engineering design for nilam oil production 4 (four) unit

distiller of 300kg & 30 (thirty) units distiller of 100kg by Fitri Agustiyono

executive summary

Preface Preface

Refers to the Standard Contract for Individual Service between Caritas Czech Republic (signed by Megan King as Head of Mission) and Fitri Agustiyono as Design Consultant of Distillation Units dated on 22 nd February 2011, so I have finished and delivered the Executive Summary which contains : Chapter (i) The Philosophy of Nilam Distillation Unit Design, Environmentally Friendly and Recommendation, (ii) Resume of Distillation Unit Designs, and (iii) Technical Review Heater Electric Utilization. I arrange and complete the nilam distillation unit design based on the individual consulting service, full supported by 2 (two) senior essential oil process and boiler experts Mr. Ir. M. Yudi Wahyudi, MT and Adhi Maryadhi, ST. And supported by 2 (two) senior drafters: Mr. Sumarsono and Mr. Yudi Permana, ST, and also supported by 2 (two) translators Mr. Anggit Saputra Dwipramana, ST, and Miss Deasy Widia, SP. Thankfully for all Caritas nilam crews in Banda Aceh, Meulaboh, Kab. Aceh Jaya, Kab. Aceh Selatan, and Kab. Gayo Lues, especially for Mr. Anom Sasrudi a production manager and Mrs. Rebecca Donomon as a project manager. Banda Aceh, April 1st 2011

Fitri Agustiyono

____________________________________________________________________ CARITAS CZECH REPUBLIC nilam empowering in province aceh 2010-2012

engineering design for nilam oil production 4 (four) unit

distiller of 300kg & 30 (thirty) units distiller of 100kg by Fitri Agustiyono

executive summary

Liist of Contents L st of Contents

Preface .......................................................................................................................... i List of Contents............................................................................................................ ii List of Pictures ............................................................................................................ iii List of Table .................................................................................................................iv Chapter 1. The Philosophy of Nilam Distillation Unit Design, Environmentally Friendly and Recommendation ...................................................................... 5
1.1 1.2 1.3 TOR (Term of Reference) ........................................................................................ 5 Design philosophy and energy saving ..................................................................... 5 Environmental Friendly and Recomendation ........................................................ 6
Efficient Biomass Consumption and Net CO2 emission .................................... 6 Waste Biomass Utilization ............................................................................. 7 Soil nutrients returning to origin field ............................................................ 7 Growing of Middle-age biomass tree ............................................................ 8

1.3.1 1.3.2 1.3.3 1.3.4

Chapter 2.
2.1 2.2 2.3

Resume of Distillation Unit Design .................................................... 9

4 (four) distillation units capacity 300kg ................................................................ 9 30 (thirty) distillation units capacity 100kg .......................................................... 10 Fuel Utilization Fuel Analysis and Production Efficiency Comparison ............ 11

Chapter 3.

Technical Review Heater Electric Utilization .................................. 12

3.1 Potencial Review of PLTMH to utilizing Heater Electic for Production Unit Design I-300 ...................................................................................................................... 12 3.2 Potencial Review of PLTMH to utilizing Heater Electic for Production Unit Design IIA-100 ................................................................................................................. 13

____________________________________________________________________ CARITAS CZECH REPUBLIC nilam empowering in province aceh 2010-2012

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engineering design for nilam oil production 4 (four) unit

distiller of 300kg & 30 (thirty) units distiller of 100kg by Fitri Agustiyono

executive summary

Liist of Piictures L st of P ctures

Picture Picture Picture Picture Picture

1-3 1-4 1-5 2-1 2-2

The illustration of proposed saving energy .............................................................. 6 the cycle of CO2 adsorbtion and CO2 releasing by the tree ................................... 7 Soil nutrients returning to origin field ...................................................................... 8 PID (pipe and instrument diagram) of Design I 300 .............................................. 9 PID (pipe and instrument diagram) of Design IIA 100 ........................................ 10

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engineering design for nilam oil production 4 (four) unit

distiller of 300kg & 30 (thirty) units distiller of 100kg by Fitri Agustiyono

executive summary

Liist of Tablle L st of Tab e

Table Table Table Table

1-1 2-1 2-2 2-3

Heating Value (Q) several famous fuels ........................................................................ 5 Comparison Fuel Utilization for distillation process ............................................... 11 Energy Efficiency between existing unit & proposed designs (A) ......................... 11 Energy Efficiency between existing unit & proposed designs (B) ......................... 11

____________________________________________________________________ CARITAS CZECH REPUBLIC nilam empowering in province aceh 2010-2012

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engineering design for nilam oil production 4 (four) unit

distiller of 300kg & 30 (thirty) units distiller of 100kg by Fitri Agustiyono

executive summary

Chapter 1. The Philosophy of Nilam Distillation Unit Design, Environmentally Friendly and Recommendation
1.1 TOR (Term of Reference) Based on TORR which become this working basic, we have designed for 4 NBC distillation units which have capacity 300 kg dry nilam per batch and placed on 4 locations in NBC areas. Each location are 1 (one) unit in Aceh Jaya District (Panga Sub-district), 1 (one) unit in Aceh Barat District (West Wodya Sub-district), 1 (one) unit in South Aceh District (Pasie Raja Subdistrict) and 1 (one) unit in Gayo Lues District (Terangun Sub-district). And we also have designed 30 (thirty) small nilam production units which have capacity 100 kg dry nilam per batch which will be placed in 4 districts: 5 units in Aceh Jaya District, 5 units in Aceh Barat District, 10 units in Aceh Selatan District, and 10 units in Gayo Lues District. 1.2 Design philosophy and energy saving Nilam oil production unit design is prepared based on rule of thumb: unit capacities determining, boiler design, raw material vessel design, condenser design, and oil separator design. Energy saving is conducted by provide heat transfer area (in boiler combustion chamber and furnace) which properly for required steam capacity with available fuel in location (biomass), also completed boiler wall construction and stack construction which possible to utilize mostly heat energy from biomass combustion. With adequate heat transfer area, will reduce fuel consumption very significant.
Table 1-1 Heating Value (Q) several famous fuels No 1 2 3 4 5 Kind of Fuel LPG Coal Kerosene Palm nutshell / coco shell Wood Biomass Heating Value (kcal/kg) 14000 5000 6000 9000 4000 4500 2000 3000

____________________________________________________________________ CARITAS CZECH REPUBLIC nilam empowering in province aceh 2010-2012

engineering design for nilam oil production 4 (four) unit

distiller of 300kg & 30 (thirty) units distiller of 100kg by Fitri Agustiyono

executive summary

1.3 Environmental Friendly and Recomendation 1.3.1 Efficient Biomass Consumption and Net CO2 emission

In the design, we recommend the unit production design with considering the simple touch in operasional, available fuel stocks, and the simple save energy combustion technology. Save energy means utilizing biomass fuel economically to produce the properly boiler steam capacity to make nilam oil in the desired production capacity.

Picture 1-1 The illustration of proposed saving energy

Different from fosil fuel combustion (BBM and coal), which impacting CO2 emission seriously (global warning and green house effect), the biomass is recommended to use because of Net CO2 emission (totally balance no CO2 emission). It is means, while biomass burned, releasing CO2, and the other while the tree as biomass source also absorbed CO2 in the all the days with photosynthesis process. If we calculated more detailed, total balance compound, tree is more and more absorbed CO2 (photosynthesis) rather than releasing CO2 whlile burned.

____________________________________________________________________ CARITAS CZECH REPUBLIC nilam empowering in province aceh 2010-2012

engineering design for nilam oil production 4 (four) unit

distiller of 300kg & 30 (thirty) units distiller of 100kg by Fitri Agustiyono

executive summary

Picture 1-2 the cycle of CO2 absorption and CO2 releasing by the tree

1.3.2

Waste Biomass Utilization

Biomass utilization decreasing from felled wood forest, is recommended with utilization waste biomass around of nilam unit production location. The meanly waste biomass are : (a) Coconut : shell, fiber, and midrib. (b) Palm: nutshell, empy fruit branch, and midrib. (c) others : rice husk, sawdust, etc. Especially for coco shell and palm nutshell, those are very interested by industrial actors both are have a high heating value until 4000 kcal/kg almost equivalent with coal heating value. Nutshell palm can be get from Palm Plantation in Aceh Barat District, Aceh Selatan District, Kota Subulussalam, and Aceh Utara District. 1.3.3 Soil nutrients returning to origin field

The nilam leaving selling phenomena is not recommended (its a big concerned) and could disturb the nilam origin field ecosystem. The soil nutrients (N, P, K, Ca, Na, S, Zn, Mn etc) which absorbed by nilam tree from origin field, must be return to the field while harvesting, with make a composting process unit beside the nilam unit production site. The element that taking form soil to become nilam oil only element C, H, and O.

____________________________________________________________________ CARITAS CZECH REPUBLIC nilam empowering in province aceh 2010-2012

engineering design for nilam oil production 4 (four) unit

distiller of 300kg & 30 (thirty) units distiller of 100kg by Fitri Agustiyono

executive summary

Picture 1-3 Soil nutrients returning to origin field

1.3.4

Growing of Middle-age biomass tree

To care the environmental balancing and ecosystem, we rekomended to growing the middle-age (2-6 years old), like: Sengon, Jabon, Lamtorogung, Rasamala, bamboo, etc to preparing local biomass need, without disturbing trees in conservation forest area.

____________________________________________________________________ CARITAS CZECH REPUBLIC nilam empowering in province aceh 2010-2012

engineering design for nilam oil production 4 (four) unit

distiller of 300kg & 30 (thirty) units distiller of 100kg by Fitri Agustiyono

executive summary

Chapter 2. Resume of Distillation Unit Design

2.1 4 (four) distillation units capacity 300kg This design named Design I - 300 In the Design I 300, distillation units will be located in certain area named NBC (Nilam Business Center) and forths in strategic location (near highway and coverage by PLN network) and have a surface weel water source (need not more than 6m deep to get the water). In the design, production will be running during 5-6 hours per batch. Design I-300 contains: (i) 1 (one) unit boiler capacity 220 240 kg steam/hour. This capacity equal to distillate rate 3,67 Liters until 4,0 Liters per minute. (ii) 2 (two) raw material vessel units Capacity 1480L or equivalent to 150 155 kg dry nilam. (iii) 2 (two) condenser units and bath, each condenser pipe length 6,5 SS pipe sticks, total 39 m. (iv) 2 (two) nilam oil separation units. (v) 1 (one) package of furnace foundation, combustion chamber, exhaust line wall, and chimney. The PID (pipe and instrumen diagram) of Design I 300 can be seen in Picture 2-1.

Picture 2-1 PID (pipe and instrument diagram) of Design I 300

____________________________________________________________________ CARITAS CZECH REPUBLIC nilam empowering in province aceh 2010-2012

engineering design for nilam oil production 4 (four) unit

distiller of 300kg & 30 (thirty) units distiller of 100kg by Fitri Agustiyono

executive summary

2.2 30 (thirty) distillation units capacity 100kg This design is designed for the certain location which covers in small groups of nilam farmers, and the location mostly far from PLN network, therefore not been completed with water pump to make up boiler. The alternative technology used is low pressure cohobation continue process (maximum 0,7bar). With the cohobating system, water/liquid overflow from nilam oil separator, injected back to boiler. The design namely Design IIA-100. Design IIA 100 contains: (i) 1 (one) boiler unit capacity 75 90 kg steam/hour. This capacity equal to distillate rate 1,25 Liters until 1,5 Liters per minute. (ii) 2 (two) raw material vessel units capacity 465L or equivalent to 50 55 kg dry nilam. (iii) 2 (two) condenser units and bath, each condenser pipe length 4,7 SS pipe sticks, total 28 meters. (iv) 1 (one) nilam oil separator (v) 1 (one) package of furnace foundation, combustion chamber, exhaust line wall, and chimney. The PID (pipe and Instrumen Diagram) of Design IIA 100 can be seen in Picture 2-2.

Picture 2-2 PID (pipe and instrument diagram) of Design IIA 100

____________________________________________________________________ CARITAS CZECH REPUBLIC nilam empowering in province aceh 2010-2012

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engineering design for nilam oil production 4 (four) unit

distiller of 300kg & 30 (thirty) units distiller of 100kg by Fitri Agustiyono

executive summary

2.3 Fuel Utilization Fuel Analysis and Production Efficiency Comparison The proposed design have amount of advantages compared with the existing traditional units in the 4 disticts.
Table 2-1 Comparison Fuel Utilization for distillation process
No Fuel Heating Value (kcal/kg) steam process Boiler and Energy Fuel Fuel Fuel Value boiler lifetime Combustion Consumption Consumption Consumption per unit capacity (hour) Chamber per batch per batch per batch (L) (kg/hour) Efficiency (kcal) (kg) 100 100 100 100 100 5 8 8 6 7 90% 75% 75% 85% 60% 377,778 725,333 725,333 480,000 793,333 27.0 145.1 145.1 53.3 264.4 Rp Fuel Cost per batch

1 2a 2A 3 4

LPG Batubara - a Batubara - A Minyak tanah Kayu bakar

14000 5000 5000 9000 3000

Rp 10,000 Rp 269,841 650 Rp 94,293 Rp 1,000 Rp 145,067 66.7 Rp 4,000 Rp 266,667 1,058 Rp 120 Rp 126,933

Vaporization Heat of Water =

680 kcal/kg

Table 2-2 Energy Efficiency between existing unit & proposed designs (A)
Type / Kode Type Specification make up boiler water system steam process Boiler and Energy Biomass Fuel Biomass Fuel Fuel Cost Fuel Cost per boiler lifetime Combustion Consumption Consumption Consumption per batch 25 kg dry capacity (hour) Chamber per batch (kcal) per batch per batch nilam (kg/hour) Efficiency (kg) (M3) 8 6 6 45% 70% 70% 171,311 1,363,886 512,914 57.1 454.6 171.0 0.228 Rp 27,410 Rp 1.819 Rp 218,222 Rp 0.684 Rp 82,066 Rp 27,410 18,185 20,517

manual, gravitasi 14.17 Existing existing 25kg 210L) separated boiler and I - 300 300kg (2 x 150) make up with pump 234.00

traditional unit (drum

IIA - 100

raw vessel separated boiler and 100kg (2 x 50) raw vessel

Cohobating system

88.00

Table 2-3 Energy Efficiency between existing unit & proposed designs (B)
Item Descriptions Existing Desain I - 300 Desain IIA - 100 ketel 25 - 30 kg 300kg (2 x 150kg) 100kg (2 x 50kg) (from drum 200L) tradisional 220 Liter 1425.4 Liter 465.4 Liter 140 Liter 210 Liter 25 kg 4,252 cm2 0.4252 m2 14.2 kg/hour 8 hours 806 L/batch 45% 171,311 57.10 kg 0.23 M3 27,410 Rp 1040 Liter 2959 Liter 300 kg 70,128 cm2 7.0128 m2 230.0 kg/hour 6 hours 9,090 L/batch 70% 1,340,571 446.86 kg 1.79 M3 214,491 Rp 320 Liter 931 Liter 100 kg 27,218 cm2 2.7218 m2 88.0 kg/hour 6 hours 2,960 L/batch 70% 512,914 170.97 kg 0.68 M3 82,066

1 Total Boiler Volume 2 Boiler volume which filled with water 3 Raw Material Vessel Volume 4 Raw Material / Feed Stock Capacity (85 L volume equivalent 10 kg dry nilam) 5 heat surface contact area (LK) 6 Steam Capacity (KS), KS = 33.33 LK 7 proces time 8 total Water Consumption (L/batch) 9 Boiler and Combustion Chamber efficiency Heat Energy Consumption per batch (to steam) Heating Value of Wood Biomass = 3.000kcal/kg 10 Biomass Consumptian per batch (kg) Biomass Consumptian per batch (M3) 4 m3 biomass = 1 ton Biomass rate per m3 = Rp 120.000,11 Biomass Fuel Cost per 25 kg dry nilam 12 Total Nilam oil per batch (yield 2.4%) 13 Total Batchs to produce 12 kg nilam oil (2batch/day) 14 Total days to produce 12 kg nilam oil

Rp Rp

27,410 Rp 17,874 Rp 20,517 1 x 25kg 2 x 150kg 2 x 50kg 0.60 kg 7.20 kg 2.40 kg 20.00 batch 10.00 day 1.67 batch 0.83 day 5.00 batch 2.50 day

____________________________________________________________________ CARITAS CZECH REPUBLIC nilam empowering in province aceh 2010-2012

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engineering design for nilam oil production 4 (four) unit

distiller of 300kg & 30 (thirty) units distiller of 100kg by Fitri Agustiyono

executive summary

Chapter 3. Technical Review Heater Electric Utilization

3.1 Potencial Review of PLTMH to utilizing Heater Electic for Production Unit Design I-300

Vaporization Heat of Water

680 kcal/kg 2833.33 kJ/kg 225 kg/hour

1 kJ = 0.24 kcal

Steam Boiler Capacity Design I-300 = Energy Consumption (2833.33 kJ/kg x 225 kg/hour) = (637,500 kJ/hour : 3600 seconds/hour = Electrical Eficiency = 80% Electrical Power Supply = PLTMH installed Capacity need = PLTMH Cost Investment per 1 kW = IDR PLTMH 260kW Cost Investment = IDR *) source : Consultant PT. WPU - Bandung

637,500 kJ/hour 177 kJ/second 177 kW 221 260 32 8.32 kW kW milion *) billion (177 / 0.8 = 221) (221 / 0.85 = 260) (range 30 - 40jt per kW) (260 x 32 = 8,320)

Each Heater unit capacity (special order) = Total Need of Heater @ 40 kW = be rounded as =

40 kW 5.53 unit (221 kW / 40kW) 6 Heater units

____________________________________________________________________ CARITAS CZECH REPUBLIC nilam empowering in province aceh 2010-2012

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engineering design for nilam oil production 4 (four) unit

distiller of 300kg & 30 (thirty) units distiller of 100kg by Fitri Agustiyono

executive summary

3.2 Potencial Review of PLTMH to utilizing Heater Electic for Production Unit Design IIA-100
Vaporization Heat of Water = 680 kcal/kg 2833.33 kJ/kg 88 kg/hour 1 kJ = 0.24 kcal

Steam Boiler Capacity Design IIA-100 = Energy Consumption (2833.33 kJ/kg x 90 kg/hour) = (249,333 kJ/hour : 3600 second/hour) = Electrical Eficiency = 80% Electrical Power Supply = PLTMH installed Capacity need = PLTMH Cost Investment per 1 kW = IDR PLTMH 102 kW Cost Investment = IDR *) source : Consultant PT. WPU - Bandung

249,333 kJ/hour 69 kJ/second 69 kW 87 102 32 3.26 kW kW milion *) billion (69 / 0.8 = 87) (87 / 0.85 = 102) (range 30 - 40jt per kW) (102 x 32 = 3,264)

Each Heater unit capacity (special order) = Total Need of Heater @ 40 kW = be rounded as =

30 kW 2.89 unit (221 kW / 30kW) 3 Heater units

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