i

FINAL PROJECT

PRELIMINARY PLANT DESIGN OF GYPSUM USING LIMESTONE

AND SULFURIC ACID WITH CAPACITY OF 100,000 TONS/YEAR

By:

LATEEFEE YANGOK

D 500 112 001

Supervisor:

1. Kusmiyati, S.T., M.T., Ph.D.

2. Eni Budiyati, S.T., M.Eng

DEPARTMENT OF CHEMICAL ENGINEERING

FACULTY OF ENGINEERING

UNIVERSITAS MUHAMMADIYAH SURAKARTA

2017

ii

THE APPROVAL SHEET

DEPARTMENT OF CHEMICAL ENGINEERING

FACULTY OF ENGINEERING

UNIVERSITAS MUHAMMADIYAH SURAKARTA

Name LATEEFEE YANGOK

Nim D500112001

Title of Final Project Preliminary Plant design of Gypsum using

Limestone and sulfuric acid with capacity of

100,000 tons/year

Supervisors 1. Kusmiyati, S.T.,M.T.,Ph.D.

2. Eni Budiyati, S.T., M.Eng

Surakarta,

August 2017

Has been approved by

First Supervisor Second Supervisor

Kusmiyati, S.T.,M.T.,Ph.D. Eni Budiyati, S.T., M.Eng

NIDN 0617037102 NIDN 0601017302

Dean of Engineering Head of Department

of Chemical

Engineering

Ir.Sri Sunarjono,M.T.,Ph.D. Rois Fatoni, S.T., M.Sc.,

Ph.D.

NIK.682 NIK.892

iii

PRELIMINARY PLANT DESIGN OF GYPSUM USING LIMESTONE

AND SULFURIC ACID WITH CAPACITY OF 100,000 TONS/YEAR

Abstract

Gypsum or calcium sulfate dihydrate requirement in Indonesia is fulfilled

with domestic production and imported from abroad. Domestic gypsum

production is still not sufficient to meet the needs of gypsum in Indonesia.

Therefore, imports from foreign countries are still needed. By establishing the

gypsum industry in Indonesia, it is expected to meet the needs of gypsum in

Indonesia

Gypsum is production from the reaction between limestone (CaCO3) and

sulfuric acid solution (H2SO4) 50% of weight in Continuous Stirred-Tank Reactor

(CSTR) ) with the capacity of product 100,000 tons/year in the reactor at the

operating conditions of temperature at 93 °C and pressure at 1 atm. Raw material

for the plant required are limestone (CaCO3) 7,549 kg/hour and sulfuric acid

solution (H2SO4) 6,898 kg/hour with the general reaction as follows like below :

CaCO3 (s) + H2SO4 (l) + H2O (l) CaSO4.2H2O (s) + CO2 (g) and the weight

ratio between the limestone and sulfuric acid entering the reactor is 1:1 in

kilograms. The residence time in the reactor was 10 minutes.

Plant will be build at 2030 in the Indarung,Padang with area is 16,940 m2

.The result of calculate that Fixed Cost (Fa) is 41,797,168,267. Regulated Cos

(Ra) is 505,053,337,480 Cost of raw material (Sa) is 1,358,239,263,511.Variable

cost (Va) is 629,447,458,716.get the value of BEP is 51.52% (at range 40% -

60%) and get the value of SDP is 51.52% for POT after tax is 1.8 years

(maksimmum 5 years). we get value of Internal Rate of Return (IRR) = 19,35%

So if this plant will be build so many advantages and very profitably.

Keywords: Gypsum, calcium sulfate dihydrate, CaSO4.2H2O

iv

PRARANCANGAN PABRIK GYPSUM DARI BATU KAPUR DAN ASAM

SULFAT DENGAN KAPASITAS 100.000 TON / TAHUN

Abstrak

Kebutuhan gipsum di Indonesia dicukupi dengan produksi dalam negeri

dan impor dari luar negeri. Produksi gipsum dalam negeri masih belum

mencukupi untuk memenuhi kebutuhan gipsum di Indonesia. Oleh karena itu

masih diperlukan impor dari luar negeri. Dengan pendirian industri gipsum di

Indonesia, diharapkan mampu mencukupi ketubutuhan gipsum di Indonesia

Gypsum diproduksi dari reaksi antara batu kapur (CaCO3) dan

larutan asam sulfat (H2SO4) 50% berat dalam Continuous Stirred-Tank Reactor

(CSTR)) dengan kapasitas produk 100.000 ton / tahun pada kondisi operasi suhu

dalam reaktor. Pada suhu 93° C dan tekanan pada 1 atm. Bahan baku untuk pabrik

yang dibutuhkan adalah batu kapur (CaCO3) 7,549 kg / jam dan larutan

asam sulfat (H2SO4) 6,898 kg / jam dengan reaksi umum seperti berikut:

CaCO3 (s) + H2SO4 (l) + H2O (l) CaSO4.2H2O (s) + CO2 (g) dan

perbandingan berat antara batu kapur dan asam sulfat yang masuk ke dalam

reaktor adalah 1: 1 dalam kilogram. Waktu tinggal di reaktor adalah 10 menit.

Pabrik akan dibangun pada 2030 di Indarung, Padang dengan luas 16.940

m2. Hasil perhitungan Biaya Tetap (Fa) adalah 41.797.168.267. Regulated Cos

(Ra) adalah 505.053.337.480 Biaya bahan baku (Sa) adalah

1.358.239.263.511.Variable cost (Va) adalah 629.447.458.716.mendapatkan nilai

BEP adalah 51,52% (pada kisaran 40% - 60%) dan mendapatkan nilai SDP adalah

51,52% untuk POT setelah pajak 1,8 tahun (maksimmum 5 tahun). kita

mendapatkan nilai Internal Rate of Return (IRR) = 19,35% Jadi jika pabrik ini

akan membangun begitu banyak keuntungan dan sangat menguntungkan

Kata kunci: Gypsum, kalsium sulfat dihidrat, CaSO4.2H2O

v

UNIVERSITAS MUHAMMADIYAH SURAKARTA

DEPARTMENT OF CHEMICAL ENGINEERING

FACULTY OF ENGINEERING

STATEMENT OF AUTHENTICITY

The undersigned below:

Name : LATEEFEE YANGOK

Nim : D500112001

Study Program : Chemical Engineering

Title of Final Project : Preliminary Plant design of Gypsum using Limestone

and sulfuric acid with capacity of 100,000 tons/year

State the fact that final project results that I make and submit this is the result of

my own work except for quotation 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 sanction both academically and law.

Surakarta, 23 September 2017

Author

Lateefee Yangok

vi

MOTTO

“Successful indeed are the believers, those who offer their Salat (prayers) with all

solemnity and full submissiveness”

[Quran: surat Al-Muminoon, verses 1-2]

“Try not to become a man of success, but rather try to become a man of value”

vii

DEDICATION

I dedicate this work to:

My beloved mother and father. Thank you for your prayer, support, love, and

education you’ve given.

My beloved sister who always gives support, and advice.

My future Faeelah Deemae who always gives support, inspiration and spirit.

All of my friends are ready for help me.

All of my classmate in the International class 2011 who gave me comfort when

learning.

Thanks’ you for all

viii

FOREWORDS

Bismillahirrohmanirrohim

Assalamualaikum warrohmatullohi wabarokatuh

The final project would like to express his deep gratitude to Alloh SWT,

the most kind who has given guidance, healthy, and ability, so that the final

project could accomplish this final project paper on time.

However, this success would not be achieved either without the helping of

many individuals and institution. Thus, his special thanks and gratefulness are

contributed to:

1. Both Parent for always provide support in completing the final project

2. Faeelah Deemae for always gives support, inspiration and spirit.

3. Kusmiyati, S.T., M.T., Ph.D. as first supervisor of final project

4. Eni Budiyati, S.T., M. Eng as second supervisor of final project

5. Rois Fatoni, ST, MSc. PhD as head of Chemical Engineering

6. Everyone who has supported the author to carry out this work placement very

well.

Author wish this report to be beneficial to those my concern.

Wabillahittaufiq wal hidayah

Wassalamu’alaikum warrohmatullohi wabarokatuh

Surakarta, 23 September 2017

Lateefee Yangok

ix

CONTENT

TITLE ....................................................................................................................... i

APPROVAL ............................................................................................................. ii

ABSTRACT ............................................................................................................. iii

ABSTRAK ............................................................................................................... iv

STATEMENT OF AUTHENTICITY ...................................................................... v

MOTTO .................................................................................................................... vi

DEDICATION ......................................................................................................... vii

FOREWORDS ......................................................................................................... viii

CONTENT ............................................................................................................... ix

LIST OF TABLES..................................................................................................... xi

LIST OF FIGURES .................................................................................................. xiii

CHAPTER I INTRODUCTION .............................................................................. 1

1.1.Background of Plant Design .............................................................................. 1

1.2.Selection of Plant Capacity................................................................................. 2

1.3.Selection of Plant Location................................................................................. 6

1.4.The Process Selection.......................................................................................... 8

1.5. Theory Description ............................................................................................ 11

CHAPTER II PROCESS DESCRIPTION ............................................................... 14

2.1.Spesification of Material...................................................................................... 14

2.2.Proses Concept .................................................................................................... 16

2.3.Thermodynamics Overview................................................................................. 17

2.4.Kinetic Overview................................................................................................. 20

2.5.Step Process......................................................................................................... 21

2.6.Mass and Heat Balance........................................................................................ 27

2.7.Layout and Plant Equipment....................................................................... …… 35

CHAPTER III EQUIPMENT SPECIFICATIONS .................................................. 40

3.1. Main Equipment ……………………………………………………………. 40

3.2. Supporting Equipment ……………………………………………………… 45

CHAPTER IV UTILITY AND LABORATORY..................................................... 57

4.1.Utility.............................................................................. …................................ 57

4.2.Laboratory .......................................................................................................... 86

x

CHAPTER V PLANT MANAGEMENT ................................................................. 91

5.1.Type of Plant ....................................................................................................... 91

5.2. Organizational Structure .................................................................................... 92

5.3. Duties and Power................................................................................................ 95

5.4. Distribution of Work Time of Employee .......................................................... 101

5.5. Employee Status and Wage System................................................................... 103

5.6. Job Position, Ammount of Employees, and Salariess .................................... 104

5.7. Employee Social Welfare.................................................................................... 105

5.8. Occupational Safety and Health.......................................................................... 106

CHAPTER VI ECONOMIC ANALYSIS ............................................................... 108

6.1. Estimation of Equipment Cost............................................................................ 108

6.2. Base of Calculation............................................................................................. 110

6.3. Cost Calculatuion ............................................................................................... 110

6.4. Calculation Result............................................................................................... 113

6.5. Economic Analysis ............................................................................................. 124

REFERENCES

APPENDIX

xi

LIST OF TABLES

Table 1.1 The Import of Gypsum Demand in Indonesia……………………………… 3

Table 1.2 The Plant of Gypsum in Indonesia………………………………………... 5

Table 1.3 The Price of Raw Material and Product........................................................ 5

Table 1.4 Selection Process Based Technical and Economic ………………………… 9

Table 2.1 The Value of Molecular Weight and ΔHf each component……………..... 18

Table 2.2 Data of Gibbs Energy of Raw Materials and Products Components……… 19

Table 2.3.Total Mass Balance……………………………………………………….. 27

Table 2.4. Mass Balance In Mixer -01………………………………………………. 27

Table 2.5. Mass Balance In Mixer -02 ……………………………………………… 28

Table 2.6. Mass Balance In Reactor…………………………………………………. 28

Table 2.7. Mass Balance In Rotary Drum Filter…………………………………….. 29

Table 2.8. Mass Balance In Rotary Dryer…………………………………………… 29

Table 2.9. Mass Balance In Ball Mill ………………………………………………. 30

Table 2.10. Mass Balance In Vibrating Screen…………………………………….... 30

Table 2.11 Heat Balance In Mixer-01 ………………………………………………. 31

Table 2.12 .Heat Balance In Mixer-02……………………………………………… 31

Table 2.13.Heat Balance In Reactor………………………………………………… 32

Table 2.14.Heat Balance In Rotary Drum Filter …………………………………… 32

Table 2.15 Heat Balance In Rotary Dryer.................................................................. 33

Table 2.16 Heat Balance In Ball Mill ……………………………………………... 33

Table 2.17 Heat Balance In Vibrating Screen …………………………………… 34

Tabel 2.18 Large of Plant Building ........................................................................... 36

Table 4.1. Demand of Cooling Water ........................................................................ 75

Table 4.2. Demand of Steam ……………………………………………………….. 76

Table 4.3. Demand of Sanitation Water ……………………………………………. 77

Table 4.4. Demand of Electrical Power of Process ………………………………… 79

Table 4.5. Demand of Electrical Power of Process ………………………………… 80

Table 4.6. Demand of Electricital Power of Utility ………………………………… 80

Table 4.7. Demand of Electricital Power of Pump ………………………………… 81

Table 4.8. Total Demand of Electrical Power of Plant …………………………….. 83

Table 4.9. Anlysis Procedure of Process Unit. …………………………………….. 88

xii

Table 5.1. Schedule of Distribution Groups of Shift Employees ………………….. 102

Table 5.2. Clasification of Position, Qualification, Ammount and Salaries of

Employee ……………………………………………………………… 104

Table 6.1 Cost Index of Equipment …………………………………………….... 108

Table 6.2 Cost of Main Equipment ............................................................................ 114

Table 6. 3 Cost of Supporting Equipment.................................................................. 114

Table 6.4 Total Cost of Unit Process ……………………………………………… 115

Table 6.5 Fixed capital investment (FCI).................................................................. 116

Table 6.6 Working capital investment (WCI) ......................................................... 117

Table 6.7 Direct manufacturing cost (DMC).............................................................. 117

Table 6.8 Indirect manufacturing cost (IMC) ……………………………………… 118

Table 6.9 Fixed manufacturing cost (FMC)............................................................... 118

Table 6.10 General expense (GE) .............................................................................. 119

Table 6.11 Cost of Raw Material................................................................................ 119

Table 6.12 Salary of Employee …………………………………………………….. 119

Table 6.13. Cost of Product ....................................................................................... 121

Table 6.14. Cost of Utility and Waste Treatment Unit............................................... 121

Table 6.15 Economic Analysis and Limitation Value ……………………………… 126

xiii

LIST OF FIGURES

Graph 1.1. The Import Gypsum Demand in Indonesia ............................................... 4

Figure 1.2. Map of Indarung City ………………………………………………….. 7

Figure 2.1. Shrinking Spherical Particles …………………………………………… 20

Figure 2.2. Flow diagram qualitative ............................................................................. 24

Figure 2.2. Flow diagram quantitative............................................................................ 25

Figure 2.3. Process Flow Diagram of Gypsum Plant ……………………………… 26

Figure 2.4. Plant Layout................................................................................................ 37

Figure 2.5. Layout of Main Process ………………………………………………… 39

Figure 4.1. Unit of Water treatment ........................................................................... 64

Figure 5.1. Flow Diagram of Plant Management of Organization ………………… 94

Picture 6.1. Graph of Chemical Cost Index ……………………………………… 109

Figure 6.2 Economic Analysis ...................................................................................... 126