i
DESIGN REPORT
PRELIMINARY DESIGN OF TITANIUM DIOXIDE PLANT FROM ILMENITE
CAPACITY OF 50,000 TON/ YEAR
Submitted in Partial Fulfilment of the Requirement for the Degree of Bachelor in Chemical Engineering
by:
Yulira Kus Rendra D 500 122 002
Supervisor:
1. Dr. Ir. H. Ahmad. M. Fuadi, M.T. 2. Ir. Nur Hidayati, M.T,.Ph.D.
CHEMICAL ENGINEERING DEPARTMENT FACULTY OF ENGINEERING
ii
VALIDATION
UNIVERSITAS MUHAMMADIYAH SURAKARTA FACULTY OF ENGINEERING
DEPARTMENT OF CHEMICAL ENGINEERING
Name : Yulira Kus Rendra
Student’s number : D 500 122 002
Title of Final Project : Preliminary Design of Titanium Dioxide Plant from Ilmenite, Capacity of 50,000 Ton/ Year
Supervisor : 1. Dr. Ir. H. Ahmad. M. Fuadi, M.T. 2. Ir. Nur Hidayati, M.T,.Ph.D.
Surakarta, March 2017
Has been approved by,
Supervisor I Supervisor II
Dr. Ir. H. Ahmad. M. Fuadi, MT Ir. Nur Hidayati, M.T., Ph.D
NIK: 618 NIK: 975
Dean of Engineering Head of Department Chemical Engineering
Ir. Sri Sunarjono, M.T., Ph.D. Rois Fatoni, S.T., M.Sc., Ph.D.
iii
UNIVERSITAS MUHAMMADIYAH SURAKARTA FACULTY OF ENGINEERING
DEPARTMENT OF CHEMICAL ENGINEERING STATEMENT OF AUTHENTICITY
The undersigned below:
Name : Yulira Kus Rendra
NIM : D 500 122 002
Department : Chemical Engineering
Title of Final Project : Preliminary Design of Titanium Dioxide from Ilmenite, Capacity of 50,000 Tons/Year
Starting the fact that final project result that I make and submit this is the result of my own work, except for quotations and summaries that everything, I have explained the sources. If the final project is plagiarism and other scientific or research work, then I am ready to accept the punishment both academically and law.
Surakarta, April 20th 2017 Author
iv ABSTRACT
Titanium dioxide is mostly used by the chemical industry as a pigment for the production of fiber, paint, cosmetics, and polymers. Titanium dioxide plant was designed with a capacity of 50,000 tons/year. Titanium dioxide plant is planned to be built in 2020 on the island of Bangka Belitung. Plant location is close to ilmenite as raw material sources. Marketing of titanium dioxide is to meet domestic demand
By reacting ilmenite with chlorine (Cl2) to produce titanium tetrachloride (TiCl4), using coke as a reducing agent in a fluidized bed reactor. reactor operated continuously at 900 ℃ and 1 atm pressure. Furthermore, the output of reactor 1 will be purified before passing it to the reactor 2, with the type of fluidized bed reactor that operates continuously at temperatures of 1000 ℃ and 1 atm pressure. In reactor 2, the reaction between titanium tetrachloride (TiCl4) and hot air will produce titanium dioxide and chlorine gas, then the chlorine (Cl2) will recycle back to the reactor 1. The production of titanium dioxide as much as 50,000 tons/year, requires raw materials ilmenite as much 18314.8573 kg/h, chlorine gas as much 27472.2860 kg/h and cokes as much 4578.7143 kg/h, as well as byproducts produced in the form of iron (III) chloride (FeCl3) as 16555.6602 kg/h. For process water, obtained from Manggar river as much as 29.9064 m3/h, electricity needs as much 639.7765 Kw, and fuel oil 2394.8983 L/h.
v MOTTO
“Allah will raise those who have believed among you and those who were given knowledge, by degrees. And Allah is Acquainted with what you do.”
(Al-Mujadillah:11)
“When a man blames others for his failures, it’s a good idea to credit others with his successes.”
vi
DEDICATION
In this final project, author dedicate to;
1. Both beloved parents for the prayer, motivation and support always given so far.
2. Argo Yulianto as older brother and his family have provided support and encouragement to the author.
3. Okti Mulatsiwi, as a older sister who has provided assistance and motivation so that the authors can complete this final project.
vii PREFACE Assalamualaikum wr.wb
Alhamdulillah, Praise Allah SWT for all grace, taufik and His guidance so that the author can completing the preliminary design with title “Preliminary Design of Titanium Dioxide from Ilmenite with Capacity 50,000 ton/year”.
In completing this final project, a lot of difficulties and obstacles that occurHowever, thanks to the help of several parties, the end of this final project can be resolved. For that, on this occasion not forget author would like to thank, in particular to :
1. Mr. Rois Fatoni, S.T., M.Sc., Ph.D., As Chairman of the Department of Chemical Engineering, Faculty of Engineering, University of Muhammadiyah Surakarta,
2. Mr. Ir. H. Ahmad. M. Fuadi, M.T., as Supervisor I, patiently providing guidance to the author so that the completion of this final project,
3. Mrs. Ir. Nur Hidayati, M.T., as Supervisor II, which has provided valuable guidance and advice to the completion of this final project, 4. The father, mother, sister and brother on sincerity provide guidance,
as well as moral and material support that always accompany author in each step until today,
5. All employees of admin in chemical engineering department, who has helped all the needs of this final project
6. All those who have helped up to the completion of this Final project. Author realizes there are still many shortcomings in this Final Project. That requires the advice and constructive criticism from readers. the authors hope that the final report will be useful
Wassalamualaikum wr.wb
Surakarta, March 2017
viii
LIST OF CONTENS
TITLE PAGE ... i
VALIDATION ... ii
STATEMENT OF AUTHENTICITY ... iii
ABSTRACT ... iv
MOTTO ... v
DEDICATION ... vi
PREFACE ... vii
LIST OF CONTENTS ... xiii
LIST OF TABLES ... xiii
LIST OF FIGURES ... xv
CHAPTER I INTRODUCTION ... 1
1.1. Background ... 1
1.2. Design of Capacity ... 2
1.2.1. Titanium dioxide consumption ... 2
1.2.2. Raw material consumption ... 3
1.2.3. Minimum capacity ... 3
1.3. Plant Location ... 5
1.3.1. Raw materials ... 6
1.3.2. Marketing... 6
1.3.3. Utility ... 6
1.3.4. Labor ... 6
1.3.5. Transport and telecom ... 6
1.4. Literature Review ... 7
1.4.1. Production process description ... 7
1.4.2. Uses of titanium dioxide ... 8
1.4.3. Physical and chemical properties ... 8
1.4.4. Process review ... 12
CHAPTER II PROCESS DESCRIPTION ... 14
ix
2.1.1. Raw material specification ... 14
2.1.2. Product specification ... 15
2.2. Concept of Process ... 15
2.2.1. Mechanism of the reaction ... 16
2.2.2. Kinetics review ... 16
2.2.3. Thermodynamics review ... 18
2.3. The Step of Process ... 21
2.3.1. Flow diagram process ... 21
2.3.2. Steps of the process ... 21
2.4. Mass and Heat Balance ... 26
2.4.1. Mass balance ... 26
2.4.2. Heat balance ... 32
2.5. Plant layout and equipment ... 38
2.5.1. Plant layout ... 38
2.5.2. Equipment plant layout ... 42
CHAPTER III EQUIPMENT SPECIFICATIONS ... 44
3.1. Reactor – 01 ... 44
3.2. Reactor – 02 ... 45
3.3. Absorber ... 46
3.4. Ball mill ... 46
3.5. Belt conveyor ... 47
3.5.1. Belt conveyor – 01 ... 47
3.5.2. Belt conveyor – 02 ... 47
3.5.3. Belt conveyor – 03 ... 48
3.6. Blower ... 48
3.6.1. Blower – 01 ... 48
3.6.2. Blower – 02 ... 49
3.7. Condenser Partial ... 50
3.7.1. Condenser partial – 01 ... 50
3.7.2. Condenser partial – 02 ... 51
x
3.8.1. Expander valve – 01 ... 52
3.8.2. Expander valve – 02 ... 52
3.8.3. Expander valve – 03 ... 53
3.9. Grate Cooler ... 53
3.9.1. Grate cooler – 01 ... 53
3.9.2. Grate cooler – 02 ... 54
3.9.3. Grate cooler – 03 ... 54
3.10. Heat Exchanger... 55
3.10.1. Heat exchanger – 01 ... 55
3.10.2. Heat exchanger – 02 ... 56
3.10.3. Heat exchanger – 03 ... 57
3.10.4. Heat exchanger – 04 ... 58
3.10.5. Heat exchanger – 05 ... 59
3.10.6. Heat exchanger – 06 ... 60
3.10.7. Heat exchanger – 07 ... 61
3.10.8. Heat exchanger – 08 ... 62
3.11. Compressor ... 63
3.11.1. Compressor – 01 ... 63
3.11.2. Compressor – 02 ... 64
3.12. Mixer ... 64
3.13. Pump ... 65
3.13.1. Pump – 01 ... 65
3.13.2. Pump – 02 ... 65
3.14. Screw Conveyor ... 66
3.14.1. Screw conveyor – 01 ... 66
3.14.2. Screw conveyor – 02 ... 66
3.15. Separator ... 67
3.15.1. Separator – 01 ... 67
3.15.2. Separator – 02 ... 68
3.16. Silo ... 68
xi
3.15.2. Silo – 02 ... 69
3.17. Tank ... 69
3.17.1. Tank – 01 ... 69
3.17.2. Tank – 02 ... 69
3.18. Vaporizer ... 71
3.19. Cyclone ... 72
3.19.1. Cyclone – 01 ... 72
3.19.2. Cyclone – 02 ... 73
3.19.3. Screening ... 74
CHAPTER IV PROCESS SUPPORT AND LABORATORY ... 75
4.1. Process Supporting Unit ... 75
4.1.1. Water supply unit... 75
4.1.2. Dowtherm supply unit ... 80
4.1.3. Electricity supply unit ... 80
4.1.4. Fuel supply unit ... 85
4.1.5. Compressed air supply unit ... 86
4.1.6. Waste treatment unit ... 87
4.2. Laboratory ... 88
4.3. Specification of Utility Equipment ... 91
CHAPTER V PLANT MANAGEMENT ... 102
5.1. Form of Enterprise ... 102
5.2. Organizational Structure ... 102
5.3. Duties and Authorities... 105
5.3.1. Shareholder ... 105
5.3.2. The board of commissioners ... 105
5.3.3. President director ... 105
5.3.4. Expert staff ... 106
5.3.5. Director of Eng. and production... 106
5.3.6. Director of finance and public... 106
5.3.7. Head of department ... 107
xii
5.4. Departments of Employee Work Hours ... 110
5.4.1. Non-shift employees ... 110
5.4.2. Shift employees ... 110
5.5. Status of Employees and Wage System ... 112
5.6. Classification of Occupation and Salaries ... 112
5.6.1. Classification of occupation ... 112
5.6.2. Number of employees and salaries ... 113
5.7. Social Welfare Employees ... 116
5.8. Production Management ... 117
CHAPTER VI ECONOMIC ANALYSIS ... 118
6.1. Fixed Capital Investment ... 124
6.2. Working Capital ... 125
6.3. Total Product Cost... 125
6.4. Production Profit ... 125
6.5. Feasibility Analysis ... 126
xiii
LIST OF TABLES
Table 1.1. Comparison the characteristic of rutile and anatase ... 1
Table 1.2. Data of Titanium dioxide import ... 2
Table 1.3. List of Titanium dioxide companies ... 4
Table 1.4. Comparison of Titanium dioxide manufacture ... 7
Table 2.1. Mass balance of Reactor 1 (R-100)... 25
Table 2.2. Mass balance of Reactor 2 (R-200)... 26
Table 2.3. Mass balance of Absorber (D-300) ... 26
Table 2.4. Mass balance of Separator 1 (H-217) ... 27
Table 2.5. Mass balance of Separator 2 (H-316) ... 27
Table 2.6. Mass balance of Vaporizer (V-313) ... 28
Table 2.7. Total mass balance ... 29
Table 2.8. Heat balance of Reactor 2 (R-200) ... 30
Table 2.9. Heat balance of Vaporizer (V-313) ... 30
Table 2.10. Heat balance of Absorber (D-300) ... 31
Table 2.11. Heat balance of Condenser partial 1 (E-216) ... 31
Table 2.12. Heat balance of Condenser partial 2 (E-217) ... 31
Table 2.13. Heat balance of Reactor 1 (R-100) ... 32
Table 2.14. Total area of Titanium Dioxide plant ... 36
Table 4.1. Sanitation water consumption ... 72
Table 4.2. Total of water consumption ... 72
Table 4.4. Electricity needs for process equipment ... 78
Table 4.5. Electricity needs for utilities equipment ... 79
Table 4.6. Electricity needs for lighting ... 80
Table 6.1. Cost index of chemical plant data ... 116
Table 6.2. Fixed capital investment ... 120
Table 6.3. Working capital ... 121
Table 6.4. Manufacturing cost ... 121
xiv
Table 6.6. Total product cost... 122
Table 6.7. Fixed cost ... 124
Table 6.8. Variable cost ... 124
Table 6.9. Regulated cost ... 125
xv
LIST OF FIGURES
Figure 1.1. Graph of Titanium dioxide import ... 3
Figure 2.1. Flow diagram of Qualitative ... 23
Figure 2.2. Flow diagram of Quantitative ... 24
Figure 2.3. Layout of Titanium dioxide plant ... 37
Figure 4.1. Water Treatment Unit ... 97
Figure 5.1. Organizational Structure ... 100
Figure 6.1. Relationship between years vs cost index ... 117
