Design Report

FINAL YEAR DESIGN PROJECT 2
SAPP
COMPANY PROFILE
NORAISHAH BINTI AMIN
RADIAH BINTI RAZALI
MOHD FAIZ BIN MOHD KHALIL
MOHD ZAKIMAN BIN OTHMAN
NUR HIDAYAH BINTI MUSA@ABDULLAH
NOR EZATY BINTI ABDUL RASHID
SAPP
PROJECT OBJECTIVES
1. To establish a foundation studies in order to develop stearic acid plant with
a capacity of 100,000 MT/year in Indonesia.
2. Establishment of proposed PFD for the plant.
3. Establishment of mechanical design and chemical design fundamental
calculation with regard to process equipment.
4. Performing Process Integration Analysis Review.
5. Performing Cost Analyses to enable investor to see the economic benefits
and attractiveness of the project.
6. Establishing a design study to develop waste water treatment to comply to
Environmental Regulation of Indonesia.
7. Performing Plant Safety and Layout studies requirements.
SAPP
PRESENTATION OUTLINES
INTRODUCTION
DESIGN OF EQUIPMENT
PROCESS CONTOL AND INSTRUMENTATION
PROCESS INTEGRATION
ENVIRONMENT, WASTE PREVENTION AND TREATMENT
ECONOMIC ANALYSIS
PLANT SAFETY AND LAYOUT
SAPP
Introduction
STEARIC ACID PRODUCTION PLANT (SAPP)
SAPP
PLANT DETAILS
I I NN T T R R OO DD UU C C T T I I OO NN
Located in Sei Mangkei, Simalungun, Sumatra, Indonesia.

The plant area is 40 hectares.
The production is 100 000 MT/year of stearic acid.
The applications of the stearic acid are in pharmaceutical product, soap and detergent,
cosmetic product, candies and fireworks.
High demand in China, Malaysia and USA (Statistic Indonesia,2014).
High quality of stearic acid as main product, palmitic acid, myristic acid and glycerol as
side product.
The plant is operated with four main unit operation, U100, U200, U300 and U400.
The company is comply with The Manpower Act of Indonesia No.13 of 2003, that every
organization need to comply with OSH.
The company must comply with the Environmental Regulation of Indonesia.
SAPP
I I NN T T R R OO DD UU C C T T I I OO NN
UNIT 200
UNIT 500
UNIT 300
UNIT 100
UNIT 400
PROCESS DETAILS
COLGATE EMERY PROCESS CONTINUOUS HIGH PRESSURE SPLITTING

SAPP
Design of Equipment
SAPP
P M E N T
I G N O F E Q U I
D E S
SPLITTING COLUMN (T-100)

Fatty acids
Introduction
28
The feedstock are the crude palm oil and water.

Natural oils-triglyceride of various fatty acids are
hydrolysed into free fatty acids and glycerine.
The counter-current splitting process in a tower
is suitable for the handling of larger feed rates.
It operates continuously.
High splitting temperature ensures the adequate
dissolving of the water phase in the fat .
Degree of splitting can be achieved up to 99%.
The products are fatty acids and Sweetwater.
(Lurgi,1991)
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Water
Crude palm oil

Steam
Sweetwater
D D E E S S I I G GN NO O F F E E Q QU U I I P PMME E N N T T
2-PHASE SEPARATOR (V-200)

DESIGNED BY: NUR HIDAYAH BINTI MUSA@ABDULLAH (2011689822)
Introduction
Separator is used to separate water and glycerine.

These mixture consists of component that do not
react chemically and have visible boundaries of
separation between the different phases.
Type of
Separator
Vertical two-phase separator.

Vertical separator preferred for separating liquid
from mixtures with high gas liquid ratio or total gas
volume (Svreek and Monnery, 2013).
SAPP
10
CHEMICAL DESIGN
MECHANICAL DESIGN
Description
Description
Operating Temperature (K)
393.25
Material of Construction
Stainless
Steel
Operating Pressure (kPa)
100
Head Cover Type
Tori Spherical
Mass Flow Rate for Vapour,
( )
0.6752
Total Weight of Column (kN)
32.12
Mass Flow Rate for Liquid,
( )
149.33
Stress in Column (N/2 )
2.54 x 103
0.58
The Resultant Longitudinal

Stress (N/2 )
4.91
Differences in Principal Stress

(N/2 )
2.32
Type of Skirt
Straight-Skirt
Support
Material of Construction of
Skirt Support
Plain Carbon
Steel
Terminal Velocity, ( )
Vapour Velocity, ( )
0.44
Vessel Diameter (m)
1.5
Total Vessel Height, ()
5.2
Volume of Vessel, V (3 )
9.19
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11
DRAWING (V-200)
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12
FALLING FILM EVAPORATOR (V-201)

DESIGNED BY: NORAISHAH BINTI AMIN (2011837938)
Introduction
To concentrate a solution of glycerine in water. The water is
vaporized and concentrated solution of glycerine is produced.
Falling film evaporator provides the highest heat transfer coefficient.
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13
CHEMICAL DESIGN
MECHANICAL DESIGN
Value
Liquid flow rate
2514.2069 kg/h
Vapour flow rate
359.7499 kg/h
Pressure of steam
injected
Steam flow rate
Energy supplied
202.7943 kW
Area of evaporator
10.197 m2
Value
4 bar
Material of
construction
Stainless steel
(SS316)
261.17 kg/h
Minimum wall
thickness
11 mm
Type of head
closure
Ellipsoidal head
Skirt support
Straight cylindrical
support
Material of skirt
support
Carbon steel
Total weight
50.7343 kN
Skirt height
1m
Height of evaporator 2.951 m
Diameter of
evaporator
Feed inlet nozzle
diameter
No. of tubes
1.1 m
Efficiency of
evaporation
Steam economy
96.89%
0.22 m
26
1.38
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14
DRAWING (V-201)
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15
P M E N T
I G N O F E Q U I
D E S
DISTILLATION COLUMN (D-300)

DESIGNED BY: RADIAH BINTI RAZALI (2011479644)
Top: Water and Myristic

acid
Introduction
Distillation is the separation of
liquid mixtures depends on the
volatility, or the differences in
boiling points in each of the
components.
Feed: Water,
Linoleic acid, Oleic
acid, Palmitic acid
and Myristic acid
Basically, the top product has

lower boiling point than the
bottom product.
Bottom : Linoleic acid,

Oleic acid, Stearic acid
Palmitic acid and
Myristic acid
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16
CHEMICAL DESIGN
MECHANICAL DESIGN
Parameter
Value
Column types
Pressure vessel
Column material
Parameters
Value
Stainless steel 304
Column Diameter, m
2.466
Column head
Torispherical head
Column height, m
21
Column diameter , mm
2.466
Number of stages
36
Design temperature, C
270.49
Column efficiency, %
43%
Design pressure N/mm2
0.132
Rmin
0.6339
Thickness of column ,mm
12
Plate thickness, mm
Skirt support height ,m
Skirt thickness, mm
12
Tray spacing, m
0.5
Total pressure drop, mm
86.6682
Skirt type
Straight Cylindrical shell
Residence time, s
16 s
Number of feed location
12
Plate material
Stainless steel 304
Bolt circle diameter, mm
1618
Insulation Material
Mineral wool
Height of column ,m
21
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DRAWING (D-300)
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18
P M E N T
DESIGNED BY: MOHD ZAKIMAN BIN OTHMAN (2011802714)
Introduction
In this column, the feed of second
distillation column is mainly consist of
palmitic, stearic, linoleic and oleic.
The operating condition is at 1mbar.
The feed temperature is 161C.
The top product is palmitic acid with
purity of 95%.
The bottom product is mainly is oleic,
linoleic and stearic.
D E S
I G N O F E Q U I
DISTILLATION COLUMN (D-301)
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41
19
Condition
Feed, F41
Distillate,
F42
Bottom, F45
Column
Plate
Flowrate
Value
82.2992 kmol/hr
Temperature
519.05 K
Pressure
Flowrate
120 kPa
49.0465 kmol/hr
Temperature
455.55 K
Pressure
0.5 kPa
Flowrate
44.9451 kmol/hr
Temperature
469.15 K
Pressure
0.5 kPa
Minimum reflux ratio, Rmin
0.6431
Optimum reflux ratio, R
0.9645
Minimum number of stages, Nmin
23
Plate efficiency, E0
0.5299
Number of Actual Stages, Nactual
41
Feed point location, Ns
15
Column diameter, Dc
2.0514 m
Column area, Ac
3.305 m2
Column height, H
24 m
Turn down
85 %
Plate pressure drop, ht
77.5003 mm
Plate material
SS 304
Downcomer Area, Ad
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0.397 m2
CHEMICAL DESIGN
20
Conditions
Value
Operating Condition & Material Construction

Operating pressure
1.2 bar
Operating Temperature
469.15 K
Design pressure
1.320 bar
Design Temperature
488.75 K
Safety Factor
MECHANICAL DESIGN
10 %
Material construction
Stainless steel 304

Design Column Dimension
Column height, hc
24 m
Shell thickness, e
12 mm
Type of head closure
Torispherical head
Thickness of head, eD
12 mm
Column Weight
Total Weight, W
315.459 kN
Vessel Support
Type
Material construction
Straight cylindrical skirt

Stainless steel
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21
D E S
I G N O F E Q U I
P M E N T
DRAWING (D-301)
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22
D E S
I G N O F E Q U I
P M E N T
t2: 40.0C
S43
T1: 182.5C
HEAT EXCHANGER (E-302)
S44
T2: 60.0C
DESIGNED BY: MOHD FAIZ BIN MOHD KHALIL (2012831684)
t1: 30.0C
Palmitic Acid Cooler (E-302)

Type
Heat Exchanger
Floating Head (Type AES)
Flowrate
Palmitic Acid
Cooling Water
10,031.81 kg/hr
70,375.95 kg/hr
Fluid Allocation
Tube
Shell
Palmitic Acid
Cooling Water
Objective
Palmitic Acid Outlet Temperature
60C
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23
P M E N T
CHEMICAL DESIGN
Parameters
Process Condition
Heat Load, Q
Heat Transfer Coefficient Calculated, Uo,calc
Heat Transfer Area, Ao
Log Mean Temperature Different, Tlm
True Mean Temperature, Tm
SI Unit
817.05 kW
267.20 W/m2.C
45.6263 m2
72.20C
68.87C
D E S
I G N O F E Q U I
Tube Side (Palmitic Acid)

Mass Flowrate, mt
Tube Side Velocity, Ut
Tube Length, L
Tube Outside Diameter, Do
Tube Inside Diameter, Di
Tube Pitch, Pt
Number of Tubes, Nt
Tube Passes, Np
Tube Per Passes, Nt/p
Heat Transfer Coefficient, ht
Pressure Drop, Pt
Shell Side (Cooling Water)
Mass Flowrate, ms
Shell Side Velocity, us
Diameter of Shell, Ds
Bundle Diameter, Db
Heat Transfer Coefficient, hs
Pressure Drop, Ps
SAPP
10031.81 kg/hr
1.0342 m/s
5.0000 m
0.0165 m
0.0140 m
0.02063 m
176 Tubes
8 Passes
22 Tubes
453.29 W/m2.C
52.27 kPa
70375.95 kg/hr
0.4848 m/s
0.4490 m
0.3930 m
1594.80 W/m2.C
28.89 kPa
24
P M E N T
I G N O F E Q U I
D E S
Parameter
Design Pressure
+ 10% Above Normal
Working Operation
MECHANICAL
DESIGN
Value (SI Unit)

Tube
0.2255
0.1485
N/mm2
N/mm2
35 kN
Bolt Diameter: 20 mm
Bolt Holes: 25 mm
Baffles
200.8 C
Type: Saddle Support

Maximum Allowable Weight:
Shell
Design Temperature
+ 10% To Cover
Support
Type: Single Segmental

Number of Baffle: 10
44.0 C
Diameter of Baffle: 0.417 m
Uncertainties In Prediction
Stainless
Carbon
Baffle Spacing: 0.449 m
Steel
Steel
Baffle Thickness: 4.80 mm
(SS316)
(A285)
Weight Load
Corrosion Allowance
1.00 mm
1.60 mm
+ Shell
5.0610 kN
Design Stress
120
135
+ Tubes
3.3090 kN
+ Taken Above The Design N/mm2 @ N/mm2 @
+ Fluid Inside Shell 7.7670 kN
Temperature
200C
50C
+ Fluid Inside Tubes 0.1310 kN
Minimum Wall Thickness
1.25 mm
7.90 mm
+ Insulator
0.6750 kN
+ Total Weight
16.9430 kN
Head & Closure
+ Front Head: Torispherical

+ End Closure: Flat Plate
Thickness = 2.04 mm
Thickness = 1.77 mm
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25
D E S
I G N O F E Q U I
DRAWING
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26
P M E N T
PACKED BED REACTOR (R-400)

DESIGNED BY: NOR EZATY BINTI ABDUL RASHID (2011492252)
Introduction
Reaction
The reaction that takes place in the reactor is the hydrogenation process.
Hydrogenation reaction is carried out under hydrogen gas pressure in presence of
Nickel catalyst, high temperature and nil moisture conditions.
Reaction of the process is considered as heterogeneous reactions because the
reactants are in liquid and gas phase meanwhile catalyst is in the solid form.
PBR will give a high conversion, simple design, and much cheaper.
SAPP
27
MECHANICAL DESIGN
CHEMICAL DESIGN
Type of Reactor
Design Orientation
Design Pressure, kPa
2200
Vertical
Design Temperature, oC
216.81
Stainless Steel 316
Wall Thickness, mm
25
Volume of reactor,
m3
18.39
Diameter of
reactor, m
2.27
Height of reactor,
m
Residence time,
sec
Operating Condition
Packed Bed
Reactor
Head and Closure Design
4.54
80.4
Type
Ellipsoidal Head
Thickness, mm
25
Support Design
Type
Skirt support
Material of construction
Stainless Steel
Skirt thickness, mm
29
Skirt height, mm
3000
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28
DRAWING (R-400)
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29
Process Control &

Instrumentation
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30
P P R R O O C C E E S S S S C C O ON N T T R R O O L L
Objectives
1. Keep Process Variables In Safe Operating Limits
2. Detect Dangerous Situation & Provide Alarm
3. Maintain Desired Production Rate

4. Maintain Desired Product Quality
5. Maintain Steady Plant Operation With Minimal Operator
Intervention
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31
Fat Splitting Column

(T-100)
Variable
Manipulated
Disturbance
Operating Temperature: 260C

Operating Pressure: 50 Bar
LV
FAT SPLITTING
COLUMN
Setpoint
TIC
FIC
TT
PG
LIC
FT
Flow
Level
Temperature
Inlet Flowrate
of Feed
Fluctuation of
Supplied Feed
Flowrate
Top & Bottom

Product
Flowrate
Fluctuation of
Inlet Flowrate
Steam Inlet
Flowrate
Fluctuation of
Inlet Feed
Temperature
Water: 12,700
kg/hr
CPO: 29,500
kg/hr
Top: 27,100
kg/hr
Bottom: 15,100
kg/hr
Operating
Temperature:
260C
SAPP
TV
FV
TIC
TT
LT
FIC
TV
LT
FT
TIC
TT
FV
TV
PG
LIC
STEAM
LV
32

Operating Pressure: 0.5 Bar
Separator (V-200)
STEAM
Variable
Manipulated
Disturbance
Setpoint
PV
Flow
Level
Pressure
Inlet Flowrate
of Feed
Fluctuation of
Supplied Feed
Flowrate
Feed Flowrate:
15,080 kg/hr
Outlet Flowrate
of Liquid
Product
Fluctuation of
Inlet Feed
Flowrate
Liquid Product
Flowrate: 2,800
kg/hr
Flowrate of
Recycled Vapor
Into Ejector
Inlet Flowrate
of Steam Into
Ejector
Operating
Pressure: 0.5
Bar
PIC
PG
FIC
SAPP
FT
PT
FV
LT
LIC
SEPARATOR
PI
LV
33
Fractionation Column
(D-301)
Top Temperature: 182.5C

Bottom Temperature: 196C
Operating Pressure: 0.005 Bar
PT
PIC
Variable
Manipulated
Disturbance
Setpoint
Flow
Inlet Flowrate
of Feed
Fluctuation of
Supplied Feed
Flowrate
Feed Flowrate:
22,550 kg/hr
Temperature
Inlet Flowrate
of Steam In
Reboiler
Fluctuation of
Inlet Feed
Temperature
Reboiler
Temperature:
196C
Level
Bottom
Product Outlet
Flowrate
Fluctuation of
Feed
Composition
and Condition
Bottom Outlet
Flowrate:
12,200 kg/hr
Pressure
Flowrate of
Recycled Vapor
Into Ejector
Inlet Flowrate of
Steam Into
Ejector
Operating
Pressure: 0.005
Bar
Ratio
Flowrate of
reflux
Flowrate of
distillate
Reflux Ratio:
2.462
PI
LV
COOLING
WATER
C.W.
RETURN
LIC
PV
STEAM
PG
(ii)
LT
FV
FIC
FT
FT
FFC
FT
FRACTIONATION
COLUMN
TT
LIC
TIC
LT
(i)
PG
STEAM
TV
CONDENSATE
PI
LV
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34
Heat Exchanger (E-302)

Variable
Manipulated
Disturbance
Setpoint
Temperature
Inlet Flowrate
of Cooling
Water
Fluctuation of
Inlet Feed
Flowrate / Inlet
Temperature of
Cooling Water
Outlet
Temperature:
60C
Palmitic Acid Cooler

Inlet Temperature: 182.5C
Inlet Pressure: 1.85 Bar
C.W.
RETURN
PI
COOLER
PI
TT
TIC
COOLING
WATER
TV
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35
Reactor (R-400)
Operating Pressure: 20 Bar
Variable
Manipulated
Disturbance
Setpoint
Flow
Inlet Flowrate
of Feed
Fluctuation of
Supplied Feed
Flowrate
Fatty Acids:
12,110 kg/hr
Hydrogen: 0.09
kg/hr
Level
Temperature
Outlet Flowrate
of Product
Inlet Flowrate
of Cooling
Water
Fluctuation of
Inlet Feed
Flowrate
Product Outlet
Flowrate:
12,200 kg/hr
Fluctuation of
Inlet Feed
Temperature /
Cooling Water
Temperature
Operating
Temperature:
130C
PG
FIC
FT
C.W.
RETURN
FV
LT
TIC
LIC
TT
COOLING
WATER
LV
TV
REACTOR
FIC
HYDROGEN
FT
FV
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36
Process Integration
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37
I N T E G R A T I O N
P R O C E S S
INTRODUCTION
OBJECTIVE
Pinch analysis is one of the methods that guarantee

minimum energy levels in design heat exchanger network.
A simple methodology for systematically analyses chemical
processes and the surrounding utility systems with the help
of the First Law Thermodynamics and Second Law
Thermodynamics (Ian, 2007).
To reduce energy consumption of the plant by exchanging

heat between the process streams.
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38
I O N
I N T E G R A T
P R O C E S S
Problem Table Algorithm

Stream
Condition
()
()
Shifted
()
Shifted
()
Hot
167.0
45
162.0
40
Hot
167.0
25
162.0
20
Hot
120.0
65
115.0
60
Hot
130.0
85
125.0
80
Hot
51.2
25
46.2
20
Hot
182.5
60
177.5
55
Hot
130.0
60
125.0
55
Cold
25.0
65
30.0
70
Cold
110.0
120
115.0
125
10
Cold
35.0
130
40.0
135
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39
MINIMUM HOT UTILITY

= 4265.0823 kW
I N T E G R A T
I O N
Cascade Diagram
MINIMUM COLD UTILITY

= 8154.3892 kW
P R O C E S S
PINCH TEMPERATURE
= 115
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40
I O N
P R O C E S S
I N T E G R A T
The Network Design Above The Pinch
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41
I O N
P R O C E S S
I N T E G R A T
The Network Design Below The Pinch
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42
I O N
I N T E G R A T
P R O C E S S
Comparison Before and After Process Integration

2. Cost Saving
1. Energy Saving Percentage

Utility
Before
Integration
(kW)
After
Integration
(kW)
Energy
Saving
(%)
Cost (USD/kJ)
Cost Before
(Source: Aspen Integration
Utilities
(USD/year)
Cost After
Integration
(USD/year)
Cost Saving
(USD/year)
Database)
Hot
4998.0159
4265.0823
14.66
2.2 x 106
3.2586 x 105
2.7807 x 105 4.7790 x 104
Cold
9557.3157
8154.3892
14.68
2.12 5x 107
6.0187 x 104
5.1352 x 104 8.835 x 103
Total
(kW)
14555.3316 12419.4715 14.67
2.4125 x 106
3. 8605 x 105 3.2943 x 105 5.6625 x 104
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43
I O N
I N T E G R A T
P R O C E S S
Conclusion
Based on economic analysis, the average cost for a heat exchanger is
around USD150,000 and after applying heat integration, the number
of heat exchanger is increased from 10 to 16.
Therefore, it can be seen that total cost of 6 extra heat exchanger
are around USD900,000 but the total cost energy saving having extra
6 heat exchanger are USD56,625/year.
It is not recommended to proceed the heat integration because the
total utilities saving per year is not high enough to recover the total
cost for additional heat exchanger.
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44
Environment, Waste
Prevention & Treatment
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45
E N V
R O N M E N T
Objectives
1. To meet the water quality standard in Indonesia of COD, BOD, pH
and oil and grease values of discharge effluent from the processing
plant.
2. To ensure that water discharge does not pollute the watershed.
3. To improve the quality of water before being recycled to the

production plant.
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46
R O N M E N T
SOURCES OF WASTE WATER IN PROCESS FLOW DIAGRAM
E N V
TOTAL WASTE
= 72,517.44 kg/day
Waste water generated

from separator V-300

from separator V-200 A
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from evaporator V-200 A
47
Effluent Requirement And Currently Applicable Water Quality Standards

Unit
Domestic
Industrial
No. 112 (2003)
BPLHD (2010)
Assumed 2030
by Ministry of
Environment
Total COD
239.46 mg /L
Total BOD
79.83mg /L
pH
<6
Oil and grease
>10
BOD
mg/L
100
60
20
COD
mg/L
150
100
TSS
mg/L
100
50
50
Phosphate
mg/L
10
Ammonia
mg/L
Total nitrogen
mg/L
10
Total COD
127.89 mg /L
Sulfide
mg/L
0.3
0.3
Total BOD
50.97 mg /L
Oil and grease
mg/L
10
pH
6-9
Phenol
mg/L
0.5
0.5
Chromium
mg/L
1.0
1.0
Oil and grease
10
6-9
6-9
6-9
BEFORE TREATED
E N V
R O N M E N T
Parameter
pH
AFTER TREATED
(Regional Control Agency of the Living Environment of

Indonesia, 2010)
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48
M EE NN TT
EE NN VV I I RR OO NN M
PROCESS FLOW DIAGRAM FOR WASTEWATER

TREATMENT
Screening
Tank
Oil-water
Separator
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Sequenching
Batch Reactor
Disinfection
Tank
49
Economic Analysis
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50
M I I CC AA NN AA LL YY SS I I SS
EE CC OO NN OO M
TOTAL INVESTMENT
1. Cost of Equipments
2. Commissioning Cost
Fixed Capital Investment (FCI)
RM 459,353,770
RM 459 million
Working Capital
RM 22,967,689
RM 23 million
(Chemical Engineering Journal, 2014)

(Kolmetz, 2014, Engineering Design)
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51
(Kolmetz, 2014, Engineering Design)
C A N A L Y S
3. Total Manufacturing Cost
TOTAL INVESTMENT
= equipment + commissioning +
E C O N O M I
manufacturing
= RM 1,536,331,665
= RM 1.54 billion
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52
S
I
C A N A L Y S
E C O N O M I
TOTAL PROFIT
1. Revenue
Products sold/year
= RM 2,609,617,500
= RM 2.6 billion/year
2. Net Annual Profit After Tax

Revenue Total manufacturing cost 35%Tax
= RM 2,609,617,500 RM 939,171,763 RM 584,656,008
= RM 1,085,789,729
= RM 1 .09 billion/year
TOTAL PROFIT
= RM 1.09 billion/year
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53
Discounted Cash Flow Diagram
INTEREST RATE is the

amount charged,
expressed as % of principle
by a lender to a debtor for
the use of assets (cash).
6,000,000,000.0
5,000,000,000.0
Cumulative Discounted Cash Flow
EE CC OO NN OO M
PAYBACK PERIOD
4,000,000,000.0
3,000,000,000.0
PAYBACK PERIOD
for 10% Interest
Rate
= 2.8 Years
2,000,000,000.0
1,000,000,000.0
0.0
0
-1,000,000,000.0
10
11
12
Year
10%
40%
44%
SAPP
54
EE CC OO NN OO M
NET PRESENT VALUE (NPV)

The purpose of net present value is to help decide whether or not
new projects are financially viable and how much is an investment
worth today.
It is the final cumulative discounted cash flow value at the end of

project life.
Accept if NPV > The Total Investment.
Net Present Value (NPV) at 10% Interest Rate = RM 5.5 billion
SAPP
55
EE CC OO NN OO M
Discounted Cash Flow Rate of Return (DCFROR)

or Internal Rate of Return (IRR)
IRR is a projects expected rate of
return on its investment.
It is the interest rate where the
present value of the inflows equals
the present value of the outflows.
In other words, it is the rate where a
projects NPV = 0.
The higher a project IRR, the more
desirable it is to undertake the
project.
SAPP
56
Plant Safety & Layout

SAPP
57
P L A N PT LS AA NF TE ST AY F& EL TA YY O U T
HAZOP
PLANT
LAYOUT
PLANT
SAFETY
AND
LAYOUT
SAPP
SOP
ERP
58
SOP
OBJECTIVES
Provide to the operator to be able to start-up and shut-down the critical equipment safely,
monitor the plant under normal operation and carry out exercises as and when problem
arises.
SOP ON
MAIN
EQUIPMENT
1.
2.
3.
4.
CHECKLIST
STAR-UP &
SHUT-DOWN
PROCEDURE
Distillation column (Utah Edu. Dept., 2008)

Heat exchanger (Sundex, 2013)
Evaporator (Fisher, 2014)
Reactor (Paras, 2013)
1. Perform HIRARC
2. Provide PPE
3. Provide Work Permit
4. LOTO
1.
2.
3.
4.
(Sinnot, 2008)
Unit 100
Unit 200
Unit 300
Unit 400
SAPP
59
HAZOP
OBJECTIVES
1. To identify possible activity that probably have the potential hazard

2. To identify the possible causes of the hazard and determine the features of
design that will be affected by the incident occur
3. To appoint the action required to mitigate with the hazard
GUIDEWORD
Guideword is used to indicate the deviations and the degree of deviate at the study
node (Sinnot,2008).
HAZOP ON MAIN
EQUIPMENT
1.
2.
3.
4.
Unit 100
Unit 200
Unit 300
Unit 400
SAPP
60
ERP
To identify an appropriate command structure and the important actions towards emergencies
respectively by their threats identified at the plant.
1.
2.
3.
4.
Health
Safety
Security
Environment
OBJECTIVES
HIRARC
EMERGENCY
PROCEDURE
1. Reporting emergency
2. Responding to emergency
(Shell, 2012)
1. Short wave radio

2. Audio public address system
EMERGENCY
DEVICES
SAPP
61
PLANT LAYOUT
1.
2.
3.
4.
5.
6.
Maximum flexibility
Maximum accessibility
Minimum distance
Convenience
Maximum security
Efficient process flow
OBJECTIVES
(Sinnot, 2008)
Product plant layout advantages:

1. The flow of product will be smooth and logical in flow lines
2. Reduced material handling cost due to mechanized handling systems and straight
flow
3. Manufacturing cycle is short due to uninterrupted flow of materials
4. Unskilled workers can learn and manage the production
(Bhavan, 2008)
1. Processing area
Machine operator area (production)
2. Non-processing area
Fire protection equipment, Auxiliary/ support workstations (production
/warehouse), Supplementary workstations (laboratories), Parking areas,
Administration building
3. Minimum distance requirement
(Sinnot, 2008)
SAPP
ACCEPTABLE
PLANT LAYOUT
PLANT AREA
ZONING
62
1.
2.
3.
4.
5.
6.
Control room
Tank farm
Designated smoking area
Waste water treatment plant
Exit/entrance point
Assembly point
PLANT
FACILITY
(Sinnot, 2008)
Plant Layout Video Link
PLANT LAYOUT
SAPP
63
Q & A SESSION
SAPP
64

Design Report

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Design Report

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FINAL YEAR DESIGN PROJECT 2

RADIAH BINTI RAZALI

MOHD FAIZ BIN MOHD KHALIL

MOHD ZAKIMAN BIN OTHMAN

NUR HIDAYAH BINTI MUSA@ABDULLAH

NOR EZATY BINTI ABDUL RASHID

Located in Sei Mangkei, Simalungun, Sumatra, Indonesia.

COLGATE EMERY PROCESS CONTINUOUS HIGH PRESSURE SPLITTING

SPLITTING COLUMN (T-100)

The feedstock are the crude palm oil and water.

Crude palm oil

2-PHASE SEPARATOR (V-200)

Separator is used to separate water and glycerine.

Vertical two-phase separator.

Operating Pressure (kPa)

Head Cover Type

Mass Flow Rate for Vapour,

Total Weight of Column (kN)

Mass Flow Rate for Liquid,

Stress in Column (N/2 )

The Resultant Longitudinal

Differences in Principal Stress

Vessel Diameter (m)

Total Vessel Height, ()

FALLING FILM EVAPORATOR (V-201)

Vapour flow rate

Height of evaporator 2.951 m

DISTILLATION COLUMN (D-300)

Top: Water and Myristic

Basically, the top product has

Bottom : Linoleic acid,

Stainless steel 304

Design pressure N/mm2

Thickness of column ,mm

Skirt support height ,m

Total pressure drop, mm

Straight Cylindrical shell

Number of feed location

Stainless steel 304

Bolt circle diameter, mm

DESIGNED BY: MOHD ZAKIMAN BIN OTHMAN (2011802714)

DISTILLATION COLUMN (D-301)

Minimum reflux ratio, Rmin

Optimum reflux ratio, R

Minimum number of stages, Nmin

Number of Actual Stages, Nactual

Feed point location, Ns

Plate pressure drop, ht

Operating Condition & Material Construction

Stainless steel 304

Type of head closure

Straight cylindrical skirt

HEAT EXCHANGER (E-302)

DESIGNED BY: MOHD FAIZ BIN MOHD KHALIL (2012831684)

Palmitic Acid Cooler (E-302)

Floating Head (Type AES)

Tube Side (Palmitic Acid)

Value (SI Unit)

Type: Saddle Support

Type: Single Segmental

Diameter of Baffle: 0.417 m

Baffle Spacing: 0.449 m

Baffle Thickness: 4.80 mm

+ Taken Above The Design N/mm2 @ N/mm2 @