Par15 Final Report

UNIVERSITAS INDONESIA
PRELIMINARY DESIGN OF PRODUCING BENZENE FROM

CATALYTIC FAST PYROLISIS OF EMPTY FRUIT
BUNCHES
Final Report
GROUP 15
GROUP PERSONNEL:
ANDIKAPUTRA B.W. (1406607893)
FARACITRA AKUWALIFAH (1406607861)
MUSTIKA SARASWATI (1406552906)
NADIRA KAMILIA PERMATASARI (1406607956)
NADYA SAARAH AMELINDA (1406552824)
CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
DEPOK
DECEMBER 2017
LIST OF GROUP MEMBERS
1. Name : Andikaputra Brahma Widiantoro

NPM : 1406607893
Date of Birth : Jakarta, 15th March 1995
Adress : Jl.Penggalang raya No 365 blok 3 bumi Bekasi baru
rawalumbu kota Bekasi 17114
2. Name : Faracitra Akuwalifah Kusumadewi
NPM : 1406607861
Date of Birth : Jakarta, 26th October 1996
Adress : Jalan K.S. Tubun IV No. 97 Slipi Palmerah Jakarta Barat
11410
3. Name : Mustika Saraswati
NPM : 1406552906
Date of Birth : Bogor,25th August 1996
Adress : Kp. Jembatan II RT02 RW07 No. 15 Citeureup Bogor
16810
4. Name : Nadira Kamilia Permatasari
NPM : 14066-7956
Date of Birth : Jakarta, 2nd January 1997
Adress : Jl. Way seputih 1/16, Komplek Pengairan, Tanjung
Duren, Jakarta 11470
5. Name : Nadya Saarah Amelinda
NPM : 1406552824
Date of Birth : Bogor, 30th September 1996
Adress : Jl. Bukit duri selatan no 4E
ii
Universitas Indonesia
PREFACE
Praise to God, The cherisher and sustainers of the worlds; God who has
been giving His blessing and mercy to the writer to complete this Final Report
entitled ― Preliminary Design Of Producing Benzene From Catalytic Fast
Pyrolisis Of Empty Fruit Bunches
This Final report is submitted to fulfill one of the requirements in
Chemical Plant Design Class as capstone course of Chemical Engineering Major
in Universitas Indonesia.
In finishing this report, the writer really gives his regards and thanks for people
who has given guidance and help, they are:
1. Prof. Dr. Ir. Widodo Wahyu Purwanto, DEA. , Dr. rer. nat. Ir. Yuswan
Muharam M.T. , Dr. Ing. Ir. Misri Gozan M.Tech., Dr. Tania Surya Utami,
S.T., M.T., and others lecturers, who has given their best guidance to the
writer in writing a great quality report and well developed chemical
product.  
2. Our Parents, who always give their supports, prayers, and blessing.  
3. All friends in Chemical Engineering Department batch 2014 who always
 give their supports.  
Finally, the writer realizes there are unintended errors in writing this final
 report. The writer really appreciates all readers giving their suggestion to
improve its content in order to be made as one of the good examples for the next
report.
Depok, December 2017
Writer Team
iii
ABSTRACT
Preliminary Design Of Producing Benzene From Fast Pyrolisis Of Empty
Fruit Bunches
Andikaputra Brahma Widiantoro, Faracitra Akuwalifah Kusumadewi, Mustika
Saraswati, Nadira Kamilia Permatasari, Nadya Saarah Amelinda
Chemical Engineering, Department of Chemical Engineering, Faculty of
Engineering, Universitas Indonesia
Benzene consumption in Indonesia is always increasing year by year.

However, the benzene supply in Indonesia is still not fill up the demand. As in
2016, the demand of benzene is about 620.587 ton. It gives potential to build
benzene plant. Empty Fruit Bunch is preferable as a raw material due to the high
production in Indonesia and high energy content in it. Catalytic fast pyrolysis
process in our plant gives high yield of benzene. This plant will be built in Teluk
Betung, Lampung with production capacity of 73,434.22 tons per year. Profit will
be gained in 4.06 years of operation with 20 years of life time and 12.23% IRR.
Keywords: benzene, empty fruit bunch, fast pyrolysis, fluidized catalytic

cracking
iv
EXECUTIVE SUMMARY
Benzene consumption in Indonesia is always increasing year by year.

However, the benzene supply in Indonesia is still not fill up the demand. As in
2016, the demand of benzene is about 620.587 ton. The supply is 291.597 per
year. This condition leads Indonesia to produce more benzene. One of these
options is producing benzene from biomass rather than from fossil resources.
Empty palm fruit is preferable because using palm biomass is often more
sustainable than using starch and oil crops. Compared to the fossil-based benzene,
the fossil resource inputs and CO2 emissions of biomass-based benzene are lower,
so based on those two parameters biomass-based product promises to be a
sustainable option.
To produce benzene, this plant will be located in Teluk Betung, Lampung.
We produce benzene through catalytic fast pyrolysis using zeolite as the catalyst
and fluidized bed reactor. The overall input and output of the mass and energy
should have had the exact value. Aspen Plus and Super Pro are used for
simulation. According to the simulation result, the mass efficiency of our plant is
28.9% and the energy efficiency is 81.603,63 kJ/kg
Heat Exchanger Network Analysis are tried to be developed but the
calculation on Cascade method shows that the result of the stream is only one tool
that produces a surplus while the rest is deficit then the HEN Analysis method can
not be applied in the calculation of the analysis because the surplus can not cover
the deficit. So that the heat used completely only for systems that can not be
recovered.
Utility is additional material or power from separated process to provide
required power or material in the main process. We have four units of utilities,
there are swater utility, air utiliy, electricity utility, and fuel utility. Water utility
is used as a make up process. Electricity is also needed to provide amount energy
in plant operations because in our plant, we have one equipment, pump, that need
electricity to operating. The need of electricity in our plant is about 40,176,338,4
kWh/ year. This electricity can we get from PT. PLN. The fuel utility need
v
natural gas for this plant is 2000 L/h. It can be obtained from IWATA Diesel
Generator which is produced by PT Indotara Persada.
Benzene is produced with certain specification to be raw material of in
many petrochemical industries in Indonesia. We use several types of equipment
for benzene production. There are 26 equipments. The types of equipment are
reactor, pump, distillation column, three phase separator, heat exchanger, grinder,
conveyor, cyclone, filter plate and also storage tank.
These equipment also needs instrumentation controls to maintain the
desired operating condition. This instrumentation controls some of variable of
plant production such as temperature, pressure, flow rate because mostly plant in
the world works in not steady state condition. On the other hand, this
instrumentation also makes our plant safely works for plant with high pressure
operating condition.
For benzene plant, Health, Safety, and Environment analysis are needed to
support our production process. First, there must be some commitments between
the workers and the management about health, safety, and environment on the
rules of production process following the Government Regulations. The
commitments are including the workers behavior and management rules. For
supporting HSE, HAZID and HAZOP are analyzed.
Through economic analysis, the feasibility of our plant is seen. The total
capital expenditure that is needed to fulfill all the equipment in the plant is USD
15,739,387.61. The operating expenditure to pay all the operational costs annually
is USD 32,830,334. The equity from our plant will be fulfilled by bank loan 60%,
investor 40%. The WACC that is calculated is 5.29%. The net value of benzene
product is US$1,050 per tons, with sales revenue US$ 20,711,947 annually. With
such revenue, the payback period is 4 years and Net Present Value is US$
27,820,660,309. The Rate of Interest for benzene plant is 12.23%.
vi
LIST OF CONTENTS
LIST OF GROUP MEMBERS ............................................................................ ii

PREFACE ............................................................................................................. iii
ABSTRACT .......................................................................................................... iv
EXECUTIVE SUMMARY ................................................................................... v
LIST OF CONTENTS ........................................................................................ vii
LIST OF FIGURES .............................................................................................. x
LIST OF TABLES ............................................................................................... xi
CHAPTER 1 INTRODUCTION ......................................................................... 1
1.1. Project Background ................................................................................... 1
1.2. Product Description (Benzene) ................................................................. 2
1.3. Analysis ..................................................................................................... 3
1.3.1. Raw Material Analysis ....................................................................... 3
1.3.2. Market Analysis .................................................................................. 4
1.3.3. Production Capacity Analysis ............................................................. 5
1.3.4. Location Analysis ............................................................................... 6
1.4. Project Objective ....................................................................................... 8
1.5. Key Challenges for The Project ................................................................ 8
CHAPTER 2 PROCESS SYNTHESIS ............................................................. 10
2.1. Process Selection..................................................................................... 10
2.1.1. Gasification ....................................................................................... 11
2.1.2. Fast Pyrolysis .................................................................................... 11
2.1.3. Catalytic Fast Pyrolysis .................................................................... 13
2.2. Selected Process ...................................................................................... 14
2.2.1. Pre-Treatment ................................................................................... 15
2.2.2. Primary Pyrolysis.............................................................................. 17
2.2.3. Catalytic Cracking ............................................................................ 19
2.2.4. Benzene Recovery (Separation) ....................................................... 21
2.3. Block Flow Diagram ............................................................................... 23
2.4. Process Flow Diagram ............................................................................ 24
2.4.1. Pre-Treatment ................................................................................... 24
2.4.2. Main Process ..................................................................................... 25
2.5. Mass and Energy Balance ....................................................................... 26
2.5.1. Overall Mass Balances ..................................................................... 26
2.5.2. Overall Energy Balance .................................................................... 26
2.6. Plant Efficiency ....................................................................................... 26
2.7. Heat Exchanger Network (HEN) ............................................................ 27
2.7.1. Steram Classification ........................................................................ 27
2.7.2. Heat Recovery Pinch Method ........................................................... 28
2.7.3. Pinch Design Method ....................................................................... 30
CHAPTER 3 EQUIPMENT DESIGN .............................................................. 32
3.1. Reactor .................................................................................................... 32
vii
3.1.1. Fast Pyrolysis Reactor ...................................................................... 32
3.1.2. Hydrolysis Reactor ........................................................................... 32
3.1.3. Catalyst Regenerator ......................................................................... 33
3.2. Storage Tank ........................................................................................... 33
3.2.1. Biomass Warehouse.......................................................................... 33
3.2.2. Benzene Tank ................................................................................... 34
3.2.3. Demine Water Tank .......................................................................... 34
3.2.4. Coagulant Tank ................................................................................. 35
3.2.5. Filtration Tank .................................................................................. 36
3.2.6. Ion Exchanger Tank .......................................................................... 36
3.3. Heat Exchanger ....................................................................................... 37
3.3.1. Heat Exchanger (E-100) ................................................................... 37
3.3.2. Heat Exchanger (E-101) ................................................................... 38
3.3.3. Heat Exchanger (H-100) ................................................................... 39
3.4. Distillation ............................................................................................... 40
3.4.1. Distillation Column .......................................................................... 40
3.5. Three Phase Separator ............................................................................. 41
3.6. Conveyor ................................................................................................. 42
3.6.1. Elevator Conveyor ............................................................................ 42
3.6.2. Belt Conveyor ................................................................................... 42
3.7. Hammer Mills ......................................................................................... 43
3.8. Filter Plate & Frame ................................................................................ 43
3.9. Cyclone ................................................................................................... 44
3.9.1. Cyclone (Cy-100) ............................................................................. 44
3.9.2. Cyclone (Cy-101) ............................................................................. 45
3.10. Flue Gas Compressor (C-100) ................................................................ 46
3.11. Pump ....................................................................................................... 46
3.11.2. Water Pump (P-102) ....................................................................... 47
3.11.3. Water Pump (P-103) ....................................................................... 47
CHAPTER 4 PROCESS CONTROL STRATEGY ........................................ 49
4.1. Plant Control Tabulation ......................................................................... 50
4.2. Piping and Instrumentation Diagram   ................................................. 53
4.2.1. Pre-Treatment ................................................................................... 53
4.2.2. Main Process ..................................................................................... 54
CHAPTER 5 PLANT LAYOUT ....................................................................... 55
5.1. Area Plant Layout ................................................................................... 55
5.1.1 Outside Battery Limit Zone .............................................................. 57
5.1.2. Total Factory Layout ........................................................................... 57
CHAPTER 6 ............................................................................................................
HEALTH AND ENVIRONMENTAL SAFETY ASSESSMENT .................. 61
6.1. HSE Aspect ............................................................................................. 61
6.1.1. Hazard Identification (HAZID)........................................................... 61
6.1.2. Hazard and Operation Safety ............................................................ 62
6.2. HSE Management ................................................................................... 62
6.2.1. Operation Details .............................................................................. 62
6.2.2. Personal Protective Equipment (PPE) .............................................. 66
viii
6.3. Material Safety Data Sheet (MSDS) ....................................................... 66
6.4. Emergency Action Plan .......................................................................... 68
6.4.1. Emergency Operating Procedures and Training ............................... 68
6.4.2. Emergency Alarm and Fire Fighting Equipment .............................. 70
6.4.3. Emergency Escape Procedures and Route ........................................ 71
6.6. Waste Management ................................................................................. 72
6.6.1. Solid Waste ........................................................................................ 72
6.6.2. Liquid Waste ...................................................................................... 73
6.6.3. Gas Waste........................................................................................... 73
6.6.4. Sound (Noise) Waste.......................................................................... 73
CHAPTER 7 ECONOMIC ANALYSIS ........................................................... 75
7.1 Cost Index ............................................................................................... 75
7.1.2. Capital Expenditure (CAPEX) ......................................................... 76
7.1.3 Comparison with Existing Plant ........................................................ 80
7.2. Operating Cost ........................................................................................ 80
7.2.1 Raw Material Cost ............................................................................. 80
7.2.2. Labor Cost ........................................................................................ 82
7.2.3. Utility Cost........................................................................................ 84
7.2.4. Maintenance Cost ............................................................................. 86
7.2.5. Insurance and Tax ............................................................................. 87
7.2.6 General Expense ................................................................................ 90
7.2.7. Cost Breakdown of Operational Expenses ...................................... 91
7.3. Economic Evaluation .............................................................................. 92
7.3.1. Price Prediction ................................................................................. 92
7.3.2. Cash Flow ......................................................................................... 93
7.3.2.1. Equity ............................................................................................... 93
7.3.3. Profitability Analysis ........................................................................ 96
CHAPTER 8 OUSTANDING ISSUE ............................................................. 102
8.1 Technical Aspect ................................................................................. 102
8.2 Economical Aspect.............................................................................. 104
CHAPTER 9 CONCLUSION .......................................................................... 105
APPENDICES ................................................................................................... 106
APPENDIX A: BLOCK FLOW DIAGRAM ................................................. 106
APPENDIX B : PROCESS FLOW DIAGRAM ............................................ 107
APPENDIX C : LIST OF EQUIPMENT SIZING ......................................... 109
APPENDIX D : PLANT LAYOUT AND HSE ............................................. 165
APPENDIX E : MATERIAL SAFETY DATA SHEET (MSDS).................. 182
APPENDIX F : PROJECT COST .................................................................. 220
ix
LIST OF FIGURES
Figure 1. 1. Benzene Structure ................................................................................ 2

Figure 1. 2. Location of Teluk Betung Industrial Area ........................................... 6
Figure 1. 3. Location of South Teluk Betung Industrial Area ................................ 8
Figure 2. 1. Conversion Technologies for Biomass .............................................. 10
Figure 2. 2. Biomass Gasifier Technology............................................................ 11
Figure 2. 3. Typical product weight yields (dry wood basis) obtained by different
modes of pyrolysis of wood. ................................................................................. 13
Figure 2. 4. Biomass Production ........................................................................... 13
Figure 2. 5. Technical Approach: CFP Process Design Options .......................... 14
Figure 2. 6. Benzene process ................................................................................ 15
Figure 2. 7. Pathway from Lignin to Benzene ...................................................... 15
Figure 2. 8. Catalytic reaction route for the convention of pyrolysis vapors with
Zeolit catalyst. ....................................................................................................... 18
Figure 2. 9. Fluidized bed reactor for CFP............................................................ 19
Figure 2. 10. Process Block Flow Diagrams of in situ CFP and ex situ CFP. ...... 19
Figure 2. 11. Reaction Pathway of Lignin Non-Catalytic/Catalytic Fast Pyrolysis.
............................................................................................................................... 20
Figure 2. 12. Aromatic selectivity from CFP of glucose over different zeolites. . 21
Figure 2. 13. Example of Benzene Production Distillation. ................................. 22
Figure 2. 14. Block Flow Diagram ....................................................................... 23
.Figure 2. 15. Process Flow Diagram for Pre-Treatment ...................................... 24
Figure 2. 16. Process Flow Diagram for Main Process ........................................ 25
Figure 2. 17. Pinch Design .................................................................................... 31
Figure 3. 1. Cyclone V-102 ................................................................................... 45
Figure 3. 2 Cyclone V-102 .................................................................................... 46
Figure 5. 1 Outside Battery Limit Values ............................................................. 55
Figure 5. 2. Inside Battery Limit Values ............................................................... 56
Figure 5. 3. Battery Limit Between Storage Tanks and Vessels ........................... 56
Figure 5. 4. Area Plant Layout .............................................................................. 58
Figure 5. 5. Equipment Plant Layout .................................................................... 59
Figure 6. 1 NFPA Guidelines ................................................................................ 67
Figure 6. 2 Explanation of NFPA ......................................................................... 68
Figure 6. 3 Evacuation Route ................................................................................ 72
Figure 7. 1 Cost Index ........................................................................................... 75
Figure 7. 2. TCI Breakdown ................................................................................. 79
Figure 7. 3 Cost Breakdown of Operational Expenses ......................................... 91
Figure 7. 4 Benzene Price History ........................................................................ 92
Figure 7. 5 The Influence of Fluctuations on NPV ............................................. 100
Figure 7. 6 The Influence of Fluctuations on IRR .............................................. 101
Figure 7. 7 The Influence of Fluctuations on Payback Period ............................ 101
Figure 8. 1. PT Trans Pacific Petrochemical benzene plant Plant Diagram ........... 103
x
LIST OF TABLES
Table 1. 1. Benzene demand in 2009-2022. ............................................................ 4

Table 1. 2. Benzene supply in 2009-2022. .............................................................. 5
Table 1. 3. Product Capacity. .................................................................................. 6
Table 2. 1. Comparison of Benzene Production Processes. .................................. 14
Table 2. 2. Comparison of Pretreatment Method .................................................. 16
Table 2. 3. Comparison of Pretreatment Method (Cont’d) ................................... 16
Table 2. 4. Operating Condition (Grinder)............................................................ 17
Table 2. 5. Overall Mass Balance ......................................................................... 26
Table 2. 6. Overall Energy Balance ...................................................................... 26
Table 2. 7. Benzene Plant Stream Classification .................................................. 27
Table 2. 8. Stream Temperature Condition ........................................................... 28
Table 2. 9. Temperature Interval Heat Balance .................................................... 29
Table 2. 10. Hot and Cold Fluid Program Table Cascade .................................... 30
Table 3. 1. Fast Pyrolysis Reactor Specification .................................................. 32
Table 3. 2. Hydrolysis Reactor Specification........................................................ 32
Table 3. 3.. Catalyst Regenerator Specification .................................................... 33
Table 3. 4.. Biomass Warehouse Specification .................................................... 33
Table 3. 5. Benzene Storage Tank Specification .................................................. 34
Table 3. 6. Specification of Storage Tank for Demineralize Water ...................... 34
Table 3. 7. Specification of Coagulant Tank......................................................... 35
Table 3. 8. Filtration Tank Spesification ............................................................... 36
Table 3. 9. Ion Exchanger Tank Spesification ...................................................... 37
Table 3. 10. Heat Exchanger Specification ........................................................... 37
Table 3. 13. Distillation Column Specification..................................................... 40
Table 3. 14. Three Phase Separator Specification................................................. 41
Table 3. 15. Elevator Conveyor Specification ...................................................... 42
Table 3. 16. Belt Conveyor Specification ............................................................. 42
Table 3. 17. Hammer Mills Specification ............................................................. 43
Table 3. 18. Filter Plate & Frame .......................................................................... 43
Table 3. 19. Cyclone Specification ....................................................................... 44
Table 3. 20. Cyclone Specification ....................................................................... 45
Table 3. 21. Flue Gas Compressor Specification .................................................. 46
Table 3. 22. Screw Pump (P-101) Specification ................................................... 46
Table 3. 23. Water Pump (P-102) Specification ................................................... 47
Table 3. 24. Water Pump (P-103) Specification ................................................... 47
Table 4. 1. Control Details .................................................................................... 50
Table 6. 1 HAZID Parameters in Considering Hazard Effect .............................. 61
Table 6. 2 HAZID Parameters in Hazard Frequency (Level of Hazard Possibility)
............................................................................................................................... 62
Table 7. 1 Cost Index from 2017 to 2022 ............................................................. 76
Table 7. 2. Components of Total Capital Investment (TCI) ................................. 77
Table 7. 3. Total Capital Investment ..................................................................... 77
Table 7. 4. Comparison with Existing Plant ......................................................... 80
xi
Table 7. 5. Raw Material Costs ............................................................................ 81
Table 7. 6. Direct Labor Cost ................................................................................ 82
Table 7. 7. Indirect Labor Cost ............................................................................. 82
Table 7. 8. Process Equipment Electricity ............................................................ 84
Table 7. 9. Supporting Electricity Requirement.................................................... 85
Table 7. 10. Water Utility Cost ............................................................................. 86
Table 7. 11. Fuel Utility Cost ................................................................................ 86
Table 7. 12. Maintenance Cost.............................................................................. 86
Table 7. 13. Insurance Cost ................................................................................... 87
Table 7. 14. Tax of Land & Building .................................................................... 87
Table 7. 15. Tax of Salary ..................................................................................... 88
Table 7. 16. Tax of Salary (continued) ................................................................. 89
Table 7. 17. Communication Cost......................................................................... 90
Table 7. 18. Product Shipping Cost ...................................................................... 90
Table 7. 19. Plant Overhead .................................................................................. 90
Table 7. 20. Printed Media Publication Cost ........................................................ 90
Table 7. 21. Website Development Cost............................................................... 90
Table 7. 22. Cost Breakdown ................................................................................ 91
Table 7. 23 Benzene Price History........................................................................ 93
Table 7. 24 Capital Loan ....................................................................................... 94
Table 7. 25. Bank Payment Scheme...................................................................... 94
Table 7. 26 Investment Payment Scheme ............................................................. 94
Table 7. 27. Overall Loan ..................................................................................... 95
Table 8. 1. Product Capacity Benchmarking of our Plant .................................. 103
Table 8. 2. Economical Benchmarking ............................................................... 104
xii
CHAPTER 1
INTRODUCTION
1.1. Project Background

Energy is one of the important factors for the life of human kind; it is a
driving force for the development. The growth of the world energy consumption
in the last two decades has been amazing.
However, the source of energy to fulfill such consumption mainly relies
on non-renewable fossil fuels with world reserve capacities decreasing
continuously. The dependence of humans on fossil resources is not limited to fuel
needs. A significant amount of petroleum feedstock is also used to produce
materials, from pharmaceuticals and plastics to asphalt for roads.
Efforts have been made to conserve the fossil fuel by looking for
renewable natural resources, such as biomass. There are many sources of biomass,
from plantation residue to the organic waste from daily life activities. In
Indonesia, the available and already collected biomass is palm empty fruit bunch.
Benzene is the starting point for many derivatives required in the
production of a wide range of goods used in everyday life. Their major
downstream products are plastics, but they are also used for solvents, additives,
and other chemicals. Based on the environmental impacts over the lifecycle of
benzene production, the fossil resource depletion and greenhouse gas emissions
make the largest impact on the environment. Because of this, it’s important to
look for more sustainable options for benzene production.
In addition, PT. Trans Pacific Petrochemical Indotama (TPPI), which was
founded in 1993, is the only petrochemical industry in Indonesia, only produce
400,000 ton of benzene per year (Chandra-Asri Petrochemicals, 2016). However,
the supply of benzene in Indonesia cannot fulfill the demand itself. With this
condition, Indonesia needs to import benzene more than 321,517 ton per year to
cover the deficiency. The figure below will show the number of import of
petroleum fuels in Indonesia.
One of these options is producing benzene from biomass rather than from
fossil resources. Palm biomass is preferable because using palm biomass is often
1
2
more sustainable than using starch and oil crops. Compared to the fossil-based
benzene, the fossil resource inputs and CO2 emissions of biomass-based benzene
are lower, so based on those two parameters biomass-based product promises to
be a sustainable option.
1.2. Product Description (Benzene)
Benzene is a hydrocarbon compound with the formula C6H6 molecule, and
its structural formula is a cyclic chain with double bonds of alternating tubes. The
position of the double bond on this carbon compound can move position. This
event is called double bond resonance. Due to the position of this uncertain
double bond, the compound is finally described as a circular specimen. The
double bonds found in benzene are called conjugated double bonds. Such a
structure was first introduced by Kekule. Compounds containing benzene rings
are known by the name of aromatic compounds. Aromatic compounds can contain
one, two, three, or more benzene rings.
Figure 1. 1. Benzene Structure

(Source: Encyclopedia Britannica, Inc, 2017)
The presence of a conjugated double bond (intercellular) on benzene,
making this hydrocarbon compound as a relatively stable and characteristic
molecule. The stability of benzene is shown by the slow reaction of the benzene
with the halogen.
In homes, benzene may be found in glues, adhesives, cleaning products,
paint strippers, tobacco smoke and gasoline. Most benzene in the environment
comes from our use of petroleum products.
This product will be a biomass-based benzene. Biomass-based benzene is
very potential in Indonesia because of the availability of the biomass as its raw
material. This is the advantages of biomass-based benzene production such as by
3
using biomass as the feedstock in benzene production, it can lower demand for
diminishing crude oil supplies, lignocellulosic feedstock has crucial advantages
over other biomass supplies because they are non-edible portion of the plant and
therefore, they don’t interfere with food supplies. Also, developing country like
Indonesia has a comparative advantage for biomass-based production because of
greater availability of land, favorable climatic conditions for agriculture and lower
labor costs. Then, use of biomass as feedstock can reduces CO2 emissions, crop
residues conversion increases the value of agricultural output, replacing fossil-
based benzene with sustainable biomass-based benzene, and costs of getting rid of
municipal solid wastes.
1.3. Analysis
1.3.1. Raw Material Analysis
The main raw material of benzene plant is from biomass. Biomass is a
photosynthetic reaction product of carbon dioxide and water, which consists of
carbon, oxygen, and hydrogen, which are in the form of macroscobsic polymeric
complex.
Raw material to be used in this plant or process is empty fruit bunch. The
need of the raw material is based on lignin contained. Empty Fruit Bunch have
higher Lignin contained than others lignocellulosic biomass. Lignin is the
compound that will be process into BTX then will be distilled into Benzene. The
lignin composition in Rice Husk is also high, but it has a very high ash, which is
not good for production. It will have a problem in the yield of Benzene itself.
The second thought is the waste availability and the waste usage. Empty
Fruit Bunch waste is lower than others lignocellulosic biomass. Also, there are a
lot of Palm Oil Industry in Indonesia; however, they don’t use the empty fruit
bunches So the empty fruit bunch are disposed as wastes. As the effect of
agricultural country, Indonesia has so many potentials to produce palm.
Based on the data, Indonesia has total 11,300,370 hectares of Palm Land in
Indonesia, and 31,284,306 ton of Total Production in 2016.
To provide our raw material, empty fruit bunch from industries that use
palm as their raw material. Empty fruit bunch have been bought from PT Bangun
4
Tata Lampung Asri, PT Adikarya Gemilang, and PT Bangun Nusa Cipta Wahana
that is located in Teluk Betung Selatan, Bandar Lampung.
1.3.2. Market Analysis
It is a well-known fact that the human population is increasing. With that
increase, the demand for chemicals, solvents and medicines is also increasing.
This demand must be met, meaning amplification in the production of chemicals,
which are required for the manufacturing of these products, is essential. Here is a
table that describes the level of fuel needs in the period 2009-2022.
Table 1. 1. Benzene Demand in 2009-2022.
Years Benzene Demand (In ton)
2009 487872
2010 470316
2011 486007
2012 546517
2013 563709
2014 582668
2015 601628
2016 620587
2017 639546
2018 658505
2019 677465
2020 696424
2021 715383
2022 734342
(Source: Ministry of Industry Indonesia, 2014)
From central statistical agency, the production of benzene in Indonesia
will increase in 2016, 2018, 2022 and 2025. In 2016, began to occur due to the
addition of biofuel production. Then, the benzene supply will increase in 2018 is
due to new benzene producers. Here are the details of biomass-based benzene
production for the period 2009-2022.
5
Table 1. 2. Benzene Supply in 2009-2022.
Years Benzene Supply (In ton)
2009 324689
2010 317522
2011 335986
2012 333558
2013 192322
2014 225414
2015 258506
2016 291597
2017 324689
2018 357781
2019 390873
2020 423964
2021 457056
2022 490148
(Source: Ministry of Industry Indonesia, 2014)
1.3.3. Production Capacity Analysis

The petrochemical industry becomes one of the strategic industries both in
terms of its position in the structure of Gross Domestic Product (GDP) of
manufacturing industry and in the context of linkages with other downstream
industries such as plastics, synthetic fibers, synthetic rubber, cosmetics, fertilizers,
textiles, and others. On the other hand, the potential sources of non-renewable fuel
replacement raw materials are already emerging, especially biomass sources. but
the processing of benzene from biomass itself in Indonesia is still relatively not so
significant therefore the supply of benzene must be increased considering the
demand for benzene increase every year. Here are the calculations for the
production capacity based on demand of benzene in Indonesia.
Therefore, to determine the capacity of benzene production, a market share
of 15% are taken from the demand of benzene. Reference of benzene production
capacity is at 2022 Thus, benzene production capacity as follows.
𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = (max 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑖𝑛 2022) × 10%
𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = (734342 𝑇𝑜𝑛𝑛𝑒/𝑌𝑒𝑎𝑟) × 10%
6
Table 1. 3. Product Capacity.
Working Time 330 Day

15% of Demand 333.791932 tonne/day
Production Capacity 110151.338 tonne/year
Based on calculations that have been done, a production capacity is
73434.225 tonne/year.
1.3.4. Location Analysis
The best location of a plant is the location where the unit cost of
production and distribution process will be low, while the price and volume of
sales of benzene products will be able to generate maximum profits for the
company.
Figure 1. 2. Location of Teluk Betung Industrial Area

(Source: Lampung Post, 2017)
Plant site selection is one of the main factors that determine the success
and survival of a plant. Therefore the plant is builded in Teluk betung, Bandar
Lampung. This is based on some factors, those are:
 Communication and electricity infrastructure
In Teluk Betung of Bandar Lampung, the area already has an industry then the
infrastructure and communications are available.
 Transportation
Transportation infrastructure in Teluk Betung has been licensed by the
industrial office of Lampung city. Facilities and infrastructure such as
provincial road, village road and alley, concrete bridge, steel bridge are
available.
7
 Availability of raw material (biomass and water)

The raw material of empty fruit bunch derived from waste PT. Tunas Baru
Lampung Tbk, which owns a subsidiary of PT Bangun Tata Lampung Asri, PT
Bangun Nusa Indah Lampung, PT Adikarya Gemilang who process oil palm
into cooking oil. based on the company's production capacity of 900,000 MT /
year, the company can supply the waste of coconut empty bunches in
accordance with our factory requirement of 2,210 Ton / year.
 The availability of water is very potential in the bay area because there is river
way kuala and for the availability of clean water can be supplied from PDAM
way rilau.
 Government policy
Specified location for the construction of this plant is in the industrial area.
Therefore, permits the establishment of the industry has been owned by the
manager of the industrial area.
 Physical Aspects of Locations
Based on research Bandar Lampung lies at an altitude of 0-700 mdpl with a flat
area until the ramps reach 60% ramps up 35% incline, and very sloping up to
steep 4%.
Bandar Lampung includes a wet tropical climate. The maximum air
temperature averaged 30.57ºC, maximum humidity averaged 89.34%, an average
intensity of irradiation 0.25 hours with an average wind speed of 2.34 km / h and
an average evaporation of 3.95 mm /day. High rainfall of 20 (> 100mm / month)
occurs during November-May and dry season (CH <100 mm / month) occurs
during June-October.
Based on these criteria, it can be concluded that the area of Teluk Betung
is the most strategic location. This is the picture shows the location of our plant.
8
Figure 1. 3. Location of South Teluk Betung Industrial Area

(Source: Google Earth, 2017)
The industrial location is on South Teluk betung and its coordinates in
5.45° "S, 105.31° "E. the industrial site is still in progress to be opened in early
2018. Until now, the current location is still used as a plantation crops.
1.4. Project Objective
The Objectives of this project are as follow.
1. This project has some objectives which are
2. Produce ethylene from bioethanol that available in Indonesia  
3. Making Indonesia one of big of benzene producent in the world  
4. Participate actively in reducing biomass waste in the world in order to save
 global environment  
5. To produce a commodity to fulfill the  needs of benzene in Indonesia  
1.5. Key Challenges for The Project
Benzene is commodity that has large gap between its demand and spply in
Indonesia. This happen because Indonesia doesn‘t have a lot of benzene plant.
However, the demand of ethylene is very high and that‘s become our chance to
fulfill the gap. Consequently, it‘s a challenge for us to compete with other
countries in order to produce a good ethylene either by its quality and quantity.
This can be done by using the high quality of raw material and high technology of
manufacturing process.
9
Furthermore it is big challenge to apply the biomass from empty fruit

bunch project in this plant. Even though there has been case studies regarding the
feasibility of applying this project in Indonesia, it can not ensure its successively
to be applied. In order to overcome this challenge, further research is needed for
this project and also obtain government‘s support in every aspect so that this
project will give profit to all parties in Indonesia.
CHAPTER 2
PROCESS SYNTHESIS
2.1. Process Selection
To determine the process that will be use, it is essential to know the basic
concepts of Benzene production from Biomass. Biomass can be converted into
different form such as Fuels, Power and Chemicals.
The three principal methods of conversion are combustion in excess air,
gasification in reduced air, and pyrolysis in the absence of air. Nowadays, the
most popular methods to process the Biomass to become Aromatics is Pyrolysis.
Pyrolysis technologies are generally categorized as “fast” or “slow” according to
the time taken for processing the feed into pyrolysis products.
Figure 2. 1. Conversion Technologies for Biomass

(Source : Energy Asia, 2010)
There are several factors that give effect to selectivity of Process. The
reaction conditions and catalyst properties are critical in maximizing the desired
product selectivity. Therefore, it is important to select a catalyst with proper
hydrogenation activity to obtain the highest yield of Benzene. There are plenty of
process alternative from each of steps in the processing Biomass into Benzene.
The process selection is then will be analyzed using heuristic approach and the
scoring method.
10 Universitas Indonesia
11
2.1.1. Gasification
Biomass gasification is a process of converting solid biomass fuel into a
gaseous combustible gas (called producer gas) through a sequence of thermo-
chemical reactions. The gas is a low-heating value fuel, with a calorific value
between 1000- 1200 kcal/Nm3 (kilo calorie per normal cubic meter). Almost 2.5-
3.0 Nm3 of gas can be obtained through gasification of about 1 kg of air-dried
biomass. Since the 1980's the research in biomass gasification has significantly
increased in developing countries, as they aim to achieve energy security.
The Gasifier technology has been customized for a range of direct-heat
application and tested successfully in the field. Silk processing, large-cardamom
drying and gasifier-based crematoria are a few examples of the applications. This
technology is slowly replacing both traditional biomass use and gas-powered
systems, as it provides an excellent de-centralized source of energy at an
affordable cost. There are two main types of biomass gasifier:
Figure 2. 2. Biomass Gasifier Technology

(Source: Biomass Gasifier Technology, 2010)
2.1.2. Fast Pyrolysis

Pyrolysis is thermal decomposition occurring in the absence of oxygen.
High temperatures and longer residence times increase biomass conversion to gas,
12
and moderate temperatures and short vapour residence time are optimum for
producing liquids. Fast pyrolysis for liquids production is currently of particular
interest as the liquid can be stored and transported, and used for energy, chemicals
or as an energy carrier In fast pyrolysis, biomass decomposes very quickly to
generate mostly vapours and aerosols and some charcoal and gas.
A high yield of liquid is obtained with most biomass feeds low in ash. The
essential features of a fast pyrolysis process for producing liquids are:
1. Very high heating rates and very high heat transfer rates at the biomass
particle reaction interface usually require a finely ground biomass feed of
typically less than 3 mm as biomass generally has a low thermal conductivity,
2. Carefully controlled pyrolysis reaction temperature of around 500 C to
maximize the liquid yield for most biomass,
3. Short hot vapor residence times of typically less than 2 s to minimize
secondary reactions,
4. Rapid removal of product char to minimize cracking of vapors,
5. Rapid cooling of the pyrolysis vapors to give the bio-oil product.
As fast pyrolysis for liquids occurs in a few seconds or less, heat and mass
transfer processes and phase transition phenomena, as well as chemical reaction
kinetics, play important roles.
Liquid yield depends on biomass type, temperature, hot vapor residence
time, char separation, and biomass ash content, the last two having a catalytic
effect on vapor cracking. A fast pyrolysis process includes drying the feed to
typically less than 10% water. Fast pyrolysis liquid has a higher heating value of
about 17 MJ/kg as produced with about 25 wt.% water that cannot readily be
separated.
13
Figure 2. 3. Typical product weight yields (dry wood basis) obtained by different modes of
pyrolysis of wood.
(Source : Ramey David et al., 2010)
Figure 2. 4. Biomass Production

(Source : Ramey David et al., 2010)
2.1.3. Catalytic Fast Pyrolysis

Catalytic fast pyrolysis (CFP) is a promising method for the direct
conversion of solid biomass into gasoline range aromatic products. CFP involves
the pyrolysis of biomass in the presence of zeolites. In the first step of this
reaction, the solid biomass is rapidly heated (>500 °C) to intermediate
temperatures (400-600°C). At these high temperatures, the biomass readily
decomposes into pyrolysis vapors. These pyrolysis vapors then enter into the
zeolite catalyst pores where they are converted into aromatics, CO, CO2, and
H2O. One advantage of CFP is that solid biomass is directly converted into liquid
aromatic fuel in a single reactor with short residence times without the need for
additional upgrading steps. Hence, conversion is rapid, continuous and
uncomplicated.
14
Figure 2. 5. Technical Approach: CFP Process Design Options

(Source: Biomass Gasifier Technology, 2010)
Catalytic fast pyrolysis of pine wood saw dust and furan (a model biomass
compound) with ZSM-5 based catalysts was studied with three different reactors:
a bench scale bubbling fluidized bed reactor, a fixed bed reactor and a semi-batch
pyroprobe reactor. The highest aromatic yield from sawdust of 14 % carbon in the
fluidized bed reactor was obtained at low biomass weight hourly space velocities
(less than 0.5 hr-1 hour) and high temperature (600 oC). The aromatic product
consists mainly of benzene (24.8 % carbon), toluene (34.1% carbon), xylene
(15.4% carbon) and naphthalene (14.9 % carbon).
Table 2. 1. Comparison of Benzene Production Processes.

Catalytic Fast
No Criteria Gasification Fast Pyrolysis
Pyrolisis
0.32 kg/100 kg of 0.77 kg/100 kg of 2.65 kg/100 kg
1 Product Yield
dry biomass dry biomass of dry biomass
Compositions of
2 Aromatic 5.50wt% 7.62wt% 14.8 wt %
Hydrocarbon
Operating Condition
3 750-900°C 500°C 500-600°c
Sustainability
4 Time of Process 1 hour 2 hour 0,5 – 1 hour
Fluidized bed Fluidized bed
fluidized bed
6 Reactor (Bubbling, (Bubbling,
reactor
circulating, dual) Spouted)
From the comparison process in Table above, the best process in terms
Product Yield, Compositions of Aromatic Hydrocarbon, Operating Condition
Sustainability, and Time of Process in the process of production of benzene plant
is the process of Catalytic Fast Pyrolisis process.
2.2. Selected Process
Catalytic fast pyrolysis is used to produce benzene.
15
Primary Catalytic
Pre-Treatment Separation
Pyrolisis Cracking
Figure 2. 6. Benzene process

(Source : Cheng et al., 2010)
The diagram will be the base for synthesis design. Basically, there are
several steps to convert biomass into benzene. These steps are Pre-Treatment,
Pyrolysis, Catalytic cracking and separation. The pathway of this process are
shown in the figure below.
Figure 2. 7. Pathway from Lignin to Benzene

In general, the process steps to reach our target 36717.1125-ton
benzene/year production synthesis is as follows.
2.2.1. Pre-Treatment
Pre-treatment is a process before the main treatment, to change the form of
biomass so it can be more manageable in the process. Pre-treatment is the process
by which surface area of the feedstock is opened up for the subsequent enzymatic
attack. In the absence of pretreatment, the requirement for cellulose enzymes is
too high to be practical.
There are three ways to pretreat the biomass itself. There are chemical,
biological, and physical. For chemical method, they use concentrated acid such as
H2SO4 and HCL. This acid will be separated glucose from lignocellulose that is in
the corn cobs well. However, this chemical method is very dangerous or
hazardous. Based on Heuristic 1 in Seider, raw materials and chemical reaction
are selected that will avoid the handling and storage of hazardous and toxic
chemicals.
16
Table 2. 2. Comparison of Pretreatment Method
Pre-Treatment Advantage Disadvantage
 Separate glucose from

 Toxic and hazardous
Chemical the lignocellulose well
 Expensive anti-
 Low temperature and
corrosive tanks
pressure
(Source: BioRefineries-Industrial Process and Design, 2013)
Table 2. 3. Comparison of Pretreatment Method (Cont’d)
Pre-Treatment Advantage Disadvantage
 Produce the low of

Biological  Destroy Lignin
cellulose
structure well
 Slow process
 Low temperature and
Physical pressure
 Cheaper than chemical
 Easy to implement
(Source: BioRefineries-Industrial Process and Design, 2013)
The other method is biological method. This method includes the
microorganism or enzyme. The research said that the existence of microorganism
will destroy the lignin structure; however, the reaction will also inhibit the
cellulose to be removed from the biomass.
The last method is physical; this method is to reduce the size of the
lignocellulose or the biomass. This method includes chipping, grinding, and
milling. For chipping the size of the biomass will be reduced until 10-30 mm and
for milling or grinding the particles size will be reduced until 0.2-2 mm. As
general, if the particle size is small, the mechanism of enzyme reaction or
microorganism will be better. This method is also cheap and not harmful and fast.
Based on this analysis that choosen, the grinding method as a pretreatment
of our raw materials. Benzene production process begins with the grinding of
Empty palm fruit bunch. Grinding is a unit operation design to break a solid
material into smaller pieces. The grinding of solid occurs under exposure of
mechanical forces hat trench the structure by overcoming of the interior bonding
forces. After the grinding the state of the solid is changed, the grain size, the grain
17
size disposition, and the grain shape. This is the step to reduce its size and to
make its size uniform. The uniform powder is 0.3 mm size. The purpose of doing
this step is to reduce Empty palm fruit bunch size so it will enlarge the contact
surface area for the next processing in pyrolysis.
In material processing, a grinder is a machine for producing fine particle
size reduction through attrition and compressive forces at the grain size level. In
general, grinding processes require a relatively large amount of energy. So, this is
the operating condition for grinder as pre-treatment process. Based on Heuristic
50 to produce the 0.33 mm size reduction process and use grinder.
Table 2. 4. Operating Condition (Grinder)

Parameter Value
Pressure 1 atm
Temperature 25o-27oC
Size Target 0.3 mm
Frequency 3000 rpm
(Source: Biorefineries-Industrial Process and Design, 2013)
2.2.2. Primary Pyrolysis

To process the biomass, Catalytic Fast Pyrolysis (CFP) are used. In CFP,
solid biomass can be directly converted into high yield of aromatics (benzene,
toluene, xylenes, naphtalenes and so on) over cheap zeolite catalysts in a single
reactor at without hydrogen supply. Biomass catalytic fast pyrolysis was separated
into two processes, primary pyrolysis of biomass and catalytic cracking of organic
vapors. In the primary pyrolysis process, biomass produced gas, water, primary
organic vapor and char via thermal pyrolysis. The biomass is fed into riser and
subsequently thermal decomposed to pyrolysis vapors under inert atmosphere. In
this process, temperature was the most important parameter influencing the
product yields distribution. During the pyrolysis process, lignin decomposition
starts with the breaking of weaker bonds (e.g., hydrogenbonds and C-OH bonds at
low temperature and proceeds through cleavage of stronger bonds (e.g., b-O4
linkages) with increasing temperatures.
18
The process is conducted in the high temperature ranging from 550OC –

700OC, high heating rate (50-1000 C/s), long residence time (>3 s) and high
catalyst-to-feedstock ratio (4-9). Pressure from 1000-1500 kPa. The reaction is
happen in Fluidized bed reactor. The particle size of feedstock for pyrolysis
should be less than 2.0 mm in a fluidized bed to obtain a relatively high liquid
yield.
Figure 2. 8. Catalytic reaction route for the convention of pyrolysis vapors with Zeolit catalyst.
Hence, the most suitable reactor for CFP of biomass is CFB combined with
catalyst regenerator which is similar to a fluid catalytic cracking (FCC) unit in
petroleum refining industry. The pyrolysis vapors were then contacted with
catalyst to form aromatics and olefins. The spent catalysts, char, and hot product
vapors were transported into cyclones (strippers) and were separated therein.
The spent catalysts mixed with char were subsequently burnt in a combustion bed
for regeneration. The regenerated catalysts were recycled to the riser for heat
carrier and reuse. The liquid production was obtained by the condensation and
collection of hot product vapors from cyclones, and the flue gas was recycled as
carrier gas. An advantage of CFB reactor is that it can be used at very high
19
throughputs.
Figure 2. 9. Fluidized bed reactor for CFP.

(Source: Biorefineries-Industrial Process and Design, 2013)
2.2.3. Catalytic Cracking

The hydrolysis sugars, which consist of glucose, xylose, arabinose, and
various organic impurities in aqueous solution, are pumped to the sugar
fermenters for butanol production
Figure 2. 10. Process Block Flow Diagrams of in situ CFP and ex situ CFP.
(Source: Royal Society of Chemistry,2013)
However, owing to the short residence time of the pyrolysis vapor in the
in-situ CFP process, a high catalyst-to-biomass ratio is necessary to ensure a
better upgrading result and a higher yield of the liquid hydrocarbon products. In
20
addition, another disadvantage of in situ CFP is that the catalytic

upgrading/cracking temperature has to be fixed to the temperature at which
pyrolysis is performed, which may not be the optimal temperature for catalyst
performance. For ex situ CFP, the catalyst is separated from the feed. The
deoxygenating and upgrading operations can be flexibly run under an
environment independent of that needed for pyrolysis, which thus enables
optimum catalyst performance to obtain the desired products under the optimized
conditions. Therefore, ex situ CFP are choosen for our plant.
After the primary organic vapors released from prior process, the vapors
(mainly heavy oil fraction) were adsorbed by the active surface of the catalyst,
and then cracked to light vapors. The light vapors then underwent series reactions
such as deoxygenation, cracking to form H2O, CO2, CO, alkanes, alkenes and
aromatic hydrocarbons. These reactions would result in a decrease of oil vapors
and increases of gas and water yields. (H. Zhang et al, 2009).
Figure 2. 11. Reaction Pathway of Lignin Non-Catalytic/Catalytic Fast Pyrolysis.

(Source: Chang et al., 2010)
This process is usually conducted at atmospheric pressure. It can be
concluded that the middle temperature (600oC), high heating rate (50–1000_C/s),
long residence time (>3 s) and high catalyst-to-feedstock ratio (4–9) are necessary
to obtain high aromatic yield from CFP of biomass.
Proper catalyst selection is crucial for high aromatic selectivity. The table
below shows catalytic fast pyrolysis of several aromatic with different catalysts.
Based on the test, zeolite catalysts can effective improve the aromatic yields. The
21
most suitable catalyst to produce Benzene is TNU-9 and 𝛽 zeolite, because it has
selectivity more than 30% for benzene.
Figure 2. 12. Aromatic selectivity from CFP of glucose over different zeolites.
(Source: John Wiley & Sons Ltd, 2016)
2.2.4. Benzene Recovery (Separation)

After the catalytic cracking process, the output is aromatic
hydrocarbon/BTX and other chemicals. Our goal product is Benzene. However,
this Benzene is contaminated with. To get the benzene, separator will be used to
separate it from BTX.
In this process, distillation is used to produce pure benzene from
aromatic/BTX feedstock. The aromatic are extracted from aromatics rich stream
using liquid/liquid extraction. The benzene is separated from the aromatic extract
in a distillation column, shown in figure. The light and heavy key components are
benzene and toluene respectively. The relative volatility for these compounds is
approximately 2.5, making this a separation with a moderate reflux to feed ratio
required.
22
Figure 2. 13. Example of Benzene Production Distillation.

(Source: John Wiley & Sons Ltd,2016)
Operating condition for this process show are:
 Operating pressure: 150 kPa
 Number of tray: 45
 Feed (stream 47) tray – 28
 Temperature: 91o
2.3. Block Flow Diagram
Process consist of two main process, those are Pre-treatment and Main Process section. The block flow diagram of our plant can be
seen in Figure 2.14. and 2.15. below.
Figure 2. 14. Block Flow Diagram
2.4. Process Flow Diagram
.Figure 2. 15. Process Flow Diagram for Pre-Treatment
2.4.2. Main Process
Figure 2. 16. Process Flow Diagram for Main Process
26
2.5. Mass and Energy Balance

2.5.1. Overall Mass Balances
We make our basis as 66555.1976 kg/hr
Table 2. 5. Overall Mass Balance
Mass Flow
Stream
In (kg/hr) Out (kg/hr)
Water 29024.7 55845.1
Air 0 4967
Biomass 66555.3 0
Benzene 0 20860.8
Hidrokarbon lain 0 13907.1
Total 95580 95580
2.5.2. Overall Energy Balance
Table 2. 6. Overall Energy Balance
Energy
Unit
In (106 kJ/day) Out (10^6 kJ/day)
M-100 1.08 0
G-100 1.08 0
R-100 0 1.231
E-100 1.74 0
E-101 1.963 0
V-100 1.61 0
V-101 0 3.486
V-102 0 2.756
TOTAL 7.47 7.473
2.6. Plant 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.
Benzene production = 19271.67 kg/hr
Feed Basis = 66555.1976 kg/hr
𝐵𝑒𝑛𝑧𝑒𝑛𝑒 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛
Mass Efficiency = 𝑥 100%
𝐹𝑒𝑒𝑑 𝐵𝑎𝑠𝑖𝑠
27
9271.67 𝑘𝑔/ℎ𝑟
Mass Efficiency = 66555.1976 𝑘𝑔/ℎ𝑟 𝑥 100%
Mass Efficiency = 28.9%

The plants convert biomass to benzene has mass efficiency as 28.9%.
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 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 7.473 . 106
Energy Efficiency = =
𝑏𝑒𝑛𝑧𝑒𝑛𝑒 𝑝𝑟𝑜𝑑𝑢𝑐𝑒𝑑 91576,8
Energy Efficiency = 81.603,63 kJ/kg
Based on the calculation, plants convert biomass to benzene has energy
efficiency as 81.603,63 kJ/kg
2.7. Heat Exchanger Network (HEN)
2.7.1. Steram Classification
There are several streams in benzene plants, but only a few streams are
necessary to evaluate the heat transfer. Flow to be evaluated is divided into two
types, namely cold fluid and heat fluid. Cold fluid is the flow of heat that requires
utilities to heat flow towards the desired temperature. Meanwhile, hot fluid is a
flow that requires a cool utility to cool the flow towards the desired temperature.
The initial temperature (termed supply temperature), final temperature (termed
target temperature), and enthalpy change of both streams are given in Table 1.
Table 2. 7. Benzene Plant Stream Classification

No. Stream In Stream Out Tin (°C) Tout (°C) Type ΔH (MW) CP (MW/°C)
1 2 3 25 145 Cold 0.293 0.002
2 3 4 145 653 Cold 32.694 0.064
3 4 8 653 600 Hot -0.349 0.007
4 8 12 600 80 Hot -1.163 0.002
5 12 13 80 327 Cold 0.026 0.0001
6 13 17 327 25 Hot 0.00001 4.62E-08
Q value as specific heat of a measured substances in each stream is

resulted from general equation. Enthalpy associated with a stream passing through
the exchanger is given by First Law of Thermodynamics:
28
𝐻 =𝑄±𝑊 (2.1)
In heat exchanger, no mechanical work is being performed
𝑊 = 0 (𝑧𝑒𝑟𝑜) (2.2)
The above equation simplifies to
𝐻=𝑄 (2.3)
2.7.2. Heat Recovery Pinch Method

The term ‘pinch’ was introduced by Linnhoff and Vredeveld to represent a
new set of thermodynamically based methods that guarantee minimum energy
levels in design of heat exchanger networks. The problem table cascade is used.
Although composite curves can be used to set energy targets, they are
inconvenient since they are based on a graphical construction. A method of
calculating energy targets directly without the necessity of graphical construction
can be developed.
Table 2. 8. Stream Temperature Condition
No. Stream In Stream Out Tin (°C) Tout (°C) T*in (°C) T*out (°C)
1 2 3 25 145 30 150
2 3 4 145 653 150 658
3 4 8 653 600 648 595
4 8 12 600 80 595 75
5 12 13 80 327 85 332
6 13 17 327 25 322 20
The basic approach can be developed into a formal algorithm known as the
problem table algorithm. The algorithm will be explained using the data from
Table 1.1 for ΔTmin. The first step is determined the shifted temperature intervals
(T*) from actual supply and target temperatures. Hot streams are shifted down in
temperature by ΔTmin/2 and cold streams up by ΔTmin/2 as detailed in Table 1.2.
Table 2. 9. Temperature Interval Heat Balance
30
After we have the problem table, we can cascade any surplus heat down
the temperature scale from interval to interval. This is possible any excess heat
available from the hot streams in an interval is hot enough to supply a deficit in
the cold streams in the next interval down. From the figure above, we can
determine the minimum utility requirement.
Table 2. 10. Hot and Cold Fluid Program Table Cascade
Ti (°C) Hot Utility Q (MW)

658.00 10.679713
0.772292
646.00 12.853931
2.946511
595.00 24.692282
16.959079
322.00 4.423876
10.703242
150.00 0.000000
0.023529
75.00 10.766129
0.109945
30.00 10.569768
0.000000
20.00 10.679714
2.7.3. Pinch Design Method
Based on Cascade table method data then we then proceed to the pinch
method This pinch design method is used for determine the use for hot or cold
fluid for heating or cooling the stream itself. The determination of the heat
transfer is based on the area above and below the pinch and also the loading of its
heat exchanger. The design is shown in the Figure 4.1.
Table Method and Pinch Design can be used to analyze HEN. In order to
use heat recovery pinch method, we have to classify the stream first.
After design Cascade table the result show, calculation on Cascade method
shows that the result of the stream is only one tool that produces a surplus while
the rest is deficit then the HEN Analysis method cannot be applied in the
calculation of the analysis because the surplus cannot cover the deficit. So that the
heat used completely only for systems that cannot be recovered.
Figure 2. 17. Pinch Design
CHAPTER 3
EQUIPMENT DESIGN
3.1. Reactor
3.1.1. Fast Pyrolysis Reactor
Table 3. 1. Fast Pyrolysis Reactor Specification

Equipment Specification
Item Reactor
Name Pyrolysis Reactor
Type Packed Bed Reactor
Code
Function Reacting lignin into BTX
Material SA 283 Grade C
Operation Data
Temperature (OC) 600
Pressure (bar) 1.04
Operation Data
Volume (m3) 116.04
Diameter (m) 4.05
Height (m) 14.19
Shell Thickness (in) 0.344
Catalyst
Type ZSM-5
Volume (m3) 74.27
Weight (kg) 53474.99
3.1.2. Hydrolysis Reactor
Table 3. 2. Hydrolysis Reactor Specification

Equipment Name Reactor
Equipment Code H-100
Function Reacting H2SO4 and EFB into Lignin,
Cellulose and Hemicellulose
Quantity 1
Equipment Type CSTR Reactor
Material Carbon Steel
Operation Data
Flow rate (ton/day) 6000
o
Material Temperature ( C) 162
Pressure (atm) 1.013
32
33
Table 3.2. Hydrolysis Reactor Specification (continued)

Construction Data
Volume (m3) 20.598
Height (m) 6.984
Diameter (m) 3.492
Wall Thickness (inch) 1.05
Pdesign (atm) 2.27
Impeller sizing (rpm) 100
3.1.3. Catalyst Regenerator
Table 3. 3.. Catalyst Regenerator Specification
Equipment Name Catalyst Regenerator
Equipment Code R-100
Function Regenerate catalyst
Number of Unit 1
Material SS 316
Operation Data
o
Regenerator Temperature ( C) 700
Catalyst Circulation Rate
40
(kg/m2s)
Pressure (atm) 1
Dimension
Regenerator Height (m) 6.59
Regenerator Diameter (m) 2.20
Regenerator Volume (m) 24.96
Regenerator Thickness (m) 9.35
3.2. Storage Tank
3.2.1. Biomass Warehouse
Table 3. 4.. Biomass Warehouse Specification

Equipment Name Biomass Warehouse
Equipment Code R-101
Function To storage biomass (empty fruit bunches)
as feed
Number of Unit 1
Material Concrete
34
Table 3.4. Biomass Warehouse Specification (continued)

Rectangle building with a triangular prism
Type
roofs
Operation Data
Temperature (oC) 25
Pressure (atm) 1
Bulk Density (kg/m3) 355
Dimension
Capacity (m3) 9390
Length (m) 36.85
Width (m) 27.64
Height (m) 9.215
Storage Time Daily
3.2.2. Benzene Tank
Table 3. 5. Benzene Storage Tank Specification

Equipment Name Benzene Storage Tank
Equipment Code
Function To storage benzene as product
Number of Unit 1
Material Stainless steel
Type Cylinder
Storage Time Weekly
Operation Data
Temperature (oC) 25
Design Pressure (atm) 5.24
Bulk Density (kg/m3) 876
Dimension
Capacity (m3) 98.78
Diameter (m) 19.35
Height (m) 41.94
Wall Thickness (mm) 9.398
Head Thickness (mm) 5.3
3.2.3. Demine Water Tank
Table 3. 6. Specification of Storage Tank for Demineralize Water
Equipment Name Demineralize Water Tank
35
Table 3.6. Specification of Storage Tank for Demineralize Water (continued)
Storage Type Liquid Storage
Function Storage for Demineralize Water
Number of Unit 1
Material Carbon Steel SA 167
Type of Tank Cylinder Vertical Concrete Foundation
Type od Head Flat Head
Operation Data
Temperature (oC) 25
Pressure (atm) 1
Mass Flow (kg/day) 76314
Bulk Density (kg/m )3 1004
Dimension
Capacity (kg/day) 76314
Volume tank (m3) 83.61
Volume of Liquid in Tank (m3) 76
Tank Diameter (m) 8.53
Tank Height (m) 17.062
Height of Liquid in Tank (m) 15.335
Design Pressure (bar) 2.88
Hydrostatic pressure (bar) 1.51
Shell Thickness (in) 0.52
Head Thickness (in) 1.84
3.2.4. Coagulant Tank
Table 3. 7. Specification of Coagulant Tank
Equipment Name Coagulant Tank
Equipment Code
Number of Vessel 1
Type Rigid Base Circular
Determination of Diameter of the Water Tank
Mass Flow Rate 3197.5 kg/h
Density 1004 kg/m3
Volume 221.73 m3
Height 4.40 M
Diameter 8.40 M
Free board 0.40 M
Wall Thickness 6 Mm
Design of Base
Thickness of base 6 Mm
36
3.2.5. Filtration Tank

In water utility, it needs to pretreatment the water to get demineralized
water. Before the water is processed in ion exchanger tank to remove the cation
and anion concentration, the water need to be free from the Suspended Solid (SS)
which will be processed in filtration tank. From the sizing calculation explain in
Appendix H can also get the specification of the filtration tank unit, as follows
Table 3. 8. Filtration Tank Spesification
Equipment Name Filtration Tank
Equipment Code T-502
Function To Filter Suspended Solid (SS)
Number of Unit 4
Filter Specification
Filter Type Slow Sand Filter
Total Surface Area (m2) 267.1425
Max. Surface Per filter (m2) 50
Number of Filters 6
Surface Area per Filter (m2) 44.53
Dimension
Filtration Rate (m/h) 0.2
Required Tank Area (m2) 356.19
Long (m) 25
Width (m) 15
Height (m) 2.4
3.2.6. Ion Exchanger Tank
The ion exchanger is the essential equipment in water pretreatment
process. The final product of water utility would be demineralized water. This is
because the water that would be sent to oxygen plant which will be used in
absorption column required the demine water. If cation or anion is not removed,
there will be a contamination in absorption process. From the sizing calculation,
the specification of the ion exchanger is shown on table below
37
Table 3. 9. Ion Exchanger Tank Spesification

Equipment Name Ion Exchanger
Equipment Code
Function To remove Cation and Anion
Number of Unit 2
Operation Data
Cation Concentration 250 mq/L
Use degasifier (Yes/No) Yes
Anion Concentration 150.25 mq/L
Running time 15 h
Throughput Flow rate 19200 m3
Ionic Load
Cation Load 4800000 eq
Anion Load 2884800 eq
Operating Capacity
Cation regeneration with HCl 1 eq/L
Anion regeneration with NaOH 0.5 eq/L
Resin Volumes
SAC 4800000 L
SBA 5769600 L
Specific Flow Rate
SAC 5.1 h-1
SBA 4.72 h-1
3.3. Heat Exchanger
3.3.1. Heat Exchanger (E-100)
Table 3. 10. Heat Exchanger Specification
Unit: E-100
Operating Condition
Data Shell Side Tube Side Unit
Fluid Stream 43 6
Fluid Flow 22308 1328 kg/h
Temperature in 123 5 °C
Temperature out 243 100 °C
Operating pressure 1000 1000 kPa
No. of passes 1 2
38
Table 3.10. Heat Exchanger Specification (continued)
Operating Condition
Fouling factor 0,00009 0,00009 m2 °C/W
Heat Duty 429 kW
LMTD 72 °C
Overall U 619 W/m2 °C
Dimension
Type of unit Fixed tube
Material SS-316 atau SA-240

Heat Transfer Area 29,868 m2
Tube OD 19,500 mm
Tube Length 4,880 m
Shell IDE 0,540 m
Tube Pitch 24 mm
Tube Thickness 1,650 mm
Number of tubes 50
Tube arrangement Triangular
3.3.2. Heat Exchanger (E-101)
Unit: E-101
Operating Condition
Fluid Stream 33 5
No. of passes 1 2
Heat Duty 429 kW
LMTD 119 °C
Dimension

39
Table 3.11. Heat Exchanger Specification (continued)
Dimension
Tube OD 19,500 mm
Tube Length 4,880 m
Shell IDE 0,540 m
Tube Pitch 24 mm
Number of tubes 30
3.3.3. Heat Exchanger (H-100)
Unit H-100
Operating Condition
Fluid Stream 5 3
No. of passes 1 4
Heat Duty 432 kW
LMTD 137 °C
Dimension
Tube OD 20,150 mm
Tube Length 4,880 m
Shell IDE 0,540 m
Tube Pitch 25 mm
Number of tubes 5
40
3.4. Distillation
3.4.1. Distillation Column
Table 3. 13. Distillation Column Specification

Equipment Name Distillation column
Equipment Code D-200
Function To separate BTX from phenol and high-
boiling aromatics compunds
Operating Data
Feed Flow Rate 16794.70 kg/h
Reflux Ratio 14.6
Column Pressure 9 bar
Number of Actual Tray 27
Condenser Temperature 30 oC
Boiler Temperature 314 oC
Stage Efficiency 80%
Construction Data
Column Height 16.46 m
Column Diameter 1.09 m
Plate Type SS Sieve tray
Material SA-283 Grade C
Shell Thickness 5.71 cm
Head Type Torispherical
Head Thickness 1.21 cm
41
3.5. Three Phase Separator
Table 3. 14. Three Phase Separator Specification

Name Separator
Code V-102
Function Separate organics aromatics, water and volatile gas
Number of Units 1
Type Vertical 3 Phase Separator
Material SS-304
Operational Data
Pressure (kPa) 900
Temperature (oC) 5
Gas Flowrate (MMSCFD) 1.40
Oil Flowrate (BOPD) 1.29
Water Flowrate (BWPD) 0.378
Construction Data
Minimum Diameter (m) 2.12
Maximum Diameter (m) 612
Gas Capacity Constraint 580.82
Retention Time Constraint 674
Diameter (m) 3.1
Height (m) 18.13
L/D 7.76
Vessel Liquid Level - beta 50%
42
3.6. Conveyor
3.6.1. Elevator Conveyor
Table 3. 15. Elevator Conveyor Specification

Equipment Name Elevator Conveyor
Equipment Code
Function Delivering biomass feed (empty fruit
bunches) from storage tank to grinder
Quantity 1
Equipment Type Elevator Conveyor
Operation Data
Flow rate (ton/h) 416.67
o
Material Temperature ( C) 25
Pressure (atm) 1 atm
Construction Data
Conveyor Length (ft) 22.96
Belt Width (Inch) 42
Power (hp) 2.815
Conveyor Speed (ft/min) 83.41
3.6.2. Belt Conveyor
Table 3. 16. Belt Conveyor Specification

Equipment Name Conveyor
Equipment Code
Function Delivering biomass feed (empty fruit
bunches) from grinder to hyrolysis reactor
Quantity 1
Equipment Type Belt Conveyor
Operation Data
Flow rate (ton/hr) 250
Material Temperature (oC) 25
Pressure (atm) 1
Construction Data
Conveyor Length (ft) 26.24
Belth width (in) 42
Power (hp) 2.128
Conveyor Speed (ft/min) 170
43
3.7. Hammer Mills
Table 3. 17. Hammer Mills Specification
Equipment Name Hammer Mill
Equipment Code
Function Grinder
Number of unit 1
Type Hammer Mill Grinder
Operation Data
Rotate Speed (r/min) 800
Pressure (atm) 1
Capacity (ton/h) 50-70
Output Size (mm) 0.01-1
Power Requirement (kWh/hour) 377.502 kWh/hour
Dimension
Width (m) 2.1
Height (m) 1.8
Length (m) 1.8
3.8. Filter Plate & Frame
This section explains the sizing and specifications for plate & frame filters
used in benzene production plant.
Table 3. 18. Filter Plate & Frame
Equipment Specifications
Equipment Name Plate and Frame Filtration
Equipment Code P&F-101
Separate lignin from other component
Function
such as hemicellulose, cellulose, etc.
Number of Unit 1
Type Hydraulic pressure/mechanical pressure
Operation Data
Temperature 162 oC
Pressure 1.013 bar
Flow rates 4,880,000 kg/hour
44
Table 3.18. Filter Plate & Frame (Continued)
Construction Data
Filter Area 93 m2
Filtrate Volumetric 22.514 L
Number of filter plates 64
Number of filter cells 65
The thickness of filter cake (cm) 15
3.9. Cyclone
3.9.1. Cyclone (Cy-100)
Table 3. 19. Cyclone Specification
Equipment Name Cyclone
Equipment Code Cy-100
Function Gas-solid separator
Number of unit 1
Type Cyclone Separator
Operation Data
Pressure (kPa) 1.013
Temperature (oC) 600
Volumetric flow rate 626526
Particle diatemer (m) 0.005
Grade efficiency (%) 97
Pressure drop (millibar) 130
Construction Data
D0 (m) 0.15
DB (m) 0.2
W (m) 0.08
S (m) 0.2
Hc (m) 0.3
H (m) 0.8
A (m) 0.15
B (m) 0.08
45
Figure 3. 1. Cyclone V-102

(Source: Walas, 1990)
3.9.2. Cyclone (Cy-101)
Table 3. 20. Cyclone Specification
Equipment Name Cyclone
Equipment Code Cy-101
Function Gas-solid separator
Number of unit 1
Type Cyclone Separator
Operation Data
Pressure (kPa) 1.013
Temperature (oC) 700
Volumetric flow rate 560428
Particle diameter (m) 0.005
Grade efficiency (%) 97
Pressure drop (milibar) 130
Dimension
D0 (m) 0.15
DB (m) 0.2
W (m) 0.08
S (m) 0.2
Hc (m) 0.3
H (m) 0.8
A (m) 0.15
B (m) 0.08
46
Figure 3. 2 Cyclone V-102

(Source: Walas, 1990)
3.10. Flue Gas Compressor (C-100)
Table 3. 21. Flue Gas Compressor Specification
Equipment Name Gas Compressor
Equipment Code C-100
To compress air that will use for HE
Function And flash drum
Amount 1
Operation Data
Inlet Temperature (K) 353
Discharge Temperature (K) 664,4735
Inlet mass flow rate (ton/day) 222,789
3.11. Pump
3.11.1. Screw Pump (P-101)
Table 3. 22. Screw Pump (P-101) Specification

Equipment code P-101
Pump Type Screw Pump
Function Pump outlet fast pyrolysis reactor
Mode of Operation Continuous
Operation Data
Water Liquid
Mass flow (kg/s) 26.83
Flow rate (m3/s) 0.02641
47
Table 3.22. Screw Pump (P-101) Specification (Comtiued)
Operation Data
Density (kg/m3) 1007
Temperature (⁰C) 5
Differential Pressure (Pa) 57,000
Specification Design
NPSHa (m) 47.09
NPSHr (m) 45.51
Head (m) 92.03
FHP (kW) 2.42
BHP (kW) 24.20
3.11.2. Water Pump (P-102)
Table 3. 23. Water Pump (P-102) Specification
Pump Type Centrifugal Pump
Function Pump for water to Heat Exchanger (B6)
Operation Data
Water Liquid
NPSHa (m) 9.37
NPSHr (m) 10.05
Head (m) 60.49
FHP (kW) 43.48
BHP (kW) 49.40
3.11.3. Water Pump (P-103)
Table 3. 24. Water Pump (P-103) Specification
Pump Type Centrifugal Pump
Function Pump for water to Heat Exchanger (B7)
48
Table 2.5. Water Pump (P-103) Specification (Continued)
Operation Data
Water Liquid
NPSHa (m) 12.49
NPSHr (m) 10.05
Head (m) 48.23
FHP (kW) 91.31
BHP (kW) 121.75
CHAPTER 4
PROCESS CONTROL STRATEGY
There are three elements that must install at the system control to make
sure that our process doing well. Each of elements has its own function
1. Transmitter, which is used for indicate the recent condition of equipment.
Transmitter will always sent electric signal to indicator controller.  
2. Indicator controller, which is used for receive the electric signal from
transmitter and determine the decision for final executed which will executed
directly by actuator or final element. Indicator controller always mounted at
the control room, so the operator on control room can monitor the process
condition and make the final instruction.  
3. Actuator or final element, which is used for directly execute toward the
process after get an instruction from operator at the control room. The final
element generally formed as control valve. This kind of controller should
always exist at the main equipment that has  a big influence for our process
and equipment that contain a hazardous material or process. So this control
system will monitor and guide the equipment to always run at the setting
condition.
49
4.1. Plant Control Tabulation
Table 4. 1. Control Details
Location
Manipulated of
No Device Control Variable Controller Control Sequence of instrumentation
Variable
Valve
When the temperature of the CSTR is not fit with the
wanted condition, the TI will give an electric signal to
Feed Cooling water Out CSTR
PI TC and then transfer that signal into a pneumatic signal
Temperature rate Reactor to flow control valve at the cooling water until the
condition become normal
CSTR
1 Reactor
(R-100) When the pressure of the CSTR is higher than the
Pressure of Feed CSTR design pressure, the pressure control valve will open to
Reactant flow
Reactor PI Reactor reduce the pressure on the CSTR
rate
If the temperature indicator shows the value that is

higher that set point so the cooling water flow rate to
Feed Fluidized the reactor jacket increase and the heat that can be
Feed Temperature Cooling water
Fluidized PI Bed Reactor transferred from reactor to cooling water will be
rate
Bed increased too and vice versa.
2
Reactor
(R-101) Pressure Safety Head of When the pressure of the CSTR is higher than the
Pressure of Valve Reactor design pressure, the pressure control valve will open to
Reactor PI
reduce the pressure on the CSTR
Table 4.1. Control Details (continued)
Control Location of
No Device Variable Manipulated Variable Controller Control Valve Sequence of instrumentation
Release more gas to decanter
Pressure Pressure Safety Valve if pressure in column
distillation PI Top product line distillation II reach the set
point
PI Release more liquid to storage

Level liquid in Flow rate liquid tank if level in column
3 column in column Bottom product line
Distillation distillation reach the set point
(V-100, More open control valve if

V101) Column temperature in column doesn't
Temperature Cooling water rate PI Condenser
reach set point.
If the temperature of the

outlet stream is below the
Heat specification, the control
Exchanger Feed valves opening will be
4 Feed flow rate PI Feed Heat Exchanger
(E-101, Temperature increased so that the flow rate
E-102) of cold utility stream will be
higher
If the pressure above set
Pressure Flash PI Top outlet Flash Drum point, pressure control will
Vapor flow rate
Drum decrease the flow of vapor.
Flash Drum
5 Release more liquid to outlet
(D-100) Level liquid in PI Bottom outlet Flash Drum
Liquid flow rate if level in flash drum reach
Flash Drum the set point
51
Table 4.1. Control Details (continued)
Control Location of Sequence of

No Device Variable Manipulated Variable Controller Control Valve instrumentation
Pump Outlet When the outlet pump flow is

7 Flow Cooling Water flow rate Coagulation higher than design, the valve
(P-100) PI Tank will be closed and vice versa.
Reduce liquid level in
Coagulant Liquid column by opening the
8 Level liquid in PI
Tank tank
Product Flow Outlet coagulant tank Level Control Valve on the
rate bottom product of the
column.

column by opening the
Filtration Level liquid in Liquid Product Flow PI Level Control Valve on the
9 tank rate Outlet filtration tank
Tank bottom product of the
column.

Outlet Kation-Anion column by opening the
Kation- Liquid Product Flow
Anion Level liquid PI Exchanger Level Control Valve on the
10 rate bottom product of the
Exchanger
column.
52
4.2. Piping and Instrumentation Diagram  
Figure 4. 1. PID for Pre-Treatment
53
4.2.2. Main Process
Figure 4. 2. PID for Main Process
54
CHAPTER 5
PLANT LAYOUT
5.1. Area Plant Layout

The space available must be enough for the whole plant and its supporting
facilities. The facility should reflect recognition of the importance of smooth
process flow. Spacing between process instruments is ruled by Inside Battery
Limit (IBL), and the spacing between supporting facilities is ruled by Outside
Battery Limit (OBL). Safety is the main consideration in the plant layout. For
example, the fire fighter unit should be placed close to the unit that may cause a
fire and there is minimum spacing for hazardous reactor and high temperature
vessel so that impact cost can be minimalized. The value of IBL and OBL is given
in Figure 5.2 and Figure 5.3.
Figure 5. 1 Outside Battery Limit Values

(Source : Process Control Structure and Applications, 2010)
55
56
Figure 5. 2. Inside Battery Limit Values

Figure 5. 3. Battery Limit Between Storage Tanks and Vessels
57
5.1.1 Outside Battery Limit Zone

The buildings included in the outside battery limit zone are office
building, include main office training centre building, R&D plant office, canteen,
health centre, mosque, mess of employee, production office, laboratory, control
room, HSE office, maintenance centre, warehouse, fire extinguisher station, and
other open area include main road, parking area, security post and void. Below is
the detail area of each building.
5.1.2. Total Factory Layout
Total factory layout of this plants are based on 2 kind of area, equipment
layout and facilities layout for workers.
 Equipment Layout
The major factor that influenced total area of the plant is equipment. Equipment
inside the process area and storage tank area is placed by following the battery
limit showed in Appendix, which we can get total area occupied including their
spacing between equipment to ensure the place is safe.
 Facilities Layout
For the supporting facilities, the spacing is used on outer battery limit figure in
Figure 5.2. Several facilities are considered in this designs, and it can be seen in
Appendix. The total area is 4208.534 m3. By estimating the dimensions and
assuming that the area used is equal to process area, we design the plant layout as
following picture.
Figure 5. 4. Area Plant Layout
58
5.2. Equipment Plant Layout
Figure 5. 5. Equipment Plant Layout
59
60
Based on Figure 5.5, the first process stream, empty fruit bunch will be
sent to the ball mill to reduce its size. The grinded empty fruit bunch then will be
sent to the hydrolysis using bucket conveyor. In hydrolysis reactor, lignin was
produced and heated before enters catalytic fast pyrolysis reactor. In catalytic fast
pyrolysis reactor, the product will be fluidized and brought to the cyclone. In
cyclone, pyrolysis product and char will be separated. The product then will be
cooled, condensed, and sent to the three-phase separator to separate volatile gas,
aromatic product, and the water. Aromatic component will be separated into
phenol and BTX by distillation. BTX will also be separated by distillation with
benzene as the main product and toluene & xylene as by-product. The catalyst in
catalytic cracking reactor will be ineffective after some time of using because of
coke formation. The catalyst will be regenerated using combustion process in
catalyst regenerator. The air for combustion process will have some pre-heating
process through some of heat exchangers in our plant.
Besides the main process, benzene plant also has water treatment to pump
water into heat exchanger. The water is placed in a settling pit to separate the
sand and other particle. The water from settling pit then will be sent to
demineralizer tank to remove its mineral before used as cold utility. After used as
cold utility, the water will experience temperature increase until reach temperature
of 100oC. To use the energy in our utility, the water will be sent to boiler where
heating process is done and the water will be evaporated into superheated steam.
The superheated steam then will be used to rotate a turbin and produce energy.
The output from turbine will be condensed to make sure that there will be no
vapor sent to the pump.
61
CHAPTER 6
HEALTH AND ENVIRONMENTAL SAFETY ASSESSMENT
6.1. HSE Aspect

6.1.1. Hazard Identification (HAZID)
Hazard Identification (HAZID) is an analysis of hazard prevention on
industrial installation by observing whole aspects.
Aspect in industrial installation:
 Information data of industrial installation (PFD, P&ID, lay out,
meteorological data, social cultural community around data, record of
events)
 Location (operating facilities, supporting facilities)
 Risk (human resource, environment, and asset)
 Trigger factor of danger (operation process, transportation, geography and
meteorology, social cultural)
 Hazard potential (huge fire and explosion, drown, environmental
contamination)
In hazard identification the analysis considering hazard effect and hazard
frequency (level of hazard possibility). HAZID parameters in considering hazard
effect are listed in table below.
Table 6. 1 HAZID Parameters in Considering Hazard Effect

Parameter Minor Major Severe
Human The accident was not
No accidents Fatal accident
resources fatal
Losses between U.S. $ Losses in excess
Losses less than
Asset 100,000 s.d. U.S. $ of U.S. $
U.S. $ 100,000
1,000,000 1,000,000
No environmental Minor damage to the Damage to the
Environment
damage environment environment
62
HAZID parameters in considering hazard frequency (level of hazard

possibility) are listed in table below
Table 6. 2 HAZID Parameters in Hazard Frequency (Level of Hazard Possibility)
Parameter Most Likely Unlikely

Frequency more than 10 times between 1 until 10 Less than 1 time
danger in the 10 years times in 10 years in 10 years
The HAZID Analysis for this plant is tabulated in Appendix.
6.1.2. Hazard and Operation Safety
Hazard and Operability Study (HAZOP) is a structured, systematic
examination of a process or operation that took place and is still in the planning
stages in which aims to identify and evaluate problems that may pose a danger to
the individual employees, equipment operation, or efficiency of the process
operation. The HAZOP analysis for benzene production is attached in Appendix.
6.2. HSE Management

6.2.1. Operation Details
In this subchapter will be explained about the shut up and shut down
procedure needed in our plant. These kind of planning is needed due to the safety
aspect and the efficiency. The procedure of each plant is explained below:
 Commissioning
o All Piping and Instrument Ascertained in Accordance with Design
The main purpose of this step is to make sure all equipment and lines have been
installed properly as it shown in P&ID. It is needed to check equipment by
equipment and line by line with P&ID as the reference. After that, identify the
location of the equipment, check all of the valve condition, checking pump,
compressor condition, and venting system. Electrical systems, instrumentation,
and control systems checkout down by appropriately qualified personnel
(Electricians and instrumentation technicians).
63
o All Equipments are Checked in Terms of Safety Aspect

The entire plant equipment must be checked in terms if safety aspect.
Beside that, ensure that every equipment is ready to start the process. Testing all
equipment signals, alarms, output devices, and communication devices to be
certain that they were operating correctly.
o Pressure Leak Testing
Leak test the pressure test by inserting a pressurized fluid which aims to
ensure connection in the equipment has been perfect and there are no leaks. Fluid
involved is inert fluid. For a non-hydrocarbon fluid system consisting of water,
air, and nitrogen. Leak test done at the maximum normal operating pressure or if
unknown, use 90% of design pressure. Leakage is characterized by a decrease in
pressure. To find out where the leaks when using gas as a fluid made with a soap
solution superimposed into the connection. If no bubbles appear then there is a
leak. All Equipment for liquid handling especially piping system, should be
thoroughly cleaned from scaling and the internal debris which accumulates during
construction. This is accomplished by blowing or washing with air, steam, water
and other suitable medium.
 Utilities Commissioning
All utilities such as various types of cooling water and electricity should be
commissioned. Typically, valves should be checked and if it is properly installed,
the total water needed for cooling system is enough for main operations and for
the electricity, and make sure that the electricity mapping should be clear and
provide proper electricity current and the capacity for the plant’s operation.
 Operational Testing
Then the next stage in the commissioning is done operational test which is the
most important stages. At the operational stage of the test, the test operating
conditions closer to the actual operating conditions. This stage lasts for 2-3 weeks
after all the equipment has been independently checking or testing. Air and water
tests should be set up in a closed loop with fluid continuously recycled, with loops
as large a possible. The loop should ideally be the same loop that will be subject
to solvent testing. Tests should continue for several days in order to give all shifts
64
a chance to conduct the same tests. All shifts should be given the opportunity to
start up and shutdown each closed loop test.
6.2.1.1. Start Up Procedure

After the commissioning phase is complete, then the plant can be declared ready
by the start-up phase. Start-up procedure in this benzene plant includes two ways
for there are two major system in this plant, pre-treatment system and main
process system. The phase of start-up phase explained below:
 Start Up for Pre-Treatment System
 Checking for water system supply.
 Pre-treatment the solid raw material
 Connect the unit into an electrical outlet and verify that power supply
switches the power switch to “On”. Set the mode switch to the “generate”
position.
 Preparing to start up the reactor for hydrolysis process.
 Turn on Bucket Elevator, Grinder, Belt Conveyor.
 Input raw material to grinder.
 After grinding process raw material that has been milled flowed using belt
conveyor to Reactor CSTR.
 Preparing to start up the mixer which will mix the catalyst to perfect the
lignin release reaction.
 Preparing to start up the Heat Exchanger.
 Preparing to open the inlet water system for reactor and Heat Exchanger
requirement.
 Check the temperature and pressure in the reactor to conform to the
specified specifications.
 If the reaction does not occur, the startup procedure should be repeated.
 Start Up for Main Process System
 Checked the condition in reactor unit.
 Open all inlet valves for the stream especially in venting system.
65
 Open utility valve for cooling water, oxygen, fuel, air, etc then check the
temperature.
 All parameter in instrument which need controlling must be set, such as
pressure and temperature. This step to ensure the equipment under
condition.
 Turn on the pump to deliver Lignin to process equipment.
 Prepare the reactor for the process. This step is maintained the temperature
and pressure in reactor. This is to avoid the shock in reactor.
 Prepare gas for the process of fast pyrolysis and catalytic cracking.
 After temperature and pressure reached, the raw material is put to the
process.
 Preparing the cyclone and blower to assist the material transport process
and to suck the air out of the atmosphere.
 Preparing to start up the compressor and Heat Exchanger.
 Preparing the flash drum and ensure the temperature and pressure in
accordance with the specification.
 Preparing to start up the distillation column and ensure the temperature
and pressure in accordance with the specifications.
 The preconditioning is done for 1 – 4 hours to see if the reaction occurs or
not.
 If the reaction does not occur, the startup procedure should be repeated.
6.2.1.2. Shut Down Process
 Shut Down for Pre-Treatment System
The Emergency Shutdown System (ESD) shall minimize the
consequences of emergency situations, related to typically uncontrolled flooding,
escape of hydrocarbons, or outbreak of fire in hydrocarbon carrying areas or areas
which may otherwise be hazardous. The safety shutdown systems based on the
following procedures:
a. Emergency Shutdown
 Manual alarm
 Shutdown all transportation of gas, liquid, and solid.
66
 Decrease the pressure and temperature of any equipment.

 In case of an emergency, simply turn the Main Power Switch to OFF. This
will stop all electricity.
b. Normal Shutdown
 Close all the inlet feed gas valve in every reactor and stop input the raw
material to equipment manually.
 Shut down the electricity in electric arc furnace.
 Shut down heating and cooling sources.
 Flooded with water or a solvent to remove deposit on the reactor
 Checked the condition in reactor unit.
 Open all inlet valves for the stream especially in venting system.
 Open utility valve for cooling water, oxygen, fuel, air, etc then check the
temperature.
 Pressure trapped between two closed valves or closed process equipment
loops should be released immediately.
 After an hour cooling the reactor (prevent thermal shock).
 Bringing the vessel to atmospheric pressure
 Eliminating undesirable materials (cleaning process).
 Preparing for opening to atmosphere.
6.2.2. Personal Protective Equipment (PPE)
Personal protective equipment, commonly referred to as "PPE", is
equipment worn to minimize exposure to serious workplace injuries and illnesses.
These injuries and illnesses may result from contact with chemical, radiological,
physical, electrical, mechanical, or other workplace hazards. Personal protective
equipment may include items such as gloves, safety glasses and shoes, earplugs or
muffs, hard hats, respirators, or coveralls, vests and full body suits.
6.3. Material Safety Data Sheet (MSDS)

MSDS is a document that contains information on the potential hazards
(health, fire, reactivity and environmental) and how to work safely with the
chemical product. It is an essential starting point for the development of a
67
complete health and safety program. It also contains information on the use,
storage, handling and emergency procedures all related to the hazards of the
material. The MSDS contains much more information about the material than the
label. MSDSs are prepared by the supplier or manufacturer of the material. It is
intended to tell what the hazards of the product are, how to use the product safely,
what to expect if the recommendations are not followed, what to do if accidents
occur, how to recognize symptoms of overexposure, and what to do if such
incidents occur.There is a common symbols used on labels to quickly provide
information of the relative hazards of a material. Most of company use the
National Fire Protection Association (NFPA) warning diamond, which appears in
figure below.
Figure 6. 1 NFPA Guidelines

(Source : NFPA, 2016)
The explanation of the figure above can be seen in Figure 6.2.
68
Figure 6. 2 Explanation of NFPA

(Source : NFPA, 2016)
Proper MSDS is needed on this plant. There are MSDSs for main material
in the plant, which are Lignocellulosic, Water, H2SO4, Benzene, Toluene, Xylene.
The MSDS can be seen at the Appendix section.
6.4. Emergency Action Plan

Emergency is any unplanned situation that can cause deaths or significant
injuries to workers, employees, customers or the public, which also poses an
immediate risk to property and environment. Most emergencies require urgent
intervention to prevent a worsening of the situation, although in some situations,
mitigation may not be possible.
6.4.1. Emergency Operating Procedures and Training
The emergency procedures should include instructions for dealing with fires,
leaks, and spills. The procedure should describe how to:
 Raise the alarm and call the fire brigade;
 Tackle a fire or control spills and leaks (when it is safe to do so);
 Evacuate the site, and if necessary nearby premises.
These instructions consist of a four-step procedure that employees
should follow during a fire. This procedure must be memorized by all employees.
Experience has demonstrated that the best response to a plant fire is first, to sound
69
the alarm, then let others know there is a fire, then to combat the fire if possible,
and finally, to evacuate if necessary. The plan works best when expressed as an
easily recalled acronym, such as SAFE:
a. S – Sound the alarm
Sound it yourself or call out to someone else to sound it. This allows the fire
department to be on its way while other activities are being performed.
b. A – Alert others
Quickly tell others in the area of the fire. Do this in a calm, firm manner. Do not
cause a panic. Secure the area for the fire department. Close all doors and
windows to prevent the spread of smoke and flames. Call security to give
verification and information about location of fire.
c. F – Fight the fire
Do this only in the case of a manageable fire, one that you have the training and
experience to fight. For example, fire in a wastebasket. If possible, two employees
should fight the fire together using two fire extinguishers. If you have any doubt
about your ability, then do not attempt to combat it.
d. E – Evacuate the area (if necessary)
There are some possible emergency situation to be happened and action that can
be done to minimize the effect from that emergency situation such as
o Gas Leak
When suspecting there are gas leak, safety procedure are as follow :
 Avoid inhaling vapors and contact with liquid or gas
 Turn off the supply also close the emergency shutdown valve (ESDV)
 Never operate any valves when being panic, because a wrong action
although just a simple action will cause to another new emergency situation
 Close the doors, windows or any gaps to block off the air vents if the leak is
near the building. It is done to prevent the gas from getting into the building.
 Move and evacuate the people upwind from the gas leak-area.
 Avoid any action which could generate smoke, such as smoking, turning is
the vehicle engine, etc.
 Immediately call the local fire station
70
 If in doubt, evacuate the building and inform the police as well as the
National Gas Emergency Service or your gas supplier
 Gather with others in the muster point nearby
o Accident of Equipment
When there is accident from equipment, safety procedure are as follow
 Check whether there are any leakage or not
 Move people away from the area and gather in assembly point
 Call the brigade, police and also ambulance
6.4.2. Emergency Alarm and Fire Fighting Equipment
There are several kinds of alarm to be used in our plant. All of alarm which used
for evacuation system has been meet the alarm system standard from OSHA. It
applies to provide an early warning for emergency actions or reaction time for
employees to safely escape the work place, the immediate work area, or both.
Type of alarms which used in this plant:
a. Audible Alarm
Audible alarm which used consists of horn and sirens. Horns produce a very loud
distinctive sound that immediately attracts attention. Horns can be useful to call
attention to critical situations. Signals other than those used for evacuation
purposes do not have to produce the temporal coded signal. Thus, sirens produce a
loud piercing wail that makes them ideally suitable for initiating a site-wide
evacuation.
b. Visible Alarm
Visual alarm which used consists of flashing/steady lights and strobe lights.
Steady lights are well suited for areas where ambient noise makes audible signals
difficult to hear, for an example in area where the compressor is in. These types of
lights come with different colored covers for increased attention and can be
ordered with rotating or flashing lights. Strobe lights use high intensity flash
tubes that are ideally suited for areas where high ambient light levels make
traditional rotating or flashing lights difficult to distinguish or where ambient
noise makes audible signals difficult to hear.
71
For firefighting, our plant has some equipment installed such as light fire
extinguisher (APAR), hydrant, and safety shower. As for firefighting equipment
should consider some parameter such as:
 Appointment of fire wardens with subsequent training
 Location of safety shower, fire hose, extinguisher and water sources
 Access for emergency services
 Provision of firewater lagoons
6.4.3. Emergency Escape Procedures and Route
The purpose of the escape procedure is to help the employee evacuate to be
predetermined assembly areas whenever the alarm sounds. Here is the procedure
of emergency escape:
a. In the event of an emergency, employees shall activate fire pull stations
without exposing themselves to serious hazards and leave the work area as
soon as possible via the emergency route assignments posted in immediate
work area.
b. All primary emergency escape routes and designated meeting locations shall
be provided to each employee by departmental managers as part of the
emergency planning process. These primary route and designated meeting
locations must be approved by the plant manager.
c. An orderly evacuation shall be supervised by departmental managers, line
supervisors, and designated wardens who will check all rooms/enclosed
spaces and report any problems via telephone or radio to plant security.
d. Each local manager or supervisor shall provide for the specialized
evacuation of any handicapped employees.
Next is about assembly point and the route from any side of our plant to go
to that assembly point. Escaping route should be the shortest and safest way to go
to assembly or meeting point in order to minimize after effect from emergency.
The Figure 6.10 will explain the escape route based on the plant layout.
72
Figure 6. 3 Evacuation Route

6.6. Waste Management
Industrial activities usually give a residue from processing which is called as
waste. Waste of processing in industry has to be handling well or else it may give
damage that affect environment or sustainability of production in plant. There are
several wastes in the result of process in our plant which classified into four kinds.
All of those wastes can be directly discarded, recycled, used again in the process,
or even can be sold to other plant as their raw material. Government gives
boundary for every industrial plant to process their waste based on Human Safety
Environment. Based on the explanation above, it is needed to classify waste in the
plant and manage them as seen below.
6.6.1. Solid Waste
Solid waste generated in this plant is lignin. Lignin is produced from fast
pyrolisis process. Lignin is formed as slurry and it is stored in a storage vessel.
This lignin slurry can be reused as fuel for boiler. If it is reformed, it will becomes
a solid cake of lignin. To maximalist the waste, the lignin slurry can be sold to
other factory. This lignin can be used as a raw material for power plant.
73
6.6.2. Liquid Waste

Liquid waste from this plant is water, whether cooling water or steam. It all
transferred to water utility. The water goes to water tube boilers, then go to water
storage by passing the steam turbine and heat exchanger to lower the temperature.
Then, the water is ready to use again in the process. The water from
demineralization which contains much mineral will be disposed to the river.
6.6.3. Gas Waste
Carbon dioxide is produced during fermentation process to supply gas
feed in gas stripping. But after all, the carbon dioxide is meant to be wasted in
amount of 2000 ppm. Another gas waste in this plant is hydrogen produced from
fermentation process. These gas emissions have met the standards of Minister
Environment Decree No. Kep.13/Menlh/3/1995 about quality standards stationary
source emissions or BSN Standards (5000 ppm). From the standards, the gas
waste can be directly released into the environment by way of venting for CO2
emission and hydrogen can be directly discharge into the air because it is not
dangerous emission. The hydrogen of the fermentation process will also be sold to
our plant costumer.
6.6.4. Sound (Noise) Waste
Noise in our plant generated from grinder, pump, and compressor. This
noise can also cause damage to mechanical system to appliance. According to
Ministry of Manpower Decree No. Kep.51/MEN/1999, Threshold Limit Value
(TLV) from noise is around 85dB for 8 hours a day or 40 hours a week. If exceed
the TLV there are some disorders that can cause such as physiological disorder
(reducing function of hearing) and also psychological disorders (mental and stress
disorder).
In order to reduce noise level there are some action that can be done which
are eliminate noise transmission to workers, eliminate noise from noise source,
and providing protection to employees. For eliminating noise from noise
equipments can be done by regular maintenance and replacing the parts that
caused noise. Eliminating noise transmission can be done by closing the engine as
soon as possible and if necessary isolate and minimize the machine from any
holes and doors. For the workers that always work around those equipments that
74
generated noise will be equipped with ear plug in order to dampening noise.
Using ear plug can decrease noise up to 20dB so that they can keep working in the
save area.
CHAPTER 7
ECONOMIC ANALYSIS
7.1 Cost Index

Cost index is important to estimate equipment cost in a certain year. In this
economic analysis, chemical engineering cost index used to predict the price of
equipment in the year of purchase. There are two types of cost index which are
commonly used: Marshall and Swift Equipment Cost and Chemical Engineering
Plant Cost Index (CEPCI). CEPCI is preferred in analyzing cost index of
methanol plant due to its simplicity. CEPCI from 1950 to 2011 is shown in Table
7.1 and Figure 7.1.
PROJECTION
800
700 y = 12.675x - 24946

R² = 0.9063
600
500
400
300
200
100
0
1995 2000 2005 2010 2015 2020 2025
Figure 7. 1 Cost Index

From Figure 7.1, it can be shown that cost index in the last two years
increases almost linearly. The average increase of cost index in 2009-2011 is
5.9%. Using this value, cost index in 2012-2034 can be predicted. The result is
given in Table 1.1.
75
76
Table 7. 1 Cost Index from 2017 to 2022

Year Cost Index
2017 827.9
2018 877
2019 929.1
2021 1042.7
2022 1104.6
To estimate equipment cost, all equipment is assumed to be bought in

2014. Based on CEPCI in Table 1.1, equipment cost in 2014 can be estimated
using equation:
cost index at present time
Present cost = original cost × cost index at original cost obtianed
(7.1)
So, in equipment cost calculation, cost each equipment in reference year is
multiplied by ratio of its CEPCI.
7.1.2. Capital Expenditure (CAPEX)
Capital expenditure should be known for convenience in cost accounting
and cost estimation. This expenditure is a one-time expense for the design,
construction, and start-up of a new plant or a revamp of an existing plant. As a
project for manufacturing a new or existing chemical by a new process progresses
from laboratory research through pilot plant development to a decision for plant
construction, a number of process-design studies of increasing complexity may be
made, accompanied at each step by capital-cost estimates of increasing levels of
accuracy as follows: order-of-magnitude estimate, study estimate, preliminary
estimate, and definitive estimate. The one which has been done up to this step is
the preliminary estimate.
Preliminary estimate is based on the individual factors method of Guthrie,
1969, 1974. This method is best carried out after an optimal process design has
been developed, complete with a mass and energy balance, equipment sizing,
selection of materials of construction, and development of a process control
configuration as incorporated into a P&ID. To apply the method, the f.o.b.
purchase cost of each piece of major equipment must be estimated. The equation
for the total capital investment by Guthrie method is
77
CTCI = 1.18(CTBM + Csite + Cbuildings + Coffsite facililities ) + CWC (7.2)

The equation above does not account for royalties or plant startup. These
additional costs should be added if they are known or can be estimated. Complete
capital investment (TCI) components can be seen on Table 1.2 below.
Table 7. 2. Components of Total Capital Investment (TCI)
(Source: Seider et al., 2003)

Capital investment on the plant same with capital expenditure. First, the
total capital investment should be calculated before we analyze it. The total
capital investment of a chemical plant is stated as a one-time expense for the
design, construction, and start-up of a new plant. With using equation such as
shown before, we can get TCI value shown in the table below.
Table 7. 3. Total Capital Investment

Type
Kind of Cost Symbol Cost Note
Cost
Total Bare-
Direct CTBM 100,249,369 Calculated
Module Cost
Cost
78
Table 7.3. Total Capital Investment (continued)

Cost of Bulk
CBulk $150,541 Calculated
Material
Site
Development Csite $624,920 Calculated
Cost
Building Plant (no buliding
CBuild $2,217,778
Cost office, etc)
Include in
Offsite
Coffsite $0 Total bare
Facilities Cost
modul cost
(CDPI =
CTBM +
Total Direct
Cbulk +
Permanent CDPI $103,242,608
Csite +
Investment
Cbulid +
Coffsite)
Engineering
and Ceng $82,594,086 (8% CTBM)
Supervision
Construction (10%
Indirect Cconstruction $10,324,260.81
Expenses CTBM)
Cost
Contingencies (15%
Ccontingency $15,486,391
Cost CTBM)
Contractor’s
Ccontractor $3,097,278 (3 % CTBM)
Fee
(CTDC =
CDPI + Ceng
+
Total
Ccontruction
Depreciable CTDC $111,502,017
+
Capital
Ccontingenc
y+C
contractor)
79
Table 7.3. Total Capital Investment (continued)

Royalties
Croyal $2,230,040 (2% CTDC)
Cost
Additional Plant Start
Cstartup $11,150,202 (10% CTDC)
Cost Up Cost
Additional
Csupport $3,583 Calculated
Cost
Total
(CTPI = CTDC + Croyal
Permanent CTPI $13,383,825
+ Cstart up)
Investment
Working Working
CWC $2,355,553 (CWC = 17.6 % CTPI)
Capital Capital
Total Capital
CTCI $15,739,378.61 (CTCI = CTPI + CWC)
Investment
In Figure 1.2 is shown the breakdown of TCI. Direct cost is the highest cost in
TCI.
Total Capital Investment

1.80%
0.00% 14.98%
0.08%
2.73%
3.68%
0.12% 76.62%
TBM Bulk Material Cost

Land Cost Building Cost
Support Facility Cost Utility Installation Cost
Contingency and Contractor Fee Working Capital
Figure 7. 2. TCI Breakdown
80
7.1.3 Comparison with Existing Plant

Based on the data obtained there are 3 Benzene plant which is already
operating in Table 7.4 to do the comparison with this Benzene plant. There are
Pertamina RU IV, Trans Pacific Petrochemical Indotama, and PT. Chandra Asri.
Table 7. 4. Comparison with Existing Plant

PBP Production Capacity
Plant CAPEX IRR
(years) (tonne/year)
US$ 11.15 73,434.22
Benzene Plant 5.17
128,565,222 %
US$
PT Chandra Asri Tbk 15% 6.78 260,000
150,000,000
US$ 14.3
PT Pertamina RU IV 6.78 120,000
119,124,000 %
Trans Pacific Petrochemical US$
15% 10 360,000
Indotama 400,000,000
7.2. Operating Cost
Operating cost is the expenses that is needed to operate a device,
component, and piece of equipment or facilities that is used for producing acetic
acid. Operational cost is usually paid in every year of production. The operational
cost is conducted into two types which are manufacturing cost and general
expense. There are some factors that is needed to be calculated such as direct
production cost, fixed charge, and plant overhead cost. Such as costs are called
manufacturing cost. For production cost, it is the cost that directly connected to
the cost of production cost such as raw material, operating labor, utility, and
maintenance.
7.2.1 Raw Material Cost
The cost of raw materials is the largest item of expense in the
manufacturing cost of product that shown in Table 7.5. The quantities of raw
materials consumed are calculated from material balances.
Table 7. 5. Raw Material Costs
Price
Annual Total Order Shipping
per Total Shipping Total Cost
Material Supplier Location Order Cost per Year Cost
tonnes per year (US$) (US$)
(tonnes) (US$) (US$/ton)
(US$)
Empty Fruit PT. Adikarya Bandar
642000 $ 10.0 6,420,000 $ 12.00 $7,704,000.00 $14,124,000.00
Bunch Gemilang Lampung
Custom ZSM-5
Catalyst Beijing 2000 $ 100.0 200,000 $ 2,800.00 $5,600,000.00 $5,800,000.00
Co., Ltd
Total (Rp) $644,000.00 $110.00 $6,620,000.00 $2,812.00 $13,304,000.00 $19,924,000.00
81
82
7.2.2. Labor Cost

Labors that will be working at this plant consist of two types, direct and
indirect labor. Direct labors are who in charge during direct operational process in
the plant, whereas indirect labors are who in charge monitoring plant survivability
and relationship with outside world.
Table 7. 6. Direct Labor Cost

Salary per
Total
Direct Labor month per Amount/Shift Total Salary/month
Worker
person (USD)
Operator $ 375.00 4 48 $ 18,000.00
Labour $ 350.00 4 48 $ 16,800.00
Technician $ 375.00 4 24 $ 9,000.00
Total Cost/month $ 43,800.00
Total Cost/year (14 Months' Salary) $ 613,200.00
Indirect cost is needed to ensure management and operation of the firm.
The wages is used based on standard of Indonesia firm with salary projection to
2020. The indirect labor cost can be seen in Table 7.7.
Table 7. 7. Indirect Labor Cost

Salary per month Total Annual
Departement Position Amount (person)
per person (US$) Salary (US$)
President
$ 3,500.00 1 $ 49,000.00
Director
Stakeholder Secretary of
President $ 1,000.00 1 $ 14,000.00
Director
Finance
$ 1,500.00 1 $ 21,000.00
Manager
Finance
Assistant
Department
Finance $ 900.00 2 $ 25,200.00
Manager
83
Table 7. 7. Indirect Labor Cost (continued)

HR and Legal
HRD and $ 800.00 1 $ 11,200.00
Manager
Legal
Training
Department $ 450.00 1 $ 6,300.00
Coordinator
HSE
HSE Engineer $ 650.00 2 $ 18,200.00
Department
Production
$ 1,500.00 1 $ 21,000.00
Manager
Process and
Production and Facility $ 850.00 3 $ 35,700.00
Maintenance Engineer
Departement Maintenance
$ 750.00 2 $ 21,000.00
Coordinator
Operational
$ 800.00 2 $ 22,400.00
Coordinator
Product
Planning and
Product $ 1,000.00 1 $ 14,000.00
Development
Planning and
Manager
Development
Product
Department
Distribution $ 750.00 1 $ 10,500.00
Supervisor
Sales and Marketing
$ 850.00 1 $ 11,900.00
Marketing Executive
Department Marketing Staff $ 600.00 2 $ 16,800.00
Supply Chain Supply Chain
$ 900.00 1 $ 12,600.00
Department Manager
Security $ 350.00 4 $ 19,600.00
General
Receptionist $ 450.00 2 $ 12,600.00
Support and
Cleaning
Service $ 325.00 2 $ 9,100.00
Service
Department
Office Boy/Girl $ 325.00 3 $ 13,650.00
Total Cost/year (14 Months' Salary) 34 $ 365,750.00
84
7.2.3. Utility Cost

Utility costs are needed to maintain the main processes of the production
such as water, electricity, and plant infrastructure.
For the electricity based on PT PLN, we categorized our plant as a large
industry (above 2000 kVA). It is mentioned that the price for the large-scaled
industry since August 2017 is IDR1100 per kWh or $0.08 per kWh.
Table 7. 8. Process Equipment Electricity

Power
Usage Power
No Equipment Code Quantity Required
Time (h) (kW)
(kWh)
1 Bucket Elevator BE-100 1 24 5.3 127.200
2 Belt Conveyor CB-100 1 24 5.3 127.200
Hammer
3 G-100 1 24 60 1,440.000
Grinder
Centrifugal
4 P-100 1 24 0.1 2.400
Pump
Centrifugal
5 P-101 1 24 0.2 4.800
Pump
Centrifugal
6 P-102 1 24 5.5 132.000
Pump
Centrifugal
7 P-103 1 24 0.2 4.800
Pump
Centrifugal
8 P-104 1 24 5.5 132.000
Pump
Centrifugal
9 P-105 1 24 0.1 2.4
Pump
10 Compressor C-100 1 24 3.39 81.36
11 Centrifugal Fan F-100 1 24 5.39 129.36
12 Centrifugal Fan F-101 1 24 5.39 129.36
85
Table 7. 8. Process Equipment Electricity (continued)

Total 2,313
Working day/year
330 days
Total electricity need/year

763,250 kWh
Total Price/year
$ 61,060.03
Table 7. 9. Supporting Electricity Requirement

Power
Usage Power
No Supporting Equipment Qty Required
Time (h) (kW)
(kWh)
1 Computers 8 8 0.25 16
Photocopy, scanner, and printer
2 1 1 1.3 1.3
machine
3 CCTV 30 24 0.02 14.4
4 Dispenser 8 8 0.35 22.4
5 Indoor Lamp 30 8 0.06 14.4
6 Outdoor Lamp 30 16 0.06 28.8
7 Absence Machine 1 24 0.001 0.024
8 Air Conditioner 16 8 0.5 64
9 Projector 3 1 0.4 1.2
Total 162.524
Working day/year 330
Total electricity need/year 53,633
Total Price/year $ 4,290.63
This plant use water that obtained from the river for process and utility.
The water treatment cost is approximately $ 0.67/m3 water (BPPT, 2015).
86
Table 7. 10. Water Utility Cost

Total Cost
Water Needs L/day m3/year Cost (US$/m3)
(US$)
Plant 91576.8 30,220 0.67 $ 20,247.63
Others 5,760 1,901 0.67 $ 1,273.54
Total Price (Rp)/year $ 21,521.17
This plant needs fuel for generator which is solar and we buy it from PT.
Pertamina.
Table 7. 11. Fuel Utility Cost

Annual
Price per Total Order Cost
Material Supplier Location Order
tonnes (US$) per Year (US$)
(tonnes)
Solar PT. Pertamina Pekanbaru 151200 $0.62 $93,744
In conclusion, the total amount for utility is US$ 180,615.
7.2.4. Maintenance Cost

Maintenance is needed to maintain the condition of the facilities or plant
equipment by repairing or replacing unusable things in order to obtain a
satisfactory state of production operation. Maintenance is required both for
factories, offices, and supporting equipment so it can be used continuously and
optimal production quality can be assured.
Table 7. 12. Maintenance Cost
Maintenance Amount (percentage) Annual Cost ($)

Main equipments 15 % of Total Bare Module Cost 141.778.896
Supporting
3% of Supporting Facilities Cost 3.049
equipments
Land and building 1% of Land and Building Cost 64.542
TOTAL 141.846.487
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7.2.5. Insurance and Tax

Insurance is cost that paid to insurance company that cooperate with our
Plant. Insurance is the way to protect the company assets, both movable and fixed.
For calculating the insurance, we have some assumption based on PP No 84 Year
2010, that is stated the assumption below.
Table 7. 13. Insurance Cost

Insurance Type Measurement annual cost dollar
Plant Insurance 0.5% of FC cost $ 424,03
Employee’s 6% of annual
$ 1,98
Insurance salary
Annual Insurance Cost $ 426,01
We also have to pay the tax of land & building. The amount is shown
below
Table 7. 14. Tax of Land & Building

Description Area (m2) Cost per m2 (Rp) Cost ($)
NJOP Earth 30000 0,00 $ 96,26
NJOP Building (Office) 4.009 259,26 $ 1.039.249,56
NJOP Building (Plant) 1.695 185,19 $ 313.951,85
Total NJOP $ 1.353.297,66
NJOPTKP $ 888,89
NJOP for PBB $ 1.352.408,77
NJKP (40% NJOP) $ 540.963,51
Debted PBB (0.5% NJKP) $ 2.704,820
Table 7. 15. Tax of Salary
Net
Salary per Insurance Total Net
Amount Bruto Position Income Taxable Salary Tax
Position month per per Insurance Income
(person) Income Cost per Income per year
person ($) month per year per year
Month
President Director $3,500.00 1 210 2,520.00 3,710.00 185.50 3,524.50 42,294.00 39,405.11 1,970.26
Secretary of
$1,000.00 1 60 720.00 1,060.00 53.00 1,007.00 12,084.00 9,195.11 459.76
President Director
Finance Manager $1,500.00 1 90 1,080.00 1,590.00 79.50 1,510.50 18,126.00 15,237.11 761.86
Assistant Finance
$900.00 2 54 1,296.00 954.00 47.70 906.30 10,875.60 7,986.71 798.67
Manager
HR and Legal
$800.00 1 48 576.00 848.00 42.40 805.60 9,667.20 6,778.31 338.92
Manager
Training Coordinator $450.00 1 27 324.00 477.00 23.85 453.15 5,437.80 2,548.91 127.45
HSE Engineer $650.00 2 39 936.00 689.00 34.45 654.55 7,854.60 4,965.71 496.57
Production Manager $1,500.00 1 90 1,080.00 1,590.00 79.50 1,510.50 18,126.00 15,237.11 761.86
Process and Facility
$850.00 3 51 1,836.00 901.00 45.05 855.95 10,271.40 7,382.51 1,107.38
Engineer
Maintenance
$750.00 2 45 1,080.00 795.00 39.75 755.25 9,063.00 6,174.11 617.41
Coordinator
Operational $800.00 2 48 1,152.00 848.00 42.40 805.60 9,667.20 6,778.31 677.83
88
Table 7. 16. Tax of Salary (continued)
Net
Salary per Insuranc Total
Amount Bruto Position Income Net Income Taxable Salary Tax
Position month per e per Insurance
(person) Income Cost per per year Income per year
person ($) month per year
Month
Product Planning and
Development $1,000.00 1 60 720.00 1,060.00 53.00 1,007.00 12,084.00 9,195.11 459.76
Manager
Product Distribution
$750.00 1 45 540.00 795.00 39.75 755.25 9,063.00 6,174.11 308.71
Supervisor
Marketing Executive $850.00 1 51 612.00 901.00 45.05 855.95 10,271.40 7,382.51 369.13
Marketing Staff $600.00 2 36 864.00 636.00 31.80 604.20 7,250.40 4,361.51 436.15
Supply Chain
$900.00 1 54 648.00 954.00 47.70 906.30 10,875.60 7,986.71 399.34
Manager
Security $350.00 4 21 1,008.00 371.00 18.55 352.45 4,229.40 1,340.51 268.10
Receptionist $450.00 2 27 648.00 477.00 23.85 453.15 5,437.80 2,548.91 254.89
Cleaning Service $325.00 2 20 468.00 344.50 17.23 327.28 3,927.30 1,038.41 103.84
Office Boy/Girl $325.00 3 20 702.00 344.50 17.23 327.28 3,927.30 1,038.41 155.76
Operator $375.00 12 23 3,240.00 397.50 19.88 377.63 4,531.50 1,642.61 985.57
Labour $350.00 12 21 3,024.00 371.00 18.55 352.45 4,229.40 1,340.51 804.31
Technician $375.00 6 23 1,620.00 397.50 19.88 377.63 4,531.50 1,642.61 492.78
Total 19,350 64 1,161 26,694.00 20,511.00 1,025.55 19,485 233,825.40 167,380. 13,156.27
89
90
7.2.6 General Expense

General expenses consist of communication cost, product shipping from
plant to port, and plant overhead. Totally, we spent $ 2,726,568 for general
expenses. The details is shown below.
Table 7. 17. Communication Cost

Communication Cost (US$)
Mail 1.776
Internet and Telephone 1.776
Annual Communication Cost 3.552
Table 7. 18. Product Shipping Cost

Production
Shipping Cost per Shipping Distance Total Shipping Cost
per year
tonne per km (US$) (km) (US$)
(tonne)
10000 0,08 100,00 81.400,00
Table 7. 19. Plant Overhead

Total Price
Price per Unit Total Price Estimation per
Equipment Qty per Unit
(US$) Year (US$)
(US$)
First Aid Kit 5 7,41 37,05 111,15
Total Plant Overhead 111,15
. Table 7. 20. Printed Media Publication Cost

Printed Media Type Total Cost (US$)
Booklet Full colour display 370,37
Table 7. 21. Website Development Cost

Types Cost / year (US$)
Creating Website Cost 148
Annual Cost 178
Total Website Development Cost 400
91
7.2.7. Cost Breakdown of Operational Expenses

After calculating all operational expenses, we can know the percentage of
each cost. Raw material is the biggest one.
After calculating all operational expenses, it can be known the percentage
of each cost. Raw material is the biggest one.
Table 7. 22. Cost Breakdown

Outcome Cost %
Raw Material 19,924,000 60.69%
Indirect Labor Salary 365,750 1.11%
Direct Labor Salary 613,200 1.87%
Utilities 180,616 0.55%
Maintenance 8,430,048 25.68%
Insurance and Tax 590,153 1.80%
General Expenses 2,726,568 8.31%
TOTAL 32,830,334 100.00%
2% 8%
Raw Material
Indirect Labor Salary
Direct Labor Salary
26%
Utilities
61% Maintenance
Insurance and Tax
General Expenses
0% 1%
2%
Figure 7. 3 Cost Breakdown of Operational Expenses
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7.3. Economic Evaluation

7.3.1. Price Prediction
Benzene is a product that we get on this preliminary design plant. From
the needs of benzene which already explained on introduction, capacity product
that we will get is around 73,434 ton/year of maximum capacity. Production sale
cost for benzene is increasing year by year.
In this section, Benzene’s price is going to be determined. Since the
product is a commodity product, the only way to determine our product’s price is
to benchmark the benzene’s price in the market and projected its price to the year
when we are ready to begin our production which is in 2020. The benzene’s price
history data that is gotten from Independent Chemical Information Pricing. The
price history data can be seen from the figure below.
Figure 7. 4 Benzene Price History

(Source: www.icis.com)
From the figure above, are going to take benzene’s price in Asia. Its price
can be seen from the table below.
93
Table 7. 23 Benzene Price History

Month Price ($/ton)
July 2016 670
September 695
2016
November 630
2016
January 2017 850
March 2017 965
May 2017 820
(Source: ww.icis.com)
From the data above, we can projected benzene price in the 2018 by making
a graph and find out its trendline. The benzene price in 2018 is 1050 USD/ton or
Rp14,222,250/ton.
7.3.2. Cash Flow
Calculation of cash flow involves the income before tax, after taxes,
depreciation, OPEX, and maintenance cost. Cash flow also can indicate
fluctuations of income over the life of the plant through net income. Percentage of
tax is 25%. The lifetime of Benzene plant is 20 years. The detail cash flow will be
shown in Appendix.
7.3.2.1. Equity
On the first year of cash flow the capital of this plant is loan from
institution like bank or investor. Bank is chosen based on the minimum rate of
interest, which is Bank Negara Indonesia with 10.25% of interest rate. Beside
bank, loan of investor is needed with 13% of interest rate. The higher the interest,
investors will be more interested in investing, but investors are constrained by the
high interest rate bank loan. The 60% of capital comes from bank and 40% from
investors. All loans are paid in 10 years. The detail scheme of payment is shown
below
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Table 7. 24 Capital Loan

Capital Source Percentage Capital Share
Bank 60% 77,139,133
Investor 40% 51,426,089
Table 7. 25. Bank Payment Scheme

Year Initial Loan Loan Interest Payment Total Payment Loan after Payment
0 64,660,798 64,660,798
1 64,660,798 3,291,235 6,466,080 9,757,314 58,194,718
2 58,194,718 2,962,111 6,466,080 9,428,191 51,728,639
3 51,728,639 2,632,988 6,466,080 9,099,068 45,262,559
4 45,262,559 2,303,864 6,466,080 8,769,944 38,796,479
5 38,796,479 1,974,741 6,466,080 8,440,821 32,330,399
6 32,330,399 1,645,617 6,466,080 8,111,697 25,864,319
7 25,864,319 1,316,494 6,466,080 7,782,574 19,398,239
8 19,398,239 987,370 6,466,080 7,453,450 12,932,160
9 12,932,160 658,247 6,466,080 7,124,327 6,466,080
10 6,466,080 329,123 6,466,080 6,795,203 0
Table 7. 26 Investment Payment Scheme

Year Initial Loan Loan Interest Payment Total Payment Loan after Payment
0 43,107,199 43,107,199
1 43,107,199 3,233,040 4,310,720 7,543,760 38,796,479
2 38,796,479 2,909,736 4,310,720 7,220,456 34,485,759
3 34,485,759 2,586,432 4,310,720 6,897,152 30,175,039
4 30,175,039 2,263,128 4,310,720 6,573,848 25,864,319
5 25,864,319 1,939,824 4,310,720 6,250,544 21,553,599
6 21,553,599 1,616,520 4,310,720 5,927,240 17,242,880
7 17,242,880 1,293,216 4,310,720 5,603,936 12,932,160
8 12,932,160 969,912 4,310,720 5,280,632 8,621,440
9 8,621,440 646,608 4,310,720 4,957,328 4,310,720
95
10 4,310,720 323,304 4,310,720 4,634,024 0
Table 7. 27. Overall Loan

Year Loan Interest
1 6,524,275
2 5,871,847
3 5,219,420
4 4,566,992
5 3,914,565
6 3,262,137
7 2,609,710
8 1,957,282
9 1,304,855
10 652,427
TOTAL 26,097,098
7.3.2.2. Depreciation
Depreciation is the reduction in value of an asset. The way to depreciate an
asset is a way to account for the decreasing value of the asset to the owner and to
represent the diminishing value of capital funds invest. Salvage value is the
estimated trade-in or market value at the end of the asset’s useful life. The salvage
value, S expressed as an estimated dollar amount or as a percentage of the first
cost, may be positive, zero, or negative due to dismantling and carry-away costs.
The list of all equipment has been elaborated in Capital Expenditure section.
In this plant design, equipment and building as our assets. The equation used in
this declining balance method of depreciation is: (Blank & Tarquin: 5th edition.
Ch.16 Authored by Dr. Don Smith, Texas A&M University):
𝑑𝑚𝑎𝑥 = 0,1 (2.1)
𝑑𝑡 = 𝑑𝑚𝑎𝑥 (1 − 𝑑𝑚𝑎𝑥 )𝑡 (2.2)
96
𝐵𝑉𝑡 = 𝐵 𝑉𝑡−1 (1 − 𝑑𝑡 )𝑡−1 (2.3)
Where:
dmax = maximum depreciation rate
dt = depreciation rate for t-year
BVt = book value for t-year 
t = year of depreciation
The depreciation rate is for main equipment, supporting and also building.
The assumption of 10% is according to main depreciation for national assets. The
Deppreciation calculation can be seen in Appendix.
7.3.3. Profitability Analysis
In profitability analysis, different methods are used for each alternative
equipment lines with its alternative location. The method will be used are WACC,
Rate of Investment (ROI), Payback Period, Net Present Value (NPV), Break Even
Point (BEP), and Internal Rate of Return (IRR).
7.3.3.1. WACC
Weighted average cost of capital (WACC) is the average rate of return a
company expects to compensate all its different investors. The weights are the
fraction of each financing source in the company's target capital structure.
Before the new business is started or developed, first thing to do is an
experiment about the business that will be held, which will be advantageous or not.
To determine a project feasible or not to do, it is necessary a feasibility analysis of
investment. Investment is called feasible if it gives more profit than the expected.
Expected minimum profit are commonly known as the MARR, while profits are
calculated on the investment feasibility analysis are known as the IRR. MARR is
calculated using WACC (Weighted Average Cost of Capital).
WACC = E/V × Re + D/V × Rd × (1 − tax rate) (7.1)
Where,
E = market value of the firm’s equity
97
D = market value of the firm’s debt

V=E+D
Re = cost of equity
Re = Rf + ßex (Rm - Rf)
Rf = risk-free rate
Rm = market return
ßex = stock's beta
Based on this calculation, WACC is 9.62%. MARR can be taken as high as
WACC which is 9.62%. Some of the usual investment parameters analyzed are
given in the sensitivity analysis
7.3.3.2. Rate of Investment (ROI)
Rate of Return (ROI) is the annual profit generated by one unit of capital
invested. The formula for calculating ROI is as follows:
𝑎𝑛𝑛𝑢𝑎𝑙𝑛𝑒𝑡𝑝𝑟𝑜𝑓𝑖𝑡
%𝑅𝑂𝐼 = ( ) × 100% (7.2)
𝑖𝑛𝑣𝑒𝑠𝑡𝑒𝑑𝑐𝑎𝑝𝑖𝑡𝑎𝑙
Annual net profit net profit used is obtained either before or after taxes.
Annual Net Profit used is the after tax annual net profit of USD 32.253.508 and
invested capital of 107.767.997 the calculation is shown by equation below:
So the ROI obtained from this plant was 30 %. From the ROI calculation,
we can see that our plant is attractive to investors because it has rate of return
value that is high enough. It is appropriate with our plant ages. The ROI that we
have calculated is form after tax cash flow.
7.3.3.3 Payback Period
Payback Period is the duration (in years) of an investment will be returned. Here
is the formula for calculating payback period taking into account the Time Value
of Money:
Payout period including interest :
(𝑑𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑏𝑙𝑒 𝑓𝑖𝑥𝑒𝑑 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡) +
(𝑖𝑛𝑡𝑒𝑟𝑒𝑠𝑡 𝑜𝑛 𝑇𝐶𝐼 𝑑𝑢𝑟𝑖𝑛𝑔 𝑒𝑠𝑡𝑖𝑚𝑎𝑡𝑒𝑑 𝑠𝑒𝑟𝑣𝑖𝑐𝑒 𝑙𝑖𝑓𝑒
(7.3)
𝑎𝑣𝑔 𝑝𝑟𝑜𝑓𝑖𝑡 𝑎𝑣𝑔 𝑑𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑜𝑜𝑛
( 𝑦𝑒𝑎𝑟 + 𝑦𝑒𝑎𝑟 )
𝑎𝑠 𝑐𝑜𝑛𝑠𝑡𝑎𝑡𝑛𝑡 𝑎𝑛𝑛𝑢𝑎𝑙𝑙𝑦
If the payback period is less than a pre-determined period, the project is

acceptable. If the payback period exceeds the predetermined period, the project is
98
rejected. The payback period for this plant is 4.066 years, after calculate use
Microsoft Excel.
Our payback period is matched with the rule of thumb. The rule of thumb
said that the tolerable payback period is about 10 years and should be done after
all the loan are fully paid.
7.3.3.4 Break Even Point (BEP)
Breakeven point (BEP) is an analysis to determine and find the amount of goods
or services to be sold to consumers at a given price to cover the costs incurred and
the profit. Calculation to find the BEP is:
𝑇𝑜𝑡𝑎𝑙 𝐹𝑖𝑥𝑒𝑑 𝐶𝑜𝑠𝑡
𝐵𝐸𝑃 = (7.4)
(𝑃𝑟𝑖𝑐𝑒 𝑝𝑒𝑟 𝑢𝑛𝑖𝑡 − 𝑉𝑎𝑟𝑖𝑎𝑏𝑙𝑒 𝑐𝑜𝑠𝑡 𝑝𝑒𝑟 𝑢𝑛𝑖𝑡)
The total fixed cost is the fixed cost values tend to be stable and not
influenced by the amount of production and the variable cost is the variable cost
of the value depends on the amount of goods produced. This BEP value shows
that we have to produce and sell at least 298,580 tons of benzene to get the
investor money back with interest.
7.3.3.5 Internal Rate of Return (IRR)
Internal Rate of Return (IRR) is a measure of the maximum of interest rate
paid on project and still break even at the end of the project life. In other words,
the IRR is the interest rate when NPV = 0, so that the formula used to calculate
the IRR is:
𝑛=𝑇
𝐶𝐹𝑛
𝑁𝑃𝑉 = ∑ − 𝑇𝐶𝐼 = 0 (7.5)
(1 + 𝑟)𝑛
𝑛=1
With the value of r is the IRR. Calculating cash flow by using Microsoft excel,
IRR of 13% from benzene plant can be obtained. Compared the IRR with MARR
(12% (IRR) > 5% (MARR)), the difference is quite high (7%). According to the
definition of IRR itself, it means that IRR will be used to compare the working
capital as project with minimum probability.
7.3.3.6. Net Present Value (NPV)
Net Present Value (NPV) is the difference between the present value of
cash inflows and the present value of cash outflows. NPV is used in capital
99
budgeting to analyze the profitability of a projected investment or project. NPV

can also be interpreted as the present value of the cash flows generated by the
investment. In calculating the NPV is necessary to determine the relevant interest
rate. This value is calculated from WACC which is calculated as 9,62 % based on
capital expenditure and tax rate. Equation 3.7 is the formula for calculating NPV.
C
NPV = ∑Tt=1 (1+r)
t
t
− C0 (7.6)
where:
Ct = net cash inflow during the period t
Co = total initial investment costs
r = discount rate, and
t = number of time periods
A positive net present value indicates that the projected earnings generated
by a project or investment (in present) exceeds the anticipated costs (also in
present). Generally, an investment with a positive NPV (NPV > 0) will be a
profitable one and one with a negative NPV (NPV < 0) will result in a net loss.
This concept is the basis for the Net Present Value Rule, which dictates that the
only investments that should be made are those with positive NPV values.
From the calculation, this plant project’s NPV value is 136.626.246 It
shows that the project is not feasible to be done in 2020 because the NPV value is
less than 0. It will be examined in sensitivity analysis about this loss.
Sensitivity Analysis
7.3.3.7. Sensitivity Analysis
Sensitivity analysis is an approach to identify the effect of several
parameter’s fluctuations on economic analysis. It is done when the plant face an
unstable condition due to many factors such as selling price fluctuations, raw
material fluctuations, and direct operating labor’s salary fluctuations. This factors
are chosen because on general literature which usually used in factory in
determining value factor influence income per year. those parameters can be
increased or decreased based on the condition. Then analysis gives decision in the
factory benefit or losing for the company.
100
The first sensitivity analysis is done with decreasing and increasing the
product price. The selling price of products is one of the important variables that
can affect the stability of production because these variables will determine the
revenue and profit to be earned by the industry.
For the operational cost change, we choose to change the raw material
cost. Changes in the cost of material which takes a lot of portion in operational
cost can affect the cost of production in the factory, so that it can be used to
analyze the stability of the project. The cost of raw materials may fluctuate,
considering the price of raw materials is determined by suppliers and distribution
of raw materials also tend to change due to changes in fuel oil. The calculation of
economic feasibility parameters to changes in operating costs is below.
Maintenance cost is the incremental cost that should considered to our
plant. Maintenance can be effect in product capacity in our plant. The fluctuation
of maintenance cost will influence net present values and influence the operating
cost, so that the IRR and payback period is affected.
Deviation vs Net Present Value

120,000,000,000
100,000,000,000
Net Present Value (Rp)
80,000,000,000
60,000,000,000
40,000,000,000
20,000,000,000
0
-20% -15% -10% -20,000,000,000 0%
-5% 5% 10% 15% 20%
-40,000,000,000
-60,000,000,000
Deviation
Product Price Raw Material Price Labor Cost
Figure 7. 5 The Influence of Fluctuations on NPV
101
Deviation vs IRR
18.00%
16.00%
14.00%
12.00%
10.00%
IRR
8.00%
6.00%
4.00%
2.00%
0.00%
-20% -15% -10% -5% 0% 5% 10% 15% 20%
Deviation
Figure 7. 6 The Influence of Fluctuations on IRR
Deviation vs Payback Period

10.000
9.000
8.000
Payback Period (year)
7.000
6.000
5.000
4.000
3.000
2.000
1.000
0.000
-20% -15% -10% -5% 0% 5% 10% 15% 20%
Deviation
Figure 7. 7 The Influence of Fluctuations on Payback Period
102
CHAPTER 8
OUSTANDING ISSUE
8.1 Technical Aspect

As a new plant we need to position our plant from other existing
benzene plants. As for benzene plant, already has some exist plants there are
PT Trans Pacific Petrochemical benzene plant and PT Chandra Asri
Petrochemical Tbk. Positioning can be seen from many aspects and two most
influenced is seen from technical and economical aspect. Basically benzene
plant technology from both plants and our plant are same but there are some
aspects that differentiate them. For processing diagram of some benzene plant
in the world can be seen as figure below.
Figure 8. 1. PT Trans Pacific Petrochemical benzene plant Plant Diagram
The other issue is about the production capaity per year. Our production
capacity is small, comared to other benzene plant that exist in Indonesia, such as
PT Chandra Asri, PT Trans Pacific Petrochemical Indotama, Skyrindo Mono
Indonesia Industri,etc. Comparasion of the production capacity between the
Benzene plant in Indonesia is summarize in the table below:
Table 8. 1. Product Capacity Benchmarking of our Plant

Production Capacity
Producer Location Product
(Ton/year)
Our Plant Teluk betung Benzene 73.434
selatan, Lampung
PT Trans Pacific Tuban, Jawa Benzene 360,000
Petrochemical Timur
Pertamina Cilacap Benzene 120.000
Kilang Cilacap
Skyrindo Mono Puloampel, Benzene 110.000
Indonesia Serang
103
104
PT Chandra Asri Ciwadan, Cilegon Benzene 260.000

Petrochemical
Tbk.
8.2 Economical Aspect

To ensure the validity of cost and investment of this project plant, we
need to find the benchmark of it. There are several Benzene plants that has been
runs in the Indonesia. For further detail comparisons look at table below:
Table 8. 2. Economical Benchmarking
PBP
Plant CAPEX (million IRR
(Years)
US$)
Benzene Plant US$ 128,565,222 12.55% 5.616
PT Chandra Asri Tbk US$ 150,000,000 15% 6.78
PT Pertamina RU IV US$ 119,124,000 14.3% 6.78
Trans Pacific Petrochemical US$ 400,000,000 15% 10

Indotama
We are going to make profit from our plant . From the Table 8.2, we can
see that investment of our plant is acceptable compared to the existing plant. The
economical comparative mostly is quite same with this company. However, our
plant has IRR smaller than the existing Benzene plant.. From economic analysis,
our payback period is about 5.616 years. It is indeed fast payback period for a
new Benzene plant that have different process and raw material to other like our
planr. Our MARR is 9,62%. Our MARR is bigger than the deposito tax in the
bank, so our plant will attract investor to invest their money into our plant rather
than keeping their money in bank. IRR of our plant is 12,55%. This percentage is
actually high enough for investor.
CHAPTER 9
CONCLUSION
 Benzene consumption in Indonesia is always increasing year by year.

However, the benzene supply in Indonesia is still not fill up the demand. As
in 2016, the demand of benzene is about 620.587 ton. The supply is 291.597
per year.
 Empty Fruit Bunches are used as raw material and the plant is going to be
built in Teluk Betung, Lampung with production capacity of benzene
73434,22 ton/year.
 The process to produce benzene are drying, grinding, catalytic fast pyrolysis,
and distillation
 The Plant Efficiency is 28.9% based on mass balance and 81.603,63 kJ/kg
based on energy balance
 This sizing is including the dimension and material construction. There are 26
equipment that we have sized.
 There are four units of utilities which are water utility, air utility, electricity
utility, and fuel utility.
 The need of electricity in our plant is about 40,176,338,4 kWh/ year from
PT. PLN.
 The fuel utility need natural gas for this plant is 2000 L/h. It can be
obtained from IWATA Diesel Generator which is produced by PT Indotara
Persada.
 The total Capital Investment we need is USD 15,739,387.61 and the
operating cost is USD 32,830,334.
 The equity from our plant will be fulfilled by bank loan 60%, investor 40%.
The WACC that is calculated is 5.29%.
 The net value of benzene product is US$1,050 per tons, with sales revenue
US$ 20,711,947 annually.
 Payback period for this plant is 4 years and Net Present Value is US$
27,820,660,309. The Rate of Interest for benzene plant is 12.23%.
105
106
APPENDICES
APPENDIX A: BLOCK FLOW DIAGRAM
107
APPENDIX B : PROCESS FLOW DIAGRAM

APPENDIX B1 : Pre-Treatment
108
APPENDIX B2 : Main Process
109
APPENDIX C : LIST OF EQUIPMENT SIZING

APPENDIX C1 : Fast Phyrolisis Reactor Sizing Calculation
To determine the dimensions of the reactor, it will be done by calculating

the differential equation of the Packed Bed Reactor (PBR). The kinetics of the
reaction rate formulas are required to further perform calculation and determine
the dimensions of the reactor. Since the kinetic of the reaction is not exist in
literature, the calculation is done by scaling the size that refers from journal. The
calculation assumes efficient reduction is neglected. Carbon Steel is used as the
material. For carbon steel SA-283 Grade C itself, it has corrosion factor value
0,125 and fallowable equal to 12,650.
 Sizing
Step 1 : Collect Literature’s Data
Total Mass Flow 46000 kg/hr

Diameter Reactor 3.816 m
Height Reactor 11.44 m
Catalyst ZSM-5
(Source : Fluidized Catalytic Cracking to convert Biomass from Stephen Boust)

Step 2: Calculate Tank’s Volume (Journal Data)
𝑉𝑡𝑎𝑛𝑘 = 𝑉𝑡𝑜𝑝 + 𝑉𝑏𝑜𝑡𝑡𝑜𝑚 + 𝑉𝑠ℎ𝑒𝑙𝑙
𝑉𝑡𝑜𝑝 = 0.0847 𝐷3
𝑉𝑏𝑜𝑡𝑡𝑜𝑚 = 0.0847 𝐷3
𝑉𝑠ℎ𝑒𝑙𝑙 = 0.7854 𝐿𝑠 3
𝑉𝑡𝑎𝑛𝑘 = 0.0847 𝐷3 + 0.0847 𝐷3 + 0.7854 𝐿𝑠 3
By assuming Ls = 4D,
𝑉𝑡𝑎𝑛𝑘 = (0.0847 + 0.0847 + (0.7854 x 4))𝐷3
𝑉𝑡𝑎𝑛𝑘 = (0.0847 + 0.0847 + (0.7854 x 4))3.8163
𝑉𝑡𝑎𝑛𝑘 = 96.706 m3
Step 3: Calculate Tank’s Volume Actual
110
Flow rate actual this plant is 55730 kg/h and the journal is 46000 kg/hr. By
assuming the actual flow rate is 1.2 times than journal’s, so the volume actual this
plant is 1.2 bigger than journal’s as well.
Vtank actual = 1.2Vtank journal
Vtank actual = 1.2 x 8.544 m3
Vtank actual = 116.04 m3
Step 4: Calculate Diameter Actual
𝑉𝑡𝑎𝑛𝑘 = 0.0847 𝐷3 + 0.0847 𝐷3 + 0.7854 𝐿𝑠 3
𝑉𝑡𝑎𝑛𝑘 = (0.0847 + 0.0847 + (0.7854 x 4))𝐷3
116.04 m3 = (0.0847 + 0.0847 + (0.7854 x 4))𝐷3
𝐷3 = 66.686 m3
D = 4.055 m
Step 5: Calculate Ls
Ls = 3.5D
Ls = 4 x 1.728 m
Ls = 14.19 m
Step 6: Calculate Volume Liquid
In this case, the tank volume is assumed
100
𝑉𝑡𝑎𝑛𝑘 = 𝑉𝑙𝑖𝑞𝑢𝑖𝑑 𝑥
80
So the liquid volume is calculated as below
80
𝑉𝑙𝑖𝑞𝑢𝑖𝑑 = 𝑉𝑡𝑎𝑛𝑘 𝑥
100
80
𝑉𝑙𝑖𝑞𝑢𝑖𝑑 = 116.04 𝑥
100
𝑉𝑙𝑖𝑞𝑢𝑖𝑑 = 92.838 m3
Step 7: Calculate Liquid Height on the Tank
𝑉𝑙𝑖𝑞𝑢𝑖𝑑 = 𝑉𝑏𝑜𝑡𝑡𝑜𝑚 + 𝑉𝑙𝑖𝑞𝑢𝑖d 𝑖𝑛 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟
𝐷2
92.838 m3 = 4.706 D3 + 𝜋 𝐻𝑙𝑖𝑞𝑢𝑖𝑑
4
𝐻𝑙𝑖𝑞𝑢𝑖𝑑 = 6.827 𝑚
111
Step 8: Calculate Pressure Vessel Design

Poperate = 14.5 psi
Ptotal = Phydrolisis + Poperate
Ptotal = (𝜌. 𝑔/𝑔𝑐 . 𝐻𝑙𝑖𝑞𝑢𝑖𝑑 ) + 1.5 psi
9.18
Ptotal = (268.56 𝑥 32.17 𝑥 6.827 ) + 145 psi = 26.47 psi
Pdesign = 105% . Ptotal

Pdesign = 105% . 26.47 psi = 27.79 psi
Step 9: Calculate Wall Thickness

(𝑃𝐷 . 𝐷𝑖 )
𝑊𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = + 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟
2(𝑓. 𝐸) − ( 0.6𝑃𝐷 )
(27.79 𝑝𝑠𝑖 𝑥 159.63 𝑖𝑛)
𝑊𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = + 0.125
2(12,650 𝑥 0.8)−( 0.6 𝑥 27.79 𝑝𝑠𝑖)
𝑊𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 0.344 𝑖𝑛

Step 10: Calculate Teoritical Volume, Diameter and Length
- Teoritical Volume
Teoritical volume = liquid volume
Teoritical volume = 92.83 m3
- Teoritical Diameter
1
𝜋𝐷2 𝐿 = 𝑉𝑇𝑒𝑜𝑟𝑖𝑡𝑖𝑐𝑎𝑙
4
1
𝜋𝐷2 (3.5𝐷) = 92.83 m3
4
D3 = 59.13 m3
DTeoritical = 3.89 m
- Teoritical Length
L = 3.5D
L =3.5 (3.89) m
L = 7.791 m
Step 11: Calculate Catalyst Volume and Weight
Condition :
 Catalyst filled 80% of the reactor
 Catalyst is ZSM-5
112
 Density of catalyst is 720 kg/m3

- Catalyst Volume
80
VCat = VReactor (100)
80
VCat = 92.838 m3 (100)
VCat = 74.27 m3
- Catalyst Weight
WCat = VCat 𝜌𝐶𝑎𝑡
WCat = 74.27 m3 x 720 kg/m3
WCat = 53474 kg
113
APPENDIX C2 :. Hydrolysis Reactor

a. General Description
The Hydrolysis process will be done in a CSTR. Besides, because this
process will be done in a high temperature, this reactor should have had a jacket to
prevent the heat go outside the system.
b. Material Construction
The material that will be used in here is specified to sugar product and also
the food product. Usually in industry, for those kind of product, the carbon steel
would be used because it will not sticky to the product and will protect the
product from contaminant.
c. Sizing
For hydrolysis tank, used CSTR tank to mix Biomass with H2SO4 as well
within 60 minutes of reaction. In CSTR that are going to used
, there will be a dished head in head and bottom reactor with assumption if the
reaction will undergo in perfect mixing.
- Operating condition
Temperature : 162oC
Pressure : 1 atm
- Volume of CSTR
To calculate the volume of CSTR, the flow rate of each material input to
hydrolysis tank should be known before. As for those flow rate has been
calculated in mass balance and will be written below.
No Stream Mass Flow (kg/h) Mass Percentage (%)
1 Empty Fruit 46.2%

25000
Bunch
2 H2SO4 0.02% 29166,67 53.8%
After the flow rate has been known, the entering condition of the fluid like flow
rate, pressure, and temperature is needed. As for the assumptions R is equal to
114
3
8,314 kPa.dm /mol K and vo is calculated below
1 𝑥𝑖
= ∑( )
𝜌𝑇 𝜌𝑖
1 0.4615 0.5384
= +
𝜌𝑇 112 1830
1
= 0.00441512
𝜌𝑇
𝜌𝑇 = 226.494 kg/m3
so, the 𝜐𝑜 is
𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 54166,67 𝑘𝑔/ℎ𝑟
𝜐𝑜 = = = 66.431 dm3/s
𝑑𝑒𝑛𝑠𝑖𝑡𝑦 226,494 𝑘𝑔/𝑚3
Assumptions:
1. Optimum vapor space is equal to 20% 
2. Ratio between diameter and height is equal to 1 : 2 (Perry, 1999)

3. Conversion number is 0,75
From those assumptions above, the volume that needed for the reactor can be
calculated by equation
𝑦𝐴𝑂 . 𝑃𝑂
𝐹𝐴𝑂 = 𝐶𝐴𝑂 . 𝜐𝑜 = 𝜐
𝑅. 𝑇𝑂 𝑜
𝐹𝐴𝑂 = 0.028 𝑥 66. 4312 𝑑𝑚3 s
𝐹𝐴𝑂 = 1.860 mol/s
In the calculation above there were no fraction gas (yA0) because in this
reaction there will not be a gas.
Based on the literature, in hydrolysis reaction with H2SO4 as a catalyst,

there is kinetic reaction (ko) that equal to 0.00205 and the energy activation is
equal to 7,69 J/mol (Muhaimin, 2011). From those data the other values can be
calculated as below.
𝐸𝑎
𝑘 = 𝑘𝑂 . 𝑒 𝑅𝑇
7.69
𝑘 = 0.0205 𝑒 8.314 𝑥 423.15
115
𝑘 = 0.02054
𝑟𝐴 = 𝑘. [𝐶𝐴 ]
𝑟𝐴 = 0.02054 𝑥 [0.004120879] = 8.4657𝑥10−5 mol/dm3.s

1
= 11812.26 dm3.s/mol
𝑟𝐴
𝐹𝐴𝑂 . 𝑋
𝑉=
−𝑟𝐴
1.860 𝑥 0.75
𝑉=
−8.46 𝑥 10−5
𝑉 = 16478.85 dm3 = 16.478 𝑚3
Adding the optimum vapor space
𝑉𝑡𝑎𝑛𝑘 = 𝑉𝑓 (100⁄80)
𝑉𝑡𝑎𝑛𝑘 = 16.478(100⁄80)
𝑉𝑡𝑎𝑛𝑘 = 20.598 𝑚3
Adding the top and bottom cover, assumption of value D : Ls is 1 : 2
𝑉𝑡𝑜𝑝 = 0.0847 𝐷3
𝑉𝑏𝑜𝑡𝑡𝑜𝑚 = 0.0847 𝐷3
𝑉𝑠ℎ𝑒𝑙𝑙 = 0.7854 𝐿𝑠 3
30.63 𝑚3 = 0.0847 𝐷3 + 0.0847 𝐷3 + 0.7854 𝐿𝑠 3
20.598 𝑚3 = 0.0847 𝐷3 + 0.0847 𝐷3 + 0.7854 (2𝐷)3
𝐷3 = 42.597 𝑚3
D = 3.492 m = 137.49 in
- Liquid Height
116
𝑉𝑙𝑖𝑞𝑢𝑖𝑑 = 𝑉𝑏𝑜𝑡𝑡𝑜𝑚 𝑐𝑜𝑣𝑒𝑟 + 𝑉𝑙𝑖𝑞𝑢𝑖𝑑 𝑜𝑛 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟
1
30.63 𝑚3 = 0.0847 𝐷3 + 𝜋𝐷2 𝐻𝑙𝑖𝑞𝑢𝑖𝑑
4
1
33.439.63 𝑚3 = 0.0847 (3.497)3 + 𝜋(3.497)2 𝐻𝑙𝑖𝑞𝑢𝑖𝑑
4
𝐻𝑙𝑖𝑞𝑢𝑖𝑑 = 4.032 𝑚
𝐻𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 = 2𝐷 = 6.984 𝑚
- Pressure Vessel Design

Poperate = 1 atm = 14.7 psi
Ptotal = Phydrolisis + Poperate
Ptotal = (𝜌. 𝑔/𝑔𝑐 . 𝐻𝑙𝑖𝑞𝑢𝑖𝑑 ) + 14.7
Ptotal = (860.14 𝑥 9.18/32.17 𝑥 4.037) + 14.7 = 31.824 psi
Pdesign = 105% . Ptotal
Pdesign = 105% . 71.68 psi = 33.41 psi = 2.27 atm
- Determining Tank Length

To calculate the tank length, selection of material is needed. In order to resistant
from corrosion, Carbon Steel (SA-285 Grade B) is suitable as the material. For
SA-285 Grade B itself, it has corrosion factor value 0,04 and fallowable equal to
12,500. From those data, the wall thickness can be calculated.
(𝑃𝐷 . 𝐷𝑖 ) + 𝑐𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟
𝑊𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 =
2(𝑓. 𝐸) − ( 0.6𝑃𝐷 )
(75.26 𝑝𝑠𝑖 𝑥 156.94 𝑖𝑛) + 0,04

𝑊𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 =
2(12,500 𝑥 0.45) − ( 0.6 𝑥 33.415 𝑝𝑠𝑖)
𝑊𝑎𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 1.05 𝑖𝑛
- Impeller Sizing
To mix the streams well, the tank uses six-blade 45 ̊ open turbine, as for the
standard design for this impeller according to Walas, 1990 is:
Di : Dt = 1 : 3
W : Di = 1 : 8
117
C:W=1:3
Where Di = impeller diameter
Dt = tank diameter
W = agitator width
C = distance from bottom of the tank
Impeller diameter = 0.333 x tank diameter
Di = 0.333 x 3.492 m = 1.33 m
Impeller width = 0.125 x impeller diameter
W = 0.125 X 1.33 m = 0.16 m
Impeller distance from the bottom of tank = 0.333 x impeller width
C = 0.333 x 0.16 = 0.055 m
𝑙𝑖𝑞𝑢𝑖𝑑 ℎ𝑒𝑖𝑔ℎ𝑡 𝑥 𝑆𝐺
𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 =
𝐷𝑡
4.60 𝑚 𝑥 0.86014
𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 =
3.987 𝑚
𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑖𝑚𝑝𝑒𝑙𝑙𝑒𝑟 = 0.9932 ≈ 1 𝑢𝑛𝑖𝑡
Impeller’s speed = 100 rpm = 1.67 rps
118
APPENDIX C3 : Catalyst Regenerator

The reactor is used for catalyst regeneration by combusting the coke in the
pore of the catalyst by hot air. The reactor is modelled as plug flow reactor (Bai,
Zhu, Jin, & Yu, 1998). For this model, the rate law of coke combustion is
𝑑𝐶𝑐
= −𝑟𝑐 𝜌𝑃 (1 − 𝜖̅)⁄𝐺𝑠 )
𝑑𝑥
−𝑟𝑐 = 𝑘𝑐 𝑃𝑂2 𝐶𝑐
Where,
Cc = Coke content on catalyst (%wt)
x = length of the reactor (m)
𝜖̅ = cross section average voidage
Gs = total catalyst flowrate (kg/m2s)
PO2 = partial pressure of O2 (atm)
Kc = 1.65 x 108 exp ( -1.612 x 105/RT)
R = 8.314 kJ/kmol K
Initial coke content on catalyst is assumed 0.05%wt and the final is
0.008%wt. Cross-section average voidage is assumed 0.8 and total catalyst flow
rate is 40 kg/m2.s.
The derivation of the equation is:
𝑑𝐶𝑐
= 𝑘𝑐 𝑃𝑂2 𝐶𝑐 𝜌𝑃 (1 − 𝜖̅)⁄𝐺𝑠 (64)
𝑑𝑥
And the equation above is solved using polymath
119
From the polymath, the length of the reactor for coke combustion is 6.586 m
The diameter of the reactor is about 1/3-1/5 L. So that
𝐿 6.586
𝐷= = = 2.195𝑚
3 3
𝑃×𝑅
𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = + 𝐶𝐴
(𝐸 × 𝑆) − (0.6 𝑃)
S is allowable stress (74514.7 psi for SS 316). E is joint efficiency 0.8 (Walas
1988). CA is corrosion allowance. For carbon steel the value of corrosion
allowance is 0.00889 m.
120
14.7 𝑝𝑠𝑖 × 1.0977 𝑚

𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = + 0.00889 𝑚
(74514.7 𝑝𝑠𝑖 × 0.8) − (0.6 × 14.7 𝑝𝑠𝑖)
𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 = 0.00935 𝑚 = 9.350 𝑚𝑚
121
APPENDIX C4 : Biomass Warehouse Sizing

This warehouse is used for stocking the raw materials (empty fruit
bunches). The raw materials are stocked monthly from the supplier around Way
Kuala.
Before it got know the warehouse specifications, these are some data
which are:
a. Bulk density of empty fruit bunches = 355 kg/m3
b. The process will be done continuously
c. The amount of raw materials is = 100,000 kg/day = 4166.67 kg/hr
 Basic Planning
Construction materials = Concrete
𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠 𝑆𝑡𝑜𝑟𝑒 = 𝑒𝑚𝑝𝑡𝑦 𝑓𝑟𝑢𝑖𝑡 𝑏𝑢𝑛𝑐ℎ𝑒𝑠 𝑎𝑠 𝑟𝑎𝑤 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙/𝑑𝑎𝑦𝑠
𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠 𝑆𝑡𝑜𝑟𝑒 = 100,000 𝑘𝑔/𝑑𝑎𝑦𝑠 𝑥 30 𝑑𝑎𝑦𝑠/𝑚𝑜𝑛𝑡ℎ
𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠 𝑆𝑡𝑜𝑟𝑒 = 3,000,000 𝑘𝑔
𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠 𝑆𝑡𝑜𝑟𝑒 = 3,000 𝑡𝑜𝑛𝑠
𝑇ℎ𝑒 𝑎𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑑𝑒𝑝𝑜𝑠𝑖𝑡𝑒𝑑
𝑅𝑎𝑤 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑉𝑜𝑙𝑢𝑚𝑒 =
𝑏𝑢𝑙𝑘 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑒𝑓𝑏
3,000,000 𝑘𝑔
𝑅𝑎𝑤 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑉𝑜𝑙𝑢𝑚𝑒 = = 8450.70 𝑚3
355 𝑘𝑔/𝑚3
𝑆𝑎𝑓𝑒𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 10%, 𝑠𝑜 90% 𝑣𝑜𝑙𝑢𝑚𝑒 𝑓𝑖𝑙𝑙𝑖𝑛𝑔 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠 𝑤𝑎𝑟𝑒ℎ𝑜𝑢𝑠𝑒

1
𝑉𝑜𝑙𝑢𝑚𝑒 𝑏𝑎𝑟𝑛 = 𝑥 8450.70 𝑚3 = 9389.67 𝑚3
0.9
𝑉𝑜𝑙𝑢𝑚𝑒 𝑏𝑎𝑟𝑛 = 𝑝 × 𝑙 × 𝑡 (
Length : Width : Height ratio = 4:3:1
 Warehouse Specification
Length = 36.85 m
Width = 27.64 m
Height = 9.21 m
122
APPENDIX C5 : Benzene Warehouse Sizing

This warehouse is used for stocking the benzene product. Before it got to
know the warehouse specifications, know some data has to be known, which are:
a. Overall density of benzene = 876 kg/m3
b. The process will be done continuously
c. The amount of benzene production is 9271.6 kg/hr
The storage tank for benzene product use cylindrical tanks because
cylinder tank is easier to fabricate and has strong structural shape. The upper end
of this cylindrical tank has ellipsoidal shape, while the bottom end of this
cylindrical tank has flat shape. The material used for the storage tank is stainless
steel. Carbon steel is avoided because it can’t withstand acidity and corrosion.
 Tank Volume
The first step for sizing the equipment is calculating the tank volume. The
calculation will be done based on the input specified in storage tank. For one day,
the benzene that will produced is 11,125.92 kg. If the storage tank can hold
benzene for 1 weeks, then the mass of benzene that is stored in the storage tank is
77,881.44 kg. By knowing the mass flow rate of benzene, can calculated the
volumetric flow rate for storage tank.
𝑘𝑔
𝑚 11,125.92 𝑑𝑎𝑦 𝑥 7 𝑑𝑎𝑦
𝑉= = = 88.90 𝑚3
𝜌 𝑘𝑔
876 3
𝑚
By considering the safety factor of storage tank which is 10% of the total
volume, it means that the storage tank capacity (working volume) cannot exceed
90% of the total volume. Therefore, the total volume is:
88.90 𝑚3
𝑉= = 98.78 𝑚3
0,9
 Diameter and Height of the Tank

To calculate the height and diameter of cylindrical tank, can used
cylinder volume formula, which is:
123
1
𝑉𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 = 𝜋𝐷2 𝑥𝐻𝑠
4
Based on the rule of thumb of cylindrical storage tank, the ratio of height
and diameter of the tank is 2:1, therefore Hcylinder = 2D, and the cylinder volume
formula can be modified into:
1
𝑉𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 = 𝜋2𝐷3
4
The tank total volume is the sum of cylinder volume and ellipsoidal head
volume. The volume of ellipsoidal head is:
1 2
𝑉ℎ 𝑒𝑙𝑙𝑖𝑝𝑠𝑜𝑖𝑑𝑎𝑙 =𝜋𝐷 𝑥𝐻ℎ
4
According to Walas (1990), the ratio between head height and diameter is
1:6, therefore Hh = 1/6 D, and the ellipsoidal head volume formula can be
modified into:
1 2 1 1
𝑉ℎ 𝑒𝑙𝑙𝑖𝑝𝑠𝑜𝑖𝑑𝑎𝑙 = 𝜋𝐷 𝑥 𝐷 = 𝜋𝐷3
4 6 24
Therefore, the total tank volume is;
1 1 13
𝑉 = 𝑉𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 + 𝑉ℎ = 𝜋2𝐷3 + 𝜋𝐷3 = 𝜋𝐷3
4 24 24
By arranging above equation, the tank diameter can be obtained:
3 24𝑉
𝑡
𝐷=√
13𝜋
3 24(406.5 𝑚3 )
𝐷=√
13𝜋
𝐷 = 19.35 ≈ 762.20 𝑖𝑛
Based on the previous rule of thumb, the tank height can be obtained from
diameter, and it is calculated below:
𝐻𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 = 2 𝑥 6.2 𝑚 = 38.71 𝑚
1
𝐻ℎ = 𝑥 6.2 𝑚 = 3.22 𝑚
6
𝐻𝑇 = 12.4 𝑚 + 1.03 𝑚 = 41.94 𝑚 = 1651.43 𝑖𝑛
 Design Pressure
124
Design pressure is needed to decide what type of tank that is going to be

used. Design pressure is affected by height of fluid, density of fluid and gravity,
as mentioned in the equation below:
𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑
𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑓𝑙𝑢𝑖𝑑 = 𝑥 ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑡𝑎𝑛𝑘
𝑡𝑎𝑛𝑘 𝑣𝑜𝑙𝑢𝑚𝑒
88.90 𝑚3
𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑓𝑙𝑢𝑖𝑑 = 𝑥 41.94 𝑚
98.78 𝑚3
𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑓𝑙𝑢𝑖𝑑 = 37.75 𝑚
The pressure of the tank is:
𝑃ℎ = 𝜌. 𝑔. 𝐻𝑓𝑙𝑢𝑖𝑑
𝑘𝑔
𝑃ℎ = 876 𝑥 9.81 𝑥 41.94 𝑚 = 360470.359 𝑃𝑎 = 3.56 𝑎𝑡𝑚
𝑚3
The design pressure is calculated by considering the safety factor of 15%.
𝑃𝑑𝑒𝑠𝑖𝑔𝑛 = 1.15 𝑥 (1 + 3.56 𝑎𝑡𝑚) = 5.24 𝑎𝑡𝑚 = 77.119 𝑝𝑠𝑖
 Thickness of Wall and Head

Wall and head thickness of storage tank is influenced by several factors, such as
corrosion factor, maximum allowable stress, joint efficiency and equipment age.
These data are varies based on the material used, for example the corrosion factor
of stainless steel is smaller than carbon steel, because stainless steel can withstand
corrosion more than carbon steel. Tank wall thickness can be calculated by using
this equation:
𝑃𝑥𝑅
𝑡𝑤 = + (𝐶 𝑥 𝐴)
𝑆𝐸 − 0.6 𝑃
While storage tank head thickness is calculated by the following equation:
𝑃 𝑥 𝐷𝑖 𝑥 𝐾
𝑡ℎ = 2𝑆𝐸−0.2 𝑃 + (𝐶 𝑥 𝐴) (98)
Where:
t = Material thickness
P = Pressure gauge
R = Shell radius
Di = Shell inner diameter
125
1 𝐷 2
K = ellipsoidal formula factor = 6 [2 + (2ℎ) ]
S = Maximum allowable stress

E = Joint efficiency
C = Corrosion factor
A = Planned equipment age
Material = Stainless Steel
Corrosion factor (C) = 0.0042 in/year
Allowable working stress (S) = 16,250 lb/in2
Connection efficiency (E) = 0.85
Planned equipment age (A) = 30 years
Therefore, the storage tank wall thickness is:
77.1197 𝑝𝑠𝑖 𝑥 762.20 𝑖𝑛 𝑖𝑛
𝑡𝑤 = 𝑙𝑏 + (0.0042 𝑦𝑒𝑎𝑟 𝑥 30 𝑦𝑒𝑎𝑟𝑠) (99)
(16250 2 0.85)−(0.6 𝑥 77.1197 𝑝𝑠𝑖)
𝑖𝑛 𝑥
𝑡𝑤 = 0.57 𝑖𝑛 ≈ 14.478 𝑚𝑚
While the storage tank head thickness is:
1 762.20 𝑖𝑛 2
77.1197 𝑝𝑠𝑖 𝑥 762.20 𝑖𝑛 𝑥 [2+( ) ] 𝑖𝑛
6 2 𝑥 1651.43 𝑖𝑛
𝑡ℎ = 𝑙𝑏 + (0.0042 𝑥 30 𝑦𝑒𝑎𝑟𝑠) (100)
(2𝑥16,250 2 0.85)−(0,2 𝑥 77.11 𝑝𝑠𝑖) 𝑦𝑒𝑎𝑟
𝑖𝑛 𝑥
𝑡ℎ = 0.37 𝑖𝑛 ≈ 9.398 𝑚𝑚 (101)
126
APPENDIX C7 : Demine Water Tank

To sizing the water demine tank produced from the water pre-tereatment process,
followed algorithm as shown:
1. Determine operating condition
The water is processed in atmospheric pressure and room temperature
because of the input is water which do not need pressure for storing the water.
Hence the operating condition is shown on table below
 Temperature = 25oC
 Pressure = 1 atm = 14.7 psi
2. Determine type and material of tank
Next, needed to choose the material and type that will be used for the tank.
For the material, the consideration is based on the economic aspect. Hence, the
material chosen is carbon steel is chosen due to its competitive price and quality with
other materials. Besides, it also depends on the function which to store water, the non
corrosive fluid and it do not need to store in certain temperature. Another reason is
the good strength of carbon steel and it is easy to get.
For the type of tank, consider the operating condition which do not need
pressure for storing so the type of vessel choosen will be cylinder vertical with
concrete foundation. The type of head is flat head.
3. Estimate liquid volume in tank

To estimate the tank volume, needed to know the capacity and the density
of the liquid stored. The capacity is based on the water needed in benzene plant.
The calculation is provided from the after HEN calculation for cold utility
𝜌 = 1004 𝑘𝑔/𝑚3
𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 76314 𝑘𝑔/𝑑𝑎𝑦
𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦
𝐿𝑖𝑞𝑢𝑖𝑑 𝑉𝑜𝑙𝑢𝑚𝑒 𝑖𝑛 𝑇𝑎𝑛𝑘 =
𝜌
𝑘𝑔
76314
𝑑𝑎𝑦
𝐿𝑖𝑞𝑢𝑖𝑑 𝑉𝑜𝑙𝑢𝑚𝑒 𝑖𝑛 𝑇𝑎𝑛𝑘 = = 76 𝑚3
1004 𝑘𝑔/𝑚3
4. Assume tank space to determine tank volume
127
Assumption will be used to design the storage tank is listed below

a. The volume of the tank space is 10%
b. Height ratio cylinder with a diameter of the cylinder is 2:1
c. Close the top and bottom cap shaped dished head (flat).
To determine the tank volume, assumed that the volume of tank is 10%
greater than the liquid volume in tank. This assumption is also based on the safety
aspect to prevent the unforeseen circumstances. Another Hence, the tank volume
would be
𝑇𝑎𝑛𝑘 𝑉𝑜𝑙𝑢𝑚𝑒 = 𝐿𝑖𝑞𝑢𝑖𝑑 𝑉𝑜𝑙𝑢𝑚𝑒 𝑖𝑛 𝑇𝑎𝑛𝑘 ∗ 1.1
𝑇𝑎𝑛𝑘 𝑉𝑜𝑙𝑢𝑚𝑒 = 76 𝑚3 ∗ 1.1 = 83.61 𝑚3
5. Calculate tank diameter and height

Tank diameter would be determined based on assumption of H/D = 2.
This based on the rule of thumb got from literature (Wallas), where H is height
and D is diameter. Hence the calculation would be
1 2
𝑉 = 𝜋 ( 𝐷) 𝐻
2
1
𝑉 = 𝜋 𝐷2 2𝐷
4
𝐷 = (2𝜋𝑉)1/3
𝐷 𝑡𝑎𝑛𝑘 = (2 𝑥 3.14 𝑥 83.61 𝑚3 )1/3 = 8.53 𝑚
Therefore,
𝐻 𝑡𝑎𝑛𝑘 = 2 × 8.53 𝑚 = 17.062 𝑚
6. Calculate Design Pressure

Height of liquid in tank is assumed to be 90% of the total height of the
tank. Hence the liquid height would be
𝐻 𝑙𝑖𝑞𝑢𝑖𝑑 𝑖𝑛 𝑡𝑎𝑛𝑘 = 90% × 17.062 𝑚 = 15.355 𝑚
To determine the design pressure, it calculates the hydrostatic pressure of
the liquid in tank
𝐻𝑦𝑑𝑟𝑜𝑠𝑡𝑎𝑡𝑖𝑐 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑖𝑛 𝑡ℎ𝑒 𝑡𝑎𝑛𝑘 = 𝜌 𝑥 𝑔 𝑥 𝐻 𝑙𝑖𝑞𝑢𝑖𝑑 𝑖𝑛 𝑡ℎ𝑒 𝑡𝑎𝑛𝑘
= 1004 𝑘𝑔/𝑚3 𝑥 9.8 𝑚/𝑠 2 𝑥 15.355𝑚
= 151087 𝑃𝑎 = 1.51 𝑏𝑎𝑟
128
With a safety margin of 15%, then

𝐷𝑒𝑠𝑖𝑔𝑛 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 1.15 𝑥 (1 + 1.51𝑏𝑎𝑟) = 2.88 𝑏𝑎𝑟 = 41.87 𝑝𝑠𝑖𝑎
7. Determine Shell and Head Thickness

Used construction material made of stainless steel with specification type
304, grade 3 (SA-167) (App. D, Brownell, p: 342)
fallowable = 18,750.00
Corrosion factor (CA) = 0.042
Connection for welding selected type double welded butt joint
Welding efficiency. (E) = 0.80 (Table 13.2, Brownell)
To calculate the shell thickness (ts), use the equation from Brownell, page 254
[𝑃𝑑 𝑥 𝐷𝑖 + 𝑐]
𝑆ℎ𝑒𝑙𝑙 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 =
[2 𝑥 (𝑓 𝑥 𝐸 − 0.6 𝑥 𝑃𝑑)]
41.86 𝑝𝑠𝑖 × 336.11 𝑖𝑛 + 0.0042
𝑆ℎ𝑒𝑙𝑙 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 (𝑡𝑠 ) = = 0.52 𝑖𝑛
2 × (16750 × 0.8 − 0.6 × 41.86 𝑝𝑠𝑖)
Therefore, or flat head thickness that could determine the thickness used in
the equation from the literature. The head thickness based on rule of thumb is 3.5
times thicker from the shell thickness. The head thickness would be
𝐻𝑒𝑎𝑑 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 (𝑡ℎ ) = 3.5 × 𝑡𝑠 = 3.5 × 0.52 𝑖𝑛 = 1.84 𝑖𝑛
Table F.1. Demine Water Tank

Equipment Demine Tank
Code T-402
Number of Unit 2
Diameter (m) 8.53
Height of Tank (m) 17.062
Shelll Thickness (in) 0.52
Head Thickness (in) 1.84
129
APPENDIX C8 : Coagulant Tank

The calculation for sizing coagulant tank is based on the data of rigid based
material. The table below shows the data that is used
Table G.1. Rigid Base Material Data Sheet
Free board (m) 0.40

Wall Thickness (mm) 6
Thickness of base (mm) 6
Then it could calculate the height of the tank with free board data. The
diameter of the coagulant tank that determined is 8.4 m with 4.4 m height. There
will be four tanks due to the big amount of water to be processed in the plant per
day. Hence, it got divided the mass flow rate to 4 tanks. The mass flow rate of
each tank would be 3197.5 kg/h.
130
APPENDIX C9 :. Filtration Tank Sizing

Filtration involves the removal of suspended and colloidal particles from the
water by passing it through a layer or bed of a porous granular material, such as
sand. Rate of filtration (loading rate) is the flow rate of water applied per unit area
of the filter. It is the velocity of the water approaching the face of the filter and
define as:
𝑄
𝑣𝑎 =
𝐴𝑠
Where va = face velocity, m/d = loading rate, m3/d.m2
Q = flow rate onto filter surface, m3/d
As = surface area of filter, m2
In this filtration method, it was choosen that Sand Filter as granular
material and Slow Sand Filter (SSF) as the technology. Design criteria for SSF
according to UK expertise is define in this table.
Table H.1. Design Criteria For SSF

Recommended Level (UK
Parameter
experience)
Design Life 10-15 years
Period of operation 24 h/day
Filtration rate 0.1 – 0.2 m/h
5 – 200 m2/ filter (min. of two
Filter bed area
filters)
Height of filter bed
Initial 0.8-0.9 m
Minimum 0.5-0.6 m
Effective size 0.15-0.3 mm
Uniformity coefficient <3
Height of underdrains + gravel 0.3-0.5 m
layer
Height of supernatant water 1m
(source: Addis Abba University)
The calculation of SSF design shown below:
1. Calculate the required tank area
131
Before calculate the tank area, the flow rate of water based on water
requirement in benzene plant is 7631 m3/day. Hence, the required tank
area calculation (Atank) would be as follows
1
𝐴𝑡𝑎𝑛𝑘 = 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑥 ( )
𝑓𝑖𝑙𝑡𝑟𝑎𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑒
𝑚3 1
7631 𝑚
𝑑𝑎𝑦 0.15
𝐴= 𝑥 ( ) = 2119.72 𝑚2
ℎ ℎ
24
𝑑𝑎𝑦
For this area, this plant can use tank with 25 m long and 15 m wide. From
typical table above, the height of the tank require could be calculated from
provided data
- System underdrain + gravel = 0.4 m
- Filter bed = 0.85 m
- Supernatant water = 1 m
So the total tank height is 2.25 m
 Thus, the dimension of the tank become 25 m long, 15 m wide and 2,25 m
height
 Finally it can be calculated the number (n) of filters by divided surface
area of (A) and maximum surface per filter which known as 50 m2. The
total surface area of filter couldbe calculated fro equation below. The
design loading rate based on the table above. So, it takes 160 m3/m2 day
𝑄
𝑣𝑎 =
𝐴𝑠
7631 𝑚3 /𝑑𝑎𝑦
𝐴= = 47.69 𝑚2
𝑚3
160 2
𝑚 𝑑𝑎𝑦
47.69 𝑚2
𝑛= = 0.953 ≈ 1
50 𝑚2
132
APPENDIX C10 : Ion Exchange Tank

In the sizing calculation of ion exchanger, the result would be the resin volumes.
It is calculated based on the surface area requirement for demineralization process
of total water needed in benzene plant. Hence, the algorithm calculation will be as
follows
Calculate
Examine Water Decide the use
Cation
Analysis of degasifier
Concentration
Calculate anion Decide Calculate

concentration reasonable throughput Q
after degasifier running time (t) (m3)
Consider the
Calculate resin
Calculate ionic aproximate
volume
load per cycle operating
required
capacity
Figure I.1.. Algorithm for Ion Exchanger Sizing Calculation
1. Examine water analysis

All ion exchange systems are designed for a given feed water. Some
variations of the feed water analysis are acceptable, and should be taken into
account, but an ion exchange system cannot be designed efficiently for vastly
different water types. For instance, a demineralization system designed for the
treatment of deep well water is completely different from a system designed to
treat reverse osmosis permeate.
The first thing to do is thus obtain a reliable water analysis. When the
water analysis is not constant, for example due to seasonal variations, it could not
take an "average composition" as the basis of design. Instead, use the "most
probable" case, design with this water, and check as a second step what will
happen with the "minimum" and "maximum"' waters. Henc, the composition of
water used for the calculation is the normalyzed worst water analysis. The data for
cation shown on table below. The concentration is in mg/l or meg/l as CaCO3
133
Table I.1. Cation Composition of Ion Exchanger Feed

Concentration
Cations
(mg/l)
Calcium (Ca) 100
Magnesium (Mg) 50
Sodium (Na) 90
Potassium (K) 10
Total 250
Meanwhile for the anion the water analyisis shown below

Table I.2. Anion Composition of Ion Exchanger Feed
Concentration
Anions
(mg/l)
Bicarbontate (HCO3) 100
Sulphate (SO4) 50
Chloride (Cl) 75
Nitrate (NO3) 25
Total 250
The water analysis will determine what resin combination is required
2. Calculate cation concentration Cc [meq/L]

As seen on the table of cation composition, the cation concentration would
be 250 mg/l as CaCO3
𝐶𝑐 = 250 𝑚𝑔/𝑙
3. Decide about the use of a degasifier
Based on literature, it mentioned that if the bicarbonate content is greater
than 0.6 to 1.0 mg/l a degasifier may be justified. As seen on the table of the anion
composition, the HCO3 concentration is 100 mg/l, greater than the requirement.
Hence, a degasifier is recommended. It would remove HCO3 and residual CO2
after degassifier estimated to be 0.25 mg/l.
4. Calculate the anion concentration Ca [meq/L]: it contains

Cl—, SO4=, NO3—, SiO2, HCO3— or residual CO2 after degasser if any. Due to the
134
use of degasifier, there is a change of anion concentration. Degassifier produced

residual CO2 that makes the composition of anion would be
𝐶𝑎 = 𝐶𝑆𝑂4 + 𝐶𝐶𝑙 + 𝐶𝑁𝑂3 + 𝐶𝐶𝑂2
𝐶𝑎 = 50 + 75 + 25 + 0.25 = 150.25 𝑚𝑔/𝑙
5. Decide about a reasonable running time t in hours between regenerations.
Benzene plant would be operated in continous operation. So, the operating hour
would be 24 hours per day. Then for the running time is 24 hours.
𝑡 = 24 ℎ
6. Using the flow rate f in m3/h calculate the throughput Q [m3]
𝑓 = 800 𝑚3 /ℎ
𝑚3
𝑄 = 𝑓 · 𝑡 = 800 . 24 = 19200 𝑚3
ℎ
7. Calculate the ionic load per cycle in eq (concentration in meq/L times

throughput in m3):
o 𝐶𝑎𝑡𝑖𝑜𝑛 𝑙𝑜𝑎𝑑 [𝑒𝑞] = 𝐶𝑐 · 𝑄 = 250 . 19200 = 4800000 𝑒𝑞
𝑚𝑔
o 𝐴𝑛𝑖𝑜𝑛 𝑙𝑜𝑎𝑑 [𝑒𝑞] = 𝐶𝑎 · 𝑄 = 150.25 . 19200 = 2884800 𝑒𝑞
𝑙
8. Consider the approximate operating capaciy of the resins as follows

o SAC: capc = 1.0 eq/L with HCl regeneration or
SAC: capc = 0.8 eq/L with H2SO4 regeneration
o SBA: capa = 0.5 eq/L
9. The resin volume V required (in litres) is equal to the ionic load [eq]
divided by the operating capacity [eq/L]:
o SAC:
𝐶𝑐 𝑄 4800000
𝑉𝑐 = = = 4800000 𝐿 .
𝑐𝑎𝑝𝑐 1
𝐶𝑎 𝑄 2884800
𝑉𝑎 = = = 5769600 𝐿
𝑐𝑎𝑝𝑐 0.5
135
10. At the end of this calculation, this must make sure that the specific flow
rate of both resin columns is compatible with the general recommendations of the
resin producer.
The specific flow rate in h—1 (often expressed in bed volumes per hour
BV/h) is equal to the flow rate in m3/h divided by the resin volume in m3. The
usual range is 5 to 50 h—1. For a compact plant with minimum investment cost,
use a specific flow rate around 30 to 35 h—1. If the specific flow rates calculated
from the resin volumes Vc and Va are too high, increase the running time t. If they
are too low, reduce the running time t.
136
APPENDIX C11 : Heat Exhanger Sizing

The type of heat exchanger that will be used is shell and tube (STHE),
because STHE can transfer heat with higher efficiency, and also the tube side is
easy to clean. The material for the STHE is carbon steel, because it has high
thermal conductivity and relatively cheap, but has long life span. These are the
step to design STHE
1. Determine the specification of fluid. The specifications are flow rate (kg/h) of
hot fluid and cold fluid, the temperature (⁰C) inlet and outlet of the fluids, the
duty, and the location of fluids that pass the tube or shell, and the type of flow
in heat exchanger which are co-current or counter current. To determine the
duty, use this equation
𝑄 = mc Cc (t 2 − t1 ) = mh Ch (T2 − T1 )
If there is a phase change, use
𝑄 = 𝑚. 𝐶𝑝. (𝑇𝑏 − 𝑇) + 𝑚. ∆𝐻𝑣
2. Determine physical properties of fluids, which are heat capacity (kJ/kg/K),
density (kg/m3), viscosity (Pa.s), thermal conductivity, and fouling factor
(W/m2/K). The fouling factor can be obtained from table below.
Figure J.1. Fouling Factors Coefficients
3. Assume value of overall coefficient, Uc (W/m2.K)
137
The value of overall coefficient can be obtained from table below
Figure J.2. Overal Heat Transfer Coefficients
4. Calculate the LMTD, correction factor, and Δt.

(T1 − t 2 ) − (T2 − t1 )
LMTD =
T −t
ln(T1 − t2 )
2 1
𝑇1 − 𝑇2
𝑅=
𝑡2 − 𝑡1
𝑡2 − 𝑡1
𝑆=
𝑇1 − 𝑡1
Δt = LMTD x FT
Value of FT is obtained from Fig. 2.19 in Chemical Engineering Design vol 6,
2005
5. Calculate the heat transfer area
𝑄
𝐴𝑜 =
𝑈𝑐 . 𝐿𝑀𝑇𝐷
138
6. Decide the type of shell and tube heat exchanger (fixed tubesheet, U-tube
etc.), outside diameter tube, inside diameter tube, tube thickness, length of
tube, number of pass, dan pitch type. Use the standard tube counts table for
this purpose.
Figure J.3. Heat Exchanger Tube Layouts

(Source: NPTEL, Chemical Engineering Design)
7. Calculate the number of tube

- Cross Flow Area of Tube
𝐴𝑡𝑢𝑏𝑒 = 𝜋 . 𝐷𝑜 . 𝑡𝑢𝑏𝑒 𝑙𝑒𝑛𝑔𝑡ℎ
- Number of tube
𝐴𝑜
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 =
𝐴𝑡𝑢𝑏𝑒
- Tube cross sectional area
𝜋
𝑇𝑢𝑏𝑒 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎 = . (𝐷𝑖2 )
4
- Area per pass
𝑛𝑜 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠
𝐴𝑟𝑒𝑎 𝑝𝑒𝑟 𝑝𝑎𝑠𝑠 = . 𝑡𝑢𝑏𝑒 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎
𝑛𝑜 𝑜𝑓 𝑝𝑎𝑠𝑠
- Tube side superfacial velocity
𝑚𝑡𝑢𝑏𝑒 1
𝑇𝑢𝑏𝑒 − 𝑠𝑖𝑑𝑒 𝑠𝑢𝑝𝑒𝑟𝑓𝑎𝑐𝑖𝑎𝑙 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = .
3600 𝑎𝑟𝑒𝑎 𝑝𝑒𝑟 𝑝𝑎𝑠𝑠
- Tube side velocity
𝑡𝑢𝑏𝑒 − 𝑠𝑖𝑑𝑒 𝑠𝑢𝑝𝑒𝑟𝑓𝑎𝑐𝑖𝑎𝑙 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦
𝑇𝑢𝑏𝑒 − 𝑠𝑖𝑑𝑒 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑢𝑡𝑢𝑏𝑒 =
𝜌
Tube side velocity about 5-15 m/s for high pressure gas and 1-4 m/s for
liquid
8. Calculate the diameter of shell
139
- Diameter bundle, Db
1
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠 𝑛1
𝐷𝑏 = 𝐷𝑜 ( )
𝐾1
The value of K1 dan n1 are obtained from table 12.4 in Chemical
Engineering Design vol 6, 2005
- Diameter shell Ds
𝐷𝑠 = 𝐷𝑏 + 𝑠ℎ𝑒𝑙𝑙 𝑏𝑢𝑛𝑑𝑙𝑒 𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒
The value of shell bundle clearance is obtained from figure 12.10 in
Chemical Engineering Design vol 6, 2005
9. Estimate tube side heat transfer coefficient
- Reynlods Number, Prandtl Number, and L/D
𝜌 𝑢𝑡𝑢𝑏𝑒 𝐷𝑖
𝑅𝑒 =
𝜇
𝐶𝑝 𝜇
𝑃𝑟 =
𝑘
𝐿 𝑡𝑢𝑏𝑒 𝑙𝑒𝑛𝑔𝑡ℎ
=
𝐷 𝐷𝑖
- Tube side heat transfer coefficient, hi
𝑘
ℎ𝑖 = 𝑗𝐻 . 𝑅𝑒 . (Pr)0.33 ( )
𝐷𝑖
The value of jH is obtainable from figure 2.23 in Chemical Engineering
Design vol 6, 2005
10. Estimate shell side heat transfer coefficient
- Baffle spacing dan tube pitch
Baffle Spacing, lB = baffle spacing coefficient x inside diameter shell
Tube pitch, pt = tube pitch coefficient x outside diameter tube
The value of baffle spacing coefficient is 0.2 – 0.5 while tube pitch
coefficient is 1.25 – 1.35
- Shell Cross Flow Area
𝑝𝑡 − 𝐷𝑜
𝐴𝑠 = . 𝐷𝑠 . 𝑙𝐵
𝑝𝑡
- Equivalent Diameter, de
1.10
For triangular pitch: 𝑑𝑒 = 𝐷𝑜
𝑥 (𝑝𝑡2 − 0.917𝐷𝑜2 )
140
1.27
For square pitch: 𝑑𝑒 = 𝑥 (𝑝𝑡2 − 0.785𝐷𝑜2 )
𝐷𝑜
- Shell-side superfacial velocity

𝑚𝑠ℎ𝑒𝑙𝑙 1
𝑆ℎ𝑒𝑙𝑙 − 𝑠𝑖𝑑𝑒 𝑠𝑢𝑝𝑒𝑟𝑓𝑎𝑐𝑖𝑎𝑙 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = .
3600 𝐴𝑠
- Shell side velocity
𝑠ℎ𝑒𝑙𝑙 − 𝑠𝑖𝑑𝑒 𝑠𝑢𝑝𝑒𝑟𝑓𝑎𝑐𝑖𝑎𝑙 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦
𝑆ℎ𝑒𝑙𝑙 − 𝑠𝑖𝑑𝑒 𝑉𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑢𝑠ℎ𝑒𝑙𝑙 =
𝜌
Tube side velocity about 5-15 m/s for high pressure gas and 0.3-1 m/s for
liquid
- Reynold Number & Prandtl Number
𝜌 𝑢𝑠ℎ𝑒𝑙𝑙 𝐷𝑒
𝑅𝑒 =
𝜇
𝐶𝑝 𝜇
𝑃𝑟 =
𝑘
- Shell side heat transfer coefficient, hs
𝑘
ℎ𝑠 = 𝑗𝐻 . 𝑅𝑒 . (Pr)0.33 .
𝐷𝑒
The value of jH is obtainable from figure 2.29 in Chemical Engineering
Design vol 6, 2005
11. Calculate the overall heat transfer coefficient, Uo
𝐷𝑜
1 1 𝐷𝑜 𝐷𝑜 (𝑚𝑚)𝑥 ln 𝐷𝑖 1
= ( + 𝑓𝑜𝑢𝑙𝑖𝑛𝑔 𝑓𝑎𝑐𝑡𝑜𝑟 𝑡𝑢𝑏𝑒) + +
𝑈𝑜 ℎ𝑖 𝐷𝑖 2𝑥𝐾 ℎ𝑠
+ 𝑓𝑜𝑢𝑙𝑖𝑛𝑔 𝑓𝑎𝑐𝑡𝑜𝑟 𝑠ℎ𝑒𝑙𝑙
Where K is thermal conductivity for heat exchanger material. For carbon
steel K = 45 Wm-1 oC-1
12. Calculate pressure drop in shell side and tube side
- Pressure drop in tube
𝐿 𝜌𝑈𝑡2
𝛥 𝑃𝑡 = 𝑁𝑃 [8 𝑗𝐹 ( ) + 2.5]
𝐷𝑖 2
The value of jF is obtainable from figure 2.24 in Chemical Engineering
Design vol 6, 2005
- Pressure drop in shell
141
𝐷𝑠 𝐿 𝜌𝑈𝑠2
𝛥 𝑃𝑠 = 8 𝑗𝐹 . . .
𝐷𝑒 𝑙𝐵 2
Pressure drop must be below 0.5 bar. If the pressure drop above 0.5 bar, must
change the value of Uc in step 3.
142
APPENDIX C12 : Distillation Column Sizing Calculation

1. Determine Heavy key and Light key of the components
2. Determine tdew and tbubble
The mole fraction of components is known by the HYSYS Simulation.
After that, calculate the vapour presure of each component by the Antoine
equation and calculate value of m by the equation of Psat/Ptotal and fraction
mole of each components in bottom.
Calculate the bubble temperature by trial-error in excel, so tbubble is

𝑚𝑖
𝛼𝑎𝑣 =
𝑚𝐻𝐾
3. Calculate the minimum tray (Nm) and optimum tray (Nopt).

To find the minimum tray, can use two ways those are by graphically and
the equation below, where:
log[ (𝑥𝐿𝐾 ⁄𝑥𝐻𝐾 )𝐷 (𝑥𝐻𝐾 ⁄𝑥𝐿𝐾 )𝐵 ]
𝑁𝑀 =
log(𝛼𝐿𝐾⁄𝐻𝐾 )𝑎𝑣
To get the Nopt is by using graphically method using the figure below:
Figure K.1. Relation between optimum-to-minmum ratio and Fensk separation factor of alfa
values
(Source: Mc Cabe, 1993)
1) Determine the value of log[ (𝑥𝐿𝐾 ⁄𝑥𝐻𝐾 )𝐷 (𝑥𝐻𝐾 ⁄𝑥𝐿𝐾 )𝐵 (𝑥𝐿𝐾 ⁄𝑥𝐻𝐾 )𝐹 ],
(𝛼𝐿𝐾⁄𝐻𝐾 )𝑎𝑣 .
2) Plot the data to the graph
143
3) Drawn a line to the left, so get Nopt/NM.
4. Calculate the Value of RM and Ropt.
Figure K.2. Optimum-minimum reflux ratio relationship to the column's feed, distillate, and
bottoms composition
4) Determine the value of log[ (𝑥𝐿𝐾 ⁄𝑥𝐻𝐾 )𝐷 (𝑥𝐻𝐾 ⁄𝑥𝐿𝐾 )𝐵 (𝑥𝐿𝐾 ⁄𝑥𝐻𝐾 )𝐹 ],
(𝛼𝐿𝐾⁄𝐻𝐾 )𝑎𝑣 .
5) Plot the data to the graph
6) Drawn a line to the left, so get the 𝑅𝑜𝑝𝑡 ⁄𝑅𝑚𝑖𝑛
5. Determining θ.
The method is finding the value of 𝑥𝐿𝐾 /𝑥𝐻𝐾 on the feed, and the value
of 𝛼𝐿𝐾 with use Figure A.3 below
144
Figure K.3. Underwood's teta vs key ratios in feed

𝛼𝑖 −𝜃 𝛼𝑖 𝑋𝑖𝐷
6. Determining , and , that will be used for determining value of
𝛼𝑖 𝛼𝑖 −𝜃
𝛼𝑖 𝑋𝑖𝐷
∑ by using Figure A.4 below
𝛼𝑖 −𝜃
Figure K. 4.Underwood's parameter for heavy key and heavier components

145
7. Calculate RM and Ropt with equation below:

𝛼𝑖 𝑋𝑖𝐷
𝑅𝑀 + 1 = ∑
𝛼𝑖 − 𝜃
Calculation of Column Diameter
1. Calculate the velocity of vapor at the stripping and rectifying section.

𝑉𝑚
𝑠𝑙𝑜𝑝𝑒 =
𝐿𝑚
𝜌𝑣
𝐹𝐿𝑉 = 𝑠𝑙𝑜𝑝𝑒 × √
𝜌𝐿
Using the graph below, it can be known the value of K which will be
used to calculate the velocity of vapor and liquid.
Figure K. 5. Correlation of FLV and K

𝜌𝑣
𝑣 = 𝐾×√
𝜌𝐿
2. Calculate the area needed for the column.

𝑄 1
𝐴= ×
𝑣 1 − 0.1
146
4𝐴
𝐷=√
𝜋
Calculation of Column Height

1. Assume that the external reflux ratio (RD)
2. Calculate the minimum reflux ratio (RDm)
(RD) is 1.5 times RDm
3. Use Gilliand equation and graph to get the number of stage and calculate
with the equation below
𝑅𝐷 − 𝑅𝐷𝑚
𝑅𝐷 + 1
’
Figure K. 6. Gilliand Equation and Graph
𝑁−𝑁𝑚𝑖𝑛
4. Calculate the number of stage with equation 𝑁+1
5. Assume that a plate spacing is 0.5 m

6. Calculate the height of Column
147
APPENDIX C13 : Three Phase Separator Sizing Calculation
Table L.1. Value of Feed Properties
Properties Value
Gas Flowrate (MMSCFD) 0.0464
Oil Flowrate (BOPD) 66.717
Water Flowrate (BWPD) 6.124
Total Liquid (BPD) 72.84
ATM Press. 14.7
Op Press (psig) 2529.46
Op Temp (F) 140
Gas Compressibility Z 0.95
Retention Time (min) t 10.00
Remove drops >__micron from gas 150
Remove H2O drops >__micron from oil 500
Remove oil drops >__micron from H2O 200
Vessel Liquid Level - beta 50%
Gas Molecular Weight 2.018
Oil Specific Gravity 0.84
Water Specific Gravity 1
Gas Viscosity m 0.009
Oil Viscosity ml 3.2
H2O Viscosity mw 0.69
1. Calculation Design Specification Information
Table L.2. Design Spesification Information
148
Variable Value Units

𝜌g = (P+Pa)(MW) 0.84 lb/cu ft
10.73*(T+460)*(z)
𝜌l = 62.4(sp. gr.) 52.42 lb/cu ft
𝜌w = 62.4(sp. Gr H2O.) 62.40 lb/cu ft
Dp= 0.00003937(micron)/12 0.000492 ft
Dw= 0.00003937(micron)/12 0.001640 ft
Do = 0.00003937(micron)/12 0.000656 ft
m=MMSCFD(1e6)(MW) 0.00286
379.4(24)(3600) lb/sec
Qa=m/rg 0.00341 acfs
Ql 0.00434 cu ft/sec
Qw 0.0004 cu ft/sec
Qm=Qa+Ql+Qw 0.01 cu ft/sec
pm=(rl*Ql+rg*Qg+rw*Qw)/Qm 31.32 lb/cu ft
Fractional area of liquids - alpha 0.5
2. Calculate CD and Minimum Diameter
Table L.3. CD and Minimum Diameter

Trial No. 1 2 3 4 5 6
Assume CD 2.01 1.18 1.03 1.00 0.99 0.99
Vt = (4gDp(𝜌l-𝜌g)/3CD𝜌g)0.5 0.80 1.05 1.12 1.14 1.15 1.15
Re = 1488(DpVt𝜌g)/𝝁 54.89 71.58 76.69 78.00 78.32 78.40
Calculated CD 1.18 1.03 1.00 0.99 0.99 0.98
0.5
𝑇𝑍𝑄
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 12 𝑥 ( ) = 0.7 𝑖𝑛
2.4𝑉𝑡(𝑃 + 𝑃𝑎)
3. Determine The Frictional Height Of Water In The Vessel
149
d x Leff (for gas capacity) 0.05
d2 x Leff (for liquid capacity) 1041
4. Calculate Maximum Vessel Diameter for Water Settling
Variable Value Unit
Vtw = 1488gDw2(pw-pl)/18 𝝁 l 0.02 ft/sec
Max Height of Oil Pad, Ho 160.91 in max
Maximum diameter = Ho/(𝜷-𝜷w) 390 in max
5. Calculate Maximum Vessel Diamter for Oil Settling
Variable Value Unit

Vtw = 1488gDw2(pw-pl)/18 𝝁 w 0.0166 ft/sec
Max Height of water, Hw 119.40 in max
Maximum diameter = Hw/ 𝜷 w 1373 in max
Maksimum Vessel Diameter = 390 inch
6. Calculate Vessel Gas and Liquid Capacity Requirements

0.5
𝑇 𝑥 𝑍 𝑥 𝑄𝑔 𝜌𝑔 𝐶𝐷
𝑑 𝑥 𝐿𝑒𝑓𝑓 = 420 [ ] [( ) ]
𝑃 𝜌1− 𝜌𝑔 𝑑𝑚
𝑑2 𝑥 𝐿𝑒𝑓𝑓 = 1.42[(𝑄𝑜 𝑡𝑟𝑜 ) + ((𝑄𝑤 𝑡𝑟𝑤 )]
7. Determine Appropriate Diameter and S-S Length
Diameter
15 16 17 18 19 20
(in)
Leff (gas) 0.00301 0.00282 0.00266 0.00251 0.00238 0.00226
Lss (gas) 1.25 1.34 1.42 1.50 1.59 1.67
150
Leff
4.62 4.06 3.60 3.21 2.88 2.60
(liquid)
Lss
6.17 5.42 4.80 4.28 3.84 3.47
(liquid)
Lss (ft) 7 6 5 5 4 4
L/D 5.20 4.13 3.53 3.00 2.53 2.10
Since L/D must be in the range of 3-5, the chosen length and diameter for the 3-
phase separator are 6 ft and 16 in.
151
APPENDIX C14 : Conveyor Sizing Calculation

- Belt Conveyor 1
Belt conveyor is used to transfer Empty Fruit Bunch from Grinding
process to Hydrolysis Reactor.
Table M. 1. Operation Condition of Belt Conveyor

Mass Flow Rate 250 Tonne/hr
Length 26.24 Ft
Angle Elevation 30 Degree
Belt Width 42 Inch
Figure M. 1 Data Capacity for Belt Conveyor

(Source : Wallas,2017)
 Velocity of Conveyor
𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦
𝑢=( ) 𝑥 100 𝑓𝑡/𝑚𝑖𝑛
𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑓𝑟𝑜𝑚 𝑓𝑖𝑔𝑢𝑟𝑒
So, the velocity of conveyor :
250 𝑡𝑜𝑛𝑛𝑒/ℎ𝑟 𝑓𝑡
𝑢 = (238.5 𝑡𝑜𝑛𝑛𝑒/ℎ𝑟) 𝑥 100 min=104.82 𝑓𝑡/𝑚𝑖𝑛 = 174.70 ft/min
152
 Power
𝑃𝑡𝑜𝑡𝑎𝑙 = 𝑃ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 + 𝑃𝑒𝑚𝑝𝑡𝑦

𝐿 𝑊
𝑃ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 = (0.4 + )( )
300 100
L = Length of Conveyor
W = Capacity (ton/hr)
Figure M.2. Pempty

(Source : Wallas, 1998)
26.24 250
𝑃ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 = (0.4 + ) (100) = 1.218 hp
300
𝑃𝑒𝑚𝑝𝑡𝑦 𝑖𝑠 𝑑𝑒𝑡𝑒𝑟𝑚𝑖𝑛𝑒𝑑 𝑏𝑦 𝑙𝑜𝑜𝑘𝑖𝑛𝑔 𝑎𝑡 𝑡ℎ𝑒 𝑔𝑟𝑎𝑝ℎ = 0.9 ℎ𝑝
153
𝑃𝑡𝑜𝑡𝑎𝑙 = 1.218 ℎ𝑝 + 0.9 ℎ𝑝 = 2.128 ℎ𝑝
- Belt Conveyor 2
Belt conveyor is used to transfer Empty Fruit Bunch from Warehouse to
Grinder.
Table M.2. Operation Condition of Belt Conveyor

Mass Flow Rate 416.67 Tonne/hr
Length 22.96 Ft
Angle Elevation 30 Degree
Belt Width 42 Inch
 Velocity of Conveyor
𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦
𝑢=( ) 𝑥 100 𝑓𝑡/𝑚𝑖𝑛
𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑓𝑟𝑜𝑚 𝑓𝑖𝑔𝑢𝑟𝑒
So, the velocity of conveyor :
416.67 𝑡𝑜𝑛𝑛𝑒/ℎ𝑟 𝑓𝑡
𝑢 = ( 499.5 𝑡𝑜𝑛𝑛𝑒/ℎ𝑟 ) 𝑥 100 min=104.82 𝑓𝑡/ min = 83.41 𝑓𝑡/𝑚𝑖𝑛
 Power
𝑃𝑡𝑜𝑡𝑎𝑙 = 𝑃ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 + 𝑃𝑒𝑚𝑝𝑡𝑦

𝐿 𝑊
𝑃ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 = (0.4 + )( )
300 100
L = Length of Conveyor
W = Capacity (ton/hr)
22.96 416.67
𝑃ℎ𝑜𝑟𝑖𝑧𝑜𝑛𝑡𝑎𝑙 = (0.4 + )( ) = 1.985 hp
300 100
𝑃𝑒𝑚𝑝𝑡𝑦 𝑖𝑠 𝑑𝑒𝑡𝑒𝑟𝑚𝑖𝑛𝑒𝑑 𝑏𝑦 𝑙𝑜𝑜𝑘𝑖𝑛𝑔 𝑎𝑡 𝑡ℎ𝑒 𝑔𝑟𝑎𝑝ℎ = 0.83 ℎ𝑝

𝑃𝑡𝑜𝑡𝑎𝑙 = 1.985 ℎ𝑝 + 0.83 ℎ𝑝 = 2.815 ℎ𝑝
154
APPENDIX C15 : Hammer Mills Sizing Calculation

Hammer Mills
It needs the empty fruit bunch for hydrolysis is about 0.33 mm size in
particles. So choose use hammer mills according to table N.1
Table N. 1 Operating Ranges for Commonly Used Size Reduction Equipment
(Source : Walas, 1990)
The power requirement for hammer mills is based on the extent of size
reduction that expressed by the following equation
𝑘𝑊ℎ 1 1
𝑊 ( ) = 10𝑊𝑖 ( − )
𝑡𝑜𝑛 √𝑑 √𝑑𝑖
Where d and di are the final and initial diameter (μm), and Wi is work
index for the material. The work index for Empty fruit bunch is 13.81.
𝑘𝑊ℎ 𝑘𝑊ℎ 1 1
𝑊 ( ) = 10 (13.81 )( − ) = 0.906857 𝑘𝑊ℎ/𝑡𝑜𝑛
𝑡𝑜𝑛 𝑡𝑜𝑛 √300 √20000
If the mass flow rate of empty fruit bunch is 416.67 ton/hour, the total power
requirement is
𝑘𝑊ℎ 𝑘𝑊ℎ 𝑡𝑜𝑛 𝑘𝑊ℎ
𝑊 ( ) = 0.906 𝑥416.67 = 377.503
𝑡𝑜𝑛 𝑡𝑜𝑛 ℎ𝑜𝑢𝑟 ℎ𝑜𝑢𝑟
To choose the dimension of hammer mills that needed, looking to the vendor
(SBM-Mining and Construction) PC4012-90 with the dimension 1800 mm x 1650
mm x 1800 mm.
155
Figure N. 1. Hammer Mill Specification

(Source: SBM-Mining and Construction Machinery, 2017)
156
APPENDIX C16 : Cyclone Sizing Calculation

To design a cyclone Cy-101, Cy-102, Cy-103, first should be calculated
the pressure drop with the equation below
4𝜌𝑔 𝑉 2
∆𝑃 =
2𝑔
∆𝑃 = 4.313 𝜌 (𝑓𝑡⁄𝑠𝑒𝑐/100)2 𝑝𝑠𝑖
Assumed that the inlet velocity is 50-150 ft/sec (Walas, 2012) and ρg is the
density of gas.
𝑙𝑏 𝑓𝑡 2
4 × 0.000324 3 × (150 𝑠 )
𝑓𝑡
∆𝑃 =
𝑓𝑡
2 × 32.2 2
𝑠
∆𝑃 = 0.4529 𝑝𝑠𝑖
Number of turns inside the cyclone is represented by the equation below.
𝑁𝑡 = [0.1079 − 0.00077 𝑉 + 1.924(10−6 )𝑉 2 ]𝑉
𝑁𝑡 = [0.1079 − 0.00077 × 150 + 1.924(10−6 ) × 1502 ]150
𝑁𝑡 = 22.563
To obtain the particle diameter, use the equation:
0.5
9𝜇𝐷
𝐷𝑝 = [ ]
4𝜋𝑁𝑡 𝑉(𝜌 − 𝜌𝑔 )
𝐷 4𝜋(𝜌 − 𝜌𝑔 )𝐷𝑝2
=
𝑁𝑡 𝑉 9𝜇
2
𝐷 4𝜋(21.0554 − 0.000324) 10
= ( )
𝑁𝑡 𝑉 9 × 1.285. 10−5 304800
𝐷
= 0.002461
𝑁𝑡 𝑉
𝐷 = 0.002461. 𝑁𝑡 𝑉
𝐷 = 8.3302 𝑓𝑡 = 2.540 𝑚
𝐷
𝑊= = 0.635 𝑚
4
𝐷
𝐷0 = = 1.270 𝑚
2
𝐷
𝐴 = = 1.270 𝑚
2
𝐻𝐶 = 2𝐷 = 5.079 𝑚
157
𝑆 = 2𝐷 + (𝐷⁄8) = 5.397 𝑚
𝐻 = 4𝐷 = 10.159 𝑚
𝐷
𝐵= = 0.635 𝑚
4
158
APPENDIX C17 : Compressor Sizing Calculation

There are some steps to sizing compressor. This has five steps to calculate
operating data what needed to know. This is the step to size every compressor
A. Determine the type of compressor, (based on volume inlet and discharge
pressure)
B. Determine heat capacity each inlet flow to compressor
C. Calculate te compressor power
D. Calculate the temperature discharge
E. Calculate the compressor head
It uses centrifugal compressor to transport gas from a process to another process.

This plant chooses centrifugal compressor because this compressor able to
transport gas in a large flow. Furthermore, this plant needs continuous flow to
transport gas to maximize working of other unit. And then, use general range of
application of compressor graph to determine which compressor used.
159
Figure P. 1.General Range of Application of Compressor

(Source: Kern, 2010)
Based on this graph, it can be known that the volume inlet flow and
discharge pressure are in centrifugal range are. This is the volume flow inlet
and discharge
pressure table.
Table P.1. Compressor Specifications
Volume Discharge
Inlet Flow Pressure
Compressor (kg/hour) (kPa)
C-100 222789,365 800
(Source: Author’s Personal Data)
After this known what type compressor that will be used, then
calculate compressor power, discharge temperature and compressor head.
This is the detail calculation of first compressor (C-101), which use to
transport gas to membrane.
 Compressor Power
160
Z = compressibility factor
R = universal gas constant
T
R1 = inlet temperature, K
P = standard pressure
T = standard temperature
E = overall efficiency
Q = gas flow rate
W = work (kJ/mol)
P2 = pressure outlet
P1 = pressure inlet
Y = heat capacity ratio
Discharge Temperature
After that, calculate the compressor power, and need to calculate the outlet
temperature from compressor. Here is the equation is to calculate discharge
temperature in compressor:
Compressor Head
Compressor head is like a compressor ability to reach maximum height of
other unit to transport gas. Here is the equation is to calculate compressor head in
compressor:
By the same calculation with the first compressor calculation, it can

calculate compressor power, discharge temperature and compressor head for
another compressor. This is the result table for each compressor
161
Table P. 2. Compressor Sizing
Volume Discharge Compressor Discharge
Compressor Inlet Flow Pressure Power Temperature

C-100 224912 800 10.08 391,4735
(Source: Author’s Personal Data)
(m3/min) (kPa) (kWh) (kPa)
Table P. 3. Flue Gas (C-101) Specification
Compression ratio 4.0

Compressor Head (m) 122207.7
Efficiency (Ep) 0.785
Pressure inlet (kPa) 100
Pressure outlet (kPa) 900
Power (kW) 10,09
162
APPENDIX C18 : Pump Sizing Calculation

Pump may be classified in two general types, dynamic and positive
displacement. Here is the upper limit of pressure and capacity of different types of
pumps.
Table Q. 1 Types of Pump
(Source: Wallas, 2012)

Positive displacement pumps are those in which energy is imparted to the
liquid in a fixed displacement volume, such as a casing or a cylinder, by the rotary
motion of gears, screws, or vanes, or by reciprocating pistons or plungers.
Centrifugal pumps are dynamic pumps. Energy is imparted to the liquid by means
of a disk with curved vanes rotating on a shaft called the impeller. The impeller
imparts kinetic energy to the fluid by means of its shape and high rotational
velocity. This energy is transformed to pressure energy when the fluid reaches the
pump casing. From so many difference types of pump decided to use centrifugal
pump based on the characterization.
For the material, there are a few materials available utilized to for this
equipment. One of the most common is by stainless steel S316 and Carbon steel.
carbon steel as the material for the pump for a noncorrosive fluid (water etc) and
stainless steel for the pump for corrosive fluid. In benzene plant there is no
corrosive material so it is decided to use carbon steel as material of pump in
benzene plant.
163
Pump is used in order to move liquid from one unit to another. For this
plant, the total pumps needed are around 6 pumps. Here is the brief description of
each pump usage.
The selected centrifugal pump as the type of pump in this plant because
the flow rate and viscosity is low, and there is no high temperature of mixture in
this plant. That used calculation based on handbook chemical engineering and
mechanical fluids course. The material that are going to use is carbon steel.
First, input all of the data that needed such as mass flow, density, pressure
suction and discharge (or pressure at destination), vapor pressure, temperature
suction, and static head in the excel.
In sizing pump, use that all the pump efficiency is 75%
∆𝑃 = 𝑃𝑎𝑡 𝑑𝑒𝑠𝑡𝑖𝑛𝑎𝑡𝑖𝑜𝑛 − 𝑃𝑎𝑡 𝑙𝑖𝑞𝑢𝑖𝑑 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑠𝑢𝑐𝑡𝑖𝑜𝑛
Then it can be calculated head by using this equation
𝐹𝐻𝑃
𝐻=
𝑔 𝑥 𝑚̇
 Head Actual
𝐻
𝐻 𝑎𝑐𝑡𝑢𝑎𝑙 =
Ƞ𝑝
 FHP
𝑑𝑊𝑝𝑜𝑚𝑝𝑎
𝐹𝐻𝑃 = 𝑚̇
𝑑𝑚
 BHP
𝐹𝐻𝑃
𝐵𝐻𝑃 =
Ƞ𝑝
 NPSHA
NPSH is calculated by many factor. The most important variable here is
the length t of pipe itself, equivalent length of valve and bending.
𝑃1(𝑎𝑡𝑚) 𝑉22 𝐹 𝑃𝑣𝑎𝑝𝑜𝑟
𝑁𝑃𝑆𝐻𝐴 = (𝑧 )
− 2 − 𝑧1 − − −
𝜌𝑔 2𝑔 𝑔 𝜌𝑔
 NPSHR
𝑃𝑠𝑢𝑐𝑡𝑖𝑜𝑛 − 𝑃𝑣𝑎𝑝𝑜𝑟
𝑁𝑃𝑆𝐻𝑅 =
𝜌𝑔
164
So power of the pump will calculate use of this equation

𝑑𝑊𝑎𝑜 −𝑑𝑊𝑝𝑜𝑚𝑝𝑎 𝑃 𝑉2
− = = ∆ ( + 𝑔𝑧 + ) + 𝐹
𝑑𝑚 𝑑𝑚 𝜌 2
Table Q. 2. Pump Summarize Calculation

Densit Hydrauli
Q Temperatur NPSH NPSH
Pump y Head c Power
(m3/h) e (oC) A R
(kg/m3) (kW)
299.16
Cy-102 7 5 1007 60.49 9.37 10.05 49.40
299.16
Cy-103 7 5 1007 48.23 12.49 10.05 121.75
299.16
Cy-101 7 5 1007 92.03 47.09 45.51 24.20
165
APPENDIX D : PLANT LAYOUT AND HSE

APPENDIX D1 : Equipment Layout Design
Area/Unit Total Area

No Name Code Quantity
(m2/unit) Occupied (m2)
Fast Pyrolysis
1 R-101 1 16.4025 16.4025
Reactor
Hydrolysis
2 R-100 1 12.194 12.194
Reactor
Catalyst
3 R-103 1 4.84 4.84
Regenerator
Biomass
4 S-100 1 1018.534 1018.534
Warehouse
5 Benzene Tank S-101 1 374.4225 30.1754
Demine Water
6 T-100 1 72.76 72.76
Tank
7 Coagulant Tank T-101 1 70.56 70.56
8 Filtration Tank T-102 1 375 375
T-103
9 Ion Exchange 2 3.37 6.74
T-104
E-100
10 Heat Exchanger 2 4.88 9.76
E-101
Distillation
D-200 1 1.1881 1.1881
Column
11
Distillation
D-201 1 0.9216 0.9216
Column
Three Phase
12 V-102 1 9.61 9.61
Separator
Elevator
13 BE-100 1 7.48 7.48
Conveyor
14 Belt Conveyor CB-100 1 8.55 8.55
166
15 Hammer Mills M-100 1 3.78 3.78

Filter
16 P-101 1 2.01 2.01
Plate&Frame
Cy-100
17 Cyclone 2 0.4 0.8
Cy-101
18 Compressor 1 0.47 0.47
P-101
19 Water Pump P-102 3 11 33
P-103
APPENDIX D2 : Supporting Facilities
Facility Dimension (m) Area (m2)
Mosque 13 15 195
Cafetaria 13 10 130
Production Office 15 11 165
Fire Extinguisher Station 15 11 165
Park 20 15 300
Park 20 15 300
Maintenance Centre 15 15 225
Utility Control Room 15 10 150
Laboratory 40 15 600
HSE Office 13 11 143
Sparepart Chemical & Supply
36.85 27.64 1018.534
Warehouse
Control Room 20 15 300
R&D Plant Office 15 11 165
Open Area (road, parking area, etc) 200
Total Area (m2) 4208.534
167
APPENDIX D3 : HAZID Analysis

Potential Hazard
Location Description Causes Frequency Prevention
Hazard Effect
High humidity
Pest Check humidity, control

To store Empty Fruit
Flood because the the pest, check drainage,
Storage Tank empty fruit Bunches are Minor Likely
drain gets clogged and check material amount
bunches damaged
Material amount periodically
exceed the storage

capacity
Grinder Organize waste biomass
Over capacity Severe Unlikely
Unit for damage entering crusher
Grinder Unit material size Noise

Surfacing tools that
Loud Operation pollution that
reduction Minor Most generate noise with a
can damage
Noise silencer, and oblige the
the hearing of
use of earplug
workers
For heating High pressure and Fire and/or Regular checking and
Heat exchanger Major Likely
and cooling temperature explosion temperature control
168
Potential Hazard
Location Description Causes Frequency Prevention
Hazard Effect
Regular checking and
Distillation Butanol High pressure and Fire and/or
Severe Likely temperature control
column purification temperature explosion
provisioning
Noise
pollution that
Unit for Loud Operation generate noise with a
Pump can damage Minor Most
water flowing Noise silencer, and oblige the
the hearing of
use of earplug
workers
Noise
pollution that
Unit for gas generate noise with a
Compressor can damage Minor Most
flowing silencer, and oblige the
the hearing of
use of earplug
workers
Unit for
Electricity Electrical Safety helmet, gloves, and
electricity Electricity current Severe Likely
Generator shock shoes, make barrier
production
Steam Utility To Produce High Pressure and Blowout and Routine inspections and
Major Likely
Unit Steam High Temperature high thermal controller instrumentation
169
in Process exposure for temperature and

pressure
Noise
Noise due to pollution that
generate noise with a
operation unit to can damage Major Likely
silencer, and oblige the
produce steam the hearing of
use of earplug
workers
170
Hazard
Location Potential Frequency
Description Causes Prevention
Hazard Effect
Low temperature Overflow from
To provide Control the output
Cold Utility Unit and high capacity cold utility Major Likely
cooling temperature
of cooling water which release to
water
which produce the environment
To distribute Protect the piping
Piping Network Damage and Major Likely
fluid in Corrosion, Failure network and control
leakage of pipe
process periodically
The contain of
Over Capacity of
Area for the pool will Minor Likely Level Control System
Waste Treatment Pool
treating the spill
Area
waste Environmental
Leakage of Pool Minor Likely Checking periodically
Pollution
Improve training and
Someone Slip Minor Likely
Quality move carefully
Spill Chemical
Laboratory Area Control Do not bring any fire
Substances
Assesment Flame Severe Unlikely source and provide some
fire exthinguisher
Provide training to the
To control Errors in operator about the
Control Room System will be Major Unlikely
operation in operating working procedure and
shut down
the plant procedures oblige supervisors to
perform daily briefing
171
Hazard
Location Description Causes Potential Hazard Frequency Prevention
Effect
To transport
Bucket elevator the material Dust from Major Most
Nature of material Using PPE
(empty fruit material
bunches)
Fluidized Regular checking and
For olefin
Catalytic High temperature Fire and/or Major Likely temperature control
production
operation explosion provision and place the
Cracking Reactor from bio-oil
reactor inside
Regular checking and
High pressure Major Likely pressure control provision
Explosion
operation and place the reactor
inside
172
APPENDIX D4 : HAZOP Analysis

Equipment
/ Equipment Possible Action
No Parameter Guideword Consequences Safeguards
Operation Code Causes Required
Unit
Damage to
Canopy over
adjacent Provide a cover
conveyor
Spillage from equipment around the
None
conveyors slinger Scrappers
Clean-up conveyor to prevent return
prevent any split below belt
Spill to the soil damaging
Belt
1 BC-100 Flow building floor or adjacent other
Conveyor
damage to other equipment
Front end
equipment
loader Flow Control
More Control the
overfills (FC)
regular basis on
hopper Supply product
a screen in the
is too much
feed belt
conveyor
173
Supply is not
appropriate
Less power portion
Increasing the
Less to move the Takes more
power
belt time to
distribute corn
cobs
2 Hammer G-100 Blade More Wrong set Particle size is Determining a Flow Control
Grinder Rotation point not enough new set point (FC)
Speed homogenous and controlled
Stock of material periodically
will be used
faster
Less Low driving Need more time Provide
power source to crush the corn additional
cobs electrical power
3 Condenser E-100, E- Flow More Overload in Filtration process Controlling Flow Control
101, E-102 pump will take time pump and flow (FC)
too long regularly
Less Blocking or Supply will be
174
leaking in decrease
pump
Pressure Low Leaking in There's still Analyze the Analyzer
filter or pipe some impurities outlet flow
to filter in outlet flow to composition
fermenter after filtration
Flow More Pump is not High input Controlling flow Flow Control
running temperature before come into (FC)
Less based on Low input condenser
required temperature
3 Condenser E-100, E- Temperature High Cooling High input Controlling the Temperature
101, E-102 water temperature temperature Control (TC)
temperature periodically
is too low
Temperature Low Water input Low input Controlling the Temperature
temperature temperature temperature Control (TC)
is too high Increase work in periodically
reboiler to
distillate the
feed
175
4 Pump P-100, P- Flow None Pump Process flow is Regular Flow Control
101, P-102, clogged hampered maintenance (FC)
P-103, More Excessive Broken pump and control the
impeller pump
performance periodically
Less Pump Processing
blockage liquid supply
hampered
Reverse Pump Reverse flow
clogged occur
5 Compressor C-100 Flow More Inlet flow is Overpressure Decrease flow Flow Control
too high into compressor (FC)
Failure in
Less control Compressor will Increase flow

system of be broken into compressor
compressor
Inlet flow is
too low
Pressure High Suction Compressor will Switch into Pressure
176
pressure is be broken secondary pump Control (PC)

too high
Control pressure
Low Suction Reverse flow periodically
pressure is occur
too low Compressor
can't distribute
the gas to the
next process
6 Distillation V-100 and Temperature High Steam equilibrium Reduce raw Temperature
Column V-101 temperature phase may not material usage Control (TC)
from reboiler occur and to heat boiler
is too high there's still
Low Steam another Increase steam
temperature component in flowrate intto
from reboiler outlet flow boiler
is too low
Level High Liquid flow Flooding Decrease the Level Control
into column inlet flow into (LC)
Mass transfer
is too high column
177
Low Liquid flow may not Increase the

into column effectively inlet flow into
is too low column
Pressure High Steam Bubbling, Reduce raw Pressure
pressure is foaming material usage Control (PC)
too high to heat boiler
Low Steam Weeping Increase steam
pressure is flowrate into
too low boiler
7 Reboiler RE-100 Temperature High Steam Inlet liquid Decrease steam Temperature
and RE- flowrate is suppose to flow to heat the Control (TC)
101 too high vaporize. So it reboiler
makes another
component join
into top product
flow
Temperature High Feed inlet is Inlet liquid Increase inlet Temperature
too low suppose to flow to heat the Control (TC)
vaporize. So it reboiler
makes another
178
component join
into top product
flow
Low Steam Reboiler is not Decrease steam
flowrate is enough to heat flow to heat the
too low the inlet flow reboiler
Feed inlet is Increase inlet
too high flow to heat the
reboiler
Flow More Valve opens Increase steam Check flow Flow Control
too wide flowrate and control and (FC)
steam maintain the
temperature controller
Less Valve opens Decrease steam periodically
too small flowrate and
steam
stemperature
8 Heat HE-101 Temperature High Hot fluid Heat transfer Decrease hot Temperature
Exchanger flowrate is may not fluid flow to Control (TC)
too much effectively heat the reboiler
179
Cold fluid Increase cold

flowrate is fluid flow to
too low heat the reboiler
Low Hot fluid Decrease hot
too much heat the reboiler
Cold fluid Increase cold
too low heat the reboiler
Flow High Valve opens Final Check flow Flow Control
too wide temperature will control and (FC)
Low Valve opens not be achieved maintain the
too small controller
periodically
9 Fluidized R-100 Pressure High Temperature Explosion Open the
Catalytic is increase pressure relief
Cracking valve
Reactor
9 Fluidized R-100 Temperature High Temperature Fire and/or Decrease the
Catalytic of cooling explosion temperature of
180
Cracking water is too cooling water

Reactor high
Low Temperature The reaction not Increase the

of cooling maximum/cannot temperature of
water is too reach maximum cooling water
high yield
10 Cyclone CY-100, Flowrate Less Separation Open valve is be Open valve is be Flow Control
CY-101
time is longer bigger bigger (FC)
More The process is Open valve is be Open valve is be

overloaded smaller smaller
11 CSTR Flowrate No Control Valve Loss of cooling , Open valve is Flow Control
Fails closed possible runaway bigger (FC)
High Control valve Cstr cools Open valve is be
fails open smaller
Low Control valve Dimished Open valve is be
fails to cooling,possible bigger
respond run away Temperature
Temperature Low Low water Low water Increase the Control (TC)
supply supply temperature
temperature temperature
181
High High water High water Decrease the

supply supply temperature
temperature temperature
182
APPENDIX E : MATERIAL SAFETY DATA SHEET (MSDS)

APPENDIX E1 : MSDS Benzene
183
184
185
186
187
APPENDIX E2 : MSDS Water
188
189
190
191
192
APPENDIX E3 : MSDS Xylene
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201
APPENDIX E4 : MSDS H2SO4
202
203
204
205
206
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APPENDIX E5 : MSDS Toluene
Toluene
Safety Data Sheet
according to Federal Register / Vol. 77, No. 58 / Monday, March 26, 2012 / Rules and Regulations
Date of issue: 03/21/2014 Version: 1.0
SECTION 1: Identification of the substance/mixture and of the company/undertaking

1.1. Product identifier
Product form : Substance
Substance name : Toluene
CAS No : 108-88-3
Product code : LC26170
Formula : C7H8
Synonyms : benzyl hydride / methylbenzene / phenylmethane / tolunol / toluol oil / toluole
BIG no : 10046
1.2. Relevant identified uses of the substance or mixture and uses advised against
Use of the substance/mixture : Solvent
1.3. Details of the supplier of the safety data sheet
LabChem Inc
Jackson's Pointe Commerce Park Building 1000, 1010 Jackson's Pointe Court
Zelienople, PA 16063 - USA
T 412-826-5230 - F 724-473-0647
info@labchem.com - www.labchem.com
1.4. Emergency telephone number
Emergency number : CHEMTREC: 1-800-424-9300 or 011-703-527-3887
SECTION 2: Hazards identification

2.1. Classification of the substance or mixture
GHS-US classification
Flam. Liq. 2 H225
Skin Irrit. 2 H315
Repr. 2 H361
STOT SE 3 H336
STOT RE 2 H373
Asp. Tox. 1 H304
2.2. Label elements

GHS-US labelling
Hazard pictograms (GHS-US) :
GHS02 GHS07 GHS08

Signal word (GHS-US) : Danger
Hazard statements (GHS-US) : H225 - Highly flammable liquid and vapour
H304 - May be fatal if swallowed and enters airways
H315 - Causes skin irritation
H336 - May cause drowsiness or dizziness
H361 - Suspected of damaging fertility or the unborn child
H373 - May cause damage to organs through prolonged or repeated exposure
Precautionary statements (GHS-US) : P201 - Obtain special instructions before use
P202 - Do not handle until all safety precautions have been read and understood
P210 - Keep away from heat, sparks, open flames, hot surfaces. - No smoking
P233 - Keep container tightly closed
P240 - Ground/bond container and receiving equipment
P241 - Use explosion-proof electrical, ventilating, lighting equipment
P242 - Use only non-sparking tools
P243 - Take precautionary measures against static discharge
P260 - Do not breathe mist, vapours, spray
P264 - Wash exposed skin thoroughly after handling
P271 - Use only outdoors or in a well-ventilated area
P280 - Wear protective gloves, protective clothing, eye protection, face protection
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Toluene
Safety Data Sheet
P301+P310 - IF SWALLOWED: immediately call a POISON CENTER or doctor/physician

P303+P361+P353 - IF ON SKIN (or hair): Remove/Take off immediately all contaminated
clothing. Rinse skin with water/shower
P304+P340 - IF INHALED: remove victim to fresh air and keep at rest in a position comfortable
for breathing
P308+P313 - IF exposed or concerned: Get medical advice/attention
P331 - If swallowed, do NOT induce vomiting
P332+P313 - If skin irritation occurs: Get medical advice/attention
P362 - Take off contaminated clothing and wash before reuse
P370+P378 - In case of fire: Use carbon dioxide (CO2), powder, alcohol-resistant foam for
extinction
P403+P233 - Store in a well-ventilated place. Keep container tightly closed
P405 - Store locked up
P501 - Dispose of contents/container to compl y with local, state and federal regulations
P235 - Keep cool
2.3. Other hazards

Other hazards not contributing to the : None under normal conditions.
classification
2.4. Unknown acute toxicity (GHS-US)
No data available
SECTION 3: Composition/information on ingredients

3.1. Substance
Substance type : Mono-constituent
Name Product identifier % GHS-US classification

Toluene (CAS No) 108-88-3 100 Flam. Liq. 2, H225
(Main constituent) Skin Irrit. 2, H315
Repr. 2, H361
STOT SE 3, H336
STOT RE 2, H373
Asp. Tox. 1, H304
Full text of H-phrases: see section 16

3.2. Mixture
Not applicable
SECTION 4: First aid measures

4.1. Description of first aid measures
First-aid measures general : Check the vital functions. Unconscious: maintain adequate airway and respiration. Respiratory
arrest: artificial respiration or oxygen. Cardiac arrest: perform resuscitation. Victim conscious with
laboured breathing: half-seated. Victim in shock: on his back with legs slightly raised. Vomiting:
prevent asphyxia/aspiration pneumonia. Prevent cooling by covering the victim (no warming up).
Keep watching the victim. Give psychological aid. Keep the victim calm, avoid physical strain.
Depending on the victim's condition: doctor/hospital. Never give alcohol to drink.
First-aid measures after inhalation : Remove the victim into fresh air. Respiratory problems: consult a doctor/medical service.
First-aid measures after skin contact : Wash immediately with lots of water. Soap may be used. Do not apply (chemical) neutralizing
agents. Remove clothing before washing. Take victim to a doctor if irritation persists.
First-aid measures after eye contact : Rinse immediately with plenty of water. Do not apply neutralizing agents. Take victim to an
ophthalmologist if irritation persists.
First-aid measures after ingestion : Rinse mouth with water. Immediately after ingestion: give lots of water to drink. Do not give
milk/oil to drink. Do not induce vomiting. Give activated charcoal. Call Poison Information Centre
(www.big.be/antigif.htm). Consult a doctor/medical service if you feel unwell. Ingestion of large
quantities: immediately to hospital.
4.2. Most important symptoms and effects, both acute and delayed
Symptoms/injuries after inhalation : EXPOSURE TO HIGH CONCENTRATIONS: Headache. Nausea. Feeling of weakness.
Dizziness. Central nervous system depression. Narcosis. Mental confusion. Drunkenness.
Coordination disorders. Disturbed motor response. Disturbances of consciousness.
Symptoms/injuries after skin contact : Tingling/irritation of the skin.
Symptoms/injuries after eye contact : Irritation of the eye tissue.
Symptoms/injuries after ingestion : Risk of aspiration pneumonia. Nausea. Abdominal pain. Symptoms similar to those listed unde r
inhalation.
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Safety Data Sheet
Chronic symptoms : ON CONTINUOUS/REPEATED EXPOSURE/CONTACT: Dry skin. Skin rash/inflammation.

Impairment of the nervous system. Tremor. Impaired memory. Impaired concentration. Brain
affection. Disturbances of heart r ate. Change in the haemogramme/blood composition.
4.3. Indication of any immediate medical attention and special treatment needed
Obtain medical assistance.
SECTION 5: Firefighting measures

5.1. Extinguishing media
Suitable extinguishing media : Preferably: alcohol resistant foam. Water spra y. BC powder. Polyvalent foam. AFFF foam.
Carbon dioxide.
Unsuitable extinguishing media : Container may slop over if solid jet (water/foam) is applied.
5.2. Special hazards arising from the substance or mixture
Fire hazard : DIRECT FIRE HAZARD. Highly flammable. Gas/vapour flammable with air within explosion
limits. INDIRECT FIRE HAZA RD. May build up electrostatic charges: risk of ignition. May be
ignited by sparks. Gas/vapour spreads at floor level: ignition hazard. Reactions involving a fire
hazard: see "Reactivity Hazard".
Explosion hazard : DIRECT EXPLOSION HAZARD. Gas/vapour explosive with air within explosion limits.
INDIRECT EXPLOSION HAZARD. may be ignited by sparks. Reactions with explosion hazards:
see "Reactivity Hazard".
Reactivity : Upon combustion: CO and CO2 are formed. Reacts violently with (some) halogens. Reacts
violently with (strong) oxidizers: (increased) risk of fire/explosion. Violent to explosive reaction
with (some) acids.
5.3. Advice for firefighters
Firefighting instructions : Cool tanks/drums with water spray/remove them into safety. Do not move the load if exposed to
heat.
Protection during firefighting : Heat/fire exposure: compressed air/oxygen apparatus.
SECTION 6: Accidental release measures

6.1. Personal precautions, protective equipment and emergency procedures
6.1.1. For non-emergency personnel
Protective equipment : Gloves. Protective goggles. Head/neck protection. Protective clothing. Large spills/in enclosed
spaces: compressed air apparatus. Large spills/in enclosed spaces: gas-tight suit.
Emergency procedures : Keep upwind. Mark the danger area. Consider evacuation. Seal off low-lying areas. Close doors
and windows of adjacent premises. Stop engines and no smoking. No naked flames or sparks.
Spark- and explosionproof appliances and lighting equipment. Keep containers closed. Wash
contaminated clothes.
6.1.2. For emergency responders

Protective equipment : Do not breathe gas, fumes, vapour or spray. Equip cleanup crew with proper protection.
Emergency procedures : Stop leak if safe to do so. Vent ilate area. If a major spill occurs, all personnel should be
immediately evacuated and the area ventilated.
6.2. Environmental precautions
Prevent soil and water pollution.
6.3. Methods and material for containment and cleaning up
For containment : Contain released substance, pump into suitable containers. Consult "Material-handling" to select
material of containers. Plug the leak, cut off the supply. Dam up the liquid spill. Try to reduce
evaporation. Measure the concentration of the explosive gas-air mixture. Dilute/disperse
combustible gas/vapour with water curtain. Provide equipment/receptacles with earthing. Do not
use compressed air for pumping over spills.
Methods for cleaning up : Liquid spill: cover with foam. Take up liquid spill into inert absorbent material, e.g.: sand, earth,
vermiculite. Scoop absorbed substance into closing containers. See "Material-handling" for
suitable container materials. Carefully collect the spill/leftovers. Damaged/cooled tanks must be
emptied. Do not use compressed air for pumping over spills. Take collected spill to
manufacturer/competent authority. Wash clothing and equipment after handling.
6.4. Reference to other sections
No additional information available
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Safety Data Sheet
SECTION 7: Handling and storage

7.1. Precautions for safe handling
Precautions for safe handling : Comply with the legal requirements. Remove contaminated clothing immediately. Clean
contaminated clothing. Handle uncleaned empty containers as full ones. Thoroughly clean/dry
the installation before use. Do not discharge the waste into the drain. Do not use compressed air
for pumping over. Use spark-/explosionproof appliances and lighting system. Take precautions
against electrostatic charges. Keep away from naked flames/heat. Keep away from ignition
sources/sparks. Observe strict hygiene. Keep container tightly closed. Measure the
concentration in the air regularly. Work under local exhaust/ventilation.
Hygiene measures : Wash hands and other exposed areas with mild soap and water before eating, drinking or
smoking and when leaving work. Do not eat, drink or smoke when using this product.
7.2. Conditions for safe storage, including any incompatibilities
Incompatible products : Strong oxidizers.
Incompatible materials : Direct sunlight. Heat sources. Sources of ignition.
Heat and ignition sources : KEEP SUBSTANCE AWAY FROM: heat sources. ignition sources.
Prohibitions on mixed storage : KEEP SUBSTANCE AWAY FROM: oxidizing agents. (strong) acids. halogens.
Storage area : Store at ambient temperature. Ventilation at floor level. Fireproof storeroom. Provide for a tub to
collect spills. Provide the tank with earthing. Under a shelter/in the open. Store only in a limited
quantity. May be stored under nitrogen. Meet the legal requirements. Keep out of direct sunlight.
Special rules on packaging : SPECIAL REQUIREMENTS: closing. clean. correctly labelled. meet the legal requirements.
Secure fragile packagings in solid containers.
Packaging materials : SUITABLE MATERIAL: metal. stainless steel. carbon steel. aluminium. nickel. polypropylene.
glass. tin. MATERIAL TO AVOID: polyethylene.
7.3. Specific end use(s)
SECTION 8: Exposure controls/personal protection

8.1. Control parameters
Toluene (108-88-3)
USA ACGIH ACGIH TWA (ppm) 20 ppm
USA ACGIH ACGIH STEL (ppm) 20 ppm
USA OSHA OSHA PEL (TWA) (ppm) 200 ppm
USA OSHA OSHA PEL (STEL) (ppm) 500 ppm 10-min peak per 8 hour shift
USA OSHA OSHA PEL (Ceiling) (ppm) 300 ppm
8.2. Exposure controls

Appropriate engineering controls : Emergency eye wash fountains and safety showers should be available in the immediate vicinity
of any potential exposure. Ensure adequate ventilation.
Materials for protective clothing : GIVE EXCELLENT RESISTANCE: No data available. GIVE GOOD RESISTANCE:
tetrafluoroethylene. viton. PVA. GIVE LESS RESISTANCE: butyl rubber. natural rubber.
neoprene. nitrile rubber. polyethylene. neoprene/natural rubber. nitrile rubber/PVC. GIVE POOR
RESISTANCE: chloroprene rubber.
Hand protection : Gloves.
Eye protection : Safety glasses.
Skin and body protection : Head/neck protection. Protective clothing.
Respiratory protection : Wear gas mask with filter type A if conc. in air > exposure limit.
SECTION 9: Physical and chemical properties

9.1. Information on basic physical and chemical properties
Physical state : Liquid
Appearance : Liquid.
Molecular mass : 92.14 g/mol
Colour : Colourless.
Odour : Aromatic odour.
Odour threshold : 0.2 - 69 ppm
0.8 - 276 mg/m³
pH : No data available
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Toluene
Safety Data Sheet
Relative evaporation rate (butylacetate=1) : 2.24

Melting point : -95 °C
Freezing point : No data available
Boiling point : 111 °C
Flash point : 4 °C
Critical temperature : 321 °C
Self ignition temperature : 480 °C
Decomposition temperature : No data available
Flammability (solid, gas) : No data available
Vapour pressure : 29 hPa
Vapour pressure at 50 °C : 109 hPa
Critical pressure : 41077 hPa
Relative vapour density at 20 °C : 3.2
Relative density : 0.87
Relative density of saturated gas/air mixture : 1.6
Density : 870 kg/m³
Solubility : Insoluble in water. Soluble in ethanol. Soluble in ether. Soluble in a cetone. Soluble in chloroform.
Soluble in carbondisulfide. Soluble in acetic acid. Soluble in ethylacetate. Soluble in petroleum
spirit.
Water: 0.05 g/100ml
Ethanol: Complete
Ether: Complete
Acetone: > 10 g/100ml
Log Pow : 2.73 (Experimental value; Other; 20 °C,Experimental value; Other; 20 °C,Experimental value;
Other; 20 °C)
Log Kow : No data available
Viscosity, kinematic : 0.690 mm²/s (20 °C)
Viscosity, dynamic : 0.0006 Pa.s (20 °C)
Explosive properties : No data available
Oxidising properties : No data available
Explosive limits : 1.3 - 7 vol %
46 - 270 g/m³
9.2. Other information

Minimum ignition energy : 0.3 mJ
Specific conductivity : 1.0 pS/m
Saturation concentration : 110 g/m³
VOC content : 100 %
Other properties : Gas/vapour heavier than air at 20°C. Clear. Volatile. Substance has neutral reaction. May
generate electrostatic charges.
SECTION 10: Stability and reactivity

10.1. Reactivity
Upon combustion: CO and CO2 are formed. Reacts violently with (some) halogens. Reacts violently with (strong) oxidizers: (increased) risk of
fire/explosion. Violent to explos ive reaction with (some) acids.
10.2. Chemical stability
Stable under normal conditions.
10.3. Possibility of hazardous reactions
10.4. Conditions to avoid
Heat. Direct sunlight. Sparks. Ope n flame.
10.5. Incompatible materials
Strong oxidizers.
10.6. Hazardous decomposition products
Carbon dioxide. Carbon monoxide.
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Safety Data Sheet
SECTION 11: Toxicological information

11.1. Information on toxicological effects
Acute toxicity : Not classified

Toluene ( \f )108-88-3
LD50 oral rat > 2000 mg/kg (5580 mg/kg bodyweight; Rat; Rat; Experimental value)
LD50 dermal rabbit 12223 mg/kg (>5000 mg/kg bodyweight; Rabbit; Rabbit; Experimental value; Other,>5000
mg/kg bodyweight; Rabbit; Rabbit; Experimental value; Other)
LC50 inhalation rat (mg/l) > 20 mg/l/4h (Rat)
Skin corrosion/irritation : Causes skin irritation.
Serious eye damage/irritation : Not classified
Respiratory or skin sensitisation : Not classified
Germ cell mutagenicity : Not classified
Carcinogenicity : Not classified
Toluene (108-88-3)
IARC group 3 - Not classifiable
Reproductive toxicity : Suspected of damaging fertility or the unborn child.
Specific target organ toxicity (single exposure) : May cause drowsiness or dizziness.
Specific target organ toxicity (repeated : May cause damage to organs through prolonged or repeated exposure.
exposure)
Aspiration hazard : May be fatal if swallowed and enters airways.
Symptoms/injuries after inhalation : EXPOSURE TO HIGH CONCENTRATIONS: Headache. Nausea. Feeling of weakness.
Dizziness. Central nervous system depression. Narcosis. Mental confusion. Drunkenness.
Coordination disorders. Disturbed motor response. Disturbances of consciousness.
Symptoms/injuries after skin contact : Tingling/irritation of the skin.
Symptoms/injuries after eye contact : Irritation of the eye tissue.
Symptoms/injuries after ingestion : Risk of aspiration pneumonia. Nausea. Abdominal pain. Symptoms similar to those listed unde r
inhalation.
Chronic symptoms : ON CONTINUOUS/REPEATED EXPOSURE/CONTACT: Dry skin. Skin rash/inflammation.
Impairment of the nervous system. Tremor. Impaired memory. Impaired concentration. Brain
affection. Disturbances of heart r ate. Change in the haemogramme/blood composition.
Likely routes of exposure : Inhalation;Skin and eye contact
SECTION 12: Ecological information

12.1. Toxicity
Ecology - general : Classification concerning the environment: not applicable.
Ecology - air : TA-Luft Klasse 5.2.5/I.
Ecology - water : Fouling to shoreline. Ground water pollutant. Toxic to fishes. Toxic to invertebrates. Harmful to
algae. Inhibits photosynthesis of algae. Harmful to bacteria. Taste alteration in fishes/aquatic
organisms.
Toluene (108-88-3)
LC50 fishes 1 24 mg/l 96 h; Salmo gairdneri (Oncorhynchus mykiss)
EC50 Daphnia 1 84 mg/l (24 h; Daphnia magna; Locomotor effect)
LC50 fish 2 13 mg/l (96 h; Lepomis macrochirus)
EC50 Daphnia 2 11.5 - 19.6 mg/l (48 h; Daphnia magna)
Threshold limit algae 1 > 400 mg/l (168 h; Scenedesmus quadricauda; Toxicity test)
Threshold limit algae 2 105 mg/l (192 h; Microcystis aeruginosa)
12.2. Persistence and degradability

Toluene (108-88-3)
Persistence and degradability Readily biodegradable in water. Biodegradable in the soil. Low potential for adsorption in soil.
Biochemical oxygen demand (BOD) 2.15 g O²/g substance
Chemical oxygen demand (COD) 2.52 g O²/g substance
ThOD 3.13 g O²/g substance
BOD (% of ThOD) 0.69 % ThOD
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Safety Data Sheet
12.3. Bioaccumulative potential

Toluene (108-88-3)
BCF fish 1 13.2 (Anguilla japonica)
BCF fish 2 90 (72 h; Leuciscus idus)
BCF other aquatic organisms 1 380 (24 h; Chlorella sp.; Fresh weight)
BCF other aquatic organisms 2 4.2 (Mytilus edulis; Fresh weight)
Log Pow 2.73 (Experimental value; Other; 20 °C,Experimental value; Other; 20 °C,Experimental value;
Other; 20 °C)
Bioaccumulative potential Low potential for bioaccumulation (BCF < 500).
12.4. Mobility in soil

Toluene (108-88-3)
Surface tension 0.03 N/m (20 °C)
12.5. Other adverse effects

SECTION 13: Disposal considerations

13.1. Waste treatment methods
Waste disposal recommendations : Remove waste in accordance with local and/or national regulations. Hazardous waste shall not
be mixed together with other waste. Different types of hazardous waste shall not be mixed
together if this may entail a risk of pollution or creat e problems for the further management of the
waste. Hazardous waste shall be managed responsibly. All entities that store, transport or handle
hazardous waste shall take the necessary measures to prevent risks of pollution or damage to
people or animals. Recycle by distillation. Do not landfill. Remove to an authorized waste
incinerator for solvents with energy recovery. Do not discharge into drains or the envi ronment.
May be discharged to company wastewater treatment plant.
Additional information : LWCA (the Netherlands): KGA category 03. Hazardous waste according to Directive
2008/98/EC.
SECTION 14: Transport information

In accordance with DOT
Transport document description : UN1294 Toluene, 3, II
UN-No.(DOT) : 1294
DOT NA no. : UN1294
DOT Proper Shipping Name : Toluene
Department of Transportation (DOT) Hazard : 3 - Class 3 - Flammable and combustible liquid 49 CFR 173.120
Classes
Hazard labels (DOT) : 3 - Flammable liquid
Packing group (DOT) : II - Medium Danger

DOT Special Provisions (49 CFR 172.102) : IB2 - Authorized IBCs: Metal (31A, 31B and 31N); Rigid plastics (31H1 and 31H2); Composite
(31HZ1). Additional Requirement: Only liquids with a vapor pressure less than or equal to 110
kPa at 50 C (1.1 bar at 122 F), or 130 kPa at 55 C (1.3 bar at 131 F) are authorized.
T4 - 2.65 178.274(d)(2) Normal............. 178.275(d)(3)
TP1 - The maximum degree of filling must not exceed the degree of filling determined by the
following: Degree of filling = 97 / (1 + a (tr - tf)) Where: tr is the maximum mean bulk temperature
during transport, and tf is the temperature in degrees celsius of the liquid during filling.
DOT Packaging Exceptions (49 CFR 173.xxx) : 150
DOT Packaging Non Bulk (49 CFR 173.xxx) : 202
DOT Packaging Bulk (49 CFR 173.xxx) : 242
DOT Quantity Limitations Passenger aircraft/rail : 5L
(49 CFR 173.27)
DOT Quantity Limitations Cargo aircraft only (49 : 60 L
CFR 175.75)
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Safety Data Sheet
DOT Vessel Stowage Location : B - (i) The material may be stowed ‘‘on deck’’ or ‘‘under deck’’ on a cargo vessel and on a
passenger vessel carrying a number of passengers limited to not more than the larger of 25
passengers, or one passenger per each 3 m of overall vessel length; and (ii) ‘‘On deck only’’ on
passenger vessels in which the number of passengers specified in paragraph (k)(2)(i) of this
section is exceeded.
Additional information
Other information : No supplementary information available.
State during transport (ADR-RID) : as liquid.
ADR
Transport document description : UN 1294 Toluene, 3, II, (D/E)
Packing group (ADR) : II
Class (ADR) : 3 - Flammable liquids
Hazard identification number (Kemler No.) : 33
Classification code (ADR) : F1
Danger labels (ADR) : 3 - Flammable liquids
Orange plates :
Tunnel restriction code : D/E
Transport by sea
UN-No. (IMDG) : 1294
Class (IMDG) : 3 - Flammable liquids
EmS-No. (1) : F-E
EmS-No. (2) : S-D
Air transport
UN-No.(IATA) : 1294
Class (IATA) : 3 - Flammable Liquids
Packing group (IATA) : II - Medium Danger
SECTION 15: Regulatory information

15.1. US Federal regulations
Toluene (108-88-3)
Listed on the United States TSCA (Toxic Substances Control Act) inventory
Listed on SARA Section 313 (Specific toxic chemical listings)
RQ (Reportable quantity, section 304 of EPA's 1000 lb
List of Lists) :
SARA Section 311/312 Hazard Classes Immediate (acute) health hazard
Fire hazard
15.2. International regulations

CANADA
Toluene (108-88-3)
Listed on the Canadian DSL (Domestic Sustances List) inventory.
WHMIS Classification Class B Division 2 - Flammable Liquid
Class D Division 2 Subdivision B - Toxic material causing other toxic effects
Class D Division 2 Subdivision A - Very toxic material causing other toxic effects
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Safety Data Sheet
EU-Regulations
Classification according to Regulation (EC) No. 1272/2008 [CLP]

Flam. Liq. 2 H225
Repr. 2 H361d
Asp. Tox. 1 H304
STOT RE 2 H373
Skin Irrit. 2 H315
STOT SE 3 H336
Full text of H-phrases: see section 16
Classification according to Directive 67/548/EEC or 1999/45/EC

F; R11
Repr.Cat.3; R63
Xn; R65
Xn; R48/20
Xi; R38
R67
Full text of R-phrases: see section 16
15.2.2. National regulations
Toluene (108-88-3)
Listed on the Canadian Ingredient Disclosure List
15.3. US State regulations

Toluene(108-88-3)
U.S. - California - Proposition 65 - Developmental Yes
Toxicity
U.S. - California - Proposition 65 - Reproductive Toxicity Yes
- Female
No significance risk level (NSRL) 7000 µg/day
SECTION 16: Other information
Full text of H-phrases: see section 16:

------ Asp. Tox. 1 Aspiration hazard, Category 1
------ Flam. Liq. 2 Flammable liquids, Category 2
------ Repr. 2 Reproductive toxicity, Category 2
------ Skin Irrit. 2 Skin corrosion/irritation, Category 2
------ STOT RE 2 Specific target organ toxicit y — Repeated exposure, Category 2
------ STOT SE 3 Specific target organ toxicit y — Single exposure, Category 3,
Narcosis
------ H225 Highly flammable liquid and vapour
------ H304 May be fatal if swallowed and enters airways
------ H315 Causes skin irritation
------ H336 May cause drowsiness or dizziness
------ H361 Suspected of damaging fertility or the unborn child
------ H373 May cause damage to organs through prolonged or repeated
exposure
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Safety Data Sheet
NFPA health hazard : 3 - Short exposure could cause serious temporary or

residual injury even though prompt medical attention was
given.
NFPA fire hazard : 1 - Must be preheated before ignition can occur.
NFPA reactivity : 2 - Normally unstable and readily undergo violent
decomposition but do not detonate. Also: may react
violently with water or may form potentially explosive
mixtures with water.
HMIS III Rating

Health : 3 Serious Hazard - Major injury likely unless prompt action is taken and medical treatment is
given
Flammability : 1 Slight Hazard
Physical : 2 Moderate Hazard
Personal Protection : H
SDS US (GHS HazCom 2012)
Information in this SDS is from available published sources and is believed to be accurate. No warranty, express or implied, is made and LabChem Inc assumes no liability resultin g from the use of this
SDS. The user must determine suitability of this information for his application.
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APPENDIX F : PROJECT COST

APPENDIX F1 : TBM Cost
Price
Cost
in
Equipment Quantity Year Index Price in year Price in year Price in 2022 Total Price Total Price
Supplier 2022 FBM
Code (unit) Basis in Year basis (Rp) basis (US$) (FOB) (Rp) (Rp) (US$)
(US$
Basis
)
Pump
P-100; P- Botou Honghai
2 2016 672.2 4,051,676 299.82 4,117,918 305 3.3 27,178,259 2011.191187
101 Pump Co., Ltd
Sentralpompa.Co
P-103 1 2016 672.2 2,987,500 221.08 3,036,344 225 3.3 10,019,934 741.4750923
m
P-104;P- Sentralpompa.Co
3 2016 672.2 2,987,500 221.08 3,036,344 225 3.3 30,059,801 2224.425277
106;P-107 m
Compressor
Shanghai Denair
K-100 1 Compressor 2016 672.2 6,752,777 499.71 6,863,180 508 2.15 14,755,837 1091.931934
Co.,Ltd
Heat Exchanger
Wenzhou 162
E-100 1 2016 672.2 21,608,922 1,599.06 21,962,212 3.17 69,620,214 5151.895804
Wuhaun 5
221
Refrigation
Accecories
Factory
Taishan Group 135,055,60 137,263,67 101
E-101 1 2016 672.2 9,994.12 3.17 435,125,844 32199.31251
Co.,Ltd 9 3 58
Siping Zhongbao
121
E-102 1 He Device 2016 672.2 16,206,691 1,199.30 16,471,659 3.17 52,215,160 3863.921854
9
Co.,Ltd
Reactor
Foshan Jct
1,107,463, 1,225,990, 4. 5,100,122,1
R-100 1 Machinery 2013 617.14 81,952 90723 377409.0368
545 893 16 14
Co.,Ltd
Wuci Teneng
675,277,00 747,549,17 4. 3,109,804,5
R-101 1 Power Machinery 2013 617.14 49,970.50 55319 230125.538
5 4 16 64
Co.,Ltd
Distillation Column
V-100;V- Zhengjiu 4.
2 2016 672.2 51,401,334 3804 52,241,710 3866 434,651,026 32164.17597
102 Machinery 16
Storage Tank
S-100 1 Mie Fibro Tech 2011 585.7 11,350,000 840 13,239,212 980 4. 55,075,122 4075.559043
222
& Engineering 16
S-101;S- Mie Fibro Tech 4.
2 2011 585.7 40,516,562 2,998.23 47,260,560 3497 393,207,855 29097.38132
102 & Engineering 16
Cyclone
Weihai Haiwang
Mining
C-100 1 2011 585.7 17,598,787 1,302.31 20,528,112 1519 1 20,528,112 20528112.16
Equipment
Co.,Ltd
Weihai Haiwang
Mining
C-101 1 2011 585.7 67,700,516 5,009.84 78,969,294 5844 1 78,969,294 78969293.77
Equipment
Co.,Ltd
Flash Drum
Weifang Jijanti
D-100 1 Equipment 2011 585.7 13,505,548 999.41 15,753,552 1166 1 15,753,552 1165.76288
Co.,Ltd
Utility
Pump
Pt. Dwijaya 3.
J-501 1 2016 672.2 8,232,000 609 8,366,587 619 27,609,739 2043.120656
Selaras 3
223
J-502;J-
Sentralpompa.Co 3.
503;J- 4 2016 672.2 2,875,000 213 2,922,004 216 38,570,456 2854.213744
m 3
504;J505
Sand Water Filter
2.
F-500 1 Pentair 2016 672.2 40,650,000 3008 41,314,599 3057 95,849,870 7092.890377
32
Ion Exchanger
R-501;R- 2.
2 Pentair 2016 672.2 40,650,000 3008 41,314,599 3057 191,699,740 14185.78075
502 32
Storage Tank
Tt-501, Mie Fibro Tech
2 2016 672.2 11,350,000 840 11,535,565 854 1 23,071,129 1707.263557
Tt-502 & Engineering
Mie Fibro Tech
Tt-503 1 2016 672.2 5,675,000 420 5,767,782 427 1 5,767,782 426.8158893
& Engineering
Aerator
Luqiang Energy
R-503;Cl-
2 Equipment 2016 672.2 13,505,548 999.41 15,753,552 1166 1 31,507,105 2331.52576
500
Co,Ltd
100,249,369.
Total Bare Module
15
224
APPENDIX F2 : Direct Cost

Location Teluk Betung
2
Land Area (m ) 50000
Cost/m2 $96.26
Total buy $4,812,842
Description Price (Rp/m2) Area (m2) Total Price ($)

Plant building 185.1852 11976 2,217,778
Office building 259.2593 2417 626,630
Road 24.4444 12084 295,387
Foundation 15% building cost 426,661
TOTAL 26477 3,566,455
Utilities Price/Unit Amount Total

Electricity $203.00 116.07 $23,562.21
Process Water $347.00 91576.8 $31,777,149.60
Total Utilities $31,800,711.81
No. Type of Cost n Based Cost (US$) Cost (US$)

1 Building Plant 20% 100,249,369.1 5 20,049,873.83
Total Contractor Fee Cost 20,049,873.83
No Type of Cost N Based Cost (US$) Cost (US$)

1 Site Development 10% 100,249,369.15 10,024,936.91
Total Contractor Fee Cost $10,024,936.91
Equipment Quantity Price per Unit Total Price ($)

Sofa 2 $305.56 $611.11
Computer 15 $333.33 $5,000.00
Receptionist Desk 1 $184.07 $184.07
Air Conditioner 20 $222.22 $4,444.44
225
Dispenser 8 $22.22 $177.78

Office Desks 10 $44.44 $444.44
Office Chairs 30 $57.78 $1,733.33
Genset 3 $10,592.59 $31,777.78
Locker (2 dor) 10 $85.19 $851.85
Meeting Desk 4 $296.30 $1,185.19
Photocopy Machine,
3 $888.89 $2,666.67
Scanner and Printer
White Board 10 $29.63 $296.30
Projector and screen 3 $361.48 $1,084.44
CCTV 25 $92.59 $2,314.81
Janitor Set 1 $370.37 $370.37
Toilet Set 1 $370.37 $370.37
Trashbin (10 Liter) 20 $2.59 $51.85
Absence machine 2 $159.26 $318.52
Pantry Set 1 $222.22 $222.22
Telephone 10 $21.11 $211.11
Lamp 75 $3.70 $277.78
Safety Google 20 $3.70 $74.07
Safety Glove 20 $0.37 $7.41
Office Car 2 $23,481.48 $46,962.96
TOTAL $101,638.89
226
APPENDIX F3 : Indirect Cost

The indirect cost in this plant includes contingency, contractor’s fee,
engineering and supervision, and COPEX.
1.2.2.1 Contingency
Cost of contingency uses 15% CTBM (Total Bare Module Cost). This cost is
used to know unpredictable cost due to miscalculation that shown in Table 1.11.
Table 1.10. Contingency Cost

No. Type of cost n Based Cost (US$) Cost (US$)
1 Contingency 15% 100,249,369.15 15,037,405.37
Total 15,037,405.37
1.2.2.2 Contractor Fee
Cost of contractor fee uses 3% of CTBM (Total Bare Module Cost). Based
on Table 1.12, cost for contractor fee is US $11,434,116.
Table 1.11. Contractor Fee

1 Contractor 3% 100,249,369.15 3,007,481.07
Total 3,007,481.07
1.2.2.3 Engineering and Supervision
Cost of engineering and supervision uses 8% of CTBM (Total Bare Module
Cost). Based on Table 1.13, cost for engineering and supervision is US
$30,490,975.
Table 1.12. Engineering and Supervision

1 Engineering and supervision 8% 100,249,369.15 8,019,949.53
Total $8,019,949.53
1.2.2.4 Construction Expenses (COPEX)
Cost of construction expenses uses 10% of C TBM (Total Bare Module
Cost). Based on Table 1.14, cost for construction expenses is US $38,113,719.
227
Table 1.13. Construction Expenses

1 Construction expenses 10% 100,249,369.15 10,024,936.91
Total $10,024,936.91
1.2.3 Working Capital
Cost of working capital uses 17.6% of CTPI (Total Permanent Investment
Cost). Based on Table 1.15, the cost of working capital is US$ 150,680,366.
Table 1.14. Working Capital

No. Type of cost N Based Cost (US$) Cost (US$)
1 Working capital 17.6% 2,355,553.26 13,383,825.35
Table 1.14. Working Capital (continued)

Total $4,805,009.09
1.2.4 Additional Cost

Beside the market research cost, there are some additional costs that will
be included in the CAPEX that includes the components mentioned in Table 1.16.
Table 1.15. Additional Cost

Installation Price ($)
Water Installation 125
Telephone Installation 56
Electricity Installation 482
Internet Installation 12
Hydrants Installation 963
TOTAL $1,638
The above costs are based on the Indonesia’s Law of Industry No 14 2001
and the service companies such as Telkom, Telkomsel, and PDAM. There are
other costs that are still need to be calculated. The calculation will be in the “Total
CAPEX” sub-chapter.
APPENDIX F4 : Depreciation
228
Supporting
Value Main Equipment Land and Building Total
Equipment
Initial
Value in 1st 82,958,831 101,639 87,300,748
year
D 8,295,883 10,164 8,730,075 17,036,122
Year 1
SV 74,662,948 91,475 78,570,673
D 7,466,295 9,148 7,857,067 15,332,510
Year 2
SV 67,196,653 82,328 70,713,606
D 6,719,665 8,233 7,071,361 13,799,259
Year 3
SV 60,476,988 74,095 63,642,245
D 6,047,699 7,409 6,364,224 12,419,333
Year 4
SV 54,429,289 66,685 57,278,020
D 5,442,929 6,669 5,727,802 11,177,399
Year 5
SV 48,986,360 60,017 51,550,218
D 4,898,636 6,002 5,155,022 10,059,660
Year 6
SV 44,087,724 54,015 46,395,197
D 4,408,772 5,402 4,639,520 9,053,694
Year 7
SV 39,678,952 48,614 41,755,677
D 3,967,895 4,861 4,175,568 8,148,324
Year 8
SV 35,711,057 43,752 37,580,109
D 3,571,106 4,375 3,758,011 7,333,492
Year 9
SV 32,139,951 39,377 33,822,098
D 3,213,995 3,938 3,382,210 6,600,143
Year 10
SV 28,925,956 35,439 30,439,888
D 2,892,596 3,544 3,043,989 5,940,128
Year 11
SV 26,033,360 31,895 27,395,900
D 2,603,336 3,190 2,739,590 5,346,116
Year 12
SV 23,430,024 28,706 24,656,310
D 2,343,002 2,871 2,465,631 4,811,504
Year 13
SV 21,087,022 25,835 22,190,679
D 2,108,702 2,584 2,219,068 4,330,354
Year 14
SV 18,978,320 23,252 19,971,611
Year 15 D 1,897,832 2,325 1,997,161 3,897,318
229
SV 17,080,488 20,927 17,974,450

D 1,708,049 2,093 1,797,445 3,507,586
Year 16
SV 15,372,439 18,834 16,177,005
D 1,537,244 1,883 1,617,700 3,156,828
Year 17
SV 13,835,195 16,951 14,559,304
D 1,383,520 1,695 1,455,930 2,841,145
Year 18
SV 12,451,676 15,255 13,103,374
D 1,245,168 1,526 1,310,337 2,557,030
Year 19
SV 11,206,508 13,730 11,793,036
D 1,120,651 1,373 1,179,304 2,301,327
Year 20
SV 10,085,857 12,357 10,613,733 20,711,947
APPENDIX F5 : Depreciation
Deviation Product Price (US$) IRR NPV (US$) PBP (year)
-15% 935 5.90% -45,550,266,735 8.651
-10% 990 7.91% -21,093,291,053 6.897
-5% 1,045 9.80% 3,363,684,628 5.762
0% 1,100 11.60% 27,820,660,309 4.947
5% 1,155 13.33% 52,277,635,991 4.351
10% 1,210 15.01% 76,734,611,672 3.875
15% 1,265 16.65% 101,191,587,354 3.504
Deviation Raw Material Price (US$) IRR NPV (US$) PBP (year)
-15% 11,014,555 13.25% 51,014,949,895 4.370
-10% 11,662,470 12.71% 43,283,520,033 4.550
-5% 12,310,385 12.16% 35,552,090,171 4.742
0% 12,958,300 11.60% 27,820,660,309 4.947
5% 13,606,215 11.04% 20,089,230,448 5.184
10% 14,254,130 10.47% 12,357,800,586 5.444
15% 14,902,045 9.90% 4,626,370,724 5.724
230
Deviation Total Labor Cost (US$) IRR NPV (US$) PBP (year)
-15% 832,108 12.22% 36,384,060,360 4.724
-10% 881,055 12.01% 33,529,593,677 4.796
-5% 930,003 11.81% 30,675,126,993 4.871
0% 978,950 11.60% 27,820,660,309 4.947
5% 1,027,898 11.40% 24,966,193,626 5.028
10% 1,076,845 11.19% 22,111,726,942 5.117
15% 1,125,793 10.98% 19,257,260,259 5.207
Maintenance Cost PBP

Deviation IRR NPV (US$)
(US$) (year)
-15% 8,635,237 12.22% 36,384,060,360 4.724
-10% 9,143,192 12.01% 33,529,593,677 4.796
-5% 9,651,147 11.81% 30,675,126,993 4.871
0% 10,159,102 11.60% 27,820,660,309 4.947
5% 10,667,057 11.40% 24,966,193,626 5.028
10% 11,175,012 11.19% 22,111,726,942 5.117
15% 11,682,967 10.98% 19,257,260,259 5.207

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UNIVERSITAS INDONESIA

PRELIMINARY DESIGN OF PRODUCING BENZENE FROM

CHEMICAL ENGINEERING DEPARTMENT

1. Name : Andikaputra Brahma Widiantoro

Depok, December 2017

Benzene consumption in Indonesia is always increasing year by year.

Keywords: benzene, empty fruit bunch, fast pyrolysis, fluidized catalytic

Benzene consumption in Indonesia is always increasing year by year.

LIST OF GROUP MEMBERS ............................................................................ ii

Figure 1. 1. Benzene Structure ................................................................................ 2

Table 1. 1. Benzene demand in 2009-2022. ............................................................ 4

1.1. Project Background

Figure 1. 1. Benzene Structure

Table 1. 1. Benzene Demand in 2009-2022.

Years Benzene Demand (In ton)

Table 1. 2. Benzene Supply in 2009-2022.

Years Benzene Supply (In ton)

1.3.3. Production Capacity Analysis

Table 1. 3. Product Capacity.

Working Time 330 Day

Figure 1. 2. Location of Teluk Betung Industrial Area

 Availability of raw material (biomass and water)

Figure 1. 3. Location of South Teluk Betung Industrial Area

Furthermore it is big challenge to apply the biomass from empty fruit

Figure 2. 1. Conversion Technologies for Biomass

Figure 2. 2. Biomass Gasifier Technology

2.1.2. Fast Pyrolysis

Figure 2. 4. Biomass Production

2.1.3. Catalytic Fast Pyrolysis

Figure 2. 5. Technical Approach: CFP Process Design Options

Table 2. 1. Comparison of Benzene Production Processes.

Figure 2. 6. Benzene process

Figure 2. 7. Pathway from Lignin to Benzene

Table 2. 2. Comparison of Pretreatment Method

Pre-Treatment Advantage Disadvantage

 Separate glucose from

Table 2. 3. Comparison of Pretreatment Method (Cont’d)

Pre-Treatment Advantage Disadvantage

 Produce the low of

Table 2. 4. Operating Condition (Grinder)

2.2.2. Primary Pyrolysis

The process is conducted in the high temperature ranging from 550OC –

Figure 2. 9. Fluidized bed reactor for CFP.

2.2.3. Catalytic Cracking

addition, another disadvantage of in situ CFP is that the catalytic

Figure 2. 11. Reaction Pathway of Lignin Non-Catalytic/Catalytic Fast Pyrolysis.

2.2.4. Benzene Recovery (Separation)

Figure 2. 13. Example of Benzene Production Distillation.

Figure 2. 14. Block Flow Diagram

.Figure 2. 15. Process Flow Diagram for Pre-Treatment

Figure 2. 16. Process Flow Diagram for Main Process

2.5. Mass and Energy Balance

Table 2. 5. Overall Mass Balance

2.5.2. Overall Energy Balance

Table 2. 6. Overall Energy Balance

2.6. Plant Efficiency

Mass Efficiency = 28.9%

Table 2. 7. Benzene Plant Stream Classification

Q value as specific heat of a measured substances in each stream is

2.7.2. Heat Recovery Pinch Method

Table 2. 8. Stream Temperature Condition

Table 2. 10. Hot and Cold Fluid Program Table Cascade

Ti (°C) Hot Utility Q (MW)

Table 3. 1. Fast Pyrolysis Reactor Specification