UNIVERSITAS INDONESIA

PRELIMENARY DESIGN OF UREA PLANT

(CO2 FROM COMBUSTION)

Report Assignment 2

GROUP 32

GROUP PERSONNEL:
ANNISA LARASATI (1306405761)
ERVANDY HARYOPRAWIRONOTO (1306370461)
PRITA TRI WULANDARI (1306370455)
RIONELI GHAUDENSON (1306413712)
SEKAR HANUN ULWANI (1306370556)

CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
SEPTEMBER, 2016
 EXECUTIVE SUMMARY

Heat Exchanger Network (HEN) is used to achieve an optimal energy

economization. HEN is a successful way to minimize energy consumption. HEN is
a system exchange of hot and cold streams to obtain a state where the minimum
utility required. HEN is widely used in processing industries to exchange heat
energy among several process streams with different supply temperature. By the
use of HEN, a large amount of utility costs such as the costs of steam and cooling
water, as well as the costs of heaters and coolers can be saved. In our plant, the
stream is divided into two streams, there are cold stream and hot stream. Cold
stream need heating to raise the supply temperature to specified target temperature,
while the hot stream require cooling to lower the supply temperature to desired
target temperature.
First thing in starting analyze heat exchanger is we have to identify streams
in our plant. Urea plant have four cold stream and six hot stream. Then, HEN Based
on the calculation we need minimum cold utility around 17 MW and minimum hot
utility around 3 MW. So, after HEN our urea plant consist of two Heat Exchanger,
four Cooler, and three Heater.
In this assignment, we also design the utility system based on the plant
necessity. Utility is divided into three group included water, electricity, and fuel.
The water utility we need for our plant is 1.6x1010 kg/year. Our water is supplied
from Botang River near from our plant location. water requirement above is water
requirement after HEN, with efficiency about 43% if compare with water
requirement before HEN.
Besides water, we need electricity. The electricity in our plant is derived
from PLN and our own power generation Plant. Our power generation is produce
1,183,248 kWh electricity per year, while our total electricity needed in our plant is
1,188,000 kWh per year. So, we need more electricity supply from PLN about 4,752
kWh or 1,568,160 kWh/year. This consumption electricity from PLN needed cost
about IDR 1,743,793,920 per year. Fuel also needed in our plant for making steam
process in boiler. Fuel needed in our plant is 9,416 kg/h or 74,574,720 kg per
year.

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 LIST OF CONTENT

EXECUTIVE SUMMARY ................................................................................... ii

LIST OF CONTENT ........................................................................................... iii
LIST OF FIGURES ............................................................................................. iv
LIST OF TABLES ................................................................................................ v
CHAPTER 1 ENERGY INTEGRATION .......................................................... 1
1.1. Stream Classification ................................................................................ 1
1.2. Heat Exchanger Network ......................................................................... 1
1.2.1. Composite Curve............................................................................... 2
1.2.2. Temperature-Interval (TI) Method .................................................... 5
1.2.3. Design of Minimum-Energi Heat Exchanger Networks ................... 8
CHAPTER 2 UTILITY ........................................................................................ 9
2.1. Water ........................................................................................................ 9
2.1.1. Water Requirement Before HEN ...................................................... 9
2.1.2. Water Requirement After HEN ....................................................... 10
2.1.3. Water Treatment Unit ..................................................................... 11
2.2. Electricity ............................................................................................... 14
2.2.1. Requirement Electricity .................................................................. 14
2.2.2. Power Generator.............................................................................. 14
2.3. Fuel ......................................................................................................... 15
2.4. Comparison of Pre-HEN with Post-HEN ............................................... 15
2.4.1. Process Flow Diagram Pre-HEN .................................................... 16
2.4.2. Process Flow Diagram Post-HEN ................................................... 18
CHAPTER 3 CONCLUSION ............................................................................ 20
REFERENCES .................................................................................................... 21
APPENDICES ..................................................................................................... 22
A.1 Process Flow Diagram of CO2 Combustion Pre-HEN ............................... 22
A.2 Process Flow Diagram of CO2 Absorption Pre-HEN ................................. 23
A.3 Process Flow Diagram of Urea Plant Pre-HEN ......................................... 24
A.4 Process Flow Diagram of CO2 Combustion Post-HEN ............................. 25
A.5 Process Flow Diagram of CO2 Absorption Post-HEN ............................... 26
A.6 Process Flow Diagram of Urea Plant Post-HEN........................................ 27

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 LIST OF FIGURES

Figure 1.1. Individual Hot Stream Graphs ............................................................. 2

Figure 1.2. Hot Fluid Composite Curve ................................................................. 3
Figure 1.3. Individual Cold Stream Graphs ........................................................... 3
Figure 1.4. Cold Fluid Composite Curve ............................................................... 4
Figure 1.5. Combined Hot and Cold Composite Curve ......................................... 4
Figure 1.6. Cascade Diagram ................................................................................. 7
Figure 1.7. Minimum Energy Design..................................................................... 8
Figure 2.1. Water Treatment Block Flow Diagram ............................................. 11
Figure 2.2. Process Flow Diagram of Water Treatment ...................................... 12

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 LIST OF TABLES

Table 1.1. Classification of stream in Urea and CO2 Capture Plant .................. 1
Table 1.2. Minimum utility requirement after pinch .......................................... 5
Table 1.3. Temperature Adjustment ................................................................... 5
Table 1.4. The Temperature Interval Heat Balance ............................................ 6
Table 1.5. Minimum utility requirement based on problem table cascade ......... 7
Table 2.1. Heating Water Requirement Pre-HEN .............................................. 9
Table 2.2. Cooling Water Requirement Pre-HEN .............................................. 9
Table 2.3. Water Process Requirement ............................................................... 9
Table 2.4. Total Water Requirement Pre-HEN ................................................. 10
Table 2.5. Heating Water Requirement Post-HEN ........................................... 10
Table 2.6. Cooling Water Requirement Post-HEN ........................................... 10
Table 2.7. Process Equipment Electricity Requirement ................................... 14
Table 2.8. Energy Produced by Power Generator ............................................. 14
Table 2.9. Fuel Consumption in Urea Plant ...................................................... 15
Table 2.10. Comparison pre-HEN and post-HEN .............................................. 15
Table 2.11. Flow Data Sheet of CO2 Combustion Pre-HEN .............................. 16
Table 2.12. Flow Data Sheet of CO2 Absorption Pre-HEN ................................ 16
Table 2.13. Flow Data Sheet of Urea Production Pre-HEN ............................... 17
Table 2.11. Flow Data Sheet of CO2 Combustion Post-HEN............................. 18
Table 2.12. Flow Data Sheet of CO2 Absorption Post-HEN .............................. 18
Table 2.13. Flow Data Sheet of Urea Production Post-HEN .............................. 19

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 CHAPTER 1
ENERGY INTEGRATION

1.1. Stream Classification

The first step in the synthesis of HENs is making the stream classification.
The stream in the process flowsheet is only classified into two types, hot process
stream and cold process stream. Hot stream is the stream in the process flowsheet
that required to be cooled, typically an effluent of an unit process, before going to
be feeded to the next unit processing to meet the required temperature. While cold
stream is vice versa, it is the stream that required to be heated. Only several number
of streams in the process flowsheet are going to be evaluated in the synthesis of
HENs, only hot and cold stream in the main process since the object is to minimize
the utilization of utilities for the main process streams.
Table 1.1. Classification of stream in Urea and CO2 Capture Plant
Cp F*Cp
Stream Stream
No T in T out Type (kJ/kgm (MW Q (MW)
In Out
ole C) C-1)
1 9 10 66 83.18 Cold 79 1.496 25.707
2 16 18 100 110 Cold 86.3 1.601 16.012
3 24 25 30 190 Cold 88 0.062 9.845
4 15 16 82 70 Hot 80 1.521 -18.247
5 14 15 100 82 Hot 80 1.523 -27.422
6 40 41 124.9 90.8 Hot 98 0.074 -2.520
7 5 6 688 115 Hot 36 0.164 -95.000
8 35 36 157 130 Hot 94 0.088 -2.384

From Table 1.1. we have ten process streams to be evaluated that consist of
four cold process streams and six hot process streams. We now are able to determine
the minimum energy requirement by calculate the minimum usage of heating and
cooling utilities when exchanging heat between the hot and cold streams in a
process. The value of the heat-capacity flow rate, FCp, which is the product of the
specific heat and mass flow rate, is assumed doesn’t vary with temperature.

1.2. Heat Exchanger Network

A principal objective in the synthesis of HENs is the efficient utilization of
energy in the hot process streams to heat cold process streams. Thus, the second
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step in synthesizing HENs is the calculation of the minimum heating and cooling
requirements for a heat-exchanger network. These calculations can be performed
without having to specify any heat-exchanger network. This second step is referred
to as maximum energy recovery (MER) targetting. MER targetting is useful in that
it determines the hot and cold utility requirements for the most thermodynamically
efficient network. Three methods are introduced to compute MER targets: the
temperature interval method (TI) method, a graphical approach (composite curve
method), and the formulation and solution of a linear program (LP). But we only
use the first two method, the TI method and composite curve method.

1.2.1. Composite Curve

The first step to determine the amount of heat can be recovered by pinch
method, composite curve is generated. Composite curve is generated for hot fluid,
cold fluid and combination of both fluids. This section describes the use of a heat
exchanger network (HEN) to recover the heat in production of riboflavin.
Composite curves consist if temperature (T)-enthalpy (H) profiles of heat
availability (the hot composite curve) and heat demands in the process (the cold
composite curve) together in a graphical representation. Before making composite
curve, we must make hot stream graph and cold stream graph first. Based on the
table 1.1 above we can make the plot of hot and cold stream based on its enthalpy
difference and temperature to be graph as seen below.
750
700
650
600
550
500
∆H (MW)

450
400
350
300
250 Stream 4 Stream 5 Stream 6
200
150 Stream 7 Stream 8
100
50
0
0 10 20 30 40 50 60 70 80 90 100 110
Suhu (oC)
Figure 1.1. Individual Hot Stream Graphs

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Those hot stream plot can be combined into one to obtained a composite hot stream
as seen as Figure 1.2 below
700
650
600
550
500
450
∆H (MW)

400
350
300
250
200
150
100
50
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Suhu (oC)

Figure 1.2. Hot Fluid Composite Curve

The plot of cold stream based on its enthalpy difference and temperature to be graph
as seen below
200
180
160
140
∆H (MW)

120
100
80
60
40
20
0
0 5 10 15 20 25 30
Suhu (oC)
Stream 1 Stream 2 Stream 3

Figure 1.3. Individual Cold Stream Graphs

Those cold stream plot can be combined into one to obtained a composite cold
stream as seen as Figure 1.4 below.

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200
180
160
140
∆H (MW)
120
100
80
60
40
20
0
0 10 20 30 40 50 60 70 80
Suhu (oC)

Figure 1.4. Cold Fluid Composite Curve

To make the pinch, both of this composite curve need to be combined and plotted
in one curve, as shown in Figure 1.5.

650
600
550
500
450
∆H (MW)

400
350
300
250
200
150
100
50
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Suhu (oC)
Composite Cold Composite Hot

Figure 1.5. Combined Hot and Cold Composite Curve

For heat exchange to occur from the hot stream to the cold stream, the hot
stream cooling curve must lie above the cold stream-heating curve. The premium
approach temperature (∆Tm) can be measured directly from the T-H profiles as
being the minimum temperature difference between the hot and cold curves. We
are using temperature difference about 5oC to get the pinch composition. At that
particular ∆Tm, the overlap shows the maximum possible scope for heat recovery

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within the process. The hot end and overshoots indicate minimum hot utility
requirement (QHmin) and minimum cold utility requirement (QCmin), as shown
below.
Table 1.2. Minimum utility requirement based on cumulative curve after pinch
Utility Q (MW)
Hot 19
Cold 73.907

1.2.2. Temperature-Interval (TI) Method

The temperature-interval method was developed by Linnhoff and Flower
(1978a, b) following the pioneering work of Hohmann (1971). One way we could
satisfy the net heating and cooling requirements in each temperature interval is
simply to transfer any excess heat to a cold utility and to supply any heat required
from a hot utility. The first step in the TI method is to adjust the source and target
temperatures using ΔTmin. ΔTmin is the minimum temperature difference as a driving
force for the heat transfer to occur. The selection of the minimum approach
temperature. ΔTmin, for the heat exchangers is a key design variable in the synthesis
of heat exchanger networks (HENs), because of its impact on lost work associated
with heat transfer. For this calculation, we choose 10oC of ΔTmin.
The first step in the TI method is to adjust the source and target temperatures
using ΔTmin. Somewhat arbitrarily, this is accomplished by reducing the
temperatures of the hot streams by 1/2ΔTmin and increasing the temperatures of hot
stream by 1/2ΔTmin.
Table 1.3. Temperature Adjustment
No Type T in T out T in* T out*
1 E-202 66 83.18 71 88.18
2 E-203 100 110 105 115
3 E-301 30 190 35 195
4 E-201 82 70 77 65
5 E-202 100 82 95 77
6 V-307 124.9 90.8 119.9 85.8
7 E-101 688 115 683 110
8 V-305 157 130 152 125

Next, the adjusted temperatures are rank-ordered, beginning with the

highest temperature. These are used to create a cascade of temperature intervals

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within which energy balances are carried out. But first we need to determine the
enthalpy differences on each interval.
Table 1.4. The Temperature Interval Heat Balance

Ti Stream Population DT DH
683 0.04
0.04 488 0.03566 17.40208
195 #### 0.04
#### 0.04 43 -0.05204 -2.23772
152 #### 0.04 0
#### 0.04 0 27 0.04237 1.14399
125 #### 0.04 0
#### 0.04 5.1 -0.05204 -0.2654
119.9 #### 0.1 0.04
#### 0.1 0.04 4.9 0.04582 0.224518
115 -0.1 #### 0.1 0.04
-0.1 #### 0.1 0.04 5 -0.04048 -0.2024
110 -0.1 #### 0.1 0.04
-0.1 #### 0.1 5 -0.07614 -0.3807
105 -0.1 #### 0.1
#### 0.1 10 0.01016 0.1016
95 #### 0.08 0.1
#### 0.08 0.1 6.82 0.08996 0.613527
88.18 0 #### 0.08 0.1
0 #### 0.08 0.1 2.38 0.01074 0.025561
85.8 0 #### 0.08 0.1
0 #### 0.08 8.8 -0.08712 -0.76666
77 0 #### 0 0.08
0 #### 0 6 -0.08727 -0.52362
71 #### 0
#### 0 6 -0.00805 -0.0483
65 #### 0
#### 30 -0.0877 -2.631
35 ####
No 1 2 3 4 5 6 7 8
Cp 79 86.3 88 80 80 98 36 94
Next, we can create the cascade diagrams.

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Ti Hot Utility Q (MW)

683 0
17.40208
195 17.40208
-2.23772
152 15.16436
1.14399
125 16.30835
-0.265404
119.9 16.042946
0.224518
115 16.267464
-0.2024
110 16.065064
-0.3807
105 15.684364
0.1016
95 15.785964
0.6135272
88.18 16.399491
0.0255612
85.8 16.425052
-0.766656
77 15.658396
-0.52362
71 15.134776
-0.0483
65 15.086476
-2.631
35 12.455476
Cold Utility

Figure 1.6. Cascade Diagram

From the cascade diagram we can conclude the minimum utility
requirements for the process.
Table 1.5. Minimum utility requirement based on problem table cascade
Utility Q (MW)
Hot 0
Cold 12.45

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1.2.3. Design of Minimum-Energi Heat Exchanger Networks

We have obtained estimates of the minimum heating and cooling
requirements. Now we can design the heat-exchanger network to determine the
minimum number of heat exchanger required. Here is our proposed HEN design.

Figure 1.7. Minimum Energy Design

From the minimum energy design we need two heat exchangers, five cold utility
(coolers) and one hot utility (heater).

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 CHAPTER 2
UTILITY

2.1. Water
In our plant, we need water as cooling and heating system. So in this chapter,
we will elaborate every water that is needed during urea synthesis and Carbon
absorption processes.

2.1.1. Water Requirement Before HEN

There is a calculation about water requirement in our plant to produce urea
befor Heat Exchanger Network (HEN). Table 2.1 shows the heating water
requirement in our plant, and table 2.2 shows the cooling water requirement in our
plant.
Table 2.1. Heating Water Requirement Pre-HEN
Heat Flow Laten Heat Steam Requirement
Heater
(kJ/h) (kJ/kg) (kg/h)
E-202 90,252,000 2,797 32,267
E-203 57,643,200 2,797 20,609
E-301 35,442,000 2,797 12,671
Total Water Requirement 65,548

Table 2.2. Cooling Water Requirement Pre-HEN

Heat Flow Delta Cooling Water
Cooler Cp
(kJ/h) T Requirement(kg/h)
E-201 65,689,200 4.2 45 347,562
E-202 98,719,200 4.2 57 412,361
V-307 9,072,000 4.2 66 32,827
E-101 342,000,000 4.2 90 904,762
V-305 8,582,400 4.2 105 19,461
Total Water Requirement 1,716,973

Table 2.3. Water Process Requirement

No Equipment Code Type Water Requirement (kg/h)
1 Evaporator V-308 Steam 1,220
2 Final Separator V-309 Steam 838
3 Dekomposer V-304 Steam 1,429
4 Carbamat Reaktor V-302 (A&B) Cooling Water 45,412
Total 48,898

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Table 2.4. Total Water Requirement Pre-HEN

No. Process needs Water Water Requirement (kg/h)
1 Water Steam Pre HEN 65,548
2 Cooling Water Pre HEN 1,716,973
3 Water Process 48,898
Total 1,831,419

2.1.2. Water Requirement After HEN

After Heat Exchanger Network, we just need water as cooling system in our
plant. There are water requirement in our plant for cooling system.
Table 2.5. Heating Water Requirement Post-HEN
Heat Flow Laten Heat Steam Requirement
Heater
(kJ/h) (kJ/kg) (kg/h)
E-203 57,643,200 2,797 20,609
Total Water Requirement 20,609

Table 2.6. Cooling Water Requirement Post-HEN

Heat Flow Delta Cooling Water
Cooler Cp
(kJ/h) T Requirement(kg/h)
E-201 65,689,200 4.2 45 347,562
V-307 9,072,000 4.2 66 32,827
V-305 8,582,400 4.2 105 19,461
Total Water Requirement 399,850

The steam used is saturated MP steam (212oC) and HP steam (350oC). The total
steam requirement is 24,096 kg/h. The total steam needed is enhanced 10% for
safety reason and 10% for leakage prevention:
𝑘𝑔 𝑘𝑔
𝑇𝑜𝑡𝑎𝑙 𝑆𝑡𝑒𝑎𝑚 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡 = 1.2 × 24,096 = 28,915
ℎ ℎ
Assume that 90% of the condensate can be reused:
𝑘𝑔 𝑘𝑔
𝑅𝑒𝑢𝑠𝑒𝑑 𝑜𝑛𝑑𝑒𝑛𝑠𝑎𝑡𝑒 = 90% × 28,915 = 26,024
ℎ ℎ
The total addition of water needed per batch is:
𝑘𝑔
𝑀𝑎𝑘𝑒𝑢𝑝 𝑤𝑎𝑡𝑒𝑟 𝑓𝑜𝑟 𝑏𝑜𝑖𝑙𝑒𝑟 = 28,915 26,024 = 2,891
ℎ
The water that is used is from Bontang River with average temperature 300C. So,
teh total requirement of water in our plant is total makeup water for boiler and water
for cooler.
𝑘𝑔 𝑘𝑔
Total Water Requirement = (1.2 x 445,262) + 2,891
ℎ ℎ

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kg
Total Water Requirement = 537,206
h
Annual water requirement for urea production is:
kg⁄ 9 kg⁄
Annual Requirement = 24 h x 330 d x 537,206 h = 4.255 x 10 year
2.1.3. Water Treatment Unit
The water requirement for the plant is derived from the Bontang River,
which is located near the plant. To ensure a continuous supply of water, it was built
on the location of the water reservoir (water intake) which is also a pre-treatment
of river water. This process contains of filtering water and impurities carried along.
Moreover, water is pumped to the plant to be processed and used as needed. Water
Treatment plant consist of several stages as shown in block flow diagram and
process flow diagram below (Figure 2.1 and 2.2).

Figure 2.1. Water Treatment Block Flow Diagram

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Figure 2.2. Process Flow Diagram of Water Treatment

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Here are the process description

a. Screening
Screening stage is the initial stage of water treatment. The purpose of screening
is to maintain the structure of the flow in the utility of the large objects that may
damage the unit of the utility facilities and other facilities from river water. At this
stage, dirt and scrap material will be screened and filtered. Whereas the smaller
particles would be bound with water in the next processes
b. Sedimentation
Sedimentation is the next filtering process after screening which the water will
be placed in a tank. In the tank, the solid particles which large in diameter (about
10 microns – 10 mm) will settle due to gravity without the aid of chemicals, while
smaller particle would be bound with water to the next processing unit.
c. Clarification
Clarification is the removal of turbidity in the water by mixing it with a solution
of Al2(SO4)3 and Na2CO3 (soda ash). Solution of Al2(SO4)3 serves as a primary
coagulant and coagulant solute Na2CO3 as an addition that serves as an adjuvant to
advance precipitation and pH neutralization. In the clarifier basin, there will be a
process of coagulation and flocculation. This stage aims to get rid of suspended
solid (SS) and colloids.
d. Filtration
Filtration in water purification is a common operation in order to get rid with
Suspended Solid (SS), including particulate BOD in water (Metcalf, 1984).
Materials that is used in the medium can be vary, from sand, anthracite (crushed
anthracite coal), carbon active granular, powdered active carbon, to gravel as a
primary filter, consider another type is quite expensive (Kawamura, 1991).The
main purpose of filtration process is to increase clearance and purity of water. This
process is also used to avoid suspended solid not to close the pores of demineralizer
resin.
e. Demineralization
This process is used to remove any ion and mineral to make the water from
it.The unit consists of anion section and cathion section with resin.

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2.2. Electricity
2.2.1. Requirement Electricity
In general, electricity is needed in our factory is divided into two sources,
included electricity for process and utilities as well as for other purposes that are
not directly related to the process of urea production and carbon capture storage.
Other purposes include the needs of offices and manufacturing area. Here are the
data of electricity needed in the process units and utilities at our plant.
Table 2.7. Process Equipment Electricity Requirement
Usage Power Energy Required
No. Equipment Code Quantity
time (h) (kW) (kWh)
1 Compressor C-101 1 24 29,500 708,000
2 Pump P-201 1 24 187 4,490
3 Pump P-202 1 24 107 2,558
4 Compressor C-301 1 24 19,000 456,000
5 Pump P-301 1 24 420 10,070
6 Pump P-302 1 24 30 715
7 Pump P-303 1 24 169 4,051
8 Pump P-304 1 24 30 720
9 Pump P-305 1 24 11 257
10 Pump P-306 1 24 28 672
TOTAL 10 240 49,481 1,187,534

2.2.2. Power Generator

In or plant, we have two generator to make an energi, there are gas turbine
and steam turbine. Gas turbine use gas combustion to produce energi and steam
energi use steam utility. Table 2.8. show us amount of energi from gas turbine and
steam turbine.
Table 2.8. Energy Produced by Power Generator
Produce Power Energy
No. Equipment Code Quantity
Time (h) (kW) Generated (kWh)
Gas C-
1 1 24 44,590 1,070,160
Turbine 102
TOTAL 1 24 44,590 1,070,160

Based on Table 2.7. and Table 2.8. our plant has continous process with
every equipment has working about 24 hours in one day. Then, we assume that our
plant running for 330 days in a year with turn around every three months about a
week. Thus we can calculate the electricity needs for the purposes of process and
utilities annually using the following equation.
𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑖𝑡𝑦 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡 = 𝑒𝑛𝑒𝑟𝑔𝑦 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡 𝑒𝑛𝑒𝑟𝑔𝑦 𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑖𝑜𝑛
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𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑖𝑡𝑦 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡 = (1,187,534 1,070,160)𝑘𝑊ℎ

𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑖𝑡𝑦 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡 = 117,374 𝑘𝑊ℎ
𝐴𝑛𝑛𝑢𝑎𝑙 𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑖𝑡𝑦 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡 = 117,374 x 330 = 38,733,420 kWh
Electricity from PLN for industries with price 1,112 IDR/ kWh. Needs of electricity
per day is: (only for others electricity requirement)
Cost for Electricity per year = 38,733,420 kWh/year x 1,112 IDR/ kWh
Cost for Electricity per year =IDR 43,071,563,040

2.3. Fuel
Fuel in our plant is needed in utility for making steam that use in our plant
to reboiler, heater, turbine, and column injection. Table 2.9. show the fuel
consumption in our Plant.
Table 2.9. Fuel Consumption in Urea Plant
Power
Net Heating Fuel Requirement
No. Equipment Requirement
Value (kJ/kg) (kg/h)
(kJ/h)
1 Steam Boiler 40,707 67,395,693 1,656

𝐴𝑛𝑛𝑢𝑎𝑙 𝐹𝑢𝑒𝑙 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡 = 1,656 𝑥 24 x 330 = 13,115,520 kg/year

𝐴𝑛𝑛𝑢𝑎𝑙 𝐹𝑢𝑒𝑙 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡 = 63.88 𝑀𝑀𝐵𝑡𝑢/ℎ 𝑥 24 x 330

𝐴𝑛𝑛𝑢𝑎𝑙 𝐹𝑢𝑒𝑙 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡 = 505,930 MMBtu/year

2.4. Comparison of Pre-HEN with Post-HEN

Our plant have calculated the requirement water before and after HEN.
Table 2.10 shows the comparison about water requirement before and after HEN,
after that we calculated efficiency of Heat Exchanger Network in our plant.
Table 2.10. 1Comparison pre-HEN and post-HEN

No. Process needs Water Water Requirement (kg/h)

1 Water Requirement Pre-HEN 1,831,419

2 Water Requirement Post-HEN 469,357
Efficiency (%) 74.372

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 2.4.1. Process Flow Diagram Pre-HEN
Process flow diagram of our urea plant is in APPENDIX A.1 up to A.3 with a flow sheet is shown in Table 2.11 below.
Table 2.11. Flow Data Sheet of CO2 Combustion Pre-HEN

STREAM 1 2 3 4 5 6 7 8 9 10 11
Temperature oC 15 441 30 1185 688 115 123 133 100 25 25
Pressure Bar 1 15 15 15 2 2 3 3 1 1 3
Mass Flow kg/hour 228,287 228,287 12,220 240,506 240,506 240,506 121,900 121,900 121,900 121,900 121,900
Liquid Flow m3/hour - - - - - - 120 120 120 120 120

Table 2.12. Flow Data Sheet of CO2 Absorption Pre-HEN

STREAM 12 13 14 15 16 17 18 19
Temperature oC 115 30 25 25 134 110 100 110
Pressure bar 2 2 2 2 1 1 1 1
Mass Flow kg/hour 240,506 184,500 1,355,720 1,355,720 1,355,720 57,406 1,393,297 94,983
Liquid Flow m3/hour - - 1358 1358 1358 - 1358 63
STREAM 20 21 22 23 24 25 26
Temperature oC 110 100 82 70 70 70 70
Pressure bar 1 2 2 2 1 1 2
Mass Flow kg/hour 1,298,314 1,298,314 1,298,314 1,298,314 1300 100 1,299,714
Liquid Flow m3/hour 1295 1295 1295 1295 5 1 1301

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 Table 2.13. Flow Data Sheet of Urea Production Pre-HEN
STREAM 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Temperature oC 30 36 36 190 110 280 377 63 34 53 189 189 22 190 190 276
Pressure Bar 20 20 175 175 2 175 90 90 90 90 175 150 150 170 175 175
Mass Flow kg/hour 43,142 43,142 43,142 43,142 82,940 82,940 126,718 119,226 63,359 182,585 17,806 393 55,867 207,921 207,921 164,419
COMPOSITION
Carbon dioxide - - - - 0.673 0.673 0.558 0.297 0.558 0.116 0.381 - - - -
Ammonia 1.000 1.000 1.000 1.000 - - 0.439 0.446 0.439 0.234 0.597 - 0.454 0.307 0.307 0.120
Urea - - - - - - - - - - - - - 0.366 0.366 0.463
Carbamate - - - - - - - 0.256 - 0.648 - - 0.546 0.217 0.217 0.114
Water - - - - 0.325 0.325 - - - - - - - 0.110 0.110 0.303
Biuret - - - - - - - - - - - - - - - -
Nitrogen - - - - 0.005 0.005 0.003 0.002 0.003 0.002 0.022 1.000 - - - -
STREAM 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58
Temperature oC 276 276 64 70 70 276 276 34 34 77 77 77 132 132 132 55
Pressure Bar 17.5 17.5 17.5 17.5 175 1.75 1.75 1.75 1.75 0.50 0.55 0.55 0.55 1 0.55 1
Mass Flow kg/hour 142,390 22,029 22,029 18,454 18,454 125,839 18,224 18,224 18,224 99,773 99,773 24,530 76,779 76,779 49,060 76,397
COMPOSITION
Carbon dioxide - 0.300 - - - - 0.308 - - - - - - - - -
Ammonia 0.066 0.700 0.484 0.519 0.519 - 0.662 0.529 0.529 - - - - - - -
Urea 0.535 - - - - 0.598 - - - 0.754 0.754 - 0.980 0.980 - 0.985
Carbamate 0.049 - 0.532 0.481 0.481 - - 0.372 0.372 - - - - - - -
Water 0.350 - - - - 0.396 - - - 0.246 0.246 1.000 0.010 0.010 1.000 0.010
Biuret - - - - - 0.006 - - - 0.008 0.008 - 0.010 0.010 - 0.005
Nitrogen - - - - - - - - - - - - - - - -

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2.4.2. Process Flow Diagram Post-HEN
Process flow diagram of our urea plant is in APPENDIX A.4 up to A.6 with a flow sheet is shown in Table 2.11 below.
Table 2.14. Flow Data Sheet of CO2 Combustion Post-HEN

STREAM 1 2 3 4 5 6 7 8 9 10 11
Temperature oC 15 441 30 1185 688 115 123 133 100 25 25
Pressure Bar 1 15 15 15 2 2 3 3 1 1 3
Mass Flow kg/hour 228,287 228,287 12,220 240,506 240,506 240,506 121,900 121,900 121,900 121,900 121,900
Liquid Flow m3/hour - - - - - - 120 120 120 120 120

Table 2.15. Flow Data Sheet of CO2 Absorption Post-HEN

STREAM 12 13 14 15 16 17 18 19
Temperature oC 115 30 25 25 134 110 100 110
Pressure bar 2 2 2 2 1 1 1 1
Mass Flow kg/hour 240,506 184,500 1,355,720 1,355,720 1,355,720 57,406 1,393,297 94,983
Liquid Flow m3/hour - - 1358 1358 1358 - 1358 63
STREAM 20 21 22 23 24 25 26
o
Temperature C 110 100 82 70 70 70 70
Pressure bar 1 2 2 2 1 1 2
Mass Flow kg/hour 1,298,314 1,298,314 1,298,314 1,298,314 1300 100 1,299,714
Liquid Flow m3/hour 1295 1295 1295 1295 5 1 1301

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 Table 2.16. Flow Data Sheet of Urea Production Post-HEN

STREAM 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Temperature oC 30 36 36 190 110 280 377 63 34 53 189 189 22 190 190 276
Pressure Bar 20 20 175 175 2 175 90 90 90 90 175 150 150 170 175 175
Mass Flow kg/hour 43,142 43,142 43,142 43,142 82,940 82,940 126,718 119,226 63,359 182,585 17,806 393 55,867 207,921 207,921 164,419
COMPOSITION
Carbon dioxide - - - - 0.673 0.673 0.558 0.297 0.558 0.116 0.381 - - - -
Ammonia 1.000 1.000 1.000 1.000 - - 0.439 0.446 0.439 0.234 0.597 - 0.454 0.307 0.307 0.120
Urea - - - - - - - - - - - - - 0.366 0.366 0.463
Carbamate - - - - - - - 0.256 - 0.648 - - 0.546 0.217 0.217 0.114
Water - - - - 0.325 0.325 - - - - - - - 0.110 0.110 0.303
Biuret - - - - - - - - - - - - - - - -
Nitrogen - - - - 0.005 0.005 0.003 0.002 0.003 0.002 0.022 1.000 - - - -
STREAM 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58
Temperature oC 276 276 64 70 70 276 276 34 34 77 77 77 132 132 132 55
Pressure Bar 17.5 17.5 17.5 17.5 175 1.75 1.75 1.75 1.75 0.50 0.55 0.55 0.55 1 0.55 1
Mass Flow kg/hour 142,390 22,029 22,029 18,454 18,454 125,839 18,224 18,224 18,224 99,773 99,773 24,530 76,779 76,779 49,060 76,397
COMPOSITION
Carbon dioxide - 0.300 - - - - 0.308 - - - - - - - - -
Ammonia 0.066 0.700 0.484 0.519 0.519 - 0.662 0.529 0.529 - - - - - - -
Urea 0.535 - - - - 0.598 - - - 0.754 0.754 - 0.980 0.980 - 0.985
Carbamate 0.049 - 0.532 0.481 0.481 - - 0.372 0.372 - - - - - - -
Water 0.350 - - - - 0.396 - - - 0.246 0.246 1.000 0.010 0.010 1.000 0.010
Biuret - - - - - 0.006 - - - 0.008 0.008 - 0.010 0.010 - 0.005
Nitrogen - - - - - - - - - - - - - - - -

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 CHAPTER 3
CONCLUSION

Based on the explanation in the previous chapter, we can conclude some

points below:
 Heat Exchanger Network Analysis is used for optimize the hot and cold for
utility.
 Minimum cold utility needed for our plant is around 17 MW and minimum
hot utility needed for our plan tis around 3 MW.
 Efficiency of water utility in our plant is around 43%.
 Utility system in our Plant consist of water utility, electricity, and fuel utility.
 Total water needed in our plant for cooling and domestic water is
1,600,000,000 kg per year which is supplied from the river Bontang.
 Our power generation plant (gas turbine and steam turbine) produce
1,183,248 kWh and our electricity requirement for the process is 1,188,000
kWh.
 Supply electricity from PLN is 4752 kWh or 1,568,160 kWh/year.
 Fuel needed in our plant is 74,574,720 kg/year for making steam process in
boiler as an utility.

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 REFERENCES

Branan, Carl. 2002. Rules of Thumb For Chemical Engineers. Houston : El-Sevier.
Brownell, Lloyd E and Edwin H. Young. 1959. Process Equipment Design. John
Wiley & Sons, inc.
Cheremisinoff , Nicholas P. 2000. Handbook of Chemical Processing Equipment.
Butterworth-Heinemann.
Coulson & Richardson. 1983. Chemical Engineering Design. Oxford : El-Sevier.
Chemical And Process Design Handbook. New York : McGraw-Hill.
Ludwig, E. E. 1997. Applied Process Design for Chemical and Petrochemical
Plants, Gulf Professional Publishing.
Perry, Robert H. 1999. Perry’s Chemical Engineers’ Handbook. McGraw-Hill
Companies, Inc.
Seider, W. D., Seader, J. D. & Lewin, D. R. 2003. Product and Process Design
Principles, John Wiley and Sons, Inc.
Sinnott, R. K. 2005. Chemical Engineering Design 4th edition. Elsevier.
Wallas, Stanley M. 1988. Chemical Process Equipment Selection and Design.
Butterworth-Heinemann.

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 APPENDICES
A.1 Process Flow Diagram of CO2 Combustion Pre-HEN

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A.2 Process Flow Diagram of CO2 Absorption Pre-HEN

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A.3 Process Flow Diagram of Urea Plant Pre-HEN

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A.4 Process Flow Diagram of CO2 Combustion Post-HEN

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A.5 Process Flow Diagram of CO2 Absorption Post-HEN

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A.6 Process Flow Diagram of Urea Plant Post-HEN

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