Anti-surging is developed for a compressor system consisting of a booster compressor and a high-p... more Anti-surging is developed for a compressor system consisting of a booster compressor and a high-pressure compressor in a serial circuit. This evaluation presented 6 options of anti-surge systems with variations of the number of Anti-surge Valve (ASV) and its combination with the addition of a Hot Gas Bypass Valve (HGBV) and Cold Gas Bypass Valve (CGBV). From the model evaluation, the option that involves a special ASV (dedicated) for each compressor and coupled with a dedicated CGBV or HGBV is the best because the compressor can be back to normal in less than 1 second (maximum time to return to normal condition is 3 seconds. Referring to these options, a dedicated ASV for each compressor provides more benefits to the security of compressor operation. However, the most appropriate option in the field will return to the issue of cost or ease of modification. For facilities that are running (brownfield), the use of tools that already exist in the field and do a little modification is t...
Pine rosin, which is derived from Pinus merkusii resin, a natural product, has demonstrated poten... more Pine rosin, which is derived from Pinus merkusii resin, a natural product, has demonstrated potential as a road marking binder. Although pine rosin has an excellent shinning property, it has some limitations, such as instability and color change. To tackle these issues, modified rosin has been developed through sequential esterification and Diels–Alder reactions, and it has shown better properties than untreated rosin. In this study, from the evaluation of untreated and treated rosins, the treated rosin showed some improvements, such as a lower acid value and higher stability, as shown by the color consistency during the oxidation test at 150 °C for 24 h in open-air conditions. Additionally, as road marking paint, the modified rosin is blended with blending materials in the range of 18–28 wt.%. The modified rosin has a softening point of 170–210 °C, a hardness of 50–71 HD, and a weight loss of 1.33–5.12 mg during the wearing test. These results are comparable to or better than those...
IOP Conference Series: Materials Science and Engineering, 2020
Pickling is a typical method used in a cold milling plant to remove impurities from hot rolled co... more Pickling is a typical method used in a cold milling plant to remove impurities from hot rolled coil by immersing the coil in strong acidic solution. The spent acidic solution or waste pickle liquor (WPL) requires certain waste treatment before it can be disposed to environment because of its metallic ion and acid content. WPL contains a number of metallic ions that can be utilized as ferric chloride coagulant. The purpose of this paper is to evaluate the kinetics of Fe2+ oxidation into FeCl3 and the performance of the ferric chloride coagulant using the proposed electrolysis configuration. The electrolysis process was conducted in ambient condition with voltage 3 & 6 V, electrolysis time of 120 minutes, and addition of excess NaCl or HCl. The result shows that metal impurities in WPL and excess chlorine do not significantly affect the Fe2+ conversion. It can also be concluded that the optimum condition for electrolysis is using 6V of voltage, 90 minutes of electrolysis time, and exc...
IOP Conference Series: Materials Science and Engineering, 2019
Sweetening process for natural gas with high content of sour gas (≥ 40% mol of CO2 & H2S) is diff... more Sweetening process for natural gas with high content of sour gas (≥ 40% mol of CO2 & H2S) is difficult to be profitable. A lot of gas fields in Indonesia has high content of sour gas. New improved cryogenic distillation process of natural gas applying the concept of CO2 freezing in the middle of the column is promising. To study the feasibility of this technology, comparison with other two methods (Absorption and Membrane process) in technical and economic aspects were elaborated. Process simulation of improved cryogenic distillation steady-state model was developed using Aspen HYSYS. CAPEX of all methods were estimated using Aspen Process Economic Analyzer. Compared to the other methods, this improved cryogenic distillation process showed tendency to have lower CAPEX and OPEX, but have some uncovered operational problems.
Acid gas removal, especially H 2 S and CO 2 , is an essential process in natural gas processing. ... more Acid gas removal, especially H 2 S and CO 2 , is an essential process in natural gas processing. In this research, 1butyl-3-methylimidazolium bromide [bmim][Br] ionic liquid was analyzed as a hydrophobic solvent with has high selectivity to H 2 S as an environmentally friendly solvent to absorb acid gas from natural gas with low H 2 S/ CO 2 concentration in ambient temperature and pressure. The absorption performance of pure [bmim][Br] ionic liquid was compared with various amine solutions, such as monoethanolamine (MEA), triethanolamine (TEA), and methyldiethanolamine (MDEA), as well as the mixture of [bmim][Br]-MDEA with various concentration. As a result, pure [bmim][Br] ionic liquid had high selectivity to H 2 S compared with conventional amine solutions. In addition, the mixture of [bmim][Br]-MDEA with the mass ratio of 1:3 provided the highest H 2 S/CO 2 selectivity of 6.2 in certain absorption conditions due to free tertiary amine attached in the cations of ionic liquids that can attract more H 2 S to its functional site.
Data reconciliation (DR) and gross error detection are two common tools used in industry to provi... more Data reconciliation (DR) and gross error detection are two common tools used in industry to provide accurate and reliable data, which is useful to analyse plant performance and basis for troubleshooting. DR techniques improve the accuracy of measurements by using redundancies in material and energy balances. This provides reliable information that could help decision making regarding plant operation, which potentially leads to financial benefit. This paper presents the utilization of plant data to perform troubleshooting of ammonia reactor, in particular the profile of catalyst activity. Bad plant data are collected and then analysed using DR to produces reconciled data, which could be used to detect and identify the gross error measurements. The input data for DR and gross error detection were gathered from Aspen HYSYS V8.8 simulations by modelling the single-bed ammonia reactor. The result presents that bad plant data could define actual system condition such as gross error measur...
A study of dinamics behavior on adiahatic exothermal reactor with a Feed-Effluent Heat Exchanger ... more A study of dinamics behavior on adiahatic exothermal reactor with a Feed-Effluent Heat Exchanger (FEHE) is reported in this paper. In practice of a chemical proces industries, configuration of the heat integration of FEHE system are easi to found at process that involving adiabatic exothermal reactor with the demand of feed's heating and of reactor product's cooling. The FEHE system configuration increase the process thermal efficiency throught the use of heat flow on the reactor product to raise the temperature of reactor feed flow. From the steady state economical point of view, this off cource be very interesting to be implemented, althought controlling and operational considerations are need to be taken into account to keep those advantages un-eliminted by operational and controlling matters. The dynamic simulation can give some illustration on how the hehavior of process operation at FEHE system is. Dynamically this system can be examined so that the boundary of operati...
The Natuna gas field is one of the largest natural gas reserves in Indonesia with estimated natur... more The Natuna gas field is one of the largest natural gas reserves in Indonesia with estimated natural gas reserves of 222 TCF. However, until now, the use of Natuna gas is still hampered because of the very high CO2 content reaching 71%, while the methane content is around 28%. The dry reforming of methane (DRM) process is one of the potential ways to be applied for solving these problems to convert CH4 and CO2 to synthesis gas containing CO and H2 as a raw material that can be applied to manufacture as intermediate products or end products in the petrochemical industry such as acetic acid. The simulation of the acetic acid production was conducted by using ASPEN HYSYS v.10, considering mass and heat balances. The PengRobinson was applied for dry reforming of methane process. In order to produce 496.8 kmol/h of the acetic acid, the 500 kmol/h for each CH4 and CO2 were used as feed gas. The total energy required is 4.7 MMBtu per ton of acetic acid. The acetic acid has a purity of 99.4%...
The presence of mercury in crude oil creates problems in oil processing in refineries, both in te... more The presence of mercury in crude oil creates problems in oil processing in refineries, both in terms of operations and health. The previous removal process of mercury has not yet optimally removed mercury in the product, due to ionic and metallic mercury species. In this study, to obtain optimum results, the process of removal of mercury begins with the process of converting ionic (non-metallic) mercury into metallic mercury thermally in the liquid phase, followed by the transfer of metallic mercury to the gas phase by instant evaporation (flashing) and reinforced by gas stripping using internal gas cone from the evaporation of an instant. The results of the optimization of the process carried out can eliminate mercury with an efficiency of more than 95%.
Palm oil mill effluent (POME) from condensate stew, hydrocyclone water, and sludge separator cont... more Palm oil mill effluent (POME) from condensate stew, hydrocyclone water, and sludge separator contains organic carbon with a COD more than 40 g/L and a nitrogen content of about 0.2 and 0.5 g/L as ammonia nitrogen and total nitrogen. At present, the POME is converted into biogas using anaerobic ponds. Biogas produced contains 60% methane (CH4) and 40% carbon dioxide (CO2) and can be purified into biomethane through CO2 absorption using water. This study evaluates the optimum pressure and feed compression stage in biogas upgrading into biomethane. The results show the rate of circulation of water needed to separate CO2 from biogas feed decreases with increasing absorber pressure due to increased solubility of CO2 in water. Water circulation pumps and biogas compressor works increase due to the increase in pressure difference needed. The optimum pressure of the biogas biogas purification unit is within the range of 7-10 bar. At the same absorber pressure, the 1 stage feed compression u...
Iron chelate liquid redox sulfur recovery (LRSR) has been one of the most frequently recommended ... more Iron chelate liquid redox sulfur recovery (LRSR) has been one of the most frequently recommended technologies for the oxidation of H 2 S in natural gas into elemental sulfur, particularly when the acid gas has a high CO 2 /H 2 S molar ratio. The process is however known to suffer from extensive oxidative ligand degradation that results in high operational costs. Moreover, poor biodegradability or toxicity of the existing ligand has become a concern. In this research, we demonstrated that gluconate, a naturally greener ligand, when coupled with manganese as the metal, has considerable potential to be a better redox agent. Manganese gluconate solution was more resistant against ligand degradation compared with iron NTA. As required, aerated solution was capable of converting dissolved NaHS into elemental sulfur. At sufficiently high pH, manganese gluconate solutions were stable enough from precipitation of manganese hydroxide, carbonate, or sulfides. An equilibrium calculation has been developed to understand the precipitation behavior.
Ammonia is one of the most important industrial commodity due to its wide function. Ammonia synth... more Ammonia is one of the most important industrial commodity due to its wide function. Ammonia synthesis reaction is an exotermic reaction. Therefore, Feed-Effluent Heat Exchanger (FEHE) is added to increase thermal efficiency. However, FEHE could lead the process to experience hysteresis phenomenon due to interaction between equipments as one steady state T feed could result several T outlet. Hysteresis phenomenon may result asset losses like explosion, leakage, and loosing material integrity. Double bed reactor configuration allows us to use several operating parameters as variation to overcome hysteresis. In this review, quenching ratio was chosen to be that varied parameter. This study aims to determine how quenching ratio affects hysteresis zone by utilizing Aspen Hysys® V8.8 as simulation tool. Simulation showed that quenching ratio would narrow hysteresis zone yet increased extinction temperature that lower the conversion. Conversion profile showed that 0.2 quenching ratio got the highest conversion for system with bed volume ratio 2:1 while total volume was 30 m 3. However, the feed temperature was fallen at hysteresis zone. Dynamic simulation showed that highest conversion feed temperature (10%∆Tf above extinct temperature) was still able to preserve stability with descending temperature approach. Hysteresis itself started to occur at 1.7%∆Tf above extinct temperature
Anti-surging is developed for a compressor system consisting of a booster compressor and a high-p... more Anti-surging is developed for a compressor system consisting of a booster compressor and a high-pressure compressor in a serial circuit. This evaluation presented 6 options of anti-surge systems with variations of the number of Anti-surge Valve (ASV) and its combination with the addition of a Hot Gas Bypass Valve (HGBV) and Cold Gas Bypass Valve (CGBV). From the model evaluation, the option that involves a special ASV (dedicated) for each compressor and coupled with a dedicated CGBV or HGBV is the best because the compressor can be back to normal in less than 1 second (maximum time to return to normal condition is 3 seconds. Referring to these options, a dedicated ASV for each compressor provides more benefits to the security of compressor operation. However, the most appropriate option in the field will return to the issue of cost or ease of modification. For facilities that are running (brownfield), the use of tools that already exist in the field and do a little modification is t...
Pine rosin, which is derived from Pinus merkusii resin, a natural product, has demonstrated poten... more Pine rosin, which is derived from Pinus merkusii resin, a natural product, has demonstrated potential as a road marking binder. Although pine rosin has an excellent shinning property, it has some limitations, such as instability and color change. To tackle these issues, modified rosin has been developed through sequential esterification and Diels–Alder reactions, and it has shown better properties than untreated rosin. In this study, from the evaluation of untreated and treated rosins, the treated rosin showed some improvements, such as a lower acid value and higher stability, as shown by the color consistency during the oxidation test at 150 °C for 24 h in open-air conditions. Additionally, as road marking paint, the modified rosin is blended with blending materials in the range of 18–28 wt.%. The modified rosin has a softening point of 170–210 °C, a hardness of 50–71 HD, and a weight loss of 1.33–5.12 mg during the wearing test. These results are comparable to or better than those...
IOP Conference Series: Materials Science and Engineering, 2020
Pickling is a typical method used in a cold milling plant to remove impurities from hot rolled co... more Pickling is a typical method used in a cold milling plant to remove impurities from hot rolled coil by immersing the coil in strong acidic solution. The spent acidic solution or waste pickle liquor (WPL) requires certain waste treatment before it can be disposed to environment because of its metallic ion and acid content. WPL contains a number of metallic ions that can be utilized as ferric chloride coagulant. The purpose of this paper is to evaluate the kinetics of Fe2+ oxidation into FeCl3 and the performance of the ferric chloride coagulant using the proposed electrolysis configuration. The electrolysis process was conducted in ambient condition with voltage 3 & 6 V, electrolysis time of 120 minutes, and addition of excess NaCl or HCl. The result shows that metal impurities in WPL and excess chlorine do not significantly affect the Fe2+ conversion. It can also be concluded that the optimum condition for electrolysis is using 6V of voltage, 90 minutes of electrolysis time, and exc...
IOP Conference Series: Materials Science and Engineering, 2019
Sweetening process for natural gas with high content of sour gas (≥ 40% mol of CO2 & H2S) is diff... more Sweetening process for natural gas with high content of sour gas (≥ 40% mol of CO2 & H2S) is difficult to be profitable. A lot of gas fields in Indonesia has high content of sour gas. New improved cryogenic distillation process of natural gas applying the concept of CO2 freezing in the middle of the column is promising. To study the feasibility of this technology, comparison with other two methods (Absorption and Membrane process) in technical and economic aspects were elaborated. Process simulation of improved cryogenic distillation steady-state model was developed using Aspen HYSYS. CAPEX of all methods were estimated using Aspen Process Economic Analyzer. Compared to the other methods, this improved cryogenic distillation process showed tendency to have lower CAPEX and OPEX, but have some uncovered operational problems.
Acid gas removal, especially H 2 S and CO 2 , is an essential process in natural gas processing. ... more Acid gas removal, especially H 2 S and CO 2 , is an essential process in natural gas processing. In this research, 1butyl-3-methylimidazolium bromide [bmim][Br] ionic liquid was analyzed as a hydrophobic solvent with has high selectivity to H 2 S as an environmentally friendly solvent to absorb acid gas from natural gas with low H 2 S/ CO 2 concentration in ambient temperature and pressure. The absorption performance of pure [bmim][Br] ionic liquid was compared with various amine solutions, such as monoethanolamine (MEA), triethanolamine (TEA), and methyldiethanolamine (MDEA), as well as the mixture of [bmim][Br]-MDEA with various concentration. As a result, pure [bmim][Br] ionic liquid had high selectivity to H 2 S compared with conventional amine solutions. In addition, the mixture of [bmim][Br]-MDEA with the mass ratio of 1:3 provided the highest H 2 S/CO 2 selectivity of 6.2 in certain absorption conditions due to free tertiary amine attached in the cations of ionic liquids that can attract more H 2 S to its functional site.
Data reconciliation (DR) and gross error detection are two common tools used in industry to provi... more Data reconciliation (DR) and gross error detection are two common tools used in industry to provide accurate and reliable data, which is useful to analyse plant performance and basis for troubleshooting. DR techniques improve the accuracy of measurements by using redundancies in material and energy balances. This provides reliable information that could help decision making regarding plant operation, which potentially leads to financial benefit. This paper presents the utilization of plant data to perform troubleshooting of ammonia reactor, in particular the profile of catalyst activity. Bad plant data are collected and then analysed using DR to produces reconciled data, which could be used to detect and identify the gross error measurements. The input data for DR and gross error detection were gathered from Aspen HYSYS V8.8 simulations by modelling the single-bed ammonia reactor. The result presents that bad plant data could define actual system condition such as gross error measur...
A study of dinamics behavior on adiahatic exothermal reactor with a Feed-Effluent Heat Exchanger ... more A study of dinamics behavior on adiahatic exothermal reactor with a Feed-Effluent Heat Exchanger (FEHE) is reported in this paper. In practice of a chemical proces industries, configuration of the heat integration of FEHE system are easi to found at process that involving adiabatic exothermal reactor with the demand of feed's heating and of reactor product's cooling. The FEHE system configuration increase the process thermal efficiency throught the use of heat flow on the reactor product to raise the temperature of reactor feed flow. From the steady state economical point of view, this off cource be very interesting to be implemented, althought controlling and operational considerations are need to be taken into account to keep those advantages un-eliminted by operational and controlling matters. The dynamic simulation can give some illustration on how the hehavior of process operation at FEHE system is. Dynamically this system can be examined so that the boundary of operati...
The Natuna gas field is one of the largest natural gas reserves in Indonesia with estimated natur... more The Natuna gas field is one of the largest natural gas reserves in Indonesia with estimated natural gas reserves of 222 TCF. However, until now, the use of Natuna gas is still hampered because of the very high CO2 content reaching 71%, while the methane content is around 28%. The dry reforming of methane (DRM) process is one of the potential ways to be applied for solving these problems to convert CH4 and CO2 to synthesis gas containing CO and H2 as a raw material that can be applied to manufacture as intermediate products or end products in the petrochemical industry such as acetic acid. The simulation of the acetic acid production was conducted by using ASPEN HYSYS v.10, considering mass and heat balances. The PengRobinson was applied for dry reforming of methane process. In order to produce 496.8 kmol/h of the acetic acid, the 500 kmol/h for each CH4 and CO2 were used as feed gas. The total energy required is 4.7 MMBtu per ton of acetic acid. The acetic acid has a purity of 99.4%...
The presence of mercury in crude oil creates problems in oil processing in refineries, both in te... more The presence of mercury in crude oil creates problems in oil processing in refineries, both in terms of operations and health. The previous removal process of mercury has not yet optimally removed mercury in the product, due to ionic and metallic mercury species. In this study, to obtain optimum results, the process of removal of mercury begins with the process of converting ionic (non-metallic) mercury into metallic mercury thermally in the liquid phase, followed by the transfer of metallic mercury to the gas phase by instant evaporation (flashing) and reinforced by gas stripping using internal gas cone from the evaporation of an instant. The results of the optimization of the process carried out can eliminate mercury with an efficiency of more than 95%.
Palm oil mill effluent (POME) from condensate stew, hydrocyclone water, and sludge separator cont... more Palm oil mill effluent (POME) from condensate stew, hydrocyclone water, and sludge separator contains organic carbon with a COD more than 40 g/L and a nitrogen content of about 0.2 and 0.5 g/L as ammonia nitrogen and total nitrogen. At present, the POME is converted into biogas using anaerobic ponds. Biogas produced contains 60% methane (CH4) and 40% carbon dioxide (CO2) and can be purified into biomethane through CO2 absorption using water. This study evaluates the optimum pressure and feed compression stage in biogas upgrading into biomethane. The results show the rate of circulation of water needed to separate CO2 from biogas feed decreases with increasing absorber pressure due to increased solubility of CO2 in water. Water circulation pumps and biogas compressor works increase due to the increase in pressure difference needed. The optimum pressure of the biogas biogas purification unit is within the range of 7-10 bar. At the same absorber pressure, the 1 stage feed compression u...
Iron chelate liquid redox sulfur recovery (LRSR) has been one of the most frequently recommended ... more Iron chelate liquid redox sulfur recovery (LRSR) has been one of the most frequently recommended technologies for the oxidation of H 2 S in natural gas into elemental sulfur, particularly when the acid gas has a high CO 2 /H 2 S molar ratio. The process is however known to suffer from extensive oxidative ligand degradation that results in high operational costs. Moreover, poor biodegradability or toxicity of the existing ligand has become a concern. In this research, we demonstrated that gluconate, a naturally greener ligand, when coupled with manganese as the metal, has considerable potential to be a better redox agent. Manganese gluconate solution was more resistant against ligand degradation compared with iron NTA. As required, aerated solution was capable of converting dissolved NaHS into elemental sulfur. At sufficiently high pH, manganese gluconate solutions were stable enough from precipitation of manganese hydroxide, carbonate, or sulfides. An equilibrium calculation has been developed to understand the precipitation behavior.
Ammonia is one of the most important industrial commodity due to its wide function. Ammonia synth... more Ammonia is one of the most important industrial commodity due to its wide function. Ammonia synthesis reaction is an exotermic reaction. Therefore, Feed-Effluent Heat Exchanger (FEHE) is added to increase thermal efficiency. However, FEHE could lead the process to experience hysteresis phenomenon due to interaction between equipments as one steady state T feed could result several T outlet. Hysteresis phenomenon may result asset losses like explosion, leakage, and loosing material integrity. Double bed reactor configuration allows us to use several operating parameters as variation to overcome hysteresis. In this review, quenching ratio was chosen to be that varied parameter. This study aims to determine how quenching ratio affects hysteresis zone by utilizing Aspen Hysys® V8.8 as simulation tool. Simulation showed that quenching ratio would narrow hysteresis zone yet increased extinction temperature that lower the conversion. Conversion profile showed that 0.2 quenching ratio got the highest conversion for system with bed volume ratio 2:1 while total volume was 30 m 3. However, the feed temperature was fallen at hysteresis zone. Dynamic simulation showed that highest conversion feed temperature (10%∆Tf above extinct temperature) was still able to preserve stability with descending temperature approach. Hysteresis itself started to occur at 1.7%∆Tf above extinct temperature
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