CPO MANUFACTURING

PROCESSES & ANALYSIS

FRICTION LOSSES OF WATER
TOWER TANKS PRODUCT

BY
HENI ISMAWATI
1107121287

PT. KIMIA TIRTA UTAMA PROFILES

PT. KTU berdiri sejak tahun : 1980, mulai operasional
tahun 1998
Luas Hak Guna Usaha (HGU) : 7.452,2 Ha
Luas Kebun Inti : 6.726.57 Ha, terdiri dari 10 Afdeling
247 Blok (TM : 6.480,96 Ha ; TBM : 45.61 Ha) dan Kebun
KKPA seluas 2.616,35 Ha .
Jumlah Karyawan s/d Mei : 2.145 orang
Jumlah Ka.Pembangunan Pabrik CPO dimulai tahun 1998
dengan kapasitas 20 ton tbs/jam. Dan extention PKS
mulai tahun 2010 menjadi kapasitas 40 ton TBS/Jam.
Pembangunan PKO dimulai Tahun 2011, dengan
kapasitas 40 ton/Jam.
Luas total PKS : 7 Ha
Luas Komposting : 2.7 Ha, komisioning di bulan Mei
2011.

MANUFACTURING SYSTEM PROCESSES

TB
S
Weight
Weight Bridge
Loading
Ramp
Lorry

Sterilizer
Autofeeder

Empty
bunch
Bunch Press
Vibrating Screen

Thresser

Bunch
Digester
Press

Crude Oil Treatment Processes

Press

Dilution air condensat

Sand Trap Tank

Vibrating Screen

Wet Oil

Clarifier Tank

Sludge Underflow

Wet Oil Tank

Sludge
Tank

Purifier Tank

Sand Tank

Vacuum Dryer

Sludge
Centrifuge

Storage Tank

Slude Pit

Kernel Treatment Processes

Press

Depericarper
Nut

Fibre

Boiler

Polishing Drum
Destoner
Ripple mill

Shell/Hoppe
r

Cracked Mixture

Kernel Dryer

LTDS 1

Shell/Cangkang
Shell/Cangkang

Kernel

Kernel Bunker

LTDS 2
Cracked Mixture

Hidrocyclone
Hidrocyclone water

WWT(Contact Pond)

Shell/Cangkang

By- Product Handling system

70-80 oC

Sludge Pit

Cooling Pond 2

Cooling Pond 1

Mixing Pond
1

Anaerobik
Pond 1

24 h
40-45oC
pH 6,87,2

Mixing Pond 2

Mixing
Pond 3

Anaerobik
Pond 2
Contact Pond
Land Aplication

Mixing
Pond 4

Anaerobik
Pond 3

WATER TREATMENT PROCESSES

Waduk
Advantage
Low dissolved solid
Disadvantage
There are high
suspended solid
Water condition
always change
following the
wheater.

Clarifier
Capasity 45 tonne
Observe parameters on clarifier FTU
(formazin turbidity unit) / NTU
(Nephelometric turbidity unit)), PH and
final conductivity, floc stability.
Chemicals Inject is min 12 meters from
Clarifier tank.

Settling Basin

Settling basin
capasity 60 m3/Hour
If there any
suspended solid in
the water, these will
turn down because a
grafity factor.

Clear Tank
Inlet clear tank:
1. clear water from settling
basin
2. Over flow from water
tower
Clear tank capasity is 46
tonne.

Sand filter
Water from clear tank flows from sand filters
top, and then falling down between medium
stone to small stone, and kwarsa.
Backwash when pressure difference between
inlet and outlet > 1 bar.
sand filter composition:
Volume sand filter 50% - 75% of tank
volume
Medium stone
-. Diameter pasir 2 4 mm
-. Komposition: 25%
Small stone
-. Diameter pasir : 0.8 2 mm
-. Komposition : 25%
Kwarsa
-. Diameter pasir : 0.5 0.7 mm
-. Komposition: 50%
Outlet capasity is 45 tonne / Hour

Water Tower

Tank capasity 90 tonne

Inlet = 45 ton / Hour
Outlet
Domestic = 45 ton/ Hour
Proses = 5 ton / Hour
RO = 40 ton / Hour and
recovery 75%
Kantor = 3 ton/ Hour

Boiler Water Treatment

MMF
MMF is a filter for ROs
inlet.
MMF have carbon active
as a media filter.

Reserve
Osmosis

Inlet 40 tonne / Hour and

recovery 75%
Outlet 45 tonne / Hour
Reject 13 tonne / Hour

Reject Tank

Inlet
1. Reject from
RO
2. Cooling water
from Boiler
Outlet
1. Cleaning
Plant

Permeate Tank
Permeate Tank Is a
closed tank where
water outlet from
RO is saved.

ANALYSIS FRICTION LOSSES OF

WATER TOWER TANKS PRODUCT
FLOW WATER TO BOILER
From App. A2 [Geankoplis, 1995] we
found :
a. = 995.68 kg/m3
b. = 0.8007
c. Cp = 6.7197 x 10-4
. We used 6 and 4 pipe, then we should
calculate the diameters of these pipe :

D3
= 0.505 ft
D4
= 0.335 ft
so, we can found A for every pipes :
A3
= 0.2001 ft
A4
= 0.0880 ft
Then flowrate value is:

= 0.3831 ft3/s

Velocity
V3
= 0.7586 ft2/s
V4

= 1.1435 ft2/s

1. Contraction Loss At Exit

Used equation 2.10-16 for
contraction from large A1 to a small
pipe A3

Because we found NRe > 4000, so it mean

the flow was turbulen. And we used
commercial steel pipe so from figure 2.10-3
[ Geankoplis, 1995] we used (material
equivalent roughness for new pipes) = 4.6
x 10-5 m atau 0.00015 ft. so,

And from /D = 2.9 x 10-4 and NRe = 7 x 106

we found friction factor for this kind of pipe f
= 0.0055. L for 6 pipe is 8 m or 26.2464 ft.
so Ff value is :

So, we found hc is :

ynold
N Re = Re
Number
D = Pipes
Diameter
ty
= densi
ity
V = veloc
sity
= visco
t
Cp = Hea
Capasity

N Re =

hc = Contraction
losses
Kc = koefisien
contraction
gc = gravity
conversion factor
( 32.174 lbm ft / Lbf
s2 )
V = velocity

2. Friction in 6-in pipe

Reynold number for 6 pipe is :

Ff = Friction losses
f = Friction factor
L = pipes length
V = velocity
gc = gravity conversion
factor
( 32.174 lbm ft / Lbf s2 )

3. Friction in the tee pipe at 6-in pipe

From table 2.10-1 Geankoplis, 1995 Kf value
for tee pipe is 1, so hf value is:
Hf = Friction
losses
Kf = Koefisien
friction
V = velocity
gc = gravity
conversion factor
( 32.174 lbm ft / Lbf
s2 )

4. Contraction from pipe 6-in to 4in

Used equation 2.10-16 for
contraction from large A3 to a small
pipe A4.

5. Friction in the 4-in pipe

Reynold number for 4 pipe is :

And from /D = 0.00044 and NRe = 7

x 106 we found friction factor for this
kind of pipe f = 0.00488 . L for 4
pipe is 264.5 m or 867.78 ft. ft. so Ff
value is :

6. Friction in swing valve at 4-in pipe

From table 2.10-1 Geankoplis, 1995 K f
value for swing valve is 2, so hf value is:

7. Friction in flowmeter at 4-in

pipe
From table 2.10-1 Geankoplis, 1995
Kf value for flow meter is 7, so hf
value is:

8. Friction in 14 elbow at 4-in pipe

From table 2.10-1 Geankoplis, 1995 Kf
value for elbow is 0.75, so hf value is:

Total friction losses from water tower

tank to deaerator tank is :

From level sistem if we assumed z2 as

a basis, z1 = H dan z2 = 0. because all
flows as turbulen so, = 1 , 1 = 0, 2
= 4 = 1.1435 ft/s. if we assumed p1
and p2 are same, we will found:

Because we didnt use a pump so Ws

value was 0. and then we subtitute
to equation 2.10-20 from Geankoplis,
1995 :

 Thankyou