BAB IV SIZING OF EQUIPMENT 4.1.Vessel and Reactor 4.1.1.

Washing Stirred Tank Reactor In the making of casein from skim milk, we use a reactor tank to mix a variation of material. This reactor tank is used to mix a material from one unit process to other process. Size and dimention of this storage tank is based on flowrate of material which entering in the tank and flowrate of material which exit from tank. To design a storage tank must follow an international standard from ANSI and Underwriter Laboratories standard. The working volume of this tank has a smaller ratio than the total volume because it uses an agitator. The head type in this tank is a standard type of reactor tank which is a flat lange head. In this reactor tank design, there is so many assumption, such as: The ratio between high and diameter of tank is 4:3 The working volume is 0,85 from the total volume The Working Volume and The Total Volume Calculation (Vk and Vr) To know the volume of storage tank/raw material tank get from setting which is storage tank is fulfilled during 24 hours and the content of reactor tank is flowed with the valve using a batch system in the process production. The flowrate of content is based on this formula:

From the formula above, we can assume that working volume of this tank is 24Q. The working volume is 85% from the total volume of this tank with the assumption that 15% from the total volume of tank is head space. The Tank Dimentional Calculation The ratio between high and dimentional of this tank is 4:3

From the formula above, H is the height of tank (m) and D is the diameter of tank (m). The Wall Thickening Of Tank Calculation The wall tank design has a cyclinder from (cylinder shell) which is in the above part of tank has a flat langed head form and the the below part of tank has a flat form. The material is made from stainless steel SS 316 (Shuler, 2002). The thickening of this wall can be calculated with this formula:

P value from the formula above can be also calculated from this formula: P (psig) = Poperasi (psia) + Static Pressure + Safety Factor Agitator Design Agitator in washing tank reactor is flat blade turbine. The design of this agitator can be calculated from the formula below: a) Diameter (di) di = 0,4 D (shuler, 2002) b) The Distance Of Agitator From The Base of Reactor (Hd) (shuler, 2002) c) The Length and Width of Blade (Pb) (Wang et al, 1979) d) The Thickening of Agitator (di) (Wang et al, 1979) 4.1.1.1 The Washing Tank Reactor 1 The reactor for washing tank reactor 1 is a stirred tank reactor with the volumetric flow rate which is entering in this reactor is ... m3/hour. Because of none literature about the kinetics reaction, so we assume that residence time of reactant in this reactor is 0,69 hour or

40 minutes. It is happening because in batch system, reactor must be reacted during 30-60 minutes, so the middle of residence times is 40 minutes. With this assumption, the working volume of washing tank reactor 1 is ....m3. For further information, the spesification of this tank can be looked in table 4.1 below: Table 4.1. Spesification Of Washing Tank Reactor 1 4.1.1.1 The Washing Tank Reactor 2 The reactor for washing tank reactor 2 is a stirred tank reactor with the volumetric flow rate which is entering in this reactor is ... m3/hour. Because of none literature about the kinetics reaction, so we assume that residence time of reactant in this reactor is 0,69 hour or 40 minutes. It is happening because in batch system, reactor must be reacted during 30-60 minutes, so the middle of residence times is 40 minutes. With this assumption, the working volume of washing tank reactor 2 is ....m3. For further information, the spesification of this tank can be looked in table 4.1 below: Table 4.2. Spesification Of Washing Tank Reactor 1 4.1.2. HCl Storage Tank In the making of casein from skim milk, we use a store tank to store a variation of material. This storage tank is used to storage a material from one unit process before flowed to other process and this tank also use to store a product. Size and dimention of this storage tank is based on flowrate of material which entering in the tank and flowrate of material which exit from tank. Storage tank which is used in this process is a bin tank. To design a storage tank must follow an international standard from ANSI and Underwriter Laboratories standard. The working volume of this tank has a smaller ratio than the total volume because it isnt use an agitator. The head type in this tank is a standard type of reactor tank which is a flat lange head. In this reactor tank design, there is so many assumption, such as: The ratio between high and diameter of tank is 4:3 The working volume is 0,85 from the total volume The Working Volume and The Total Volume Calculation (Vk and Vr)

To know the volume of storage tank/raw material tank get from setting which is storage tank is fulfilled during 24 hours and the content of reactor tank is flowed with the valve using a batch system in the process production. The flowrate of content is based on this formula:

From the formula above, we can assume that working volume of this tank is 24Q. The working volume is 85% from the total volume of this tank with the assumption that 15% from the total volume of tank is head space. The Tank Dimentional Calculation The ratio between high and dimentional of this tank is 4:3

From the formula above, H is the height of tank (m) and D is the diameter of tank (m). The Wall Thickening Of Tank Calculation The wall tank design has a cyclinder from (cylinder shell) which is in the above part of tank has a flat langed head form and the the below part of tank has a flat form. The material is made from stainless steel SS 316 (Shuler, 2002). The thickening of this wall can be calculated with this formula:

P value from the formula above can be also calculated from this formula: P (psig) = Poperasi (psia) + Static Pressure + Safety Factor From the above formula, we can calculate a storage tank design for HCL which the table can be showed below:

Table 4.3. Spesification Design For HCL Storage Tank HCL Storage Tank Code Operation Methods Operation Temperature ( C) Pressure (atm) Volume (m3) Residence Time Design Temperature ( C) Pressure (atm) Volume (m3) Residence Time Dimention Height (m) Diameter (m) Thickness (mm) Materials Spesification 4.1.2. Water Storage Tank In the making of casein from skim milk, we use a store tank to store a variation of material. This storage tank is used to storage a material from one unit process before flowed to other process and this tank also use to store a product. Size and dimention of this storage tank is based on flowrate of material which entering in the tank and flowrate of material which exit from tank. Storage tank which is used in this process is a bin tank. To design a storage tank must follow an international standard from ANSI and Underwriter Laboratories standard. The working volume of this tank has a smaller ratio than the total volume because it isnt use an agitator. The head type in this tank is a standard type of reactor tank which is a flat lange head. In this reactor tank design, there is so many assumption, such as: The ratio between high and diameter of tank is 4:3 The working volume is 0,85 from the total volume The Working Volume and The Total Volume Calculation (Vk and Vr) To know the volume of storage tank/raw material tank get from setting which is storage tank is fulfilled during 24 hours and the content of reactor tank is flowed with the 2,168 1,626 3,81 carbon steel type SA 283 grade C
0 0

Continous 27 1 4,1 24 27 1,21 4,05 24

valve using a batch system in the process production. The flowrate of content is based on this formula:

From the formula above, we can assume that working volume of this tank is 24Q. The working volume is 85% from the total volume of this tank with the assumption that 15% from the total volume of tank is head space. The Tank Dimentional Calculation The ratio between high and dimentional of this tank is 4:3

From the formula above, H is the height of tank (m) and D is the diameter of tank (m). The Wall Thickening Of Tank Calculation The wall tank design has a cyclinder from (cylinder shell) which is in the above part of tank has a flat langed head form and the the below part of tank has a flat form. The material is made from stainless steel SS 316 (Shuler, 2002). The thickening of this wall can be calculated with this formula:

P value from the formula above can be also calculated from this formula: P (psig) = Poperasi (psia) + Static Pressure + Safety Factor From the above formula, we can calculate a storage tank design for HCL which the table can be showed below:

Table 4.4. Spesification Design Water Storage Tank Water Storage Tank Code Operation Methods Operation Temperature ( C) Pressure (atm) Volume (m3) Residence Time Design Temperature ( C) Pressure (atm) Volume (m3) Residence Time Dimention Height (m) Diameter (m) Thickness (mm) Materials Spesification 7,639 5,72 4,733 Stainless steel 316
0 0

Continous 27 1 198 24 27 1,69 196,88 24

4.2. Pump Mostly, a centrifugal pump is a valve which used in chemical processing and gas processing. This valve is used to flow a liquid with has a variation of property and suspension with has the highest suspended solid, for example is a cement slurry. Besides that, this valve can also use for a liquid with has the highest corrosivity. The advantage of this centrifugal pump are: Volume is relatively constant with the variation of pressure (head) Can be used for a liquid with the lowest flowrate and the highest pressure, so this pump, so this pump can also used to process in our casein plant which has a lowest flowrate. Has the great perform for the highest viscocity of fluid. Giving a Steady State Operation Has the smallest size Using for the smallest suspended solid. The sizing of this pump design which is used is the input power of feed. To calculate of pump design, we can use a bernaulli equation below:

From the equation above, Ws is the pump work to fluid. The input power of pump is not the same with its output power to the fluid. Because there is an efficiency factor of pump which a half of energy input losses to change with the heat. In this sizing, the efficiency factor of pump in our plant is 90%. The construction of centrifugal pump can look in this figure below:
Notes: 1. Delivery Line 2. Shaft line 3. Suction Line 4. Impeller 5. Pump Casing 6. Back Plate 7. Motor Shaft 8. Motor 9. Stainless Shroud and Sound Insulation

Figure 4.1. Main parts of centrifugal pump Sources: Dairy Processing Handbook

For the spesifaction for pump, can be looked in the table below. 4.2.1 The Pump 1 Table 4.2. Spesification Of Pump 1 4.2.2. The Pump 2 Table 4.3. Spesification Of Pump 2 4.2.3. The Pump 3 Table 4.4. Spesification Of Pump 3 4.3. Heat and Exchanger The heat exhanger in our plant is a gasketed plate heat exchanger (PHE). There is an assumption in the sizing of heat exchanger, such as:

 The heat input = the heat output, The operation is steady state. A gasketed plate heat exchanger consists of a stack of closely spaced thin plates clamped together in a frame. A thin gasket seals the plates around their edges. The plates are normally between 0.5 and 3mm thick, and the gap between them is 1.5 to 5 mm. Plate surface areas range from 0.03 to 1.5 m2, with a plate width:length ratio from 2.0 to 3.0. The size of plate heat exchangers can vary from very small, 0.03 m2, to very large, 1500m2. The maximum flow rate of fluid is limited to around 2500 m3/h. The basic layout and flow arrangement for a gasketed plate heat exchanger is shown in Figure 4.2. Corner ports in the plates direct the flow from plate to plate. The plates are embossed with a pattern of ridges, which increase the rigidity of the plate and improve the heat transfer performance. Plates are available in a wide range of metals and alloys, including stainless steel, aluminum, and titanium.

Figure 4.2. Gasketed Plate Heat Exchanger Source: Chemical Process Design

The advantages and disadvantages of plate heat exchangers, compared with conventional shell and tube exchangers, are as follows: Advantages 1. Plates are attractive when material costs are high. 2. Plate heat exchangers are easier to maintain. 3. Low approach temps can be used, as low as 18C, compared with 5 to 108 C for shell and tube exchangers. 4. Plate heat exchangers are more flexible; it is easy to add extra plates. 5. Plate heat exchangers are more suitable for highly viscous materials.

6. The temperature correction factor, Ft, will normally be higher with plate heat exchangers, as the flow is closer to true counter-current flow. 7. Fouling tends to be significantly less in plate heat exchangers; see Table 4.6. Table 4.6. Fouling Factor Coefficient For Heat Exchanger

Source: Chemical Engineering Principles

Disadvantages 1. A plate is not a good shape to resist pressure, and plate heat exchangers are not suitable for pressures greater than about 30 bar. 2. The selection of a suitable gasket is critical; see Table 4.7. Table 4.7. Suitable Gasket For Gasketed Plate Heat Exchanger

Source: Chemical Engineering Principles

3. The maximum operating temperature is limited to about 2500C, due to the performance of the available gasket materials. The design procedure is similar to that for shell and tube exchangers: 1 . Calculate duty, the rate of heat transfer required. 2 . If the specification is incomplete, determine the unknown fluid temperature or fluid flow rate from a heat balance. 3 . Calculate the log mean temperature difference, TLM. 4 . Determine the log mean temperature correction factor, Ft 5 . Calculate the corrected mean temperature difference TM = FT X TLM. 6 . Estimate the overall heat transfer coefficient

7 . Calculate the surface area required 8 . Determine the number of plates required total surface area/ area of one plate. 9 . Decide the flow arrangement and number of passes. 1 0 . Calculate the film heat transfer coefficients for each stream 1 1 . Calculate the overall coefficient, allowing for fouling factors. 1 2 . Compare the calculated with the assumed overall coefficient. If it is satisfactory, say -0 % to + 1 0 0 % error, proceed. If it is unsatisfactory, return to step 8 and increase or decrease the number of plates. 1 3 . Check the pressure drop for each stream. Estimation of the Temperature Correction Factor For plate heat exchangers, it is convenient to express the log mean temperature difference correction factor, Ft, as a function of the number of transfer units, NTU, and the flow arrangement. The correction will normally be higher for a plate heat exchanger than for a shell and tube exchanger operating with the same temperatures. For rough sizing purposes, the factor can be taken as 0.95 for series flow. The number of transfer units is given by:

where ti is stream inlet temperature (0C), t0 is stream outlet temperature (0C), and TLM is log mean temperature differences. Log mean temperature correction factor of PHE can be looked in the figure below:

Figure 4.3 Log Mean Temperature Coefficient For PHE Source: Chemical Process Design

Typically, the NTU will range from 0.5 to 4.0, and for most applications will lie between 2.0 to 3.0. Heat Transfer Coefficient The equation for forced-convective heat transfer in conduits can be used for plate heat exchangers; see equation 1 2 .1 0 . The values for the constant C and the indices a,b,c will depend on the particular type of plate being used. Typical values for turbulent flow are given in the following equation, which can be used to make a preliminary estimate of the area required:

where h p is plate film coefficient and Re is reynold number =

, w is

mass flow rate per channel, kg/ s, Gp is mass flow rate per unit cross sectional area = w/ A f, kg/ m 2 s, p is channel velocity, d e is equivalent hydraulic diameter, taken as the twice the gap between plates, m, and A f is cross sectional area for flow, m 2 . The corrugations on the plates will increase the projected plate area and reduce the effective gap between the plates. For rough sizing, where the actual plate design is not known, this increase can be neglected. The channel width equals the plate pitch minus the plate thickness. There is no heat transfer across the end plates, so the number of effective plates will be the total number of plates less two. Pressure Drop The plate pressure drop can be estimated using a form of the equation for flow in a conduit

where Lp is path length p is G p / . The value of the friction factor, jf, will depend on the design of the plate used. For preliminary calculations the following relationship can be used for turbulent flow:

The transition from laminar to turbulent flow will normally occur at a Reynolds number of 100 to 400, depending on the plate design.With some designs, turbulence can be achieved at very low Reynolds numbers, which makes plate heat exchangers very suitable for use with viscous fluids. The pressure drop due the contraction and expansion losses through

the ports in the plates must be added to the friction loss. Kumar (1984) suggests adding 1.3 velocity heads per pass, based on the velocity through the ports.

where p is the velocity through the port /Ap (m/s), and is mass flow through the port (kg/s), and Ap is area of the port = d2pt/4 (m2), dpt is port diameter (m), and Np is number of passes. Number of plates in GPHE can be calculated as: Number of Plates = Total Heat Transfer Area / Effective Are Of One Plate For the spesification heat excahnger in our plant can be looked in table below: Table 4.5. The Spesification Of Plate Heat Exchanger Heat Exchanger Type Gasketed Plated Heat Exchanger 26430,68 kW Duty 3688,17 m^2 Area Required 2,61 NTU 0,006 m Hydraulic Mean Diameter Countercurrent Floating Head Type Of Flow Superheated Steam 500 1 atm Heating Agent 0,94 Correction Factor Series flow n-pass-n-pass Flow Arragement 4900 Number Of Plates 0,75 m2 Effective Plate Area 1,5 m Effective Length 0,5 m Width 3 mm Plate Spacing Area 20,330C LMTD Embossing Pattern Plate Pattern Titanium 0,2% Materials Carbon Steel Frame Gasket Model Yes with rubber line Connection Plates

4.4. Centrifugal Decanter densitas skim milk = 1041 kg/m3, densitas hcl 1184 kg/m3 4.5. Fluidized Bed

ATTACHMENT A. Sizing Of Equipment HCL Storage Tank Operating Condition Inlet temperature Pressure Inlet flow rate Duration Of Storage Density, Safety factor = 27 OC = 300,15 K = 1 atm = 120,53 kg/jam = 1 hari = 24 jam = 770,6 kg/m3 = 20 %

a. Calculation Of Tank Capacity

b. Calculation Of Tank Dimention 1. Height and Diameter of Tank

Assuming that the ideal ratio between height and diameter of tank (D/H) is (Wallas, 1998). Maka, D = 3/4 H, so the height and diameter is (Gavin, 2008) :

So, the diameter of tank is (D) =

2. The Height Of Solute In Tank

3. Design Pressure

Atmospheric Pressure = 1 atm

Safety Factor = 5 % Design Pressure

4.

The Thickness Of Tank

Material Spessification : (brownell and young) Type Of Plate : carbon steel type SA 283 grade C

Recommendation Of Stress,S : 12650 psia Connecting Efficiency,Ej Corrotion Factor (c) R = D/2 = 0,32 in Static Pressure = 14,7 psia P (psig) = Poperasi (psia) + tekanan statis + faktor keamanan = 0 + 14,7 psia + 20 psia = 34,7 psia = 19,8 psig : 80 % = 0,8 : 0,15 in

So, the standard thickness of tank is 0,15 in

Plate Heat Exchanger Operation Condition Volume skim milk : 991039,33 kg/h Tin skim milk (T2) : 550

Tout skim milk (T1) : 780 Tin steam (t2) : 250 Tout steam (t1) : 500 c skim milk = 4 c water =4,2 1. Duty : Skim milk flow rate : 991039,33/3600 = 275,98 L/s v = m = 0,27598 * 1041 = 287,29 kg/s Q = m c T =287,29 x 4 x (23) = 26430,68 kW Water flow rate: = = 440,511 kg/s

2. Logaritmic Temperature Mean Difference (LMTD) TLM = 3. NTU NTU = (to-ti) / LMTD = (78-25) / 20,33 = 2,61 Try 2:2 pass arragement 4. Correction Factor From figure 12.4, Ft = 0,94 5. Area Required From table 2.2, take the overall coefficient, steam-viscous organic, to be 375 W/m20C, so the area will be : A= 6. Number of Plates: From the standard plate heat exchanger (Gavin,2008), effective plate area is 0,75 m2, effective length is 1,5 m and width is 0,5 m, so the number of plates is Number Of Plates (NOP) = 7. Number of Channel Per Mass Number of Channel Per Mass = (NOP-1)/2 = 2449,5 8. Channel Cross Sectional Area : An ideal plate spacing area is 3 mm (Gavin, 2008), so channel cross sectional area is : Channel Cross Sectional Area = Plate Spacing x width = 0,003 x 0,5 = 0,0015 m2. 9. Hydraulic Mean Diameter = 4917,570256 = 4900 = = 3688,17 m2

= 20,330C

Hydraulic Mean Diameter = 2 x plate spacing = 2 x 0,003 = 0,006 m. Water Storage Tank Operating Condition Inlet temperature Pressure Inlet flow rate Duration Of Storage Density, Safety factor = 27 OC = 300,15 K = 1 atm = 6836,45 kg/h = 1 day = 24 hour = 1000 kg/m3 = 20 %

a. Calculation Of Tank Capacity

b. Calculation Of Tank Dimention 1. Height and Diameter of Tank

Assuming that the ideal ratio between height and diameter of tank (D/H) is (Wallas, 1998). Maka, D = 3/4 H, so the height and diameter is (Gavin, 2008) :

So, the diameter of tank is (D) =

2. The Height Of Liquid In Tank

3. Design Pressure

Atmospheric Pressure = 1 atm

Safety Factor = 5 % Design Pressure

4. The Thickness Of Tank

Material Spessification : (brownell and young) Type Of Plate : stainless steel 316

Recommendation Of Stress,S : 76500 psia Connecting Efficiency,Ej Corrotion Factor (c) R = D/2 = 112,5 in : 80 % = 0,8 : 0,15 in

P (psig) = Poperasi (psia) + tekanan statis + faktor keamanan = 0 + 14,7 psia + 20 psia = 34,7 psia = 19,8 psig