Pengembangan Heat Exchanger Network Pada Proses Produksi Urea Teknologi ACES

Elfarianti, Nina Adriana and Nisa, Alvina Choirun (2021) Pengembangan Heat Exchanger Network Pada Proses Produksi Urea Teknologi ACES. Undergraduate thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Pabrik Urea didirikan di Gresik, Jawa Timur dengan kapasitas produksi sebesar 462.000 ton/tahun atau sekitar 1.400 ton/hari. Urea diproduksi dari CO2 dan NH3 murni serta proses yang digunakan adalah ACES lisensi Toyo Engineering Corporation, Jepang. Proses produksi Urea teknologi ACES terdiri dari enam unit. Pertama, Unit Sintesis, gas CO2 dan NH3 liquid direaksikan menjadi Urea dan air. Kedua, Unit Purifikasi, ekses gas NH3 dan Amonium Karbamat yang tidak terkonversi dipisahkan dari larutan Urea dengan pemanasan steam. Ketiga, Unit Recovery, CO2 dan NH3 diserap dari Unit Purifikasi dengan absorbent berupa process condensate menjadi larutan Karbamat dan dikembalikan ke Unit Sintesis. Keempat, Unit Konsentrasi, larutan Urea dipekatkan konsentrasinya hingga 99,7%. Kelima, Unit Prilling, larutan Urea dispray dari atas Prilling Tower membentuk butiran-butiran Urea prill yang siap didistribusikan. Dan keenam, Unit Process Condensate
Treatment, dimana process condensate yang masih mengandung CO2 dan NH3 dihidrolisa menghasilkan air proses. Pada pabrik Urea ini, kami mengoptimalkan jaringan HEN’s dengan menggunakan metode pinch. Dari hasil simulasi menggunakan Aspen Energy Analyzer V10 didapatkan adanya cross pinch pada kondisi existing pabrik asam sulfat yang dapat mempengaruhi luas area, capital cost, total cost, jumlah shells dan penambahan satu alat heat exchanger terhadap kondisi retrofit design berupa heater. Total cost untuk existing design sebesar 6,937 x 10-2, sedangkan untuk retrofit design sebesar 7,323 x 10-3. Total heat
exchanger dari target optimum kondisi operasi sebesar 7 unit, sedangkan pada kondisi existing dan retrofit sebesar 6 dan 7 unit heat exchanger dan effisiensi masing-masing heat exchanger pada kondisi existing dan retrofit sebesar 35% dan 77%. Berdasarkan analisa ekonomi, diperoleh persentasi Internal Rate of Return (IRR) sebesar 23,2% dan nilai NPV sebesar Rp. 685.943.237.480. Pay Out Time (POT) 3,29 tahun dan nilai Break Event Point (BEP) sebesar 33,87%.
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The Urea factory was established in Gresik, East Java with a production capacity of 462,000 tons/year or around 1,400 tons/day. Urea is produced from pure CO2 and NH3 and the process used is ACES licensed by Toyo Engineering Corporation, Japan. The Urea production process of ACES technology consists of six units. First, the Synthesis Unit, CO2 gas and liquid NH3 are reacted to become Urea and water. Second, Purification Unit, excess NH3 gas and unconverted Ammonium Carbamate are separated from Urea solution by steam heating. Third, in the Recovery Unit, CO2 and NH3 are absorbed from the Purification Unit with the absorbent in the form of process condensate becoming a Carbamate solution and returned to the Synthesis Unit. Fourth, Unit of Concentration, the Urea solution is concentrated to 99.7%. Fifth, Prilling Unit, Urea solution is sprayed from the top of the Prilling Tower to form prill Urea granules that are ready to be distributed. And sixth, Unit Process Condensate Treatment, where process condensate which still contains CO2 and NH3 is hydrolyzed to produce process water. At this Urea plant, we optimize the HEN's network using the pinch method. From the simulation results using Aspen Energy Analyzer V10, it is found that there is a cross pinch on the existing condition of the sulfuric acid plant which can affect the area, capital cost, total cost, number of shells and the addition of one heat exchanger to the retrofit design condition in the form of a heater. The total cost for the existing design is 6,937 x 10-2, while for the retrofit design it is 7,323 x 10-3. The total heat exchanger from the optimum target operating conditions is 7 units, while in the existing and retrofit conditions it is 6 and 7 heat exchanger units and the efficiency of each heat exchanger in the existing and retrofit conditions is 35% and 77%. Based on the economic analysis, the percentage of Internal
Rate of Return (IRR) is 23.2% and the NPV value is Rp. 685,943,237,480. Pay Out Time (POT) 3.29 years and a Break Event Point (BEP) value of 33.87%.

Item Type:	Thesis (Undergraduate)
Uncontrolled Keywords:	Urea, ACES, Pinch
Subjects:	T Technology > TJ Mechanical engineering and machinery > TJ263 Heat exchangers T Technology > TP Chemical technology > TP155.5 Chemical plants--Design and construction
Divisions:	Faculty of Vocational > 24305-Industrial Chemical Engineering
Depositing User:	Alvina Choirun Nisa
Date Deposited:	23 Aug 2021 02:58
Last Modified:	23 Aug 2021 02:58
URI:	http://repository.its.ac.id/id/eprint/88848

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