UNIVERSITAS INDONESIA

COVER PAGE

PRODUCTION OF BIO-ASPHALT FROM RUBBER AND BIO-

OIL

Draft Assignment 2

GROUP 3

GROUP PERSONNEL:

DAVITA KRISTABEL MANDALA 1406605830

NABILA HANA DHIA 1406573394
NABILA PUTRI SALSABILA 1406533466
NUR ANNISA 1406605862
SILVA AMANAT TAQWA 1406533604

CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
DEPOK
SEPTEMBER, 2017
EXECUTIVE SUMMARY

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 TABLE OF CONTENTS

COVER PAGE ....................................................................................................... i

EXECUTIVE SUMMARY ................................................................................... ii
TABLE OF CONTENTS ..................................................................................... iii
TABLE OF FIGURES ......................................................................................... iv
LIST OF TABLES ................................................................................................ v
CHAPTER 1. HEAT EXCHANGER NETWORKING .................................... 1
1.1. Heat Exchanger Information .................................................................... 1
1.2. Heat Recovery Pitch ................................................................................. 1
1.2.1. Composite Curves ............................................................................. 1
1.2.2. Problem Table Algorithm ................................................................. 1
1.3. Pinch Design Method ............................................................................... 1
CHAPTER 2. UTILITY ....................................................................................... 3
2.1. Utility........................................................................................................ 3
2.2. Water Utility ............................................................................................. 3
2.2.1. Water for Main Process ..................................................................... 3
2.2.2. Cooling Water Utility........................................................................ 3
2.2.3. Heating Utility................................................................................... 3
2.2.4. Steam Utility ..................................................................................... 3
2.2.5. Total Water Needed Per Day ............................................................ 3
2.3. Electric Utility .......................................................................................... 3
2.3.1. Electricity for Plant Operation .......................................................... 4
2.4. Fuel Utility ............................................................................................... 9
2.4.1. Fuel Mass .......................................................................................... 9
2.4.2. Fuel Generator ................................................................................. 10
CHAPTER 3. CONCLUSION ........................................................................... 12
3.1. Conclusion .............................................................................................. 12
REFERENCES .................................................................................................... 13

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TABLE OF FIGURES

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LIST OF TABLES

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 1. CHAPTER 1.
HEAT EXCHANGER NETWORKING

1.1. Heat Exchanger Information

1.2. Heat Recovery Pitch

1.2.1. Composite Curves

1.2.2. Problem Table Algorithm

1.3. Pinch Design Method

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 2. CHAPTER 2.
UTILITY

2.1. Utility
Utility is a supporting operational unit which is very important to support main
process unit in a plant. Plant couldnt be operated if theres no utilities to support
its production process. In the plant, there are several utilities which are required;
water utility, air utility, fuel utility, and electrical utility (process equipment) as well
as water treatment. Water is a utility needed both for the main process and to support
the process. Electricity is the utility needed by process equipment to do its function.
Without electricity, there wont be any processes. Fuel is needed as power for steam
boiler and generator.
2.2. Water Utility

2.2.1. Water for Main Process

2.2.2. Cooling Water Utility

2.2.3. Heating Utility

2.2.4. Steam Utility

2.2.5. Total Water Needed Per Day

2.3. Electric Utility

Electric utility is the electricity that required to operate the plant. Electricity
is needed to operating equipment, chilling water, domestic, and office use. Since
bio-asphalt plant is continuous, the power that needed in the process will calculated
based on the flow rate (ton/h). The flow rate on each process can be found at mass

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and energy balance chapter. After that, the power requirement (kWh) is calculated
from time usage (h) and power (kW) in each equipment.
2.3.1. Electricity for Plant Operation
The type of electricity needed for equipment to run the process before and
after HEN applications are presented in table lalala.
Electricity for Process Uses Before HEN
Time Power
Equipment Duty Power
No Process Quantitiy Used Efficiency needed
Name (kW) (kWh)
(h) (kWh)
Conveyor to
1 1 3 1 3 0.8 3.75
Shredder
2 Shredder 1 136.4 1 136.4 0.75 181.87
Conveyor to
3 1 2.2 1 2.2 0.75 2.93
Fluid Bed Dryer
Dehumidifier for
1 25 1 25 0.7 35.7
Air Treatment
Blower for Air
4 Pre-treatment 1 1.8 1 1.8 0.8 2.25
Inlet to FBD
Electric Heating
5 for Air Inlet to 1 2 1 2 0.75 2.7
FBD*
6 Fluid Bed Dryer 1 24.25 1 24.25 0.75 32.33
7 Blower to PFSR 1 1.8 1 1.8 0.8 2.25
Electric Cooling
8 1 21.1 1 21.1 0.75 28.13
from FBD*
Conveyor to
9 1 2.2 1 2.2 0.75 2.93
Electric Heating
Fast Pyrolysis Electric Heating
10 1 2 1 2 0.75 2.7
to PFSR*
11 Gas Cyclone 1 4.47 1 4.47 0.9 49.7
12 Condenser 1 343.5 1 343.5 0.9 381.67
Condensation Pump from
13 Condenser to 1 3 1 3 0.75 4
Electric Cooling
14 Electric Cooler* 1 2.7 1 2.7 0.75 3.6
Cooling Pump from
15 Electric Cooling 1 3 1 3 0.75 4
to Tank
Pump for
16 Distilled Water 1 4.5 1 4.5 0.75 6
Extraction
to Blending Tank
and
Blending Tank
Centrifugation
17 for Adding 1 8.3 1 8.3 0.8 10.375
Distilled Water

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Pump between
18 1 7 1 7 0.75 9.3
Blending Tank
Pump for
Propylene Glycol 1 2 1 2 0.75 2.7
to Blending Tank
Pump for
Demineralization 1 4.5 1 4.5 0.75 6
Water
Blending Tank
19 for Adding 1 2.2 1 2.2 0.75 2.93
Propylene Glycol
Blower to
20 1 0.2 1 0.2 0.75 0.27
Electric Cooling
21 Electric Cooler* 1 0.4 1 1.56 0.75 2.08
Pump to
22 1 8.4 1 8.4 0.75 11.2
Centrifuge
Decanter
23 1 57.5 1 57.5 0.75 76.7
Centrifuge
Blower to
24 Electric Cooling 1 0.2 1 0.2 0.75 0.27
(Vent)
Electric
25 1 3.9 1 3.9 0.75 5.2
Cooling*
Pump to Flash
26 1 8.1 1 8.1 0.75 10.8
Drum
Blower to
28 1 0.2 1 0.2 0.75 0.27
Electric Cooling
Flash
Electric
29 Vaporization 1 171.62 1 171.62 0.75 228.83
Cooling*
Pump from Flash
30 Drum to 1 61.2 1 61.2 0.75 81.6
Blending Tank
Conveyor for
31 1 3 1 3 0.8 3.75
Rubber Powder
32 Blending Tank 1 0.3 1 0.3 0.75 0.4
Pump between
33 1 2.2 1 2.2 0.75 2.93
Blending Tank
34 Electric Heater* 1 55 1 55 0.9 61.11
Pump to Electric
35 Heater for Conv. 4 185 1 740 0.9 822.22
Mixing and
Asphalt
Heating
36 Blending Tank 1 0.78 1 0.78 0.75 1.04
Pump to
Blending Tank
37 5 185 1 925 0.9 1027.78
for Conv.
Asphalt
Blower to
38 1 1.5 1 1.5 0.75 2
Electric Cooler
39 Electric Cooler* 1 7.73 1 7.73 0.75 10.3

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Pump to Storage
40 1 22 1 22 0.75 29.33
Tank
41 Storage Tank 1 0.8 1 0.8 0.75 0.94
Pump from Bio-
asphalt Storage
42 1 22 1 22 0.75 29.33
Tank to
Distributor
Pump for
Demineralization
43 1 4.5 1 4.5 0.75 6
Water Storage to
Condensate Tank
Utility
Pump from
Supplier to
44 4 185 1 740 0.9 822.22
Petroleum
Storage Asphalt
Pump from
Supplier to
45 1 2 1 2 0.75 2.7
Propylene Glycol
Storage
Total 4017.085
(Source: Private Data, 2017)
The integration of Heat Exchanger Network (HEN) helps to reduce the duty
of electrical heater and cooler because heat exchanger has exchange the heat so the
temperature differences has decreased and the electrical heater or cooler need lower
duty than before. Table above with * marked present the unit that change after HEN,
calculation can be seen below:
After HEN Electricity
Time Power
Equipment Duty Power
No Process Quantitiy Used Efficiency needed
Name (kW) (kWh)
(h) (kWh)
1 Electric Heater 1 2 1 2 0.75 2.7
Pre-treatment
2 Electric Cooler 1 10.21 1 10.21 0.75 13.61
3 Fast Pyrolysis Electric Heater 1 2 1 2 0.75 2.7
4 Cooling Electric Cooler 1 1.375 1 1.375 0.75 1.83
5 Extraction Electric Cooler 1 0.002 1 0.002 0.75 0.0027
and
6 Centrifugation Electric Cooler 1 0.8 1 0.8 0.75 1.067
Flash
7 Electric Cooler 1 162.76 1 162.76 0.75 217
Vaporization
8 Mixing and Electric Heater 1 35.1 1 35.1 0.9 39
9 Heating Electric Cooler 1 5.75 1 5.75 0.75 7.67

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After making Heat Exchanger Network (HEN), we can compare the energy
for hot and cold utility before and after HEN, as well as energy efficiency
calculation. The energy efficiency calculation listed in table below
Comparison Before and After HEN Electricity
Utility Load (kW) Difference Efficiency
Utility
Before HEN After HEN (kW) (%)
Hot 66.51 44.4 22.11 33.24%
Cold 278.14 241.18 36.96 13.3%

Therefore, bio-asphalt plant electricity requirements for manufacturing area

is 4017 kW per hour (with HEN). This electricity demand is supplied by PLN from
PLTU Cilegon, West Java. Assuming that the plant runs for 24 hour for 330 days
per year, so the electricity requirements for this area is 31,814,640 kW per year
based on below calculation.
4017 24 hour 330 days
P= x x = 31,814,640 kW per year
hour day year

2.3.2. Lighting
Plant area needs lighting to illuminate the room when it gets dark, whether
its the office or production area. Lamp used as the lighting source and the equation
to calculate the power of lamps needed is:
(N..LLF.UF.n)
E= A

With
E = Illuminance
N = Total number of lamp
= Total of lumen
LLF = Light loss factor = 0.8 (SNI)
UF = Utility factor = 0.8 (SNI)
n = Number of lamp each lamp point
A = Area building
Fluorescent lamp PL-C type 26 watt with lumen 1800 Lm used as lamp type
in this bio-asphalt plant. With calculation above, we can calculate power needs for
office, production area, and other area in the plant.
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Power Needed by Office Equipment and AC

Number Total of Area
No Name LLF UF n E Units
of lamp lumen (m2)
1 Office 400 1800 0.8 0.8 1 2000 230.4 lx
2 Production 2500 1800 0.8 0.8 1 15000 192 lx
3 Other 150 1800 0.8 0.8 1 1500 115.2 lx
Total E 537.6 lx
Luminous efficiency / watt for Fluorescent and LED 60 lm/w
Office operation hour 10 h
Production operation hour 24 h
Other place operation hour 12 h
Total Power 411.8 kWh
(Source: Private Data, 2017)

2.3.3. Office Equipment and Air Cooling

The electricity needed in office for the employees to do their work, and also
for air conditioner to make it comfortable for them are listed in this section.
Equipment name, quantity, and power for each one can be seen in table lalala:
Power Needed by Office Equipment and AC
Power Operating Total power per
No. Equipment Name Quantity
(kW) time (h) Day (kWh)
1 Computer 50 0.14 10 70
2 Photocopy machine 2 0.1 10 2
3 Dispenser 5 0.25 24 30
4 Pantry utensil 1 2 2 4
5 Refrigator 2 0.05 24 2.4
6 CCTV 30 0.0084 24 6.048
8 AC 1PK 30 0.84 10 252
10 Telephone 10 0.01 10 1
11 Television 2 0.068 10 1.36
Total 368.808
(Source: Private Data, 2017)
2.3.4. Total Electricity
Total electricity is counted by calculating all electricity needed. From that
calculation, the total electricity needed by bio-asphalt plant is about 74,910.608
kWh.
Total Electricity Needed
No. Application Power (kWh)
1 Main Equipment 74,130
2 Lighting 411.8

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3 Office equipment & AC 368.808

Total 74,910.608
(Source: Private Data, 2017)
2.4. Fuel Utility
Fuel is needed for operating generators set to back up supply of electricity and
for steam source used in boiler coil. In this plant, the generator used is set with rate
power 4000 kW, because the demand of electricity for the whole process of this
plant amounted to 3089 kW. The power is expected to back up the electricity needs
of the plant, if the supply of electricity from PLN down. Diesel is needed for diesel
engine generators as its fuel. For boiler, coal is used because the price is cheap and
stable. Coal is easy to burn and produces high energy upon combustion. The
efficiency for boiler using coal is higher than using electricity. But the negative
effect is it produces lots of carbon dioxide which leads to global warming.
2.4.1. Fuel Mass
Steam is an essential agent for many process, mainly for heating agent used
in stripping process to regenerate the expensive material. Steam is generated by
boiler that will be distributed to any units that require steam like heat exchanger.
Boiler has three minimum utility that are water, fuel, and other additive chemical
utility. Water utility had been calculated above, so the total water needed to convert
into steam are known. Uncontrolled NOx emissions from coal-fired utility boilers
are smallest than natural gas-boilers. Therefore, we choose coal as the fuel of boiler
than the other. To calculate the fuel mass, first the Boiler Thermal Output have to
be calculated first. Assumption used for calculating BTO are:
- Operation basis = 1 hour
- Boiler efficiency = 75%
- Gross Calorific Value for coal = 4200 kcal/kg
All calculation and number will be shown below.
Calculation of mass fuel before HEN
Because there are three boilers in the plant, the calculation of each boiler energy
consumption can be seen in table lalala:
Mass Fuel Calculation Before HEN
Total Coal
No. Name Duty (kcal/h)
Needed (kg/h)

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1 Boiler 1 (for Oxidation) 425381.44 101.28

Boiler 2 (for Flash
2 3917625.8 932.76
Evaporation)
3 Boiler (for Storage Tank) 20676.89 4.92
Total 1038.96
(Source: Private Data, 2017)
From table above, fuel required by boiler before HEN is estimated 1 ton/h or
in a day basis it would be 24 ton/day.
Calculation of mass fuel after HEN
The estimation of the fuel mass ultilized in the boiler with the calculation of
the requirement of fuel while the plant is using HEN can be seen in table lalala:
Mass Fuel Calculation After HEN
Total Coal
No. Name Duty (kcal/h)
Needed (kg/h)
1 Boiler 1 (for Oxidation) 361047.8 85.96
Boiler 2 (for Flash
2 3689138.9 878.36
Evaporation)
3 Boiler (for Storage Tank) 20676.89 4.92
Total 969.24
(Source: Private Data, 2017)
From table above, fuel required by boiler before HEN is estimated 0.9 ton/h or
in a day basis it would be 21.6 ton/day. The type of coal used is bituminous coal.
The price of coal is 519 IDR/kg, so for our plant we need 11,210,400 IDR for one
day production.
The difference of the total fuel requirements before and after HEN applications
can be seen on the tables above, heat exchanger network makes the requirement of
steam is much less where the saving of coal used to provide steam reaches the number
of 10%.

2.4.2. Fuel Generator

Since electricity is the crucial part of production process, taking precaution
if there is an electricity black out is necessary. The precaution is by purchasing a
back-up generator. The back-up generator used must be able to provide electricity
needed for the whole plant. Since the plant need around 96,408 kWh per day the
generator need to at least fill 75% of our needs which is 72,306 kWh. For fulfil the
electricity demand, plant must request special order to generator manufacturer

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personally because the maximum usual generator capacity sold in general between
range 2000 2400 kW.
If bio-asphalt plant used general generator capacity, it will need many unit
to fulfill the energy, generated high vibration, more fuels needed and more pollution
resulted. For example, using generator manufactured by Kohler Power Systems
KD2250 with 2400 kW capacity, specifications:
Generator Specification
Generator Characteristics Specification
Voltage 220 to 380 volt
Frequency 50 or 60 Hz
RPM 1500 or 1800
Price 259 million IDR
Fuel consumption 411 liter/hour
(Source: Kohler Power Systems, 2015)
The fuel used is diesel for industries with price 8.200 IDR/liter include tax.
Needs of diesel per day production is:
Production time/day = 24 hour
Fuel needed = 411 liter/hour (2400 kW)
Power needed/day = fuel needed x production time = 9864 liter
Cost of electricity = Power needed/day x diesel price = 78,129,600 IDR
Generator needed = 72,306 kWh / 2400 kWh = 30 unit

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 3. CHAPTER 3.
CONCLUSION

3.1. Conclusion

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REFERENCES

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