lamp.perht.neraca massa.doc

LAMPIRAN APERHITUNGAN NERACA MASSA

PERHITUNGAN NERACA MASSA

Komponen Kode Berat Molekul (gr/mol)

UREA U 60.06

BIURET B 103.09

WATER W 18

MELAMIN M 126.144

AMONIA A 17.031

CARBONDIOKSIDA C 44.01

Basis perhitungan : 1 jam operasi

Waktu produksi : 330 hari kerja /tahun

1 hari : 24 jam

Kapasitas produksi : 25.000 ton/tahun

: 25.000 ton/th x 103 kg/ton x 1 th/330 hari x 1 hari/24 jam

: 3.156,6 kg/jam

Komposisi produk

M : 99,9%

U : 0,05%

B : 0,05%

PRARANCANGAN PABRIK MELAMINPROSES BASF KAPASITAS 25.000 ton/tahun


Komposisi bahan baku urea prill

U : 99,3%

B : 0,57%

W : 0,13%

Komposisi urea melt

U : 99,43%

B : 0,57%

Konversi reaksi : 95%

Yield : 95% ( Ullman Vol A 16 )

Gambar. Diagram Alir Neraca Massa



NERACA MASSA DI MASING – MASING ALAT

1. Neraca Massa di Sekitar Cyclone

Dirancang 99% Melamin terpisah sebagai produk pada cyclone, dengan

kemurnian produk 99,9%.

(Ullman Vol. A.16)

Neraca massa total

F8 = F9 + F10

F9 = Fproduk = 3.156,6 kg/jam

Neraca massa komponen

Urea (U)

U8 = U9 + U10

U9 = 0,05% x F9

= 0,05% x 3.156,6 kg/jam = 1,6 kg/jam

U10 = U8 – U9

U10 = U8 – 1,6

Biuret (B)

B8 = B9 + B10

B9 = 0,05% x F9

= 0,05% x 3.156,6 kg/jam = 1,6 kg/jam



B10 = B8 – B9

B10 = B8 – 1,6

Melamin (M)

M8 = M9+ M10

M9 = 99,9% x F9

= 99,9% x 3.156,6 kg/jam = 3.153,4 kg/jam

M9 = 99% x M8

M8 = M9/99%

= 3.153,4 kg/jam / 0,99 = 3.185,2 kg/jam

M10 = M8 – M9

= 3.185,2 – 3.153,4 = 31,8 kg/jam

Amonia (A)

A8 = A9 + A10

A9 = 0 kg/jam

A10 = A8 – A9

A10 = A8 – 0 = A8

Carbondioksida (C)

C8 = C9 + C10

C9 = 0 kg/jam

C10 = C8 – C9

= C8 – 0 = C8



Komponen Input Output

Arus 8 Arus 9 Arus 10

U U8 1,6 U8 – 1,6

B B8 1,6 B8 – 1,6

M 3.185,2 3.153,4 31,8

A A8 = A10 0 A8 = A10

C C8=C10 0 C8 = C10

Total 3.156,6

2. Neraca Massa di Sekitar Scrubber dan Tangki

Asumsi :

Arus 4,5,6 merupakan arus siklus

Komposisi arus 4,5,6 adalah sama

Off gas arus 14 bebas dari melamin,urea dan biuret



Neraca massa total

F3 + F12 = F5+ F14


Urea(U)

Yield = 95%

= (mol M9 / mol U3) x 6

Mol U3=( Mol M9 x 6 ) / Yield

= (( M9 / BM M ) x 6 ) / Yield

= ((3.153,4 / 126,144) x 6 ) / 0,95

= 157,88

U3 = Mol U3 xBM U

= 157,88 x 60,06

= 9482,6 kg / jam

U14 = 0

U12 = U5 + U14 – U3

= U5 + 0 – 9.482,6

= U5 – 9.482,6

Biuret (B)

Arus 3 hanya terdiri dari urea dan biuret

F3 = U3 + B3

B3 = F3 – U3

U3 = 99,43% x F3



F3 = ( 9.536,9 / 0,9943 ) = 9.536,9 kg/jam

B3 = F3 – U 3

= 9.536,9 – 9.482,6 = 54,3 kg/jam

B14 = 0

B5 = B3 = 54,3 kg/jam

B14 = 0 kg/jam

B3 + B12 = B5 + B 14

54,3 + B12 = 54,3 + 0

B12 = 0

Melamin (M)

M3 = 0 kg/jam

M14 = 0 kg/jam

M3 + M12 = M5 + M14

0 + M12 = M5 + 0

M12 = M5

Amonia (A)

A3 = 0 kg/jam

A5 = 0 kg/jam

A3 + A12 = A5 + A14

0+ A12 = 0 + A14

A12 = A14

Carbondioksida (C)

C3 = 0 kg/jam



C5 = 0 kg/jam

C3 + C12 = C5 + C14

0 + C12 = 0 + C14

C12 = C14


Arus 3 Arus 12 Arus 5 Arus 14

U 9.482,6 U5 – 9.482,6 U5 0

B 54,3 0 54,3 0

M 0 M12=M5 M12=M5 0

A 0 A12=A14 0 A12=A14

C 0 C12=C14 0 C12=C14

Total 9.536,9

3. Neraca Massa di Sekitar Melter

Asumsi :

Arus 1 hanya terdiri dari urea, biuret dan air

Air menguap semua

Biuret tidak ada yang menguap



Urea tidak ada yang menguap, komposisi lelehan urea 99,43% dan biuret

0,57%

Neraca massa total

F1 = F2 + F3


Urea (U)

U1 = U2 + U3

U2 = 0

U1 = U3 = 9.482,6 kg/jam

Biuret (B)

B1 = B2 + B3

B2 = 0

B1 = B3 = 54,3 kg/jam

Melamin (M)

M1 = M2 + M3

M1 = M2 = M3 = 0 kg/jam

Amonia (A)

A1 = A2 + A3

A1 = A2 = A3 = 0 kg/jam

Carbondioksida (C)

C1 = C2 + C3

C1 = C2 = C3 = 0 kg/jam



Air (W)

F1 = U1+B1+W1

= 9.482,6 + 54,3 + W1

U1 + B1 = 99,87% F1

F1 = ( U1 + B1 ) / 0,9987

= 9.536,9 / 0,9987 =9.549,3 kg/jam

W1 = F1 – U1 – B1

= 9.549,3 – 9.482,6 – 54,3

= 12,4 kg/jam

W2 = W1 – W3

= 12,4 – 0

= 12,4 kg/jam



U 9.482,6 0 9.482,6

B 54,3 0 54,3

W 12,4 12,4 0

M 0 0 0

A 0 0 0

C 0 0 0

Sub Total 9.549,3 12,4 9.536,9

Total 9.549,3



4. Neraca Massa di Sekitar Arus Purging

Neraca massa overall

F1 = F2 + F9 + F11

F11 = F1 – F2 - F9

F1- F2 = F3

F11 = F3 - F9

F3 = U3 + B3

= 9.482,6 + 54,3 = 9.536,9 kg/jam

F11 = 9.536,9 – 3.156,6 = 6.380,3 kg/jam

Neraca massa total

F10 = F11 + F12


Urea (U)

Urea yang dipurging = 5% dari urea fresh – urea pada produk

U11 = 5% x U3 – U9

= 5% x 9.482,6 – 1,6 = 472,5 kg/jam

U12 = U 10 – U 11

= U 10 – 472,5



Biuret (B)

B11 = B3 – B9

= 54,3 – 1,6 = 52,7 kg/jam

B10 = B11

B12 = B10 – B11

= 52,7 – 52,7 = 0 kg/jam

Amonia (A)

Pada keadaan steady state diharapkan semua amonia dipurging

Mol A11 = 95% x mol U3

= 95% x ( U3 / BM U )

= 0,95 x ( 9.482,6/60,06 ) = 150

A11 = mol A11 x BM A

= 150 x 17,031 = 2.554,5 kg/jam

A12 = A10 – A11

= A10 – 2.554,5

Karbondioksida (C)

Pada keadaan steady state diharapkan semua karbondioksida dipurging

Mol C11 = ( 3/6 ) x 95% x mol U3

= ( 3/6 ) x 0,95 x ( 9.482,6/60,06 ) = 74,959

C11 = mol C11 x BM C

=74,959 x 44,01 = 3.300,5 kg/jam

C12 = C10 – C11

= C8 – 3.300,5



Melamin (M)

M11 = F11 – U11 – B11 – A11 – C11

= 6.380,3 – 472,6 – 52,7 – 2.554,5 – 3.300,5 = 0 kg/jam

M12 = M10 – M11

= 31,8 – 0 = 31,8 kg/jam


Arus 10 Arus11 Arus 12

U U10 472,6 U10 – 472,6

B B10 52,7 0

M 31,8 0 31,8

A A10 2.554,5 A10 – 2.554,5

C C10 3.300,5 C10 – 3.300,5

Total 6.380,3



5. Neraca Massa di Sekitar Reaktor

Reaksi pembentukan melamin :

6U → M + 6A + 3C

Keterangan : U : Urea

M : Melamin

A : Amonia

C : Carbondioksida

Konversi =

Neraca massa total

F5 + F 16 = F7

M7 = M5 + M hasil reaksi

M hasil reaksi = M7 – M5

M7 = M8

M hasil reaksi = M7 – M5

= 3.185,2 – 31,8 = 3.153,4 kg/jam



Berdasarkan stoikiometri :

Mol A hasil reaksi = 6 x mol M hasil reaksi

= 6 x ( 3.153,4 kg/jam / 126,144 )

= 149,990

A hasil reaksi = mol A hasil reaksi x BM A

= 149,990 x 17,031

= 2.554,5 kg/jam

Mol C hasil reaksi = 3 x mol M hasil reaksi

= 3 x ( 3.153,4 kg/jam / 126,144 )

= 74,995

C hasil reaksi = mol C hasil reaksi x BM C

= 74,995 x 44,01

= 3.300,5 kg/jam

Mol U yg bereaksi = 6 x mol M hasil reaksi

= 6 x ( 3.153,4 kg/jam /126,144 )

= 149,990 kg/jam

U yang bereaksi = mol U yang bereaksi x BM U

= 149,99 x 60,06

= 9.008,4 kg/jam

U yg dibthkan = U bereaksi / konversi

= 9.008,4 kg/jam / 0,95

= 9.482,6 kg/jam



Fl uidizing gas = 1, 65 Nm3/kg U x U yg dibutuhkan

= 1, 65 Nm3/kg U x 9.482,6 kg/jam

= 15.646,2 Nm3/jam

Untuk campuran gas perbandingan mol = perbandingan volume

A : C = 2 : 1 (USPTO, 2.152.505)

Arus 16

U16 = 0 kg/jam

B16 = 0 kg/jam

M16 = 0 kg/jam

A16 = 2/3 x fluidizing gas x ρA

= 2/3 x 15.646,2 Nm3/jam x 0,77088 kg/m3

= 8.040,9 kg/jam

C16 = 1/2 x (A16/BM A) x BM C

= 1/2 x (8.040,9 kg/jam / 17,031) x 44,01

= 10.389,3 kg/jam

Arus 5

U5 = U yg dibutuhkan

= 9.482,6 kg/jam

B5 = 54,3 kg/jam

M5 = 31,8 kg/jam

A5 = 0 kg/jam

C5 = 0 kg/jam



Arus 7

U7 = U yang tidak bereaksi

= U yang dibutuhkan – U yang bereaksi

= 9.482,6 kg/jam – 9.008,4 kg/jam

= 474,2 kg/jam

B7 = B5 + B16

= 54,3 + 0

= 54,3 kg/jam

M7 = M8

= 3.185,2 kg/jam

A7 = A5 + A 16 + A hasil reaksi

= 0 + 8.040,9 + 2.554,5

= 10,595,4 kg/jam

C7 = C5 + C16 + C hasil reaksi

= 0 + 10.389.3 + 3.300.5

= 13.689,8 kg/jam





U 9.482,6 0 474,2

B 54,3 0 54,3

M 31,8 0 3.185,2

A 0 8.040,9 10.595,4

C 0 10.389,3 13.689,8

Subtotal 9.568,7 18.430,2

27.998,9Total 27.998,9

6. Neraca Massa di Sekitar Desublimer

Neraca massa total

F8 = F15 + F7


Massa arus 15 diperoleh dari trial dengan neraca panas

Arus 15 hanya terdiri dari A dan C



Urea (U)

U7 = 474,2 kg/jam

U15 = 0 kg/jam

U8 = U7 + U15

= 474,2 + 0 = 474,2 kg/jam

Biuret (B)

B7 = 54,3 kg/jam

B15 = 0 kg/jam

B8 = B7 + B15

= 54,3 + 0 = 54,3 kg/jam

Melamin (M)

M 7 = 3185,2 kg/jam

M15 = 0 kg/jam

M8 = M7 + M15

= 3185,2 + 0 = 3185,2 kg/jam

Massa Amonia dan Carbondioksida pada arus 15 diperoleh dari trial neraca panas

di desublimer.

Arus 15 = 3,407 x Arus 16

Amonia (A)

A7 = 10.595,4 kg/jam

A15 = 1608,55 kmol/jam x 17,031 kg/kmol = 27.395,2 kg/jam

A8 = A7 + A15

= (10.595,4 + 27.395,2) kg/jam = 37.990,6 kg/jam



Carbondioksida (C)

C7 = 13.689,8 kg/jam

C15 = 804,29 kmol/jam x 44,01 kg/kmol = 35.396,80 kg/jam

C8 = C7 + C15

= (13.689,8 +35.396,80) kg/jam = 49.086,6 kg/jam



U 474,2 0 474,2

B 54,3 0 54,3

M 3.185,2 0 3.185,2

A 10.595,4 27.395,2 37.990,6

C 13.689,8 35.396,8 49.086,6

Sub total 27.998,9 62.792,0

90.790,9Total 90.790,9



7. Neraca Massa di Sekitar Arus Percabangan

Neraca massa total

F14 = F15 + F16


Urea (U)

U15 = 0 kg/jam

U16 = 0 kg/jam

U14 = U15 + U16

U14 = 0 + 0 = 0 kg/jam

Biuret (B)

B15 = 0 kg/jam

B16 = 0 kg/jam

B14 = B15 + B16

B14 = 0 + 0 = 0 kg/jam

Melamin (M)

M15 = 0 kg/jam

M16 = 0 kg/jam

M14 = M15 + M16

M14 = 0 + 0 = 0 kg/jam



Amonia (A)

A15 = 27.395,2 kg/jam

A16 = 8.040,9 kg/jam

A14 = A15 + A16

A14 = 27.395,2 + 8.040,9 = 35.436,1 kg/jam

Carbondioksida (C)

C15 = 35.396,8 kg/jam

C16 = 10.389,3 kg/jam

C14 = C15 + C16

C14 = 35.396,8 + 10.389,3 = 45.786,1 kg/jam



U 0 0 0

B 0 0 0

M 0 0 0

A 35.436,1 27.395,2 8.040,9

C 45.786,1 35.396,8 10.389,3

Sub Total

81.222,2

62.791,98 18.430,2

Total 81.222,2



8. Neraca Massa di Sekitar Scrubber

Neraca massa total

F6 + F12 = F13 + F14


Urea (U)

U6 + U12 = U13 + U14

U6 + 0 = U13 + 0

U6 = U13

Biuret (B)

B6 + B12 = B13 + B14

B6 + 0 = B13 + 0

B6 = B13

Melamin (M)

M6 + M12 = M13 + M14

M6 + 31,8 = M13 + 0

M6 + 31,8 = M13



Amonia (A)

A6 + A12 = A13 + A14

A6 + 35.436,1 = A13 + 35.436,1

A6 = A13

Carbondioksida (C)

C6 + C12 = C13 + C14

C6 + 45.786,1 = C13 + 45.786,1

C6 = C13

Arus 6 diperoleh dari trial neraca panas di sekitar scrubber.

Arus 6 = 0,85 x arus 5

Urea (U)

U5 = 157,88 kmol/jam

U6 = 0,85 x U5

= 0,85 x 157,88 kmol/jam = 134,198 kmol/jam

= 134,198 kmol/jam x 60,06 kg/kmol = 8.059,93 kg/jam

U13 = U6 = 8.059,93 kg/jam

Biuret (B)

B5 = 0,53 kmol/jam

B6 = 0,85 x 0,53 kmol/jam = 0,4505 kmol/jam

= 0,4505 kmol/jam x 103,09 kg/kmol = 46,4 kg/jam

B13 = B6 = 46,4 kg/jam

Melamin (M)

M5 = 0,25 kmol/jam



M6 = 0,85 x 0,25 kmol/jam = 0,2125 kmol/jam

= 0,2125 kmol/jam x 126,144 kg/kmol = 26,8 kg/jam

M6 + 31,8 = M13

M13 = 26,8 + 31,8 = 58,6 kg/jam

Amonia (A)

A6 = 0,85 x A5

= 0,85 x 0 = 0 kg/jam

A13 = A6 = 0 kg/jam

Carbondioksida (C)

C6 = 0,85 x C5

= 0,85 x 0 = 0 kg/jam

C13 = C6 = 0 kg/jam



U 8.059,9 0 8.059,9 0

B 46,4 0 46,4 0

M 26,8 31,8 58,6 0

A 0 35.436,1 0 35.436,1

C 0 45.786,1 0 45.786,1

Sub total 8.133,1 81.254,0 8.164,9 81.222,2

Total 89.387,1 89.387,1



9. Neraca Massa di Sekitar Tangki

Neraca massa total

F4 = F3 + F13


Urea (U)

U3 = 9.482,3 kg/jam

U13 = 8.059,9 kg/jam

U4 = U3 + U13

U4 = 9.482,6 + 8.059,9 = 17.542,5 kg/jam

Biuret (B)

B3 = 54,3 kg/jam

B13 = 46,4 kg/jam

B4 = B3 + B13

B4 = 54,3 + 46,4 = 100,7 kg/jam

Melamin (M)

M3 = 0 kg/jam

M13 = 58,6 kg/jam



M4 = M3 + M13

M4 = 0 + 58,6 = 58,6 kg/jam

Amonia (A)

A3 = 0 kg/jam

A13 = 0 kg/jam

A4 = A3 + A13 = 0 + 0 = 0 kg/jam

Carbondioksida (C)

C3 = 0 kg/jam

C13 = 0 kg/jam

C4 = C3 + C13 = 0 + 0 = 0 kg/jam



U 9.482,6 8.059,9 17.542,5

B 54,3 46,4 100,7

M 0 58,6 58,6

A 0 0 0

C 0 0 0

Sub total 9.536,9 8.164,9

17.701,8Total 17.701,8



NERACA MASSA OVERALL



Urea 9.482,6 0 1,6 472,6

Biuret 54,3 0 1,6 52,7

Melamine 0 0 3.153,4 2.544,5

Amonia 0 0 0 3.300,5

CO2 0 0 0 0

Water 12,4 12,4 0 0

Sub total 9.549,3 12,4 3.156,6 6.380,3

Total 9.549,3 9.549,3


lamp.perht.neraca massa.doc

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