Executive Summary - Design of 34 Nilam Unit Production 4 @300kg + 30 @100kg

engineering design for nilam oil production 4 (four) unit executive summary distiller of 300kg & 30 (thirty) units distiller of 100kg by Fitri Agustiyono

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

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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 22nd 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



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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 TOR (Term of Reference) ........................................................................................ 5

1.2 Design philosophy and energy saving ..................................................................... 5

1.3 Environmental Friendly and Recomendation ........................................................ 6 1.3.1 Efficient Biomass Consumption and Net CO2 emission .................................... 6 1.3.2 Waste Biomass Utilization ............................................................................. 7 1.3.3 Soil nutrients returning to origin field ............................................................ 7 1.3.4 Growing of Middle-age biomass tree ............................................................ 8

Chapter 2. Resume of Distillation Unit Design .................................................... 9

2.1 4 (four) distillation units capacity 300kg ................................................................ 9

2.2 30 (thirty) distillation units capacity 100kg .......................................................... 10

2.3 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



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Picture 1-3 The illustration of proposed saving energy .............................................................. 6 Picture 1-4 the cycle of CO2 adsorbtion and CO2 releasing by the tree ................................... 7 Picture 1-5 Soil nutrients returning to origin field ...................................................................... 8 Picture 2-1 PID (pipe and instrument diagram) of Design I – 300 .............................................. 9 Picture 2-2 PID (pipe and instrument diagram) of Design IIA – 100 ........................................ 10



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Table 1-1 Heating Value (Q) several famous fuels ........................................................................ 5 Table 2-1 Comparison Fuel Utilization for distillation process ............................................... 11 Table 2-2 Energy Efficiency between existing unit & proposed designs (A) ......................... 11 Table 2-3 Energy Efficiency between existing unit & proposed designs (B) ......................... 11



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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 Sub-district) 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 Kind of Fuel Heating Value (kcal/kg)

1 LPG 14000

2 Coal 5000 – 6000

3 Kerosene 9000

4 Palm nutshell / coco shell 4000 – 4500

5 Wood Biomass 2000 – 3000



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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.



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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 (it’s 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.



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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.



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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



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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



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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

Table 2-2 Energy Efficiency between existing unit & proposed designs (A)

Table 2-3 Energy Efficiency between existing unit & proposed designs (B)

No Fuel Heating

Value

(kcal/kg)

steam

boiler

capacity

(kg/hour)

process

lifetime

(hour)

Boiler and

Combustion

Chamber

Efficiency

Energy

Consumption

per batch

(kcal)

Fuel

Consumption

per batch

(kg)

Fuel

Consumption

per batch (L)

Fuel Value

per unit

Fuel Cost

per batch

1 LPG 14000 100 5 90% 377,778 27.0 10,000Rp 269,841Rp

2a Batubara - a 5000 100 8 75% 725,333 145.1 650Rp 94,293Rp

2A Batubara - A 5000 100 8 75% 725,333 145.1 1,000Rp 145,067Rp

3 Minyak tanah 9000 100 6 85% 480,000 53.3 66.7 4,000Rp 266,667Rp

4 Kayu bakar 3000 100 7 60% 793,333 264.4 1,058 120Rp 126,933Rp

Vaporization Heat of Water = 680 kcal/kg

Type / Kode Type Specification make up boiler

water system

steam

boiler

capacity

(kg/hour)

process

lifetime

(hour)

Boiler and

Combustion

Chamber

Efficiency

Energy

Consumption

per batch (kcal)

Biomass Fuel

Consumption

per batch

(kg)

Biomass Fuel

Consumption

per batch

(M3)

Fuel Cost

per batch

Fuel Cost per

25 kg dry

nilam

Existing existing 25kgtraditional unit (drum

210L)manual, gravitasi 14.17 8 45% 171,311 57.1 0.228 27,410Rp 27,410Rp

I - 300 300kg (2 x 150)separated boiler and

raw vesselmake up with pump 234.00 6 70% 1,363,886 454.6 1.819 218,222Rp 18,185Rp

IIA - 100 100kg (2 x 50)separated boiler and

raw vesselCohobating system 88.00 6 70% 512,914 171.0 0.684 82,066Rp 20,517Rp

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

1 Total Boiler Volume 220 Liter 1425.4 Liter 465.4 Liter

2 Boiler volume which filled with water 140 Liter 1040 Liter 320 Liter

3 Raw Material Vessel Volume 210 Liter 2959 Liter 931 Liter

4 Raw Material / Feed Stock Capacity 25 kg 300 kg 100 kg

(85 L volume equivalent 10 kg dry nilam)

5 heat surface contact area 4,252 cm2 70,128 cm2 27,218 cm2

(LK) 0.4252 m2 7.0128 m2 2.7218 m2

6 Steam Capacity (KS), KS = 33.33 LK 14.2 kg/hour 230.0 kg/hour 88.0 kg/hour

7 proces time 8 hours 6 hours 6 hours

8 total Water Consumption (L/batch) 806 L/batch 9,090 L/batch 2,960 L/batch

9 Boiler and Combustion Chamber efficiency 45% 70% 70%

Heat Energy Consumption per batch (to steam) 171,311 1,340,571 512,914

Heating Value of Wood Biomass = 3.000kcal/kg

10 Biomass Consumptian per batch (kg) 57.10 kg 446.86 kg 170.97 kg

Biomass Consumptian per batch (M3) 0.23 M3 1.79 M3 0.68 M3

4 m3 biomass = 1 ton 27,410Rp 214,491Rp 82,066Rp

Biomass rate per m3 = Rp 120.000,-

11 Biomass Fuel Cost per 25 kg dry nilam 27,410Rp 17,874Rp 20,517Rp

1 x 25kg 2 x 150kg 2 x 50kg

12 Total Nilam oil per batch (yield 2.4%) 0.60 kg 7.20 kg 2.40 kg

13 Total Batchs to produce 12 kg nilam oil (2batch/day) 20.00 batch 1.67 batch 5.00 batch

14 Total days to produce 12 kg nilam oil 10.00 day 0.83 day 2.50 day



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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 1 kJ = 0.24 kcal

2833.33 kJ/kg

Steam Boiler Capacity Design I-300 = 225 kg/hour

Energy Consumption

(2833.33 kJ/kg x 225 kg/hour) = 637,500 kJ/hour

(637,500 kJ/hour : 3600 seconds/hour = 177 kJ/second

177 kW

Electrical Eficiency = 80%

Electrical Power Supply = 221 kW (177 / 0.8 = 221)

PLTMH installed Capacity need = 260 kW (221 / 0.85 = 260)

PLTMH Cost Investment per 1 kW = IDR 32 milion *) (range 30 - 40jt per kW)

PLTMH 260kW Cost Investment = IDR 8.32 billion (260 x 32 = 8,320)

*) source : Consultant PT. WPU - Bandung

Each Heater unit capacity (special order) = 40 kW

Total Need of Heater @ 40 kW = 5.53 unit (221 kW / 40kW)

be rounded as = 6 Heater units



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3.2 Potencial Review of PLTMH to utilizing Heater Electic for

Production Unit Design IIA-100

Vaporization Heat of Water = 680 kcal/kg 1 kJ = 0.24 kcal

2833.33 kJ/kg

Steam Boiler Capacity Design IIA-100 = 88 kg/hour

Energy Consumption

(2833.33 kJ/kg x 90 kg/hour) = 249,333 kJ/hour

(249,333 kJ/hour : 3600 second/hour) = 69 kJ/second

69 kW

Electrical Eficiency = 80%

Electrical Power Supply = 87 kW (69 / 0.8 = 87)

PLTMH installed Capacity need = 102 kW (87 / 0.85 = 102)

PLTMH Cost Investment per 1 kW = IDR 32 milion *) (range 30 - 40jt per kW)

PLTMH 102 kW Cost Investment = IDR 3.26 billion (102 x 32 = 3,264)

*) source : Consultant PT. WPU - Bandung

Each Heater unit capacity (special order) = 30 kW

Total Need of Heater @ 40 kW = 2.89 unit (221 kW / 30kW)

be rounded as = 3 Heater units

Documents

Executive Summary - Design of 34 Nilam Unit Production 4 @300kg + 30 @100kg