF ..................................................................... 194 Table D.10 Cation Composition of Ion Exchanger Feed .................................... 195 Table D.11 Feed of Turbine T-401 ..................................................................... 199 Table D.12 Output of Turbine T-401 .................................................................. 199 Table D.13 Typical Velocity of Fluid in Pipeline ............................................... 201 Figure D.1 Design Data for Various Packing ..................................................... 176 Figure D.2 Flooding Line Graph ......................................................................... 177 Figure D.3 Capacity of Zeolit to Adsorp Nitrogen ............................................. 181 Figure D.4 Polymath Calculation of Reactor Sizing ........................................... 184 Figure D.5 Fouling Factors Coefficients ............................................................. 186 Figure D.6 Overal Heat Transfer Coefficients .................................................... 187 Figure D.7 Rateau Turbine Diagram ................................................................... 200 Figure D.8 Valve Size for Sch. 40 ...................................................................... 202 APPENDIX E: MSDS APPENDIX F: ECONOMIC ANALYSIS

Table F.1 Total Equipment Cost ......................................................................... 228 Table F.2 Piping Cost of Copper Smelter Plant .................................................. 232 Table F.3 Piping Cost of Sulfuric Acid Plant ..................................................... 232 Table F.4 Piping Cost of Oxygen Plant .............................................................. 233 Table F.5 Piping Cost of Power Plant ................................................................. 234 Table F.6 Piping Cost of Water Utility ............................................................... 234 xiv


Table F.7 Cost of Valve ...................................................................................... 234 Table F.8 Total Building Cost ............................................................................. 235 Table F.9 Supporting Equipment Cost ................................................................ 235 Table F.10 Engineering and Supervision Cost .................................................... 236 Table F.11 Construction Expenses ...................................................................... 236 Table F.12 Contingencies Cost ........................................................................... 236 Table F.13 Contractor’s Fee ................................................................................ 237 Table F.14 Royalties and Plant Start Up Cost..................................................... 237 Table F.15 Additional Cost ................................................................................. 237 Table F.16 Working Capital Cost ....................................................................... 237 Table F.17 Utility Cost ........................................................................................ 238 Table F.18 Waste Treatment Cost ....................................................................... 238 Table F.19 Maintenance Cost ............................................................................. 238 Table F.20 Labor Need per Equipment ............................................................... 239 Table F.21 Direct Labor Cost.............................................................................. 239 Table F.22 Indirect Labor Cost ........................................................................... 239 Table F.23 Operating Overhead Cost.................................................................. 240 Table F.24 Taxes and Insurance Cost ................................................................. 240 Table F.25 Cash Flow ......................................................................................... 241 Figure F.1 FM factor for heat exchanger FOB cost ............................................ 227 Figure F.2 FL factor for heat exchanger FOB cost ............................................. 227 APPENDIX G: PLANT LAYOUT

Figure G.1 Copper Smelter Plant Layout ............................................................ 242 Figure G.2 Oxygen Plant Layout ........................................................................ 242 Figure G.3 Sulfuric Acid Plant Layout ............................................................... 243 Figure G.4 Water Utility Plant Layout ................................................................ 243 Figure G.5 Power Plant Layout ........................................................................... 244 Figure G.6 Total Plant Layout ............................................................................ 245

xv


CHAPTER I BACKGROUND

1.1

Background

Indonesia is a green country with a lot of natural resources. One of natural resources that has been commodity is mining and mineral. According the law no.4/2009 it has been stated that mineral and coal in Indonesia miner area is unrenewable natural resources that had a role to enrichen the society of Indonesian therefore the management should be done in Indonesia. However, the usage is not optimal, where still the commodity without maximum management is forced to be export. Based on data from ministry of energy and mineral (ESDM) production of concentrate copper in Indonesia nearly nearl y 2,38 million Metrictonne (MT). From 100% production, at least 70% of copper concentrate is exported as raw material and the rest 30% is going to be process in Indonesia to become copper cathode. The potential of copper is big b ig with 4,925 million metric met ric tonne ore with proven reserves r eserves approximately 4,161 million tonne ore (Data from ministry ESDM, 2011). In fact, according to International Copper Study Group (ICSG) report in 2014 the reserves of copper in Indonesia contribute 4% from all over the world. The usage of coppes is dominated from the sector of contruction, equipment, and manufacturing. Considering the resources of copper in Indonesia still high and the usage of copper is varied therefore improvement for sales value by doing process in Indonesia is a must. At a recent, there’s only one company to smelting copper it is PT. Smelting

Gresik. This company processing copper concentrate to become copper product (main product) with 99,99% purity. To fullfiled the demand of copper cathode on domestic and Asia, in 2009 the capacity of production is improve become 300.000 metric tonne per year where the copper concentrate is supplied by PT. Freeport Indonesia. PT. Freeport Indonesia has reached 1 – 1,2 million metric tonne to produce copper concentrate, however from 100% production, only 30% that can be processes in i n PT. Smelting Gresik. The condition conditio n make PT. Freeport had to export the rest of copper concentrate, while Indonesia is importing copper cathode. Based 1


2 on Law no.4/2009 it was stated that mining product should be processed in Indonesia and the usage is to enrich the society. Considering there’s only one company in smelting Industry and also Indonesia still doing import copper cathode then the opportunity to build another smelting company should be done. 1.2

Project Objective

The objective of our integrated copper smelter is produce copper cathode which has purity 99.9%. This copper will supply the international market. Furthermore, our plant will support governvent regulation No.4 in 2009 on mineral which pushed Indonesia to implement the advancement mineral‟s value -added in

the country, particularly particularl y copper. Based on data, copper concentrate production in Indonesia is around 2.39 million tonnes per year, even though only around 1 million ton per year of concentrate that process by PT. Smelting Gresik. As a result, there are opportunity of around 1,4 million copper concentrate which can be processed to copper cathode. Our plant will process around 870,525 tonnes copper con centrate in a year to obtain 320,000 tonnes copper cathode. 1.3.

Basic Theory

Copper is one of the basic chemical elements. It is commonly used to produce a wide variety of products, including electrical wire, wire, cooking pots and pans, pipes and tubes, automobile radiators, and many others. Copper is also used as a pigment and an d preservative preserv ative for paper, pape r, paint, textiles, and wood. It is combined with zinc to produce brass and with tin to produce bronze. Mining produces ores with less than 1 percent copper. Concentration is accomplished at the mine sites by crushing, grinding, and flotation purification, resulting in ore with 15 to 35 percent copper. copper . Ore concentration is roasted to reduce impurities, including sulfur, antimony, arsenic, and lead. The roasted product, calcine, serves as a dried and heated charge for the smelting furnace. Smelting of roasted (calcine feed) or unroasted (green feed) ore concentrate produces matte, a molten mixture of copper sulfide (Cu2S), iron sulfide (FeS), and some heavy heav y metals. Converting the matte yields a high-grade "blister" copper, with 98.5 to 99.5 percent copper. Typically, blister copper is then fire-refined in an anode furnace, cast into "anodes", and sent to an electrolytic refinery for further impurity elimination. Universitas Indonesia

3 In the smelting process, either hot calcine calcin e from the roaster or raw unroasted concentrate is melted with siliceous flux in a smelting furnace to produce copper matte. The required heat comes from partial oxidation of the sulfide charge and from burning external fuel. Most of the iron and some of the impurities in the charge oxidize with the fluxes to form a slag on top of the molten bath, which is periodically removed and discarded. Copper matte remains in the furnace until tapped. Converting produces blister copper by eliminating the remaining iron and sulfur present in the matte. Air, or oxygen-rich air, is blown through the molten matte. Iron sulfide is oxidized to form iron oxide (FeO) and SO2. Blowing and slag skimming continue until an adequate amount of relatively pure Cu2S, called "white metal", accumulates in the bottom of the converter. A final air blast ("final blow") oxidizes the copper sulfide to SO2, and blister copper forms, containing 98% to 99% coppers. The blister copper is removed from the converter for subsequent refining. The SO2 produced throughout the operation is vented to pollution control devices. Fire refining and electrolytic refining are used to purify blister copper even further. In fire refining, blister copper is usually mixed with flux and charged into the furnace, which is maintained at 1100°C (2010°F). The impurities are removed as slag. The remaining copper oxide is then subjected to a reducing atmosphere to form purer copper. The fire-refined copper is then cast into anodes for even further purification by electrolytic refining. Electrolytic refining separates copper from impurities by electrolysis in a solution containing copper sulfate (Cu2SO4) and sulfuric acid (H2SO4). The copper anode is dissolved and deposited at the cathode. As the copper anode dissolves, metallic impurities precipitate and form a sludge. Cathode copper, 99.95 to 99.96 percent pure, is then cast into bars, ingots, or slabs. 1.4

Market Analysis

Market analysis is the most fundamental in the design of a factory. This analysis needs to be done to determine the potential of the product in the market. Results of market analysis that has been done can be used to determine the design capacity of the plant, and the factory will be built. As we mention in background, the use of copper is the 3rd most metal that industry needed. In industrial, copper is used for equipment, construction and Universitas Indonesia

4 infrastructure. However, market for copper cathode in domestic is not profitable since the needs for copper cathode has been fullfiled by the competitor. Here’s the

detail of supply and demand market domestic that has been studied by ministry of energy (ESDM) and ministry of trade (KEMENPERIN). From the table below we can see that the demand of copper cathode has been fullfiled. And we can conclude that the market of copper cathode in domestic is not profitable. Table 1.1 Supply and Demand Balance Copper Products Unwrought Copper

Basic Copper

Copper Cathode

Others

Tonne

Thousand USD

Tonne

Thousand USD

Tonne

Thousand USD

879,696

N/A

281,718

1,168,897

1,816

1,375,466

295

3,588

66,067

610,992

6,306

48,688

Dalam Negeri

227,811

3,588

217,615

610,992

6,306

48,688

Expor

652,180

N/A

130,170

1,168,897

1,816

1,375,466

1. Pasokan Mineral

Produksi Impor

2. Konsumsi Mineral

(source: Report of Supply Demand Mineral ESDM, 2011)

Although in Indonesia market for copper cathode is not profitable but in overseas this commodity still has the market value. From the data that we collected, we see that there’s there’ s an imbalance in 2015 and 2016. In 2015 there’ s 6,2% imbalance

between refined Cu production and Cu consumption and in 2016 there’s 9,18% imbalance between production and the consumption. Here’s the data about world

consumption Table 1.2 World Refined Copper Usage and Demand

Criteria World Refined Cu Consumption Copper Price LME cash (c/lb)

World Refined Cu Production

2009

2010

2011

2012

2013

2014

2015

2016

17655

18598

19746

20912

22067

23245

24256

25329

234

315

330

390

410

380

360

360

18361

18344

18816

19583

20565

21928

22821

23198

(source: AQM Copper inc&International Study Copper Group (ICSG), 2016)

Copper consumption expanded at an annual pace of 10.1%. Here’s the detail about the needs of copper refined in the future. Universitas Indonesia

5

Figure 1.1 World Copper Forecast

(source: AQM Copper inc,2016)

In Indonesia, there’s two company that concern in exploring the copper

concentrate and that is PT. Freeport and PT. Newmont Indonesia. From 100 % copper concentrate that produced by PT. Newmont Indonesia and PT. Freeport. There are just 30% that are processed to be refined copper, and the remaining will be export on copper concentrate form. Law no. 04/2009 stated that the duty for processing and purification of mineral has to be done in Indonesia including copper concentrate. Based on that fact it will be our opportunity for our plant to fullfiled the law. Not only that, our plant also can reduce the export value of copper concentrate. The main product of our plant is refined copper (contains 99% of copper). Based on the data from ministry energy and mineral (ESDM) the need in domestic has been fullfiled so it will be better if we consider to export our product. We will target our product in region asia such as China, and India. Our copper smelter plant has acid sulphate (H2SO4), gypsum, copper slag, anode slime, and copper telluride as byproduct and this also our opportunity to sell it to another industry. Acid sulphate can be use for fertilizer, gypsum for cementing, copper slag for cement and concrete, anode slime for gold, and copper telluride for semi conductor. If we want to sells our acid sulphate we can sell to PT. Pupuk Sriwijaya (PUSRI) in West Sumatera; PT. Pupuk Iskandar Muda Lhoksumawe Aceh; PT. Pupuk Kujang in West Java; and PT. Pupuk Kaltim.


6 1.5

Capacity Analysis

From the ESDM data on table 1.1, we can see that the demand of copper cathode has been fullfiled. Although in Indonesia market for copper cathode is not profitable but in overseas this commodity still has the market value. Based on the Supply and Demand of World Refined Copper Data, we have around 2,131,000

2,131,000  15%320,000 320,365000/ / 876 /

deficit production. Then, we take 15% market share, so we get tonne/year

Then we convert the demand of copper to be our market capacity product.

1.6

Raw Material Analysis

Indonesia has copper as a natural source with amount of 4,925 million tons of ore with saving or backing up with amount of 4,161 million tons of ore. Indonesia is in the fourth position of the greatest copper exporter countries in the world, after Chile, Peru, and Australia. Indonesia has two major copper mining company, PT Freeport Indonesia and PT Newmont Nusa Tenggara. Limestone potential in Indonesia is quite big and is almost spread evenly in all over Indonesia. The amount of limestone in Indonesia is about 28,678 billion tone. Mostly limestone exists in West Sumatera with amount of about 23,23 billion tone or almost 81,82 % of all limestone natural source in Indonesia. Silica sand in Indonesia is found as sediment precitipated. The highest reserve in west Sumatera and the other reserve in West Borneo, South Sumatera, South Borneo, and Bangka Belitung Island. The producer of silica sand is PT. Byan Technolog y Indonesia. PT. Byan Technology in Surabaya, east Java. East Java is a place with high reserve of silica sand. Coal is the most important energy source for Power Generation. Indonesia is one of the largest coal producers and exporters in the world. Since 2005, when production exceeded Australia, Indonesia became the leading exporter of thermal coal. The three regions with the largest coal reserves in Indonesia are South Sumatra, South Kalimantan and East Kalimantan.


7 1.7

Plant Location Analysis

Plant site selection is one of the main factors that determine the success and survival of a plant. The location we selected based on: the location near raw material, the location near the buyer, the location has support facility (water, electricity, transportation, and land availability) and also labor availability. From the four criteria above, we selected that Gresik, Madura, and Timika has the potential to be analyze Based on the criteria that we selected, the next page contains the detail of comparison from 3 locations: Table 1.3 Location Comparison Criteria

Raw Material Analysis (Silica, Copper Consentrate, Limestone)

Transportation

Utilities (Water and Power Plant)

Worker (Fee and Salary)

By Product Market

Gresik Far from PT. Freeport

Madura

Timika (Papua)

Far from PT. Freeport

Near PT. Freeport

There's PT. SAMAC Mining as silica supply which is near from Gresik

Source of silica in Madura is poor, therefore it can be delivered by ship from another region.

There is several limestone mining in East Java.

There's a lot of mount of limestone in Madura,

Good transport by use international harbor in Surabaya Gresik Power Plant with the capacity 12.814 GWh(PT.PJB) Water can be from Berantas &Bengawan SoloRiver Minimum wage is Rp3.042.500 PT Pupuk Gresik can buy H2SO4 as feed in fertilizer industry and cement industry (PT Semen Gresik) which can buy our slag.

Source of silica in Papua is poor, therefore it can be delivered by ship from another region. Main source of limestone in Papua is Paniai

the transportation can be delivered using suramadu bridge which near International harboour have Madura PTBA Power station with capacity 400-megawatt (MW)

PT. Freeport has power generating with capacity 385MW it can be transmit to Timika

water can be from coast in Madura

Water can supply from river in Timika

Minimum wage to be paid is Rp1.350.000

Minimum wage to be paid is Rp2.487.000

No industrial petrochemical and fertilizer

No industrial petrochemical and fertilizer

Timika is lack both of land and water transporation


8 Table 1.4 Location Selection Result Scoring Criteria Raw Material Analysis (Silica, Copper Consentrate, Limestone)

Transportation Utilities (Water and Power Plant) Worker (Fee and Salary) By Product Market Total

Priority

Gresik

Madura

Timika

5

5

25

3

5

5

25

3

4

12

4

3

4

12

4 3 4

4 2 4 75

16 6 16

3 4 3 63

4 3 4

4 2 4 75

16 6 16

From the evaluated that has been done above, we selected Gresik is a location for our Smelter plant. To be detailed our plant will be contruted in Manyar, Gresik district. This location is selected because is only 20 Km away to PT. Petrokimia, 43 Km away from PT. Semen Gresik, and 38 Km to international harbor Tanjung Perak not only that the location is near with the coast, if we want to build jetty for our plant the space still exists. Here’s the detail of the location with the coordinates 7°04'36.1"S and 112°36'04.1"E.

Figure 1.2 Smelter Plant Location

(source: Google Maps)


CHAPTER II PROCESS SELECTION

2.1

Process Selection Alternative

Before process selection, we should consider some alternative process and analyze each alternative process. The alternative will be explained below. 2.1.1

Copper Smelter Plant The method that are used to form copper cathode from copper ore consists

of pyrometallurgical and hydrometallurgical process. Pyrometallurgical used high temperatures

to

extract

metals,

such

as

smelting.

Meanwhile,

the

hydrometallurgical is one of the extractive metallurgy method involving the use of aqueous chemistry for the recovery of metals from ores, concentrates, and recycled or residual materials About 80% of the world’s copper -from ore is produced by concentration/smelting/refining of sulfide ores. 2.1.1.1 Mitsubishi Process The Mitsubishi process employs three furnaces connected by continuous gravity flows of molten material. They are smelting furnace, slag cleaning furnace, converting furnace. The smelting furnace blows oxygen-enriched air, dried concentrates, SiO2 flux and recycles into the furnace liquids via vertical lances. It oxidizes the Fe and S of the concentrate to produce -68% Cu matte and Fe-silicate slag. Its matte and slag flow together into the slag cleaning furnace. The slagcleaning furnace separates the smelting furnace's matte and slag. Its matte flows continuously to the converting furnace. Its slag (0.7-0.9% Cu) flows continuously to water granulation and sale or stockpile. The converting furnace blows oxygen-enriched air, CaCO, flux and granulated converter slag 'coolant' into the matte via vertical lances. It oxidizes the matte's Fe and S to make molten copper. A major advantage of the process is its effectiveness in capturing SO2. It produces two continuous strong SO2 streams, which are combined to make excellent feed gas for sulfuric acid or liquid SO2 manufacture. The advantage of Mitsubishi Copper smelting is, 9


10 1. Higher oxygen utilization in concentrates smelting and matte conversion, by virtue of the higher intensity reaction zone directly below the furnace lances. 2. Flexibility in treating a wide range and grade of concentrates and secondary materials such as refinery anode scrap and scrap copper. 3. Furnace size are minimized since only short furnace retention times are required. 4. Efficient capture of feed particles into the melt resulting in reduced carryover or unsmelted dust to downstream equipment. Carryover from the smelting furnace is typically 2 to 5% of the total solids fed to the furnace. 5. Slag from the smelting furnace typically contains 0.5 to 0.7% copper. 6. Continuous production of off-gases resulting in more stable operation of downstream gas handling equipment and acid plant operation. 2.1.1.2. Copper Isasmelt Process Ausmelti Isasmelt copper smelting entails dropping moist solid feed into a tall cylindrical furnace while blowing oxygen-nriched air through a vertical lance into the furnace’s matteislag bath (Pritchard and Hollis, 1994). The products of the

process are a mattelslag mixture and strong SO, offgas. The matte slag mixture is tapped periodically into a fuel-fired or electric settling furnace for separation. The settled matte (-60% Cu) is sent to conventional converting. The slag (0.7% Cu) is discarded. The offgas (25% SO,) is drawn from the top of the smelting furnace through a vertical flue. It is passed through a waste heat boiler, gas cleaning and on to a sulfuric acid plant. A small amount of oxygen is blown through the side of the smelting furnace or lance (about halfway up) to ensure that sulfur leaves the furnace as SO, rather than S. This prevents sulfur condensation in the gas cleaning system. Most of the energy for smelting comes from oxidizing the concentrate charge. The principal product of the furnace is a matte slag mixture. It is tapped into a hydrocarbon fired or electric settling furnace. The products after settling are 60% Cu matte and 0.7% Cu slag. The advantages of the process are: 1. its small 'footprint', which makes it easy to retrofit into existing smelters 2. its small evolution of dust. Universitas Indonesia

11

Figure 2.1 Isasmelt Furnace

(source: Extractive Metallurgy of Copper, Davenport)

Figure 2.2 Mount Isa Copper Isasmelt Plant

(source: https://www.saimm.co.za/Journal/v097n04p161.pdf)

2.1.1.3 Hydrometallurgical Extraction Process Hydrometallurgy is one of the method of processing copper by extraction of metal from ore by preparing an aqueous solution of a salt of the metal and recovering the metal from the solution. Hydrometallurgical extraction entails: 1. sulfuric acid leaching of Cu from broken or crushed ore to produce impure Cu-bearing aqueous solution 2. transfer of Cu from this impure solution to pure, high-Cu electrolyte via solvent extraction electroplating pure cathode copper from this pure electrolyte. The leaching is mostly done by sprinkling dilute sulfuric acid on top of heaps of broken or crushed ore (-0.5% Cu) and allowing the acid to trickle through to collection ponds. Extraction and stripping are carried out in large mixer-settlers. The Cu-loaded organic phase goes forward to another mixerisetter ('stripper') where Cu is stripped from the organic into pure, strongly acidic, high-Cu electrolyte for electrowinning. Then when the organic phase is subsequently put into contact with high acid electrolyte [step (c) above], the Cu is stripped from the organic into the electrolyte at high Cu++ concentration, suitable for electrowinnin g. The last stage of hydrometallurgic extraction of chopper is electrowinning. Pure metallic copper (less than 20 ppm undesirable impurities) is produced at the cathode and gaseous O2 at the anode. Universitas Indonesia

12

Figure 2.4 Copper Solvent Extraction

Process

(source: Extractive Metallurgy of Copper, Davenport) Figure 2.3 Hydrometallurgical Extraction Process


2.2.1.4 Flash Smelting Process In flash smelting furnace, copper concentrate, silica flux, pure oxygen, oxygen enriched air, and hydrocarbon fuel are introduced at the top of the reaction shaft. The results in controlled oxidation of the concentrate’s Fe and S, a large evolution of heat and melting of the solids. The process is continuous. Flash smelting has some significant advantages over conventional smelting, which is high recovery of copper and other valuable metals, low investment and operating costs for smelter and acid plant, continuous process, and high sulfur recovery. The periodic tapping and transportation of the matte from the flash smelting furnace cause fugitibe emissions of SO2 gasses and some loss of heat energy. However, the flash furnace has such a drawback as a difficulty with lowering the copper grade of slag. The flash converting furnace can produce continuous off-gas flows at relatively high SO2 contents because high levels of the oxygen enrichment can be utilized and the furnace is sealed. So it can achive more than 99.8% sulfur capture. The scheme of the flash smelting process is on Figure 2.5 below. Universitas Indonesia

13

Figure 2.5 Flash Smelting Process


2.1.2

Oxygen Plant

2.1.2.1 Pressure Swing Adsorption (PSA) Pressure swing adsorption (PSA) is a technology used to separate some gas species from a mixture of gases under pressure according to the species’ molecular characteristics and affinity for an adsorbent material. The basic principle of this process is adsorption. The adsorption process is based on the ability of some natural and synthetic materials to prefentially adsorb nitrogen. Zeolites are typically used in adsorption-based process for oxygen. Nitrogen is adsorben and an oxygen-rich effluent stream is produced until the bed is saturated with nitrogen. The advantages of pressure swing adsorptions (PSA) are: 1.

PSA units can be placed on-site which makes the nitrogen readily available

2. Low to moderate capital cost. Cost-effective nitrogen production of relatively high purities. 3. Quick installation and start-up. During shutdown, less money is lost. While the disadvantages of PSA are: 1.

High maintenance equipment but noisy operation

2.

There is possible down time with respect to the compressor that is being used.

Figure 2.6 Schematic of a Pressure Swing Adsorption Unit

(source: Smith, 2001) Universitas Indonesia

14 2.1.2.2 Cryogenic Distillation Cryogenic air separation is currently the most efficient and cost-effective technology for producing large quantities of oxygen, nitrogen and argon as gaseous or liquid product. To achive the low distillation temperatures an Air Separation Unit (ASU) requires a refrigeration cycle that operates by means of the Joule-Thomson effect. The advantages of cryogenic distillation are: 1. Providing a feed stream of clean, dry and compressed air 2. Produce large quantities of high purity of nitrogen. 3. Can produce both gaseous and liquid products. 4. Liquid forms of cryogenic gases are easier and cheaper to transport. While the disadvantages of cryogenic distillation are: 1. Cryogenic process has a very large capital cost, due to the use of compressors and turbines. Packing is not as effective at low temperatures. 2. High energy costs to cryogenically cool gases. Large site space and utility requirements 3. Special cryogenic equipment, such as valves and pumps, required. Cryogenic separation also requires numerous of heat echangers, insulators, which add more costs. On figure 2.7 below we can see the schematic of cryogenic distillation process.

Figure 2.7 Schematic of a Conventional Cryogenic Air Separation Unit

(source: American Journal of Oil and Chemical Technologies, Iran)

2.1.2.3 Membrane Separation Membrane separation is a technology which selectively separates (fractionates) materials via pores and/or minute gaps in the molecular arrangement of a continuous structure. The membrane used in this method consists of a bundle of selectively permeable hollow fibers. These fibers allow the fast gases (which is Universitas Indonesia

15 oxygen, carbon dioxide and water vapor) to permeate the memberane wall much faster than the slow gas (nitrogen). The advantages of membrane separation are: 1. At low flow rates (up to 40,000 SCFH) this process is economical. 2. Simplest process in terms of calculation and engineering design. 3. It doesn’t cost a lot for repairs and maintenance , lowest tax and insurance. 4. Requires the least amount of equipment. While the disadvantages are: 1. The purity of nitrogen is not good enough for certain process. 2. Membranes are expensive. Uneconomical for high purity requirements, and large output 3. The energy cost is higher than chemical treatment, although less than evaporation. On figure 2.10 below we can see the schematic of membrane air separation process.

Figure 2.8 Schematic of a Conventional Membrane Air Separation Unit

(source: Smith, 2001)

2.1.3

Sulfuric Acid Plant One of the byproduct of the smelting process is sulfur from the annode

furnace, so we will make its own plant. 2.1.3.1 Lead Chamber Process In the original lead chamber process, sulfur and potassium nitrate are ignited in a room lined with lead foil. Potassium nitrate, or saltpeter is an oxidizing agent oxidizes the sulfur to sulfur trioxide according to the reaction: 6 KNO3(s) + 7 S (s)  3

K 2S + 6 NO (g) + 4 SO 3 (g). The floor of the room was covered with water.

When the sulfur trioxide reacted with the water, sulfuric acid was produced: SO3(g) Universitas Indonesia

+ H2O(l)

↔

16 H2SO4(aq) This process was a batch process and resulted in the

consumption of potassium nitrate. 2.1.3.2 Single Contact Process The principle of contact process is the oxidation reaction of SO2 gas with oxygen from the air by using solid catalyst, then absorbed it into SO3 absorption to produce sulfuric acid. The catalyst used is Pt because it can be activated at temperature above 400oC. The sulfur trioxide is absorbed by concentrated sulfuric acid in absorbers, preceded if necessary by oleum absorbers. In the absorbers, the sulfur trioxide is converted to sulfuric acid by the existing water in the absorber acid.

Figure 2.9 The Single Contact Process

(source: Smith, 2001)

2.1.3.3 Double Contact Process Compared to the single contact process, this process has higher yield process and less of SO2 emission which does not converted. In the other configuration, gas which go outside from absorption tower will be heated again through the heatexchanger, then go back to the last step of converter. Thus, the SO3 content will be decrease. The reaction is: SO2(g) + ½ O2(g)  SO3(g) The degree of conversion obtained is about 99.6%, depending on the arrangement of the contact beds and of contact time preceding the intermediate absorber. After cooling the gases to approximately 160 – 190°C in a heat exchanger, the sulfur trioxide already formed is absorbed in the intermediate absorber in sulfuric acid with a concentration of 98.5 – 99.5 wt%. The intermediate absorber is preceded by an oleum absorber if required. The sulfur trioxide formed in the secondary stage absorbed in the final absorber. Universitas Indonesia

17

Figure 2.10 Double Contact Process (source: Smith, 2001)

2.2

Process Selection

The alternative process mentioned above, either for copper smelter plant, sulfuric acid plant, or oxygen plant, will be scored by some criterias. Some criteria used in this process selection are: energy requirement, product purity, emmision and waste, complexity process, production rate, cost investment and capacity. The “concept scoring” matrix with value of scoring: 1: poor, 2: fair, 3: good, 4: very

good, 5: excellent. 2.2.1

Copper Smelter Plant For the copper smelting process, the comparison of the process is shown on

the table below. Table 2.1 Copper Smelter Technology Selection

Criteria

Mitsubishi

Isamelt

Flash Smelting

Energy Requirment

4 Furnaces needed

The feed is moist solid, need more heat for drying

Transportation of matte from flash smelting furnace cost fugitive emission of SO2 and loss of energy

Matte Grade of Copper

65-69%

50%

45-50%

Emmision & Waste

Eliminating fugitive emissions form furnaces and ladles due to its 3 furnaces connected by enclosed launders that operates contnuously

Small evolution of dust, but low captured SO2

Dust carryover rates are high due to solid material reaction in gas phase

Furnaces more complicated

Simple process

Simple process

990

2255

5815

Melt movement by launder reduce cost

Small footprint is needed

Cost for decoupling and converting operation is high

Complexity Process Production Rate (1000 t/yr) Cost Investment

(source: various

sources )


18 Table 2.2 Copper Smelter Technology Selection Result Mitsubishi

Isasmelt

Flash

Criteria

Weight (%)

Point

Score

Point

Score

Point

Score

Energy Requirment

15

4

0.6

4

0.6

4

0.6

Product Purity

25

5

1.25

4

1

4

1

Emmision & Waste

15

5

0.75

3

0.45

4

0.6

Complexity Process

15

4

0.6

5

0.75

4

0.6

Production Rate

10

3

0.3

4

0.4

5

0.5

Cost Investment

20

5

1

5

1

4

0.8

2.2.2

Oxygen Plant The criteria for selecting the process that will be used in oxygen plant are: Table 2.3 Oxygen Purification Method Selection Pressure Swing Adsorption (PSA)

Criteria

Membrane

Oxygen Purity

Membrane air separation can achieve 99% of oxygen purity The capacity for membrane separation is only 1-8,000 Nm3/h oxygen

Capacity

Complexity

Cryogenic distillation can achive 99% of oxygen purity The capacity for cryogenic distillation can produce oxygen above 10,000 Nm3/h The most complex process is cryogenic distillation, because it used a refrigeration system High, the use of refrigerant added more cost.

The PSA can produce 97% oxygen purity The capacity for pressure swing adsorption can produce 500-10,000 Nm3/h oxygen

Low; one main equipment.

More complex because it used adsorbent which is need to be regenerate periodically

Low

Low

Cost Investment

Cryogenic Distillation

Hence, the scoring process of oxygen plant based on criteria explained above is shown on the table below Table 2.4 Oxygen Purification Method Selection

Parameter

Weight (%)

Membrane

Pressure Swing

Cryogenic

Separation

Adsorption

Distillation

Point

Score

Point

Score

Point

Score

Purity

20

5

1.0

5

1.0

5

1.0

Capacity

30

3

0.9

4

1.2

5

1.5

Complexity

30

5

1.5

5

1.5

3

0.9

Cost

20

5

1.0

5

1.0

3

0.6

Total

100

4.4

4.7

4.0 Universitas Indonesia

19 2.2.3

Sulfuric Acid Plant The comparison of the alternative process in the sulfuric acid plant is shown

below. Based on the data that we got from the literature, we make the scoring based on some criteria. The weight given represents our priority of choosing the process. According to the total score below, the process chosen is double contact. Hence, the method that will be applied in the sulfuric plant will have two absorbers. Table 2.5 Sulfuric Acid Plant Technology Selection Criteria

Lead Chamber Process

Single Contact

Double Contact

Low

Low

High

About 70% High sulfur dioxide emission

About 97.5-98.5% High sulfur dioxide emission

About 99.6% The remaining of sulfur dioxide need to be removed is reduced

Medium

Medium

High

Medium

Medium

Lead

Vanadium Oxide

Energy Requirement Product Purity Emmision & Waste Complexity Process Cost Investment Catalyst

High (15% higher than single contact) Vanadium Oxide

Table 2.6 Sulfuric Acid Plant Method Selection Result Priority (%)

Criteria

Lead Chamber Process

Single Contact

Double Contact

Point

Score

Point

Score

Point

Score

Energy Requirment

15

5

0.75

5

0.75

4

0.6

Product Purity

30

3

0.9

4

1.2

5

1.5

Emmision & Waste Complexity Process

20 15

3 5

0.6 0.75

3 5

0.6 0.75

5 4

1 0.6

Cost Investment

20

5

1

5

1

4

0.8

Total

2.3

Process Description

2.3.1

Copper Smelter Plant

4

4.3

4.5

The overall process in Mitsubishi Copper Smelter plant entails three main furnaces which are smelting furnace, cleaning furnace, and converting furnace. the output of the converting furnace is fed to anode furnace, then casted, and finally it is electrorefined to get the cathode copper.


20

Figure 2.11 Mitsubishi Copper Smelting Diagram and Equipment


The Smelting (S) Furnace is the first stage of copper production in the Mitsubishi Process. It is a continuous-operation furnace that produces a high-grade copper sulfide matte as well as a silicate slag. Matte smelting process condition is 1250oC and 1 atm. The feed of smelting furnace is dried concentrates (containing 30% Cu, 25% Fe, 30% S, and moisture content about 0,5%) mixed with coal, silica sand, and recycled slag from converter furnace. The mixed feed injected into smelting furnace through vertical lances, together with oxygen enriched air. The concentrates are bath-smelted instantly, producing a high-grade matte about 68% copper and silicate slag. The oxidation raction occurs in smelting furnace are 2 CuFeS2 + O2  Cu2S + 2 FeS + SO 2 2 FeS + 3 O 2  2 FeO + 2 SO2 2 Cu2S + 3 O 2  2 Cu2O + 2 SO2 FeO + SiO2  FeSiO3 Cu2O + FeS  Cu2S + FeO The electric slag-cleaning furnace (3600 kW) is elliptical with three or six graphite electrodes arranged in two pairs of three. It is a process where molten matte and slag containing metal that had been transferred from the smelting furnace through a launder be heated by two sets of delta-type electrodes (2100 & 1500 KVA). Slag celaning furnace accepts matte and fayalite slag (2FeO SiO 2) from the smelting furnace and separates them into layers by the difference of specific gravity. The process condition of slag cleaning furnace is 1250oC and 1 atm. Residence times in the furnace are 1 to 2 hours. The purpose of the electrodes and electrical power is to keep the slag hot and fluid. Heat is obtained by resistance to electric


21 current flow between the graphite electrodes in the slag - selectively heating the slag to 1250°C. Only a tiny amount of offgas is generated in the electric furnace.

Figure 2.12 Smelting Furnace


Figure 2.13 Slag Cleaning Furnace


The converting furnace blows oxygen-enriched air blast (30-35 volume% O2), CaCO3 flux and converter slag granules onto the surface of the matte. In this circular furnace, matte is continuously converted to blister copper. Inputs to this furnace include: oxygen enriched blowing air (30-35%), limestone flux, coolant, anode scrap, and molten copper matte. The air enrichment here is lower than that of the S-Furnace. The Converting Furnace reactions are highly exothermic so that the heat balance must be carefully controlled to hold the bath temperature as low as Universitas Indonesia

22 possible. Converting furnaces process condition is 1250 C and 1 atm. The converter o

reactions are: Cu2S (matte) + O2 3 FeS (matte) + 5 O2 CaCO3 (flux)

2 Cu (blister) + SO2 Fe3O4 (slag) + 3 SO2 CaO (slag) + CO2

In addition, some Cu2S is oxidized to Cu2O: Cu2S (matte) + 2 O2

2 Cu2O (slag) + SO2

2 Cu2O + Cu2S

6 Cu + 5 O2

This process produces 1. blister copper (99% Cu and 0.5% S) 2. molten slag (mostlly as Cu2O, 14% Cu) 3. SO2 offgas (< 0.3 ppm SO2 or 25-30% vol SO2)

Figure 2.14 Composition of Converter Product from Smelting Copper Scrap

(source: http:/ www.epa.govirpdweb00/docs/source-management/tsd/scrap_tsd_041802_apc2.pdf)

The C furnace uses a multi-lance system (similar to that of the S-Furnace) to inject flux, oxygen-enriched air, and coolant down into the high intensity reaction zone in the melt. Limestone, however, is the chosen flux for the C-Furnace, since a more fluid ternary slag of the Cu2O-CaO-Fe3O4 type is desired. The C-Furnace has several advantageous environmental features since it is one stationary furnace instead of several rotary type furnaces. It is tightly sealed and can produce much smaller volume of gas with higher SO2 concentration for the acid plant feed. At the anode furnace, a process that occurs in the blister is oxidation and reduction. The reaction as shown below Cu2S + O2  2 Cu + SO 2


23 This process aims to be produced copper refinery which will be ready in casting the next process. The final stage in the smelter is casting, uses technology called casting of the English Hazelett Caster. This process takes place in two stages where the first will be in the refined copper into copper continuous cast strip by a Hazelett Twin Belt Caster. Then, continuous copper strips had to be cut into pieces by hydraulic shearing machine anode. Almost all copper is treated electrolytically during its production from ore. It is electrorefined from impure copper anodes or electrowon from leach solvent extraction solutions. Electrorefining entails: 1. Electrochemically dissolving copper from impure copper anodes into CuSO4H2SO4-H2O-electrolyte 2. Selectively electroplating pure copper from this electrolyte without the anode impurities. 3. It produces copper essentially free of harmful impurities 4. Elimination of unwanted impurities; cathode copper typically has a purity > 99.9 % wt Cu, with < 0.005 % total metallic impurities; Electrorefining produces the majority of cathode copper (ca. 95%). Overall copper electrorefining is the sum of both reactions above would be Cuimpure  Cu pure The process for electrorefining copper is typical of those carried out in aqueous solution. The electrolyte is copper sulfate (0.7 molar) and sulfuric acid (2 molar) and the way in which the purification of the copper occurs can be seen by considering the metals likely to be found. 2.3.2

Oxygen Plant From the discussion on the selecting process above, we chose pressure

swing adsorption (PSA) technology to be implement on our oxygen plant. Pressure swing adsorption process rely on the fact that under high pressure, gases tend to be attracted to solid surfaces, or adsorbed. The process starts when air is fed into compressor after going through a filter. The compressor will compress the air from 1 bar until 5 bar, in 2 stages of compression. The main objective is that the adsorption process will take place when Universitas Indonesia

24 the pressure is high and under ambient temperature, so after a stage of compression , the gas need to be cooled down by cooling water in heat exchangers. Next it will enter a drum tank, to be storage, and then the PSA process will start. Air, is passed under pressure through a vessel containing an adsorbent bed of zeolite that attracts nitrogen more strongly than it does oxygen part or all of the nitrogen will stay in bed, and the gas coming out of the vessel will be enriched in oxygen. When the bed reaches the end of its capacity to adsorb nitrogen, it can be regenerated by reducing the pressure, thereby releasing the adsorbed nitrogen. Then it is ready for another cycle of producing oxygen enriched air. Using two adsorbent vessels allows nearcontinuous production of the target gas. It also permits so-called pressure equalization, where the gas leaving the vessel being depressured is used to partially pressure the second vessel. This results in significant energy savings, and is common industrial practice. 2.3.3

Sulfuric Acid Plant The use of DCDA system adds 10 to 15% to the cost of the plant in

comparison with the older Single Absorption Process. The conversion is aided by a catalyst. The converter consists of a tall cylindrical vessel of sufficient diameter (generally 3.5 to 5.5m) to give a low gas velocity, inside which there are three or four trays for quantities of catalyst. Between the catalyst sections there are devices for cooling the gases to keep the temperature entering the later catalyst sections in the region of 405 to 440oC. After the passage through the first catalyst tray when the gas temperature has risen from about 410oC to over 600oC, the gases pass into an external waste heat boiler to raise steam and bring the gas temperature down to 430oC and at this temperature the gases enter the second catalyst tray. On passing through the catal yst the temperature again rises but this time not so much, and after the second tray sufficient heat can be removed by superheating the steam raised in the waste heat boilers. The super heater tubes are led from the boiler into a space underneath the catalyst bed in the path of the gases. The temperature is again brought down to about 430oC and after the third pass the gases are similarly cooled. In the final section, which contains most of the catalyst, the temperature rise is small as the reaction has been brought near the equilibrium value in the previous passes and only relatively Universitas Indonesia

25 small amounts of sulfur dioxide and oxygen remain to react. After leaving the catalyst the gases are at 400 to 450oC; the gases then pass through an air cooler to the absorbers. The catalyst consists of vanadium in the form of small pellets or cylinders. The speed of the reaction depends on the activity of the catalyst. A conversion of sulfur dioxide to trioxide of between 98 and 99% is achieved. The gas leaving the reactor is cooled further in a heat exchanger as mentioned above and before entering the absorption tower where the Sulfur trioxide is absorbed in a recirculated stream of concentrated sulfuric acid. The sulfuric acid is maintained at desired concentration (usually 98% H2SO4) by the addition of water and its temperature is controlled in the desired range of 70 to 90oC measured at the tower inlet by cooling the recirculated acid. Our plant uses a Double Contact Double Absorption Process (DCDA). The gas after passing through three catalyst bed goes to the first absorption tower where the Sulfur trioxide is removed. The gas is then reheated to about 420oC, passed through the fourth catalyst bed, then cooled and sent to a second absorption tower. The effect of removing sulfur trioxide product at the first absorption stage is to push the reaction equlibrium of remaining sulfur dioxide and oxygen in the direction of more product. In the reaction 2 SO2 + O2 → 2 SO3

2.4

BFD and PFD

The BFD and PFD designs can be seen on Appendix B. 2.5

Mass Balance

2.5.1

Mass Balance of Copper Smelter Below is the overall mass balance of copper production which will be

detailed for each process unit in Appendix A. Our target product is Cu refined copper with purity 99.99%. Below is mass balance of copper smelting process.


26 CuFeS2

SiO2

SiO2

O2

O2

Cu

CaCO3

Fe2S3 FeO FeSiO3 CaO CaO-Fe2O4 SO2 CO2

Figure 2.15 Overall Mass Balance of Copper Smelter Table 2.7 Overall Mass Balance of Copper Smelter

Component CuFeSs O2 SiO2 CaCO3 Fe2S3 Cu FeO FeSiO3 Fe3O4 CaO SO2 CO2 Other metals total

2.5.2

Input (tonne/day) 2385.5 1760 516 186 -

Output (tonne/day) 398.76 62 27.04 876 16.54 999 25.4 1830.4 -

-

5.25

4847.5

4240.4

Oxygen Plant The overall mass balance of the oxygen plant can be seen below. The output

is two, one is at the top of the adsorber column, which is the purified oxygen, and the other is at the bottom of the adsorber column, which is nitrogen. Table 2.8 Overall Mass Balance of Oxygen Plant

Component

O2 N2

Input (tonne mole/day)

82 367

Output (tonne mole/day) Purified O2 78 8.6

N2 4 348


27 2.5.3

Sulfuric Acid Plant The overall mass balance of the oxygen plant can be seen below. Table 2.9 Overall Mass Balance of Sulfuric Acid Plant Component

Input (tonne/day)

SO2 SO3 H2SO4

1860 5200

2.6

Energy Balance

2.6.1

Copper Smelter

SO2 -

Output (tonne/day) H2SO4 SO3 200 5460 -

In the copper smelter plant, we calculate the energy consumption needed for each equipment based on the data of energy from the literature. Table 2.10 Energy Requirement for Each Equipment Operation

Btu/ton

Smelting

22.68 9.20 12.21

Electric Furnace Outokumpu flash Mitsubishi reactor Converting

6.50 8.16 6.25

Electric Furnace Outokumpu flash Mitsubishi reactor Gas Cleaning

7.73 8.16 6.25

Electric Furnace Outokumpu flash Mitsubishi reactor Electrorefining

5.61 6.29 Outokumpu flash 6.29 Mitsubishi reactor (source: An Assessment of Energy Requirements in P roven and New Copper Processes report) Electric Furnace

Table 2.11 Overall Energy Balance of Copper Smelter Total (104kJ)

2385

4 10 kJ 128.6934

Cleaning Slag

2648

65.875

174437

Converting Furnace

1587

31.8308

50514.2

Anode Furnace

886

95.5

84604.14

Electrorefining

881

59.1294

51979.2

Hazelet Caster

881

18

15858

Operation

Feed (tons)

Smelting Furnace Mitsubishi

TOTAL

306949.5


28 2.6.2

Oxygen Plant The overall energy balance in oxygen plant comes from its two

compressors. Table below shows the overall energy balance of oxygen plant. Table 2.12 Overall Energy Balance of Oxygen Plant

2.6.3

Equipment Compressor 1 (MW)

Energy (MW) 11.3

Compressor 2 (MW)

8.75

Total (MW)

20.05

Sulfuric Acid Plant Most of equipment in sulfuric acid plant produce and requies energy. Table 2.13 Overall Energy Balance of Sulfuric Acid Plant

Equipment

2.7

Mass Efficiency

2.7.1

Copper Smelter

Input

Output

HE E-301

-17.6

-16.6

HE E-302

-18.4

-18

HE E-303

-18.5

-18.8

HE E-304

-18.2

-18.2

HE E-305

-21.7

-21.7

HE E-306

-21.7

-21.7

HE E-307

-22

-21.9

HE E-308

-21.9

-21.8

1st Bed Converter

-7.2

-7.1

2nd Bed Converter

-8.3

-8.3

3rd Bed Converter

-9.2

-9.2

4th Bed Converter

-9.6

-9.6

Pump P-301

-14.6

-14.6

Pump P-302

-12.8

-12.8

Mass efficiency obtain from mass of refined copper product divided by mass of copper concentrate.

     ×100%    2385.8765totnnesonnes 36.94 % Universitas Indonesia

29 2.7.2

Oxygen Plant The efficiency of the oxygen plant is,

         8378 93.9%

2.7.3

Sulfuric Acid Plant Efficiency of sulfuric acid can be determined by its SO2 converter because

most off SO3 will be absorbed by concentrated H2SO4 completely (Matthew, 2013).

       0.42341792 3800   99.2% 2.8

Heat Exchanger Network (HEN) Network

2.8.1

Heat Exchanger Information In smelter plant, there are several streams which are needed to anal ysis their

heat transfer. The flows of stream are evaluated into two main types, hot fluid and cold fluid. Hot fluid is when the fluid has temperature decrease, which requires a cold utility to cool the flow towards the temperature target. Cold fluid is when the fluid has the temperature increase that its flow requires hot utility to heat flow towards desired temperature. The table below shows the data of hot fluid and cold fluid in our oxygen plant with the initial temperature, final temperature, and enthalpy for each stream which needed to be evaluated. Table 2.14 Oxygen Plant Stream Classifications No.

Stream In

Stream Out

Molar Flow (kgmol/hr)

Tin (oC)

Tout (oC)

Type

Q (kJ/hr)

Q (MW/day )

Cp (kJ/kgmo l oC)

1

1a

1b

11010

152

32

HOT

38314800

0.4434

29

2

2a

2

11010

124

32

HOT

29496230.4

0.3413

29.12

3

C1

C2

15910

32

64

COLD

-38728758.4

-0.4482

76.07

4

C3

C4

15580

31

56

COLD

-29656530

-0.3432

76.14


Table 2.15 Sulfuric Acid Stream Classification

No.

Stream In

Stream

Mass Flow

Molar Flow

Tin

Tout

Out

(tonne/day)

(kgmol/hr)

(oC)

(oC)

Type

Q

Q (kJ/hr)

(MW/day)

Cp (kJ/kgmol oC)

1

1

1'

1860

1476

1200

1100

HOT

7216164

0.083

48.89

2

1'

2

1860

1476

1100

800

HOT

21165840

0.245

47.8

3

2

3

1860

1476

800

377

HOT

29100860.3

0.336

46.61

4

4

5

2560

2148

776

357

HOT

40239536.5

0.465

44.71

5

6

7

2560

2006

633

327

HOT

28340808.1

0.328

46.17

6

8

9

2560

1933

478.5

317

HOT

14694289.1

0.17

47.07

7

10

11

2560

1927

329

127

HOT

17123283.5

0.198

43.99

8

13

14

800

1850

26.85

115

COLD

-12336813

-0.142

75.65

9

14

15

800

1850

115

293.5

COLD

-25083891

-0.29

75.96

10

15

16

800

1850

293.5

305

COLD

-1614134.3

-0.0187

75.87

11

18

19

700

1619

22.13

117

COLD

-11690080

-0.135

76.11

12

19

20

700

1619

117

125

COLD

-978135.04

-0.0113

75.52

13

20

21

700

1619

125

200

COLD

-9214943.3

-0.107

75.89

14

21

21'

700

1619

200

218

COLD

-2220620.4

-0.0258

76.2

30


31 2.8.2

Heat Recovery Pinch Method Linnhoff and Vredeveld has introduced the “pinch” term to design the heat

exchanger networks by the set of thermodynamically based on methods that guarantee minimum energy. There are two methods that can be used to determine the pinch from heat exchanger network, those are composite curve and problem table cascade. The first step is determined the shifted temperature intervals (T*) from actual supply and target temperatures. Hot streams are shifted down in temperature by ΔTmin/2 and cold streams up by ΔT min/2 as detailed in the table

below, in this case of our plant, Tmin that we used is 15. Table 2.16 Shifted Temperatures in Oxygen Plant Stream In

Stream Out

Type

T in

Tout

Tin*

Tout*

1a

1b

HOT

152

32

137

17

2a C1 C3

2 C2 C4

HOT COLD COLD

124 32 31

32 64 56

109 47 46

17 79 71

Meanwhile the shifted temperature in sulfuric acid plant is shown as below Table 2.17 Shifted Temperature in Sulfuric Acid Stream In

Stream In

Type

Tin

Tout

Tin*

Tout*

1

1'

HOT

1200

1100

1185

1085

1'

2

HOT

1100

800

1085

785

2

3

HOT

800

377

785

362

4

5

HOT

776

357

761

342

6

7

HOT

633

327

618

312

8

9

HOT

478.5

317

463.5

302

10

11

HOT

329

127

314

112

13

14

COLD

26.85

115

41.85

130

14

15

COLD

115

293.5

130

308.5

15

16

COLD

293.5

305

308.5

320

18

19

COLD

22.13

117

37.13

132

19

20

COLD

117

125

132

140

20

21

COLD

125

200

140

215

21

21'

COLD

200

218

215

233

2.8.2.1 Cascade Curve After we have the problem table, we can cascade any surplus heat down the temperature scale from interval to interval. This is possible any excess heat Universitas Indonesia

32 available from the hot streams in an interval is hot enough to supply a deficit in the cold streams in the next interval down. Since our smelter plant is high temperature process, it is known that the utility that require only from cold utility to cooling our equipment. For heat utility our plant is no longer needed since we have excess heat. From the table below, we know the minimum utility requirement based on the problem table cascade meth od. Table 2.18 Minimum Utility Requirements

Utility

Q (MW)

Hot

0

Cold

23.258

To see the minimum utility requirement, we used the grand composite curve. The grand composite curve is help to understanding the interface between the process and utility system. The grand composite curve is obtained by plotiing the problem table cascade.


Figure 2.16 Cascade Table

33


34 Table 2.19 Utility Requirement Ti

∆H

Q 0

1185

14271444 14271444

1085

41804748 56076192

785

3956002.56 60032195

761

36815415.78 96847610

618

53833480.97 150681091

463.5

35366332.16 186047423

362

5592808.2 191640232

342

951364.26 192591596

320

768075.36 193359671

314

256025.12 193615696

312

-367956.61 193247740

308.5

228988.76 193476729

302

-12359629.8 181117099

233

-5435837.64 175681261

215

-22566754.5 153114507

140

423797.55 `

137

153538304

90218.8 153628523

132

716.28 153629239

130

2535914.52 156165154

112

1130179.83 157295334


35 Table 2.19 Utility Requirement (cont’d) 109

-25006412.7 132288921

79

-16158466.3 116130455

71

-48475399 67655056

47

-809534.59 66845521

46

1563415.432 68408936

41.85

2438725.399 70847662

37.13

12881211.16 83728873

Cold Utility (Kj)

43.258

Cold Utility (MW)

17

2.8.2.2 Composite Curves Composite curve is generated for hot fluid, cold fluid and combination of both fluids. This section describes the use of a heat exchanger network (HEN) to recover the heat in production of sulfuric acid and oxygen. Composite curves consist if temperature (T)-enthalpy (H) profiles of heat availability in the process (the hot composite curve) and heat demands in the process (the cold composite curve) together in a graphical representation.

H OT

1200

COLD

1000 800 ) C o ( T

600 400 200 0 0

10

20

30

ΔH

40 (MW/day)

50

60

70

Figure 2.17 Combined Composite Curves Universitas Indonesia

36 The premium approach temperature (ΔT min) can be measured directly from the T-H profiles as being the minimum vertical difference di fference between the hot and cold co ld curves. This point of minimum temperature difference represents a bottleneck in heat recovery and is commonly refer as the ‘pinch’. We are using temperature

difference about 10oC to get the pinch composition.

HOT

1200

COLD

1000 800 ) C o ( T

600 400 200 0 0

10

20

30

ΔH

40

(MW/day)

50

60

70

Figure 2.18 Combined Composite Curves After Pinch

Figure above shows that the pinch is being at 1100oC for cold fluid and 1090oC for hot fluid, as we use 10 oC as the minimum temperature difference. The hot end and overshoots indicate minimum hot utility requirement (QHmin) and minimum cold utility requirement (QCmin), as shown below. Table 2.20 Minimum Utility Requirement After Pinch

2.8.3

Utility

Q (MW)

Cold

30.2

Hot

0

Pinch Design Method This pinch design method is used to determine the use of hot or cold fluid

for heating or cooling the stream. The determination of the heat transfer is based on the are above and below the pinch and also the loading of it’s heat exchanger.

The design is shown in the figure below. After we have all the exchanger network analysis, we revised the PFD that is shown in the next section. Universitas Indonesia

Figure 2.19 Pinch Design Method

37


38 2.9

Utility Analysis

Utility plant is supporting facilities to running the process from the beginning until the end of product. For our plant, we require several utilities. They are electricity, water, and fuel. In this assignment. 2.9.1

Water The water needed for our main process will be provided as the cooling agent

to reduce the temperature of the stream entering the heat reactor before going to the next process. For example, in sulfuric acid plant the feed temperature reach 1200oC as the outlet of the furnace. Hence, we need to cool down the temperature before it enters the next equipment. The feed into this cooling water system is treated water from the Bengawan Solo river. 2.9.1.1 Water as Feed of Heat Exchangers On table below shown the utility of water needed before HEN Table 2.21 Water Consumption Before HEN

Plant

Equipment

Unit

Copper Smelter

Anode Furnace Electrorefining

Oxygen

Heat Exchanger

F-104 P-101 E-201 E-202 E-304 E-305 E-302 E-301 E-303 E-306 E-307

Sulfuric Acid

Heat Exchanger

Total Total (tonne/hr)

Mass of Water (tonne/day)

53 8.8 6878 6734 800

700

15112 629.67

The water needed for cooling in power plant is not included in the calculation because we used the water from the oxygen plant. After HEN calculation is done by cascade and composite curve method, the total water consumption needed for this plant is shown below Universitas Indonesia

39 Table 2.22 Water Consumption After HEN

Q(MW)

Q (Kj)

M (kg)

m (tonne/s)

m (tonne/hr)

1.9

6840000

1636364

0.02513

90.4762

8

28800000

6889952

0.10582

380.952

11

39600000

9473684

0.1455

523.81

7.8

28080000

6717703

0.10317

371.429

4

14400000

3444976

0.05291

190.476

4.7

16920000

4047847

0.06217

223.81

Total

1780.95

The calculation of the water consumption after HEN is using the specific heat of water, 4.19 kJ/kgoC, with the temperature difference (∆T) 15 oC. The temperature chosen based on the rule of thumb that states the cooling water could cool down the hot stream about 15oC. 2.9.1.2 Water Pretreatment Process Water pretreatment process is a process unit to treat water from impurities to pure water which fulfill the specification water in using of main process. In this plant design, the source would be from Bengawan Solo River. The water will be used as feed water of heat exchanger. The pretreatment is important to use in preventing corrosion and scalling in the process equipment which can reduce the production and cause revenue losses. The quality of water still needs to be maintained due to its BOD and COD level. Furthermore, we need the water pretreatment process which process will be explained below. The PFD is shown in Appendix B. The BFD is shown on figure below

Figure 2.20 BFD of Water Treatment Process


40 The treated water has to fulfill the specification which needs certain process from water source to be specified as the feed water of process. The description for each process will be explained further a. Screening Screening stage is the initial stage of water treatment. The purpose of screening is to maintain the structure of the flow in the utility of the large objects that may damage the unit of utility facilities and facilitate the separation and remove solid particles carried in large lake. At this stage, the particles will be filtered without the added of chemicals.

Figure 2.21 Raw Water Screening

(Source: kopar.fi/page/raw-water-screening)

b. Coagulation and Flocculation Alum added to the water as a coagulant to help small particles stick together so that they can be removed more easily. Mixing speed is gradually reduced to allow the Alum to form sticky particles called "floc" which attract the dirt particles which can be more easily removed.

Figure 2.22 Coagulation and Flocculation Process

(Source: koshland-science-museum.org)


41 c. Sedimentation The clumps sink to the bottom of the sedimentation basins, trapping larger organic materials. d. Filtration Filtration in water purification is a common operation in order to get rid with Suspended Solid (SS), including particulate BOD in water (Metcalf, 1984). Materials used in the medium can vary: sand, anthracite (crushed anthracite coal), carbon active granular, powdered active carbon and garnet stones. The most commonly used in Africa and Asia are sand and gravel as a primary filter, consider another type is quite expensive (Kawamura, 1991)

Figure 2.23 Filtration Unit

(Source: chemistry.wustl.edu)

e. Demineralization Far more resin is used for water purification than for any other purpose. It is therefore appropriate to discuss water treatment examples when outlining the application of the principles of ion exchange technology. Industrial ion exchange units are produced in sizes ranging from a few litres up to vessels holding several tonnes of resin. Service runs between regenerations usually range from 12 to 48 hours. The two major types of treatment applied to water are water softening - the replacement of 'hard' ions such as Ca2+and Mg2+ by Na+ and demineralisation the complete removal of dissolved minerals. Both of these treatments are outlined below. Demineralisation virtually all the dissolved matter in natural water supplies is in the form of charged ions. Complete deionization (i.e. demineralisation) can be achieved by using two resins.


42 The water is first passed through a bed of cation exchange resin contained in a vessel similar to that described for softeners. This is in the hydrogen ion form brought about by the use of a strong acid regenerant (either hydrochloric or sulphuric). During service, cations in the water are taken up by the resin while hydrogen ions are released. Thus, the effluent consists of a very weak mixture of acids. The water now passes through a second vessel containing anion exchange resin in the hydroxide form for which sodium hydroxide is used as the regenerant. Here the anions are exchanged for hydroxide ions, which react with the hydrogen ions to form water. Such twin bed units will reduce the total solids content to approximately 1-2 mg L-1. With larger units, it is usual to pass water leaving the cation unit through a degassing tower. This removes most of the carbonic acid produced from carbon dioxide and bicarbonate in the feed water and reduces the load on the anion unit. Without degassing the carbonic acid would be taken up by the anion bed after conversion to carbonate.

Figure 2.24 Ion Exchange Unit

(Source:buildingcriteria1.tpub.com)

f. De-aeration De-aeration serves to heat the water that comes out of the ion exchanger and condensate tool marks before it is sent as feed water. In this de-aerator, water is heated to 100°C so that the gases dissolved in the water such as O2 and CO2 can be eliminated, because these gases can cause corrosion. The heating is done by using a heating coil inside the de-aerator.


43 2.9.2

Fuel Fuel utility is used to determine how much fuel that must be prepared in a

period time. Fuel is used to burn copper concentrate, silica, limestone on the furnace unit. The fuel that we use is coal, which is bituminous coal that fits for metallurgical process. The coal is used in smelting furnace, converting furnace, and anode furnace. Below is the calculation to determine fuel consumption. Assumption: we use medium-volatile bituminous coal, with heating value of

Heating Value  13840 Btu/lb  32247 kJ/kg

2.9.2.1 Smelting Furnace

On smelting furnace, we use coal to melt copper concentrate and silica. So, there will be a phase change, and latent heat calculation will be done.

CuFeSSiO 2385. 5 t o nne/d 99. 4 t o nne/h 516QQtonne/d21. 5 t o nne/h  +Q Q m ∙ λ + m ∙ λ       t o nne MJ t o nne Q(99.4 hr ×144.6 tonneMJ)+(21.5 hrMJ×236.87 toMJnne) Q14372.6 hr +5092.MJ 70 hr Q19465.3 hr  Coal Heating Value32447 kgkJ × 10MJkJ × 10tonnekg 32247 toMJnne MJ 19465, 3 Coal Mass 32247 toMJnneh 0.61 tohrnne 14.5 todaynne

2.9.2.2 Converting Furnace

On converting furnace, we use coal to melt limestone, and further heat the copper (I) sulfide. So, there will be a phase change for the limestone, and here is the calculation.

CaCO  186 tonne/d 7.75 tonne/h CuS1033. 5 tonne/d0.27 tonnemole/h


QQ +Q Qm ∙ λ +m ∙ ∫ Cp dT  t o nnemol e Q 0.27 h ×∫ 9.38+0.0312T+20.97 T MJ e 59038 MJh Q 0.27 tonnemolh e ×218660totnneonnemol Q  m ∙ λ 7.75 MJhr ×531.6 toMJnne Q 4120MJ hr MJ MJ QQ +Q 59038 h +4120 hr 63158 h Coal Heating Value32447 kgkJ × 10MJkJ × 10tonnekg 32247 toMJnne MJ 63158 Coal Mass 32247 toMJnneh 1.96 tonneh 47 todaynne

44

2.9.2.3 Anode Furnace

On anode furnace, we use coal to further melt copper (I) sulfide and copper. Here is the calculation.

  167719/ /0.0.0443772  / ℎ  / ℎ  QQ  +Q  ∫ 5.44+0.001462   0.472 ℎ × [(5.45  . 10− .4184)]/ℎ  0.472 ℎ × 23   10.86 /ℎ Universitas Indonesia

  ∫ 9.38+0.0312 +20.9  0.437 ℎ .[(2099.7  . 10− .4184)]/ℎ   384 /ℎ   +kJMJ39510kg/ℎ MJ Coal Heating Value32447 ×  × 32247

45

kg 10 kJ t o nne t o nne MJ 395 Coal Mass 32247 tohMJnne 0.02 tonneh 0.48 tonned  14.5 tonne/d+47 tonne/d+0.48 tonne/d / 2.9.3

Air Air is used in oxygen plant as a feed to adsorb the nitrogen, and produce

pure oxygen. Oxygen is consumed by copper smelter plant and sulfuric acid plant. Oxygen is used in copper smelter plant for the combustion of coal to melt copper concentrate, silica, and limestone. While oxygen in sulfuric acid plant is used to oxidize sulfur dioxide into sulfur trioxide with the help of catalyst. 2.9.4

Electricity In general, the electricity requirement in this plant can be divided as process,

utility unit, and another requirement. The electricity consumption of our main process is listed on the table below


46 Table 2.23 Electricity Consumption

Plant

Copper Smelter

Equipment

Unit

Power (kW)

Slag Cleaning Furnace

F-102

3600

C-201

11.54

C-202

5.59

C-203

3.15

C-104

1.89

C-105

0.33

Hazelet Caster

PM-101

100

Pump

P-101

3.36

K-201

300

K-202

305

P-301

1.239

P-302

1.083

P-401

117.9

Belt Conveyor

Oxygen

Compressor

Sulfuric Acid

Pump

Power Plant

Pump Total

4451.082

Total (kWh/day)

106825.97

The electicity requirement in our plant would be supplied from the power plant which use the steam produced from the main plant as the feed. The copper smelter plant need such big power supply. Electricity supply from PLN would not be a good idea due to the high cost of the copper smelter operation plant. Hence, we decided to build the power plant that using steam turbine as power supply to minimize the electricity requirement. Excess heat on copper smelter plant, can be utilized to drive the steam turbine. Economizer is installed on the furnace to utilized the heat from flue gas on the furnace to heat up the steam from oxygen plant and finally it is used to drive the steam turbine. This power plant uses a closed loop system. The PFD of the power plant is shown in the Appendix B.


CHAPTER III EQUIPMENT SIZING

3.1

Furnace

3.1.1

Smelting Furnace Table 3.1 Specification of Smelting Furnace Specifications

Name

Smelting Furnace

Code

F-101

Function

To produce 68% Cu matte and Fe

Shape

Circular

Copper production rate

876

ton/day

Operating Condition

Liquid, Off Gas Temperature

o

1250

C

Dimensions

Diameter Height

10.1

m

4

m

Number of Lances

Outside Pipe Diameter

10

cm

Inside Pipe Diameter

5

cm

Layer Thickness

3.1.2

Slag layer thickness

0.1

m

Matte layer thickness

1.4

m

Slag Cleaning Furnace Table 3.2 Slag Cleaning Furnace Specification Design Name


Code

F-102

Function

To accepts molten matte and

Material

Stainless Steel SA-240

Dimension Shape

Elliptical

Width

6

m

Length

12.5

m

Height

2

m

47


48 Table 3.2 Slag Cleaning Furnace Specification Design (cont’d)

Electrodes Material

Graphite

Number

6

Diameter

0.4

m

Electricity Min Voltage

90

V

Max Voltage

120

V

Min Current

5.5

kA

Max Current

12

kA

Power Rating

3600

kW

Applied Power

3000

kW

Operation

3.1.3

T

1250

C

P

2

atm

Residence Time

2

hour

Anode Furnace Table 3.3 Specification of Anode Furnace

Name Code Function Capacity

Anode Furnace F-104 To produce anode 320000 tones/year Dimensions

Diameter 3.12 m Length 12.5 m Number of Unit 2 Production Details Anode production 400 tones/cycle Oxidation Duration 5 hours Air Flowrate Air 50 Nm3/minutes Oxygen 5 Nm3/minutes Anode Casting Casting Rate 100 tonne/hour Automatic yes Anode mass 370 kg


49 3.2

Electrolytic Cell Table 3.4 Specification of Electrolyic Cell

Name Project

Electrolytic Cell

Code

P-201

Function

Remove impurities in copper

Capacity Cathode Cu 266700 tones/day Electrolytic Cell Dimensions Material Polymer

Length

6.3 m

Width

1.2 m

Depth

1.4 m Anode Specification Purities of Cu 99.5% Length 0.974 m Width 0.934 m Thickness 0.045 m Mass 370 kg Cathodes Specification

Type Length Width Thickness Plating Times

Isa Stainless Steel 1m 1m 0.01 m 7 days Electrolyte

Temperature inlet

65oC

Temperature Outlet

63oC

Volumetric Rate

Cu H2SO4

3.3

Caster

3.3.1

Hazelett Caster

52 kg/m3 173 kg/m3

Table 3.5 Specification of Hazelett Caster

Name of Project

Hazelett Caster

Code of Project

PM-201 Dimension

Length Between Molten Copper

3.81 m

Width of Cast Strip

0.93

Length of Lug

0.18 m


50 Table 3.5 Specification of Hazelett Caster (cont’d) Dimension

Thickness of Cast Strip

0.045 m

Thickness of Lug

0.027 m Casting Details

Casting rates

100 tones/day

Caster use

9 hours/day

Method of cutting

Hydraulic sheer

Power consumption

100 kwh/tones

Table 3.6 Specification of Hazelett Caster

PM-203

Code of Project

150

Casting angle Casting belt width

508 mm

Casting belt thickness

1.1 mm

Casting bar height range

70-75 cm

Casting bar width range

100-132 cm

Nominal cast range

40-62 ton/hr 10.5 – 13.7 m/min

Nominal Caster speed

3.4

Belt Conveyor

3.4.1

Belt Conveyor C-101 Table 3.7 Specification of Belt Conveyor C-101 Equipment Specification C-101

Name Material loaded

CuFeS2 Parameters

Capacity

99.40

ton/h

27.610

kg/s

Speed

94.89

ft/min

0.482

m/s

Required mass flow

99.40

ton/h

27.610

kg/s

Maximum mass flow

125.70

ton/h

34.917

kg/s

in

1.3716 0

m

Width Angle 1

54 0

Angle 2

5

5

Length 1

1200

ft

365.760

m

Length 2

60

ft

18.288

m

Height

10

ft

3.048

m Universitas Indonesia

51 Table 3.7 Specification of Belt Conveyor C-101 (cont’d) Parameters

Power

16.92

Hp

Belt material

3.4.2

12.448

kW

SL-516

Belt Conveyor C-102 Table 3.8 Specification of Belt Conveyor C-102 Equipment Specification Name C-102 Material loaded SiO2 Capacity 21.50 ton/h 5.972 Speed 81.52 ft/min 0.414 Required mass flow 21.50 ton/h 5.972 Maximum mass flow 31.65 ton/h 8.792 Width 42 in 1.0668 Angle 1 0 0 Angle 2 5 5 Length 1 1200 ft 365.760 Length 2 60 ft 18.288 Height 10 ft 3.048 Power 8.11 Hp 5.962 Belt material SL-516

3.4.3

kg/s m/s kg/s kg/s m

m m m kW

Belt Conveyor C-103 Table 3.9 Specification of Belt Conveyor C-103 Equipment Specification C-103 Name Material loaded Coal Capacity 0.60 ton/h 0.168

kg/s

Speed

5.37

ft/min

0.027

m/s

Required mass flow

0.60

ton/h

0.168

kg/s

13.51

ton/h

3.753

kg/s

30 0 5

in

0.762 0 5

m

Length 1

1200

ft

365.760

m

Length 2

60

ft

18.288

m

Maximum mass flow Width Angle 1 Angle 2

Height Power Belt material

10 1.10

ft Hp

3.048 0.807

m kW

SL-516


52 3.4.4

Belt Conveyor C-104 Table 3.10 Specification of Belt Conveyor C-104

Equipment Specification C-104

Name Material loaded

CaCO3 Parameters

Capacity Speed Required mass flow Maximum mass flow

ton/h

2.153

kg/s

68.84

ft/min

0.350

m/s

7.75

ton/h

2.153

kg/s

13.51

ton/h

3.753

kg/s

in

0.762 0

m

Width Angle 1

30 0

Angle 2

5

5

Length 1

1200

ft

365.760

m

Length 2

60

ft

18.288

m

Height

10

ft

3.048

m

Power

4.61

Hp

3.392

kW

Belt material

3.4.5

7.75

SL-516


Equipment Specification C-105 Name Material loaded Coal Capacity 1.96 ton/h 0.544 kg/s Speed 17.39 ft/min 0.088 m/s Required mass flow 1.96 ton/h 0.544 kg/s Maximum mass flow 13.51 ton/h 3.753 kg/s Width 30 in 0.762 m Angle 1 0 0 Angle 2 5 5 Length 1 1200 ft 365.760 m Length 2 60 ft 18.288 m Height 10 ft 3.048 m Power 1.76 Hp 1.297 kW Belt material SL-516


53 3.4.6


Equipment Specification C-106 Name Material loaded Coal

3.4.7

Capacity Speed Required mass flow

0.02 0.18 0.02

ton/h ft/min ton/h

0.006 kg/s 0.001 m/s 0.006 kg/s

Maximum mass flow

13.51

ton/h

3.753

Width Angle 1 Angle 2 Length 1 Length 2 Height Power Belt material

30 0 5 1200 0 10 0.81

in

kg/s

0.762 m 0 5 365.760 m 0.000 m 3.048 m 0.596 kW

ft ft ft Hp

SL-516


Equipment Specification C-107 Name Material loaded Cu

Capacity

36.72

ton/h

10.200

kg/s

Speed

96.12

ft/min

0.488

m/s

Required mass flow

44.06

ton/h

12.240

kg/s

Maximum mass flow

45.84

ton/h

12.733

kg/s

in

1.2192 0

m

Width Angle 1

48 0

Angle 2

0

0

Length 1

200

ft

60.960

m

Length 2

0

ft

0.000

m

Height

0

ft

0.000

m

Power

2.41

Hp

1.773

kW

Belt material

SL-516


54 3.4.7


Equipment Specification C-108 Name Material loaded Cu Capacity 36.50 ton/h 10.139 Speed 95.55 ft/min 0.485 Required mass flow 36.50 ton/h 10.139 Maximum mass flow 45.84 ton/h 12.733 Width 48 in 1.2192 Angle 1 0 0 Angle 2 0 0 Length 1 200 ft 60.960 Length 2 0 ft 0.000 Height 0 ft 0.000 Power 2.60 Hp 1.915 Belt material SL-516

3.5

Adsorber Column

3.5.1

Adsorber Column R-201

kg/s m/s kg/s kg/s m

m m m kW

Table 3.15 Specification of Adsorber Column R-201

R-201

Name Vessels

1 Number Insulation type External Insulation 2.029721 m Diameter 6.089162 m Height Adsorbent Bed Ag-A Zeolit Type Mass per vessel 6.892357 tonne 700 kg/m3 Density Operation 5 bar Pressure o 29 C Temperature 240 min Duration


55 3.5.1

Adsorber Column R-202 Table 3.16 Specification of Adsorber Column R-202

R-202

Name Vessels

1

Number Insulation type

External Insulation

Diameter

2.029721

m

Height

6.089162

m

Adsorbent Bed

Ag-A Zeolit

Type Mass per vessel

6.892357

tonne

Density

700

kg/m3

Operation Pressure

5

bar

Temperature

29

o

Duration

240

min

3.6

Absorber Column

3.6.1

Absorber Column R-302

C

Table 3.17 Specification of Absorber Column R-302 Equipment Specification

Name

Absorber Column

Code

R-302 To absorb SO3 and produce H2SO4

Function Number of Unit

1

Material Type

Carbon Steel Packing Packing Width and Height

Tower Diameter

3.09361374

m

Height of Packing

11.88847672

m

Permissible Tensile Stress

kg/cm2

Mechanical Design

Working Pressure

101300

N/m2

Design Pressure

106365

N/m2

0.106365

N/mm2

Permissible Stress

950

N/mm2

Join Eff (j)

0.85


56 Table 3.17 Specification of Absorber Column R-302 ( cont’d)

Corrosion Allowance Outer Diameter

3 3.15361374

Operating Condition

200

o

C

80

o

C

Output Gas,T

81

o

C

Output H2SO4, T

111

o

C

H2SO4 Production

0.98

Input Gas, T Input H2SO4, T

3.6.1

Absorber Column R-303 Table 3.18 Specification of Absorber Column R-303 Equipment Specification

Name

Absorber Column

Code

R-303

Function To absorb SO3 and produce H2SO4 Number of Unit

1

Material Type

Carbon Steel Packing Packing Width and Height

Tower Diameter

3.09361374

m

Height of Packing

11.88847672

m

Permissible Tensile Stress

kg/cm2

Mechanical Design

Working Pressure

101300

N/m2

Design Pressure

106365

N/m2

0.106365

N/mm2

Permissible Stress

950

N/mm2

Join Eff (j)

0.85

Corrosion Allowance Outer Diameter

3 3.15361374

Operating Condition

Input Gas, T

200

o

C

Input H2SO4, T

80

o

C

Output Gas,T

81

o

C

Output H2SO4, T

111

o

C

H2SO4 Production

0.98


57 3.7

Packed Bed Reactor Table 3.19 Specification of Packed Bed Reactor R-301 Equipment Specification

Code Function Number of Units Operation Type

R-301 Oxidation of Sulfur Dioxide 1 Continuous Packed Bed Reactor

Operational Data

Inlet Temperature (oC)

439

Outlet Temperature ( oC) Pressure (bar)

500 2

Catalyst

Type Weight (kg)

V2O5 42165

Density (lb/ft3)

33.8 8

Diameter (mm) Dimension

3.8

Number of Bed Diameter (m) Total Height (m) Height of bed 1

4 3.133 12.5 3.510013

Height of bed 2

3.384656

Height of bed 3 Height of bed 4

3.13394 2.507152

Filter Equipment Table 3.20 Specification of Cyclone FG-301 Equipment Specification

Name Function

FG-301 Separate atmosphere air with dust and other solid particle Fluid Data

Volume Flow

362.5

Density of gas

1225

Density of solid

8930 kg/m3

Particle Diameter

50 mikron Dimension

Diameter Cyclone

53.26 cm


58 Table 3.20 Specification of Cyclone FG-301 ( cont’d) Dimension

3.9

Diameter Collecting Hopper (Dc)

12.95 cm

A

6.475 cm

W

1.67 cm

Do

6.475 cm

Hc

19.425 cm

H

32.375 cm

B

4.856 cm

Heat Exchanger Table 3.21 Specification of E-101

3.9.1

E-101Equipment Specification

Equipment Code

Construction - Each Shell

E-101

Material

carbon steel

Type

Shell and Tube

Total Fluid Enter

kg/hr

Vapor Phase In Vapor Phase Out

bar

Design Temperature

o

Shell Side

Tube Side

Flue Gas

Cooling Water

77500

62500

1

1

0.9908

1

1

4

m

3

Heat Transfer Area

m2

23.38

Baffle Information

Temperature Out

o

C

1000

350

Baffle Cut

Pa.s

0.00006

0.00002

kJ/kgK

0.90

2.06

Pressure

bar

2

3

Velocity

m/s

0.75

Pressure Drop

bar m 2K/W

Overall Coeff.

500

Length

Baffle Spacing

Heat Exchanged

1400

0.686

148

Fouling Resistance

6

m

1200

Specific Heat

4

ID

o

Viscosity

Tube Side

Shell Construction Information

Temperature In

C

C

Passes per Shell

Performance of One Unit

Fluid Allocation

Design Pressure

Shell Side

mm

342.77

%

45.00

Tube Information

Tubecount per Shell

50

Inside Diameter

mm

44.8

9.04

Outside Diameter

mm

50.0

0.35

0.41

Pitch

mm

67.5

0.000250

0.000125

kW

4816.93

W/m2K

232.71

Pitch Type

LMTD

triangular pitch

K

843


59 3.9.2

E-201 Table 3.22 Specification of E-201 Equipment Specification

Equipment Code


E-201

Material

carbon steel

Type

bar

Design Pressure

Shell and Tube

o

C

Design Temperature Passes per Shell


Shell Side

Tube Side

5

6

250

120

1

2

Shell Side

Tube Side

Air

Cooling Water

ID

m

318800

286600

Length

m

1.5625

Vapor Phase In

1

0

Heat Transfer Area

m2

91.13

Vapor Phase Out

1

0

o

152

32

o

120

40.5

Fluid Allocation kg/hr

Total Fluid Enter

C

Temperature In

C

Temperature Out

Pa.s

Viscosity

0.00024


0.790

Baffle Information

Baffle Spacing Baffle Cut

0.00764

mm

394.76

%

45.00

Tube Information

kJ/kgK

1.02

4.23

Pressure

bar

2.5

2

Inside Diameter

mm

34.0

Velocity

m/s

0.88

8.92

Outside Diameter

mm

38

Pressure Drop

bar

0.50

0.14

Pitch

mm

51.3

0.000167

0.000125

Specific Heat

2

m K/W

Fouling Resistance

kW

Heat Exchanged

3.9.3

153

Pitch Type

triangular pitch

3602.44

2

Overall Coeff.

Tubecount per Shell

W/m K

233.07

LMTD

K

99

E-202 Table 3 23 Specification of E-202 Equipment Specification

Equipment Code


E-202

Material

carbon steel

Type

Shell and Tube

Design Temperature

Total Fluid Enter

kg/hr

Vapor Phase In

Temperature In Temperature Out Viscosity

Shell Side

Tube Side

Air

Cooling Water

318800

21970

1

0

Baffle Cut

Pa.s

0.00023

0.00955

m/s

0.34

Pressure Drop

bar

Overall Coeff.

412.01

Baffle Spacing

Velocity

Heat Exchanged

m2

65

Pressure

Fouling Resistance

Heat Transfer Area

95

2

2

m K/W

4

1.74

C

2.5

1

m

o

bar

120

Length

22

4.20

250

1.003

120

1.01

6

m

0

kJ/kgK

Specific Heat

5

ID

1 C

C

Tube Side


o

Vapor Phase Out

o

Passes per Shell


Fluid Allocation

bar

Design Pressure

Shell Side

Baffle Information

mm

501.40

%

45.00

Tube Information

Tubecount per Shell

132

Inside Diameter

mm

46.0

9.72

Outside Diameter

mm

50

0.42

0.42

Pitch

mm

67.5

0.000167

0.000125

kW

3357.36

W/m2K

225

Pitch Type LMTD

triangular pitch K

60.64


60 3.9.4


Equipment Code


E-203

Material

carbon steel

Type

kg/hr

Total Fluid Enter

Shell Side

Tube Side

Air

Cooling Water

318800

33330

Length

m

1.5

95

35

Baffle Spacing

o

C

65

55

Baffle Cut

Pa.s

0.00022

0.00013

kJ/kgK

1.01

2.30

Pressure

bar

2.5

2

Velocity

m/s

0.48

Pressure Drop

bar

Viscosity Specific Heat

Fouling Resistance

m K/W

m

Heat Transfer Area

244.16

Baffle Information

mm

455.99

%

45.00

Tube Information

Tubecount per Shell

104 mm

46.0

8.54

Outside Diameter

mm

50

0.08

0.07

Pitch

mm

67.5

0.000167

0.000125

Pitch Type

triangular pitch

3207.32

2

W/m K

Overall Coeff.

2

Inside Diameter

kW

Heat Exchanged

3.9.5

2

4

0.912

o

Temperature Out

1

m

1

C

250

ID

0.9908

Temperature In

250

C


1

Vapor Phase Out

6

Passes per Shell

1

Vapor Phase In

5

o

Design Temperature


Fluid Allocation

Tube Side

bar

Design Pressure

Shell and Tube

Shell Side

225

LMTD

K

45


Equipment Code


E-204

Material

carbon steel

Type

bar

Design Pressure

Shell and Tube

Design Temperature

o

C

Passes per Shell


Shell Side

Tube Side

5

6

150

300

1

4

Shell Side

Tube Side

Air

Cooling Water

318800

33330

Vapor Phase In

1

1

Vapor Phase Out

1

1

o

65

35

Baffle Spacing

o

C

32

80

Baffle Cut

Pa.s

0.00020

0.00015

kJ/kgK

39.00

37.00

Pressure

bar

2.5

2

Inside Diameter

mm

46.0

Velocity

m/s

0.45

8.54

Outside Diameter

mm

50

Pressure Drop

bar

0.32

0.23

Pitch

mm

67.5

0.000167

0.000125

Fluid Allocation Total Fluid Enter

Temperature In Temperature Out Viscosity Specific Heat

Fouling Resistance Heat Exchanged Overall Coeff.

kg/hr

C

2

m K/W kW

4246.38

2

263.34

W/m K


ID

m

1.094

Length

m

1.875

Heat Transfer Area

m2

461.38

Baffle Information

mm

547.07

%

45.00

Tube Information

Tubecount per Shell

164

Pitch Type

LMTD

triangular pitch

K

85


61 3.9.6


Equipment Code


E-205

Material

carbon steel

Type

Tube Side

Air

Cooling Water

318800

280600

1

0

Vapor Phase In

5

200

100

1

2

C

Passes per Shell

Shell Side kg/hr

Total Fluid Enter

8

o

Design Temperature


Fluid Allocation

Tube Side

bar

Design Pressure

Shell and Tube

Shell Side


ID

m

1.283

Length

m

1.67

Heat Transfer Area

m2

634.80

1

0

o

124

31

Baffle Spacing

o

C

80

43

Baffle Cut

Pa.s

0.00023

0.00780

kJ/kgK

1.01

4.23

Pressure

bar

5

2

Inside Diameter

mm

46.0

Velocity

m/s

0.47

9.92

Outside Diameter

mm

50

Pressure Drop

bar

0.48

0.06

Pitch

mm

67.5

0.000167

0.000125

Vapor Phase Out C


2

m K/W

Fouling Resistance Heat Exchanged

3950.99

2

234.87

W/m K

Overall Coeff.

3.9.7

kW

Baffle Information

mm

641.62

%

45.00

Tube Information

Tubecount per Shell

270

Pitch Type

triangular pitch

LMTD

K

62



E-206

Shell Side

Tube Side

8

5

150

100

1

4

Equipment Code Material

carbon steel

Type

Shell and Tube

Design Temperature

Total Fluid Enter

kg/hr

Vapor Phase In

Temperature In Temperature Out Viscosity

Shell Side

Tube Side

Air

Cooling Water

318800

33510

1

0

Length

m

1.4

Heat Transfer Area

m2

470.76

23

Baffle Spacing

o

55

56

Baffle Cut

C

Pa.s

0.00021

Baffle Information

0.00930 4.20

Pressure

bar

5

2

Velocity

m/s

0.65

Pressure Drop Fouling Resistance

bar m2K/W

Overall Coeff.

0.846

80

1.01

Heat Exchanged

m

0

kJ/kgK

Specific Heat

ID

1 C

C


o

Vapor Phase Out

o

Passes per Shell


Fluid Allocation

bar

Design Pressure

mm

423.04

%

45.00

Tube Information

Tubecount per Shell

86

Inside Diameter

mm

46.0

9.79

Outside Diameter

mm

50

0.45

0.45

Pitch

mm

67.5

0.000167

0.000125

kW

2227.17

W/m2K

206.55

Pitch Type

LMTD

triangular pitch

K

22


62 3.9.8


Equipment Code


E-207

Material

carbon steel

Type

Shell and Tube

Design Temperature

kg/hr

Total Fluid Enter Vapor Phase In

o

C

Passes per Shell


Fluid Allocation

bar

Design Pressure

Shell Side

Tube Side

Air

Cooling Water

318800

33510

1

0

Shell Side

Tube Side

8

5

150

150

1

4


ID

m

0.905

Length

m

1.55

Heat Transfer Area

2

m

437.59

1

0

Temperature In

o

55

35

Baffle Spacing

Temperature Out

o

C

32

74

Baffle Cut

Pa.s

0.00020

0.00617

kJ/kgK

1.00

4.23

Pressure

bar

5

2

Inside Diameter

mm

46.0

Velocity

m/s

0.63

9.32

Outside Diameter

mm

50

Pressure Drop

bar

0.48

0.46

Pitch

mm

67.5

m2K/W

0.000167

0.000125

Vapor Phase Out C

Viscosity Specific Heat

Fouling Resistance

kW

Heat Exchanged

3.9.9

mm

452.50

%

45.00

Tube Information

Tubecount per Shell

102

Pitch Type

triangular pitch

2040.85

2

W/m K

Overall Coeff.

Baffle Information

193.12

LMTD

K

25


Equipment Code


E-301

Material

carbon steel

Type

Shell and Tube

Design Temperature

Total Fluid Enter

kg/hr

Shell Side

Tube Side

SO2 Gas

Cooling Water

77500

29170

ID Length

1

1

Vapor Phase Out

1

1

o

1000

254

Baffle Spacing

o

C

900

370

Baffle Cut

Pa.s

0.00050

0.00039

kJ/kgK

0.88

2.00

Pressure

bar

2

2

Velocity

m/s

0.97

Pressure Drop

bar

Temperature Out Viscosity Specific Heat


C

2

m K/W

5

5

1100

450

1

2

m

0.710

m

2.50

2

m

Heat Transfer Area

25.03

Baffle Information

mm

354.85

%

45.00

Tube Information

Tubecount per Shell

64

Inside Diameter

mm

46.0

9.20

Outside Diameter

mm

50

0.43

0.44

Pitch

mm

67.5

0.000250

0.000125

kW

2828.75

2

149.25

W/m K

C

Tube Side


Vapor Phase In

Temperature In

o

Passes per Shell


Fluid Allocation

bar

Design Pressure

Shell Side

Pitch Type LMTD

triangular pitch K

643


63 3.9.10 E-302 Table 3.30 Specification of E-302 Equipment Specification

Equipment Code


E-302

Material

carbon steel

Type

Shell and Tube

Design Temperature

kg/hr


o

C

Passes per Shell


Fluid Allocation

bar

Design Pressure

Shell Side

Tube Side

SO2 Gas

Cooling Water

77500

33330

1

1

Shell Side

Tube Side

5

5

1000

300

1

2


ID

m

0.613

Length

m

1.50

Heat Transfer Area

m2

28.78

1

1

o

900

114

Baffle Spacing

o

C

750

261

Baffle Cut

Pa.s

0.00048

0.00013

kJ/kgK

0.87

2.23

Pressure

bar

2

2

Inside Diameter

mm

34.0

Velocity

m/s

1.00

9.78

Outside Diameter

mm

38

Pressure Drop

bar

0.45

0.40

Pitch

mm

51.3

0.000250

0.000125

Vapor Phase Out C


Fouling Resistance

2

m K/W kW

Heat Exchanged

mm

306.72

%

45.00

Tube Information

Tubecount per Shell

81

Pitch Type

triangular pitch

3363.50

2

W/m K

Overall Coeff.

Baffle Information

153.59

LMTD

K

630

3.9.11 E-303 Table 3.31 Specification of E-303 Equipment Specification

Equipment Code


E-303

Material

carbon steel

Type

Shell and Tube

Design Temperature

Total Fluid Enter

kg/hr

Vapor Phase In

Shell Side

Tube Side

SO2 Gas

Cooling Water

77500

286600

1

0

Heat Transfer Area

m2

93.63

C

500

45

Baffle Cut

Pa.s

0.00043

0.07640

kJ/kgK

0.85

4.23

Pressure

bar

2

2

Velocity

m/s

0.99

Pressure Drop

bar


m K/W

Baffle Information

mm

400.95

%

45.00

Tube Information

Tubecount per Shell

75

Inside Diameter

mm

46.0

8.92

Outside Diameter

mm

50

0.49

0.28

Pitch

mm

67.5

0.000250

0.000125

kW

4596.18

2

158.52

W/m K

4

1.48

Baffle Spacing

2

1

m

o

Specific Heat

100

Length

32

Viscosity

900

0.802

750

Temperature Out

5

m

0

Temperature In

5

ID

1 C

C

Tube Side


o

Vapor Phase Out

o

Passes per Shell


Fluid Allocation

bar

Design Pressure

Shell Side

Pitch Type LMTD

triangular pitch K

577



Equipment Code


E-304

Material

carbon steel

Type

Shell and Tube

Design Temperature

kg/hr


Shell Side

Tube Side

SO2 Gas

Cooling Water

77500

29170

1

1

Heat Transfer Area

Baffle Spacing

377

254

Baffle Cut

Pa.s

0.00034

0.00013

kJ/kgK

0.82

2.19

Pressure

bar

2

2

Velocity

m/s

0.89

Pressure Drop

bar

Fouling Resistance

m K/W

m

75.57

Baffle Information

mm

443.59

%

45.00

Tube Information

Tubecount per Shell

97 mm

46.0

9.78

Outside Diameter

mm

50

0.43

0.46

Pitch

mm

67.5

0.000250

0.000125

Pitch Type

triangular pitch

2697.57

2

W/m K

Overall Coeff.

2

Inside Diameter

kW

Heat Exchanged

4

1.25

C

2

1

m

o

Specific Heat

300

Length

125

Viscosity

700

0.887

500

Temperature Out

5

m

1

C

5

ID

1

Temperature In

C

Tube Side


o

Vapor Phase Out

o

Passes per Shell


Fluid Allocation

bar

Design Pressure

Shell Side

150

LMTD

K

540


Equipment Code


E-305

Material

carbon steel

Type

bar

Design Pressure

Shell and Tube

Design Temperature

o

C

Passes per Shell


Shell Side

Tube Side

5

5

850

250

1

4

Shell Side

Tube Side

SO2 Gas

Cooling Water

106700

33330

Vapor Phase In

1

1

Vapor Phase Out

1

0.185

o

775

27

Baffle Spacing

o

C

357

115

Baffle Cut

Pa.s

0.00044

0.00850

kJ/kgK

0.86

4.20

Pressure

bar

2

2

Inside Diameter

mm

46.0

Velocity

m/s

0.72

17.32

Outside Diameter

mm

50

Pressure Drop

bar

0.20

1.53

Pitch

mm

62.5

0.000250

0.000125




kg/hr

C

2

m K/W kW 2

W/m K


ID

m

0.984

Length

m

1.75

Heat Transfer Area

m2

137.55

Baffle Information

mm

196.86

%

45.00

Tube Information

Tubecount per Shell

126

Pitch Type

triangular pitch

12726.04 190

LMTD

K

462



Equipment Code


E-306

Material

carbon steel

Type

Shell and Tube

Design Temperature

kg/hr


o

C

Passes per Shell


Fluid Allocation

bar

Design Pressure

Shell Side

Tube Side

SO3 Gas

Cooling Water

106700

33330

1

0.185

Shell Side

Tube Side

5

5

750

350

1

4


ID

m

0.838

Length

m

2

Heat Transfer Area

2

m

131.12

1

0.8343

o

633

115

o

C

327

293.5

Pa.s

0.00040

0.00240

kJ/kgK

0.84

4.00

Pressure

bar

2

2

Inside Diameter

mm

46.0

Velocity

m/s

2.25

30.47

Outside Diameter

mm

50

Pressure Drop

bar

4.17

0.30

Pitch

mm

65

m2K/W

0.000250

0.000125

Vapor Phase Out C


Fouling Resistance

kW

Heat Exchanged


mm

335.32

%

45.00

Tube Information

Tubecount per Shell

84

Pitch Type

triangular pitch

9142.06

2

W/m K

Overall Coeff.

Baffle Information

200

LMTD

K

342


Equipment Code


E-307

Material

carbon steel

Type

bar

Design Pressure

Shell and Tube

Design Temperature

o

C

Passes per Shell


Shell Side

Tube Side

5

5

600

220

1

2

Shell Side

Tube Side

SO3 Gas

Cooling Water

106700

21970

Vapor Phase In

1

0

Vapor Phase Out

1

0

o

478.5

22

Baffle Spacing

o

C

317

117

Baffle Cut

Pa.s

0.00033

0.00950

kJ/kgK

0.81

4.20

Pressure

bar

2

2

Inside Diameter

mm

46.0

Velocity

m/s

1.00

9.98

Outside Diameter

mm

50

Pressure Drop

bar

0.48

0.04

Pitch

mm

62.5

0.000250

0.000125




kg/hr

C

2

m K/W kW 2

W/m K


ID

m

0.663

Length

m

2.5

Heat Transfer Area

m2

41.65

Baffle Information

mm

165.87

%

45.00

Tube Information

Tubecount per Shell

54

Pitch Type

triangular pitch

4652.65 250

LMTD

K

320



Equipment Code


E-308

Material

carbon steel

Type

Shell and Tube

Design Temperature

kg/hr


Shell Side

Tube Side

SO3 Gas

Cooling Water

106700

21970

1

0

Heat Transfer Area

m2

467.34

C

127

125

Baffle Cut

Pa.s

0.00026

0.00236

kJ/kgK

0.76

4.20

Pressure

bar

2

2

Velocity

m/s

5.76

144.48

Pressure Drop

bar

203.50

1.05

0.000250

0.000125


m K/W kW

4777.67

W/m2K

192.04

4

2

Baffle Spacing

2

1

m

o

Specific Heat

250

Length

117

Viscosity

500

0.802

329

Temperature Out

5

m

0.24

Temperature In

5

ID

1 C

C

Tube Side


o

Vapor Phase Out

o

Passes per Shell


Fluid Allocation

bar

Design Pressure

Shell Side

Baffle Information

mm

200.48

%

45.00

Tube Information

Tubecount per Shell

75

Inside Diameter

mm

46.0

Outside Diameter

mm

50

Pitch

mm

62.5

Pitch Type

triangular pitch

LMTD

K

157


Equipment Code


E-401

Material

carbon steel

Type

Shell and Tube

Design Temperature

Total Fluid Enter

kg/hr

Vapor Phase In

o

C

Passes per Shell


Fluid Allocation

bar

Design Pressure

Shell Side

Tube Side

Steam

Cooling Water

41670

62500

1

0

Shell Side

Tube Side

5

5

350

200

1

4


ID

m

0.884

Length

m

2

Heat Transfer Area

m2

30.01

0

0.5

o

276

78

Baffle Spacing

o

C

132

150

Baffle Cut

Pa.s

0.00019

0.00356

kJ/kgK

1.99

4.18

Pressure

bar

2

2

Inside Diameter

mm

46.0

Velocity

m/s

0.88

8.96

Outside Diameter

mm

50

Pressure Drop

bar

0.43

0.01

Pitch

mm

67.5

0.000167

0.000125

Vapor Phase Out Temperature In Temperature Out Viscosity Specific Heat


C

2

m K/W kW

3346.31

2

2000.00

W/m K

Baffle Information

mm

441.78

%

45.00

Tube Information

Tubecount per Shell

96

Pitch Type LMTD

triangular pitch K

55



Equipment Code


E-402

Material

carbon steel

Type

Total Fluid Enter

kg/hr

Steam

ID

m

0.756

41670

62500

Length

m

2

1

0.5

150

Baffle Spacing

C

276

280

Baffle Cut

Pa.s

0.00019

0.00019

kJ/kgK

2.40

4.90

Pressure

bar

2

2

Velocity

m/s

0.87

Pressure Drop

bar

Fouling Resistance Heat Exchanged

2

m K/W

m

23.35

Baffle Information

mm

378.08

%

45.00

Tube Information

Tubecount per Shell

75

Inside Diameter

mm

46.0

8.98

Outside Diameter

mm

50

0.44

0.02

Pitch

mm

67.5

0.000167

0.000125

kW

2261.55

2

1790.00

W/m K

Overall Coeff.

2

Heat Transfer Area

350

Specific Heat

2

Steam

o

Viscosity

1


1

Temperature Out

350

Tube Side

0.9908 C

450

C

Passes per Shell

o

Temperature In

5

Shell Side


5

o

Design Temperature


Fluid Allocation

Tube Side

bar

Design Pressure

Shell and Tube

Shell Side

Pitch Type

triangular pitch

LMTD

K

74


Equipment Code


E-403

Material

carbon steel

Type

Shell and Tube

Design Temperature

Total Fluid Enter

kg/hr

0.706

62500

62500

Length

m

1.5

280

Baffle Spacing

C

421

320

Baffle Cut

Pa.s

0.00028

0.00019

kJ/kgK

2.13

4.00

Pressure

bar

2

2

Velocity

m/s

0.72

Pressure Drop

bar m2K/W


Heat Transfer Area

2

m

12.63

Baffle Information

mm

353.03

%

45.00

Tube Information

Tubecount per Shell

54

Inside Diameter

mm

46.0

9.04

Outside Diameter

mm

50

0.42

0.49

Pitch

mm

67.5

0.000167

0.000125

kW

2837.76

2

1870.00

W/m K

4

m

485

Specific Heat

1

ID

o

Viscosity

400

Steam

o

Temperature Out

550

Steam

1

C

5


0.9908

Temperature In

5

Tube Side

1

Vapor Phase Out

C

Tube Side

Shell Side

1

Vapor Phase In

o

Passes per Shell


Fluid Allocation

bar

Design Pressure

Shell Side

Pitch Type LMTD

triangular pitch K

150



Equipment Code


E-404

Material

carbon steel

Type

kg/hr

Total Fluid Enter

Tube Side

Temperature In Temperature Out Viscosity Specific Heat Pressure Velocity Pressure Drop Fouling Resistance Heat Exchanged Overall Coeff.

500

1

4

Steam

Steam

ID

m

0.850

62500

62500

Length

m

1.5

2

1

m Heat Transfer Area Baffle Information

20.33

mm

424.97

%

45.00

0.9908

1

580

320

Baffle Spacing

o

C

485

400

Baffle Cut

Pa.s

0.00032

0.00021

kJ/kgK

2.20

2.90

bar

2

2

m/s bar m 2K/W kW W/m2K

650

C


o

C

5

o

Design Temperature

1


5

Passes per Shell

Performance of One Unit Shell Side

Fluid Allocation

Tube Side

bar

Design Pressure

Shell and Tube

Shell Side

36.35 0.11 1.86 0.00 0.000167 0.000125 4354.60 1780.00

Tube Information

Tubecount per Shell

87

Inside Diameter Outside Diameter Pitch Pitch Type

mm mm mm

46.0 50 67.5 triangular pitch

K

165

LMTD


Equipment Code


E-405

Material

carbon steel

Type

Shell and Tube

Design Temperature

Total Fluid Enter

kg/hr

Vapor Phase In

Shell Side

Tube Side

Steam

Cooling Water

62500

250000

0.95

0

0

0

o

81

32

o

C

78

78.2

Pa.s

0.00020

0.00760

kJ/kgK

39.00

37.00

Pressure

bar

2

2

Velocity

m/s

0.72

Pressure Drop

bar

Vapor Phase Out Temperature In Temperature Out Viscosity Specific Heat


C

2

m K/W

o

C

Passes per Shell


Fluid Allocation

bar

Design Pressure

Shell Side

Tube Side

5

5

150

150

1

4


ID

m

0.861

Length

m

2

Heat Transfer Area

m2

423.75

Baffle Information


mm

430.67

%

45.00

Tube Information

Tubecount per Shell

90

Inside Diameter

mm

46.0

7.46

Outside Diameter

mm

50

0.89

0.14

Pitch

mm

67.5

0.000167

0.000125

kW

2292.20

W/m2K

425

Pitch Type

LMTD

triangular pitch

K

14


69 3.10

Storage Tank

3.10.1 Storage Tank T-201 Table 3.42 Specificatin of Storage Tank for Sulfuric Acid Equipment Specification

Equipment Name

Sulfuric Acid Tank

Equipment Code

T-201

Storage Type

Liquid Storage

Function

Storage for H2SO4

Number of Unit

1

Material

Carbon Steel SA 167

Type of Tank

Cylinder Vertical Concrete Foundation

Type od Head

Flat Head

Operation Data

Temperature (oC)

30

Pressure (bar)

2

Mass Flow (kg/h)

28437.5

Bulk Density (kg/m3)

1842

Dimension

Capacity (kg/h)

682500

Volume tank (m3)

407.5732899

Volume of Liquid in Tank (m 3)

370.5211726

Tank Diameter (m)

6.377302582

Tank Height (m)

12.75460516

Height of Liquid in Tank (m)

11.47914465

Design Pressure (bar)

3.532994666 25.29

Hydrostatic Pressure (bar)

2.072169275

Shell Thickness (in)

0.212035665

Head Thickness (in)

0.742124829

3.10.2 Storage Tank T-402 Table 3.43 Specification of Storage Tank for Demineralize Water Equipment Specification

Equipment Name

Demineralize Water Tank

Equipment Code

T-402

Storage Type

Liquid Storage

Function

Storage for Demineralize Water

Number of Unit

2 Universitas Indonesia

70 \ Table 3.43 Specification of Storage Tank for Demineralize Water ( cont’d) Equipment Specification

Material

Carbon Steel SA 167 Cylinder Vertical Concrete Foundation

Type of Tank Type od Head

Flat Head Operation Data

Temperature (oC)

30 2

Pressure (bar) Mass Flow (kg/h)

890475 3

Bulk Density (kg/m )

1004 Dimension

Capacity (kg/h)

890475

Volume tank (m3)

975.6200199 3

Volume of Liquid in Tank (m )

886.9272908

Tank Diameter (m)

8.530909854

Tank Height (m)

17.06181971

Height of Liquid in Tank (m)

15.35563774

Design Pressure (bar)

2.887502694

Hydrostatic pressure (bar) Shell Thickness (in)

1.510871908 0.526092676

Head Thickness (in)

1.841324367

3.11 Warehouse 3.11.1 Warehouse TK-101 Table 3.44 Specification of Warehouse TK-101

Equipment Name Equipment Code Function Number of Unit Type Temperature Pressure Bulk Density Capacity Length Width Height

Equipment Specification Slag Warehouse

TK-101 store for slag 1 Rectangle building with a triangular prism roofs Operation Data 30°C 1 atm 3848.41 kg/ m3 Dimension 31,987.5 tons 37 m 28 m 10 m


71 3.11.2 Warehouse TK-102 Table 3.45 Specification of Warehouse TK-102 Equipment Specification Equipment Name Anode Warehouse Equipment Code TK-102 Function Store for Anode Slime Number of Unit 1 Type Rectangle building with a triangular prism roofs Operation Data Temperature 30°C Pressure 1 atm Bulk Density 5000 kg/ m3 Dimension Capacity 157.5 tons Length 6 m Width 4.5 m Height 2 m

3.11.3 Warehouse TK-103 Table 3.46 Specification of Warehouse TK-103 Equipment Specification Equipment Name Copper Cathode Warehouse Equipment Code TK-103 Function Store for Copper Cathode Number of Unit 1 Type Rectangle building with a triangular prism roofs Operation Data Temperature 30°C Pressure 1 atm Bulk Density 8930 kg/ m3 Dimension Capacity 26280 tons Length 26.5 m Width 20 m Height 7 m

3.12

Coagulant Tank Table 3.47 Specification of Coagulant Tank Equipment Specification

Equipment Name

Coagulant Tank

Equipment Code

T-501

Number of Vessel

4

Type

Rigid Base Circular


72 Table 3.47 Specification of Coagulant Tank (cont’d) Determination of Diameter of the Water Tank

Mass Flow Rate

222618.75

kg/h

Density

1004

Volume

221.73

m3

Height

4.40

m

Diameter

8.40

m

Free board

0.40

m

Wall Thickness

kg/m3

6

mm

6

mm

Design of Base

Thickness of base

3.13

Filtration Tank Table 3.48 Specification of Filtration Tank Equipment Specification

Equipment Name

Filtration Tank

Equipment Code

T-502

Function

To Filter Suspended Solid (SS)

Number of Unit

4 Filter Specification

Filter Type

Slow Sand Filter

Total Surface Area (m2) Max. Surface Per filter (m2)

267.1425 50

Number of Filters

6

Surface Area per Filter (m2)

44.53

Dimension

Filtration Rate (m/h) Required Tank Area (m2)

3.14

0.2 356.19

Long (m)

25

Width (m)

15

Height (m)

2.4

Ion Exchanger Tank Table 3.49 Specification of Demine Water Tank Equipment Specification

Equipment Name Equipment Code Function

Ion Exchanger V-502 & V-503 To remove Cation and Anion Universitas Indonesia

73 Table 3.49 Specification of Demine Water Tank (cont’d)

Number of Unit

2

Operation Data Cation Concentration

Use degasifier (Yes/No) Anion Concentration Running time Throughput Flow rate Ionic Load Cation Load Anion Load Operating Capacity Cation regeneration with HCl Anion regeneration with NaOH Resin Volumes SAC SBA Specific Flow Rate SAC SBA

3.15

250 mq/L Yes 150.25 mq/L 15 h 19200 m3 4800000 eq 2884800 eq 1 eq/L 0.5 eq/L 4800000 L 5769600 L 5.1 h-1 4.72 h-1

High Pressure Turbine Table 3.50 Specification of Turbine T-401

Name Code

Steam turbine T-401 Reducing pressure to Function produce electricity Number of Unit 1 Operating Condition Inlet Temperature Up to 500 Celcius Inlet Pressure Up to 101 Bar Gas Flow Up to 15000 M3/h Unit Specification Shaft Speed Up to 3600 RPM Dimension (LxWxH) 1x1x1.3 RPM

3.16

Pump

3.16.1 P-301 Table 3.51 Specification of Pump P-301 Pump Identification

Name Code Function Amount (unit)

Pump P-301 Transfer water into E-307 1 Universitas Indonesia

74 Table 3.51 Specification of Pump P-301 (cont’d) Pump Identification

Mode of Operation Continuous Material Composition Type Fluid Liquid Operating Condisiton

Mass flow (kg/s) Flow rate (m3/s) Density (kg/m3) Temperature (oC)

8.102777778 0.008119444 997.3 22.12

Specification Design

Type Material NPSHa (m) Head (m)

Centrifugal CS A 285 10.48853423 22.27529913 Utility

FHP (kW) BHP (kW)

1.326614721 1.768819628

3.16.2 P-302 Table 3.52 Specification of Pump P-302 Pump Identification Code P-302 Function Transfer water into E-305 Amount (unit) 1 Mode of Operation Continuous Material Composition Type of fluid Water Operating Condition Mass flow (kg/s) 9.166666667 Flow rate (m3/s) 0.009277778 Density (kg/m3) 996.1 o Temperature ( C) 26.85 Specification Design Type Centrifugal Material CS A-285 NPSHa (m) 10.00451002 Head (m) 34.84116885 Utility FHP (kW) 2.347423751 BHP (kW) 3.129898335

3.16.3 P-201 Table 3.53 Specification Pump P-201

Name Code Function Amount (unit)

Pump Identification Pump

P-201 Transfer water into E-205 1 Universitas Indonesia

75 Table 3.53 Specification Pump P-201 (cont’d) Pump Identification Mode of Operation Continuous

Type fluid

Material Composition Water

Operating Condisiton Mass flow (kg/s) 79.44444444 Flow rate (m3/s) 0.079777778 Density (kg/m3) 994.6 o Temperature ( C) 32 Specification Design Type Centrifugal Material CS A-285 NPSHa (m) 12.70941704 Head (m) 9.197232794 Utility FHP (kW) 5.370417516 BHP (kW) 7.160556687

3.16.4 P-202 Table 3.54 Specification Pump P-202 Pump Identification

Name Code

Pump P-202

Function Amount (unit) Mode of Operation

1 Continuous

Material Composition

Type Fluid

Water Operating Condisiton

Mass flow (kg/hr) Flow rate (m3/s) Density (kg/m3) Temperature (oC)

280600 0.078111111 994.9 31

Specification Design

Type Material NPSHa (m) Head (m)

Centrifugal CS A-285 12.50132387 9.504604907 Utility

FHP (kW)

5.445108946


76 3.16.5 P-101 Table 3.55 Specification Pump P-101 Pump Identification

Name

Pump

Code Function

P-101 Transfer H2SO4 into electrolytic cell

Amount (unit)

1

Mode of Operation

Continuous

Operating Condiiton

Mass flow (kg/s)

52.77777778

Flow rate (m3/s)

0.028527778

Density (kg/m3)

1844

o

Temperature ( C)

26.85 Specification Design

Type

Centrifugal

Material

Metal

NPSHa (m)

14.66242959

Head (m)

17.05144771 Utility

FHP (kW)

0.661454076

BHP (kW)

0.881938767

3.16.5 P-101 Table 3.56 Specification Pump P-401

Name Code

Pump Identification Pump P-401

Function Transfer water into E-401 Amount (unit) 1 Mode of Operation Continuous Operating Conditon Mass flow (kg/s) 18.88888889 Flow rate (m3/s) 0.017397222 Density (kg/m3) 972.8 Temperature (oC) 35 Type Material NPSHa (m) Head (m)

Specification Design Multistage centrifugal Pump

Carbon steel 4.207051475 595.2029034 Utility

FHP (kW) BHP (kW)

99.16080371 110.1786708


77 3.16.5 P-501 Table 3.57 Specification Pump P-501 Pump Identification Pump P-501

Name Code Function

Take Water River

Amount (unit) 1 Mode of Operation Continuous Material Composition Type of Fluid Water River Operating Condition Mass flow (kg/s) 494.4444444 Flow rate (m3/s) 0.495555556 Density (kg/m3) 994.9 o Temperature ( C) 31 Specification Design Type Submerged Pump Material Carbon Steel NPSHa (m) 51.50248049 Head (m) 19.43797843 Utility FHP (kW)

70.64085329 94.18780439

BHP (kW)

3.17

Compressor

3.17.1 K-100 Table 3.58 Specification Compressor K-100 Equipment Specification

Code of Project

K-100

Function

To transfer heating media into heat exchanger

No. Unit

1

Type

Centrifugal

Material

CRA (corrosion Resistant Alloy) Operating Data

Compressor Power

474.375 kw

Efficiency (%)

75

Temperature Inlet (0C)

759.8

Temperature Outlet (0C)

776

Pressure Inlet (kPa)

154

Pressure Outlet (kPa)

165

Head (m)

1225


78 3.17.2 K-101 Table 3.59 Specification Compressor K-101 Equipment Specification

Code of Project

K-101

Function No. Unit

To transfer heating media into HE 1

Type

Centrifugal

Material

CRA (corrosion resistant Alloy) Operating Data

Compressor Power

41.309 kw

Efficiency (%)

75

Temperature Inlet (0C)

632.5

Temperature Outlet (0C)

633.9

Pressure Inlet (kPa)

135

Pressure outlet (kPa)

136

Head (m)

106


Code of Project

K-102

Function

To transfer heating media into HE

No. Unit

1

Type Material

Centrifugal CRA (corrosion resistant alloy) Operating Data

Compressor Power

161.636 kw

Efficiency (%) Temperature Inlet ( 0C)

75 472.8

Temperature Outlet ( 0C) Pressure inlet (kPa)

478.5 135


140

Head (m)

417


Code of Project

K-201

Function

To compress air atmosphere

No. Unit

1

Type

Reciprocating

Material

Carbon Steel Universitas Indonesia

79 Table 3.61 Specification Compressor K-201 (cont’d) Operating Data

Compressor Power

10808.5 kw

Efficiency (%)

75

Temperature Inlet 0 ( C) Temperature Outlet (0C) Pressure inlet (kPa)

31

100


250

Head (m)

9700

152.6


Code of Project Function No. Unit Type Material

K-202 To compress air from HE 1 Reciprocating Carbon Steel Operating Data Compressor Power 8181 kw Efficiency (%) 75 0 Temperature Inlet ( C) 32 0 Temperature Outlet ( C) 124.4 Pressure inlet (kPa) 245.2 Pressure Outlet (kPa) 500 Head (m) 7285

3.18

Piping Table 3.63 Piping Specification of Copper Smelter Plant

8

ID (inch) 6.85130803

OD (inch) 8.625

8

6.85130803

8.625

0.322

1.5 1.25 0.38 1 1 0.38 1.25 0.75 10

1.499949794 1.097725931 0.283463867 1.032189433 0.871887618 0.246740468 1.264331402 0.73102575 9.992959225

1.9 1.66 0.675 1.315 1.315 0.675 1.66 1.05 10.75

0.145 0.14 0.091 0.133 0.133 0.091 0.14 0.113 9.271

Stream In

Nominal Size (inch)

19 Pump to Electrolytic Cell 2B 9B 13B 5B 10B 14B 1 2 3

Wall thickness (inch)

0.322


80 Table 3.64 Piping Specification of Sulfuric Acid Plant Nominal Size (Inch) 1.25

ID (Inch) 1.2643314

OD (inch) 1.66

1.25 1.25 1.25 1.25 1.5 1.5 1.5 1.5 1 1 1 1 5 5 5 5

1.2643314 1.2643314 1.2643314 1.2643314 1.44557751 1.44557751 1.39764015 1.39764015 1.37219489 1.37219489 1.37009482 1.37009482 4.28008238 4.28008238 4.28008238 4.28008238

1.66 1.66 1.66 1.66 1.9 1.9 1.9 1.9 1.315 1.315 1.315 1.315 5.563 5.563 5.563 5.563

0.14 0.14 0.14 0.14 0.14 0.145 0.145 0.145 0.145 0.133 0.133 0.133 0.133 0.258 0.258 0.258 0.258

16

5

4.28008238

5.563

0.258

17

4

4.00399293

4.5

0.237

18

4

4.00399293

4.5

0.237

19

4

4.00399293

4.5

0.237

20

4

4.00399293

4.5

0.237

21

4

4.00399293

4.5

0.237

21'

4

4.00399293

4.5

0.237

23

6

5.66605157

6.625

0.28

24

0.5

1.51323764

0.84

0.109

25

2.5

4.67072168

2.875

0.203

26

8

6.85130803

8.625

0.322

27

1.5

1.51323764

1.9

0.145

Stream

1 1' 2 2' 3 4 5 6 7 8 9 10 11 12 13 14 15

Wall Thickness (Inch)


Table 3.65 Pipinng Specification of Oxygen Plant

Table 3.66 Pipinng Specification of Power Plant

81


82 Table 3.67 Piping Specification of Water Pretreatment Plant Stream

Nominal Size (inch)

ID (Inch)

OD (inch)

Wall Thickness (Inch)

Water from Bengawan Solo River

34

31.28069

34

0.75

3.19

Valve Table 3.68 Valve Size of Copper Smelter Plant Stream

Flow (tonne/day)

Flow (gpm)

SG

Gf

dP

Cv, max

Valve Size (in.)

2B 5B 9B 10B 13B 14B 2 1

1120 920 600 930 40 70 530 1860

205.52 168.82 110.1 170.655 7.34 12.845 97.255 341.31

1.104 2.264 1.104 2.264 1.104 2.264 0.6218 1.104

1.104 2.264 1.104 2.264 1.104 2.264 0.6218 1.104

5 5 5 5 5 5 5 5

193.1451 227.1994 103.4706 229.6689 6.898038 17.28691 68.59339 320.7588

4 5 3 5 1 1,5 3 5

Table 3.69 Valve Size of Oxygen Plant Stream

Flow (tonne/day)

Flow (gpm)

SG

Gf

dP

Cv, max

Valve Size (in.)

4, 1, 1A, 1B, 1C, 1D, 1E, 2A, 2, 2B, 2C

1860

341.31

1

1

5

305.2769

5

C1, C2

6879

1262.2965

1

1

5

1129.032

16

18, 19

528

96.888

1

1

5

86.65926

3

14, 14A, 16

795

145.8825

1

1

5

130.4813

4

C3, C4

6734

1235.689

1

1

5

1105.234

16

13, 13A, 15

804

147.534

1

1

5

131.9584

4

7

60

11.01

1

1

5

9.847643

1

Table 3.70 Valve Size of Sulfuric Acid Plant Flow (tonne/day)

Flow (gpm)

SG

Gf

dP

Cv, max

Valve Size (in.)

1860

341.31

1.104

1.104

5

320.7588

5

528

96.888

1

1

5

86.65926

3

12, 13, 14, 15, 16,

804

147.534

1

1

5

131.9584

4

23

400

73.4

1.84

1.84

5

89.05329

3.00

24

120

22.02

1.84

1.84

5

26.71599

1.5

26

500

91.75

1.84

1.84

5

111.3166

5

28

500

91.75

1.84

1.84

5

111.3166

5

25

2.4

0.4404

1.84

1.84

5

0.53432

0.75

27

2.4

0.4404

1.84

1.84

5

0.53432

0.75

Stream

1, 1', 2, 2', 3, 4, 5, 6, 7, 8, 9, 10, 11 18, 19, 20, 21, 21, 21'


83 Table 3.71 Valve Size of Power Plant Flow

Flow

(tonne/day)

(gpm)

1500

6A, 7A, 8A

Stream

Valve Size

SG

Gf

dP

Cv, max

275.25

1

1

5

246.1911

5

1001

183.6835

1

1

5

164.2915

4

3A, 4A, 5A

1500

275.25

1

1

5

246.1911

5

1A, 2A

6000

1101

1

1

5

984.7643

16

C4, A, B, C, D, E, F, G, H

(in.)

Table 3.72 Valve Size of Water Utility Stream

Flow

Valve

Flow (gpm)

SG

Gf

dP

Cv, max

42744

7843.524

1

1

5

7015.461

16

H

175.2

32.1492

1

1

5

28.75512

2

I

38496

7064.016

1

1

5

6318.248

16

J

4224

775.104

1

1

5

693.2741

16

A, B, C, D, E, F, G

(tonne/day)

Size (in.)


CHAPTER IV PROCESS CONTROL STRATEGY

4.1

Plant Control Tabulation Table 4.1 Control Tabulation of Copper Smelter Plant

Unit

Equipment Name

Process Variable

Smelting Furnace

F-101

Temperature

Converting Furnace

F-103

Temperature

Converting Furnace

F-104

Temperature

Belt Conveyor

C-101 / C-102 / C-103 / C104 / C-105 / C-106 / C-107 / C-108

Conveyor Speed

-

Proportional Integral ST

Motor Speed

Speed Indicator Controller SIC

Economizer

E-101

Temperature

Thermocouple & Temperature Element

Proportional Integral TT

Flue Gas Flow

Temperature Control Valve TCV

Sensor

Thermocouple & Temperature Element Thermocouple & Temperature Element Thermocouple & Temperature Element

Controller P/PI/PID

Proportional Integral TT Proportional Integral TT Proportional Integral TT

84

Manipulated Variable OxygenEnriched Air Flow OxygenEnriched Air Flow OxygenEnriched Air Flow

Final Control Element

Sequence of Instrumentation

Temperature Control Valve TCV Temperature Control Valve TCV

If the furnace temperature is too low, the temperature control valve will open in which the flow of oxygen-enriched air will increase

Temperature Control Valve TCV If the input of the component is too much based on the analysis done on the output of the furnace, we can adjust the input by controlling the motor speed of belt conveyor When the temperature of outlet heat exchanger more or less than design, the transmitter will transfer signal to temperature control valve to open and close.


Table 4.2 Control Tabulation of Oxygen Plant Unit

Equipment Name

Heat Exchanger

E-201 / E-202 / E-203 / E-204 / E-205 / E-206 / E-207

Compressor

Pump

Adsorber Column

K-201 / K-202

P-201 / P-202

Process Variable

Sensor

Controller P/PI/PID

Manipulated Variable



Temperature



Cooling Water Flow Rate


If the outlet temperature of the the heat exchanger not fit with the wanted condition, then the valve will adjust the flow of cooling water until the condition become normal again.

Pressure

Pressure Gauge & Pressure Element

Proportional Integral PT

Air Flow Rate

Pressure Safety Valve

When the pressure outlet flow from compressor the controller will send a signal to give a higher power to the compressor motor. If the pressure outlet flow is higher from its initial flow condition, the control procedure is likely the same but, the final action is decreasing power to compressor motor until the condition become steady normal condition.

Flow

Flow Element & Flowmeter

Flow Control


Flow Indicator Controller FIC

When the outlet pump flow is higher than design, the valve will be closed.

Pressure

Pressure Gauge & Pressure Element

Pressure Controller

Air Flow Rate

Pressure Control Valve PCV

When the pressure of the adsorber is higher than the design pressure, the pressure control valve will open to reduce the pressure on the adsorber.

Temperature



When the temperature of the of the adsorber is not fit with the wanted condition, the TT will give an electric signal to TIC and then transfer that signal into a pneumatic signal to flow control valve at the cold fluid inlet (cooling water or steam) until the condition become normal.

R-201 / R-202 Proportional Integral TT

85

Air Flow Rate


Table 4.3 Control Tabulation of Sulfuric Acid Plant Unit

Equipment Name

Process Variable

Sensor

Controller P/PI/PID



Heat Exchanger

E-301 / E-302 / E-303 / E-304 / E-305 / E-306 / E-307

Temperature





Reactor

R-301

Temperature





Pressure

Pressure Safety Valve & Pressure Gauge

-

Top Product Flow Rate


Level

Mechanical Float

Proportional Integral LT

Liquid Product Flow Rate

Level Indicator Controller LIC

Pressure

Pressure Safety Valve & Pressure Gauge


Top Product Flow Rate of Absorber Column


When the pressure of the tank is higher than the design pressure, the pressure valve control will open to reduce the pressure on the tank.

Level

Mechanical Float




Reduce liquid level in column by opening the Level Control Valve on the bottom product of the column.

Absorber Column

Storage Tank

R-302 / R-303

TT-301

86


If the outlet temperature of the the heat exchanger not fit with the wanted condition, the valve will adjust the flow of CW until the condition become normal again. If the inlet converter reactor not fit with the wanted condition, the valve will adjust the flow of CW until the condition become normal again. When the pressure of the absorber is higher than the design pressure, the pressure control valve will open to reduce the pressure on the absorber. Reduce liquid level in column by opening the Level Control Valve on the bottom product of the column.


Table 4.4 Control Tabulation of Power Plant Unit

Pump

Heat Exchanger

Steam Turbine

Equipment Name

P-401

E-401 / E402 / E-403 / E-404 / E405

T-401

Process Variable

Sensor

Controller P/PI/PID




Flow


Flow Control



When the outlet pump flow is higher than design, the valve will be closed. But, if the o utlet pump flow is lower than design, the valve will be opened.


If the outlet temperature of the the heat exchanger not fit with the wanted condition, the TT will give an electric signal to TY and then transfer that signal into a pneumatic signal to the control valve at the cold fluid inlet (cooling water or steam) so the valve will adjust the flow until the condition become normal again.


When the pressure outlet flow from compressor is lower about 5% than each intial flow condition, the controller will send a signal to give a higher power to the compressor motor until the condition become normal condition. And if the pressure outlet flow is higher from its initial flow condition, the control procedure is likely the same but, the final action is decreasing power to compressor motor until t he condition become steady normal condition.

Temperature

Pressure


Pressure Element & Pressure Gauge



87


Air Flow Rate


Table 4.5 Control Tabulation of Water Utility

Unit

Equipment Name

Pump

P-501

Coagulant Tank

T-501

Filtration Tank

V-501

Kation Exchanger

V-502

Anion Exchanger

V-503

Water Tank

T-502

4.2

Controller P/PI/PID




Flow


Flow Control



When the outlet pump flow is higher than design, the valve will be closed. But, if the outlet pump flow is lower than design, the valve will be opened.

Level

Mechanical Float




Reduce liquid level in column by opening the Level Control Valve on the bottom product of the column.

Process Variable

Sensor

Piping and Instrumentation Diagram

The P&ID can be seen on Appendix C. 88


CHAPTER V PLANT LAYOUT

5.1

Area Plant Layout

The plant layout has several objectives such as minimize investment in equipment, minimize overall production time, utilize existing space effectively, safety, operation process, minimize material handling cost, minimize variation in types of material equipment, facilitate the manufacturing process, and facilitate the organizational structure. As mentioned before, our plant will be located in the Gresik due to the consideration as mentioned of. Our plant is located near to the sea which we decided to build a harbor as the loading and unloading of buying raw material and exporting the product we produced. This plant is divided into several areas, there is the main process plant, and utility plant, where the river water that will be used in water cooler to cooling the air that will be compress, and also a power plant. There is flare outside the process area. In the other side of the plant, there are the supporting area and building, such as the security post, main office, mosque, clinic, laboratories, fire station, and also the assembly point and parking area. We also consider the position of equipment and the building with the HSE aspect. Between the office and the process area we have a canal to block the effect of heat and other effect of accident, and also to transport the water back to the river. The design of the plant layout will determine the efficiency of the production process and influence how long survival or success of an industrial workplace. A good plant layout design can simplify the process of monitoring the production process and also facilitate resetting plant layout if there are plans in the future plant expansion. The plant layout is made by considering the following: 

The space available must be enough for the whole plant and its supporting facilities.



Spacing between process instruments is ruled by Inside Battery Limit (IBL), and the spacing between supporting facilities is ruled by Outside Battery Limit(OBL).



Safety is the main consideration in the plant layout The spacing rule of thumb between equipment can be seen on the figure below.

89


90

Figure 5.1 Typical Spacing for Plant Equipment

(source: Assesment Methodology for Equipment Layout, Chem. Eng. Dept, UI, 2015)

Figure 5.2 Typical Spacing for Plant Equipment

(source: GAPS Guideline, 2015)

Our plant is divided into two zone which each of them has certain functional such as safety rule. The zone is red zone, and blue zone. a.

Red Zone Red zone is a process zone which consist of process train, utilities, flare stacks

and storage and loading. The process train of our plant consist of copper smelting Universitas Indonesia

91 plant, oxygen plant, and sulfuric acid plant. The utilities consist of steam turbine power plant, water pretreatment, and waste water treatment. The red zone is dangerous, so the workers are suggested to wear minimum standard PPE (Personal Protective Equipment) which consist of shoes, earplug, helmet, coverall, and glasses. Considering the danger of this zone, all of worker are suggested to wear minimum standard PPE (Personal Protective Equipment) which consist of shoes, earplug, helm, and glasses. The red zone is necessary to design the layout specifically due to the potential fire and explosion impact. b. Blue Zone Blue zone is the area of the plant which is not directly related to the process. It consists of office area, clinic, laboratory, mosque, firefighting, and parking lot area. This area is quite safe and does not need safety equipment or PPE (Personal Protective Equipment). There is a rule of thumb of plant layout spacing based on Center for Chemical Process AIChe Industry Technology Alliance. The figure below is the zone that has been explained earlier.

N GUESTCARPARK(FORSECURITY ADMISSION)

SECURITY

MOTORCYCLEPARKING AREA

W

E

MAIN GATE

S CHEMICAL ENGINEERING DEPARTMENT FACULTYOF ENGINEERING UNIVERSITASINDONESIA

CARPARKINGAREA

DEPOK

PROJECT

PRELIMINARYDESIGN OFCOPPER SMELTER PLANT DRAWING NO.

BLUE ZONE

2

ASSEMBLY POINT

DATE

11/16/2016 GROUP

PAR13

OFFICE BUILDING MOSQUE

CLINIC K3 BUILDING ASSEMBLYPOINT

FIRESTATION

LAB MECHANICAL AND ELECTRICAL BUILDING

CANAL

CANAL

CENTRAL CONTROL ROOM

POWER PLANT WATER UTILITY

ASSEMBLYPOINT

SULFURIC ACID PLANT

OXYGEN PLANT

RED ZONE RAW MATERIAL STORAGE COPPER SMELTER PLANT

ASSEMBLYPOINT

PRODUCT STORAGE

LOADING AND UNLOADING

FLARE

Figure 5.3 Red and Blue Zone Universitas Indonesia

CHAPTER VI HEALTH, SAFETY, AND ENVIRONMENTAL MANAGEMENT

6.1

HSE Aspect

6.1.1

HAZID Hazard Identification (HAZID) is an analysis of hazard prevention on

industrial installation by observing whole aspects. Aspect in industrial installation: a. Information data of industrial installation (PFD, P&ID, lay out, meteorological data, social cultural community around data, record of events) b. Location (operating facilities, support facilities) c. Risk (human resource, environment, asset, image) d. Trigger factor of danger (operation process, transportation, geography and meteorology, social cultural) e. Hazard

potential

(huge

fire

and

explosion,

drown,

environmental

contamination) In hazard identification, the analysis considering hazard effect and hazard frequency (level of hazard possibility). HAZID parameters in considering hazard effect are listed in table below. Table 6.1 HAZID Parameters (Hazard Effect)

Parameter

Minor

Major

Severe

Human Resources

No accidents

The accident was

Fatal accident

not fatal Asset

Environment

Losses less than

Losses between

Losses in excess

U.S. $ 100,000

U.S. $ 100,000 –

of U.S. $

U.S. $ 1,000,000

1,000,000

No environmental

Minor damage to

Damage to the

damage

the environment

environment

(source: Geoff Wells, 1996)

93


94 Table 6.2 HAZID List Location

Potential Hazard

Conveyor System

The Velocity of conveyor is to high

Smelting Furnace Unit

Electrolitic Cells


Converter Furnace

Anode Furnace

Melting Furnace

Casting System

Fire & Explosion

Hazard Frequency Effect Copper Smelter Plant Power motor which used is Minor Most higher than it should be Causes

High Temperature and Pressure Inside the Furnace

Severe

Likely

Most

Barriers and other protecting covering, including the mobile shields should be used or set up to protect workers against the splashes of molten metal and electromagnetic radiation

Likely

Application of explosion protection system. Cascade control which operates automatically responds temperature and product moisture change

Electrical Hazard

Explosion

High Temperature Inside the Furnace

Fire & Explosion

High Temperature & Pressure Inside the Furnace

Severe

Likely

Explosion

High Temperature Inside the Furnace

Severe

Likely

Fire & Explosion

High Temperature & Pressure Inside the Furnace

Severe

Likely

coming in contact with metal splashes or be exposed to electromagnetic radiation

Charging a furnace with impure or moist scrap metal and alloys, Molten metal also emits electromagnetic radiation in the furnace and pouring areas

Severe

Severe

Control/ monitoring periodically Routine check on the Slag Cleaning Furnace condition. Placing a temperature and pressure contro

Electrolytic cells may emit large quantities of dusts

Severe

Prevention

Most

Routine check on the Slag Cleaning Furnace condition. Placing a temperature and pressure control Application of explosion protection system. Cascade control which operates automatically responds temperature and product moisture change Routine check on the Slag Cleaning Furnace condition. Placing a temperature and pressure control Barriers and other protecting covering, including the mobile shields should be used or set up to protect workers against the splashes of molten metal and electromagnetic radiation


95 Table 6.2 HAZID List (cont’d) Location

Potential Hazard

Causes

Hazard Effect

Frequency

Prevention

Safety ear plug provisioning

Oxygen Plant

Air Compressor Unit

Noise Pollution

Compressor Sound

Major

Most

Piping Network

Damage and leakage of pipe

Corrosion, failure

Major

Likely

Drum

Leaking, Crack and material exposure

Major

Likely

Adsorber Unit

Explosion

Severe

Likely

Defficiency on the welded joint, Exposure to the wind, Corrosion Overpressure in the adsorber unit

Protect the piping network and control periodically Make sure the Drum is properly design, Do a routine maintenance and weld inspection Control and monitoring the pressure

Sulfuric Acid Plant

Water Pump

Noise Pollution

Loud operation noise

Piping Network

Damage and leakage of pipe

Heat Exchanger Unit

Water Utility Unit

Absorber

Converter

Acid Storage Tank

Outout will not have temperature as specified before Overflow which release to the environment Explosion The reaction will not run optimally There is a leak in the storage tank, so that the acid released into the environment

Major

Most

Safety ear plug provisioning

Corrosion, failure

Major

Likely

Protect the piping network and control periodically

Cold water flow is too low, feed inlet is to high

Major

Likely

Control/monitoring periodically

High capacity of cooling water which produce

Minor

Most

Control the flow capacity

Overpressure in the absorber unit

Severe

Unlikely

Control and monitoring the pressure

The reaction uncontrolled

Major

Likely


Corrosion

Severe

Unlikely

Routine Inspection. Protect the storage tank with cathodic protection

Water Utility System

Tank/Vessel

Water flooding Leakage

Overcapacity

Minor

Likely

Minor

Likely

Pump

Noise pollution


Minor

Most

Piping Network

Leakage and damage of pipe

Corrosion, Failure

Major

Likely

Checking tank/vessel level periodically Surfacing tools that generate the noise and oblige the use of earplug Protect the piping network and control periodically Universitas Indonesia

96 Table 6.2 HAZID List (cont’d) Potential Hazard

Location

Causes

Hazard Effect

Frequency

Prevention

Likely

Checking level periodically

Likely


Most

There should be valves to release the pressure and prevent over speed

Most

Surfacing tools that generate the noise and oblige the use of earplug

Water Utility System

Ion Exchange Unit

Water flooding

Overcapacity

Minor

Power Plant

Heat Exchanger

Steam Turbine

Pump

6.1.2

Outout will not have temperature as specified before Over speed in steam turbine which will make rotor failure in steam turbine Noise pollution

Cold water flow is too low, feed inlet is to high Boiler in HRSG too hot


Major

Major

Minor

HAZOP Hazard and Operability Studies (HAZOP) was first developed by ICI, a

British chemical company. Hence, HAZOP is more often implemented in the chemical industry. But along with the increasing need for hazard analysis techniques, several other industries, such as food industry, pharmaceutical, and mining (including oil and gas drilling offshore), also began to implement many HAZOP. The main purpose of HAZOP is to identify: a. The dangers (hazards) are a potential (especially that endanger human health and the environment) b. All sorts of problems operational capability (operability) on each process as a result of irregularities against the design goals (design intent) processes in plants as well as plants that have new activity or will be operated. For HAZOP, there are a few parameters that we use in, meaning for each parameter can be seen in table below. For each unit, there is deviation that are not write because we consider that deviations have probability very low.


97 Table 6.3 HAZOP Parameter Guide Word No or not

More Less As well as Part of Reverse Other than Early Late Before After

Meaning Complete negation of the design intent

Quantitative increase Quantitative decrease Qualitative modification/increase Qualitative modification/decrease Logical opposite of the design intent Complete substitution Relative to the clock time Relative to the clock time Relative to order or sequence Relative to order or sequence (source: Geoff Wells, 1996) Table 6.4 HAZOP List

Location

Parameter

Guide Words

Possible Cause

Consequences

Action Required


Belt Conveyor

Smelting Furnace

Slag Furnace

Less

Energy supply too low

Production will be too slow

Ensure that electricity supply is stable, use small generator if needed to stabilize electricity supply

More

Improper set point, machine is not in good condition so there is deviation with the set point

There will be material queue to the next process

Calculate the set point accurately, clean the machine periodically.

More

Improper set point on belt conveyor

more

Improper set point on belt conveyor so the product of smelting furnace not suitable with the spec.

Belt Speed

flow rate

flowrate

Will be harm exhaust gas release to the environment Will be harm to the next process, and disturb the next process, furthermore can make defect to the equipment process

Calculate the set point accurately, clean the machine periodically. Calculate the set point accurately, clean the machine periodically


Less Electrolytic Cell

Pipe/ line leakage

Will harm the equipment

Install Flow Control

Level control valve pails open

Electrolytic process will be not optimal, so there will be unnecessary chemicals concentration exhaust release to next process.

Install Flow Control

flow rate More


98 Table 6.4 HAZOP List (cont’d) Location

Parameter

Guide Words

Possible Cause

Consequences

Action Required

Less

Low input flowrate, FIC failure

Compressor Failure

Install flow indicator

More

Process fluid valve failure

Over-pressure

Install flow indicator

Oxygen Plant

Compresso r

Adsorber

Drum

Flow

Less

Gas pressure is too low, defect on compressor function

Pressure deficiency in the column operation, mass transfer is not effective

More

Gas pressure is too high, valve before entering adsorber is inadvertently opened

Overpressure in the column operation, mass transfer is not effective

Pressure

Pressure

More

No

Pump

Heat Exchanger

Flow

Flow Temperature

Less

The defection of Explosion or drum valve on the leakage, the harm pipeline before exhaust gas will be reentering the damage the drum environment Sulfuric Acid Plant Failure of inlet Process fluid cooling water temperature is not vapor lowered accordingly Pipe leakage

Close the pressure output valve so that the pressure could reach the specified pressure in the column operation, Install the pressure control Open the pressure output valve so that the pressure inside the column will not accumulated to prevent damages in the column

Install Valve

Install high temperature alarm TAH

Process fluid temperature too low

Install flow meter

More

Inlet valve failed open

Output of process fluid temperature

Install low temperature alarm TAL before and after the process

Less

Less flow carried upstream due to pressure drop Gas pipe leakage

Less conversion and SO3 Release hazard gases as above

Install flow and temperature indicator as above.

More

More flow carried upstream Increase in pressure

Equilibrium conversion in may not reached

Less

Too much heat removed by heat exchangers

Higher conversion if enough catalyst is available.

Install flow and temperature indicator as above. Regular test on catalyst. Install thermocouples as above and regular check on boiler efficiency



Heat Exchanger

Parameter

Flow Temperature

Guide Words

More Less

Possible Cause

Action Required

Sulfuric Acid Plant Heat exchangers Inefficiency in heat fail to remove exchanger also affects specified heat other beds temperature

Install thermocouples as above and regular check on boiler efficiency

Less inlet gases carried upstream

Less production of H2SO4

Instal flow indicator and controller

More inlet gas

Increased load on downstream equipment

Control the inlet gases

Flow More

Consequences

More H2SO4 needed for absorption Insufficient conversion to meet environmental. Requirement. Less production of H2SO4

Install thermocouples as above and gas bypass to control gas temperatures. Check catalyst activity and plug of catalyst.

Failure in heat exchanger

Install thermocouples as above and gas bypass to control gas temperatures.

More

Outlet gas pipe partial blockage

Increase pressure downstream

Install pressure relief valve Shut down and clear pipes.

As Well As

Breakage of catalyst and chips carried downstream by gases

Damage to downstream equipment and loss of catalysts

Install layers of porous silica.

No absorption in column Pressure build up in pipe Gasess escape into the surrounding

Ensure liquid feeds to the absorber and other process units shutdown Install low flow alarm onto the FIC. Install kick-back on steam on upstream pumps and ensure pressure relief system is tolerable. Plant emergency shutdown procedure

Less Catalyst Converter

Temperature

More

Pressure

Catalyst

Intermediet Absorber

Intermediet Absorber

Flow

Temperature

Reaction rate not reach equilibrium, less conversion Too much cooling in heat exchanger Higher temperature carried from previous bed. Insufficient cooling

No

Less

Flow stopped upstream Line blockage or the isolation valve shut in error Line fracture

Sulfuric Acid Plant High liquid flow Accumulation of at loading point. liquid in the column Leaking inlet No absorption in flange column

Regular patrolling of feed transfer lines



Parameter

Guide Words

More Intermediet Absorber

Temperature Less

Flow

Consequences

Action Required

Sulfuric Acid Plant Pump at maximum Possible reduction in discharge or absorption efficiency pump May cause flooding malfunction Increased feed Increased dissolved Over cooling gases in acid (impurities)

More

Insufficient cooling

Decreased absorption, higher pollution

No

Line blockage

Less

Pipe/ line leakage

Line rupture Decrease in H2SO4 production 2. Health and safety hazard because it is toxic Increase pressure in tank

More Acid Storage Tank

Possible Cause

Pressure

More

Temperature

Less

Level control valve pails open LCV fails shut or isolation valve closed in error Lower inlet stream temperatures or over capacity from cooling circuit

Ratio control on liquid feed streams. Install high level alarm on the FIC Ensure accurate temperature control on the internal cooling circuit Ensure accurate temperature control on the internal cooling circuit Regular inspection Install suitable alarms to column to indicate low flow. Install low level alarm Install low level alarm

Increase pressure in tank

Covered by control and alarms

Insufficient drying

Install high level alarm ontic on H2SO4 outlet.

Water Ulitity System

Failure of inlet cooling water vapor Pipe leakage

Process fluid is stopped

Install high temperature alarm TAH

Process fluid is lower

More

Inlet valve failed open

purifying process in not maximal

High

Input flow rate is too large Output flow rate is too small

Flooding

Install flow meter Install low temperature alarm TAL before and after the process Close the inlet valve to reduce the flowrate

Low

Input flow rate is too small

Material damage and process is not running optimum

Open the inlet valve to increase flowrate

High

Input flow rate is too large

Flooding

Close the inlet valve to reduce the flowrate

No Pump

Ion Exchanger

Tank

Flow

Less

Level

Level

Open the output valve



Parameter

Guide Words

Possible Cause

Consequences

Action Required

Water Ulitity System

Tank

High

Output flow rate is too small

Low

Input flow rate is too small

Open the inlet valve to increase flowrate

The rpm of motor is too low

Rechecking inspection/maintenance regime will be suitable toward the specification

Level

Rpm of motor

Turbine

Flow More

Heat Exchanger

less Temperature more Storage Tank

Level

Less

Open the output valve

Material damage and process is not running optimum Power Plant

Less

Less

Flooding

Less flow carried upstream due to pressure drop Gas pipe leakage More flow carried upstream Increase in pressure drop Gas pipe leakage Too much heat removed by heat exchangers Heat exchangers fail to remove specified heat Low input flowrate, high output flow rate

6.2

HSE Management

6.2.1

Operational Details

The power generated is low

Heat transfer is not maximal Install flow control Heat transfer is not maximal

product is offspec Can be harmful for the next process Flowrate decreases

install flow control, and checking the temperature periodically

Install Level Indicator

In this subchapter, will be explained about the start up and shut down procedure needed in our palnt. These kind of planning is needed due to the safety aspect and the efficiency. The procedure of each plant is explained below. 6.2.1.1 Copper Smelter Plant 1.

Start-Up Procedure Start up procedures in this copper smelting plant includes two ways for there

are two major system in this plant, smelting system and electrorefinin g system. The procedures are: Universitas Indonesia

102 a. Smelting System During initial stages of the plant commissioning and operation, concentrate feed rates were maintained at between 80 t/h and 100 t/h, after which a step-wise increase in production to design capacity was achieved following construction of the new oxygen and acid plants. Matte and slag grades have been well controlled since start-up and are currently achieving the design target of 55 wt. % Cu in matte and less than 0.75 wt.% Cu in slag. Cold commissioning teams finalize construction and cold commission the furnace, lance service, feed system, product handling system and Mitsubishi designed and supplied process control system. For our system, the schematic procedures are: 

Checking for oxygen and silica supply.



Pre-treating the solid raw material



Input raw material to primary furnace manually. Generating steam as the pre-heater of air to make auto ignition in the primary furnace firebox.

After combustion process happened for several times, synchronizing the gas preheater (between flue gas as the hot fluid and air from blower as the cold fluid) and stop running the steam generator and start running the scrubber to absorb flue gas. 

Collecting copper from primary furnace bottom product while slag will flow into slag recovery furnace continuously.



Preparing to start up slag recovery furnace for the next 12 hours by applying step three to five then emptying and cleaning the primary furnace.



Collecting tin from slag recovery furnace bottom product while hardhead will flow into hardhead recovery furnace continuously.

b.

Electro-Refining System The principal technical objective of the refinery is to produce high purity

cathode copper. Other important objectives are to produce this pure copper rapidly and with a minimum of energy. For electro-refining system, the start-up p rocedures are: 

Making sure that the arrangement of the anodes and cathodes in the electrolytic cells are right. Universitas Indonesia

103 

Installing anode and cathode in parallel system.



Pumping the electrolyte to electro-refining tank. Check chemical conditions,

particularly

electrolyte

composition,

temperature,

and

circulation rate.

2.



Test and verifying the output voltage.



Connecting electricity and turning AC into DC by using rectifier.



Check electrical conditions, particularly current density.

Shut Down Procedure Shut down procedures of this plant include two ways too, smelting system

and electro-refining system. The procedures are: a. Smelting System

For smelting unit system, there are two kind of shut down procedures. They are normal shut down and emergency shutdown. Normal shutdown process is done by turning off air blower by closing the input valve. Emergency shutdown process is a force shut down process, the blower is turned off without reducing speed process and flue gas valve is opened fully to make sure all gas left the furnace. The emergency shutdown process is used for the emergency situation such as if the system is brake out and need maintenance immediately. b. Electro-Refining System

For the electro-refining system, the shutdown process is simple. The shutdown process will be done by turning off the connection of current from the electrical circuit. 6.2.1.2 Oxygen Plant 1.

Start-Up Procedure The successful long term performance of the Pressure Swing Adsorbed

depends on operation and maintenance of the system. This includes the initial plant start-up and operational start-ups and shut-downs. Preventing the problems not only a matter of system design but also a matter of proper commissioning and operation. Before beginning to start-up the upstream process facilities, should be Universitas Indonesia

104 commissioned and ready for operation. Start up and commissioning of air separation plant is taken up after following activities: a. Make a visual inspection of the machine and make sure all parts are properly attached. b. Connect the oxygen outlet to the application c. Connect the unit into an electrical outlet and verify that power supply switch the power switch to “On”. Set the mode switch to the “generate” position.

d. Open the inlet air valve. Check all upstream and downstream fittings thorou ghly e. Turn on the compressed air supply. Follow air compressor manufacturer’s startup instructions. Check the air pressure. Listen for the sound of the compressor to start operating. The storage tank pressure gauge should indicate a pressure increase after approximately 15 minutes. 2.

Shut Down Procedure The safety shutdown systems based on the following procedures:

a. Emergency Shutdown In case of an emergency, simply turn the Main Power Switch to OFF. This will stop all generator functions immediately. Oxygen supply can be shut off manually closing the Oxygen product ball valve located on the optional product receiv er tank. b. Normal Shutdown 

Switch the PSA Mode switch to the "DESORB" mode and allow 2 minutes for the PSA tower to safely depressurize. When the PSA tower is completely desorbed, the tower pressure gauge will read zero.



Turn the power switch to the off position and unplug generator from its power.



Close the (customer installed) shutoff valve on the inlet air line. Turn the (customer installed) inlet air (pressure-relieving) pressure regulator down until the pressure in the air line is zero.



Close the valves at the inlet and outlet of the oxygen receiver tank. The receiver tank pressure gauge should read zero. (Note: The receiver tank is Universitas Indonesia

105 pressurized with high purity oxygen even though the receiver tank pressure gauge reads zero.) 

Empty the receiver tank by opening 2-way valve beneath the receiver tank



Check to confirm that the inlet pressure regulator gauge, PSA tower pressure gauge, oxygen receiver gauge, oxygen outlet pressure gauge all read zero before attempting any maintenance.

6.2.1.3 Sulfuric Acid Plant 1.

Start-Up Procedure The start-up procedure for sulfuric acid plant are:

a. During start-up, the initial heating of the converter should be carried out using dry air to minimize the water condensation on the catalyst. MECS recommends a single dry blow, but some clients continue dry blows until all passes are between 100oC and 170oC (212 and 340oF). Using only a single dry blow reduces the heat-up time by approximately 24 hours. b. Acid should be circulating through all of the towers. With the acid circulating, the drying tower will dry the ambient air and the absorbing towers will absorb any SO3 that is formed during the converter heat-up. c. As the converter is heating, the vent gases in the start-up vents (at the economizers) may become cloudy as SO3 gas is evolved from the catalyst when it reaches approximately 300oC (570oF). If these emissions are not acceptable, shut down the main compressor and change the blinds so that the combustion gases flow through the final tower to the stack. In some plants a start-up bypass duct is provided to bypass the interpass tower. Restart the main compressor to continue the heating process. d. After the catalyst, has reached the specified temperatures, the plant is ready to start with. Shut off the fuel supply, and shut down the main compressor. e. Initiate SO2 supply 30% to 40% of full rate. It is recommended that this be done using approximately 7% to 8% SO2 gas feed at a reduced blower rate. f. A gradual temperature rise will be observed in the first pass within a few minutes of sulfur dioxide admission. For the initial start-up with new catalyst, this Universitas Indonesia

106 temperature rise (measured at the first pass outlet) should peak within forty-five minutes at a maximum of 20 oC to 50oC (35 oC to 90oF) above the expected outlet operating temperatures for the given gas strength. This temperature maximum will begin to drop after approximately thirty minutes to eventually line out at the expected operating temperature for the given SO2 strength gas stream. There will not be a tremendous temperature rise during the initial start-up with new catalyst since the catalyst is almost completely sulfated prior to operation. g. Slowly increase the sulfur flow Hold this outlet temperature until the inlet temperatures to each pass of catalyst are near the design temperatures. The pass 1 outlet temperature should not exceed 630oC (1160oF) to prevent damage to the catalyst. h. The plant should be stabilized before attempting to increase the plant rate. The plant rate can slowly be increased by adjusting the main compressor pressure. The rate of feed adjustment should be dictated by the emissions and the bed inlet temperatures. Raising the rate slowly minimizes process upsets and helps to keep everything under control. The feed rate increase will not generate a large temperature rise during the initial start-up with new catalyst since the catalyst is almost completely sulfated prior to operation. 2.

Shut Down Procedure Condensed moisture or acid may cause weakening and partial disintegration

of the catalyst, leading tohigh pressure drop and a possible permanent decrease in conversion efficiency. The catalyst ishygroscopic (attracts moisture), especially if SO2 or SO3 gas is left in contact with the catalyst. Therefore, during a plant shutdown, moist air must be precluded, to the maximum possible extent, from the catalyst and the converter / heat exchanger system. a. Short Term Shutdown Adjust heat exchanger bypasses to raise the temperatures in the converter by 28°C (50°F) in each pass. Shut down the sulfur feed flow and the main compressor.


107 b. Long Term Shutdown If any shutdown is to be of such length that the catalyst temperatures will fall below the dew point ofsulfuric acid (i.e. the point where moisture or acid would condense), the converter system should firstbe purged with dry air to remove the SO2 and SO3 prior to shutdown. Shut off the sulfur feed and decrease the main compressor volume to approximately 50%. Purge the converter / heat exchanger system with dry air until all the equipment is cooled down and the SO2 and SO3 are purged from the catalyst passes (approximately four hours). After purging the system, care should be taken so that moist air does not subsequently reach thecatalyst. Natural draft will bring in moist air through the plant stack and the air inlet. Valves can beshut and blanks installed to prevent moist air intrusion. If maintenance work is performed on theconverter, the length of time that the man ways are open should be minimized. If the shutdown plans require the plant to be held down for long periods, in excess of several months, and sulfuric acid will not be circulated through the towers on a regular basis, it will be very difficult tomaintain a dry environment for the catalyst. In this case, it is recommended that the catalyst isremoved from the converter and stored in moisture resistant packages in a dry warehouse until theplant is ready to start up again. The packages should be labeled with the catalyst converter location so that the catalyst can be replaced in the same location later. 6.2.2

Personal Protection Equipment (PPE) Personal protection equipment for employee is the main standard for a

company to protect its employees. There are some types of personal protection equipment: 1. Respiratory Protection Equipment Respirator or air purifying respirator which serves to clean the air that has been contaminated in the form of dust, gases, metal vapors, smoke and fog, and protect the work force has been a breath of danger, composed of chemical respirator (gas Universitas Indonesia

108 and vapor contaminants), mechanical filter respirator (dust, mists, metal fumes, acids) and a cartridge or canister respirator (mixed gas/vapor to solid particles equipped with a filter). 2. Protection Equipment for Hands Hand Gloves is equipment used for hazardous work hand in case of contact between the hand with heat, chemicals or other dangerous hands. Usually this type of hand gloves hanging from its use in the existing conditions in the work, namely: a. Asbestos gloves made of leather, PVC should be used if the heat generated in the factory work, such as welding gloves to be used must pass through the wrist. b. Rubber gloves, made of synthetic material, vinyl as well as natural, to protect hands from chemicals caustic acids, alkalis and various types of other solvents. c. Gloves canvas/leather, wear gloves of canvas or heavy cotton is typically used when the main danger is very high heat caused by friction. d. Gloves with chrome leather or PVC material with special design, to reduce the hazard when in contact with sharp objects. e. Glove fabric type is used to work under normal conditions. 3. Protection Equipment for Legs Safety shoes is a safety shoes are used to protect workers against accidents caused by heavy items falling to the feet, protruding nails, liquid metal, and so on. Standard for leg protection is ANSI Z41.

4. Protection Equipment for Eye Protecting the eyes from debris and splashing subtle body chemicals that cause irritation to the eyes or even injure the eyes. This tool can also protect your eyes from impact workers against a hard object. Standard for eye protection is ANSI Z87.1. 5. Protection Equipment for Ear


109 Ear protective devices commonly used in the area located the tools that can cause noise. For protection against ear every employee who dealt with the process equipment required to use earplugs. Earmuffs are divided into two types: a. Thermal earmuffs are earmuffs used in cold environments to keep one's ears to keep warm. b. Acoustic earmuffs, also known as ear defenders. This tool is coated with sound dampening materials, such as thermal earmuffs and headphones in appearance, which is used as hearing protection from noisy sound. 6. Protection Equipment for Head This protection equipment for head or safety helmet is a protective device that is used to protect the head from impact by hard objects while working in the field, whether it's due to hit by accident or because of a fall or stumble. Standard for safet y helmet is ANSI Z89.1 7. Body Protection Equipment Body Protection Equipment is a coverall protection which serves to avoid direct contact of leakage or spillage of product and medium product in the form of liquid. To clean up the spill using absorbent material must be non-combustible inorganic. In addition, protective clothing or clothing that workers should not be used that has a crease on the bottom of his pants. 6.2.3

MSDS A Material Safety Data Sheet (MSDS) is a document that contains

information on the potential hazards (health, fire, reactivit y and environmental) and how to work safely with the chemical product. It is an essential starting point for the development of a complete health and safety program. It also contains information on the use, storage, handling and emergency procedures all related to the hazards of the material. The MSDS contains much more information about the material than the label. MSDSs are prepared by the supplier or manufacturer of the material. It is intended to tell what the hazards of the product are, how to use the product safely, what to expect if the recommendations are not followed, what to do Universitas Indonesia

110 if accidents occur, how to recognize symptoms of overexposure, and what to do if such incidents occur. The key to the hazards associated with the numerical ratings is provided below. Table 6.5 Explanation of HMIS

0 - ordinary combustible hazards in a fire Health Hazard Ratings

1 - slightly hazardous 2 – hazardous 3 - extreme danger 4 – deadly 0 - will not burn

Flammability Hazard Ratings

1 - will ignite if preheated 2 - will ignite if moderately heated 3 - will ignite at most ambient conditions 4 - burns readily at ambient conditions 0 - stable and not reactive with water

Reactivity Hazard Ratings

1 - unstable if heated 2 - violent chemical change 3 - shock and heat may detonate 4 - may detonate (source: HMIS, 2014) Table 6.6 HMIS Protective Equipment Code

HMIS Code A

Required Protective Equipment

B

safety glass safety glass, gloves

C

safety glass, gloves, protective apron

D

face shield, gloves, protective apron

E

safety glass, gloves, dust respirator

F

safety glass, gloves, protective apron, dust respirator

G

safety glass, gloves, vapor respirator

H

splash goggles, gloves, protective apron, vapor respirator

I

safety glass, gloves, dust respirator, vapor respirator

J

splash goggles, gloves, protective apron, dust respirator, vapor respirator

K

airline mask or hood, gloves, full suit, boots

L-Z

site-specific label (source: HMIS, 2014)

For our plant, we are going to summarize the main material in our plant. There are copper concentrate, limestone, silica sand, suluic acid, copper cathode Universitas Indonesia

111 and oxygen. In this section, we will describe each criteria for health and safety of each components. Below, we are going to summarize each raw materials of our product. 1. Copper Concetrate Formula

:

CuFeS2

Appearance

:

Solid, copper colored, odorless

Based on MSDS we get, this material score for health =1, fire = 2, and reactivity = 1. Copper concentrate is finely ground material that is not flammable or combustible under normal conditions of transport and storage. However, when heated strongly in air for a sufficient time it will burn, releasing toxic and irritating sulphur dioxide gas as well as possible copper and iron oxide fumes. Contact with strong acids will generate flammable and highly toxic hydrogen sulphide gas. Inhalation or ingestion of copper concentrate dust or copper oxide fume may produce irritation of the upper airways. Possible cancer hazard due to the silica content. Protective clothing are required for fire emergency response personnel due to the potential for release of high concentrations of sulphur dioxide from burning concentrate. The metals content in this product have low direct bioavailability and pose little immediate ecological risk. To store this material must provide wellventilated area away from sources of combustion, acids and strong oxidizers 2. Limestone Chemical Name

:

Calcium Carbonate

Formula

:

CaCO3

Appearance

:

White, odorless, granular solid

Based on MSDS rating, limestone shows that they give hazard rating of health=2, fire=0, reactivity = 0, and personal protection = E. from this hazard rating, we can conclude that limestone can cause temporary or minor injury. It will not burn and it is stable. Limestone potentially cause acute health effect if its dust contact with our eyes or inhaled by human because it can cause irritation. It is slightly hazardous in case of skin contact because it can irritate our skin and slightly Universitas Indonesia

112 hazardous in case of ingestion and inhalation. Limestone potentially cause chronic health effect such as toxic to kidneys and repeated or prolonged exposure to the substance can produce target organ damage. There is no special effect in fire hazard unless it contacts with fluorine. Limestone will ignite and burn fiercely. Personal protection used are safety glasses, gloves, and dust respirator. 3. Silica Sand Chemical Name

:

Silicon Dioxide

Formula

:

Si-O2

Appearance

:

Solid, white, odorless

From MSDS silica sand it shows that they give hazard rating of health =1, fire = 0, reactivity = 0 and personal protection=E. For health, the rating is 1 which means that it’s slightly dangerous. For fire the rating is 0 which means that it will

not burn ignite if there’s a fire. For reactivity, the rating is 0 which means that it is stable and it will not react with water. This material is slightly hazardous in case of skin contact (irritant), of eye contact (irritant), of ingestion, of inhalation. So, the workers must use personal protection such as Safety glasses, Lab coat, and Dust respirator. To store this material the container must provide well ventilation to keep exposure to airborne contaminants below the exposure limit. 4. Sulfuric Acid Chemical Name

:

Hydrogen Sulfate

Formula

:

H2-SO4

Appearance

:

Colorless, odorless

From MSDS sulfuric acid it shows that they give hazard rating of health =3 , fire = 0, reactivity = 2, For health the rating is 3 which means that it’s extremely danger. For fire the rating is 0 which means that it will not burn ignite if there’s a fire. For reactivity, the rating is 2 which means that it is violent chemical change. Eventough the material is non-flammable. However, products of decompostion include fumes of oxides of sulfur. Will react with water or steam to produce toxic and corrosive fumes. Reacts with carbonates to generate carbon diox ide gas. Reacts Universitas Indonesia

113 with cyanides and sulfides to form poisonous hydrogen cyanide and hydrogen sulfide respectively. A place that store this material should provide well ventilated area and should be store with coated fiberboard drum using a strong polyethylene inner package. Since this product quite danger, a worker should use personal protection such as Face shield with Full suit, and Vapor respirator. 5. Copper Cathode Chemical Name

:

Copper Cathode

Formula

:

Cu (99,9%)

Appearance

:

Solid with Reddish color

Copper cathode is a Metallic product which poses little or no immediate hazard in solid form. However, this product still also has hazardous if this material repeatedly exposure to human can discolor skin and hair and irritate the skin; may cause mild dermatitis, runny nose, and irritation of the mucous membranes. Repeated ingestion may damage the liver and kidneys. In order to minimize the hazard, worker should use gloves to handle our product this is because most Particulate may enter the body through cuts, abrasions or other wounds on the surface of the skin. Since our operation may generate dust, fume or mist, the use ventilation is a must to keep exposure to airborne copper below the TLV. If ventilation alone cannot so control exposures, use approved respirators selected according to local regulations 6. Oxygen Product Name

:

Oxygen

Formula

:

O2

Appearance odor and state

:

Odorless and colorless

Based on MSDS, oxygen shows that they give hazard rating of health=0, fire=0, and reactivity = 0. From this hazard rating, we can conclude that oxygen has no significant risk to health. It will not burn and it is stable material. Breath ing 80% or more oxygen at atmospheric pressure for more than a few hours may cause nasal stuffiness, cough, sore throat, chest pain and breathing difficulty. Breathing oxygen Universitas Indonesia

114 at higher pressure increases the likelihood of adverse effects within a shorter time period. Breathing pure oxygen under pressure may cause lung damage and also central nervous system effects resulting in dizziness, poor coordination, tingling sensation, visual and hearing disturbances, muscular twitching, unconsciousness and convulsions. Breathing oxygen under pressure may cause prolongation of adaptation to darkness and reduced peripheral vision. Oxygen is nonflammable but will support combustion. Use extinguishing media appropriate for surrounding fire. A place with high oxygen concentration should provide ventilation and/or local exhaust to prevent accumulation of high concentrations of gas (greater than 23%). There is no special personal protection needed but safety shoes and work gloves are recommended when handling cylinders. Clothing exposed to high concentrations may retain oxygen 30 minutes or longer and become a potential fire hazard. Stay away from ignition sources. 7. Sulfur dioxide Chemical Name

:

Sulfurdioxide

Formula

:

SO2

Appearance

:

Gas, colorless, odor

Based on MSDS, sulfur dioxide has been giving rating for health=3, fire=0 and reactivity=0. This means that sulfur dioxide could cause serious temporary or residual injury even though prompt medical attention was given. This material is poisonous by inhalation and may irritate the eyes, nose, throat, and sinuses, resulting in choking, coughing, and sometimes bronchoconstriction. Eventough the material is extremely dangerous, but this material is stable and will not burn in order to prevent risk, the worker should wear a self-contained breathing apparatus and appropriate personal protective equipment (PPE). To store this material Store only where temperature will not exceed 125°F (52°C). Firmly secure containers upright to keep them from falling or being knocked over. Install valve protection cap, if provided, firmly in place by hand. Store full and empty containers separately. Use


115 a first-in, first-out inventory system to prevent storing full containers for long periods. 8. Sulfur Trioxide Chemical Name

:

Sulfurtrioxide

Formula

:

SO3

Appearance

:

clear, odorless

Based on MSDS, sulfur trioxide has been giving rating for health=3, fire=0 and reactivity=2. This material is categorized as extremely dangerous where Inhalation of the spray mist may produce severe irritation of respiratory tract, characterized by coughing, choking, or shortness of breath. Severe over-exposure can result in death. Inflammation of the eye is characterized by redness, watering, and itching. Skin inflammation is characterized by itching, scaling, reddening, or, occasionally, blistering. This material also reactive with oxidizing agents, metals, alkalis,

moisture.

The

product

may

undergo

hazardous

decomposition,

condensation or polymerization, it may react violently with water to emit toxic gases or it may become self-reactive under conditions of shock or increase in temperature or pressure. the workers who handled this material should use gloves, full suit, vapor respirator and be sure to use an approved/certified respirator or equivalent. Wear appropriate respirator when ventilation is inadequate and also face shield. 9. Coal Product Name

:

Bituminous Coal

Formula

:

C

Appearance

:

Black Powder

Based on HMIS rating, coal shows that they give hazard rating of health=1, fire=3, reactivity = 0, and personal protection = E. From this hazard rating, we can conclude that coal can cause temporary or minor injury. Coal is stable material. The principal health hazard associated with coal occurs during its mining and transport. Coal workers’ pneumoconiosis (CWP) can occur in miners after as little as 15 years Universitas Indonesia

116 of excessive inhalation of respirable coalmine dust. Respirable quartz particles and free silica may be co-implicated. Coal dust is deposited in the lungs where its site of action is the lung parenchyma, lymph nodes and hila. The severity of the disease is directly related to the amount of coal dust in the lungs. In the simple stages, the disease is detectable by x-ray as round, irregular "macules" of 1-5 mm. This stage typically does not change lung function or shorten life. The chronic stage of CWP, however, involves massive pulmonary fibrosis that does impair pulmonar y function and shorten life. Chronic Bronchitis (lung inflammation, coughing attacks, difficult breathing, etc.) and emphysema can result from excessive coal dust inhalation. Rheumatoid arthritis can be exacerbated by pneumonias leading to rapidly developing lung damage (Caplan’s Syndrome). Fire will be occur when coal is

exposed to flame of temperature in excess of 127oC. It is highly combustible and/or explosive when in dust or powder form. Coal dust may react slowly with oxygen at room temperature. Heat accelerates the process, which could lead to spontaneous ignition in piles of coal dust. Personal protection are used in the management of this material are respiratory protection, safety glasses, and gloves. 6.3

Emergency Action Plant

There are several emergency action responses if some incident happen that will be executed for the safety of the employee and others element of plant, such as: 6.3.1

Emergency Operating Procedures or Training The emergency procedures should include instructions for dealing with

fires, leaks and spills. The procedure should describe how to: 

Raise the alarm and call the fire brigade;



Tackle a fire or control spills and leaks (when it is safe to do so);



Evacuate the site, and if necessary nearby premises. These instructions consist of a four-step procedure that employees should

follow during a fire. This procedure must be memorized by all employees. Experience has demonstrated that the best response to a plant fire is first, to sound Universitas Indonesia

117 the alarm, then let others know there is a fire, then to combat the fire if possible, and finally, to evacuate if necessary. The plan works best when expressed as an easily recalled acronym, such as SAFE:

a. S – Sound the alarm Either sound it yourself or call out to someone else to sound it. This allows the fire department to be on its way while other activities are being performed. b. A – Alert others Quickly tell others in the area of the fire. Do this in a calm, firm manner. Do not cause a panic. Secure the area for the fire department. Close all doors and windows to prevent the spread of smoke and flames. Call security to give verification and information about location of fire. c. F – Fight the fire Do this only in the case of a manageable fire, one that you have the training and experience to fight. For example, fire in a wastebasket. If it possible two employees should fight the fire together using two fire extinguishers. If you have any doubt about your ability to fight the fire, then do not attempt to combat it. d. E – Evacuate the area If necessary. Alarm which used for evacuation system is an alarm system standard from OSHA. It applies to provide an early warning for emergency actions or reaction time for employees to safely escape the work place, the immediate work area, or both. Type of alarms which used in this plant is: 1. Audible Alarm Audible alarm which used consists of horn and sirens. Horns produce a very loud distinctive sound that immediately attracts attention. Horns can be useful to call attention to critical situations. Signals other than those used for evacuation purpos es do not have to produce the temporal coded signal. Thus, sirens produce a loud piercing wail that makes them ideally suitable for initiating a site-wide evacuation. 2. Visible Alarm Universitas Indonesia

118 Visual alarm which used consists of flashing/steady lights and strobe lights. Steady lights are well suited for areas where ambient noise makes audible signals difficult to hear, for an example in area where the compressor is in. These types of lights come with different colored covers for increased attention and can be ordered with rotating or flashing lights. Strobe lights use high intensity flash tubes that are ideally suited for areas where high ambient light levels make traditional rotating or flashing lights difficult to distinguish or where ambient noise makes audible signals difficult to hear. 6.3.1.1 Medical Emergencies Whenever an employee or visitor is injured or develops a medical emergency condition on plant property, follow the protocol below and notify your immediate supervisor as soon as possible. Medical emergency instruction: a. Dial the plant infirmary and inform the nurse of emergency and its location in the plant. b. If the nurse cannot be reached, dial emergency call, and inform any hospital or fire department of the medical emergency. Give the dispatcher the nature and location in the plant of medical emergency. c. Unless you have been designated by management to be a first aid responder, do not provide first aid. Make the victim as comfortable as possible until medical help arrives 6.3.1.2 Emergency Escape Procedures The purpose of the escape procedure is to help the employee evacuate to predetermined assembly areas whenever the alarm sounds. Here is the procedure of emergency escape: a. In the event of an emergency, employees shall activate fire pull stations without exposing themselves to serious hazards and leave the work area as soon as possible via the emergency route assignments posted in your immediate work area. Universitas Indonesia

119 b. All primary emergency escape routes and designated meeting locations shall be provided to each employee by departmental managers as part of the emergency planning process. These primary route and designated meeting locations must be approved by the plant manager. c. 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. d. Each local manager or supervisor shall provide for the specialized evacuation of any handicapped employees. 6.3.2

Firefighting A firefighting strategy should consider:



Appointment of fire wardens, with subsequent training;



Location plans of safety shower, fire hoses, extinguishers, and water sources.



Access for emergency services;



Provision of firewater lagoons. There are several important aspects in fire fighting equipments, which are:

a.

Fire Extinguisher Fire extinguisher is the equipment that is used to extinguish the fire in small

scale. This equipment usually in tubular form and used to extinguish the fire in the emergency situation. Fire extinguisher which will be used in our plant is class B fire extinguisher. This type usually used for flammable liquids and gases. We chose this type because some raw materials that we use are flammable. b.

Fire Hydrant Fire hydrant is a permanent system that is used to extinguish the fire. It uses

pressurized water which flowed through pipes and fire hose to extinguish the fire. In our plant, there are class 2 of building hydrant system. This type has 1,5 inch diameter of a hose. This type usually used for untrained people. c.

Safety shower and eyewash station Universitas Indonesia

120 Safety showers and eye wash stations are the emergency facilities which shoud be available in every chemical laboratory. They are used by laboratory workers in case of splash of toxic or corrosive chemicals or fire. This equipment should also provide a drainage system for the excess water and should not come into contact with any electrical equipment that may become a hazard when wet, and should be protected from freezing when installing emergency equipment outdoors. Whereas, an emergency blangket should be available near the shower to prevent from shock and cover the place for removal of clothes. 6.3.3

Evacuation Area Evacuation areas is an important thing to be planned when there is an

emmergency situation occurs. All of employee should have to get out from the plant immediately and go the nearest assembly point. Our plant have been declared the assembly point in the some place. First point is near to the mosque. Second, it is placed near to the central control room. Third, the assembly point is near to the raw material storage, then the fourth is placed near to the product storage. Besides that, in this plant design, we build fire station near to the mechanical and electrical building which is also near to the process area. When the emmergency situation occurs, sometimes due to the intensity of the accident, we should initial the emmergency shutdown when the situation such as below: a. An electric power failure while the process production operates. b. Manual alarm c. Equipment failure If there is an emmergency situation, the plant should be shutdown as the shutdown prosedure to minimize the risk of failure. Worker can follow escape route to save themselves as the simulation given routinely. If the emmergency shutdown has been initiated, the plan will not cause any damage to the worker or community. Thus, the escape route and shutdown procedure are essentially need in the plant design. The red arrows indicate evacuation routes from each point of the plant leading to assembly point. Universitas Indonesia

121

N GUESTCARPARK(FORSECURITY ADMISSION)

SECURITY

MOTORCYCLEPARKING AREA

W

E

MAIN GATE

S CHEMICALENGINEERINGDEPARTMENT FACULTYOF ENGINEERING UNIVERSITASINDONESIA DEPOK

CAR PARKING AREA PROJECT

PRELIMINARYDESIGN OFCOPPER SMELTER PLANT DRAWING

DATE

NO.

11/16/2016

2

ASSEMBLY POINT

GROUP

PAR13

OFFICE BUILDING MOSQUE

CLINIC K3 BUILDING ASSEMBLY POINT

FIRESTATION

LAB MECHANICAL AND ELECTRICAL BUILDING

CANAL

CANAL

CENTRAL CONTROL ROOM

POWER PLANT WATER UTILITY

ASSEMBLY POINT

SULFURIC ACID PLANT

OXYGEN PLANT

RAW MATERIAL STORAGE COPPER SMELTER PLANT

ASSEMBLY POINT

PRODUCT STORAGE

LOADING AND UNLOADING

FLARE

Figure 6.1 Evacuation Route Map

6.4

Waste Management

Waste of processing in industry has to be handling well or else it may give damage that affect environment or sustainability of production in plant. All of those wastes can be directly discarded, recycled, used again in the process, or even can be sold to other plant as their raw material. 6.4.1

Solid Waste Solid waste in our plant consist of anode slime and copper slag. Anode

slimes are collected from the bottom of the electrolytic cells during the refining of copper. Anode slime consists many precious components such as Cu, Pb, Sn, Zn, Ni, Fe, As, Sb, SiO2, MgO, Ag, and Au. According to Freeport Indonesia report, anode slime can be used for gold and silver. In our plant, we produce anode slime Universitas Indonesia

122 approximately 5.25 tonnes/day and we will try sell this material to the related industry. For copper slag, also from Freeport report, it can be used for raw material concrete and cement. Copper slag is a by-product which obtained during the matte smelting and refining of copper (Biswas and davenport, 2002). In our plant, we produce copper slag at least 1000 tonnes/day. Since the product has a large amount it will be beneficial if we sell it to the related industry. 6.4.2

Liquid Waste In our plant, liquid waste comes from cooling water. All of the output

cooling water flow will be recycled and us ed again as input in the process. We chose recycling because the cooling water used in our plant has been through the mineralization process in water utility unit. Mineralization process require high operating cost so it’s such wasting money if we always dispose the output cooling water that been mineralized. The other reason we chose recycling is because in our plant the cooling water mostly not directly contacted with other material so that the contamination from other substances can be minimized and can be used again in the process. Treatment needed in recycling the cooling water waste of our plant is lowering its temperature by using heat exchanger. Heat exchanger used in order to minimize contamination from other substance as we know the cooling water been mineralized before. As the cooling component, sea water (without mineralization) is used in order to exchanging its heat. So, the effluent will only be sea water used as cooling water. However, since the liquid waste is also coming from SO3 reduction system, the waste water has to pass the mineralized unit to remove any substance if we want to use it again as a recycled of feed water. 6.4.3

Gas Waste In our plant, gas waste comes from sulfuric acid plant. In our sulfuric acid

plant, we want to make SO2 into sulfuric acid which is going to be sell to fertilizer industry. However, this plant produce gas waste specifically sulfur trioxide (SO3) which comes from absorber. Since SOx is a pollutant that is dangerous, we decide to reduce again the amount of SO3 before it will burn using flare stack. One of Universitas Indonesia

123 alternative SO3 reduction system is salt solution spray + Wet-type ESP (WEP). This system can collect SO3 mist very effectively from the water saturated gas at downstream of FGD system (flue gas desulfurization). The dissolved salts applicable in this system can be any salts of Na, Mg and K. In a journal that we get the salt that is injected is sodium based, so that the solution of NaHSO3 and Na2SO4 are injected. Sprayed droplet including salt solution is drying up in the flue gas, and absorbing SO3 on its surface. Salt solution droplet does not react with SO2, and it absorbs selectively only SO3, so that SSS is very effective for SO3 reduction. 6.4.4

Sound Pollution Noise in our plant generated from many equipment such as pump, and

compressor. This noise can also cause damage to mechanical system to appliance. According to Ministry of Manpower Decree No. Kep.51/MEN/1999, Threshold Limit Value (TLV) from noise is around 85dB for 8 hours a day or 40 hours a week. If exceed the TLV there are some disorders that can cause such as physiological disorder (reducing function of hearing) and also psychological disorders (mental and stress disorder). In order to reduce noise level there are some action that can be done which are eliminate noise transmission to workers, eliminate noise from noise source, and providing protection to employees. For eliminating noise from noise equipment can be done by regular maintenance and replacing the parts that caused noise. Eliminating noise transmission can be done by closing the engine as soon as possible and if necessary isolate and minimize the machine from any holes and doors. For the workers that always work around the equipment that generated noise will be equipped with ear plug in order to dampening noise. Using ear plug can decrease noise up to 20 dB so that they can keep working in the save area.


124 CHAPTER VII CAPITAL ESTIMATE

In this chapter, there will be explained about several calculation and analysis needed to be done to estimate the economic analysis for this plant. The calculation need several assumptions as shown below 1. Plant lifetime is 20 year; start from 2020 (including the equipment purchase and based on the benchmarking). 2. The main plant, copper smelter has a total production of 320,000 tonnes/year copper cathode that is done in continuous production. In estimating equipment cost, we use index value to estimating price at present time, the equation is shown below.

              

7.1

(6.1)

Total Equipment Cost

The price of equipment is calculated for purchasing in 2020. The prediction cost is done by using cost index, explained in the previous sub-chapter. The table on Appendix F shows the cost of all the equipment. 7.2

Total Bulk Material Cost

Bulk material cost calculated from piping, controller, and electricity cost. The details of each component can be seen in Appendix E. Table 7.1 Total Bulk Material Cost Component

Cost (USD)

Piping Copper Smelter

6350.175

Piping Sulfuric Acid

24320

Piping Oxygen Plant

3157.71

Piping Power Plant

2831.211

Piping Water

7128

Valve

160,791

Total

204,578


125 7.3

Site Development Cost

In our plant site development cost consist of site preparation cost and land cost. The wide area of our plant is Table 7.2 Building Plant Cost Building

Building (Plant)

5,994,083

Building (Office)

11,988,166

Others

2,997,041 Total

7.4

Cost (USD)

20,979,290

Building Cost

Building costs are costs required to build some buildings that exist in our factory based on the results of our calculations in Plant Layout. This cost is based on the volume of each of the buildings that will determine the cost of materials to construct the building. The total is USD 46,582,653. 7.5

Supporting Equipment Cost

Supporting facilities is equipment needed to accelerate production process which is including in the entire area of plant building. The amount of these supporting equipment is determined from the number of employees and also their needs, with total USD 1,252,500. 7.6

Engineering and Supervision Cost

The engineering costs, sometimes referred to as home office costs or contractor charges, include the costs of detailed design and other engineering services required to carry out the project construction design and engineering. We use 8% of Total Direct Permanent Investment Cost. 7.7

Construction Expenses

Construction is the item else that is included into indirect plant cost and consist temporary construction and operation, construction tools and rentals, home office personnel located at the construction site, construction payroll, travel and living, taxes and insurance, and other construction overhead. This expense item is occasionally included under equipment installation, or more often under


126 engineering, supervision, and construction. We use 10% of Total Direct Permanent Investment Cost. The calculation shown in table below. 7.8

Contingencies Cost

Contingency charges are extra costs added into the project budget to allow for variation from the cost estimate. In order to compensate for unpredictable expense, minor process changes, price changes, and estimating errors, a contingency charge is applied against the direct plant cost. We use 15% of Total Direct Permanent Investment as contingency cost because in this plant there might be unpredictable costs due to the miss-calculation. The calculation shown in table below. 7.9

Contractor’s Fee

The contractor’s fee depends upon the size, complexity, and location of the

plant. We use 3% of Total Direct Permanent Investment. The calculation shown in table below 7.10

Additional Cost

Additional cost consists of royalties cost, plant startup cost, and others. Estimate royalties cost is equal to 2% of CTDC and plant startup cost is equal to 10% of CTDC. 7.11

Working Capital

We use 17.6% of Total Permanent Investment for working capital.


127 7.12

Calculation of Total Capital Investment Table 7.3 Total Capital Investment Type Cost

Direct Cost

Kind of Cost

Symbol

Cost (USD)

Note

Total Bare-Module Cost

C TBM

59,940,828

Calculated

Cost of Bulk Material

C Bulk

214,021

Calculated (valve+pipe)

Site Development Cost

C site

10,461,528

Calculated

Building Plant Cost

C Build

20,979,290

Calculated

Supporting Equipment Cost

CSupport

1,252,500

Calculated

91,595,668

(CDPI = CTBM + Cbulk + Csite + Cbulid + Csupport)

Total Direct Permanent Investment

Indirect Cost

Additional Cost

Working Capital

CDPI

Engineering and Supervision

Ceng

7,327,653

(8% CTBM)

Construction Expenses

Cconstruction

9,159,567

(10% CTBM)

Contingencies Cost

C contingency

13,739,350

(15% CTBM)

Contractor’s Fee

Ccontractor

2,747,870

(3 % CTBM)

Total Depreciable Capital

CTDC

124,570,108

Royalties Cost

Croyal

2,491,402

(CTDC = CDPI + Ceng + Ccontruction + Ccontingency + C contractor) (2% CTDC)

Plant Start Up Cost

Cstartup

12,457,011

(10% CTDC)

Additional Cost

C support

7,066

Calculated

Total Permanent Investment

CTPI

139,525,587

(CTPI = CTDC + Croyal + Cstart up)

Working Capital

C WC

24,700,000

(CWC = 17.6 % CTPI)

Total Capital Investment

CTCI

164,225,587

(CTCI = CTPI + CWC)


CHAPTER VIII OPERATING COSTS

Manufacturing cost associated with day-to-day operation of copper smelter plant have to estimated before economic feasibility of a proposed process can be assessed. Manufacturing consist of direct manufacturing cost, fixed cost, and general expense. 8.1

Equity

In building a factory, the most important factor to be looked at is whether the plant is porfitable or not. To the factory must be assessed its equity. To reduce the risk, the owner can borrow money from the bank and investor. However, for this plant we will use 40% of equity capital from the bank loans and 60% from the investors. The table below shows the total equity from investor and banks. Table 8.1 Financial Interest

8.2

Capital Source

Percentage

Capital Share [USD]

Bank BCA

4%

6,568,924

Bank Citibank

4%

6,568,924

Bank of America

6%

9,853,386

ANZ Panin Bank

6%

9,853,386

Standard Chartered Bank

4%

6,568,924

Bank Mandiri

6%

9,853,386

BNI

10%

16,422,310

Investor I

30%

49,266,931

Investor II

30%

49,266,931

TOTAL

100%

164,223,104

Raw Material Cost

Copper concentrate is raw material from PT. Freeport Indonesia by 70% and PT. Newmont Nusa Tenggara by 30%. Our limetone delivered from Rembang with the delivery cost is 0.2 USD/tonne.km. While silica is delivered from Tuban with delivery the cost of 0.2 USD/tonne.km. The coal is delivered from PT. Jaya Shakti Barutama, Kecamatan Manyar-Gresik, with the delivery cost of 0.2 USD/tonne.km.

128


129 Table 8.2 Raw Material Cost Raw Material

Capacity [tonnes/day]

Price [USD/tonne]

Total Price [USD/year]

Copper Concentrate

2390

1,800

1,570,230,000

Silica

516

90

16,950,600

Limestone

186

55

3,733,950

Coal

62

60

3,720

Total [USD/year] (source: various sources)

8.3

1,590,918,270

Utility Cost

The utility on our plant is water utility, for process and as a cooling water. The utility requirements are obtained from the material and energy balances. As requirements increase, the unit cost declines. The table on Appendix F shows the total utility cost. 8.4

Waste Treatment Cost

The waste treatement in our plant consists of dust treatment and SO2 gas treatment. For dust treatment that include in nonhazardous solid waste disposal we need 38 USD/tons. Since our dust production is 500 tonne/year, so waste treatment cost of our plant is 19,000 USD/year. 8.5

Labor Cost

8.5.1

Direct Labor Cost To operate our plant and keep the processes continously generating product,

we need labors. Direct labor cost involves expense cost for worker that is directly related in plant process such as operator, technician, etc. Our integrated smelter plant operates continously 24 hour and it requires workers to keep monitoring the processes. Operating costs for this labor can be calculated from the estimated number of daily labor and the necessary shift. (Sinnott, 2005). We assume effective production activity of our plant in a year is 360 days. The direct labor cost can be seen on Appendix F. 8.5.2

Indirect Labor Cost Indirect labor cost calculates salaries for worker that are not directly related

with the plant process. It will involve executives and clerical wages. Here we consider non-field worker that that does not related to engineering department or Universitas Indonesia

130 anything about technical aspect. This includes administrative cost that can also contributes in calculation of general expenses cost. The indirect labor cost can be seen on Appendix F. 8.6

Maintenance Cost

Maintenance cost are devided into four categories: Wages and benefits (MW&B) in our plant is 10% of TCI, while the salaries and benefits is equal to 25% of MW&B. Total annual cost of maintenance is USD 37,747,887/year. 8.7

Operating Overhead Cost

Overhead cost is devided into four categories: general plant overhead, provision for the services of the mechanical department and for the employee relations department, as well as business services, with the total annual operating overhead cost equal to the sum of these four categories or (7.1+2.4+5.9+7.4) = 22.8% of M%O-SW&B. The total operating overhead cost is USD 5,038,584/year. 8.8

Local Taxes and Insurance Cost

Annual property taxes are assessed by the local municipality as a percentage of the total depreciable capital, CTDC, with arrange from 1% for plants located in sparsely populated areas to 3% when located in heavily populated areas. Property taxes are not related to federal income taxes levied by the Internal Revenue Service and considered below. This corresponds to a process of low risk located away from a heavily populated area. 8.9

Depreciation

Depreciation is the reduction in value of an asset. The assets of our plant come from equipment and building cost. The method used to depreciate an asset is a way to account for decreasing value of the asset to the owner and to represent the diminishing value (amount) of the capital funds invested in it. 8.10

Cost of Manufacture

After we have known direct manufacturing cost, operating overhead, and fixed cost; now we can calculate total annual cost of manufacture (COM) for our plant. It is the sum of those mentioned before. By determining cost of manufacture, we will be able to obtain total production cost later. Annual cost of manufacture we Universitas Indonesia

131 that we have calculated is shown below: Cost of Manufacture (COM) = Raw Material + Utilities + Operation (laborrelated) + Maintenance + Operating Overhead + Property Tax + Insurance + Depreciation.

General expenses (GE) refer to activities that are conducted by the central operations of a company, perhaps at the corporate headquarters, and are financed from profits made by thecompany from their operating plants (Seider, 2003). This expenses are mostly related with distribution of product, administrative of employee (indirect labor), and other general possible expense beside costs that we have obtained before. Table 8.3 Cost of Manufacture Variable

Cost [USD/year]

Raw Material Cost

1,590,918,270

Direct Operating Labor

1,377,300

Utiliy Cost

533,075

Total Variable Cost

1,592,828,645 Fixed Cost

Indirect Labor

1,479,333

Maintenance Cost

37,771,314

Safety and Environmental Cost Property Taxes and Insurance Cost Royalties Cost

64,869 10,789,784 1,642,231

Total Fixed Cost

51,747,532

Direct Production Cost

1,644,576,177

General Expense

8.11

Sales Expense

328,915,235

Direact Research

15,787,931

Allocated Research

1,644,576

Administrative Expense

6,578,305

Management Incentive Compensation

4,111,440

TOTAL GE

357,037,488

ANNUAL PRODUCTION COST

2,001,613,665

Operating Cost (OPEX) Breakdown

If we have calculated cost of manufacture and general expenses, we can calculate total production cost for our plant. It represents total plant outcome that involves all aspect. This expense will be a consideration of business investation of Universitas Indonesia

132 the plant which is also compared by sales income later. The formula of total production cost (C) is shown below: Total Production Cost = Cost of Manufacture (COM) + General Expenses (GE) Total production cost of our plant is around 2 billion USD, consist of variable cost, fixed cost, and general expense. Table 8.4 OPEX Breakdown

Variable

Cost [USD/year]

Raw Material Cost

1,590,918,270

Direct Operating Labor

1,377,300

Utiliy Cost

533,075

Indirect Labor

1,479,333

Maintenance Cost

37,771,314

Safety and Environmental Cost

64,869

Insurance Cost

10,789,784

General Expenses

357,037,488

Total [USD/year]

1,999,971,434

OPEX Breakdown

18%

Raw Material Cost

2% 0% 1% 1% 0% 0%

Direct Operating Labor Utiliy Cost Indirect Labor Maintenance Cost Safety and Environmental Cost Insurance Cost 78%

General Expenses

Figure 8.1 OPEX Breakdown Diagram


CHAPTER IX ECONOMIC EVALUATION

9.1 9.1.1

Investment Feasibility Analysis Income

Our product included copper cathode is a main product, slag and gypsum as waste product, we decided to sell our waste to cement Plant. Sulfuric acid to fertilizer plant and anode slime for gold and silver refining industries. The price of commodity is determined by the market supply and demand, operational cost, etc. Income of our plant is shown in table below. Table 9.1 Income of The Plant

9.1.2

Product

Capacity [tonnes/year]

Product Price [USD/ton]

Total [USD/year]

Copper

321565

6.700,00

2.154.485.500,00

H2SO4

265000

250,00

66.250.000,00

Slime

70000

3.510,00

245.700.000,00

Slag

387265

150,00

58.089.750,00

CaSO4

64000

1.100,00

70.400.000,00

Cash Flow

Calculation of cash flow involves the income before tax, after taxes, depreciation, and salvage value of equipment called the after -tax cash flow (ATCF). Revenue in this factory is the revenue generated from the product ferronickel and slag meanwhile the cash flow-out can be derived from investment, cost, and loans. Percentage of tax is 30 %. We estimate our plant age is 30 years. Our cash flow calculates using Microsoft Excel. The annual cash flow contains inflow and outflow. Inflow comes from income before and after taxes and residual value or salvage value. Cash flow out of which is the cost of investment, and operating. Details of the calculation of the cash flow in and out can be seen on Appendix F. So, the figure below is the cash flow before and after tax. For calculating the cash flow, the selling product is 100% sold out.


134 The reasons why we brave to sell it 100% from the first year because our product is cheap and the consumer is determined and only one. The graph below on Appendix F cash flow diagram of our plant. For after tax cash flow, this cash flow is calculated with tax. tax . The income tax we assume is 30% after depreciation according to Direktorat Jenderal Pajak, 2013.Because it is after tax, the cash flow will have the lower cumulative income; this after tax cash flow is used for calculating the profitability analysis such as,IRR and Payback Period. The calculations of after tax and before tax cash flow are shown in the appendix. 9.2

9.2.1

Profitability Analysis

IRR Internal Rate of Return (IRR) is a measure of the maximum of interest rate

paid on project and still break even at the end of the project life. In other words, the IRR is the interest rate when NPV = 0, so that the formula used to calculate the IRR is:

= = 1+  0

(9.1)

With the value of r is the IRR. Calculating cash flow by using Microsoft excel, we obtain IRR of 35,17 % from our copper smelter plant. If we compare the IRR with MARR (35,17% (IRR) > 23,46% (MARR)), the difference is quite high (11,71%). According to the definition of IRR Itself, It means that IRR will be used to compare the working capital as project with minimum probability. Comparing IRR of our plant to other competitors, the value is below other bigger plants that have IRR value about 35,17%. It’s almost equal with our plant. Those facts give us a good

impact, so that our plant and product may be compared with other plant and also visible to be built. 9.2.2

NPV Net Present Value (NPV) shows s hows the net benefits ben efits received by b y a project over

the life of the project at a certain interest rate. NPV can also be interpreted as the present value of the cash flows generated by the investment. In calculating the NPV Universitas Indonesia

135 is necessary to determine the relevant interest rate. In this calculation, the interest rate used is the interest rate on the bank loan for start-up capital, average amounting to 11,7%. A project can be counted as feasible if the NPV>0, which means the project is profitable or provide benefits if implemented. If NPV<0, NPV<0, the project is not eligible to run because it does not generate profit. Cash flow in year-n year-n drawn into

,0  1+

present value with a reasonable reas onable interest rate by b y using the following formula: (9.2)

MARR value for our product is 23,46% based on average WACC. By MARR 23,46%, we obtained NPV $ 2.164.107.388,44. The rule of thumb of NPV is the NPV should be positive with high interest (higher than 10%). If the NPV is negative the project will be stopped. Our NPV is positive and high. It means that the project can be implemented. Analysis for negative NPV will be explained in sensitivity analysis. 9.2.3

Payback Period Payback Period is the duration (in years) of an investment will be returned.

Here isthe formula for calculating payback period taking into account the Time Value of Money:

                +                                     ∶ (         +  )

(9.3)

If the payback period is less than a pre-determined period, the project is acceptable. If the payback period exceeds the predetermined period, the project is rejected. The payback period for this plant p lant is 4,39 years, after calculate calc ulate use Microsoft Excel. Excel . Our payback period is matched with the rule of thumb. The rule of thumb said that the tolerable payback period is about 10 years and should be done after all the loan are fully paid. Figure below shows the cumulative cash flow


136 s 12,000 n o i l i 10,000 ) l D M S U ( 8,000 w o l f h 6,000 s a C e 4,000 v i t a l u 2,000 m m u C -

0

5

(2,000)

10

15

20

25

30

Years

Figure 9.1 Profile of Cummulative Cash Flow

9.2.4

Break Event Point (BEP) Breakeven point (BEP) is an analysis to determine and find the amount of

goods or services to be sold to consumers at a given price to cover the costs incurred

  

and the profit / profit. Calculation to find the BEP is:

(9.4)

The total fixed cost is the fixed cost values tend to be stable and not influenced by the amount of production and the variable cost is the variable cost of the value depends on the amount of goods produced. In this case the BEP can be

 164.$6700/121.246 24495 

previously seen from the graph, grap h, Payback Period occurs on o n 4.4 years.

(9.5)

This analysis is almost the same with payback period however this analysis used the number of goods or package that we sell to get the profit. We should sell at least 24495 tonnes copper cathode, and for the by product we should sell at least 32728 tonnes.

 164.$5010/121.246 32728 

(9.6)


137 9.3

Cost Breakdown

Cost breakdown is consisted of cost breakdown for capital cost and operational cost. Cost Breakdown is used to map out the contribution of the details for capital and operating costs. Capital cost breakdown consisted of direct cost breakdown, indirect cost breakdown, total capital cost breakdown.

Capital Cost Breakdown

15% Direct Cost

9%

Indirect Cost

56% 20%

Additional Cost Working Capital

Figure 9.2 Capital Cost Breakdown

9.4

Sensitivity Analysis

There is always unstability condition in factory. It can happen because of the changes experienced by a plant and can be caused by various factors. These changes can give benefit or even destruction to a plant. Therefore, the sensitivity analysis against some changes need to be done to analysis what variables that can affect the stability of manufacturing. Sensitivity analysis will provide an overview of the extent to which a decision will be consistent despite the change in the factors or parameters that influence it. Sensitivity analysis is an analysis tool to see the feasibility of investment decision if the influence factors or parameters changed. Decision is called sensitive decisions when each change parameter values or factor calculation will change investment In this section, we’re going to make a sensitivity analysis from cash flow.

The variable that we use to see the effect towards the cash flow is selling price, and raw material cost. Even though there are utility cost that higher than both of Universitas Indonesia

138 the raw material and distribution cost, utility is rarely become fluctuated than the distribution especially which is include the gasoline price. Parameters used in the sensitivity analysis is NPV, IRR, and Payback Period. Table 9.2 Raw Material Price Flutuation Change

Raw Material Price Unit (USD)

IRR

NPV(USD)

PP (years)

-10%

1,431,826,443

57,46%

5,167,220,679

3,33

-7%

1,479,553,991

49,75%

4,266,286,692

3,55

-5%

1,511,372,357

45,2%

3,665,664,033

3,76

0%

1,590,918,270

35,2%

2,164,107,388

4,39

5%

1,670,464,184

26,8%

662,550,742

5,240

7%

1,702,282,549

23,5%

61,928,084

5,690

10%

1,750,010,097

19,4%

-839,005,902

6,550

Table 9.3 Product Price Fluctuation Change

Product Price (USD)

IRR

NPV (USD)

PP (years)

-10%

2,335,432,725

17.04%

-1,235,763,467

7,11

-7%

2,413,280,483

22,3%

-215,802,210

5,93

-5%

2,465,178,988

25,9%

464,171,961

5,36

0%

2,594,925,250

35,2%

2,164,107,388

4,39

5%

2,724,671,513

45,0%

3,864,042,816

3,75

7%

2,776,570,018

49,8%

4,544,016,987

3,56

10%

2,854,417,775

57%

5,563,978,244

3,32

Since the most material that changed significantly is copper concetrate as raw material, and copper cathode as our main product we choose this material to analyze. The detail of the most significantly material is shown IRR sensitivity analysis, NPV sensitivity analysis, and payback period sensitivity analysis. 9.4.1

IRR Sensitivity Analysis We’re going to analysis the IRR based on price product fluctuation, and raw

material. We can see that the change of price and raw material give an impact for IRR. When the price of product change lower, then IRR is lower. When the price of raw material change to higher, then th en the IRR is lower. Lower IRR because income is low then outcome is higher. When the IRR is bigger because income is bigger than outcome. Universitas Indonesia

139

IRR Sensitivity Analysis 70.00% 60.00% 50.00% 40.00%

Raw Material Price

30.00%

Product Price

20.00% 10.00%

-15%

-10%

0.00% -5% 0%

5%

10%

15%

Figure 9.3 IRR Sensitivity Analysis

9.4.2

NPV Sensitivity Analysis We’re going to analysis the NPV based on price product fluctuation, and

raw material. NPV is being increase and decrease because of product price and raw material price change. When the price is change on 10% lower than price product now. Its result impact is NVP being negative. Based on the rule of thumb NPV must higher than 1. When its negative, the project not eligible to run. when change of price raw material higher 10% than normal price.

NPV Sensitivy Analysis $6,000,000,000.00 $5,000,000,000.00 $4,000,000,000.00 $3,000,000,000.00 Raw Material

$2,000,000,000.00

Product Price

$1,000,000,000.00 $0.00 -15%

-10% -5% 0% -$1,000,000,000.00

5%

10%

15%

-$2,000,000,000.00

Figure 9.4 NPV sensitivity Analysis Universitas Indonesia

140 9.4.3

Payback Period Sensitivity Analysis We’re going to analysis the payback period based on price pr oduct

fluctuation, raw material. We see that the impact price fluctuation of product and raw material is giving effect for payback period. When the change of price is higher than normal price, then payback period is being faster. When the raw material is being higher then payback period is being longer.

Payback Period Sensitivity Analysis 8 7 6 5 Raw Material

4

Product Price

3 2 1 0 -15%

-10%

-5%

0%

5%

10%

15%

Figure 9.5 Payback Period Sensitivity Analysis

Product price is the most significant parameter that affected our plant. In order to maintain this parameter, we have to find out which from all our product that play the biggest role. Based on our calculation in revenue section, it is known that copper cathode is the biggest parameter that play affected the product price. It is because copper cathode is the most expensive from our product,and also the the biggest product that we sell.


CHAPTER X OUTSTANDING ISSUES

10.1

Technical Aspect

Since raw material of copper smelter plant is copper concentrate that contain copper, sulfur, oxygen, and other metal impurities, it need process to separate that impurities. In our copper smelter, we use Mitsubishi process to recover copper. Concentrates are processed continuously in high-temperature furnaces (>1200oC) by Mitsubishi process which is very feasible to produce high purity copper anodes. Then copper anodes convert to copper cathodes in refining section. Concentrate burning obtained SO2 which converts to H2SO4 in sulphuric acid plant with double contact processes. The oxygen consumption is supplied by pressure swing adsorption processes. These plants need electricity supplied by heat recovery from copper smelter plant. Comparing to the existing copper smelter plant, PT. Smelting Gresik, we are offered to build, is more efficient due to the the process system selected. It is also beneficially implemmented by using pressure swing adsorption. In the existing copper smelter plant, they use cryogeni c process of the oxygen plant. Since cryogenic process is cold process that need temperature below zero, it will need refrigerant and extra treatment like insulation. Of course, it will need more investment cost due to the expensive of building plant by using cryogenic processes.The utilities consumption of the existing copper smelter is bigger than our plant design. The use of crygenic process also influence the total utilities consumption need. Therefore, the total capital investment cost of our plant is reasonable and can be acceppted. The production capacity of copper cathode is around 320,000 tons/year which will be used as electronic product, industry machinery and equipment, construction, transportation, and others. Besides, sulfuric acid produced has capacity 265,000 tons/year which plays significant roles as fertilizer feed, chemical feedstock, metal-ore leaching, and pulp-paper industries.

141


142 10.2

Economical Aspect

Comparing profitability analysis with existing copper smelting, our plant has more profitable. Investment cost of our plant 165 million USD. Furthermore, our plant has investment cost that lower compared than existing plant which has investment 340 million USD. Lower of investment cost of our plant because there is difference process in oxygen plant. Our plant used pressure swing adsorption (PSA) process, while PT. Smelting Gresik used cryogenic process. Beside that, our copper smelter has operating cost is about USD 1.99 billion, payback period is 4.28 years, IRR 35.17%, and MARR 23.46 %. Based on data, other copper smelter has IRR around 20% and payback period 7-9 year. So, we can conclude that value of IRR and payback period of our plant is logic. Market target of our plant is domestic and foreign contries like China and India. Copper makes vital contribution to sustaining and improving society such as creates job opportunities for many field and local people. Building an integrated copper smelter plant is great opportunity to support government regulation in reducing the export of copper raw material. Furthermore, the high value-added products obtained not only empower Indonesia mineral sector, but also support other industries in ASEAN and in the world.


CHAPTER XI CONCLUSION

Based on the discussion above, we can conclude that: 1. Raw material for our plant is natural gas, silica, copper concentrate, limestone and coal 2. PT. Smelco Indonesia has the capacity 320,000 tonnes/year to produce copper cathode, and the needs for copper concentrate is 876 tonnes/year. 3. PT. Smelco Indonesia main product will be focused to sell overseas, since domestic market is not profitable. 4. PT. Smelco Indonesia is divided into several areas, which is office area and process area. Office area (blue zone) includes parking area, mosque, laboratory, firefighting, clinic, and mechanical and electrical building. While process area (red zone) includes all of the process, from utility to side process plant, and main process plant, storage area, and unloading and loading dock. Our plant will be built in 6.582 ha land construction in Gresik, Jawa Timur. 5. Copper smelter method we use is Mitsubishi process, oxygen plant method we use pressure swing adsorption process, and for sulfur acid plant is double contact process. 6. Mass efficiency for copper smelter is 37%, for oxygen plant is 95,33%, and for sulfuric acid plant is 99,2% 7. Utility system in our plant consist of water, air, electricity, and fuel. Total water consumption of our plant as the cooling feed is 1780.95 tonne/hr which source is treated water from Bengawan Solo River. Fuel needed in our plant is 62 tonne/day of bituminous coal which is used for combution process of the furnace in our copper smelter plant. Air utility used to produce pure oxygen for sulfuric acid plant and copper smelter plant requirement is 527 tonne/day. 8. Total electricity needed in PT. Smelco Indonesia is 106852.97 kWh/day which will be consumed as the power source of our main equipment in 143


144 copper smlter plant, oxygen plant, and sulfuric acid plant meanwhile our power plant could be produced 280320 kWh/day. 9. Our plant has 19 process equipments such as belt conveyor, packed bed reactor, heat exchangers, absorber, adsorber, compressor, pump, expander, filter, storage tank, furnace, electrorefining, casting machine, and steam turbine. 10. The piping instrumentation diagram includes a graphic representation of the equipment, piping, and instrumentation. 11. The controlled parameter for our plant is temperature, flow rate, pressure, level and concentration. 12. PT. Smelco Indonesia need some Health, Safety, and Environment analysis based on HAZID and HAZOP to support our production process. For supporting HSE, we need to analyze. In our plant, protective actions for life safety include evacuation area and process, firefighting, plant shutdown, PPE for all the workers, and also four assembly points in case of emergency. 13. The liquid waste of our plant is waste water from the heat exchanger process. The solid waste is copper slag and anode slime, the gas waste is flue gas. 14. The capital investment (CAPEX) for our product is USD 164,225,587 Meanwhile, operating cost consists of manufacturing cost and general expenses. The total operating cost (OPEX) in our project is USD 1,999,971,434 per year. 15. The price of copper cathode is USD 6,700/ton 16. The payback period of our company is 4.4 year. It is indeed fast payback period. 17. The BEP of our company is 24495 ton for copper cathode and 32728 ton for byproduct until we have profit. 18. IRR of our company 35.7% which is actually high enough for investor. 19. NPV, or Net Present value of our product with MARR 23.46% the calculation result is USD 2,164,108,000 20. Based on Sensitivity Analysis, the problem will occured if material cost suddenly increased by 10% resulting in negative value of IRR. Universitas Indonesia

REFERENCES

Ashar, N. G. and Golwalkar, K.R. 2013. A Pratical Guide to Manufacture of Sulfuric Acid. Springer. Daniela Rojas et al., 2013. Copper Market Trends Report, s.l.: A Cochilco Research and Policy Planning Department Publication. Davenporth, William G. et al. 2002. Extractive Metallurgy of Copper 4th Edition. Oxford, UK: Elsevier Science Ltd. Davenporth, William G. et al. 2011. Extractive Metallurgy of Copper 5th Edition. Oxford, UK: Elsevier Science Ltd. Davenporth, William G. and E. H. Partelpoeg. 1987. Flash Smelting: Analysis, Control and Optimization. Pergamon Press. Dattilo, M. and Lutz, L.J. (1999) Merrlin composite anodes for copper electrowinning. In copper 99-Cobre 99 Proceedings of the Fourth International Conference, Vol. I l lElectrorefining and Electrowinning of Copper, ed. Dutrizac, J.E., Ji, J. andRamachandran, V., TMS, Warrendale, PA, 597 601. Delplancke, J.L., Winand, R., Gueneau de Mussy, J.P. and Pagliero, A. (1999) Newanode

compositions

for

copper

electrowinning

and

copper

electrodeposition at highcurrent density. In Copper 99-Cobre 99 Proceedings of the Fourth InternationalConference, Vol. III Electrorefining and Electrowinning of Copper, ed. Dutrizac, J.E., Ji,J. and Ramachandran, V., TMS, Warrendale, PA, 603 608. Douglas, Louie. 2010. Sulfuric Acid Plant Fundamentals. Vancouver, Canada: WorleyParsons. Hanniala, P., Helle, L. and Kojo, I.V. (1999) Competitiveness of the Outokumpu Flash Smelting technology now and in the Third Millennium. In Copper 99Cobre 99Proceedings of the Fourth International Conference, Vol. V Smelting Operations and Advances, ed. George, D.B., Chen, W.J., Mackey P.J. and Weddick, A.J., TMS, Warrendale, PA, 221 238

145


146 International Copper Study Group, 2016. Preliminary Data For May 2016, s.l.: International Copper Study Group. Ivanova, Svetlana and Robert Lewis. 2012. Producing Nitrogen via Pressure Swing Adsorption. AICHE group. Jaya, Aprilia. 2013. Practical Engineering Guidelines for Processing Plant Solutions: Engineering Design Guideline for Air Separation Units. Malaysia Kementrian Energi dan Sumber Daya Mineral., 2012. Kajian Supply Demand Mineral, s.l.: Pusat Data dan Informasi Energi dan Sumber Daya Mineral.

KLM Technology Group. 2013. Air Separation Units (Engineering Design Guideline). Malaysia: KLM Technology Group. Kojo, Ilkka V. and Hannes Storch. 2006. Copper Production with Outokumpu Flash Smelting; an Update. ResearchGate. Kojo, Ilkka V. et al. 2000. Flash Smelting and Converting Furnaces: A 50 Year Retrospect. Liu, Jin and Torstein A. Utigard. Study of Oxygen Flash Smelting of Nickel/Copper Concentrates. Paper. Metal Mining Agency of Japan. 1988. Flash Furnace Copper Smelting. DOWA Mining Co., Ltd. NFM BREF. 2014. Process to Produce Copper and Its Alloys. Scott, Peter. Oxygen – Pressure Swing Adsorption. IChem Ltd. Sugiyono, Agus. 2014. Kebutuhan dan Penyediaan Energi di Industri Smelter Tembaga. Indonesia: ResearchGate.

Smale, D., 2015. Review and Outlook for Copper, Nickel, Lead, and Zinc. Tokyo, International

Copper

Study

Group,International

Lead

and

Zinc

Group,International Nickel Study Group Seider, W.D., Seader, J.D. and Lewin, D. R. 2003. Product and Process Design Principles. John Wiley and Sons, Inc. Smith, Robin. 2007. Chemical Process Design and Integration, 2nd Edition. UK: University of Manchester. Smith, A.R. 2000. A Review of Air Separation Technologies and Their Integration with Energy Conversion Process. USA: Elsevier. Universitas Indonesia

147 st

The Mitsubishi Process, Copper Smelting for the 21 Century. The World Copper Fsctbook. 2014. International Copper Study Group (ICSG). Ziaeee, M. and M. Naser Zare. 2015. Combination Mutual Pressure Swing Adsorption and Cryogenic Distillation to Optimize Separation Unit.


APPENDIX

APPENDIX A: Mass and Energy Balances

A.1 1.

Mass Balance of Copper Smelter Plant Smelting Furnace

Figure A.1 Smelting Furnace Equipment

Table A.1 Smelting Furnace Mass Balance Component

CuFeSs SiO2 O2 CaCO3 Cu2S Cu Fe2S3 FeO FeSiO3 Fe3O4 CaO CaO.Fe3O4 SO2 CO2 Coal Total

In (tonne/day)

Out (tonne/day)

1B 2385.5

2B -

3B -

11B -

1 -

4B -

5B -

2385.5

1120 1120

516 516

25.04 16.54 25.4 488.6 537.4

14.5 14.5

62 1033.5 537.4 16.54 999 1236.2

321 915.2 2586.44

148


149 2.


Figure A.2 Slag Cleaning Furnace Equipment

Table A.2 Slag Cleaning Furnace Mass Balance Component

CuFeSs SiO2 O2 CaCO3 Cu2S Cu Fe2S3 FeO FeSiO3 Fe3O4 CaO CaO.Fe3O4 SO2 CO2 Total

3.

In (tonne/day)

Out (tonne/day)

4B

6B

7B

62 1033.5 537.4 16.54 999 2648.44

1033.5 537.4 16.54 1587.44

62 999 1061

Converting Furnace

Figure A.3 Converting Furnace Equipment Universitas Indonesia

150 Table A.3 Converting Mass Balance Component


4.

In (tonne/day) 6B 8B 9B 600 186 1033.5 537.4 16.54 1587.44 186 600

2 47 47

Out (tonne/day) 10B 11B 12B 71.36 103.35 749.3 25.04 16.54 25.4 488.6 848 71.36 537.4 852.65

Anode Furnace

Figure A.4 Anode Furnace Equipment Table A.4 Anode Furnace Mass Balance Component


In (tonne/day) 12B 167 719 886

13B 40 40

3 0.48 0.48

Out (tonne/day) 14B 6.4 -

67.2 73.6

15B 881.25 881.25 Universitas Indonesia

151 5.

Casting Table A.5 Casting Machine Mass Balance Component

CuFeSs SiO2 O2 CaCO3 Cu2S Cu Fe2S3 FeO FeSiO3 Fe3O4 CaO CaO.Fe3O4 SO2 CO2 Total

6.

In (tonne/day)

Out (tonne/day)

15B -

16B -

881.25 881.25

881.25 881.25

Electrolytic Cell

Figure A.5 Electrolytic Cell Equipment Table A.6 Electrolytic Cell Mass Balance Component

CuFeSs Cu Fe2S3 FeO FeSiO3 Fe3O4 CaO SO2 CO2 Other metals Total

In (tonne/day)

Out (tonne/day)

16B -

17B -

18B -

881.25 881.25

876 876

5.25 5.25 Universitas Indonesia

152 A.2

Mass Balance of Oxygen Plant Table A.7 Mass Balance in

Component

out

4

1

5

O2 (tonnemole/day)

82

82

0.000

N2 (tonnemole/day)

357

357

0.000

Dust

0.001

0.001

0.001

Total

440

440

0.001

P [atm]

1

1

1

T [K]

300

300

300

Table A.8 Compressor Mass Balance in

out

in

out

1

1a

1e

2a

O2 (tonnemole/day)

82

82

82

82

N2 (tonnemole/day)

357

357

357

357

Dust

0.001

0.001

0.001

0.001

Total

440

440

440

440

P [atm]

1

5

2.45

5

T [K]

300

425

305

297

Component

Table A.9 Heat Exchanger Mass Balance E-201 and E-202 E-201 Component

m (tonne/day)

E-202

in

out

in

out

1a

C1

1b

C2

1b

18

1c

19

7652

6878

7652

6878

7652

700

7652

700


m (tonne/day)

E-204

in

out

in

out

1c

14

1d

14a

1d

14a

1e

16

7652

800

7652

800

7652

800

7652

700


in 2a

E-206 out

C3

2

C4

in 2

out 13

2b

13a


153 Table A.12 Heat Exchanger Mass Balance E-207 E-207 Component

in

m (tonne/day)

out

2b

13a

2c

15

7652

6734

7652

6734

Table A.13 Adsorber Mass Balance in

Component

A.3 1.

out

2

7

6

O2 (tonnemole/day)

82

78

4

N2 (tonnemole/day)

357

8.6

348

Total

440

87

352

P [atm]

5

5

5

T [K]

302

302

302

Mass Balance of Sulfuric Acid Plant Heat Exchangers Table A.14 Heat Exchanger E-301 and E-302 Mass Balance E-301 Stream

In 1

m (tonne/day)

Out 21

1860

E-302 In 15

1’

700 1860

Out 15

1’

800 1860

2

16

800 1860

800

Table A.15 Heat Exchanger E-303 and E-304 Mass Balance E-303 Stream

m (tonne/day)

E-304

In

Out

2

C1

2’

1860

6878

1860

In C2

2’

6878 1860

Out 20

3

21

700

1860

700


m (tonne/day)

In

E-306 Out

In

Out

4

13

5

14

6

14

7

15

2560

800

2560

800

2560

800

2560

800


m (tonne/day)

In

E-308 Out

In

Out

8

18

9

19

10

19

11

20

2560

700

2560

700

2560

700

2560

700


154 2.

Converter Table A.18 Bed Converter Mass Balance 1st Converter Stream

In

m(tonne/day)

3.

2 nd Converter

3 rd Converter

Out

In

Out

In

Out

4 th Converter In

Out

3

22

4

5

6

7

8

9

10

1860

700

2560

2560

2560

2560

2560

2560

2560

Absorber Table A.19 Absorber Mass Balance In

Stream

A.4

Out

11

23

25

26

m (tonne/day)

2560

2100

100

1000

Stream

24

26

27

28

m (tonne/day)

4560

1000

100

5560

Energy Balance of Copper Smelter Table A.20 Total Energy Requirements of Copper Smelter Plant Feed (tons) 104 kJ Total (104kJ)

Operation

Smelting Furnace Mitsubishi

2385

128.6934

306949.5

2648

65.875

174437

Converting Furnace Mitsubishi Reactor

1587

31.8308

50514.2

Anode Furnace Mitsubishi (2)

886

95.5

84604.14

881

59.1294

51979.2

881

18

15858

Cleaning Slag Mitsubishi

Electro Refining Electric

Reactor

Reactor

Furnace

Hazelet Caster TOTAL

A.5

684341.84

Energy Balance of Oxygen Plant

1. 1st Compressor Table A.21 Energy Requirements of 1 st Compressor Condition

Input

Output

Q-compressor

1

1a

Temperature (K)

-

300

426

Pressure (atm)

-

1

2.5

Heat Flow (MW)

10.8

0.5

11.3

Total Heat Flow (MW)

11.3


155 nd

2. 2 Compressor Table A.22 Energy Requirements of 2 nd Compressor Input Condition

Q-compressor

1b

2a

Temperature (C)

-

303

424.3

Pressure (Bar)

-

2.5

5

0.57

8.75 8.75

Heat Flow (MW) Total Heat Flow (MW)

A.6

Output

8.18 8.75

Energy Balance of Sulfuric Acid Plant

1. Heat Exchangers Table A.23 Heat Exchanger E-301 and E-302 Energy Balance E-301 Stream

E-302

In

Out

1

21

In

Out

15

1’

15

2

16

115 1100

109

1100

114

950

250

1’

T[oC]

1200

P[bar] Heat Flow (MW)

2

1.7

1.9

1.4

1.9

1.6

1.8

1.3

-5.6

-11

-5.8

-10.8

-5.8

-12.6

-6

-12

Table A.24 Heat Exchanger E-303 and E-304 Energy Balance E-303 Stream

E-304

In

Out

In

Out

2

C1

2’

C2

2’

20

3

21

o

T[ C]

950

6878

800

6878

800

700

377

700

P[bar] Heat Flow (MW)

1.8

1.4

1.6

0.98

1.6

1.8

1.54

1.7

-11.8

-7.2

-11.0

-6

-12.5 -6.4

-12.4 -6.4

Table A.25 Heat Exchanger E-305 and E-306 Energy Balance E-305 Stream

In

E-306 Out

In

Out

4

13

5

14

6

14

7

15

T[oC]

776

27

357

115

634

115

327

294

P[bar]

1.65

2

1.35

1.7

1.36

1.7

1.35

1.6

Heat Flow (MW)

-7.1

-14.6

-8.3

-13.4

-8.3

-13.4

-9.2

-12.5


156 Table A.26 Heat Exchanger E-307 and E-308 Energy Balance E-307 Stream

E-308

In

o

T[ C] P[bar] Heat Flow

Out

In

Out

8

18

9

19

10

19

11

20

479 1.4 -9.2

22 2 -12.8

317 1.2 -9.6

117 1.8 -12.3

329 1.2 -9.6

117 1.8 -12.3

127 1.1 -10

125 1.75 -11.8

2. Converter Table A.27 Bed Converter Energy Balance 1st Converter Stream

3.

In

2 nd Converter

3 rd Converter

4 th Converter

Out

In

Out

In

Out

In

Out

3

22

4

5

6

7

8

9

10

T[oC]

377

27

776

357

634

327

479

317

329

P[bar]

1.54

2

1.65

1.35

1.36

1.35

1.4

1.2

1.2

Heat Flow (MW)

-7.2

0.01

-7.1

-8.3

-8.3

-9.2

-9.2

-9.6

-9.6

Absorber Table A.28 Absorber Energy Balance Intermediete Stream

In

Final

Out

In

Out

11

23

25

26

24

26

27

28

T[oC]

127

30

130

130

27

130

130

130

P[bar]

1.1

1.2

1.1

1.1

1.5

1.1

1.2

1.2

Heat Flow (MW)

-10

-3

-5.2

-5.2

-3.5

-5.2

-6.4

-6.4

4. Pump Table A 29 Pump Energy Balance P-301 Stream

P-302

In

Out

In

Out

13’

13

18’

18

T[K]

27

27

22

22

P [atm]

1

2

1

2

Heat Flow (MW)

-14.6

-14.6

-12.8

-12.8


APPENDIX B: BFD and PFD

Figure B.1 BFD of Copper Smelter Plant

157


To Flare Stack Dust, Condensate

Air

O2 N2

Filter

O2 N2

Compressor

O2 N2

Drum

O2 N2

Adsorber

O2

Drum

N2 Drum

O2

To Copper Smelter Plant & Sulfuric Acid Plant

To Copper Smelter Plant

Figure B.2 BFD of Oxygen Plant

158


H2SO4

O2

SO3

SO2

Heat Exchanger

Reactor

SO3

Heat Exchanger

SO3

+ Vanadium catalyst

To Flare Stack

Adsorber

H2SO4

to H2SO4 Storage

Figure B.3 BFD of Sulfuric Acid Plant

159


Figure B.4 PFD Before HEN Copper Smelter I

160


P-101 Pump

C-108 Belt Conveyor

From Casting

TK-102 / TK-103 Storage

C-109 Belt Conveyor

P-101 Electrolytic Cell

16B

C-108

Cu

17B

C-109 P-101 H2SO4

19B

V-101

CV-101

TK-103

18B

P-101

Anode Slime

TK-102

c

1 6B

1 7B

1 8B

19 B

T (K)

1 52 3

1 5 23

1523

299

P (atm)

1

1

1

1

Component (tonne/day) -

-

SiO2

-

876

-

-

O2

-

-

-

-

CuFeSs

CaCO3

-

-

-

-

-

-

Cu2S

-

-

-

-

Cu

881.3

-

-

-

Fe2S3

-

-

-

-

-

-

-

-

DEPARTEMEN TEKNIKK IMIA

Fe3O4

-

-

-

-

-

FAKULTASTEKNIK

CaO

-

-

-

-

UNIVERSITASINDONESIA

FeO FeSiO3

CaO.Fe3O4

-

-

-

-

-

SO2

-

-

-

-

CO2

-

-

-

-

-

-

5 .25

-

Other metals

-

NAME NAME

SIGNATURE

DATE

Group 13

CORRECTEDBY

PFD PICTURE NO.

PRELIMINARY DESIGN OF COPPER SMELTER

PFD – 001/2016 WITHOUT SCALE

Figure B.5 PFD Before HEN Copper Smelter II

161


P-201 E-201 K-202 Pump Heat Exchanger Compressor

K-201 Compressor

FG-201 Air Filter

E-202 Heat Exchanger

R-201 Adsorber

R-202 Adsorber

D-201 / D-202 Drum

7 CV-210

O2

Power Plant, Water Utility

CV-208

CV-203

D-201

Power Plant, Water Utility

Air

CV-205

C4

C2

4

2 V-202 E-202

2a 1

1a

V-201

E-201

R-201

1b

R-202

CV-204

FG-201 CV-206

CV-201 5

C3

K-201 C1

CV-202

K-202

CV-207

N2

6 CV-209

Water Utility

D-202

P-201 Dust

To Flare NAME

DEPARTEMEN TEKNIKKIMIA FAKULTASTEKNIK

NAME

SIGNATURE

DATE

Group 13


Stream

4

5

1

1a

1b

2a

T (K)

3 02

3 02

3 00

4 25

3 05

3 97

P (atm) Mass Flow (tonne/day)

1

1

1

2.5

2.45

5

7652

0

2 302 5

6 3 02 5

7 302 5

C1 3 05 1.5

C2 3 37 0.98

C3 3 04 1.5

CORRECTED BY

C4

PFD

3 29 0.98

7652 7652 7652 7652 7652 7652 7652 6878 6878 6734 6734

PICTURE NO.



Figure B.6 PFD Before HEN Oxygen Plant

162


P-301 Pump

E-301 / E-302 Heat Exchanger

E-303 / E-306 / E-307 R-301 Heat Exchanger Packed Bed Reactor

R-302 R-302 Final Intermediate Adsorber Adsorber

P-302 Pump


TT-301 Acid Storage Tank

H2SO4 Storage To Flare Stack

25 11 23

E-307 10

9

O2 Storage

22

19

27

20

To Flare Stack

R-302 24 8

Economizer, Copper Smelter Plant

E-306

21'

26 6

7

R-303

4 5

18

Water Utility

E-305

17

14

3

28

R-301

P-301

TT-301

15

SO2

1

1'

E-304

2

E-301

13 12

E-303

E-302

16

21


P-302 NAME

DEPARTEMEN TEKNIKKIMIA 1 T(K) P (atm)

1'

2

3

4

5

6

7

8

9

10

11

1473 1373 1073 650 1049 630 906

600 751

590

602 400

2

1 .8 5

-

-

1 .7

1.6

1.6

1.3

1 .3

1 .3

1 .3

1 .2

1 .2

-

-

-

-

-

-

-

-

12

13

298 500

0.97

2

1

14

15

17

18

19

20

21 21'

22

388 566.5 297 295 390 398 473 491 303 1 .8

1 .6

1

2

1 . 7 1 .7

2

2

1 .2

23

303 1 .2

24

25

26

FAKULTASTEKNIK

NAME

403 403 403 12 .

1 .1

1 .2

186 0 1 860

H2O

-

SO3

H2SO4

-

-

-

700 -

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

8 00

800

800

-

2560

-

-

-

800 -

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

1 00

-

700 700 700 700 700 700 -

-

-

-

-

-

-

-

-

-

-

-

-

1000

4560

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

DATE

CORRECTED BY

-

70 0 2 560 25 60 256 0 2 560 25 60 256 0 256 0

SIGNATURE

Group 13


Component (tonne/day)

O2 SO2

Water Utility

-

-

-

-

-

-

3100 2100

PFD PICTURE NO.


BFD – 003/2016 WITHOUT SCALE

Figure B.7 PFD Before HEN Sulfuric Acid Plant

163


K-201 Compressor

FG-201 Filter

P-201 Pump

K-202 Compressor

E-201 / E-202 / E-203 / E-204 Heat Exchanger

R-202 Adsorber

R-201 Adsorber

E-205 / E-206 / E-207 Heat Exchanger

D-201 / D-202 Drum

CV-210 To Oxygen Plant CV-203

O2

7

CV-208

D-201

To Sulfuric Acid Plant

CV-205 13a

C2

C4

14a

19

Air 4

1b 1 FG-201

2a

1d

1c

E-201

E-202

V-202 E-204

E-203

2b

2 E-205

E-206

2c E-207

1e

R-202

R-201

1a

V-201

CV-204 5

13

C1 C3

16

14

18

CV-201

15

K-202

CV-206

K-201 CV-202

CV-207

N2

6

Water Utility

CV-209

P-201

D-202


From Sulfuric Acid Plant

Dust




To Flare

NAME


Stream

4

5

1

1b

2a

2

6

7

T(K)

3 03

3 03

3 03

4 15

3 03

4 24

3 03

3 03

3 03

P (atm) Mass Flow (tonne/day)

1

1

1

2.5

1a

2.45

5

5

7652

0

5

5

C1 3 05 1.5

C2

C3

3 37 0.98

7652 7652 7652 7652 7652 7652 7652 6878 6878

C4

3 04 1.5

6734

NAME

6734

DATE


3 29 0.98

SIGNATURE

Group 13

CORRECTED BY

PFD PICTURE NO.



Figure B.8 PFD After HEN Oxygen Plant

164


R-301 Packed Bed Reactor

E-302 / E-303 / E-304 / E-307 / E-308 Heat Exchanger

P-301 Pump


P-302 Pump


R-302 Intermediate Adsorber

R-302 Final Adsorber

TT-301 Acid Storage Tank

H2SO4 Storage To Flare Stack

25 11 23

E-308 10

9

O2 Storage

22

19

27

20

To Flare Stack

R-302 24 8


E-307

21'

26

6

7

R-303

4

From O2 Plant

5

18

Water Utility

E-306

17

14

3

C1

TT-301

15

SO2

1

1'

2

E-301

E-302

13

E-304

E-303

16

E-305

2'

21

C2

Economizer, Copper Smelter Plant 1'

2

3

4

5

T(K) 1473 1373 1073 650 1049 630 1 .8 5 1 . 7 1 6 . 1.6 1.3 P (atm) 2

6

7

8

9

10

11

906 600

751 590

602 400

1.3

1.3

1.3

1.2

-

-

-

1.2

12

13

298 500

0 . 97

2

1

14

15

1 7 18

19

20

21 21'

23

388 566.5 297 295 390 398 473 491 303 18 .

1.6

1

2

1 .7

1. 7

2

2

24

25

403 403 1.1

26

27

403 403

12 .

12 .

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

1 .2

-

1.2

-

-

-

100

-

100

-

-

4560

-

Component(tonne/day)

O2 SO2

-

-

18 60 18 60

H2O

-

SO3

H2 SO4

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

8 00

800

800

-

2560

-

-

-

-

-

-

-

70 0 7 0 0 2 560 2 560 2 560 2 56 0 2 56 0 2 56 0 2 56 0

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

800 -

-

700 700 700 700 700 700 -

-

-

-

-

-

-

-

3120 2120

-

FAKULTASTEKNIK

12

To O2 Plant

Water Utility

P-302 NAME

DEPARTEMENTEKNIKKIMIA 1

28

R-301

P-301

NAME

SIGNATURE

DATE

Group 13


CORRECTED BY

PFD PICTURE NO.



Figure B.9 PFD After HEN Sulfuric Acid Plant

165


Figure B.10 PFD of Pre-Water Treatment

166



P-401 Pump

E-402 Evaporator

From Economizer, Copper Smelter Plant

E-405 Condenser


6A

T-401 Steam Turbine

From Economizer, Copper Smelter Plant

3A

5A 6A

A

C

B

E-401

E-402

E

D

E-404

E-403

4A

7A

M

Z

P-401

Electricity

F

T-401 H

2A

From Oxygen Plant

C4

G

E-405 Stream P (Kpa) T (celcius) Mass Flow (tonne/d)

C4

A

B

C

98

5000

5000

5000

D 5000

E 5000

F

G

H

50

45

45

1A 90

56

79

264

280

320

400

81

78

78

70

1500

1500

1500

1500

1500

1500

1500

1500

1500

6000

2A 85 78 1500

3A

4A

5A

6A

7A

8A

133

120

110

120

110

90

400

485

320

300

276

132

1500

1500

1500

1500

1500 1500

From Oxygen Plant

NAME


1A

NAME

SIGNATURE

DATE

Group 13


CORRECTED BY

PFD PICTURE NO.



Figure B.11 PFD of Power Plant

167


C-107 Belt Conveyor

From Casting

P-101 Pump

C-108 Belt Conveyor

P-101 Electrolytic Cell

TK-102 / TK-103 Storage

16B MCC

ST

C-107

M

PI

SIC

FAH

PI

TI FRC

FAL

FCV

TI

FT

19B

PI

FY

TI

Cu

17B

FE MCC

ST

M

C-108

SIC

P-101

TK-103

8"

H2SO4 & CuSO4

8" Sch 40 CS

18B

8" Sch 40 CS

P-101

PI

TI

Anode Slime

TK-102

16 B

17 B

T (K)

15 2 3

15 2 3

18B 15 2 3

19 B 299

P (atm)

1

1

1

1

Component (tonne/day) -

-

-

-

SiO2

-

876

-

-

O2

-

-

-

-

CaCO3

-

-

-

-

Cu2S

-

-

-

-

Cu

881.3

-

-

-

Fe2S3

-

-

-

-

CuFeSs

FeO

-

-

-

-

FeSiO3

-

-

-

-

Fe3O4

-

-

-

-

-

-

-

-

-

-

-

-

SO2

-

-

-

-

P&ID

CO2

-

-

-

-

-

-

5.25

-


CaO CaO.Fe3O4

Other metals

NAME

DEPARTEMEN TEKNIK KIMIA FAKULTAS TEKNIK UNIVERSITAS INDONESIA

NAME

SIGNATURE

DATE

Group 13

CORRECTED BY PICTURE NO.

P&ID – 001/2016

WITHOUT SCALE

Figure C.2 P&ID of Copper Smelter Plant

169


APPENDIX D: SIZING CALCULATION ALGORITHM

D.1

Belt Conveyor

D.1.1 Belt Conveyor C-101 CuFeS2 has bulk density 4100 kg/m3 to be transported at 99.4 ton/hr a horizontal distance of 1260 ft up an incline of 5o. 1. Required Speed

 maxim mumassmasflows flow ×100   119.99.43 ×100 94.89 ft/min Conveyor length1200 dicosstanceθ60 + dicosθstance Conveyor length  cos0 + cos5  1260.23 ft  ×  60 ×  5  5.24  Power( 0..4+ 300L )(100W )+0.001 HW+ 100uc .  0.4 + 16. 9+0.2 hp001x5.24x99.4 + 94.89 

2. Conveyor length

3. Rise (H)

4. Power

D.2

Absorber Column

Table D.1 Component of Absorption Column Component

Kmols

Fraction

MW

N2

92.31679

0.047907

28

O2

890.064

0.461891

32

SO2

0.339152

0.000176

64

SO3

944.23

0.49

80

Total

1926.95

0.999974

174


175 1. The average of molecular weight of the incoming gas

 1+2+∑ 3+ 55.335 /  127          22.4   1.686 /

2. Density of gas mixture calculation

3. Liquid and gas flowrate calculation

   944. 4 23    94. 4 23   849. 8 07       67,984.56  Table D.2 Properties of Absorber Feed Properties

Mol (kmoles)

Mass (kgs)

Water present in incoming gas

311.1505501

30492.754

Sulfuric acid formed

311.1505501

30492.754

Free SO3 with it

2.783125672

222.65005

    30492.754 +222.65 25114.69        98%              98%   67,984.56 25114.69  42869.866  3       0.1802  80  ℎ  100% +   0.1802  80 1.0889   3  ℎ  0.02  1.0889  0.03267   ℎ1.0889 +0.03267 1.12157   3    1.12167 0.2157  0.2157 42869.866  - Calculating Weight of 98% acid needed for the absorption in the tower (W)


Thus, liquid flowrate is given as

And gas flowrate

4. Column Section

97.95 / 97.966 /  1850 / 29.6 /  1.686 /

176

In this case of absorber, there are two kind of column, tray column and packing column. We have chosen packing column for the reason below: 

The gas material which enter to the absorber column is an acid liquid, the corrosive one.



From the economic side, packing column is cheaper than tray column especially for corrosive liquid



The result of pressure drop in packing column is lower than tray column. The gas and liquid contact in packing column is better to the higher area contact.

5. Material Selection The packing that chosen is Rasching ring packing. The specification of the packing chosen is seen on the table given from Richardson abd Coulson as below

Figure D.1 Design Data for Various Packing

(Sourcce: Richardson and Coulson) Universitas Indonesia

177 Table D.3 Packing Specification

Ceramic, Rasching Rings

Material

Size (in)

3

Nominal Size (mm)

76

Bulk Density (kg/m 3)

561

Surface area (m2/m3)

69

Packing Factor (m-1)

65

Voidage (%)

75

6. Diameter Calculation Table D.4 Industrial Absorber Specification

  (){()}.   0.099

Then we have to get K 4 from the graph below by plotting the FLV at the flooding line. K 4 at flooding line based on the number of the FLV is 3.6

Figure D.2

Flooding Line Graph

.

∗   . 13.1−. 


 ∗ //2   1.2

178

Designing for a pressure drop of 42 mm water per m of packing

Then,

And G* is get as below

Cross section area required

Diameter required

.  1. 1 . 2 %  {3.6} 100% %    57.57.73 % ∗  % 100  ∗ ∗ 3.94 2    ∗    7.51  .  4 ()   3.3.0936 0936 

Hence. the diameter which is calculated from this approach is 3.09 meter. 7. Number of Stage 8. Height of Packing Calculation Volumetric flowrate of the entering gas is given by

       17.56 /       2.2.3333 // 2824   1015. 10136005.04  50.50.999   2824    16.16.55 //   

Gas velocity at the bottom of tower

Mass flowrate at the top of tower

Volumetric flowrate at the top of tower


  9.9.8282 3/3/       1.1.3 // 2      +    1.1.8282 //      2.2.4343 //         13.13.04 // 

179

Gas velocity at the top of tower

Average Gas Velocity

Average Gas Velocity in the Packing

Liquid flow

Given that 

Surface area of packing = 69 m2/m3



Liquid density = 1850 kg/m3

Then.

       1.686  − 2.2.772778.22101100 −  −   1.252.77210 8.2 10− 2.005

The average properties of the gas at the temperature are given as follows.

Schmidt Number

As given in the literature, the Reynold number is calculated for the Standard Wetted Wall Column habing the diameter. d = 0.083 ft = 0.0253 m Then. we have to calculate the co-relation by the formula below. Universitas Indonesia

−.   .            ( ( ) () ( ) 0.04 (  )

With

so we get that

180

  1

 0.239    ℎℎ   518.38  5 6  3   67984. 1871.82 /ℎ 8080 . 0.0.45454  1871. 3   0.311            6167.79    ℎℎ        11.88 

Surface area packing (A)

The mean driving force given 0.09 atm SO3 absorbed

Area of packing (AP)

Height of packing require

Therefore, the height of packing required is 11.88 m. 9. Thickness Calculation

Table D.5 Data for Shale Thickness Calculation Inner Diameter (m) Height of pack req (m)

3.09361374 11.88847672

Skirt Height (m) Density of mat column (kg/m 3) Wind pressure (kg/m 2) 

2 7700 130

Material Selection

Carbon steel Permissible tensile stress (f) = 950 kg/cm2 

Calculation

Thickness of shell.

Where,

 +    2 Universitas Indonesia

181 Working Pressure

= 101.3 N/m2

Design pressure. (p) = 0.106 N/m2 Permissible stress

= 95 N/mm2

Joint efficiency (J)

= 0.85

Corrosion allowance = 3 mm Hence. ts = 3.002 We take thickness as 3.002 mm D.3

Adsorber Column

Given data, O2 required

= 51 tonnes/hour = 2092.34 kmol/hour

Air required

= 100/21 x (O2 required) = 11087.99 kmol/hour

N2 required

= 79/21 x (O2 required) = 8995.66 kmol/hour

Oxygen purity = 90% From table below we know zeolyte capacity to adsorp N2

Figure D.3 Capacity of Zeolit to Adsorp Nitrogen

(source: Wallas)

Mol balance of O2 in top column, assume that all only N2 that adsorbed in top column, so that all of O2 flow to top column. O2 purity

= O2 in A / (O2 in A + N 2 in A)

N2 in A

= (O2 in A/ O2 purity) - O2 in A Universitas Indonesia

182 = (2092.34.75/0.9) – 2092.34 = 232.48 kmol Total N2 need to be adsorbed = N2 in feed – N2 in A = 8995.65 kmol – 232.48 kmol = 8763.17 kmol

   8763.17   × 1.12  × 000.11  7. 302 7.302         1.07 / 10.43     /50% 20.8/647         20.8647   2.069 

Assume that 50% of adsorber full of zeolite,

Height of adsorber

Based on rule of thumb we decide, H = 3D. Hence, the height of adsorber would be

D.4 a.

Packed Bed Reactor

3 3  2.069 6.208 

Reaction Rate

Table D.6 Flow Information of Reactor

Component

Symbol

SO2 O2 SO3 N2

A B C D Total

Fa (Kmol/h)

X

1476 830.7 0 92.3 2399

0.615256 0.346269 0 0.038474 1


183

b.

Material Balance

c.

Energy Balance

d.

Momentum Balance

Based on those equation, we calculate with polymath and the result is


184

Figure D.4 Polymath Calculation of Reactor Sizing

From the polymath, we know the conversion of the reactor is 85%, since we used 4631 tubes consisting 20lb catalyst each tube, we get.

   33. 926208 / 2740.23     100% 80%  2740.23  3425.29  96.65  41  14     4   4 96.6   5  3. 1 3  12.5 

Rule of thumb: volume of catalyst is 80% volume of reactor

Rule of thumb: for packed bed reactor, ratio H/D is 4

D.5

Filter Equipment

With: Universitas Indonesia

185 d 1

= Mean diameter of particle separated at the standard condition=30

d 2

= Mean diameter of the particle separated in the proposed design=50

Dc1

= Diameter of the standard cyclone=8 inchs

Dc2

= Diameter of proposed cyclone,mm

Q1

= Standard flow rate, which amount is

-

For high efficiency design = 223 m3/h

-

For high throughput design

= 669 m3/h

= Proposed flow rate, m3/h = 362.5

Q2

∆1 ∆2  

= Solid fluid density difference in standard design = 2000 kg/m 3 = Density difference,proposed design = 8000 kg/m 3 = Test fluid viscocity

= 0.018 mN s/m2

= Viscocity,proposed fluid = 0.018 mN s/m 2

/ 2 1 ∆1 2  21[1  2  ∆2  1] / 2 223 2000 0. 0 18  5030[0.203   362.5  8000  0.018] 2 0.5326 53.26 



Dc

= 0.1295 m



A

= 0.5Dc = 0.06475 m



W

= 0.5 Dc x 0.2 Dc = 0.01677 m



D0

= 0.5 Dc = 0.06475 m



Hc

= 1.5 Dc = 0.19425 m



H

= 2.5 Dc = 0.323 m



B

= 0.375 Dc = 0.04585 m Universitas Indonesia



 

∆ = 4,313

186 2

Where is gas density, for air is 0.0765 lbm/ft3 and V is gas velocity, which assumed 150 ft/s.

D.6

Heat Exchanger

∆4.313  0.0765  150100 0.742 

The type of heat exchanger that will be used is shell and tube (STHE), because STHE and the material for the STHE is carbon steel, because it has high thermal conductivity and relatively cheap, but has long life span. 1. Determine the specification of fluid.

mCt tmCT T .  .  +.∆

If there is a phase change, we use

2. Determine physical properties of fluids, which are heat capacity (kJ/kg/K), density (kg/m3), viscosity (Pa.s), thermal conductivity, and fouling factor (W/m2/K). The fouling factor can be obtained from table below.

Figure D.5 Fouling Factors Coefficients

3. Assume value of overall coefficient, Uc (W/m2.K)


187

Figure D.6 Overal Heat Transfer Coefficients

4. Calculate the LMTD, correction factor, and Δt.

LMTD T tlnTT ttTt       Δt = LMTD x F T

Value of FT is obtained from Fig. 2.19 in Chemical Engineering Design vol 6, 2005

5. Calculate the heat transfer area

   . 

6. Decide the type of shell and tube heat exchanger (fixed tubesheet, U-tube etc.), outside diameter tube, inside diameter tube, tube thickness, length of tube, number of pass, dan pitch type. Use the standard tube counts table for this purpose. 7. Calculate the number of tube -

Cross Flow Area of Tube

  .  .  ℎ


188 - Number of tube

         4 .      .       3600 .  1          ,     

-

Tube cross sectional area

-

Area per pass

-

Tube side superfacial velocity

-

Tube side velocity

Tube side velocity about 5-15 m/s for high pressure gas and 1-4 m/s for liquid 8. Calculate the diameter of shell -

Diameter bundle, D b

         (  )

The value of K 1 dan n1 are obtained from table 12.4 in Chemical Engineering Design vol 6, 2005

-

Diameter shell Ds

  +ℎ  

The value of shell bundle clearance is obtained from figure 12.10 in Chemical Engineering Design vol 6, 2005

9. Estimate tube side heat transfer coefficient -

Reynlods Number, Prandtl Number, and L/D

-

Tube side heat transfer coefficient, hi

         ℎ


ℎ   .  . Pr.

189

The value of jH is obtainable from figure 2.23 in Chemical Engineering Design vol 6, 2005

10. Estimate shell side heat transfer coefficient -

Baffle spacing dan tube pitch Baffle Spacing, lB = baffle spacing coefficient x inside diameter shell Tube pitch, pt = tube pitch coefficient x outside diameter tube The value of baffle spacing coefficient is 0.2 – 0.5 while tube pitch coefficient is 1.25 – 1.35

     .  .  ..  0.917       0.785 ℎ     3600 . 1        ℎ  ,   ℎ   

-

Shell Cross Flow Area

-

Equivalent Diameter, de For triangular pitch: For square pitch:

-

Shell-side superfacial velocity

-

Shell side velocity

Tube side velocity about 5-15 m/s for high pressure gas and 0.3-1 m/s for liquid

       ℎ   .  . Pr.. 

-

Reynold Number & Prandtl Number

-

Shell side heat transfer coefficient, hs


190 The value of jH is obtainable from figure 2.29 in Chemical Engineering Design vol 6, 2005

      l n  1 ( ℎ1 +  )  + 2    + ℎ1 +  ℎ

11. Calculate the overall heat transfer coefficient, Uo

Where K is thermal conductivity for heat exchanger material. For carbon steel K = 45 Wm-1 oC-1 12. Calculate pressure drop in shell side and tube side -

Pressure drop in tube

        [8  ()+2.5] 2

The value of jF is obtainable from figure 2.24 in Chemical Engineering Design vol 6, 2005

-

Pressure drop in shell

         8  .  .  . 2

Pressure drop must be below 0.5 bar. If the pressure drop above 0.5 bar, we must change the value of Uc in step 3. D.7

Storage Tank

D.7.1 Water Demine Tank 1. Determine operating condition 

Temperature = 25oC



Pressure = 1 atm = 14.7 psi

2. Determine type and material of tank 1. Estimate liquid volume in tank

   1004 /   894075 /ℎ        894075      1004 /ℎ  886.93  Universitas Indonesia

191 2. Assume tank space to determine tank volume a. The volume of the tank space is 10% b. Height ratio cylinder with a diameter of the cylinder is 2:1 c. Close the top and bottom cap shaped dished head (flat).

    ∗1.1  886.93  ∗1.1  975.62 

3. Calculate tank diameter and height Tank diameter would be determined based on assumption of H/D = 2. This based on the rule of thumb we got from literature (Wallas), where H is height and D is diameter. Hence the calculation would be

(12 )   14 2 2/  2  3.14  886.93 / 8.53   2 ×8.53 17.062 

Therefore,

4. Calculate Design Pressure

Height of liquid in tank is assumed to be 90% of the total height of the tank. Hence the liquid height would be

   90% ×17.062 15.355 

To determine the design pressure we calculate the hydrostatic pressure of the liquid in tank

     ℎ                  ℎ      1004 151087 / 9.8/1.51 15.355 

With a safety margin of 15%, then

   1.15 1 +1.51 2.88   41.87 


192 5. Determine Shell and Head Thickness Used construction material made of stainless steel with specifications type 304, grade 3 (SA-167) (App. D, Brownell, p: 342) f allowable = 18,750.00 Corrosion factor (CA) = 0.042 Connection for welding selected type double welded butt joint Welding efficiency. (E) = 0.80 (Table 13.2, Brownell) To calculate the shell thickness (ts) we use the equation from Brownell, page 254

ℎ ℎ  2     0.+6  ℎ ℎ  2 41.×1867506  ××336.0.8 0.11 6×41.+0.080426  0.52   ℎ3.5 × 3.5 × 0.52  1.84  Table D.7 The Result of Storage Tank Sizing

D.8

Equipment

Demine Tank

Sulfuric Acid Tank

Code Number of Unit Diameter (m) Height of Tank (m) Shelll Thickness (in) Head Thickness (in)

T-402 2 8.53 17.062 0.52 1.84

T-201 1 6.38 12.75 0.21 0.74

Warehouse

D.8.1 Warehouse TK-101  

Bulk density for slag is 3848.41 kg/m3 The process will be done with feed flow rate is 1066.25 tonne/day

Basic Planning

The stocks will be available for 30 days of productions, which is

    1066. 2 5   ⁄ 30   31987. 5       31987.5 ∶ 3848.41 /   8311.88   ∶ 90%  9235.43  ℎ  8311. 8 8   ℎ     ℎ     ℎ  ℎ  ℎ ℎ ∶ ℎ ∶ ℎ  4∶ 3∶ 1

To ensure that the Warehouse is safe and not overloaded, we decided to make the Warehouse is 90% filled. So the Warehouse volume would be


193 D.8.2 Warehouse TK-102 The Warehouse is used to stocking the Anode Slime. The Anode Slime are stocked for 30 days. The Warehouse is a rectangle building with a triangular prism roofs. Some specifications that should be known are 

Bulk density for Anode Slime is 5000 kg/m3



The processs will be done with feed flow rate is 5.25 tonne/day

Basic Planning


  5.25 ⁄ 30   157.5      157.5 ∶ 5000 3⁄  31.5 3 ℎ  90% . ℎ ℎ31.5    ℎ  90%  35    ℎ ∶ℎ     ℎ     ℎ  ℎ  ℎ ℎ ∶ ℎ  4∶ 3∶ 1 Raw material Volume

To ensure that the Warehouse is safe and not overloaded, we decided to make the

D.8.3 Warehouse TK-103 The Warehouse is used to stocking the Copper Cathode. The Copper Cathode are stocked for 30 days. The Warehouse is a rectangle building with a triangular prism roofs. Some specifications that should be known are Bulk density for copper cathode is 8930 kg/m3 The processs will be done with feed flow rate is 876 tonne/day  Basic Planning 


     876 ⁄  30   26280     26280 / 8930 /  2942.89 3 ℎ  2942. 8 9 3∶ 90%  3269. 8 8 3   ℎ  ℎ  ℎ  ℎℎ

To ensure that the Warehouse is safe and not overloaded, we decided to make the Warehouse is 90% full. So the Warehouse volume is


ℎ ∶ ℎ ∶ ℎ  4∶ 3∶ 1

D.9

194

Coagulant Tank

Table D.8 Rigid Base Material Data Sheet Free board (m) Wall Thickness (mm) Thickness of base (mm)

D.10

0.40 6 6

  

Filtration Tank

Where va = face velocity, m/d = loading rate, m3/d.m2 Q = flow rate onto filter surface, m3/d As = surface area of filter, m2 In this filtration method, we choose Sand Filter as granular material and Slow Sand Filter (SSF) as the technology. Design criteria for SSF according to UK expertise is define in this table. Table D.9 Design Criteria For SSF Parameter

Recommended Level (UK experience)

Design Life

10-15 years

Period of operation

24 h/day

Filtration rate

0.1 – 0.2 m/h

Filter bed area

5 – 200 m2/ filter (min. of two filters)

Height of filter bed Initial Minimum

0.8-0.9 m 0.5-0.6 m

Effective size

0.15-0.3 mm

Uniformity coefficient

<3

Height of underdrains + gravel layer

0.3-0.5 m

Height of supernatant water

1m

(source: Addis Abba University)

The calculation of SSF design shown below: 1. Calculate the required tank area Before calculate the tank area, the flow rate of water based on water requirement in our plant is 42742 m3/day. If we store this big amount of Universitas Indonesia

195 water in one storage tank, the dimension would be unrealistic. Thus, we make it to 4 vessels. Flow rate of each vessels would be 10685 m3/day. Hence, the required tank area calculation (Atank ) would be as follows

      1    10685. 5 6    24 ℎ  0.115 /ℎ 356.19 

For this area, we can use tank with 25 m long and 15 m wide. The calculation of other four vessels of filtration tank would be the same because of the same flow rate and so do other specifications. 

From typical table above, the height of the tank require could be calculated from provided data - System underdrain + gravel = 0.4 m - Filter bed = 0.85 m - Supernatant water = 1 m So the total tank height is 2.25 m



Thus, the dimension of the tank become 25 m long, 15 m wide and 2,25 m height

D.11

Ion Exchanger

     42742.160 8/ 267.14   267. 1 4   50  5.34 ≈6

1. Examine water analysis Table D.10 Cation Composition of Ion Exchanger Feed Cations

Concentration (mg/l)

Calcium (Ca)

100

Magnesium (Mg)

50

Sodium (Na)

90

Potassium (K)

10

Total


196 Table D.10 Cation Composition of Ion Exchanger Feed (cont’d) Anions

Concentration (mg/l)

Bicarbontate (HCO3)

100

Sulphate (SO4)

50

Chloride (Cl)

75

Nitrate (NO3)

25

Total

250

The water analysis will determine what resin combination is required 2. Calculate cation concentration Cc [meq/L] As seen on the table of cation composition, the cation concentration would be 250 mg/l as CaCO3

 250 /

3. Decide about the use of a degasifier

Based on literature, it mentioned that if the bicarbonate content is greater than 0.6 to 1.0 mg/l a degasifier may be justified. As seen on the table of the anion composition, the HCO3 concentration is 100 mg/l, greater than the requirement. Hence, a degasifier is recommended. It would remove HCO3 and residual CO2 after degassifier estimated to be 0.25 mg/l. 4. Calculate

the

anion

concentration

Ca [meq/L]:

it

contains

Cl — , SO4=, NO3 — , SiO2, HCO3 — or residual CO2 after degasser if any Due to the use of degasifier, there is a change of anion concentration. Degassifier produced residual CO2 that makes the composition of anion would be

   + + +  50+75+25+0.25150.25 /

5. Decide about a reasonable running time t in hours between regenerations Our plant would be operated in continous operation. So, the operating hour would be 24 hours per day. Then for the running time we chose to be 24 hours.

24 ℎ

6. Using the flow rate f in m3/h calculate the throughput Q [m3]

 800 /ℎ    ·  800 ℎ . 2419200 


197 7. Calculate the ionic load per cycle in eq (concentration in meq/L times throughput in m3): o

o

   ·· 150. 2502.5192004800000   . 192002884800 

8. Consider the approximate operating capaciy of the resins as follows o

SAC:

capc =

1.0

eq/L

with

HCl

regeneration

or

SAC: capc = 0.8 eq/L with H 2SO4 regeneration o

SBA: capa = 0.5 eq/L

9. The resin volume V required (in litres) is equal to the ionic load [eq] divided by the operating capacit y [eq/L]: o

SAC:

     4800000 4800000  . 1     2884800 0.5 5769600 

10. At the end of this calculation, we must make sure that the specific flow rate of both resin columns is compatible with the general recommendations of the resin producer. D.12

Pump

To size a pump, firstly things that must be defined: 

The flow rate of liquid the pump is required to deliver



The total differential head the pump must generate to deliver the required flow rate



Other key considerations for pump sizing are the net positive suction head available (NPSH) and the power required to drive the pump Here’s the algorithm to find the parameter that we state above:

1. Calculate Head

2. Calculate WHP


198 3. Calculate BHP

4. Calculate NPSHa

*We can assume that the velocity is constant

5. Calculate NPSHr

*Note: The calculation NPSH should make NPSHa>NPSHr D.12 

Compressor

Compressor Power

With A

= Conversion Factor

Za

=Compresibility factor

R

= Universal Gas Constat

T1

=Inlet Temperature

Ps

=Standart Pressure

E

=Overall efficiency

q

=gas flow rate

P2

=Pressure Outlet

P1



=Pressure Inlet



Discharge Temperature

= Heat capacity ratio

 ∑∑.. 1. 99 Universitas Indonesia

199 Compressor Head



with

∆ℎ1  

= Head = Suction temperature = Compesibility Factor = Universal gas law = Molecular weight = Heat capacity ratio

P2

= Pressure Outlet

P1

= Pressure Inlet

D.13

High Pressure Turbine

1. Determination type of steam turbine. Table D.11 Feed of Turbine T-401

Criteria

Input

Mass Flow (kg/s)

6250

Temperature (oC)

400

Pressure (kPa)

5000

Vapor Fraction

1

Enthalpy (kJ/kg)

-2,288 x 105

Table D.12 Output of Turbine T-401 Criteria Mass Flow (kg/s) Temperature (oC) Pressure (kPa) Vapor Fraction Enthalpy (kJ/kg)

Output 6250 81.32 50 0.9562 -2,409 x 105

1) Curtis Turbine.

Curtis turbine is used to power generated up to 4000 kW. 2) Reaction Turbine.

Same with Curtis turbine, reaction turbine is used for low output power and therere chemical reaction in the process. Universitas Indonesia

200 3) Rateau Turbine.

Rateau turbine is used to power generated from 4000 kW up to above 30,000 kW

Figure D.7 Rateau Turbine Diagram

Based on international design standard, the turbine with output power 11680 kW, can be operated with speeds up to 4000 rpm, and usually used 3600 rpm. Based on Rataeu turbine, can be known the enthalpy change per stage is 25 kJ/kg. So the number of stage which needed for this turbine is

  ∆      ∆    4,84≈5 

So the turbine uses five stages. From equation of Rataeu turbine, diameter of turbine is

 ,  60. 0 00 × 1 , 0 00×∆ℎ /    3.147× ,  60. 0 00 × 1 , 0 00×121 /6. 5   3.147×5 524,5 

Hence, the diameter of turbine in the power plant would be 542.5 mm D.14

Piping Calculation

1. Stated the flow velocity Universitas Indonesia

201 The flow velocity for a type of fluid can be found in a table below. Table D.13 Typical Velocity of Fluid in Pipeline Fluid

Typical Velocity

(ft/min) 4000

(m/s) 20

Acetylene, steel pipe Air, 0-30 psi, steel pipe 4000 20 Ammonia, liquid, steel pipe 360 1.8 Ammonia, gas, steel pipe 6000 30 Benzene, steel pipe 360 1.8 Bromine, liquid, glass pipe 240 1.2 Bromine, gas, glass pipe 2000 10 Calcium Chloride, steel pipe 240 1.2 Carbon Tetrachloride, steel pipe 360 1.8 Chlorine, liquid, steel pipe 300 1.5 Chlorine, gas, steel pipe 2000 - 5000 10 - 25 Chloroform, liquid, steel or copper pipe 360 1.8 Chloroform, gas, steel or copper pipe 2000 10 Ethylene, gas, steel pipe 6000 30 Ethylene Dibromide, glass pipe 240 1.2 Ethylene Dichloride, steel pipe 360 1.8 Ethylene Glycol, steel pipe 360 1.8 Hydrogen, steel pipe 4000 20 Hydrogenchloric Acid, liquid, rubber lined pipe 300 1.5 Hydrogenchloric Acid, gas, rubber lined pipe 4000 20 Methyl Chloride, liquid, steel pipe 300 1.5 Methyl Chloride, gas, steel pipe 4000 20 Natural gas, , steel pipe 6000 30 Oil lubricating, steel pipe 300 1.5 Oxygen, stainless steel 1800 - 4000 9 - 20 Propylene Glycol, steel pipe 300 1.5 Perchlorethylene, steel pipe 360 1.8 Steam, 0-30 psi, saturated, steel pipe 4000 - 6000 20 - 30 Sulfuric acid 240 1.2 Sulfur Dioxide, steel pipe 4000 20 Styrene, steel pipe 360 1.8 Trichlorethylene, steel pipe 360 1.8 Vinyl Chloride, steel pipe 360 1.8 Vinylidene Chloride, steel pipe 360 1.8 Water, steel pipe 180 - 480 0.9 – 3 (source : http://www.engineeringtoolbox.com/fluid-velocities-pipes-d_1885.html )

2. Other Data Another data that we used is Flow rate Q (m3/h) where it can be seen from

the simulation. Universitas Indonesia

202 3. Calculation 

Find the surface area of pipe



Calculate the inside diameter (ID)



Find the nominal size of pipe,

     √ 43.14

D.15

Valve Calculation To determine the size of valve that will be used in our plant, we do the

calculation by following algorithm as follows 1. Determine the flow rate of each stream, and convert it into US gpm (gallons per minute). 2. Search specific gravity data for each fluid and divide it with the basis fluid. 3. Determine the pressure drop, which is 5 psi. 4. Calculate the Cv,max with the equation,

, 2 √ ∆

5. After we got the value of Cv,max then we can know the valve size with this table.

Figure D.8 Valve Size for Sch. 40


APPENDIX E: MSDS

E.1

Copper Concetrate

203


204


205


206


207 E.2

Limestone


208


209

E.3

Silica Sand


210


211 E.4

Sulfuric Acid


212


213 E.5

Copper Cathode


214 E.6

Oxygen


215


216


217

E.7

SO2


218


219


220 E.8

SO3


221


222 E.9

Coal


223


224


APPENDIX F: ECONOMIC ANALYSIS

F.1

Purchase Equipment Cost

a. Conveyor The copper smelter plant has a solid raw material and product. Hence, this plant is needed conveyor to distribute the material and product. There are eight belt conveyors being used. The calculation is based on Product and Process Design Principle by Sieder. The equation to calculate the cost of conveyor belt is shown below

W = Width (in)

 16.9 

L = Length (ft) D = Diameter (in) b. Filter In our plant, there are one filter used in oxygen plant to filter the natural gas before it is processed further. The calculation is based on Product and Process

 exp11.4320.1905ln +0.0554ln 

Design Principle by Sieder. The equation is shown below.

Where:

A = Filtering area (ft2) c. Reactor Packed bed reactor is needed in the sulfuric acid plant to process the byproduct from copper smelter plant, SO2. We only need one reactor and will be calculated based on Product and Process Design Principle by Sieder.

Where,

 CS

S = Characteristic size, volue (ft 3) C = Cost constant (Reactor =15000) n = Index for equipment type (Reactor = 0.6)

d. Compressor There are five compressors in our plant that is used in our plant. The calculation is based on Product and Process Design Principle by Sieder. The price 225


226 is depends on the material being used, compressor type, also the power required to compress the gas. In our plant, we only use the centrifugal compressor.

      exp7.2223+0. 8     

Where: PC = Power (hp)

FM = Compressor Material (SS =2.5) FT = Compressor type

e. Pump There are seven pumps used in our plant and utility. These equipments are calculated based on equation in Product and Process Design Principle by Sieder. The calculation required some data such as flow rate, Q, and head of pump, H. The

  exp9.29510.6019ln+0.0519ln

equation is shown below

Where,

(1.7) (1.8)

FM = Pump Material FT = Pump type

f. Tank The tank that will be calculated in this section including tank, filtration, and ion exchanger tank. The calculation is based on the equation in Sieder as shown below. The S for tank calculation is the capacity of the tank.

 CS

Where, S = Characteristic size, volume (ft 3) C = Cost constant (Tank = 2900)

n = Index for equipment type (Reactor = 0.6)

g. Heat Exchanger The total heat exchanger used in our plant is 21. For calculating heat its FOB price we use Seider, Seider, and Lewis book (2004). The equation is shown below

 

Where CB is calculated based on the type of heat exchanger used. The formula as seen below Universitas Indonesia

227

We use fixed head for all of our heat exchanger in our plant. As for FM is material factor for combination of tube and shell material as given in table below

Figure F.1 FM factor for heat exchanger FOB cost

(Source: SSL, 2004)

The material chosen for all the heat exchanger is carbon steel.

   +(100)

FL is factor for tube length correction that is determined from table below

Figure F.2 FL factor for heat exchanger FOB cost

(Source: SSL, 2004)

(1.15) The bare module factor that is used is the one for the shell and tube exchanger which amounted 3.17 (SSL, 2004).


F.2 Equipment Cost Table F.1 Total Equipment Cost Year Basis

Bare Module Factor

Bare Module Cost in 2020 (USD)

954,510

2000

2.15

3,992,370

195,360

195,360

2000

2.15

817,120

581,990

581,990

2000

2.15

2,434,250

1

3,273,110

3,273,110

2000

2.15

13,690,220

1

2,366,400

2,366,400

2000

2.15

9,897,780

No

Equipment Code

Qty.

Price/Unit (USD)

1

K-100

1

954,510

2

K-101

1

3

K-102

1

4

K-201

5

K-202

Total Price (USD) Compressor

Pump

1

P-301

1

2,050

2,050

2000

3.3

13,161

2

P-302

1

4,130

4,130

2000

3.3

26,514

3

P-201

1

3,080

3,080

2000

3.3

19,774

4

P-202

1

3,070

3,070

2000

3.3

19,709

5

P-101

1

2,530

2,530

2000

3.3

16,243

6

P-401

1

3,700

3,700

2000

3.3

23,754

7

P-501

1

7,970

7,970

2000

3.3

51,167

Furnace

1

F-101

1

406,553

406,553

2000

1.86

1,774,670

2

F-102

1

397,803

397,803

2000

1.86

1,736,477

3

F-103

1

246,960

246,960

2000

1.86

1,078,022

4

F-104

2

370,812

741,623

2000

1.86

3,237,306

228


Table F.1 Total Equipment Cost (c ont’d) No

Equipment Code

Qty.

Price/Unit (USD)

Total Price (USD)

Year Basis

Bare Module Factor


Electrorefining

1

P-201

1

75,000

75,000

2015

2.45

206,290

151,500

2016

1.3

413

151,500

2016

1.3

197,817

2000

4.16

Caster 1

PM-201

1

151,500

2

PM-202

1

151,500

Adsorber Column

1

R-201 & 202

2

Zeolit

2

46,197

92,394

17,300

670,000 825694.2857

Absorber Column

1

R-201 & 202

2

46,503

680000

2000

4.16

722,493

Tank

1

T-201

1

90,000

90,000

2004

1.41

203,500

2

T-402

2

140,000

280,000

2004

1.41

633,000

3

T-501

4

60,000

240,000

2004

1. 41

542,600

4

T-502

4

140,000

560,000

2004

1.41

1,265,800

5

V-502

2

100,000

200,000

2004

1.41

452,100

1

ST-101

1

388,340

2000

2.15

1,581,080

Turbine

388,340

229


Table F.1 Total Equipment Cost (c ont’d) No

Equipment Code

Qty.

Price/Unit (USD)

Total Price (USD)

Year Basis

Bare Module Factor


Conveyor

1

C-101

1

269,400

269,400

2000

1.61

843,810

2

C-102

1

186,250

186,250

2000

1.61

583,370

3

C-103

1

149,670

149,670

2000

1.61

468,790

4

C-104

1

133,040

133,040

2000

1.61

416,710

5

C-105

1

166,300

166,300

2000

1.61

520,890

6

C-106

1

149,670

149,670

2000

1.61

468,790

7

C-107

1

106,430

106,430

2000

1.61

333,360

8

C-108

1

106,500

106,500

2000

1.61

333,580

1

F-101

1

78,380

2000

2.32

360,000

2004

4.16

621,210

Filter

78,380 Reactor

1

R-301

1

93,160

93,160

230


Table F.1 Total Equipment Cost (c ont’d) Year Basis

Bare Module Factor


10,000

2000

3.17

61,670

10,000

2000

3.17

61,670

30,000

30,000

2000

3. 17

185,009

1

20,000

20,000

2000

3. 17

123,339

1

30,000

30,000

2000

3. 17

185,009

E-205

1

50,000

50,000

2000

3. 17

308,348

7

E-206

1

30,000

30,000

2000

3. 17

185,009

8

E-207

1

30,000

30,000

2000

3. 17

185,009

No

Equipment Code

Qty.

Price/Unit (USD)

1

E-101

1

10,000

2

E-201

1

10,000

3

E-202

1

4

E-203

5

E-204

6

Total Price (USD)

Heat Exchanger

9

E-301

1

20,000

20,000

2000

3. 17

123,339

10

E-302

1

20,000

20,000

2000

3.17

123,339

11

E-303

1

50,000

50,000

2000

3.17

308,348

12

E-304

1

50,000

50,000

2000

3.17

308,348

13

E-305

1

80,000

80,000

2000

3.17

493,356

14

E-306

1

100,000

100,000

2000

3.17

616,695

15

E-307

1

70,000

70,000

2000

3.17

431,687

16 17

E-308 E-401

1 1

280,000 80,000

280,000 80,000

2000 2000

3.17 3.17

1,726,746 493,356

18

E-402

1

90,000

90,000

2000

3.17

555,026

19

E-403

1

90,000

90,000

2000

3.17

555,026

20

E-404

1

100,000

100,000

2000

3.17

616,695

21

E-405

1

400,000

400,000

2000

3.17

2,466,780 59,940,828

Total

231


232 F.3 Total Bulk Material Table F.2 Piping Cost of Copper Smelter Plant Stream

L (ft)

Nominal Size (inc)

OD (inc)

Price/L (USD)

Total Cost (USD)

H2SO4

12

8

8.625

24.77

297.24

Out P-101

4.5

8

8.625

24.77

111.465

2B

12

1.5

1.9

6.21

74.52

9B

12

1.25

1.66

4.95

59.4

13B

12

0.38

0.675

2

24

5B

4.5

1

1.315

3.45

15.525

10B

4.5

1

1.315

3.45

15.525

14B

4.5

0.38

0.675

2

9

E-101

10.5

1.25

1.66

4.95

51.975

2

10.5

0.75

1.05

2.83

29.715

E-101

45

10

10.75

87.73

3947.85

4B

4.5

26

26

120

540

6B

4.5

10

10.75

88

396

12B

4.5

6

6.625

40.85

183.825

11B

4.5

10

10.75

87.73

394.785

7B

4.5

1

1.315

3.45

15.525

15B

4.5

6

6.625

40.85

183.825

Table F.3 Piping Cost of Sulfuric Acid Plant Stream

L (ft)

Nominal Size (inc)

OD (inc)

Price/L (USD)

Total Cost (USD)

1'

1.5

1.25

1.66

4.95

8

2

1.5

1.25

1.66

4.95

8

2'

1.5

1.25

1.66

4.95

8

3

3

1.25

1.66

4.95

15

4

3

1.25

1.66

4.95

15

5

4.5

1.5

1.9

6.21

28

6

4.5

1.5

1.9

6.21

28

7

5.1

1.5

1.9

6.21

32

8

1.5

1

1.315

3.45

6

9

5.4

1

1.315

3.45

19

10

20.535

1

1.315

3.45

71

11

20.535

1

1.315

3.45

71

12

10.02

5

5.563

32.26

324

13

10.02

5

5.563

32.26

324

14

10.02

5

5.563

32.26

324

15

10.02

5

5.563

32.26


233 Table F.3 Piping Cost of Sulfuric Acid Plant (cont’d) Stream

L (ft)

Nominal Size (inc)

OD (inc)

Price/L (USD)

Total Cost (USD)

16

10.02

5

5.563

32.26

324

17

8.769

4

4.5

24.77

218

18

8.769

4

4.5

24.77

218

19

8.769

4

4.5

24.77

218

20

8.769

4

4.5

24.77

218

21

8.769

4

4.5

24.77

218

21'

8.769

4

4.5

24.77

218

23

21.072

6

6.625

40.85

861

25

1.2525

0.5

0.84

2.54

4

24

14.319

2.5

2.875

12.45

179

26

30.81

8

8.625

66.7

2056

27

1.2525

1.5

1.9

6.21

8

Total

6345

Table F.4 Piping Cost of Oxygen Plant Stream

L (ft)

Nominal Size (inc)

OD (inc)

Price/L (USD)

Total Cost (USD)

4

3

3

3.5

15.71

47.13

5

45

3

3.5

15.71

706.95

1

3

3

3.5

15.71

47.13

1A

2.4

3

3.5

15.71

37.704

1B

2.4

3

3.5

15.71

37.704

1C

2.4

3

3.5

15.71

37.704

1D

2.4

3

3.5

15.71

37.704

1E

2.4

3

3.5

15.71

37.704

2

2.4

3

3.5

15.71

37.704

2B

2.4

3

3.5

15.71

37.704

2C

5.4

3

3.5

15.71

84.834

C

13.5

3

3.5

15.71

212.085

C1

15

3

3.5

15.71

235.65

C3

15

3

3.5

15.71

235.65

13

10.5

3

3.5

15.71

164.955

14

10.5

3

3.5

15.71

164.955

2

2.4

3

3.5

15.71

37.704

2B

2.4

3

3.5

15.71

37.704

C4

19.5

3

3.5

15.71

306.345

C2

19.5

3

3.5

15.71

306.345

19

19.5

3

3.5

15.71

306.345

Total


234 Table F.5 Piping Cost of Power Plant Stream

L (ft)

Nominal Size (inc)

OD (inc)

Price/L (USD)

Total Cost (USD)

Pump to E-401

2.4

4

4.5

24.77

59.448

E-401

2.4

4

4.5

24.77

59.448

E-402

2.4

4

4.5

24.77

59.448

E-403

2.4

4

4.5

24.77

59.448

E-404

2.4

4

4.5

24.77

59.448

T-401

7.5

4

4.5

24.77

185.775

HE to HE

2.4

4

4.5

24.77

59.448

HE to HE

2.4

4

4.5

24.77

59.448

from Economizer

45

4

4.5

24.77

1114.65

from Economizer

45

4

4.5

24.77

1114.65

Total

2831.21

Table F.6 Piping Cost of Water Utility Price/L (USD)

Total Cost (USD)

Stream

L (ft)

Nominal Size (inc)

A

30

16

110

3300

B

1.5

16

110

165

D

1.5

16

110

165

E

0.9

16

110

99

F

0.9

16

110

99

G

1.5

16

110

165

H

9

16

110

990

I

9

16

110

990

J

10.5

16

110

1155

Total

7128

Table F.7 Cost of Valve Type

Quality

Price/Unit (USD)

FOB 2016 (USD)

Gate Valve

210

500

105,000

114733.3706

Globe Valve

60

200

12,000

13112.38521

Check Valve

67

450

30,150

32944.86784

Total

FOB 2020 (USD)

160,791


235 F.4 Building Cost Table F.8 Total Building Cost Building Facilities

Quantity

Price per Qty

Price

Control Room

5

255,768

1,278,841

Laboratory

1

502,886

502,886

Maintenace Shop

1

265,500

265,500

Engineering Building

2

2,385,494

4,770,988

Mess

1

3,826,632

3,826,632

Mess Hall

1

765,576

765,576

Town Square

1

6,098,501

6,098,501

Park/Forest

4

965,425

3,861,701

Clinic

1

711,704

711,704

Mosque

1

849,632

849,632

Security Post

6

159,304

955,822

Warehouse

3

592,342

1,777,025

Parking Area

4

494,900

1,979,600

Port Building

1

1,309,736

1,309,736

Fence Bar

4

3,591,000

14,364,000

Gate

2

913,986

1,827,973

Fire Station

4

359,134

1,436,536 46,582,653

Total

F.5 Supporting Equipment Cost Table F.9 Supporting Equipment Cost Supporting Equipment

Quantity

Price per Piece (USD)

Price (USD)

Computer

55

500

27,500

Fax

5

50

250

Desk

80

180

14,400

Chair

170

9

1,530

Cetral AC

15

3,000

45,000

Dispenser

15

44

660

Microwave

5

110

550

Cupboard

10

266

2,660

Locker

100

31

3,100

Sofa

8

220

1,760

Meeting Desk and Chair

20

177

3,540

Receptionist Desk and Chair

5

266

1,330


236 Table F.9 Supporting Equipment Cost (cont’d) Supporting Equipment

Quantity

Price per Piece (USD)

Price (USD)

White Board

25

4

100

Generator

10

11

110

Office Car

25

17,000

425,000

Distribution Car

15

45,000

675,000

Television

15

200

3,000

Office Equipment

20

310

6,200

Canteen Chair

100

150

15,000

Canteen Desk

40

4

160

Pantry Utensils

8

300

2,400

Printer

15

100

1,500

Neon Lamp

2000

5

10,000

Photocopy Mechine

15

550

8,250

CCTV

35

100

3,500

Total Supporting Equipment Cost

1,252,500

F.6 Working Capital Extra Cost Table F.10 Engineering and Supervision Cost No

1

Type of Cost

Engineering and Supervision

N

Based Cost (USD)

Cost (USD)

8%

59,940,828

7,327,653

Total

7,327,653

Table F.11 Construction Expenses No

Type of Cost

N

Based Cost (USD)

Cost (USD)

1

Construction

10%

59,940,828

9,159,567

Total

9,159,567

Table F.12 Contingencies Cost No

Type of Cost

N

Based Cost (USD)

Cost (USD)

1

Contingencies Cost

15%

59,940,828

13,739,350

Total

13,739,350


237 Table F.13 Contractor’s Fee No

Type of Cost

N

Based Cost (USD)

Cost (USD)

1

Contractor’s Fee

3%

59,940,828

2,747,870

Total

2,747,870

Table F.14 Royalties and Plant Start Up Cost No

Type of Cost

N

Based Cost (USD)

Cost (USD)

1

Royalties Cost

2%

124,570,108

2,491,402

2

Plant Start Up Cost

2%

124,570,108

2,491,402

Total

2,491,402

Table F.15 Additional Cost Component

Cost (USD)

Industry Design Permission

129

Brand

583

Water Installment

1,153

Electricity Installment

2,400

Communication Line Installment

1,200

Hydrant Installment

1,000

Internet Network Installment

600

Total

7,066

Table F.16 Working Capital Cost No

Type of Cost

N

Based Cost (USD)

Cost (USD)

1

Working Capital

17.6%

139,525,587

24,700,000

Total

24,700,000


238 F.7 Utility, Maintenance,Waste Treatment Cost Table F.17 Utility Cost Utility

Typical factor in SI unit

Need [m 3 /day]

Total [USD/day]

Cooling water

0.04

[USD/m3]

17762

1,710

Process water

0.5

[USD/m3]

1500

750

Total Utility Cost per Day

[USD/day]

2,460

Total Utility Cost per Year

[USD/year]

897,812

(source: various sources) Table F.18 Waste Treatment Cost

Utility

Cost USD/GJ

Description

Thermal System

Waste Disposal (Solid and Liquid) Waste Water Treatment

Cost based on thermal efficiency of fired heater using natural gas a. 90% efficient b. 80% efficient a. Nonhazardous

Cost USD/Comisssion Unit

12.33 13.88

Based on process heating duty USD 36/tonne USD 2002000/tonne

b. Hazardous

USD 41/1000m3

a. Primary (filtration) b. Secondary (filtration+activaed sludge) c. Tertiary (filtration, activated sludge, and chemical processing)

USD 43/1000m3 USD 56/1000m3

(source: Turton, 2013) Table F.19 Maintenance Cost

Maintenance Cost [USD/year]

Wages and Benefit (MW&B)

16,422,310

Salaries & benefit (engineers & supervisory personnel)

4,105,578

Materials and maintenance

16,422,310

services

Maintenance overhead Total [USD/year]

for

821,116 37,771,314


239 F.8 Direct Labor Cost Table F.20 Labor Need per Equipment

Equipment

Quantity

Factor

Total Labor/ shift

0.15 1 1 0.1 1 0.5 1 0.5 4 3 4

0.75 2 6 0.9 21 3.5 1 4 8 15 24 85 344

Compressor 5 Turbine 2 Reactor 6 Storage 9 HE 21 Pump 7 Filter 1 Conveyor 8 Caster 2 Furnace 5 Electrolytic Cell 6 Total labor/ shift Total labor/ day

Table F.21 Direct Labor Cost

Number of Employees 344 40 20

Workforce

Salary [USD/month.labor] 275 270 270

Salary [USD/month] 94,600 10,800 5,400

265

3,975 114,775 1,377,300

Operator Technician Warehouseman Mill-hand 15 Total Salary per Month 419 Total per year [USD/year]

F.9 Indirect Labor Cost Table F.22 Indirect Labor Cost

President Director

Number of Employees 1

Monthly Salary [USD/month] 4,100

Yearly Salary [USD/year] 57,400

Vice President Director Expert Staff

1 1

2,900 1,300

40,600 18,200

Secretary of President Director

1

500

7,000

Production Manager Technical Manager Finance Accounting Manager Marketing Manager HR & GA Manager Process Officer

1 1 1 1 1 2

1,650 1,650 1,650 1,650 1,650 1,000

23,100 23,100 23,100 23,100 23,100 28,000

Job Title


240 Table F.22 Indirect Labor Cost (cont’d)

Job Title

R&D Officer Utility Officer Machine Officer Electrical Employee Instrument officer Safety Officer Accounting Officer Administration Officer Human Resource Officer Public Relation Officer Security Officer Marketing Officer Production Employee Technical Employee Finance & Accounting Employee Marketing Employee Doctor Nurse Security Cleaning Service Driver

Number of Employees 1

Monthly Salary [USD/month] 1,000

Yearly Salary [USD/year] 14,000

4 5 5 1 1 1 1 1 1 1 1 70 10

1,000 1,000 1,000 1,000 1,000 1,000 1,000 1,000 1,000 1,000 1,000 417 417

56,000 70,000 70,000 14,000 14,000 14,000 14,000 14,000 14,000 14,000 14,000 408,333 58,333

20

417

116,667

15 3 8 15 15 5

417 1,250 400 250 250 250 TOTAL [USD/year]

87,500 52,500 44,800 52,500 52,500 17,500

TOTAL

195

1,479,333

F.10 Operating Overhead Cost, Taxes and Insurance Table F.23 Operating Overhead Cost Operating Overhead [USD/year]

General plant overhead

1,569,937

Mechanical dept. services

530,683

Employee relations dept.

1,304,595

Business services

1,636,272

Total Annual Operating Overhead [USD/year]

5,041,487

Table F.24 Taxes and Insurance Cost Property Taxes and Insurance

[USD/year]

4,068,167

Insurance and Employee Benefit

[USD/year]

6,721,617

Total

[USD/year]

10,789,784 Universitas Indonesia

F.11 Cash Flow Table F.25 Cash Flow Tahun

Kapasitas Penjualan

opex (USD)

Depreciation f=10%

Revenue (USD)

Cash expanese (USD)

All expansese (USD)

Gross Profit (USD)

NPBT (USD)

2016

NPAT (USD)

Cash Flow (USD)

(164.121.246)

CCF (USD)

(172.327.308)

2017

0,5

(2.001.583.912) (15.997.838)

1.297.462.625

(2.001.583.912)

(2.017.581.750)

(704.121.287)

(720.119.125)

(504.083.387)

(497.684.252)

(670.011.560)

2018

0,7

(2.001.583.912) (12.798.270)

1.816.447.675

(2.001.583.912)

(2.014.382.182)

(185.136.237)

(197.934.507)

(138.554.155)

(133.434.847)

(803.446.407)

2019

0,9

(2.001.583.912) (10.238.658)

2.335.432.725

(2.001.583.912)

(2.011.822.570)

333.848.813

323.610.155

226.527.109

230.622.572

(572.823.835)

2020

1

(2.001.583.912) (8.190.908)

2.594.925.250

(2.001.583.912)

(2.009.774.820)

593.341.338

585.150.430

409.605.301

412.881.664

(159.942.171)

2021

1

(2.001.583.912) (6.552.721)

2.594.925.250

(2.001.583.912)

(2.008.136.632)

593.341.338

586.788.618

410.752.032

413.373.121

253.430.950

2022

1

(2.001.583.912) (5.242.148)

2.594.925.250

(2.001.583.912)

(2.006.826.060)

593.341.338

588.099.190

411.669.433

413.766.292

667.197.242

2023

1

(2.001.583.912) (4.193.755)

2.594.925.250

(2.001.583.912)

(2.005.777.667)

593.341.338

589.147.583

412.403.308

414.080.810

1.081.278.052

2024

1

(2.001.583.912) (3.355.004)

2.594.925.250

(2.001.583.912)

(2.004.938.916)

593.341.338

589.986.334

412.990.434

414.332.436

1.495.610.487

2025

1

(2.001.583.912) (2.684.021)

2.594.925.250

(2.001.583.912)

(2.004.267.933)

593.341.338

590.657.317

413.460.122

414.533.730

1.910.144.218

2026

1

(2.001.583.912) (2.147.209)

2.594.925.250

(2.001.583.912)

(2.003.731.120)

593.341.338

591.194.130

413.835.891

414.694.774

2.324.838.992

2027

1

(2.001.583.912) (1.717.747)

2.594.925.250

(2.001.583.912)

(2.003.301.659)

593.341.338

591.623.591

414.136.514

414.823.613

2.739.662.604

2028

1

(2.001.583.912) (1.374.166)

2.594.925.250

(2.001.583.912)

(2.002.958.078)

593.341.338

591.967.172

414.377.020

414.926.687

3.154.589.291

2029

1

(2.001.583.912) (1.099.437)

2.594.925.250

(2.001.583.912)

(2.002.683.349)

593.341.338

592.241.901

414.569.331

415.009.106

3.569.598.397

2030

1

(2.001.583.912)

(879.432)

2.594.925.250

(2.001.583.912)

(2.002.463.344)

593.341.338

592.461.906

414.723.334

415.075.107

3.984.673.504

2031

1

(2.001.583.912)

(703.579)

2.594.925.250

(2.001.583.912)

(2.002.287.490)

593.341.338

592.637.760

414.846.432

415.127.863

4.399.801.367

2032

1

(2.001.583.912)

(562.853)

2.594.925.250

(2.001.583.912)

(2.002.146.765)

593.341.338

592.778.485

414.944.939

415.170.081

4.814.971.448

2033

1

(2.001.583.912)

(450.381)

2.594.925.250

(2.001.583.912)

(2.002.034.292)

593.341.338

592.890.958

415.023.670

415.203.823

5.230.175.270

2034

1

(2.001.583.912)

(360.223)

2.594.925.250

(2.001.583.912)

(2.001.944.135)

593.341.338

592.981.115

415.086.781

415.230.870

5.645.406.140

2035

1

(2.001.583.912)

(288.128)

2.594.925.250

(2.001.583.912)

(2.001.872.039)

593.341.338

593.053.211

415.137.247

415.252.498

6.060.658.638

2036

1

(2.001.583.912)

(230.578)

2.594.925.250

(2.001.583.912)

(2.001.814.490)

593.341.338

593.110.760

415.177.532

415.269.763

6.475.928.402

2037

1

(2.001.583.912)

(184.417)

2.594.925.250

(2.001.583.912)

(2.001.768.329)

593.341.338

593.156.921

415.209.845

415.283.612

6.891.212.013

2038

1

(2.001.583.912)

(147.606)

2.594.925.250

(2.001.583.912)

(2.001.731.517)

593.341.338

593.193.733

415.235.613

415.294.655

7.306.506.668

2039

1

(2.001.583.912)

(118.034)

2.594.925.250

(2.001.583.912)

(2.001.701.945)

593.341.338

593.223.305

415.256.313

415.303.527

7.721.810.195

2040

1

(2.001.583.912)

(94.473)

2.594.925.250

(2.001.583.912)

(2.001.678.385)

593.341.338

593.246.865

415.272.805

415.310.595

8.137.120.790

2041

1

(2.001.583.912)

(75.476)

2.594.925.250

(2.001.583.912)

(2.001.659.388)

593.341.338

593.265.862

415.286.104

415.316.294

8.552.437.084

2042

1

(2.001.583.912)

(60.447)

2.594.925.250

(2.001.583.912)

(2.001.644.359)

593.341.338

593.280.891

415.296.624

415.320.803

8.967.757.886

2043

1

(2.001.583.912)

(48.367)

2.594.925.250

(2.001.583.912)

(2.001.632.278)

593.341.338

593.292.972

415.305.080

415.324.427

9.383.082.313

2044

1

(2.001.583.912)

(38.651)

2.594.925.250

(2.001.583.912)

(2.001.622.562)

593.341.338

593.302.688

415.311.881

415.327.342

9.798.409.654

2045

1

(2.001.583.912)

(30.940)

2.594.925.250

(2.001.583.912)

(2.001.614.852)

593.341.338

593.310.398

415.317.279

415.329.655

10.213.739.309

2046

1

(2.001.583.912)

(24.789)

2.594.925.250

(2.001.583.912)

(2.001.608.701)

593.341.338

593.316.549

415.321.584

415.331.500

10.629.070.809

241


244 58 m

1800 mm

1900 mm

5000 mm

m m 0 0 7

HE (E-403)

m m 0 0 9

HE (E-404)

5500 mm

5000 mm

5000 mm

2300 mm 2300 mm m m 0 0 0 2

Turbine (T-401)

5000 mm

m 0 3

m m 0 0 8

m m 0 0 8

Evaporator (E-402)

Condenser (E-405)

30000 mm

5000 mm

5000 mm

2500 mm 2300 mm

5000 mm

m m 0 0 9

HE (E-401)

m m 0 0 8 1

Pump (P-401)

Figure G.5 Power Plant Layout

G.2 Total Plant Layout


PAR13_FINALREPORT

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