PT.

KALTIM PARNA INDUSTRI

COMPANY PRESENTATION
Sekilas Info PT. KPI

PT. KPI AT A GLANCE

Corporate Profile

Ammonia Plant 1,500 MTPD

1st NATIONAL PRIVATE Company
Over 200 employees

The Most Efficient

AMMONIA PRODUCER
IN THE WORLD
KPI Milestone

2000
Construction

2001 1998
EPC Contract MHI
Production
NG Flow & Industrial Area

N
KPA

K-4

K-3

K-2

K-1

OCI

KMI
Market Share

60 %

30 %

10 %
Ammonia Downstream

Urea, NPK, DAP

Ammonium Nitrate

Acrylonitrile
Proses Utilitas PT. KPI

UTILITY PROCESS PT. KPI

Utility Main Process

COOLING SYSTEM

CHLORINATION

WATER TREATMENT

STEAM GENERATION

NITROGEN SEPARATION

INSTRUMENT AIR

ELECTRICAL SYSTEM

AMMONIA STORAGE
Utility Process Diagram
Sea Compressed
Water ELECTRICAL Air

NaOCl
SYSTEM

SWI Basin
AMMONIA
AIR STORAGE
Make Up Feed

N2 IA
Generator Dryer
Cl2 Unit Thermal
SWCT
Desalination

OCS Process Desalt Nitrogen Instrument

Condensate Water Reverse High Purity Air
Osmosis
MPE
Mix Bed
LP
Polisher Steam WHB HP
CCW Steam
Demin
Make Up
Water
Deaerator
PLANT PKB MP
Steam
Sea Water Intake System
Sea
Water

SWI Basin
Sea Water Intake System

 Sea Water as the main

resources for steam
generation and cooling
fluid

 Intake system consist of :

-Intake Line
-Seawater basin
-Vacuum Pump
-Rotary Screen
-SWI Pump
Sea Water Intake System

Intake Line
 Line connect SW to basin
 Floating type line advantage :
- avoid dirt/pollution
- temp. fluctuation low
 Chemical injection :
- NaOCl
Sea Water Intake System

Sea Water Basin / Pit

 SW Storage (6 x 4 x 9 m)
 OPR range 35 – 60 %
 Interlock (I-234) LIA-2102
- STOP P-2102 A/B
- Alarm 28% Trip 18%
Sea Water Intake System

Rotary Screen
 Filtering suction SWI Pump
 Moving wire mesh type
(travelling screen)
 Flushing by wash pump
Sea Water Intake System

Vacuum Pump (P-2104 A/B)

 Vacuum pump for P-2102 A/B
suction and intake pipe
 Water Ring Type (vacuum
conditioned by water circulation)
 Driver : 2.2 kW
 P. des : -620 mmHg
 P. opr : -350 mmHg
Sea Water Intake System

SWI Pump (P-2102 A/B)

 Transfer SW from basin to user
(Desal, CT, Cl2 Unit, Sulfate mixer)
 Cpcty : 1700 m3/h
 Driver : 250 kW
 P. des : -0.64/3.23 KG
 Troubleshooting :
- Winding temp. high
- Alarm PIA-2102 L
Cooling System
Sea
Water

SWI Basin

AIR
Make Up

SWCT

OCS

MPE

CCW

PLANT
Cooling System

OPEN SWCT demin.

CIRCULATION water
MPE

plant

CLOSED
CIRCULATION

 Cooling system adopt open
circulation system (SWCT) &
closed circulation (MPE) system.
 Advantages :
-Less SW consumption & chemical used
-Cooling Temp. independent to temp. SW supply
-Can use HE carbon steel type
 Dis-Advantages :
-Large area for SWCT
-Corrosive environtment
-Additional maintenance cost
Cooling System

Cooling Tower Cell (CT-2101 A-E)

 Cooling SW circulation with air as cooling media
 Cpcty : 17000 m3/h (Make up : 500 – 570 m3/h)
 Alarm level basin LICA-2101 L (93%)
 Included :
- Drift eliminator (prevent water loss due to
evaporation)
- Water distributor (distribute water spray)
- Filler pack
 Chemical injection :
- Sulfate (maintain pH 7 – 8.2)
- Dispersant (avoid koagulasi/settlement)
- Biocide + NaOCl (avoid bio-fouling)
Cooling System

CT Induce Draft Fan (K-2101

A-E)
 Pull air cooling in CT (counter
current with SW flow)
 Driver : 180 kW (122 rpm)
Cooling System

Sea Water Circulation

Pump (P-2103 A-C)
 SW circulation pump to MPE
 Cpcty : 9000 m3/h
 Run 2 & Standby Auto 1
 P. des : 0/3.66 KG
 Driver : 1200 kW
 Interlock (I-233) Auto start if
Press. SW circulation PIA-
2101 LL (1.8 KG)
Cooling System

Side Filter (CT-2101-X1)

 Filtering SW circulation to
reduce suspended solid
 PT. des : 6 KG/50oC
 Packing filter : Gravel, Fine
sand, Anthracite
 Include Backwash as timer
function/manual (interlock auto
start backwash PDHH-21101)
Cooling System

Backwash Water Pit (CT-2101-

T1)
 Receive backwash waste water
 Cpcty : 210 m3
 Interlock (auto start/stop CT-2101-
P1) Level pit LA-21001 H/L
(70/10.5) %
Cooling System

Blower Pit Side Filter (CT-2101-K1)

 Backwash water pit aeration
 Cpcty : 210 Nm3/h
 Output : 5.5 kW

Backwash Transfer Pump (CT-2101-P1

A/B)
 Transfer backwash waste water to outfall
 Cpcty : 8 m3/h
 Driver : 22 kW
 Cooling System

CW System Pump (P-2301 A/B/C)

 Circulating Plant CCW
 Cpcty : 8600 m3/h
 P.des : 0.2/3.9 KG
 Driver : 1190 kW (PM-2301C stndby)
 Interlock (I-231) auto start (PM) if
press. CW PIA-2301 LL (2.5 KG)
 Water spec. :
- Press. 3.2 KG
- Temp. 35 – 37oC
- Flow. 16500 – 17000 T/h
- Eliminox 100-150 ppm & Fe < 2 ppm
 Cooling System

Turbine P-2301 A/B (TS-2301 A/B)

 Steam turbine for CW circulation pump (P-
2301 A/B)
 Sub Unit :
- Condenser Turbine E-2302 (condens.
Exhaust steam)
- Aux. LO Pump (backup LO press.)
- Gland ejector (vacuum gland condenser)
- Gland condenser (condensing steam leak)
- Main/Starting ejector (vacuum E-2302,
release gas) -0.89 KG
- Cond. Pump E-2301-P1 (transfer
condensate to F-2402 / RC Tank
Cooling System

CCW Cooler (E-2301 A-F)

 Cooling CW circulation with SW
circulation
 Type : Plate Exchanger (MPE)
 PT. des : 6 KG/60oC
 Cooling System

CW Head Tank (T-2301)

 Avoid air trapped in line CCW and
make-up loss CW
 Cpcty : 15.8 m3
 Auto level control H/L (80/70)%

CW Booster Pump for K-0201 (P-2304 A/B)

 Transfer CW to K-0201 (flue gas blower)
 Cpcty : 6.3+2.2 m3h
 P.des : 2.4/9.4 KG
 Driver : 11 kW
 Interlock (I-232) Autostart if Press. to K-0201 LL ( 6 KG)
Chlorination
Sea
Water

NaOCl
SWI Basin

AIR
Make Up Feed

SWCT Cl2 Unit

OCS

MPE

CCW

PLANT
Chlorination

Chlorination Unit (Z-2102)

 Produce NaOCl from SW with electrolysis reaction

- (Direct Rx.) NaCl + H2O + 2F  NaOCl + H2 

- (Anoda Rx.)2Cl-  Cl2 + 2e-

- (Catoda Rx.) 2Na + 2H2O + 2e-  2NaOH + H2 

- (Elektrolizer Rx.) 2NaOH + Cl2  NaCl + NaOCl + H2O

 User :
- SWI (0.1 – 0.2 ppm Cl2 free)
- CT (0.2 – 0.5 ppm Cl2 free)
 Interlock :
- Press. SW supply PAL-21021 L (< 2 KG)
- Flow SW to generator FAL-21021 L (< 20m3/h 30 sec.)
Chlorination

SW Supply Pump (Z-2102 –P1

A/B)
 SW pump to electrolysis unit
 Cpcty : 30 m3/h
 Motor : 5.5 kW
Chlorination

Transformer/Rectifier (Z-2102 –
X3)
 Convert AC to DC
 Design 33 V 3200 A (6 Cell)
 OPR 2000 A max. (5 cell)
Chlorination

Hypochlorite Generator (Z-2102 –

X1)
 Ion electrolysis reaction
 SW electrolyzed to chlorine in anode side
and caustic in catode side
Chlorination

Dehydrogen Drum (Z-2102 –X2)

 Hydrogen Separator
 Using water flow to spin the blower
Desalination & SWRO
Sea
Water

NaOCl
SWI Basin

AIR
Make Up Feed

Cl2 Unit Thermal

SWCT
Desalination

OCS Process Desalt

Condensate Water Reverse
Osmosis
MPE

CCW

PLANT
Desalination

Desalination Unit (Z-2201)

 Produce distillate water (design <15 mS/cm)
 Cpcty : 100 T/h (thermal desalt, triple effect)
 Evaporating SW using MLP steam (8.5 KG) and
Condensing distillate with SW supply
 P. vacuum -0.92 KG, Temp. 1st effect <70oC
 Desalination

Vent Ejector (Z-2201-J2/3)

 Vacuum for Condenser and Vent
trapped air when initial start-up
 Use MLP Steam
 Desalination

Condenser Ejector (Z-2201-

E2)
 Condensing exhaust ejector and
preheat SW spray
 Desalination

Main Ejector (Z-2201-J1)

 Main Vacuum for Condenser and inlet
line for steam supply to 1st effect
 Opr . Range -0.92 to -0.9 KG
 Desalination

Evaporator (Z-2201-E1)
 Evaporate SW Supply
 Use MLP steam in 1st effect
 Temp. 1st effect 64 – 65oC
 Desalination

R1/R2 Condenser
 Condensing distilate product
and preheat sea water feed
 Desalination

Brine Blow Down Pump

(Z-2201-P2)
 Transfer brine concentrate
to SW line return (outfall)

Distillate Pump
(Z-2201-P2)
 Transfer distillate product to
Desal tank
Desalination

Desal Water Storage Tank Desal Water Pump

(T-2201)
 Receive distillate product,
process & turbine condensate
 Cpcty : 1616 m3
 Alarm LIA-2201 H/L (85/25.5)%
(P-2201 A/B)
 Transfer RC water to
demin unit and seal pump
 Cpcty : 590 m3/h
 P. des : -0.1/5.1 KG
 Driver : 132 kW

Desal Water Start-up Pump

(P-2202 )
 Transfer desal water which is used
to desuperheat MP steam at start-up
 Cpcty : 7 m3/h
 P. des : -0.1/13.9 KG
 Driver : 22 kW
Sea Water Reverse Osmosis
Sea Water Reverse Osmosis
Sea Water Reverse Osmosis
Demineralization
Sea
Water

NaOCl
SWI Basin

AIR
Make Up Feed

Cl2 Unit Thermal

SWCT
Desalination

OCS Process Desalt

Condensate Water Reverse
Osmosis
MPE
Mix Bed
Polisher
CCW
Demin
Water

PLANT
Demineralization

Mix Bed Polisher (F-2401 A/B/C)

 Demineralize RC water with ion exchange resin (design < 0.2 mS/cm)
 Cpcty : 175 m3/h/train
 Resin type :
- Strong Base Anion adsorb cation
- Strong Acid Cation adsorb anion
 Regen resin using sulfate (30”) and caustic (35”) injection
 Regen mode : Auto, Compel, Double regen
Demineralization
Demineralization

Cation: [Rc --]2Mg++ + H2SO4  2 Rc-H+ + MgSO4

Anion : [Ra+]2 SO4 -- + 2 NaOH  2Ra+OH- + Na2SO4
Demineralization

Regen Pump (P-2402)

 Transfer demin water for
backwash/rinsing when MBP
regen
 Cpcty : 60 m3/h
 Driver : 15 kW
 P. des : 0/4.5 KG
Demineralization

Sulfate Tank (T-2405)

 Storage sulfate (98% wt)
 Cpcty : 3.8 m3/h
 Additional Sulfate Service
Tank (T-2403) and ejector
for dilution (4-6% wt)

Caustic Tank (T-2406)

 Storage caustic (40 % wt)
with mixer propeller
 Cpcty : 10.3 m3/h
 Additional Caustic Service
Tank (T-2404) and ejector
for dilution (4-6% wt)
Demineralization

Demin Tank (T-2401)

 Receive demineralization water
 Cpcty : 2453 m3/h
 Alarm LIA-2401 H/L (93/18.9) %
Demineralization

Deaerator Feed Water Pump

(P-2401 A/B)
 Transfer demin to deaerator unit & CW
header
 Cpcty : 280+85 m3/h
 Driver : 110 kW
 P. des : 0/6.5 KG
 Interlock I-241 (auto start ) :
- DFW Press. PIA-2401 L (5.4 KG)
- Deaerator level LSLL-0211 L (48%)
Demineralization

Neutralizing Pit (T-2402)

 Receive regen waste and control
waste water pH to normal
 pH control with injection sulfate &
caustic (pH control 6 – 9)
 Cpcty : 320 m3
Demineralization

Air Blower MBP & Neut.

Pit
(K-2401 A/B)
 Air injection to MBP when
regen for mixing resin and
to pit for circulation (avoid
settlement)
 Cpcty : 415 m3/h
 Driver : 11 kW
Demineralization

Neutralizing Water Pump

(P-2403 A/B)
 Transfer treated water to KIE
pond or SWCT (makeup)
 Driver : 22 kW
 Waste Water Treatment

Waste Water Treatment

System
 Treat waste water from plant using
chemical injection and aeration.
 Waste resources :
- Diluted aMDEA (T-0304) and rain
water (T-1101)
- Off spec water (Z-0801/0901)
- Blow down WHB (V-0211) and
PKB (H-1101)
 Spec. treated water :
- pH 6 – 9 (injection sulfate T-2405
or caustic T-2406)
- Ammonia content 0.3 kg/ton
product
 Waste Water Treatment
MDEA Collection Sump Waste aMDEA Pump (P-
Pit 0306)
(T-0304)  Transfer waste (diluted) aMDEA
 Receive MDEA to T-2901
waste/drain CO2 Area.  Auto start level 80%
 Cpcty : 7.5 m3  Auto stop level 14.8%
Contaminated Rainy Drain Water Pit Pump (P-1101
Water Transfer Pit A/B)
(T-1101)  Transfer drain water (rain, diluted
 Receive rainy water & aMDEA) to T-2901
plant drained water  Auto start level 60%
 Cpcty : 2.7 m3  Auto stop level 20%
Waste Water Treatment

Air Blower Neut. Pit (K-

2901)
 Air injection to circulating
Neutralizing Pit (T-2901) neutralizing pit
 Receive waste and control pH  Cpcty : 33 Nm3/h
with injection sulfate/caustic  P. des : 1.03/1.33 KG
 Cpcty : 2.7 m3  Driver : 1.5 kW
 Interlock :
- (I-295) pH AIA-2911 H (inject
Sulfate)
- (I-294) pH AIA-2911 L (inject
Caustic)

Treated Waste Water Pit

(T-2902)
 Receive treated waste water
 Cpcty : 36 m3
Waste Water Treatment

Treated Water Pump (P-2901

A/B)
 Transfer treated waste water to
chemical pond (KIE)
 Cpcty : 25 m3/h
 P. des : -0.4/3 KG
 Driver : 15 kW
 Interlock :
- (I-292) Auto stop LIA-2911 L (13.8%)
- (I-293) Auto start LIA-2911 H (65%)
Steam Generation
Sea
Water

NaOCl
SWI Basin

AIR
Make Up Feed

Cl2 Unit Thermal

SWCT
Desalination

OCS Process Desalt

Condensate Water Reverse
Osmosis
MPE
Mix Bed
LP
Polisher Steam WHB HP
CCW Steam
Demin
Make Up
Water
Deaerator
PLANT PKB MP
Steam
Steam Generation

Deaerator (V-0251)
 Stripping demin water to release
diluted gas (O2, CO2, etc.)
 BFW spec :
- pH : 9.2 – 9.5
- Cd : < 0.2 mS/cm
- Eliminox : 400 - 450 ppb
- DO : < 2 ppb
 Chemical injection :
- Ammonia -> pH control
- Eliminox -> DO control
 Interlock/Control :
-Level LICA-0211 -> (I-241) LL
Autostart P-2401
-Pressure PICA-0224 (SL
Injection) & PICA-02242 (vent
system)
Steam Generation

Turbine Pump BFW

(TS/P-0251 A/B)
 Transfer BFW to user (V-0201, H-
1101, Desuperheater)
 2 Stage Pump :
- HP (116 KG) to V-0251
- Inter-stage (65 KG) to H-1101
 Spec :
-TS/P-0251 A -> Back Press
Turbine (MPS) & Centrifugal
Pump
-PM-0251 B -> Motor Centrifugal
Pump (1630 kW) -Standby-
 Interlock (I-251) autostart P-0251 B
if PSLL-0225 (Press. disch. LL)
 Steam Generation - HP

Serial BFW
Preheater
 E-0205 (Coil) by
Flue Gas H-0201
 E-0502 (S&T) by SG
Outlet R-0502
 E-0212 A/B (S&T) by
CG Outlet R-0204
 E-0213 A/B (S&T) by
CG Outlet R-0205
 E-0217 (S&T) by CG
Outlet R-0204
BFW Flash Drum (V-0252)
 Flashing circulated High Pressure
BFW
 Control :
- Circulation HC-0211
- Level LICA-0205 (LV-0205)
Steam Generation - HP

Steam Drum (V-0201)

 Receive HP BFW & Storage
sat’d HP Steam
 Level control by LICA-0201
signal to FIC-0220
 Interlock (IS-21) Level
LSLL-020 1/2/4 (2 of 3)

Blow Down Drum (V-

0211)
 Receive blow down from V-
0201, E-0208, E-0501
 Flow control from V-0201
(FIC-0251), E-0208 (HV-
0212), E-0501 (HV-0503)
 Level control by LICA-0203,
drain to T-2901/T-2402
Steam Generation - HP

Serial Waste Heat

Boiler
 Produce sat’d High
Pressure Steam (115 KG)
 E-0501 (S&T) by SG
Outlet R-0502
 E-0208 (S&T) by RG
Outlet R-0203
Serial HP Superheater
 Produce superheated
High Pressure Steam
(510oC)
 E-0209 (S&T) by CG
Outlet R-0204
 E-0500 (S&T) by RG
Outlet R-0203
 E-0203 (Coil) by Flue Gas
Steam Generation - MP

Package Boiler Unit (H-1101)

 Produce superheat MP Steam (42 KG & 395oC)
 Cpcty : 60 T/h (OPR 30/40 T/h)
 Interlock :
- Level steal drum LIA-11011 LL (-180 mm)
- UV Scanner XL-11061/2 (OFF/4mA)
- Motor FD Fan XL-11071 (MCC OFF)
- Fuel Press. PS-11051 L (2.5 KG) & PS-11052 H (2.4 KG)
 Steam Generation - MP

Economizer (H-1101-E1)
 Pre-heat BFW using flue gas
 Steam Generation - MP

Superheater (H-1101-
E3)
 Superheat steam MP from
steam drum
 Temp. outlet set by
desuperheater to 390oC

Force Draft Fan (H-1101-

K1)
 Air supply for combustion
 Cpcty : 1200 m3/min
 PS. des : 460 mmH2O/1490 rpm
 Driver : 132 kW
Steam Generation - MP

Sampling Cooler (E-1101-E1/2)

 Cooler sampling point

Blow Down Drum (V-1101)

 Receive cont. blow down waste
 Blow down to maintain water quality

Cont. Blow Down Cooler (E-

1101)
 Cooler waste blow down

Blow Down Tank (H-1101-T1)

 Receive waste blow down after
cooled
 PT. des : 0.9 KG/100oC
Nitrogen Generator
Sea Compressed
Water Air

NaOCl
SWI Basin

AIR
Make Up Feed

N2
Generator
Cl2 Unit Thermal
SWCT
Desalination

OCS Process Desalt Nitrogen

Condensate Water Reverse High Purity
Osmosis
MPE
Mix Bed
LP
Polisher Steam WHB HP
CCW Steam
Demin
Make Up
Water
Deaerator
PLANT PKB MP
Steam
Nitrogen Generator

N2 Generator Unit
 Produce N2 99.97 %vol (O2 content max
300 ppm, Trip 500 ppm
 Type Pressure Swing Adsorption -
molecular sieve (MSC) pressurized flow.
 2 vessel by turns operation (300 Nm3/h)
 Process Feed Air AVG 1400 Nm3/h (MAX
1540 Nm3/h) MIN 13.7 KG
 Electricity 1000 VA
Nitrogen Generator

Feed Air Buffer Drum (V-

4203)
 Receive N2 Generator Feed Air
from K-0421 3rd / K-4101
 Press design 16 KG
 Temp design 60oC
Nitrogen Generator

N2 Generator PSA Unit (Z-4201-X1)

 P&T DSG – 12 KG / ambient
 Operation step :
1. Adsorption (pressurized flow enter the
molecular sieve, O2 stuck in porous)
2. Pressure Equalization (some product
from service vessel enter the regenerated
vessel to press up)
3. Regeneration (regeneration vessel
depressurized to release O2, then purged
by some N2 product)
Nitrogen Generator

Gas N2 Holder Tank

(V-4201)
 Receive N2 product from PSA Unit
 Press design 16 KG
 Temp design 60oC
 PSV-4201 (16 KG)
 Nitrogen Generator

Nitrogen Import KMI

 Flow 150 – 300 Nm3/h

Nitrogen for IA System

 Emergency if IA Dryer fail

Gas N2 Buffer Tank (V-4202)

 Receive N2 supply to header/user
 Press design 16 KG
 Temp design 60oC
 PSV-4202 (16 KG)
 Tank press control PICA-04202 ar.
12 KG (backup supply by T-4201)
 Dry Gas Seal press control PICA-
4203 ar. 5 KG
 N2 Header press control PICA-
08002 ar. 3-5 KG
Nitrogen Generator

Liquid N2 Tank (T-4201)

 Storage N2 Liquid for backup
supply
 P&T design 16 KG & -196oC
 Press up Tank by Pressurized
Vaporizer (E-4202) Ambient
Air Fin type

Pressurized Vaporizer (E-

4202)
 Suit condition T-4201
 Type Ambient Air Fin
 P&T design 16 KG & -196oC
N2 Vaporizer (E-4201)
 Press up N2 supply to V-4202
 Type Ambient Air Fin
 P&T design 16 KG & -196oC
 Capacity 1000 Nm3/h
IA Dryer
Sea Compressed
Water Air

NaOCl
SWI Basin

AIR
Make Up Feed

N2 IA
Generator Dryer
Cl2 Unit Thermal
SWCT
Desalination

OCS Process Desalt Nitrogen Instrument

Condensate Water Reverse High Purity Air
Osmosis
MPE
Mix Bed
LP
Polisher Steam WHB HP
CCW Steam
Demin
Make Up
Water
Deaerator
PLANT PKB MP
Steam
IA Dryer

Air System
 Air system :
1. Instrument Air (8 KG) → Operate instrument device (valve)
2. Service Air (8.5 KG) → IA, Utility (flushing, hand pump, N2 Gen.)
3. Process Air (36 KG) → Secondary Reformer (further NH3 reaction)
 Supply system :
1. Service/Process Air → Air Compressor (K-0421)
2. Instrument Air
- Normal (supply SA > 8 KG) → Disch. 3rd stage K-0421 via V-0423
- SA < 7.4 KG → Disch. 4th stage K-0421 via V-0421 (PICA-4101 Open)
- SA < 7 KG → Emergency IA Comp. K-4101 (PSL-4101 auto start)
- Worst case → N2 for replace SA
Electrical System
Ammonia Storage
TERIMA KASIH

THANK YOU
@ardyankaje
2013