Package Boiler BF-4101

Air sucked by the turbine into a fan assisted pembakar space at the same time with NG fuel by pipeline, and water from the incoming water so that there demin combustion, steam is generated here and then flowed through the superheater and desuperheater to the header. Steam low pressure in the blowdown to a flash tank and steam discharged (vent), while the flue gas (flue gas) in the economizer is used.

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Water Treatment Plant.

Water Treatment Plant serves to treat the raw water into clean water with the help of chemicals such as alum injection, Chlorine, Caustic and coag-aid.

Water treatment process consists of several stages.
- Clarifier System.
System clarifier serves to Coagulasi-Dan Flocculation Process, which took place here to reduce the amount of total suspended solid and turbidity in raw water.
- Chemical Injection System.
Chemical injection is needed in the alum clarifier, coagulant aid, caustic and chlorine that allows the process floculasi, coagulasi, sedimentation, and the sterilization occurred.
- System Sand Filter.
sand filter works to filter out colloidal particles passing from the clarifier, sand filter which is equipped with a backwash and rinse system.
- Filtered Water Storage.
Production of clean water from sand filters are stored in the filtered water storage and distributed to each use by separate pumps.

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Water Treatment.

New Technologies Clean Water Treatment with catalysts.
Recently, Hitachi's research team announced that they had found a new technology in water treatment. They have succeeded in developing catalyst technology to describe organic substances contained in water. The catalyst used is an active catalyst when subjected to ultraviolet light. It is said that more than 90 percent of organic matter including Dioxins can be described this way.

The advantages of this technology compared to existing technology for this is to simply use the catalyst without the use of additives. The cost of this process is much cheaper than existing technology today, for example, than by using the membrane. In addition, decomposition of organic matter with this technology requires a relatively short time.

The downside of this technology is the threshold concentration of pollutants that are still relatively small, under 100 ppm. Thus, for waste water which has a high concentration of organic substances is very high preliminary process is required to reduce the content of organic substances.

Catalysts are substances that can accelerate or stimulate the occurrence of a reaction. In this case the reaction of organic matter decomposition. For this water treatment process, the catalyst used was Titan Oxide. Titan Oxide became stronger after oxidizing ultraviolet light illuminated. Titan has an active oxide will oxidize organic substances there.

Water purifier designed by Hitachi has a simple form. Namely in the form of a cylindrical reactor with a source of ultraviolet light in the middle. Meanwhile, the catalyst attached to the cylinder wall with adhesives. Waste water is passed to the reactor cylinder and organic substances contained in them will be described by the catalyst in the cylinder wall. Currently, Indonesia is facing serious problems of clean water. It seems that we can put hope in the development of this technology.

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Ion exchanger.

River water and ground water at first accommodated in existing attraction that has a pump to flow into the mixing tub and given as flokulan alum. Water that has been poured into the tub alum to give time penggumpal flocculation impurities in the water. Water with impurities Flok-Flok pengendap poured into the tub to Flok-formed Flok down and separate from the water. Water coming out of the tub pengendap cleared but there were still floating impurities, therefore the water and then filtered with a filter to separate these particles.

Filtered water still contains dissolved substances that cause hardness. To remove dissolved impurities which are used substances that can absorb the ions in the solution. With the ion exchanger, water is expected to be used in the process has a hardness 0 even as little as possible to avoid crust.

Ion Exchange Equipment Condition

The process of removal of ions dissolved in water may involve a cation exchanger (cation exchanger) resin in the form of Na (R-Na). Process-sodium-ion exchange is the process most widely used to soften water. In this softening process, calcium ions and magnesium are removed from the high water berkesadahan by cation exchange with sodium. When the exchange resin was finished removing most of the 346 calcium and magnesium ions to its capacity limit, the resin was then regenerated back into the sodium form using a saline solution with a pH between 6 and 8. Polystyrene resin exchange capacity of 650 kg/m3 when the amount diregenerasikan with 250 g of salt per kilogram of hardness is removed.



To exchange cations or hydrogen natirum cycle typically used synthetic resin, styrene-sulfonat type divinilbenzena. These resins are very stable at high temperatures (up to 150 oC) and in pH between 0 and 14. In addition, this material is very resistant to oxidation. Total cation exchange capacity can reach 925 kg per cubic meter CaCO3 ion exchange with hydrogen cycle and up to 810 kg per cubic meter CaCO3 cycle in practice natrium.Namun operating capacity is not that high.

Softening of water in the reaction below, the symbol R indicates radical cation exchanger. These resins remove ions Ca 2 + and Mg 2 + cause hardness.
Reaction as follows:
CaCO3 + 2 R-Na -> R2-Ca + Na2C03
MgCO3 + 2 R-Na-> R2-Mg + Na2C03

When the furnace is a cation exchanger has been its ability to produce soft water, softener unit was stopped; then laundered through (backwash) to clean and classify the resin particles in the furnace was again: and then regenerated with a solution of common salt (sodium chloride) to remove calcium and magnesium in the form of soluble chloride and cation exchanger and returns it to the form of sodium.

Furnace was washed again to clean it from the side that can dissolve
and the excess salt; then returned to operation to further soften the water. Regeneration reaction using water gararn (NaCI) can be described as follows:
R2-Ca + 2 NaCI -> 2 R-Na + CaCl2
R2-Mg + 2 NaCI -> R-Na + MgCl2

While the anion content is not removed by the anion exchanger (anion exchanger). If the content is high anion, blowdown is usually done most of the water away and replaced with water-pollutant impurities kondensat.Selain above, there are various kinds of gases dissolved in water (C02, CF4, 02, H2S). Gas is eliminated by deaerator before entering the boiler. Deaerator works by heating the boiler water so that the gases can exit.

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Ion Exchange operates the tool.

In the double column process, the raw water first entered the field penulcar cation. Here sernua cations contained in the water (especially calcium ions, magnesium and sodium) exchange with hydrogen ions. Dalarn next column containing an anion exchanger, the anions (mainly chloride ions, sulphate and bicarbonate) exchanged with hydroxyl ions. Hydrogen ions from the cation exchanger and hydroxyl ions from the anion exchanger to form a bond and produce water.

After the water formed the ion exchange resins must be regenerated. Implementation of regeneration in double kolorn process is very simple. Into the cation exchange column asarn chloride flowed into the thin and anion exchanger columns streamed dilute sodium hydroxide solution. Excessive Regeneran further rinsed with water.

At the campfire mix - single column, cation exchange resins and anion exchanger mixed together in a single column. With the mix of fire can be achieved levels of water purity is much higher than with a double column process. In contrast, in the process of regeneration of resin mixture fire more complex exchange.

Working steps on fire regeneration mixture: Pernisahan cation exchange resins and anion exchange classification by using water (washing back from the bottom up). In this case the anion exchange resin that is lighter (much lighter color) will be above the cation exchange resin 349 is more severe (mostly darker). Washing should be held back until the two resin layers seen a sharp separation.

1. For regeneration, together with water regeneran channeled through two layers of dilute chloride resin acids derived from the bottom up through the cation exchange resin, and expelled from the column at the height of pernisah layer. Dilute sodium hydroxide solution flows from top to bottom through the anion exchange resin, was also issued at the height part of the separator layer.
2. Excess second regeneran then washed with water
3. Water surface elevation in the second column is derived and mixed exchange resins by compressed air entering from the bottom of the column.
4. Repeated washing with water pit mix from top to bottom, until the gauge shows the condition of the conductivity of the desired purity.

Now the installation is ready for operation again. Both the installation and the installation pclunakan water demineralisasi, then transfer from the operating conditions of the regeneration process, the implementation of their own regeneration, and pengalilian kembah to 350 operating conditions can be done either manually or automatic.

To achieve water quality or optimal performance and to prevent damage to the exchange resin, then the work instructions provided by the manufacturer of the installation (eg on the order of operations, the quantity and concentration regeneran, regeneration time and washing time) should be followed closely.

Caution: When working with Dain acid bases necessary for regeneration, personal safety equipment appropriate to be used. Waste water which came out in the regeneration can be acidic, alkaline or saline. and therefore in relation to environmental protection should be treated as chemical waste water.

The size of an installation performance ion exchange is the quantity of fluid produced per hour (or interval between two regeneration). Performance depends on the size or quantity instrument exchange, the quantity of ions to be separated (in terms of water purity has certain desired) and at the required level of purity. For the semi-continuous operation (when the water treatment bolch not stop in the middle) required two units are connected in parallel. Because the process of exchange and regeneration process can not take place at the same time, both units are working in turn, in exchange for one another when being regenerated.

Several types of exchange process is often combined together. For example to ease the burden of installing the main kolorn campfire mix (to improve perforinansinya) can be installed a water softener column in front of him.

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Internal Processing.

In boiler water treatment aimed at controlling corrosion, scale and foam that comes with the addition of chemicals. Corrosion can be prevented by removal of oxygen and adjust the pH is alkaline. Crust (scaling) is controlled by binding hardness in water. To control scale and corrosion are used WQ containing sodium bisulfite and sodium triphosphate. Sodium bisulfite will bind oxygen so that corrosion can be avoided. 'm Natritum phosphate compounds will react with the cause of hardness 356 to form Ca3 (PO4) 2 in the form of mud and tend to settle at alkaline pH. Mud will gather at the bottom of the kettle and was issued with the blowdown.

2 NaHS03 + O2 -> 2 NaHSO4
2 Na3PO4.12 H2O + 3 CaCO3 -> Ca3 (PO4) 2 + 3 Na2CO3 + 4 H2O
2 Na3PO4.12 H2O + 3 CaSO4 -> C43 (PO4) 2 + 3 Na2SO4 + 2 H2O
Cooling Tower (cooling tower)

Cooling tower water used to cool the condensate before entering into the kettle. Water is passed on the lattice - the lattice, forming a curtain of water and given a blower at the top to suck out hot air and in the lattice.

Some cooling tower made of red wood, which is a kind of wood is very resistant (durable) if the constant contact with the water 357. Material Form (internal packing) is usually a wooden structure that is placed horizontally. Tower space is very large, usually more than 90% so that the pressure drop (pressure drop) of air can be as low as possible.

Surface area of contact between air and water not only on the liquid film on the surface of the packing, but also on the surface of water droplets falling and resembles the rain. The flow of air and water in the cooling tower can be cross or opposite directions (counter current) or a combination of both.

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Steam boilers.

As already mentioned above that the boiler is an aircraft that is used to change the water in it into steam by heating. With the IAR intermediaries such material, then in the boiler must be no room or place of water.

instance, for boiler water pipes, water in the pipapipa, while foreplay from the outside (around) the tube. In contrast to the fire tube boilers, water in the pipes around the fire. How to put the fire pipes or water pipes are made in such a way that a water circulation and the formation of a good steam. With a 359 heat required for the formation of steam, the boilers should be complemented with a kitchen. Kinds of kitchen construction should also be placed such that the circulation of water in a kettle perfect.

In the combustion of fuel to the combustion air as well. Air circulation is made so that burning fuel can be run well. Steam formed in the kettle has a greater pressure than the outside air pressure, the boiler must be able to withstand the vapor pressure. Boiler strength depends of the shape and material.

Form a stronger to withstand greater pressure than in a round convex shape and the shape of a cylinder because it is difficult to change such a shape that is caused by pressure from within. But the round convex shape is not used for the boiler because of its construction is difficult to do. Therefore boilers generally made in the form of a cylinder.

Material for the boiler must be good because in addition to endure high pressure should also be resistant to high temperatures. Usually used Siemens-Martin steel is tough and easy to do.

scheme in the boiler process.

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Boiler Maintenance and thermal fluid heater.

Tasks and periodic checks on the outside of the boiler. All the doors of access and work areas must be treated with airtight gasket 362 is effective to use. Chimney system must have a connection that effectively closed and if necessary isolated.

Shell boilers and parts thereof should be well insulated and must ensure that the insulation is sufficient. If insulation is used in boilers, pipes and hot water cylinder installed several years ago, almost certainly the insulation is thin, although apparently in good condition. Keep in mind that insulation is installed when the fuel cost is very low. The addition would be better thickness.

At the end of warm-up time / use, during the summer, the boiler must be fully closed and fully covered the surface of the plate with dessicant inserts. (Only applicable to boilers that are not operated between the heating time / usage.)

Increasing steam and hot water boilers.

Dirt in the boiler water that collects in the boiler, has a concentration limit depends on the type and boiler load. Boiler blow down should be minimized, but the density of water provision should be maintained. Heat from blow down water should be used.

In steam boilers, water treatment is sufficient to prevent the formation of foaming (the formation of foam / froth) or priming and consequently carry the excess water and chemicals into the steam system? For the steam boiler, whether the automatic control of the water surface to work? The existence of interconnection pipes can be very dangerous. Is pengecekkan has done regularly for air leaks around the boiler, door or between the boiler and chimney? The former will reduce the efficiency, the latter can reduce the quality of steam and drought led to condensation, corrosion, and Smutting.

required ratio of fuel / air is set. Detector and the existing control equipment should be labeled and checked periodically. Display lock should have a manual tuner and alarm. Testing should be done, or installation of permanent indicators for monitoring the condition of burner pressure conditions / operating temperature.

In the boiler fuel oil or gas, the system wires to disable links fussible / shutdown if there is a fire or overheating across the street through which employees, must be placed in a position above his head. Emergency shutdown facility located at the exit boiler room.

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Utilities Systems Air Press.

Plant industries using compressed air for the entire production operation, which is produced by compressed air units that range from 5 horsepower (hp) to over 50,000 hp. DepartemenEnergi U.S. 364 (2003) reported that 70 to 90 percent loss of compressed air in the form of heat that can not be used, friction, misuse and noise. Thus, the compressor and the compressed air system becomes an important area for improving energy efficiency in industrial plant.

Is a valuable record that the cost to run the compressed air system is much higher than the price the compressor itself (see Figure 5-11). Energy savings from system improvements can range from 20 to 50 percent or more of electricity consumption, resulting in thousands and even hundreds of thousands dollars. Compressed air system is managed properly can save energy, reduce maintenance, reduce the time termination of operation, increase production and improve quality.

Compressed air system consists of the supply, which consists of kompesor and air treatment, and the demand, which consists of distribution & storage systems and end user equipment. Parts supply is properly managed will result in cleaner air, dry, stable, sent on the pressure required a cost effective manner.

Part request properly managed to minimize waste and 365 air compressed air usage for tepat.Perbaikan implementation and achievement of peak performance of the compressed air system requires the system of supply and demand and the interaction between the two.
Main Components Compressed Air System

Compressed air system consists of the following major components: air filters, inter-stage cooling, after-coolers, air dryers, water content spending traps, receiver, piping network, filter, regulator and lubrication (see Figure 5-12).

1. Sign Air Filter: Prevent the dust into the compressor; Dust causes sticky valve / faucet, damaging the cylinder and excessive consumption.
2. Inter-stage cooling: Menurunan the air temperature before entering the next stage to reduce the compression work and increase efficiency. Usually used water cooling.
3. After-Coolers: The goal is to remove the water content in the air with a temperature decrease in water-cooled heat exchangers.
4. Air Dryer: The remains of the water content after the after-cooler is removed by using air dryers, for compressed air for pneumatic tools and equipment must be free of water content. Water content is removed by using the adsorbent like silica gel / activated carbon, or refrigerant dryer, or heat from the dryer compressor itself.
5. Spending Traps Moisture: Trap expenditure diguakan water content to remove water content in compressed air. It resembles the steam trap traps. Various types of traps used is manual expenditure faucet, valve or the automatic spending based on time and others.
6. Recipient: The recipient is provided as a store of air and pulse output penghalus air - to reduce the pressure variation from the compressor.

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