Revisi Tk11 Report Assignment 1

UNIVERSITAS INDONESIA
PRELIMINARY DESIGN OF ETHYLENE PRODUCTION FROM COAL

GASIFICATON
REPORT ASSIGNMENT 1
GROUP 11
GROUP PERSONNEL:
Ikhsan Nur Rosid
(1106007691)
Ikhwan Muttaqin
(1106010925)
Nuri Liswanti Pertiwi
(1106015421)
Ranti Fabrianne
(1106020522)
Sirly Eka Nur Intan
(1106005055)
CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
UNIVERSITAS INDONESIA
DEPOK
2014
EXECUTIVE SUMMARY
Entering the era of free trade, Indonesia is required to be able to compete
with other countries in the field of industry. Ethylene is one of the important
compounds in the petrochemical industry chain and organic chemicals largest in
the world. Until 2005, the only plant in Indonesia which produces ethylene is PT.
Chandra Asri Petrochemical Indonesia. Ethylene products from PT. Chandra Asri
is almost all of those consumed of polymer grade, which is mostly used as a raw
material of Linear Low Density Poliethyelene (LLPDE) Poliethylene Plant and
High Density (HDPE) Plant PT. Chandra Asri, while a small portion is sold to PT.
Peni and PT. Asahimas Subentra Chemical. Considering the needs for ethylene
increasing both ethylene groups of chemical grade and polymer grade, while
ethylene producers themselves can be said is still limited, it can be said that the
market share for the ethylene plant is still very open, both domestic and foreign
markets.
The raw material of ethylene plant is coal. In Indonesia, the condition of
coal reserves is very abundant and is the energy source with the largest reserves
compared with natural gas and petroleum. Considering the carbon
composition, price, and hardness then bituminous coals are
selected. While coal suppliers selected from PT Bukit Asam and
PT Adaro which is located in southern Sumatra. The supply of oxygen
can be fulfilled by some companies such as PT. Air Liquid and PT. Air Product.
We preferred to PT. Air Product Indonesia, since they has technology
which called oxygen production on-site and mostly produce
gaseous oxygen. By 2014, the MSE is Rp2.443.000 in Cilegon.
That number are considered rational for the petrochemical
industry because of the labor in this sector is mostly skilled and
trained workers.
Each gasifier has advantage and disadvantage, such as fixed bed has
advantage in high conversion and total of gasification media is small, fluidized
bed has advantage in feedstock (coal rank) because all variant of coal capable
become feed, and entrained bed has advantage in high purity of product. From
scoring, we choose gasifier that will be used is Entrained Bed Reactor. This type
of gasifier is choosen because high purity of product. Meanwhile, ethylene
synthesis is done using Methanol-to-Olefin technology based on scoring. This
plant is then simulated via ASPEN HYSYS 7.3. The mass efficiency of this plant
is 45,47% while the energy efficiency is 27.080 kJ/kg.
2
Universitas Indonesia
CONTENTS
EXSECUTIVE SUMMARY.................................................................................ii
CONTENTS..........................................................................................................iii
LIST OF FIGURE..................................................................................................v
LIST OF TABLE...................................................................................................vi
CHAPTER I INTRODUCTION...........................................................................1
1.1.
Background...............................................................................................1
1.2.
Review Literature......................................................................................2
1.1.1.
Ethylene.............................................................................................2
1.1.2.
Coal....................................................................................................5
1.1.3.
Types of Coal and Its Application......................................................6
1.1.4.
Coal Gasification................................................................................7
1.2.
Market Analysis.........................................................................................8
1.3.
Capacity Analysis....................................................................................10
1.4.
Raw Material Analysis............................................................................12
1.5.
Plant Location Analysis...........................................................................16
CHAPTER II PROCESS SELECTION............................................................20

2.1. General Process...........................................................................................20
2.2.
Alternative Process..................................................................................20
2.2.1.
Gasification Technology..................................................................21
2.2.2. Acid Gas Removal Technology............................................................21

2.2.4. Synthesis Ethylene................................................................................22
2.3.
Process Selection.....................................................................................28
2.3.1.
Gasification Technology..................................................................28
2.3.2.
Synthesis Ethylene...........................................................................35
2.4.
Process Description.................................................................................36
2.4.1.
Block Flow Diagram........................................................................36
2.4.2.
Process Flow Diagram.....................................................................38
2.4.3.
Process Description..........................................................................43
CHAPTER III MASS & ENERGY BALANCE...............................................57

3.1.
Mass Balance for Equipment..................................................................57
3.1.1.
Gasification Unit..............................................................................57
3.1.2.
Acid Gas Removal Unit...................................................................60
3
3.1.3.
Water Gas Shift Unit........................................................................64
3.1.4.
Synthesis Methanol Unit..................................................................68
3.1.5.
Synthesis Ethylene Unit...................................................................71
3.2.
Energy Balance for Equipment...............................................................76
3.2.1.
Gasification Unit..............................................................................76
3.2.2.
Acid Gas Removal Unit...................................................................76
3.2.3.
Water Gas Shift Unit........................................................................77
3.2.4.
Synthesis Methanol Unit..................................................................78
3.2.5.
Synthesis Ethylene Unit...................................................................79
3.3.
Overall Mass Balance..............................................................................80
3.4.
Overall Energy Balance...........................................................................80
3.5.
Mass Efficiency.......................................................................................81
3.6.
Energy Required per Unit Product and Energy Efficiency.....................81
CHAPTER IV CONCLUTION..........................................................................82
REFERENCES.....................................................................................................83
4
LIST OF FIGURE
Figure 1.1. Coal and Utilization......................................................................................6
Figure 1.2. Coal Gasification Process.............................................................................7
Figure 1.3. Prediction Cpacity Production, Consumption, Imports.................................10
Figure 1.4. Coal Development Process............................................................................13
Figure 1.5. Coal Quality Based on Coal Type.................................................................13
Figure 1.6. Plant Location...............................................................................................17
Figure 1.7. Indonesias Coal Reverse..............................................................................17
Figure 1.8. Target Market, Coal Mining, and Plant Location..........................................18
Figure 2.1. Black Box of This Plant................................................................................20
Figure 2.2. Simple Flow Diagram for the MTO process by UOP....................................25
Figure 2.3. General Block Diagram Flow of Fischer Tropsch.........................................27
Figure 2.4. Fixed Bed Gasifier........................................................................................31
Figure 2.5. Fluidized Bed Gasifier..................................................................................32
Figure 2.6. Entrained Bed Gasifier..................................................................................33
Figure 2.7. Block Flow Diagram for This Plant..............................................................37
Figure 2.8. Process Flow Diagram for Gasification Unit.................................................38
Figure 2.9. Process Flow Diagram for Acid Gas Removal Unit......................................39
Figure 2.10. Process Flow Diagram for Water Gas Shift Unit.........................................40
Figure 2.11. Process Flow Diagram for Synthesis Methanol Unit...................................41
Figure 2.12. Process Flow Diagram for Synthesis Ethylene Unit....................................42
Figure 2.13. Methanol to Olefins Reactor.......................................................................51
Figure 2.14. Reaction to Produce Ethylene and Propylene..............................................51
Figure 2.15. Diagram of Temperature versus Selectivity.................................................52
Figure 2.16. Feed Effect to Selectivity............................................................................53
Figure 3.1. The Hysis Simulation for Gasification Unit..................................................57
Figure 3.2. The Hysis Simulation for Acid Gas Removal Unit........................................60
Figure 3.3. The Hysis Simulation for Water Gas Shift Unit............................................64
Figure 3.4. The Hysis Simulation for Synthesis Methanol Unit......................................68
Figure 3.5. The Hysis Simulation for Synthesis Ethylene Unit.......................................72
5
LIST OF TABLE
Table 1.1. Data Capacity Production, Consumption, Exports, Imports Ethylene Year
Periode 2005 - 2009....................................................................................9
Table 1.2. Average Coal Price According to the Type......................................................14
Table 1.3. Raw Material Selection...................................................................................14
Table 1.4. The Composition of Bituminous Coal............................................................14
Table 1.5. Bituminous Coal Physical Properties..............................................................15
Table 1.6. Oxygen Physical Properties............................................................................16
Table 2.1. Scoring the type of Gasifier............................................................................34
Table 2.2. Scoring Synthesis Ethylene............................................................................35
Table 2.3. Condition Operation in Each Equipment (Methanol to Olefin)......................55
Table 2.4. Condition Operation in Refrigeration Train....................................................55
Table 3.1. Mass Balance on Mixer..................................................................................57
Table 3.2. Mass Balance on Slurry Pump........................................................................58
Table 3.3. Mass Balance on Gasifier...............................................................................58
Table 3.4. Mass Balance on Cooler Raw Syngas.............................................................59
Table 3.5. Mass Balance on Cyclone Separator...............................................................59
Table 3.6. Mass Balance on Raw Syngas Compressor....................................................60
Table 3.7. Mass Balance on Raw Syngas Cooler.............................................................61
Table 3.8. Mass Balance on Absorber Column................................................................61
Table 3.9. Mass Balance on Rich DEPG Pump...............................................................62
Table 3.10. Mass Balance on Stripper Column................................................................62
Table 3.11. Mass Balance on Rich DEPG Cooler............................................................63
Table 3.12. Mass Balance on Rich DEPG Pump.............................................................63
Table 3.13. Mass Balance on Expander...........................................................................64
Table 3.14. Mass Balance on Reboiler............................................................................65
Table 3.15. Mass Balance on High Temperature Shift.....................................................65
Table 3.16. Mass Balance on Reboiler............................................................................66
Table 3.17. Mass Balance on Low Temperature Shift.....................................................67
Table 3.18. Mass Balance on Cooler...............................................................................67
Table 3.19. Mass Balance on Compressor.......................................................................69
Table 3.20. Mass Balance on Heat Exchanger.................................................................69
Table 3.21. Mass Balance on Reactor..............................................................................70
6
Table 3.22. Mass Balance on Separator...........................................................................70

Table 3.23. Mass Balance on Tank..................................................................................71
Table 3.24. Mass Balance on Distillation Column...........................................................71
Table 3.25. Mass Balance on Distillation Column...........................................................72
Table 3.26. Mass Balance on MTO Reactor....................................................................73
Table 3.27. Mass Balance on Water Separator.................................................................73
Table 3.28. Mass Balance on Demethanizer....................................................................74
Table 3.29. Mass Balance on Deethanizer.......................................................................75
Table 3.30. Mass Balance on Ethylene Tower.................................................................75
Table 3.31. Gasification Unit Energy Balance.................................................................76
Table 3.32. Acid Gas Removal Unit Energy Balance......................................................77
Table 3.33. Water Gas Shift Unit Energy Balance...........................................................78
Table 3.34. Methanol Synthesis Energy Balance.............................................................79
Table 3.35. Energy Balance on Synthesis Ethylene.........................................................79
Table 3.36. Mass Balance Overall...................................................................................80
Table 3.37. Energy Balance Overall................................................................................81
7
CHAPTER I
INTRODUCTION
1.1.
Background
Entering the era of free trade, Indonesia is required to be able to compete
with other countries in the field of industry. Industrial development in Indonesia

are very influential on the resistance of the Indonesian economy. Many sectors of
the chemical industry are holding role to the improving industry in Indonesia. The
innovation of production processes and new plant construction oriented to
reducing our dependence on foreign products and to increase foreign exchange is
required, one of which with the addition of ethylene plant.
Ethylene is one of the important compounds in the petrochemical industry
chain and organic chemicals largest in the world. Ethylene is the basic ingredient
for various intermediate products and final products such as plastics, resins, fibers,
elastomers, solvents, surfactants, coatings, and antifreeze. Generally, ethylene
products are divided into two groups, namely polymer grade and chemical grade.
Polymer grade has a purity of up to 99%, while for chemical grade purity ranged
from 92 until 94%. Polymer grade is the largest consumer of the raw material of
ethylene, which is up to 45% of the total production of ethylene. Besides the
polymer grade, ethylene was also consumed by a group of chemical grade. These
groups include chemical grade such as ethanol, ethylene oxide, vinyl acetate,
ethylene solvents, and so on.
Until 2005, the only plant in Indonesia which producing ethylene is PT.
Chandra Asri Petrochemical Indonesia. Ethylene products from PT. Chandra Asri
is almost all of those consumed of polymer grade, which is mostly used as a raw
material of Linear Low Density Poliethyelene (LLPDE) Poliethylene Plant and
High Density (HDPE) Plant PT. Chandra Asri, while a small portion is sold to PT.
Peni and PT. Asahimas Subentra Chemical. Along with the development of the
times, the needs for ethylene is also increased, up to the year 2009 there were
already four plant in Indonesia that produces ethylene, namely PT. Salim Group,
PT. Pertamina, PT. Shell, and PT. Chandra Asri Petrochemical.
1
The development of domestic ethylene import according BPPN statistics,

ethylene imports in 2010 reached 641.0000 tons. The needs for polymer grade of
ethylene in the country in 2010 was 1.3 million tons per year. Global ethylene
demand in 2015 is expected to reach 160 million tons, which each year will
experience an increase of 5.5%. Considering the needs for ethylene increasing
both ethylene groups of chemical grade and polymer grade, while ethylene
producers themselves can be said is still limited, it can be said that the market
share for the ethylene plant is still very open, both domestic and foreign markets.
Product ethylene produced can be sold for the benefit of polymer grade or
chemical grade.
The raw material of ethylene plant is coal. In Indonesia, the condition of
coal reserves is very abundant and is the energy source with the largest reserves
compared with natural gas and petroleum. Coal reserves are spread almost each
island in Indonesia, with the biggest reserves are in the island of Sumatra and
Balikpapan. Based on data from the Geological Agency, Ministry of Energy and
Mineral Resources, Indonesia's coal reserves in 2010 amounted to 21000 million
tonnes. When viewed from the coal reserves, estimated coal reserves in Indonesia
will expire 71 years from now. The estimates based on assumptions about the
level of production 391 million tonnes per year and not new reserves are found
(Komaidi, 2013). In addition, the development of coal production over the past
few years continues to show increased rapidly, with an average production
increase of 15.68% per year. It makes the process of coal gasification becomes
very feasible conducted as a raw material of ethylene production.
1.2.
Review Literature
1.1.1. Ethylene
Ethylene is lightest hydrocarbon olefin (double chain) with a molecular
weight of 16, colorless, flammable, and slightly fragrance. The properties of
ethylene is determined based on double bond, the main reaction is an addition
reaction produces saturated hydrocarbons and their derivatives or polymers (Kirk
& Othmer, 1977). Now, almost all ethylene made from natural gas, ethane,
propane, and other paraffin and heavy fractions of crude oil, naphtha, kerosene,
and gas oil. A small amount of ethylene gas obtained from refinery output
(catalytic cracking). Some ways of making ethylene according to Mc. Ketta
(1984) are:
a. Hydrocarbon Pyrolysis
This technique is most widely used in the manufacture of ethylene. The
reaction equation of hydrocarbon pyrolysis is:
C7H16
C5H12 + 1/3 C4H8 + 1/3 C3H8 + 1/3 C4H10 + 1/3 C3H
Large-scale production is done by hydrocarbon raw material pyrolysis and

added with the ratio in a steam heater and pyrolysis continued by separation of the
resulting mixture of gas passing through a complex operating system. This
process is produces a complex mixture of hydrocarbon products and will be more
complex again as more with the weighs of the hydrocarbon molecules in the
pyrolysis.
High yield selectivity toward the desired olefins and olefins (ethylene,
propylene, butadiene), methane results, and minimum coking can be achieved by
operating the heater at high temperature pyrolysis (750-900C), short residence
time, and low partial pressures. The addition of steam serves to reduce the
hydrocarbon partial pressure and the amount of carbon deposited in the tube wall.
The weight ratio of steam to hydrocarbon varies from 0.3 to 1.0 for ethane to gas
oil. Changes in the carbon chain paraffinic and naftenik to olefins.
b. Ethanol Dehydration
Manufacture of ethylene from ethanol dehydration followed the following
equation:
C2H5OH
C2H4 + H2O
The reaction occurs with activated alumina catalyst and phosphoric acid.
Ether formation occurs at a temperature of 230C, while at temperatures 300400C ethylene obtained with a minimum content of ether. Ethylene yield can
reach 94-99% from the theoretical values depending on the process used. Further
purification is used to separate acetaldehyde, acids, other hydrocarbons, CO2, and
water. The process is developed on a small scale in Europe, America, and
Australia in the 60's, before the development of the ethylene plant produces
ethylene cheaper, that of hydrocarbons.
c. Propylene Dispropotionation
In this process, which is relatively cheap propylene converted into ethylene
and butylene higher price with the help of tungsten oxide-silica catalyst.
2C2H6
C2H4 + C4H8
d. Ethylene From Coal

An indirect manner and process of considering alternative oil and natural
gas supplies are running low while coal still more. This method involves three
processes, namely:
Production of synthesis gas from coal gasification process (process Lurgi,
Koppers-Totzek, Winkler).
Synthesis gas is converted to hydrocarbons by the Fischer-Tropsch process.
Ethylene is made by pyrolysis of hydrocarbons or hydrated ethanol is obtained.
This process runs in South Africa that do not contain petroleum but rich in
coal. From all the above, the most widely used is a hydrocarbon pyrolysis process,
which consists of three stages, is :
Synthesis.
Recovery.
Purification.
The process is carried out at high temperature between 1500 - 2000F.
Techniques used in the production of ethylene by means of pyrolysis of

hydrocarbons in general according to Kirk & Othmer (1977), among others:
Fired tubular heater.

Regenerative stove.
Moving bed / refractory pebbles.
Generation of heat by combustion in air or oxygen use.
The electric arc.
Contact with tin.
Both the first-mentioned process, ie the process by using tubular and
regenerative heater fired stove has been run commercially. Of the six above
process, this time almost all the ethylene plant using tubular fired heater in its
production. Recovery and purification of ethylene is a complex process, given the
results of pyrolysis is also very complex. The process is run commercially for this
purpose are :
Fractionation at low temperatures and high pressures.
Adsorbtion and fractionation at low temperatures.

Fractionation at low temperature and low pressure.
Extraction solvent
For the record fractionation process at low temperatures and high pressures
are used in 75% ethylene plant operating in the United States. In the design of this
ethylene plant licensing process there are 3 most dominant and widely used,
namely Kellogg, Lammus, and Linde. Among the licensor third, Kellogg process
with the front end demethanizer scheme that was developed around 1960 had an
estimated 40% of all existing plant in the world, due to the high thermodynamic
efficiency.
1.1.2. Coal
Coal is a fossil fuel that its formation requires certain conditions and in a
long time. Coal is the remains of plants that change shape, which originally
accumulated dirawa and peatlands. Hoarding silt and other sediments, together
with a shift of the earth's crust (known as tectonic shifts) swamps and peat buried
to a depth that is often very deep. With such hoarding, plant material is exposed to
high temperature and pressure and causes the plants undergo a process of physical
and chemical change and transform the plant into peat and then coal, a process
known acoalification (Bell, 2011).
Quality of each coal deposit is determined by varying the temperature and
pressure as well as the length of time the formation of the so-called "organic
maturity". Initially the peat is converted into lignite (bararmuda stone) or brown
coal (brown coal). Influenced by temperature and pressure constant, a young coal
which changes gradually add organic maturity and young converts coal into a subbituminous coal. Chemical and physical changes continued until coal becomes
harder and the color is black and form a bitumen or antrasi. Under the right
conditions, an increase in the organic maturity continue, finally forming
anthracite.
1.1.3. Types of Coal and Its Application

Figure below shows the classification of coal. It can be seen that the coal
generally is divided into two main groups, namely low quality coal or soft coal
and hard coal. This classification is based on the carbon content and the humidity,
the more the carbon content of the coal, the better. While it is inversely
proportional to the moisture of coal, the coal, the coal moisture smaller the better.
Figure 1.1. Coal and Utilization

(Source: Research and Development Center for Mineral and Coal Technology, 200B, 2006)
Low quality coal there are two types, namely lignite and sub-bituminous.
Coal is usually more gentle with fragile materials such as soil and gloomy color.
This coal has a relatively high humidity levels and low carbon content so that the
content of energy or low calorific value. This type of coal utilization for power
generation typically, the source of energy for industry, and cement production.
While coal with higher quality or hard coal are generally more powerful and often
brilliant black like glass, the higher carbon content and lower moisture levels
make this coal has a higher heating value. Anthracite is the most excellent quality,
having carbon content and higher energy and lower humidity levels. Utilization of
coal types are also more widely, in addition to power plants and cement industry,
coal is also used in the manufacture of iron and steel industry.
1.1.4. Coal Gasification

Coal gasification is the process of converting the carbon in the coal to gas
(syngas) using gasification medium (gasification agent). Substance used as a
medium is air or oxygen, water or steam, and carbon dioxide. The gas produced
diverse as carbon monoxide and hydrogen which is the main product, carbon
dioxide, steam, methane and even gases such as NO% and SO%, although in
small amounts. Stages in the gasification process can be seen in the picture below
along with an explanation.
Figure 1.2. Coal Gasification Process

(Source: www.esptk.fti.itb.ac.id, 2010)
a. Drying (Evaporation of Moisture)

Phase Drying (Evaporation of Moisture) Is the stage where the evaporation
of water content in the coal. This process depends on the type of coal,
subbituminous coal to the type of humidity can reach 35% by weight, while the
smaller bituminous about 5% by weight. This process can be avoided in the
gasifier by means treatment first coal input (dehydration).
b. Pyrolysis
Is a chemical process of decomposition by means of heating at minimal or
no oxygen conditions. Coal will experience cracking on this process at
temperatures of about 250oC to above. The result of this process is charcoal, water
vapor, tar vapors, and gases. The purpose of this stage is to facilitate the formation
of syngas at the gasifier reaction. In the pyrolysis process resulting CO, CO2, CH4,
H2O, H2, and tar.
c. Formation of Volatile Substances (Combustion of Volatile Matter)
Substance reacts with oxygen pyrolysis results to generate the heat required
by the next process, gasification by steam. The process of oxidation (burning) is a
homogeneous reaction is exothermic and provide heat or energy for
heterogeneous reaction process. The reaction below is a common homogeneous

reaction.
C ( s ) +O2 ( g ) CO2 ( g ) H rxn=393.98 kJ / gmole
2CO ( g )+ O2 ( g ) 2 CO 2 ( g ) H rxn=566.65 kJ /gmole
2 H 2 ( g ) +O2 ( g) 2 H 2 O ( g ) H rxn =484.23 kJ /gmole

d. Gasification (Heterogenous Reaction)
At this stage, the bias char reacts with water vapor and carbon dioxide to
produce hydrogen and carbon monoxide gases as the main component. At this
stage is the stage that occurs digasifier or gasification processes. This process is
dependent on the selection of the gasifier itself, where each gasifier it has
advantages and disadvantages. The following reactions occur in this process.
C ( s ) + H 2 O ( g ) CO ( g )+ H 2 ( g ) H rxn=+131.46 kJ / gmole
C ( s ) +CO 2 ( g ) 2 CO ( g ) H rxn=+172.67 kJ / gmole
C ( s ) +2 H 2 ( g ) CH 4 ( g ) H rxn=74.94 kJ / gmole
At this stage also formed methane in certain circumstances. To adjust the
ratio of H / C to fit the needs, usually arranged so that the case of water-gas shift
reaction reaction that aims to convert CO to H2.
CO ( g ) + H 2 O ( g ) CO 2 ( g ) + H 2 ( g ) H rxn=41.21 kJ /gmole
e. Slagging
Inside there is also a coal of ash content (ash) in which the amount depends
on the type of coal and the coal geography. This ash is separated by slagging
process.
1.2. Market Analysis
In planning the construction of a plant, in addition to the availability of raw
materials are cheap and easily should also be noted that the development of the
market of goods to be produced in this case is a short chain olefins ethylene.
Therefore, it takes a market analysis which includes the development of
production, export, import and consumption.
Based on the data table below, the development of ethylene production in
Indonesia has decreased the period 2005 2009. In contrast, domestic
consumption has increased an average of 7.8% per year from 2005 to 2009
reached 1,118,000 tons capacity so that the necessary import as much as 660,000
tons in 2009 to meet the needs primarily of ethylene as a feedstock for the
production of ethylene derivatives such as polyethylene, vinyl acetate, ethylene
oxide, ethyl benzene, and so forth. With conditions that increased imports for
domestic needs, is no longer possible to export abroad.
Table 1.1. Data Capacity Production, Consumption, Exports, Imports Ethylene Year Period 20052009
Capacity x 1000 ton
2005
2006
2007
2008
2009
Production
510
Konsumsi
847
Ekspor
0
Impor
337
(Source: Ministry of Industry, 2011)
460
754
0
294
540
801
0
261
488
931
0
444
455
1118
0
660
Based on data from each of the five years from 2005 to 2009 made the
prediction capacity of domestic production and consumption for the period 2010
until 2025 and depicted in Table 1.2. and Figure 1.3. As for the import of data
from the years 2010 to 2025 is the difference of the capacity of production and
consumption each year from predicted results. From the results obtained estimates
of data that needs to ethylene will continue to increase until it reaches a capacity
of 11,171,000 tonnes, while production in the year only 2,263,000 tonnes that will
be required for the import of 8,908,000 tonnes outside.
Table 1.2. The Prediction Capacity Production, Consumption, and Imports Ethylene Year Period
2010-2025
Year
2010
2011
Consumpti
on
(tonne/year
)
1109000
1296000
Productio
n
(tonne/yea
r)
468000
460000
Import
(tonne/yea
r)
641000
836000
10
2012
2013
2014
2015
2016
2017
2018
2019
2020
2021
2022
2023
2024
2025
1459000
1600000
1754000
1999000
2374000
2820000
3350000
3978000
4725000
5613000
6667000
7918000
9404000
11171000
430000
427000
421000
405000
481000
571000
679000
806000
957000
1137000
1351000
1604000
1905000
2263000
1029000
1173000
1333000
1594000
1893000
2249000
2671000
3172000
3768000
4476000
5316000
6314000
7499000
8908000
(Source: Authors Personal Data)
12000000
10000000
8000000
Capacity, tonne/year
6000000
Consumption
4000000
Production
Import
2000000
0
Years
Figure 1.3. The Prediction Capacity Production, Consumption, Imports

(Source: Authors Personal Data)
Of the real data and the predictions that have been discussed previously
showed an imbalance between production capacity and domestic consumption.
Domestic production capacity is still very small compared to consumption
necessitating an increase in ethylene production capacity in the country. In 2012,
producers of ethylene producer, PT. Chandra Asri produce ethylene with a
capacity of 600,000 tons and PT. Pertamina with a capacity to produce 405,000
11
tons of propylene. With two of the manufacturers producing olefins, it is an

opportunity for the establishment of an ethylene plant can help cover the
imbalance of production and domestic consumption will be a short chain olefins.
1.3. Capacity Analysis
The production capacity of a plant can be determined by
market analysis that have been made. Market analysis indicates
any opportunities that can be taken by the new manufacturers to
invest in ethylene industry. Opportunities can be maximized
among the competition with other manufacturers, both the
existing manufacturers and new manufacturers. This opportunity
is greater due to higher economic growth in Indonesia which
always above 5 percent in the last ten years. Stable economic
growth for years will be followed by growth in the industrial
sector as a result of the increasing ability of consumers to buy
the commodities.
Capacity analysis is needed to determine the production
capacity according to manufacturers's ability. Although there is
an opportunity to benefit from the gap between demand and
supply, there should be anticipation of the possibility of
competition between manufacturers of ethylene. Rivalry can be a
competition with manufacturers which had already producing and
new competitors that could emerge later on.
Based on the analysis of the ethylene market, ethylene
demand in Indonesia has grown on year to year. Although
ethylene demand growth followed by growth in ethylene
production, but the amounts are relatively insignificant. This is
illustrated by the persistence of the difference between the
demand and supply of ethylene in Indonesia. Market analysis
concludes that there is a difference or deficit between supply and
12
demand for ethylene in Indonesia amounted to 2,671,000 tons

per year in 2018.
That figure could not necessarily be used as a new
ethylene capacity of a plant to be built. Since the existing
manufacturers are still very likely to expand their production
capacity and the possibility of new competitors in the coming
years.
The
existing
existing
manufacturers
could
produce
ethylene ranged from 250,000 tons to 550,000 tons.

Based on the figure of deficit of ethylene supply and the
existing manufacturers production capacity, our factory will
produce 400,000 tons of ethylene per year. That figure is
equivalent to the production of 1212 tons of ethylene per day.
Our production capacity is equal to 30 percent of the gap
between supply and demmand of ethylene in Indonesia. The rest,
70 percent, is our anticipation for the probability of rivalry.
We are very confident that the production capacity of
400,000 tons of ethylene per year will be able to be absorbed by
the market. Considering the ethylene consumption which is
continously increasing every year, the gap of 896,000 tonnes will
increase following the growth of demand for ethylene. Production
capacity of 400,000 tons is also the most ideal figure to get some
profits. Due to the growing production capacity, it is better to get
a category of economically feasible before build the plant and
consider the possibility of competition with competitors.
1.4. Raw Material Analysis
Coal is a fossil fuel that its formation requires certain
conditions and lasts within a long time. Coal is the remains of
plants that deformed and originally accumulated in swamps and
peat bogs. Stockpiling of silt and other sediments, along with a
shift of the earth's crust (known as tectonic shifts) burried
13
swamps and peat to a depth which is often very deep. With such
piling, plant material is exposed to high temperature and
pressure and causes the plants undergo a process of physical
and chemical change and transform the plant into peat and then
coal, now it is called the coalification process.
One of the indicators of the quality of coal is the content of
carbon, these are the carbon composition for the five types of
coal:
Anthracite coal is the highest grade, with glittering black color

(luster) metallic, containing between 86% - 98% of the
elements of carbon (C) with a water content of less than 8%.

Bituminous containing 68-86% of carbon element (C) and
water content of 8-10% by weight. This Grade of coal is the
most mined in Australia.

Sub-bituminous contains less carbon and more water, and
thus it's a source of heat which less efficient compared to
bituminous.
Lignite or brown coal is very soft coal which contains 35-75%
water by weight.
The quality of coal is also determined by the temperature
and pressure as well as the length of time for the formation of

the so-called organic maturity. Initially the peat is converted into
lignite (lignite) or brown coal. This is the type of coal with low
organic maturity. Influenced by temperature and pressure
constant, a young coal which changes gradually add organic
maturity and young coal converts into a sub-bituminous coal.
Chemical and physical changes continue to occur until these
coals became harder and the color is black and form a bitumen
or antrasi. Under the right conditions, an increase in the organic
maturity can continue, finally forming anthracite. Figure 1.4
shows coal development process.
14
Figure 1.4. Coal development process

(Source : Habiburrohman, 2012)
There are two types of low-quality coal, the lignite and subbituminous. The coal is usually more gentle with fragile materials
such as soil and gloomy colored. The coal is young, has a fairly
high moisture levels and low carbon content, thus the energy
content or heating value is low, the use of the average of coal is
to generate electricity, industrial and energy sources for the
production of cement.
Figure 1.5. Coal Quality Based on Coal Type

Coal with higher quality or hard coal are generally more

powerful and often brilliantly black like glass, the higher content
of carbon and lower moisture levels make this coal has a higher
15
heating value. Anthracite is the most good quality of carbon

content and thus it has higher energy and lower humidity levels.
The use of coal is greater, in addition to power generation and
cement industries, coal is also used in the manufacture of iron
and steel industry.
By 2010, the average selling price of coal at the mines that
produce each of the four main types of coal are :
Table 1.2. Average Coal Price According to The Type
Price per Ton
Coal Type
($)
18.76
14.11
60.88
59.51
Lignit
Sub-bituminuos
Bituminous
Anthracite
(Source : www.esdm.go.id)
The selection of coal based on several parameters such as

the composition of carbon, the price and hardness level. Followed
by an assessment of each type of coal to get the type of coal that
will be used. Below is a table of assessment for the selection of
raw materials :
Table 1.3. Raw Material Selection
The
Raw
Composit
Material
ion of
Lignit
Subbituminous
Bituminous
Anthracite
Price
Coals
Total
Hardness
Score
Carbon
-1
+1
-1
-1
+1
-1
+1
+1
0
0
+1
-1
+2
0
(Source : Authors Personal Data and gather from any sources)
Bituminous coal has several advantages when compared

with other types of coal. Bituminous coal has high carbon
content. Although the carbon content in the anthracite coal is
higher, but it also harder. Consequently size reduction process is
more difficult when using anthracite coal. It means more time
and bigger cost to reduce the coal size. While the sub-bituminous
16
coal and lignite contains less even very low carbon. The water
content in the lignite and sub-bituminous coal also very high.
Coal with a low carbon content and high water content will
produce ethylene in a very low yield. So that ethylene production
using lignite and sub-bituminous need more coal when compared
to ethylene production with bituminous coal. Although the price
of bituminous coal is more expensive than the two types of coal,
but it will actually save storage space and transport costs since
less coal is needed.
Considering the carbon composition, price, and hardness
then bituminous coals are selected. While coal suppliers selected
from PT Bukit Asam and PT Adaro which is located in southern
Sumatra.
Bituminous coals have composing components with the
following composition :
Table 1.4. The Composition of Bituminous Coal
Component
Moisture
Ash
Sulfur
% Weight
1.0 10.0
4.0 20.0
0.5 2.2
Table 1.4. The Composition of Bituminous Coal (Contd)
Component
Fixed carbon
Volatile
matter
and
another
and
elemental
% Weight
50.0 72.0
compounds (H2, N2, and
17.0 37.0
Cl2)
Here is physical properties for bituminous coal :

Table 1.5. Bituminous Coal Physical Properties
Physical Properties
Igniton temperature
Melting point
Average specific gravity
% volatility by volume
Vapour density (air = 1)
Solubility in water
Data
260o 365oF
750oF
1.43
Negligible
N/A
Non-soluble
17
(Source : MSDS of Bituminous Coal)

Since the gasification unit need oxygen feed, we have to get
oxygen supply. We preferred to have a partnership with a third

party. Thus, it is not necessary for us to build the unit. They will
build their own air separation unit as oxygen supply in our site. It
is more efficient than we build the unit ourself.
Oxygen can be produced from air. The air will be processed
by fractination to seperate the component such as nitrogen,
oxygen even helium. The fractination components of air is done
by cryogenic temperature. The air will be condensed or
liquifaction and then will be separate with cryogenic distillation to
seperate all component with high purity. The process can use
zeolite as membran filter to improve the purity of gas. Oxygen
with high purity, 90% to 93% can be produced from this process.
Here is physical properties for oxygen :
Table 1.6. Oxygen Physical Properties
Physical Properties
Molecular weight
Moleculr formula
Data
32 g/mole
O2
Boiling/condensation
-183oC (-297.4oF)
Melting/freezing
point
point
-218.4oC (-361.1oF)
Critical temperature
-118.6oC (-181.5oF)
Vapor density
Specific volume
Gas density
1.105 (air = 1)
12.0482
0.083
(Source : MSDS of O2)
The supply of oxygen can be fulfilled by some companies such as PT. Air
Liquid and PT. Air Product. We preferred to PT. Air Product Indonesia,
since they has technology which called oxygen production on-site
18
and mostly produce gaseous oxygen. The technology which used

by PT. Air Product Indonesia is PRISM. PAT. Air Product Indonesia
will build a oxygen supply facilites in our plant which will be
managed by PT. Air Product Indonesia. The oxygen supply
facilites
will
be integrated
with
our
process
plants.
This
technology has low investment and low operating cost. This

technology is economical alternative to supply oxygen for our
plants by cryogenic treatment. The range of purity from this
technology is 90%-93% and the capacity is 200-10.000 Nm3/hour.
1.5. Plant Location Analysis
The selection of appropriate location of the plant will
adversely impact the operating and capital costs which is should
be inculcated by investors to build a plant. It will directly affect
the economic value and feasibility of the plant to be built. To
choose
the
right
location,
there
are
several
factors
of
considerations that must be considered. Because of these factors

will affect the continuity of the production of the plant in the
future.
We will build a plant in Cilegon, Banten. Here is the
candidate location for this plant in Cilegon :
19
Figure 1.6. Plant Location

(Source : www.maps.google.com)
The selection of the location of the plant in Cilegon is

determined by various factors of considerations, such as:
a. Raw Material Availability
Our factorys main raw material is the coal. So the proximity of this plant
with the areas rich in coal reserves that have been explored is crucial. Here is a
map of the distribution of coal reserves in Indonesia:
Figure 1.7. Indonesias Coal Reserve

(Source : www.esdm.go.id)
From the map above, the southern part of Sumatra and

Borneo is the the area with the largest coal reserves and
production in Indonesia. Although Cilegon not really close to
20
Borneo and Sumatra, but closer to the geographical location of

southern Sumatra. The coal will be used as raw material in this
plant comes from PT. Bukit Asam and PT. Adaro, these companies
are in the province of South Sumatra.
b. Target Market Location
Petrochemical company is widely built in Java, especially
around Cilegon and Greater Jakarta. So the site selection in
Cilegon make this plant location closer to the consumer and not
really far from coal mine in South Sumatra. Here is an illustration
of strategic Cilegon if viewed in terms of the location of the
target market and the location of the coal mine :
Figure 1.8. Target Market, Coal Mining and Plant Location

(Source : www.maps.google.com)
c. Infrastructure and Transportation

Cilegon is now connected with the Jakarta-Merak Toll Road.
So access to and from the Greater Jakarta is very easy. In
addition, the location of Cilegon which is on the northwest coast
of Java island is an area that lives within range of industrial port
of IPC II. So it will be very easy transporting coal by sea.
d. Workers Availability
As an industrial city, Cilegon has a reserve of human
resources reliable in quality and quantity. By 2014, there are
approximately 398,304 inhabitants in Cilegon with a workforce of
60,000 people. In addition, the availability of labor from the area
21
around and outside Cilegon is also relatively large. It can be seen

from the number of workers from several areas in Java such as
Greater Jakarta, West Java, Central Java and East Java.
e. Government Policy and Sosio-Geographical Circumstance
Cilegon social circumstances today are very heterogeneous.
Nevertheless hardly ever there is a riot on a large scale in
Cilegon within the last few decades. This condition makes Cilegon
has been chosen by many companies to set up their factories.
By 2014, the MSE is Rp2.443.000 in Cilegon. That number
are considered rational for the petrochemical industry because of
the labor in this sector is mostly skilled and trained workers.
CHAPTER II
PROCESS SELECTION
2.1. General Process

The goal of this plant is convert coal become ethylene. Figure 2.1. shows
black box for this plant.
BLACK BOX
Syngas
Ethylene
Propylene
Ethane
Propane
Buthene
Penthene
HCOOH
H2O
Methane
Methanol
Figure 2.1. Black Box of This Plant
(Source : Authors Personal Data)
Input for this plant is syngas. The input will be processed in black box and
the result is ethylene, propylene, ethane, propane, buthene, penthene, HCOOH,
H2O, methane, and methanol. This process will be started in gasification process.
In this gasificication process, coal will be converting become syngas first. This
process will be continued to synthesis of ethylene and the result is ethylene.
2.2.
Alternative Process
Process production ethylene from coal has many kind of altrnative process.
Study literature to find available process is needed which can be used to produce
ethylene from coal. First, coal will be gasified and produce synthesis gas. This
product will be fed to the next process to synthesis olefin such as ethylene.
22
23
2.2.1. Gasification Technology

Coal gasification is a series of reaction steps that convert coal containing C,
H, and O, as well as impurities such as S and N, into synthesis gas and other
forms of hydrocarbons. Synthesis gas is mixture between from hydrocarbon gas
and carbon monoxide that converts result from coal.
In total gasification, coal reacts with solvent, consist of air, oxygen, steam,
carbon dioxide or mixture of the gas. All organic materials from coal will be
changed become gas product so residue in the reactor is dust. The main reaction
that happen in the gasification process by using air is called coal partial
combustion. Gas product that resulted is also called producer gas or low calorie
gas because it contains carbon monoxide and nitrogen also the heat value of this
gas approximately 1780 calorie/litre.
This conversion is generally accomplished by introducing a gasifying agent
(air, oxygen, and or steam) into a reactor vessel containing coal feedstock where
the temperature, pressure, and flow pattern (fixed bed, fluidized bed, or entrained
bed) are controlled. The proportions of the resultant product gases (CO, CO 2, CH4,
H2, H2O, N2, H2S, SO2, etc.) depend on the type of coal and its composition and
the gasifying agent (or gasifying medium).
The composition of gas that resulted from gasification process depends on
feedstock (type of coal are used), operation temperature, and influence of steam.
At the high temperature, gas that resulted contains rich carbon dioxide, whereas at
the low temperature, gas that resulted contains rich carbon monoxide. Moisture in
coal or steam that added into reactor could increase hydrogen and carbon
monoxide proportion in the gas product and heat value of gas. In case excessive
water or steam that added, process temperature would decrease resulted rich
carbon dioxide effected low heat value.
The next step after become syngas is acid gas removal. In high temperature
processes, all sulfur components in the feed are converted to H 2S or COS, which
are undesirable components and require acid gas removal technology to be
treated.
Actually, water gas shift reaction is not classified as one of the principal
gasification reaction. It cannot include in the analysis of chemical reaction that
24
involve syngas. Among all reactions involving syngas, so equilibrium constant is

least strongly dependant on the temperature.
Syngas product from a gasifier contains a variety of gaseous species such as
carbon monoxide, hydrogen, carbon dioxide, methane, and water (steam). Water
gas sfift reaction is one of the major reactions in the steam gasification process,
both water and carbon monoxide are presents.
2.2.4. Synthesis Ethylene
a. Method 1 Dehydration of Methanol
Methanol to olefin production starts from syngas conversion into methanol.
Synthesis gas (syngas) is a mixture that contains hydrogen, carbon monoxide and
carbon dioxide as principal components and methane and steam as secondary
components. Methanol synthesis from syngas commonly conducted over
CuO/ZnO/Al2O3 catalyst. In this type of catalyst, Al2O3 plays role as a support.
The reactions involved in methanol synthesis from syngas are:
CO+ H 2 CH 3 OH
CO2 +3 H 2 CH 3 OH + H 2
CO+3 H 2 O CH 3 OH + H 2 O
There are several side reactions that can occur beside the reactions
mentioned above. One of the main byproducts that produced in methanol
synthesis is dimethyl ether. The reaction of dimethyl ether synthesis can be written
below :
2CH 3 OH CH 3 O CH 3+ H 2 O
The typical methanol synthesis technology involves several steps, namely

syngas compression, catalytic synthesis, crude methanol distillation and recycle &
recovery. There are several well-known methanol synthesis technology, such as
Conventional ICIs 100-atm Methanol Process, Haldor Topsoe A/S Low-Pressure
Methanol Synthesis Process, Kvaerner Methanol Synthesis Process, Krupp Uhdes
Methanol Synthesis Technology, Lurgi Oel-Gas-Cheme GmbH Process, Syntetix
LPM Process and Liquid Phase Methanol Process.
The Conventional ICIs 100-atm Methanol Process was first developed in
1972 when Cu/ZnO/Al2O3 catalysts system was announced. This process
originally consists of two section, reforming and synthesis. Haldor Topsoe A/S
Low-Pressure Methanol Synthesis Process is designed to produce methanol from
25
natural or associated gas feedstocks, including a two-step reforming process to

generate syngas mixture for methanol synthesis. Kvaerner Methanol Synthesis
Process is similar to Haldor-Topsoe process, the difference is that in this process
carbon dioxide can be used as a supplementary feedstock to adjust the syngas
ratio. Krupp Uhdes Methanol Synthesis Technology has flexibility of feedstock
choice, including natural gas, liquefied petroleum gas or heavy naphta. Lurgi OelGas-Cheme GmbH Process is meant to produce methanol in a single-train plant
with feedstocks from natural gas or ail-associated gas. Meanwhile, Syntetix LPM
Process is an impoved version of ICIs technology. This process is designed to
handle natural gas feedstock, but also capable of handling other hysdrocarbon
feedstock like naphta, coal and other petrochemical offgas stream. The last
commercial technology for methanol production is Liquid Phase Methanol
Process. In this process, the reaction carries out in a slurry reactor using
Cu/ZnO/Al2O3 catalyst.
Methanol is produced from the process before can be used to synthesis
olefin. Product from this process is not only ethylene, but also propylene.
Methanol to olefin (MTO)
enables low costs of production ethylene (and
propylene) in regions that do not have large resrves of ethane. MTO is used in
some country to fill the gap between ethylene demand and supply.
The conversion of methanol to olefins and other hydrocarbons products has
been widely studied. This method is developed and licensed by UOP. This process
use SAPO-34 catalyst, silicoaluminumphosphates. SAPO-34 has unique pore
size, geometry and acidity created a more selective route for methanol conversion
to ethylene and propylene with reduced heavy by product.
MTO process utilises a fluidised reactor and regenerator system to convert
methanol to olefins using a proprietary, SAPO-34 Catalyst. MTO process can be
operated on crude, or undistilled methanol, as well as with pure methanol. The
choice of feedstock quality generally depends on project spesific situations
because there can be advantages in either case. Figure 2.2. ilustrates a simple flow
diagram for the MTO process by UOP.
The methanol feed is preheated and then introduced into the reactor. The
conversion of methanol to olefins requires a selective catalyst that operates at
moderate to high temperatures. The reaction is exothermic so heat can be
recovered from the reaction. Carbon aor coke accumulates on the catalyst and
26
requires removal to maintain catalyst activity. The coke should be removed by

combustion with air in a catalyst regenerator system. A fluidised bed reactor and
regenerator system is ideally suited for the MTO process because it allows for
heat removal and continuous catalyst regeneration. The rractor operates in the
vapor phase at temperature 650-1000oF and pressure between 15 and 45 psig. A
slipstream of catalyst is circulated to the fluidised bed regenerator to maintain
high activity.
The reactor effluent is cooled and quenched to seperate water from the
product gas is compressed and then unconverted ixygenates are recovered and
returned to the reactor. The reactor provides very high conversion so there is no
need for a large recycle stream. After the oxygenate recovert section, the effluent
is further processed in te fractionation and purification section to remove
contaminants and separate the key products from the by product components.
Ethylene and propylene are produced as polymer grade products and sent to
storage. The havier component can be sent to OCP reactor where it is selectively
converted to light olefins.
Figure 2.2. Simple Flow Diagram for the MTO process by UOP
(Source : A, Grefory, et.al. Hydrocarbon Engineering)
b. Fermentation and Dehydration of Bio-Ethanol

Ethanol to olefin is a similar process to methanol to olefin. Syngas produced
in the gasification process can be converted into ethanol using metal catalyst of
microbial catalyst. Currently, syngas conversion to ethanol using metal catalyst is
used in industries. The types of metal-based catalyst for producing ethanol from
27
syngas are Rh-based catalyst. However, this technology is limited in selectivity of

conversion and some catalysts used are sensitive to poisoning. These catalysts are
also required severe condition with complex composition in producing ethanol.
To overcome this problem, microbial agent is developed to convert syngas
to ethanol. Several bacteria are able to convert syngas into ethanol as part of their
metabolism. The overall stoichiometric reaction of ethanol production from
syngas is shown below :
6 CO2 +3 H 2 O CH 3 CH 2 OH + 4 CO 2
2CO 2 +6 H 2 CH 3 CH 2 OH + 3CO 2
(2)
(1)
1
6 CO+6 H 2 2 CH 3 CH 2 OH +2CO 2
(3)
Microbials that are able to convert syngas into ethanol belong to acetogen
class. Acetogens are microorganisms that can use gases like CO 2, H2, and CO as
well as other substrate like sugar to produce ethanol, acetate and cell carbon via
acetyl-CoA pathway.
There are several kinds of reactors that can be used for processing syngas
fermentation to ethanol. Trickle-bed reactor (TBR) that consists of vertical tubular
reactor can be used for fermentation by attaching the microorganisms into packed
solid material. Other reactor that can be used for fermentation is continuous
stirred-tank reactors (CSTR). In CSTR, a continuous flow of gas bubbling through
the liquid which consists of a dilute solution of essential nutritions needed by the
microorganisms to grow and survive. Beside TBR and CSTR, packed-bed reactor
(immobilized-cell reactors) also can be used for syngas fermentation. This reactor
usually consists of columns packed with microorganisms that are immobilized
into biocatalyst reactor.
The production of ethanol from syngas basis using microbial agent is
currently not available on a commercial basis. This technology has disadvantages
in reaction time of water-gas shift reaction due to the slow cell growth of the
microorganisms. The fermentation is also often limited by low productivity and
the rate of syngas that can be transferred into the liquid.
Meanwhile, the ethanol dehydration to produce ethylene usually consists of
three sections, which are reaction and quenching section, the compression, caustic
28
washing and drying section, and the purification section. The reaction occurs in
four stages of adiabatic, fixed-bed reactor. The output from the last reactor is then
quenched to reduce its water content. After quenched, the output is compressed
and sent to as caustic washing column to reduce CO2 content. This stream is then
dried in a drying system that consists of two molecular sieve beds. The stream is
separated into vapor and liquid components before being fed into two different
ethylene columns to remove C3+ residues from the dehydration reaction. The
overhead product that consists of ethylene is then undergoes CO removal in a
stripper column.
c. Fischer Tropsch
Fischer-Tropsch process can also be used for converting syngas produced in
coal gasification process into olefins. Fischer-Tropsch is a reaction that converts
syngas that consists of carbon monoxide and hydrogen into liquid hydrocarbon.
Syngas produced in gasification process is purified first from impurities like
hydrogen sulfide, carbon dioxide, tars and slag, before entering the FischerTropsch reactor. There are three main reactions and two side reactions in FischerTropsch reactor :
Main reaction
Alkanes
nCO+ ( 2n+ 1 ) H 2 C n H 2 n+ 2+ n H 2 O
Alkenes
nCO+2n H 2 C n H 2 n +n H 2 O
Water-gas shift
CO+H 2 O CO2 + H 2
Side reaction
Alcohol
C H 2
nCO+ 2n H 2 H
Boudouard reaction
2CO C +C O2
The product from the reactor varies according to the reaction temperature,
catalyst, pressure and syngas composition (H 2/CO ratio). The products then
undergo separation to separate the fractions produced from the reactions. The
hydrocarbon fraction produced in the reactor includes ethylene, propylene, LPG,
naphtha, and longer hydrocarbon chain fraction. The product that is used for
29
olefin production is naphtha fraction, so other fraction than ethylene, propylene

and naphtha need to be reformed into naphtha first.
The formed naphtha is then being cracked to produce olefins. The overall
cracking process of naphtha can be seen in the figure below :
Figure 2.3. General Block Diagram Flow of Fischer Tropsch

(Source : www.fisher.com)
The first step of the olefin production is cracking naphtha into ethylene and
other various products in a furnace. This process is called pyrolysis, which can be
defined as thermal cracking of petroleum hydrocarbon with steam. The cracked
gas is then quenched to preserve the current gas composition and prevent
undesirable side reactions. After being cooled, the cracked gas is then compressed
in a turbine driven centrifugal compressor with typically four or five stages and
interstage cooling. Prior entering the compressor and after each interstage cooling,
the gas is dried to prevent the formation of hydrates and ice. Between 3rd and 4th or
4th and 5th stages, acid gas removal system is also placed to prevent formation of
hydrates and ice in the next step. The compressed gas is the fractionated in
distillation column to produce different products and fractions at specified
qualities.
2.3.
Process Selection
In this sub bab, we would select the gasification technology that we use.
This selection consider many variables (based on the literature), such as type of
coal that used (coal rank) as raw material, efficiency from energy side and utility
(total of gasification media), also capital cost from technology that we used,
conversion of carbon, and purity of syngas as output from gasifier. In this sub bab,
30
we also select the acid gas removal technology and continous process from syngas
resulting ethylene.
2.3.1. Gasification Technology
a. Selection of Gasification Process based on Reaction
Steam Gasification
The steam gasification reaction is endothermic, so this process requiring
heat input for the reaction to proceed in its forward direction. Usually, an excess
amount of steam is also needed to promote the reaction. However, excess steam
used in this reaction hurts the thermal efficiency of the process. Therefore, this
reaction is typically combined with other gasification reactions in practical
applications. The H2-to-CO ratio of the product syngas depends on the synthesis
chemistry as well as process engineering. Reaction of steam gasification is shown
below.
o
C(s) + H 2 O(g ) CO(g) + H 2 (g) H 298 =131.3 kJ /mol (2.1)

In the case of catalytic steam gasification of coal, carbon deposition reaction
may affect the catalysts life by fouling the catalyst active sites. This carbon
deposition reaction is more likely to take place whenever the steam concentration
is lacking.
Carbon Dioxide Gasification
The reaction of coal with CO 2 is endothermic, similar to the steam
gasification reaction. Reaction of carbon dioxide gasification is shown below.
C(s) +2 CO2 (g) 2 CO(g ) H o298=172.5 kJ /mol
(2.2)
The reverse reaction is a carbon deposition reaction that is a major culprit of
carbon fouling on many surfaces, such as process catalyst deactivation. This
gasification reaction is thermodynamically favored at high temperatures (T >
680oC). The reaction, if carried out alone, requires high temperature (for fast
reaction) and high pressure (fir high reactant concentrations) for significant
conversion. However, this reaction in practical gasification applications is almost
never attempted as a solo chemical reaction, because of a variety of factors
incluidng low conversion, slow kinetic rate, low thermal efficiency, unimpressive
process economics, etc.
Hydrogasification
Direct addition of hydrogen to coal under high pressure forms methane. This
reaction is called hydrogasification and may be written as.
31
C(s) +2 H 2(g ) CH 4(g) H 298 =74.8 kJ /mol
(2.3)
This reaction is exothermic and is thermodynamically favored at low

temperatures (T < 670C), unlike both steam and CO 2 gasification reactions.
However, at low temperatures, the reaction rate is inevitably too slow. Therefore,
high temperature is always required for kinetic reasons, which in turn requires
high pressure of hydrogen, which is also preferred from equilibrium
considerations. This reaction can be catalyzed by K2CO3, nickel, iron chlorides,
iron sulfates, etc. However, use of catalyst in coal gasification suffers from serious
economic constraints because of the low raw material value, as well as difficulty
in recovering and reusing the catalyst. Therefore, catalytic coal gasification has
not been practiced much.
Partial Oxidation
Gasifying agent in partial oxidation is oxygen, which may be supplied as
pure oxygen or as air. Partial oxidation sometimes called as combustion. The
reactions for partial oxidation are shown as follows.
1
o
C(s) + O CO(g ) H 298 =111.4 kJ / mol
2 2( g)
(2.4)
1
o
CO(g) + O CO 2(g ) H 298
=393.5 kJ /mol
2 2 (g)
(2.5)
Partial oxidation involves a complex reaction mechanism that depends on

how fast and efficiently combustion progresses. The reaction pathway is further
complicated because of the presence of both gas phase homogenous reactions
and heterogeneous reaction between gaseous and solid reactans. Combustion or
oxidation of coal is much more complex in its nature than oxidation of carbon.
Coal is not a pure chemical species, rather it is a multifunctional,
multispecies, and heterogeneous macromolecule. It was found that in a region
where chemical reaction rate is controlling the overall rate. Typically in a low
temperature region where the kinetic rate is much slower than the diffusional rate
of reactant, the catalytic effect of mineral matter is a determining factor for coal
reactivity. It was also found that for high temperature regions where the external
mass transfer rate controls the overall rate, the reactivity of coal decreased with
increasing coal rank.
From the explanation, we can combine partial oxidation with steam
gasification. Partial oxidation can increase the reactivity of coal because our raw
32
material is low rank coal. Partial oxidation produce carbon monoxide and steam
gasification produce hydrogen. Besides that, both reactions can complete each
other in heat. Partial oxidation is exothermic process that would produce heat
from its reaction. Heat will be used for steam gasifying because its reaction is
endothermic and require heat.
b. Selection of Gasification Technology
Based on the reactor configuration. As weel as by the method of contacting
gaseous and solid streams, gasification process can also be categorized into the
following 3 types :
Fixed Bed Gasifier

It also called as fixed bed reactor because solids in the bed stay together
regardless of the movement of the hardware that supports of the bed. Coal is
supported by a grate and the gasifying media (steam, air, or oxygen) pass upward
through the supported bed, whereby the product gases exit from the top of the
reactor in the fixed bed reactor. Only noncaking coals can be used in the fixed bed
reactor. Coal and gaseous streams move counter currently. The temperature at the
bottom of rreactor is higher than that at the top. Because of the lower temperature
at the top for coal devolatiliation,relatively large amounts of liquid hydrocarbons
area also produced in this type of gasifier.
Figure 2.4. Fixed Bed Gasifier

(Source : ETSAP, 2010)
33
The residence time of the coal is much longer than that in a suspension
reactor, thus providing ample contact time between reactants. Ash s removed from
the bottom of reactor as dry ash or slag. The example of this type of reactor are
Lurgi and Wellman Galusha gasifiers.
Fluidized Bed Gasifier

It uses finely pulverized coal particles. The gas (or gasifying medium) flows
upward through the bed and fluidizes the coal particles. Owing to the ascent of
particles and fluidizing gas, larger coal surface area is made available, which
positively promotes the gas-solid chemical reaction, which in turn results in
enhancement in carbon conversion.
Figure 2.5. Fluidized Bed Gasifier

This type of reactor allows intimate contact between gas and solid coal
fines, at the same time providing relatively longer residence times than entrained
flow reactor. Dry ash is either removed continuously from the bed, or the gasifier
is operated at such a high temperature that it can be removed as agglomerates.
Such beds, however, have limited ability to handle caking coals, owing to
operational complications in fluidization characteristics. Winkler and Synthane
processes use this type of reactor.
Entrained Bed Gasifier
34
In this reactor, there is no bed of solids. This reactor system uses finely
pulverized coal particles blown into the gas stream before entry into the reactor,
with combustion and gasification occuring inside the coal particles suspended in
the gas phase. Because of the entrainment requirement, high space velocity of gas
stream and fine powdery coal particles are very essential to the operation of this
type of process. Because of the very short residence time (i.e., high space
velocity) in the reactor, a very high temperature is required to achieve good
conversion in such a short period of reaction time. This can also be assisted by
using excess oxygen.
Figure 2.6. Entrained Bed Gasifier

This bed configuration is typically capable of handling both caking and

noncaking coals without much operational difficulty. Examples of commercial
gasifiers that use this type of reactor include the Koppers-Totzek gasifier and
Texaco gasifier.
In the sub bab selecting gasification technology, we would select gasifier
that we used. In the previously paragraph, we have been already explained that
gasifier technology that we selected depends on various factor.
Conversion
Conversion always become one of the factor in selecting reactor, because it
clarify how many carbon in coal can reacts with gasification media (oxygen and
steam).
35
Total of gasification media

Gasification media that we used are steam and oxygen. Total of gasification
media that we used will be effected in utility cost.

Feedstock (coal rank)
Definition of feedstock (coal rank) is type of coal as input. Because in
Indonesia, there are so many varieties of coal.
Purity of Product
Product of the gasification process is synthetic gas. Purity of synthetic gas
means that pure from moisture.
Cost
Cost is investation cost from reactor unit that we used.
Priority grade at the table 2.1. are feedstock (coal rank), cost (OPEX), purity
of product (free from tars and oils), conversion, and total of gasification media.
Coal is used in the gasification will be variative appropriate condition in
Indonesia. Flexibility capability of reactor to process all variant of coal as feed
and stable product is important. So, feedstock become first factor to select this
grasifier. Second, cost is investation cost where it will be influence to economic
analysis. Third factor is purity of product. It is important because syngas will
become as raw material in synthesis methanol process. Higher purity of product
affected in easy treatment and more economic. The second last of the factor are
conversion and total of gasification media.
Table 2.1. Scoring the type of Gasifier
Gasifier
Conversio
Type
Fixed Bed
Fluidized Bed
Entrained
n
5
2
Bed
Total of Gasification
Purity of
3
5
Media
5
3
Product
1
3
Feedstock
Cost
1
5
2
In the table 2.1, we show that each gasifier has advantage and disadvantage,
such as fixed bed has advantage in high conversion and total of gasification media
36
is small, fluidized bed has advantage in feedstock (coal rank) because all variant
of coal capable become feed, and entrained bed has advantage in high purity of
product.
From scoring in the table 2.1., we choose gasifier that will be used is
Entrained Bed Reactor. This type of gasifier is choosen because high purity of
product.
2.3.2. Synthesis Ethylene

From three methods option in section 2.1.3, we should to make scoring
process to select the best method to implement for the plant synthesis etyhelene
unit. In this scoring process, we use several parameters, such as how much
equipment needed, cost, raw material and the complexity the process. The
following table shows the score of available method. From this step, we will have
one method for produce ethylene. The process selection for produce ethylene will
explain in the following table:
Table 2.2. Scoring Synthesis Ethylene
Method
s
1
2
3
Equipment Needed
Raw Material
4
3
1
4
4
4
Cos
Complexit
t
4
3
1
y
4
4
2
Total
16
14
8
Raw Material
All of three methods have same raw material. From process before will
produce synthesis gas. So the score is same.

Equipment Needed
From all of three methods, methods one has the best score. Method one us
the simplest process. Method two is fermentation process and actually use batch
reactor. The process use many batch reactor, so the process can be called
contiunes (semi-batch).
Method three has a lot of equipment because the synthesis gas will be
convert to synthesis crude oil and then will reacted to produce ethylene.Thath
process need many equipment and unit, such as fischer-tropsch, treatment,
distillation section and ethylene production section.
Cost
37
Based on the amount of total equipment needed, more equipment means

more cost to spend to buy those equipment and also to maintain those equipment.
So, we can assume that more equipment nedded will cause higher cost for capital
cost and operational cost. Method three use fischer-tropsch which is expensive
process and use many catalyst for the process until produce the ethylene.
Complexity
Complexity is how easy the process to react or convert raw matrial/feed to
become the final product. From the equipment needed and process scheme, we
can see that method 1 is the highes complexity. Method 1 is the easiest one
because the process is relatively fast and not needed many process treatment.
Method two is almost same with method one, but to process the ethanol should be
procced by fermentation which is need long time enough. Method three has many
path of process because synthesis gas will be convert to synthesis crude oil which
has many treatment to forwarded to the next process. Method three also use
thermal cracking which has long and need a lot of equipment process.
Complexity means how easy the process to convert raw material to be
ethylene. It also related to the much amount of equipment involve on the process.
So, the best for this parameter is method one.
2.4.
Process Description
2.4.1. Block Flow Diagram

The coal to ethylene process used for this project typically incorporates the
following process oerations, shown in Figure 2.7.
38
Figure 2.7. Block Flow Diagram for This Plant

39
2.4.2. Process Flow Diagram
Figure 2.8. Process Flow Diagram for Gasification Unit

40
Figure 2.9. Process Flow Diagram for Acid Gas Removal Unit
41
Figure 2.10. Process Flow Diagram for Water Gas Shift Unit
42
Figure 2.11. Process Flow Diagram for Synthesis Methanol Unit

43
Figure 2.12. Process Flow Diagram for Synthesis Ethylene Unit

44
2.4.3. Process Description

2.4.3.1.
Gasification Technology
Coal is pre-processed by methods such as crushing, sizing and drying to
prepare it for the coal gasification process. Coal is crushed into fine particles until
the diameter of coal is less than 100 mesh. Crushed coal feedstock combining
with water in a tank would make slurry. We have to control the water content of
coal less than 20% feed, so that the coal doesnt absorb much water. In process,
we use pure water in making slurry to avoid impurities in water that can hamper
the process. The criteria of coal slurry in gasification process are homogeneous
coal size, low viscosity, and contain high coal carbon. The slurry is introduced
with oxygen through the feed-injector (burner) into the refractory-lined gasifier.
Then crushed coal is entering conversion process. During the coal
conversion process, the coal is decomposed in a high pressure and temperature
using steam and an oxygen supply, represented by the following equations.
In gasifying agent selection, steam and oxygen was chosen. Gasifying
agent reacts with coal in partial oxidation combine with steam gasification. First,
reaction will occur in exothermic. Then, the heat from that reaction would be
using in endothermic for the next reaction. In this process will produce raw
syngas. In gasifiers, carbon in coal slurry is converted to syngas, and the mineral
matters are transformed to ash/slag. The majority of the ash is melted and
deposited on the walls of the gasifier, forming a liquid slag, which flows out of the
bottom of the gasifier and finally solidifies in a water bath. However, a small
fraction of the ash is entrained as fly ash with the raw syngas out of the gasifier to
downstream processing.
Our plant use entrained flow reactor for gasification unit. Entrained bed
gasifier is horizontal gasifier operates at atmospheric pressure or a little higher
than atmospheric pressure. If this gasifier operates at high pressure, so the results
are a few tars and oil in gas product will be made. This gasifier can operates at
low pressure to maintain ash, so it will be dry solid. This gasifier can also operates
at temperatures above melting point of ash, so it will be liquid melted.
The shape of raw material in entrained bed gasifier must be small (< 0.1
mm) and homogen. The fuel will be entered into gasifier together with
45
gasification medium at high flowrate (oxygen and steam) in specific operation so

it can made particles. The fuel and gasification medium flow in the same direction
(co current). The shape of material pull through approximately 80 % less than
200 mesh (44 m). The residence time of this gasifier is about 1 10 seconds.
Because of the short residence time, entrained flow gasifiers must operate at high
temperatures to achieve high carbon conversion of about 99%. Since the gasifier
operates at a high temperature, the destruction of tar and oil yields a very pure
syngas. Operation temperature of this gasifier is high, more than 1000oC and
uniform in the entire side of gasifier in order that more producer gas is obtained
and producer gas is not bind tar and methane.
Ash is taken as slag because operation temperature more than melting
point of ash. Output temperature of product at this type of gasifier approximately
900 1400oC. Control at this gasifier are flowrate of the fuel, oxygen, and steam.
Efficiency of gasifier will be determined by operation temperature, particle size,
and injection rate of steam.
The advantage of this type gasifier are not too observe characteristics of
raw material, suitable for small raw material, producer gas involving a few of tar,
ash is taken as slag, product at high temperature need quenching to cleaning,
cooling can do by reuse so the result is more efficient.
The gasification process occurs generally around 1500 C, which is in the
slagging temperature range (Sheida et al, 2008). The pressure requirement is
between 30-70 bar. The produced syngas is cooled in a water quench because it is
suitable for providing conditions for CO shift reaction, required in the coal-tomethanol process. In using the quench process for syngas cooling, the gaseous
effluent leaves through the bottom of the reactor with the liquid ash and enters the
cooling vessel.
Molten/sticky ash in the fly ash could cause fouling of the syngas cooler.
One method to reduce syngas cooler fouling is to maximize slag and minimize fly
ash. For ash/intermediate char-slag particles to be trapped in the slag layer and not
rebound (elastic reflection), particle surface stickiness and slag surface stickiness
are critical among many factors, such as particle velocity, surface tension,
46
temperature, size, and impact angle. Particles with certain carbon conversion at
temperature above the ash fusion temperature are sticky.
2.4.3.2. Acid Gas Removal
Raw Syngas from gasification unit contain impurities such as H 2S.
Impurities limit applicability of syngas to chemical synthesis, so this plant need
acid gas removal unit.
Physical solvents tend to be favored over chemical solvents when the
concentration of acid gases or other impurities is very high. Unlike chemical
solvents, physical solvents are non-corrosive, requiring only carbon steel
construction.
At low partial pressures, physical solvents are impractical because the
compression of the gas for physical absorption is expensive. However, if the gas is
available at high pressure, physical solvents might be a better choice than
chemical solvents.
From the explanation above, physical solvent is the best choice for acid
gas removal method. Compare with another method, physical solvent have the
cheapest cost because it dont need increase feed pressure or special material for
service. Physical solvent only need carbon steel construction.
A number of physical solvents are available for use in acid gas treating
processes. Four of the solvents are considered here: Dimethyl Ether of
Polyethylene
Glycol
(DEPG),
Propylene
Carbonate
(PC),
N-Methyl-2-
Pyrrolidone (NMP), and Methanol (MeOH).

DEPG is a mixture of dimethyl ethers of polyethylene glycol
(CH3O(C2H4O)nCH3 (n is between 2 and 9) used to physically absorb H2S, CO2,
and mercaptans from gas streams. DEPG can be used for selective H 2S removal
which requires stripping, vacuum stripping, or a reboiler. The process can be
configured to yield both a rich H2S feed to the Claus unit as well as bulk CO 2
removal. Selective H2S removal with deep CO2 removal usually requires a twostage process with two absorption and regeneration columns. H 2S is selectively
removed in the first column by a lean solvent that has been thoroughly stripped
with steam, while CO2 is removed in the second absorber.
47
The second stage solvent can be regenerated with air or nitrogen for deep
CO2 removal, or using a series of flashes if bulk CO 2 removal is required. DEPG
also dehydrates the gas and removes HCN. Compared to the other solvents, DEPG
has a higher viscosity which reduces mass transfer rates and tray efficiencies and
increases packing or tray requirements, especially at reduced temperatures. Since
it is sometimes necessary to reduce temperature to increase acid gas solubility and
reduce circulation rate, this could be a disadvantage. DEPG requires no water
wash to recover solvent due to very low vapor pressure. DEPG is suitable for
operation at temperatures up to 347F (175C). The minimum operating
temperature is usually 0F (-18C).
Selexol was the chosen solvent for acid gas removal. Among the other
solvents, DEPG give the minimum cost because DEPG dont need water wash to
recovery or refrigerant for its process. Besides that, selexol can remove H 2S, CO2,
mercaptans and HCN from syngas.
The inlet raw syngas is contacted counter current in packed bed with
Selexol solvent. The temperature of syngas gets reduced in absorber. The amount
of H2S removed from the gas stream is about 95% of the total H 2S contained.
Column is maintained around 150C and 6 MPa.
After the acid gas removal process, the acid gas produced is usually
emitted in the form of H2S which tends to be highly toxic. It is necessary to
convert this H2S gas into two alternative products of sulfur using additional
process.
2.4.3.3. Water Gas Shift
Clean syngas that contain low impurities continue to water gas shift
process. The governing equation for water-gas shift reactor is as follows.
Water gas shift is to adjust CO/H2 ratio of gas become 1:2. Steam is
added to CO-H2 feed mixture before entering the water-gas shift reactor to convert
CO to CO2 and additional H2. The water-gas shift reaction is commonly run at low
temperature since thermodynamic equilibrium favors high conversion of CO and
steam to CO2 and H2 in the presence of catalysts that enhance the reaction rate.
Although the equilibrium favors formation of product at lower temperatures, the
reaction kinetics is faster at elevated temperatures.
48
Because of that, water gas shift has two stages. The first step involves a
high temperature step operating at 310-450C, which reduces CO content to 23%. The second stage uses a low temperature water gas shift catalyst operates at
210240C. Most of the CO shift reaction out in industry, are converting 90% CO
to H2 in the first HTS reactor, and the 90% of the remaining CO is converted in
LTS reactor. The exit gas of the HTS unit must be cooled. This is usually done by
quenching with water, thus providing additional steam to the process.
2.4.4.4. Synthesis Ethylene
a. Overall Process Description
Syngas to Methanol
The overall process that occurs at methanol plant consists of four stages,
which is syngas compression, methanol reactor and distillation section. H2S free
syngas from gasification unit is compressed from 20 bar to 43 bar. After
compression, syngas is then going through gas/gas exchanger to raise the gas
temperature before entering the reactor. Syngas is cross-exchanged with the hot
gas exiting the methanol reactor until it reaches the temperature of 235C.
Methanol reactor is a shell and tube reactor, which the catalysts are packed
in tubes. The catalyst used in this reactor is copper-based S 3-86 catalyst. The
main reactions of methanol synthesis which are mentioned before take place in
this reactor. Besides producing methanol, this reactor is also producing several
byproducts, such as dimethyl ether, methyl formate, ethanol and isobutanol. The
production of byproduct in the reactor depends on CO2/CO ratio, feeds purity and
catalysts age. This reactor is kept in isothermal state, because isothermal reactor
produces fewer byproducts, provides high heat reaction recovery and easier
temperature control. Generated heat from the isothermal reaction in methanol
synthesis is used to heat water in the boiler. The steam generated in the boiler is
used in steam separator.
Methanol exiting the reactor is now about 260C in temperature and 4%
methanol by volume. The exiting stream is then cross-exchanged with the feed
stream. The product of methanol reactor is then transferred into vertical separator
and crude methanol tank, before entering the distillation section. Vertical separator
separates raw methanol and purge gas. Raw methanol will enter the next process,
while purge gas will be compressed before circulated again to methanol reactor
49
with fresh steam. After being separated in vertical separator, methanol is stored
temporarily in crude methanol tank. Methanol is also added by NaOH 1-2% for
neutralizing the acids produced by side reactions in methanol reactor.
Since methanol content in the output of methanol reactor is only about 4%
weight, methanol needs to be purified. Raw methanol is purified in distillation
section until it reaches AA grade. The steam needed for distillation process is
provided by boiler which is heated by the heat generated in methanol reactor. The
distillation section consists of two stages, topping section and refining section.
Topping section separates methanol and heavier alcohol with impurities such as
CO, CO2, H2, N2, CH4, aldehyde, ketone and dimethyl ether, while refining section
separates methanol and heavier alcohol. The product of this section is AA grade
methanol.
Methanol To Olefins
Methanol to olefin synthesis process is a commercially valuable process,
particularly because of the high-demand for ethylene. Today these compounds are
created mainly through the non-catalytic cracking of naphtha under steam. The
methanol to olefin (MTO) process, however, uses a molecular-sieve catalyst that
efficiently converts methanol into olefins (propylene and ethylene). The
molecular-sieve under consideration is silicon, aluminum, phosphate and oxygen
based, and is hence called SAPO-34.
The mechanisms MTO leading to the production of large organic
compounds inside the pores of the catalyst, the role of these organic compounds in
the formation of propylene and ethylene, the discrepancy between observed
product ratios of propylene and ethylene and corresponding thermodynamic
predictions, and finally, the reactivity of the products under MTO conditions.
Large organic compounds are typically N-methyl-benzenes formed after a kinetic
induction period, and only in the presence of impurities in the methanol feed. The
successive methlyation of N-methyl-benzene is followed by de-ethylation and depropylation to produce ethylene and propylene respectively, the less methyl
substituted the benzene is, the higher the selectivity for ethylene. Under typical
reaction temperatures (~650 K), thermodynamics predicts that the ratio of
propylene to ethylene is between 0.5-1. Feeding propylene back into the catalyst
lowers selectivity for propylene, indicating that it can act as both a product and a
reactant. The same holds for ethylene.
50
MTO process converts methanol to ethylene and propylene at above 80%

carbon selectivity in a fluid bed reactor with continuous regeneration. Because of
the quick deactivation of MTO catalyst, a kind of high efficiency fast fluidized
bed reactor is adopted, the activity of deactivated catalyst is recovered by burning
the coke in the regenerator. Coke accumulates on the catalyst must be removed to
maintained catakyst activity. The catalyst is maintained by continuous transfer of
coked catakyst from reactor to the regenerator where the coke is burned by air.
The carbon selectivity apporaches 90% if the heavier fraction such as butenes are
also accounted for as part of the product. From this process will produce coproduct include very small amounts of C1-C4 parrafins, hydrogen, CO and CO2, as
well as ppm levels of havier oxygenates.
Methanol will enter the MTO reactor to react for produce olefins, the
reaction is :
2CH3OH
C2H4 +
2H2O
3CH3CH2OH
C3H6 +
3H2O
MTO reaction is conversion of alcohol (methanol) into a light alkene
(ethylene and propylene). To increase the selectivity ethylene, the reaction can be
added by water.
The reaction will produce water, so the stream which is output from reactor
will be continue to water separation and then will compressed to light olefin
recovery. From this section the ethylene and propylene will be separated until the
grade that we want. The detail of process will be explained in the next section.
b. Process Description On The Equipment
Syngas to Methanol
1. Compressor
Compressors function is to compress gases exiting from the acid gas
removal unit from 5170 kPa into 27500 kPa. This compressor is driven by electric
motor.
2. Gas/gas Exchanger
Gas/gas exchanger is needed to raise syngas temperature before entering
methanol reactor. Syngas temperature needs to be adjusted to match with the
catalyst of methanol reactors activity.
3. Methanol Reactor
Synthesis of syngas into ethanol takes place in this reactor. Heated syngas
feed will enter the tube side of the reactor, in which the catalysts are packed. This
reactor operates at temperature of 324,7C and pressure of 25000 kPa.
51
4. Vertical Separator
Vertical separator separates raw methanol from byproducts produced in
methanol synthesis reactor. This separator operates at 10000 kPa and 75C.
5. Crude Methanol Tank
Crude methanol tank stores raw methanol temporarily before fed into the
distillation process. This tank operates at 0,5 bar and 70C.
6. Distillation Column
There are two distillation columns in this unit, which are the topping column
and refining column. Topping column is used to remove byproducts from
methanol and heavier alcohol fraction and operates at 3,5 bar and 130C.
Meanwhile, refining column is used to purify methanol so it reaches AA grade.
Refining column operates at 40 bar and 150C.
Methanol To Olefins
1. Reactor
The spesification of reactor R-101 is
Function
: Place where the methanol conversion to olefins is held
Type
: Fluidized Bed Reactor with Regenerator
Operation
: P = 15 to 45 psig and T = 650 to 1000 OF
Characteristic
: Conversion 80%-90%
Figure 2.13. Methanol to Olefins Reactor

In this reactor, methanol will be held to dehydration reaction with shape

selective transformation to low molecular weight alkenes, such as ethylene,
propylene and havier alkenes fraction and also impurities. The impurities from
this reaction is H2O, H2, COx, light paraffins, and coke.
52
The reactor in MTO reactor use particular molecular sieve catalyst, that is
SAPO-34. Sapo-34 is a porous mineral, a crystalline silicon aluminum phosphate
molecular sieve (zeoliteis a crystalline aluminum silicate).It is like aluminumphosphate with some of the phosphorous (P+5) atoms substituted by silicon (S+4)
atoms. SAPO-34 is a caalyst for the methanol to olefins reaction.
The catalyst will give direction of reaction to produce ethylene and
propylene. The reaction is not only produce the ethylene and propylene, but also
produce the impurities and also the intermediet product like mechanisms below :
Figure 2.14. Reaction to Produce Ethylene and Propylene

The yield of olefins increases with the number of methyl groups on benzene.
Increasing space velocity of methanol, decreased ethylene selectivity. Addition of
water increased ethylene selectivity When benzenes approximately have 2
methyls, then transition occurs for making more propylene.
From experiment, SAPO-34 is more selective towards ethylene at elevated
temperatures. Both correlations increase ethylene content with increasing
temperature because the reaction are endothermic. SAPO-34 has a higher molar
ratio.
Figure 2.15. Diagram of Temperature versus Selectivity
53
Selectivity for ethylene decreases with additional ethylene in the feed.

Indicates that ethylene is being consumed to form other products. It is called
ethylene to propylene. Selectivity for propylene decreases with additional
propylene in the feed. Indicates that propylene is being consumed to form other
products. It is called propylene to ethylene.
Figure 2.16. Feed Effect to Selectivity

2. Separation Train
Distillationis a process which is generally used to separate a mixture of two
or more liquids based on their boiling points. However, what happens in a
distillation column is essentially a series of flashes, which are connected with
recycle loops. The liquid from each tray comes to equilibrium (ideally) with the
vapor, and the vapor rises up to the next tray and the liquid falls to the tray
beneath it. Each tray has a different temperature because a reboiler on the bottom
and a condenser at the top maintain a temperature gradient across the column.
When it reaches very low temperatures, the gas mixture becomes a liquid.
The different components making up the gas are then separated by carefully
boiling them off in a process known as distillation (or fractionation).
The cryogenically chilled stream is processed through a series of distillation
columns. Several columns are needed to seperates out th desired product. This
process section consists a demethanizer, ethane/ethylene and propane/propylene
splitters.
In this separation section, the dried gases are cooled to -120 C/-184 F and
pass through the demethanizer. The C1 or methane cut is further separated to
recover methane, and the bottom product is sent to the de-ethaniser. The de-
54
ethaniser top product is sent through an ethanelethylene splitter.. The bottoms of

the de-ethaniser are sent to the depropaniser for separation of the propylene. The
bottoms of the depropaniser are sent to the will recycled to the process.
3. De-Ethaniser
The de-ethanizer column functions as a fractionator to separate out as much
ethane as possible. The liquid feed is introduced on the top tray of the de-ethaniser
column, which is heated and operating at 25-30 bar/360-435 psi pressure. An
asymmetrical separation is effected so that a very low concentration of ethane
exits by way of the bottom product, and some heavier components remain in the
top product.
4. Ethylene Fractionator
The de-ethaniser top product is usually sent to the ethylene fractionator,
where ethylene is separated at very high purity by cryogenic distillation from the
ethane. The product from Ethylene fractinator are 99.95% ethylene, 0.01%
methane and 0.04% ethane. The operation condition of ethylene fractionator are at
pressure 15 atm amd temperature -37.5 OC.
Table 2.3. Condition Operation in Each Equipment (Methanol to Olefin)
Equipment
Function
Type
Amount
Condition
Operation
De-ethaniser
To seperate ethane
contain from
hydrocarbon feed
Sieve tray
Plate Tower
P = 30 atm
T= -36 - 135oC
Ethylene
fractinator
To seperate
ethylene contain
from hydrocarbon
feed
Sieve tray
Plate Tower
P= 15 atm
T=-37.5 (-16)
o
C
No
55
CHAPTER III
MASS & ENERGY BALANCE
From the process in chapter II, we can calculate mass and energy balance of
the plant. Mass balance will be evaluated each equipment. From this chapter, we
will know how much coals needed to produce ethylene with our capacity, 400.000
tons per year. Then, we will know the energy needed to generate the process from
start until ethylene produced. In this chapter, mass and energy balance will be
calculated each unit and then each equipment.
3.1.
Mass Balance for Equipment
3.1.1. Gasification Unit
Figure 3.1. The Hysys Simulation for Gasification Unit

Mixer (M 100)
Table 3.1. show about the mass balance for the mixer M 100 which contains
of C, H2, O2, S, N2 (stream 2) and H2O (stream 4) as the composition inlet and
outlet. In the table 3.1, we can see mass balance in mixer.
Table 3.1. Mass Balance on Mixer
Component
s
C
CO
CO2
Input (ton/d)
2
4
3030.66.
0.00
0.00
0.00
0.00
0.00
Output (ton/d)
5
3030.66
0.00
0.00
Table 3.1. Mass Balance on Mixer (Contd)
Component
Input (ton/d)
Output (ton/d)
56
s
H2O
H2
O2
H2S
S
N2
TOTAL
2
588.03
212.59
1031.32
0.00
18.99
23.97
4905.60
4
2063.85
0.00
0.00
0.00
0.00
0.00
2063.85
5
2651.89
212.59
1031.32
0.00
18.99
23.97
6969.45
Slurry Pump (JC - 101)

Table 3.2. show about the mass balance for the slurry pump JC 101 which
contains of C, H2, O2, S, N2, and H2O as the composition inlet and outlet. In the
table 3.2, we can see mass balance in slurry pump.
Table 3.2. Mass Balance on Slurry Pump
Component
s
C
CO
CO2
H2O
H2
O2
H2S
S
N2
TOTAL
Input (ton/d)
5
3030.66
0.00
0.00
2629.82
3.23
33.19
0.00
18.99
0.84
5679.85
Output (ton/d)
6
3030.66
0.00
0.00
2629.82
3.23
33.19
0.00
18.99
0.84
5679.85
Gasifier (R 101)
The type of gasifier that we use in this plant is entrained flow gasifier. It
accepts almost any type of coal, including caking coal, without any major
operational restrictions. It has the highest operating temperature (around 1400
1500C) of all the conventional gasifiers. The process has a track record of over
50 years of safe operation. The overall thermal efficiency of the gasifier is 85 to
90%. The time on stream (TOS) or availability is better than 95%.
Then, table 3.3. is about the result of mass balance from gasifier which stream
8 (oxygen), stream 3 (water, hydrogen, oxygen, nitrogen), and stream 6 (carbon,
57
water, hydrogen, oxygen, sulphur, nitrogen) as the input and stream 16 and 10
(carbon monoxide, carbon dioxide, water, hydrogen, hydrogen sulphide, nitrogen)
as the ouput
Table 3.3. Mass Balance on Gasifier
Component
s
C
CO
CO2
H2O
H2
O2
H2S
S
N2
TOTAL
Input (ton/d)
8
3
6
0.00
0.00
3030.66
0.00
0.00
0.00
0.00
0.00
0.00
0.00
22.07
2629.82
0.00
212.56
3.23
1926.49
1030.99
33.19
0.00
0.00
0.00
0.00
0.00
18.99
0.00
23.96
0.84
1926.49
1289.60
5679.85
Output (ton/d)
16
10
0.00
0.00
0.00
5395.97
0.00
2622.91
0.00
361.21
0.00
467.74
0.00
0.00
0.00
20.18
0.00
0.00
0.00
23.97
0.00
8892.01
Cooler Raw Syngas (E 101)

Cooler raw syngas is an cooler which has function to cooling raw syngas after
gasification process and before enter to cyclone. Table 3.4. below is the table of
mass balance between stream 11(the result of gasification) and stream 11 as the
component whic willl be entered to the cyclon.
Table 3.4. Mass Balance on Cooler Raw Syngas
Component
s
C
CO
CO2
H2O
H2
O2
H2S
S
N2
TOTAL
Input (ton/d)
10
0.00
5395.97
2622.91
361.21
467.74
0.00
20.18
0.00
23.97
8892.01
Output (ton/d)
11
0.00
5395.97
2622.91
361.21
467.74
0.00
20.18
0.00
23.97
8892.01
Cyclone Separator (FG 101)
58
Cyclone separator has function to separate raw syngas from slag/ash. Table 3.5.
shows about mass balance stream 11 as input and stream 12 and 15 as the
ouput.
Table 3.5. Mass Balance on Cyclone Separator
Component
s
C
CO
CO2
H2O
H2
O2
H2S
S
N2
TOTAL
Input (ton/d)
11
0.00
5395.97
2626.91
361.21
467.74
0.00
20.18
0.00
23.97
8896.01
Output (ton/d)
15
12
0.00
0.00
1.75 5395.96
1.30 2625.61
339.86 21.35
0.13
467.74
0.00
0.00
3.32
20.15
0.00
0.00
0.04
23.97
341.22 8554.79
3.1.2. Acid Gas Removal Unit

Figure 3.2. shows about the hysis simulation for acid gas removal unit. Acid gas
removal is a step after gasification. The purpose of the process is to remove
undesired component from syngas, such as H2S or CO2
Figure 3.2. The Hysys Simulation for Acid Gas Removal Unit
Raw Syngas Compressor (JC 201)

Table 3.6. show about the mass balance for the compressor which contains of
stream 12 as the composition inlet and stream 13 as composition outlet. In the
table 3.6, we can see mass balance in raw syngas compressor.
59
Table 3.6. Mass Balance on Raw Syngas Compressor
Input (ton/d)
12
5370.60
2654.79
20.98
464.15
19.82
24.46
0.00
8554.79
Component
CO
CO2
H2O
H2
H2S
N2
DEPG
TOTAL
Output (ton/d)
13
5370.60
2654.79
20.98
464.15
19.82
24.46
0.00
8554.79
Raw Syngas Cooler (E 201)

Table 3.7. below is the table of mass balance between stream 13 (input) and
stream 14 (output).
Table 3.7. Mass Balance on Raw Syngas Cooler
Componen
t
CO
CO2
H2O
H2
H2S
N2
DEPG
TOTAL
Input (ton/d)
13
5370.60
2654.79
20.98
464.15
19.82
24.46
0.00
8554.79
Output (ton/d)
14
5370.60
2654.79
20.98
464.15
19.82
24.46
0.00
8554.79
Absorber Column (T 201)

Absorber column is used to absorb raw syngas become clean syngas using
DEPG solvent. The type of absorption in this this process is amine absorption.
Then, table 3.8. is about the result of mass balance from absorber column
which stream 14 and 31 as the input and stream 15 and 32 as the ouput.
Table 3.8. Mass Balance on Absorber Column
Component
CO
CO2
H2O
H2
H2S
Input (ton/d)
14
31
5370.60
0.00
2654.79
0.00
20.98
6008.55
464.15
0.00
19.82
0.36
Output (ton/d)
32
15
5345.82
22.10
1901.84
751.62
0.92
6028.57
463.68
0.24
0.15
20.05
60
N2
24.46
0.00
24.35
0.09
Table 3.8. Mass Balance on Absorber Column (Contd)
Component
DEPG
TOTAL
Input (ton/d)
14
31
50822.85
0.00
8554.79 56831.75
Output (ton/d)
32
15
0.00
50822.85
7736.76 57645.53
Rich DEPG Pump (J 201)

Rich DEPG Pump is used to flowing the DEPG solvent by increasing the
pressure of the liquid. In this case, the DEPG solvent is pumped to absorber
column to absorb undesired component. Table 3.9 shows about the mass
balance of the Rich DEPG Pump.
Table 3.9. Mass Balance on Rich DEPG Pump
Componen
t
CO
CO2
H2O
H2
H2S
N2
DEPG
TOTAL
Input (ton/d)
15
22.10
751.62
6028.57
0.24
20.05
0.09
50822.85
57645.53
Output (ton/d)
16
22.10
751.62
6028.57
0.24
20.05
0.09
50822.85
57645.53
Stripper Column (T 202)

Stripper column is used to regenerate raw syngas. Then, table 3.10. is about the
result of mass balance from stripper column which stream 16 as the input and
stream 17 and 23 as the ouput
Table 3.10. Mass Balance on Stripper Column
Componen
t
CO
Input (ton/d)
16
22.10
Output (ton/d)
17
23
22.10
0.00
61
CO2
H2O
H2
H2S
N2
DEPG
TOTAL
751.62
6028.57
0.24
20.05
0.09
50822.85
57645.53
751.6
2
21.68
0.24
19.69
0.09
1.10
816.4
8
0.00
6006.91
0.00
0.36
0.00
50821.75
56829.02
Rich DEPG Cooler (E 203)

Rich DEPG Cooler is used to cooling the DEPG solvent. Table 3.11. shows
about the mass balance of the Rich DEPG Cooler which is stream 27 as the
input and stream 28 as the output.
Table 3.11. Mass Balance on RICH DEPG Cooler
Componen
t
CO
CO2
H2O
H2
H2S
N2
DEPG
TOTAL
Input (ton/d)
27
0.00
0.00
6006.91
0.00
0.36
0.00
50821.75
56829.02
Output (ton/d)
28
0.00
0.00
6006.91
0.00
0.36
0.00
50821.75
56829.02
Rich DEPG Pump (J 204)

Rich DEPG Pump is used to flowing the DEPG solvent by increasing the
pressure of the liquid. In this case, the DEPG solvent is pumped to absorber
column to absorb undesired component. Table 3.12 shows about the mass
balance of the Rich DEPG Pump.
Table 3.12. Mass Balance on Rich DEPG Pump
Componen
t
CO
CO2
H2O
H2
H2S
Input (ton/d)
26
0.00
0.00
6006.91
0.00
0.36
Output (ton/d)
27
0.00
0.00
6006.91
0.00
0.36
62
N2
DEPG
TOTAL
0.00
50821.75
56829.02
0.00
50821.75
56829.02
3.1.3. Water Gas Shift Unit

Figure 3.3. shows about the hysis simulation for water gas shift reaction unit.
Water gas shift reaction is a final step in gasification. The purpose of the process
is to increase ratio CO and H2.
Figure 3.3. The Hysys Simulation for Water Gas Shift Unit
Expander (K 100)
Table 3.13. show about the mass balance for the expander which contains of
stream 21 as the composition inlet and stream 22 as the composition outlet. In
the table 3.13, we can see mass balance in slurry pump.
Table 3.13. Mass Balance on Expander
Componen
Input (ton/d)
Output (ton/d)
t
C
CO
CO2
H2O
H2
O2
21
0
5910.55
2101.60
92.59
512.54
0.00
22
0
5910.55
2101.60
92.59
512.54
0.00
63
C1
C2
C3
H2S
S
N2
C2H5OH
CH3OH
TOTAL
0.00
0.00
0.00
60.96
0.00
27.35
0.00
0.00
8553.60
0.00
0.00
0.00
60.96
0.00
27.35
0.00
0.00
8553.60
Reboiler (E 106)
Table 3.14. show about the mass balance for the reboiler which contains of
stream 22 as the composition input and stream 29 as composition output
Table 3.14. Mass Balance on Reboiler
Componen
Input
Output
t
C
CO
CO2
22
0
5910.55
2101.60
29
0
5910.55
2101.60
Table 3.14. Mass Balance on Reboiler (Contd)
Componen
Input
Output
t
H2O
H2
O2
C1
C2
C3
H2S
S
N2
C2H5OH
CH3OH
TOTAL
22
92.59
512.54
0.00
0.00
0.00
0.00
60.96
0.00
27.35
0.00
0.00
8553.60
29
92.59
512.54
0.00
0.00
0.00
0.00
60.96
0.00
27.35
0.00
0.00
8553.60
High Temperature Shift (GBR 102)

High temperature shift operating at 310 450C, which reduces CO content to
2 3%. Table 3.15. show about the mass balance for the high temperature shift
which contains of stream 29 and stream 30 as the composition input and stream
31 and dummy 1 as composition output.
Table 3.15. Mass Balance on High Temperature Shift
64
Componen
t
C
CO
CO2
H2O
H2
O2
C1
Input
29
0
5910.55
2101.60
92.59
512.54
0.00
0.00
30
0.00
0.00
0.00
162.49
0.00
0.00
0.00
Output
31
DUMMY 1
0.00
0.00
5985.54
0.00
1983.78
0.00
50.77
0.00
507.14
0.00
0.00
0.00
0.00
0.00
Table 3.15. Mass Balance on High Temperature Shift (Contd)
Componen
t
C2
C3
H2S
S
N2
C2H5OH
CH3OH
TOTAL
Input
29
0.00
0.00
60.96
0.00
27.35
0.00
0.00
8553.60
30
0.00
0.00
0.00
0.00
0.00
0.00
0.00
162.49
Output
31
DUMMY 1
0.00
0.00
0.00
0.00
0.60
0.00
0.00
0.00
27.35
0.00
0.00
0.00
0.00
0.00
8555.22
0.00
Reboiler (E 107)
Table 3.16. show about the mass balance for the reboiler which contains of
stream 31 as the composition input and stream 32 as composition output.
Table 3.16. Mass Balance on Reboiler
Component
C
CO
CO2
H2O
H2
O2
C1
C2
C3
H2S
S
N2
C2H5OH
Input
31
0.00
5985.54
1983.78
50.77
507.14
0.00
0.00
0.00
0.00
0.60
0.00
27.35
0.00
Output
32
0.00
5985.54
1983.78
50.77
507.14
0.00
0.00
0.00
0.00
0.60
0.00
27.35
0.00
65
0.00
CH3OH
8555.22
TOTAL
0.00
8555.22
Low Temperature Shift (GBR 103)

Low temperature water gas shift catalyst operates at 210 240C. The 90% of
the remaining CO is converted in LTS reactor. Table 3.17. show about the mass
balance for the low temperature shift.
Table 3.17. Mass Balance on Low Temperature Shift
Componen
t
C
CO
CO2
H2O
H2
O2
C1
C2
C3
H2S
S
N2
C2H5OH
CH3OH
TOTAL
Input
32
0.00
5985.54
1983.78
50.77
507.14
0.00
0.00
0.00
0.00
0.60
0.00
27.35
0.00
0.00
8555.22
33
0.00
0.00
0.00
162.49
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
162.49
Output
34
DUMMY
0.00
0.00
5911.83
0.00
2099.59
0.00
4.99
0.00
512.45
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.60
0.00
0.00
0.00
27.35
0.00
0.00
0.00
0.00
0.00
8556.84
0.00
Cooler (E 108)
Before syngas enter to the next step, syngas is cooled first in cooler. Table 3.18.
below is the table of mass balance in cooler
Table 3.18. Mass Balance on Cooler
Componen
t
C
CO
Input
34
0.00
5911.83
Output
35
0.00
5911.83
Table 3.18. Mass Balance on Cooler (Contd)
Componen
t
CO2
H2O
Input
34
2099.59
4.99
Output
35
2099.59
4.99
66
H2
O2
C1
C2
C3
H2S
S
N2
C2H5OH
CH3OH
TOTAL
512.45
0.00
0.00
0.00
0.00
0.60
0.00
27.35
0.00
0.00
8556.84
512.45
0.00
0.00
0.00
0.00
0.60
0.00
27.35
0.00
0.00
8556.84
3.1.4. Synthesis Methanol Unit
Figure 3.4. The Hysys Simulation for Water Gas Shift Unit
Methanol synthesis unit is the unit that converts syngas into methanol. To
fulfill the production capacity, this unit has to produce 4577.65 tonnes of
methanol per day. The mass balance of methanol synthesis unit can be
summarized in the table below:
Compressor (JC 401)

Table 3.19. Mass Balance on Compressor
Component
CH3OCH3
CO
Input
41 (tonne/day)
0
3864.31
Output
42 (tonne/day)
0
3864.31
67
Table 3.19. Mass Balance on Compressor (Contd)
Input
41 (tonne/day)
4056.62
54.18
556.03
0
24.27
8555.441
Component
CO2
H2O
H2
CH3OH
N2
TOTAL
Output
42 (tonne/day)
4056.62
54.18
556.03
0
24.27
8555.441
From the table above, we can see that the input and output mass flow of the
compressor is balanced. There is no change of component composition in this
equipment because compressor only raise the streams pressure but not changing
its composition
Heat Exchanger (E 401)

This heat exchanger is needed to exchange heat from methanol reactors feed
(stream 42) with the output of methanol reactor (stream 44). The heated stream
42 is then named stream 43, while the cooled stream 44 is named stream 45.
Table 3.20. Mass Balance on Heat Exchanger
Input
Output
Component
42
45
44
43
CH3OCH3
CO
CO2
H2O
H2
CH3OH
N2
TOTAL
(tonne/day)
0
3864.31
4056.62
54.18
556.03
0
24.27
8555.441
(tonne/day)
30651.21
67357.35
312262.93
1441.67
1697.78
2681.37
25732.42
441824.74
(tonne/day)
28525.88
70599.30
312763.57
405.64
2233.24
1564.80
25732.42
441824.85
(tonne/day)
0
3864.31
4056.62
54.18
556.03
0
24.27
8555.44
From the table above, we can see that the input and output streams mass flow is
balanced. This balance can be seen as stream 42 has the same mass flow as stream
43, while stream 44 has the same mass flow as stream 45. There is no change of
composition in this equipment because there is only heat exchange in this equipment
without reaction.
68
Reactor (R 401)
Table 3.21. Mass Balance on Reactor
Component
CH3OCH3
CO
CO2
H2O
H2
CH3OH
N2
TOTAL
Input
44 (tonne/day)
28525.88
70599.30
312763.57
405.64
2233.24
1564.80
25732.42
441824.85
Output
45 (tonne/day)
28525.88
70599.30
312763.57
405.64
2233.24
1564.80
25732.42
441824.85
From the table above, it can be seen that the input and output of this reactor is
balanced in the term of mass. The input and output stream has the same mass flow
although they had different composition. The different composition is caused by
the reaction occurs in this reactor.
Separator (FG 401)

Table 3.22. Mass Balance on Separator
Component
CH3OCH3
CO
CO2
H2O
H2
CH3OH
N2
TOTAL
Input
43 (tonne/day)
28525.88
70599.30
312763.57
405.64
2233.24
1564.80
25732.42
441824.85
Output
62 (tonne/day)
28617.96
67301.00
311640.54
358.19
1697.39
1582.76
25729.45
436927.31
46 (tonne/day)
8637.559
239.3709
2643.997
4602.792
1.648575
4667.079
12.60311
20805.05
From the table above, we can see that the input and the output of this equipment is
already balanced in term of mass. The two output streams mass flow if added is
equal to the inputs mass flow. Composition changes can also seen in the table,
because there are component separated in this equipment
Distillation Column (T 401)

Table 3.24. Mass Balance on Distillation Column
Component
CH3OCH3
Input
47 (tonne/day)
8637.559
Output
51 (tonne/day)
0
61 (tonne/day)
8637.558
69
CO
CO2
H2O
H2
CH3OH
N2
TOTAL
239.3709
2643.997
4602.792
1.648575
4667.079
12.60311
20805.05
0
0
4602.792
0
4666.816
0
9269.607
239.3709
2643.997
0
1.648575
0.264219
12.60311
11535.44
From the table above, we can conclude that the input and outputs mass flow is
already balanced. If we add the two outputs mass flow, we will obtain the same
amount as the inputs mass flow. The table also show the amount of impurities
such as dimethyl ether, carbon dioxide, carbon monoxide, hydrogen, and nitrogen
removed from the raw methanol.
Distillation Column (T 402)

Table 3.25. Mass Balance on Distillation Column
Component
CH3OCH3
CO
CO2
H2O
H2
CH3OH
N2
TOTAL
Input
51 (tonne/day)
0
0
0
4602.792
0
4666.816
0
9269.607
Output
55 (tonne/day)
56 (tonne/day)
0
0
0
0
0
0
25.60812
4577.184
0
0
4666.349
0.466414
0
0
4691.957
4577.65
From the table above, we can see that the inputs mass flow is already balanced
with the outputs mass flow. The addition of the two outputs mass flow is the
same with the inputs mass flow. From the table, we also can see how much water
that is removed to produce methanol grade AA
70
3.1.5. Synthesis Ethylene Unit
Figure 3.5. The Hysys Simulation for Synthesis Ethylene Unit

Synthesis ethylene unit is a net of equipments to convert methanol to

ethylene. From the plants. we hope that 1095.89 tons per day. Mass and energy
balance will be calculated by hysys simulation. Hysys simulation will give the
information of mass flow and energy flow and then we can evaluate about mass
and energy balance. The mass and energy balance for synthesis ethylene unit will
be explain bellow.
The mass balance for this unit is :
MTO Reactor (R-501)
Table 3.26. Mass Balance On MTO Reactor
Component
Methanol
Ethylene
Propylene
Buthene
Penthene
Ethane
Propane
Methane
Water
REAKTOR R-501
Feed (Ton/d)
4583.59
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Product(Ton/d)
769.78
1401.16
258.84
1.37
1.36
3.66
0.00
1.93
2139.89
Table 3.26. Mass Balance On MTO Reactor (Contd)
Component
Formic Acid
TOTAL
REAKTOR R-501
Feed (Ton/d)
4583.59
Product(Ton/d)
5.58
4583.60
71
From the table above. we can see that the mass flow inlet to reactor is equal
wih outlet from reactor.
Water Separation (V-501)

Table 3.27. Mass Balance On Water Separator
Componet
Methanol
Ethylene
Propylene
Buthene
Penthene
Ethane
Propane
Methane
Water
Formic Acid
TOTAL
Water Separator
Inlet(Ton/d)
Top(Ton/d)
769.78
300.45
1401.16
1401.15
258.84
258.84
1.37
1.37
1.36
1.36
3.66
3.66
0.00
0.00
1.93
1.93
2139.83
463.00
5.58
6.00
4583.60
2437.38
Bottom(Ton/d)
469.32
0.0051
0.0002
0.00
0.00
0.00
0.00
0.00
1676.88
0.14
2146.36
From the table above. the inlet stream to water separation wil be separated
according to the operation condition. The mass flow inlet is equal with sum of
mass flows from outlet ( Top and Bottom).
Demethanizer (T-501)
Table 3.28. Mass Balance On Demethanizer
Component
Methane
Demethanizer
Inlet(Ton/d)
Top(Ton/d)
1.93
1.93
Bottom(Ton/d)
0.0003
Table 3.28. Mass Balance On Demethanizer (Contd)
Component
Ethane
Propane
Ethylene
Propylene
Butene
Pentene
Water
Hydrogen
Methanol
Formic Acid
TOTAL
Demethanizer
Inlet(Ton/d)
Top(Ton/d)
3.66
3.66
0
0
1401.15
1401.00
258.84
258.83
1.37
1.37
1.36
1.36
463.00
19.57
0
0
300
133.68
5.43
5.04
2437.22
1826.47
Bottom(Ton/d)
0.0002
0
0.15
0.0098
0.0000
0.0000
443.42
0
166.77
0.39
610.46
72
From the table above. we can see that the inlet will be distillated by
demethanizer to seperate stream inlet to result rich methane stream. The mass
flow of inlet is equal as with sum of outlet mass flow (top and bottom).
Deethanizer (T-502)
Table 3.29. Mass Balance On Deethanizer
Component
Methane
Ethane
Propane
Ethylene
Propylene
Butene
Pentene
Water
Hydrogen
Deethanizer
Inlet(Ton/d)
Top(Ton/d)
1.93
1.93
3.66
3.66
0
0
1401.00
1400.99
258.83
258.63
1.37
0.72
1.36
0.04
19.57
0.12
0
0
Bottom(Ton/d)
0
0
0
0.00
0.20
0.64
1.32
19.45
0
Table 3.29. Mass Balance On Deethanizer (Contd)
Component
Methanol
Formic Acid
TOTAL
Inlet(Ton/d)
134
5.04
1826.48
Deethanizer
Top(Ton/d)
0.0004
0.0000
1666.12
Bottom(Ton/d)
133.68
5.04
160.36
From the table above. we can see that the inlet will be distillated by
deethanizer to seperate stream inlet to result rich ethane and ethylene stream. The
mass flow of inlet is equal as with sum of outlet mass flow (top and bottom).
Ethylene Tower (T-503)

Table 3.30. Mass Balance On Ethylne Tower
Component
Methane
Ethane
Propane
Ethylene
Propylene
Butene
Pentene
Water
Ethylene Tower
Inlet(Ton/d)
Top(Ton/d)
1.93
1.79
3.66
2.53
0
0.0000
1400.99
1364.65
258.63
9.27
0.72
0.0000
0.047
0.0000
0.12
0.10
Bottom(Ton/d)
0.14
1.19
0.0000
36.33
249.35
0.72
0.047
0.019
73
Hydrogen
Methanol
Formic Acid
TOTAL
0
0.0004
0.0000
1666.12
0.0000
0.0000
0.0000
1378.07
0.0000
0.0004
0.0000
288.05
From the table above. we can see that the inlet will be distillated by ethylene
tower to seperate stream inlet to result rich ethylene stream. The mass flow of
inlet is equal as with sum of outlet mass flow (top and bottom)
So from the last unit. our plant can produce the final product with ethylene purity
is 99% and side product that propylene with 80%.
3.2.
Energy Balance for Equipment
3.2.1. Gasification Unit

Table 3.31. Gasification Unit Energy Balance
Equipmen
t
M-101
J-101
R-101
E-101
In (x1014 kJ/h)
2.000E+00
-3.637
4.000E+00
-1.349
-4.986
5.000E+00
-1.708
Q7
2.458
7.497
3.000E+00
-5.075
6.000E+00
-1.708
8.000E+00
-7.764
-1.455E+15
1.000E+01
-1.713
Out (x1014 kJ/h)

5.000E+0
0
1
1.600E+0
1
1
Q8
1.100E+01
-2.098
1.200E+0
1
1.500E+0
1
-2.098
2.457
-1.713
0.00
-1.713
1.100E+0
-3.279
-1.708
-1.708
1.000E+0
-1.713
FG-101
-1.708
-1.708
6.000E+0
Require (x1014kJ/h)
-1.283E+15
-2.098
3.848
1.750
-3.463
-1.874
-2.245
-4.119
2.021
74
Overall Duty (kJ/h)
-15.1
3.2.2. Acid Gas Removal Unit

Table 3.32. Acid Gas Removal Unit Energy Balance
Equipmen
t
JC-201
In (x1014 kJ/h)
1.200
-6.328
Q8
1.296
Out (x1014 kJ/h)

1.300
-5.033
E-201
1.300E+01
-6.199
Require (x1014 kJ/h)
-6.199
-6.199
1.400E+0
1
1.166
-6.373
Table 3.32. Acid Gas Removal Unit Energy Balance (Contd)
Equipmen
t
14
In (x10 kJ/h)
14
Out (x10 kJ/h)

Q9
-6.199
T-201
3.100E+01
-1.502
1.400E+01
-6.373
1
3.200E+0
1
-7.875
J-201
T-202
1.500E+01
-1.601
Q10
4.823
3.223
1.600E+01
-1.600
Q10
4.823
1
2.600E+0
1
Q11
3.223
J-204
E-203
2.600E+01
1.380
Q12
7.537
8.917
-1.373
2.700E+01
-5.390
2.700E+0
1
Q13
2.800E+0
1
-8.848
-1.600
-1.600
1.900E+0
-1.570
-1.601
-6.991
1.600E+0
kJ/h)
1.744
-4.629
1.500E+0
Require (x1014
4.823
-9.889
1.380
-5.681
-1.419E+15
1.741E+15
-1.373
-1.373
1.290
1.029E+15
-1.502
75
-1.373
Overall Duty (kJ/h)
-2.121
-1.161
30.1
3.2.3. Water Gas Shift Unit

Table 3.33. Water Gas Shift Unit Energy Balance
Equipmen
In (x1014kJ/h)
32
-1.769
t
JC301
E301
-1.769
-1.785
2.549
7.641
33
Q14
Out (x1014kJ/h)
33
-1.785
Q
1.561
-2.240
34
-1.530
-1.530
Require
-1.545
2.294
Table 3.33. Water Gas Shift Unit Energy Balance (Contd)
Equipmen
t
R301
In (x1014 kJ/h)
34
-1.530
36
E302
38
R302
37
39
E303
40
Out (x1014kJ/h)
38
-1.531
DUMMY
-8.866
0.00
1
-1.040E+15
-1.531
-1.531
39
-1.641
Q15
1.099
-1.531
-5.421
-8.867
40
-1.642
-1.641
DUMMY
0.00
-1.051E+15
-1.642
-1.642
41
-1.680
Q16
3.782
-1.642
2.103
Overall Duty (kJ/h)
Require
-8.865
-9.890
-8.866
-3.744
-21.72
3.2.4. Synthesis Methanol Unit

Energy balance of Methanol Synthesis Unit can be seen on the table below :
Table 3.34. Methanol Synthesis Energy Balance
Equipment
JC-401
E-401
Input (kJ/h)
41
-4.54E+10
42
-4.54E+10
45
-4.38E+10
Output (kJ/h)
42
-4.54E+10
44
-4.38E+10
43
-4.04E+10
Duty (kJ/h)
0.00E+00
-1.57E+09
-3.43E+09
76
44
-4.38E+10
43
-4.04E+10
47
R-401
FG-401
T-401
45
-4.38E+10
46
-5.64E+10
60
49
0.00E+00
1.60E+10
Table 3.34. Methanol Synthesis Energy Balance (Contd)
Equipment
T-401
E-406
E-403
T-402
E-404
E-407
Input (kJ/h)
Output (kJ/h)
-5.64E+10
-1.84E+09
-1.73E+09
50
48
-1.73E+09
-1.20E+09
60
59
-1.84E+09
-2.09E+09
51
53
57
-3.47E+08
-4.54E+08
-7.62E+08
54
52
-4.54E+08
-4.12E+08
57
58
-7.62E+08
-4.57E+08
Overall Duty (kJ/h)
Duty (kJ/h)
-5.28E+10
-5.37E+08
2.56E+08
8.69E+08
-4.19E+07
-3.05E+08
-4.16E+10
3.2.5. Synthesis Ethylene Unit

Table 3.35. Energy Balance on Synthesis Ethylene
No
1
2
3
4
5
6
7
8
9
10
11
Equipment
R-501
E-501
V-501
K-501
E-502
T-501
K-502
T-502
K-503
E-503
T-503
Inlet (x107
Outlet (x107
Duty (x107
kJ/h)
-2.55
-2.55
-2.66
-5.04
-4.77
-5.48
1.69
1.67
2.48
2.44
2.58
kJ/h)
-2.55
-2.66
-3.41
-4.77
-5.48
-6.16
1.67
1.25
2.44
2.58
2.30
kJ/h)
-0.24
0.11
7.52
-2.69
0.71
0.67
0.24
0.43
4.30
0.18
0.279
State
Balance
Balance
Balance
Balance
Balance
Balance
Balance
Balance
Balance
Balance
Balance
From table above. if we sum the inlet column and sum outlet coulmn which
added with duty column. The inlet column will has same energy with outlet and
duty column.
77
3.3.
Overall Mass Balance

From process flow diagram in previous chapter, we can calculate mass and
energy balance for this plant using Aspen HYSYS V7.3.

Table 3.36. Mass Balance Overall
Component
Inlet
C
CO
CO2
H2O
H2
O2
S
N2
Total
Mass Flow ( Ton/d)

3030.66
0
0
588.03
212.59
1031.32
18.99
23.97
4905.60
Component outlet Mass Flow (ton/d)

C
Methane
Ethane
Propane
Ethylene
Propylene
Butene
Pentene
Hydrogen
Methanol
Formic Acid
S
N2
Total
222.31
79.2271
149.991
0
1451
105.88
5.61
5.59
0
3.14
2.28
18.99
23.9739
4905.60
3.4.
Overall Energy Balance

Table 3.37. Energy Balance Overall
Component
Inlet
C
CO
CO2
Energy Flow ( kJ/h)

-87068
-4259301
-9173407
Component
outlet
Methane
Ethane
Propane
Energy Flow (kJ/h)

-4681250
-2824600
-2361136
Table 3.37. Energy Balance Overall (Contd)
Component
Inlet
H2O
H2
O2
H2S
S
N2
Energy Flow ( kJ/h)

-13984027
-4143973
-270609
-886442
8503897
-304632
Component
outlet
Ethylene
Propylene
Butene
Pentene
Water
Methanol
Formic Acid
H2S
S
Energy Flow (kJ/h)

1868921
486405
-124818
-401271
-13434111
-6290313
-8236739
-886442
8503897
78
Total
-24605564
N2
Total
-304632
-24605564
(Source : Author Personal Data)
From the table above, we can see that the total of inlet mass and inlet energy
is will be equal with mass outlet and energy outlet.
3.5.
Mass Efficiency
From mass balance calculation above, we can calculate mass efficiency for
main product produced in this plant. It can be done by dividing amount main
product produced with raw material used.
mass efficiency ethylene=
mass efficiency Total=
et h ylene produced
1451
=
x 100 =45.47
Feed Coal
3030.66
et h ylene produced
2125
=
x 100 =80.03
Feed Coal
3030.66
We can see that from our plants convert coal to ethylene by five units has
mass efficiency as 45.47 % and total efficiency is 80.03%.
3.6.
Energy Required per Unit Product and Energy Efficiency

From energy balance calculation above, we can calculate energy required
for a unit main product produced in this plant. It can be done by dividing amount
total energy required with main product produced.
Energy efficiency=
Energy Require
37,938,399,336
=
Et h ylene Produced
1,378,076
Energy efficiency=27,080 kJ / Kg
We can see that from our plants convert coal to ethylene by five units has
energy efficiency as 27.080 kJ/kg.
CHAPTER IV
CONCLUSION
1. Ethylene production is still limited compared to the increasing demand, while
coal as one of ethylene feedstocks is abundant in Indonesia.
2. Raw material for coal will be supplied from PT Bukit Asam and PT Adaro,
while oxygen will be supplied from PT Air Products integrated facility
within the plant.
3. The plant will be located in Cilegon.
4. The plant will consists of five units, which are Gasifier Unit, Acid Gas
Removal Unit, Water Gas Shift Unit, Methanol Synthesis Unit and Ethylene
Synthesis Unit.
5. Gasifier technology that is chosen in Entrained Bed Gasifier, while the
ethylene synthesis will be done using Methanol-to-Olefin technology.
6. The plant has mass efficiency of 45,74% while the energy efficiency of the
plant is 27.080 kJ/kg.
REFERENCES
79
Anonymous. 2014. www.maps.google.com. Accessed on 12 September 2014 at

20.10
Anonim.
(2013).
Ethylene
via
Ethanol
Dehydration.
Accessed
from
http://base.intratec.us/home/chemical-processes/ethylene/ethylene-viaethanol-dehydration at 18th September 2014

Anonim. (2008). Methanol Plant Process Description. Accessed from
http://www.ippe.com/plants/600304/process_description.pdf
at
12th
September 2014
Anonymous. 2014. Statistik Batubara. www.esdm.go.id. Jakarta: Direktorat
Jenderal Mineral dan Batubara Kementerian ESDM. Accessed on 12
September 2014 at 19.17
Asma. A. et al. (2008). Ethanol Conversion from Syngas-Microbial Conversion.
Accessed
from
http://bioweb.sungrant.org/Technical/Biofuels/Technologies/Biofuels+from
+Syngas/Ethanol+from+Syngas/Default.htm at 18th September 2014
Fisher Controls International LLC. (2010). Chapter 1: Ethylene Production.
Accessed from www.fisher.com at 18th Sepetember 2014
Habiburrohman.
Muhammad.
2012.
Perancangan
Pabrik
Gas
Sintesis
Menggunakan Proses Gasifikasi Batubara Sebagai Bahan Baku Pembuatan

Bahan Bakar Cair. Depok: Universitas Indonesia.
He. J. et al. (2008). Research on ethanol synthesis from syngas. Journal of
Zhenjiang University Science A. 2008 9(5):714-719
Sunggyu. L.. Speight. J. G.. Loyalka. S. K. (2007). Handbook of Alternative Fuel
Technology. Boca Raton: CRC Press
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UNIVERSITAS INDONESIA

PRELIMINARY DESIGN OF ETHYLENE PRODUCTION FROM COAL

CHEMICAL ENGINEERING DEPARTMENT

Types of Coal and Its Application......................................................6

Raw Material Analysis............................................................................12

Plant Location Analysis...........................................................................16

CHAPTER II PROCESS SELECTION............................................................20

2.2.2. Acid Gas Removal Technology............................................................21

Block Flow Diagram........................................................................36

Process Flow Diagram.....................................................................38

CHAPTER III MASS & ENERGY BALANCE...............................................57

Mass Balance for Equipment..................................................................57

Acid Gas Removal Unit...................................................................60

Water Gas Shift Unit........................................................................64

Synthesis Methanol Unit..................................................................68

Synthesis Ethylene Unit...................................................................71

Energy Balance for Equipment...............................................................76

Acid Gas Removal Unit...................................................................76

Water Gas Shift Unit........................................................................77

Synthesis Methanol Unit..................................................................78

Synthesis Ethylene Unit...................................................................79

Overall Mass Balance..............................................................................80

Overall Energy Balance...........................................................................80

Energy Required per Unit Product and Energy Efficiency.....................81

Table 3.22. Mass Balance on Separator...........................................................................70

with other countries in the field of industry. Industrial development in Indonesia

The development of domestic ethylene import according BPPN statistics,

C5H12 + 1/3 C4H8 + 1/3 C3H8 + 1/3 C4H10 + 1/3 C3H

Large-scale production is done by hydrocarbon raw material pyrolysis and

d. Ethylene From Coal

Production of synthesis gas from coal gasification process (process Lurgi,

Techniques used in the production of ethylene by means of pyrolysis of

Fired tubular heater.

Fractionation at low temperatures and high pressures.

Adsorbtion and fractionation at low temperatures.

1.1.3. Types of Coal and Its Application

Figure 1.1. Coal and Utilization

1.1.4. Coal Gasification

Figure 1.2. Coal Gasification Process

a. Drying (Evaporation of Moisture)

heterogeneous reaction process. The reaction below is a common homogeneous

2 H 2 ( g ) +O2 ( g) 2 H 2 O ( g ) H rxn =484.23 kJ /gmole

Capacity x 1000 ton

(Source: Authors Personal Data)

Figure 1.3. The Prediction Capacity Production, Consumption, Imports

tons of propylene. With two of the manufacturers producing olefins, it is an

demand for ethylene in Indonesia amounted to 2,671,000 tons

ethylene ranged from 250,000 tons to 550,000 tons.

Anthracite coal is the highest grade, with glittering black color

elements of carbon (C) with a water content of less than 8%.

most mined in Australia.

and pressure as well as the length of time for the formation of

Figure 1.4. Coal development process

Figure 1.5. Coal Quality Based on Coal Type

Coal with higher quality or hard coal are generally more

heating value. Anthracite is the most good quality of carbon

Price per Ton

The selection of coal based on several parameters such as

(Source : Authors Personal Data and gather from any sources)

Bituminous coal has several advantages when compared

Table 1.4. The Composition of Bituminous Coal (Contd)

compounds (H2, N2, and

Here is physical properties for bituminous coal :

(Source : MSDS of Bituminous Coal)