Measurement of ammonia level at PT pupuk sriwidjaja palembang smokestacks

THAI NGUYEN UNIVERSITY UNIVERSITY OF AGRICULTURE AND FORESTRY MUHAMMAD FARID RASYID DWI CANDRA MEASUREMENT OF AMMONIA LEVEL AT PT PUPUK SRIWIDJAJA PALEMBANG SMOKESTACKS BACHELOR THESIS STUDY MODE : Full Time MAJOR : Environmental Science and Management FACULTY : Advance Education Program Office BATCH : (2013-2018) TYPE : On-the-Job Training (OJT) Thai Nguyen, 25/09/2018 DOCUMENT PAGE WITH ABSTRACT Thai Nguyen University of Agriculture and Forestry Degree Program Bachelor of Environmental Science and Management Student Name Muhammad Farid Rasyid Dwi Candra Student ID DTN1454290078 Thesis Tittle Measurement of Ammonia Level at PT Pupuk Sriwidjaja Palembang Smokestacks Supervisor (s) Rahmawati Do Tuan Tung Supervisor’n Signature (s) Abstract : Muhammad Farid Rasyid Dwi Candra, Measurement of Ammonia Level At PT Pupuk Sriwidjaja Palembang Smokestacks Guided by Rahmawati PT Pupuk Sriwidjaja Palembang is one of the fertilizer industries that contribute air pollution emissions to the environment Environmental management of PT Pupuk Sriwidjaja Palembang for air quality is good Measurement of ammonia level at PT Pupuk Sriwidjaja have done continuously and coordinated Ammonia emissions released by the production process are still below the standard or safe limits Keywords PT Pupuk Sriwidjaja, Ammonia, Emission, Management, Level, Management, Control Number of Pages Date of Submission 44 25 September 2018 i ACKNOWLEDGEMENT First and foremost, I would like to thank Allah SWT, our Almighty God, who by His grace and blessings, I had the opportunity to accomplish this study Second, I would like to express my gratitude to my advisors, Mrs Rahmawati Superintendent of Department of Occupational Safety and Health and the Environment and Mr Do Tuan Tung of Thai Nguyen University of Agriculture and Forestry (TUAF), for their constructive criticism and efficacious supervision, leading to the success of this study Also, to the staff officers from the Pupuk Sriwidjaja Company, for all the help during my stay in Palembang Moreover, I highly appreciate all the help and effort from my palembang friends, Mr Muzakki and Mr Okky, which without their guides throughout my daily lives in Palembang, would have been impossible And also, to Mr Annas for their assistance in data collection Finally, for the unconditional love and uncountable advice and moral support from both of my parents, papa, mama, and my grandmother , I would like to give my sincerest gratefulness, which without it, I would not have the courage and strength to carry out this study #Gadgetalk #Gadgetnet #Welcometoreallife Sincerely Muhammad Farid Rasyid Dwi Candra ii TABLE OF CONTENTS ACKNOWLEDGEMENT ii TABLE OF CONTENTS iii LIST OF TABLES vi CHAPTER I INTRODUCTION 1.1 Rationale 1.2 Purpose 1.3 Benefits CHAPTER II LITERATURE REVIEW CHAPTER III WORK METHODS 3.1 Location and Time 3.2 Tools and Equipment 3.3 Data Collection Methods CHAPTER IV GENERAL CONDITIONS OF PT PUPUK SRIWIDJAJA PALEMBANG 4.1 History of PT Pupuk Sriwidjaja 4.2 Vision, Mission, and Corporate Culture 11 4.2.1 Vision 11 4.2.2 Mission 11 4.2.3 Corporate Culture 12 4.3 Company Logo 13 4.4 Company Policy 14 4.5 Corporate Organizations 15 4.6 PT Pupuk Sriwidjaja Production Process 18 CHAPTER V MEASUREMENT OF AMMONIA LEVEL AT PT PUPUK SRIWIDJAJA SMOKESTACKS 31 iii 5.1 Ammonia Emission Source PT Pupuk Sriwidjaja Palembang 31 5.1.1 Prilling Tower 31 5.2 Results of Ammonia Emission Monitoring (NH3) PT Pupuk Sriwidjaja 32 5.3 Air Pollution Control PT Pupuk Sriwidjaja Palembang 37 CHAPTER VI CONCLUSION AND SUGGESTION 45 6.1 Conclusion 45 6.2 Suggestions 45 REFERENCES 46 APPENDICES 49 iv LIST OF FIGURES Figure Department of Occupational Safety and Health and Environment PT Pupuk Sriwidjadja Palembang Figure Dreager Ammonia Tubes Figure Dreager Accuro Manual Tube Pump Figure Logo PT Pusri Sriwidjaja Palembang 13 Figure Prilling tower 32 Figure Ammonia NH3 Data PT.Pusri 2013 35 Figure Ammonia NH3 Data PT Pusri 2014 36 Figure Ammonia NH3 Data PT Pusri 2015 36 Figure Ammonia NH3 Data PT Pusri 2016 37 Figure 10 Ammonia NH3 Data PT Pusri 2017 37 Figure 11 Green Barrier 38 Figure 12 Drone Shot of Green Barrier 38 Figure 13 Purge Gas Recovery Unit 41 Figure 14 Scrubber 44 v LIST OF TABLES Table Annual production capacity of PT Pupuk Sriwidjaja 11 Table Daily production capacity of PT Pupuk Sriwidjaja Palembang 18 Table Locations and sources of immovable emissions of PT Pupuk Sriwidjaja 31 Table List of Carbon Absorbing Plant (CO2) PT Pupuk Sriwidjaja Palembang 39 vi LIST OF ABBREVIATIONS AOP : Ammonia Optimization Project CH4 : Methane CO2 : Carbon Dioxyde FWP : Field Work Practice GMS : Gas Metering Station GTG : Gas Turbine Generator NH3 : Ammonia PB : Package Boiler PET : Pusri Effluent Treatment PIHC : PT Pupuk Indonesia Holding Project Pusri : Pupuk Sriwidjaja SMK : Safety Management System SOE : State Owned Enterprise TQM : Total Quality Control Management UOP : Urea Optimization Project WHB : Waste Heat Boiler WWTP/IPAL: Waste Treatment Installation Unit vii CHAPTER I INTRODUCTION 1.1 Rationale Air is an important factor in life that must be protected for survival Air pollution is the entry or inclusion of substances, energy, and other components into the ambient air by human activities, so that ambient air quality drops to a certain level that causes ambient air can nott fulfill its function (PP RI No 41/1999) Industrial development is increasing in line with the development of science Increasing population growth rate brings correlation of increasing food demand followed by increased production in the agricultural sector, as well as the construction of chemical fertilizer factories The consequence of industrial development process is the increase of waste issued by the industry including air waste that can change the ambient air quality (Fardiaz S 1997) Development without accompanied by good environmental management efforts can lead to air pollution either directly or indirectly PT Pupuk Sriwidjaja Palembang is one of the largest urea fertilizer industry and the first built in Indonesia The main products of PT Pupuk Sriwidjaja Palembang are ammonia and urea, besides fertilizer factories also produce air pollution emissions which can affect human health and environment Therefore it is necessary to control and monitor the quality of ambient emissions and air quality continuously and coordinated in the factory environment of PT Pupuk Sriwidjaja Palembang and around with reference to Governor Regulation of South Sumatera of 2012 on the Standard of NonMoving Source Emissions, Decree of the Minister of Environment No 133 of 2004 (Attachment 1) on Emission Quality Standards for Fertilizer Industry Activities 1.2 Purpose The objectives of the Field Work Practice (FWP) activities are as follows: (1) Identify sources of emissions of ammonia in PT Pupuk Sriwidjaja Palembang (2) Knowing the results of monitoring the quality of ammonia emissions of PT Pupuk Sriwidjaja Palembang 1.3 Benefits Benefits of Field Work Practice (FWP) activities are as follows: (1) To get insight and extensive knowledge of the works world, be able to apply and develop the knowledge gained during the lecture (2) Establish good relationships between universities and companies, as well as students (3) Can complete one of the requirements of finalizing the Final Project in the Study Program Figure Ammonia NH3 data PT Pusri 2014 Ammonia NH3 DATA PT.PUSRI 2015 200 Pusri IB Pusri IV 180 Pusri II Standard 600 Pusri III 500 160 140 127,79 130,37 128,21 80 94,74 85,2 79,66 78,15 78,1 77,52 74,55 71,6276,52 71,52 65,98 62,21 65,12 55,69 66,7 50,37 91,87 61,67 60 40 124,08 400 112 120 100 140,36 35,53 86,58 87,37 85,69 85,214 300 83,15 82,37 78,13 82,02 81,66 76,15 75,15 75,15 74,96 74,39 71,23 63,9 66,06 63,92 56,71 200 48,25 46,37 33,92 32,41 100 20 Desember November October September August July June May April March February January Ammonia NH DATA PT.PUSRI 2015 Figure Ammonia NH3 data PT Pusri 2015 Ammonia NH3 DATA PT.PUSRI 2016 200 600 Pusri IB Pusri IV 180 160 Pusri II Standard 146,28 Pusri III 120 147,54 132,41 121,32 131,75 140 500 152,41 144,58 127,5 400 102,35 92 300 90,24 88,36 86,24 85,2 82,24 81,5 80,97 80,95 80,64 80,25 80,23 80,68 79,5 78,9 81,66 75 74,44 78,247575 82,5 78,2 78 77,56 76,78 75,66 80 65,89 71,65 69,7587,32 70,11 68,6 65,51 69,9266,95 64,98 60,54 60 200 60 100 40 100 20 Desember November October September August July June May April March February January Ammonia NH3 Data PT.PUSRI 2016 36 Figure Ammonia NH3 data PT Pusri 2016 Ammonia NH3 Data PT.PUSRI 2017 200 600 Pusri IB Pusri IV 180 Pusri II B Standard Pusri III 500 160 144,2 140 400 120 100 80 100 98,12 94,28 93,65 87,44 81,57 71,77 60,41 60 99,17 98,78 96,83 96,8 98,21 96,37 96,22 98,3 96,22 98,71 94,77 300 94,41 95,45 92,76 91,65 91,25 90,71 90,69 90,65 90,25 90,4 88,36 85,2 83,63 82,16 80,8 85,66 76,15 75,25 70,64 65,36 63,9 62,45 62,23 73,64 57,8 200 55,65 48,75 40,3 40 100 20 Desember November October September August July June May April March February January Ammonia NH3 Data PT.PUSRI 2017 Figure 10 Ammonia NH3 data PT Pusri 2017 5.3 Air Pollution Control PT Pupuk Sriwidjaja Palembang 5.3.1 Green Barrier Green barrier or green area is an open field without a building that has a size, shape, and a certain limit in which there are green plants The location of green barrier of PT Pupuk Sriwidjaja Palembang is in the southwest Green barrier is a green area designated as a conservation area by PT Pupuk Sriwidjaja Palembang in allocating waste from plant operations This green barrier area has area of 28.2 Ha Plants grown in green areas or green barriers or around the complex area of PT Pupuk Sriwidjaja Palembang are very effective in reducing carbon emissions caused by 37 production activities In addition, this green barrier also serves as a guardrail that can reduce air temperature, windbreaks, noise inhibitors and reduce the spread of dust caused by factory vehicles and factory operations Green barrier located in PT Pupuk Sriwidjadja Palembang can be seen in figure 11 and 12 Figure 11 Green barrier (Source : PT Pupuk Sriwidjaja) PT Pupuk Sriwidjaja Palembang not only build green barrier as a green area, but PT Pupuk Sriwidjaja Palembang also plant crops around factory and residential complex that can be seen in figure 12 Figure 12 Drone shot of green barrier (Source : PT Pupuk Sriwidjaja) 38 Planting plants conducted by PT Pupuk Sriwidjaja Palembang has a spacing of m between plants It is expected to create aesthetic value so that the environment becomes cool and comfortable In general, the type of cultivated plant is a fast growing plant species List of plants located around PT Pupuk Sriwidjaja Palembang plant can be seen in Table Table List of Carbon Absorbing Plant (CO2) PT Pupuk Sriwidjaja Palembang No Plant Name Acacia (Acacia mangium) Numbe r of Tree 738 Angsana (Pterocarpus indicus) 241 Bamboo (Bambuseae sp) 1.240 Banyan (Ficus benjamina) Duku (Lansium domesticum) Flamboyant (Delonix regia) Semarang (Syzgium samarangens e) Area Absorpt ion CO2 (ton/yea r/tree) Absorption total CO2 (ton/year) Jl Bayam, Green Barrier 0.02 17.16 0.74 178.34 0.03 19.22 Jl Kembang Sepatu, Jl Flamboyan, Jl Sutiam Arjanggi, Jl Damar, Green Barrier Jl Hasan Kasim, Area Gedung Diklat, Green Barrier 14 Jl Melur, Area Gedung Harplek 1.92 26.85 Jl Brigjen 0.04 3.86 Jl Melur 0.14 0.84 0.25 11.75 47 Jl Dahlia, Area Gedung Diklat, Area Jalan Ikan 39 10 11 12 13 14 15 16 17 18 19 Teak (Tectona grandis) Lute (Sandoricum koetjape) Kemang (Mangifera kemanga) Kepel (Sterelechoca rpus buharol) Kerai Payung (Fillicium decipiens) Ketapang (Termalia cattapa) Lobi-Lobi (Flacourita inermis) Mahongani(S wittenia marcophylla) Manggo (Mangifera indica) Mangosteen( Gracinia mangostana) Matoa (Pometia pinnata) Pulai (Alstonia scholaris) 444 Green Barrier, Area Gedung Diklat, Area Gedung Harplek, Area Gedung Annex 1.2 532.80 16 Area Tanaman Langka 1.27 20.32 12 Area Tanaman Langka 1.25 14.96 12 Area Tanaman Langka 1.11 13.30 349 Jl Ibrahim Zahir, Jl Johar 0.78 272.22 72 Jl Bayam, Jl Melur, Green Barrier 0.76 54.43 10 Area Tanaman Langka 0.03 0.30 626 Jl Mahoni, Jl Flamboyan, Jl Bayam, Jl Brigjen Hasan Kasim, Green Barrier 7.42 46.45 168 Area Tanaman Langka, Jl Dahlia 1.25 209.50 11 Area Tanaman Langka, Jl Dahlia, Area Gedung GSG 0.002 0.02 Area Tanaman Langka 11.88 106.91 1249 Jl Mahoni, Green Barrier 3.14 3921.86 40 20 21 22 Rambutan (Nephelium lappaceum) Manila Sapodilla(Ma nilkara zapota) Soursop (Annona muricata) 35 Area Tanaman Langka, Jl Dahlia 0.0002 0.01 33 Area Tanaman Langka, Jl Brigjen 0.006 0.19 143 Jl Brigjen Hasan Kasim, Area Wisma Anggrek 0.08 11.24 23 Tanjung (Mimuspos elengi) 570 24 Trembesi (Samanea saman) 255 Jl Bayam, Jl Melur, Jl Flamboyan, Jl 5.04 2872.80 Brigjen Hasan Kasim, Green Barrier Area Gedung Anex, Area Gedung GSG, 28 7264.95 Green Barrier, Gedung BPOK Source : PT Pupuk Sriwidjaja (2014) 5.3.2 Purge Gas Recovery Unit (PGRU) Figure 13 Purge gas recovery unit 41 PT Pupuk Sriwidjaja Palembang is very concerned about environmental aspects and pollution caused by the production process, one of them is air pollution Purge Gas Recovery Unit (Figure 12) is an additional unit within Ammonia Plant which serves to process exhaust gases originating from Ammonia Plant for reuse which can be seen in Figure 12 The flue gas itself contains ammonia and H2 Exhaust gases containing H2 consist of high and low pressure H2 from IV plant (107 F), factory III (108F), and factory II-B (109 F) Purge Gas Recovery Unit was first built in 1985 at Ammonia Plant Pusri IV factory with a total capacity of 1.800 Nm3/h with coldbox system In 2001 PGRU was rebuilt in Ammonia Plant Pusri factory III with membrane technology which has a total capacity of 27.000 Nm3/h In the year 2017, both PGRU located in Ammonia Plant Pusri III factory and in Ammonia Plant Pusri IV factory is already using membrane technology This is because in coldbox technology is very susceptible to changes in operating temperature, if the temperature of the environment increases then low operating temperature is difficult to achieve and operation is not perfect The principle of separation of PGRU is based on the difference of partial pressure of the gases in the mixture PGRU is designed for 90% H2 recovery with HP H2 product purity of 93%, LP H2 of 91%, and 99% liquid 99% ammonia In carrying out the recovery process, PGRU has four process stages: pretreatment, LP scrubber, separator membrane, and ammonia recovery Pretreatment is a step that works to process HP H2 HP H2 gas purge goes to the bottom of High Pressure Scrubber (C-211) and is contacted with water The resulting 42 liquid ammonia is purified on a recovery system to obtain 99% pure ammonia Part Top High Pressure Scrubber is a gas with a temperature of 18°C saturated with water The gas formed will enter the separation membrane stage At the LP Scrubber stage, a low pressure exhaust gas enters the bottom of the Low Pressure Scrubber (C-231) and is contacted with water from the top of the Low Pressure Scrubber The upper gas stream contains about 0.5% ammonia The gas stream is combined with an unsaturated flow from the separation membrane step to fuel the plant The flow of liquid ammonia from Low Pressure Scrubber is pushed up with a Low Pressure Scrubber (P-232 A / B) pump At the separation membrane stage, the gas temperature derived from the Top High Pressure Scrubber is raised to remove the gas from saturation and optimize the state The gas temperature is raised to 35°C by an E-216 feed heater The heated gas passes through six separating membranes (M203-A to M203-F) at high pressure and 12 low-pressure separator membranes (M204-A to M204-L) The product H2 pressure at high pressure membrane is 68.3 kg/cm2g, while the product pressure at low pressure membrane is 30.3 kg/cm2 The unsaturated flow is continued to fuel the plant Ammonia recovery stage is the step of reuse of exhaust gas into raw material in urea unit The flow of liquid ammonia from High Pressure Scrubber (C-211) and Low Pressure Scrubber (C-213) is heated inside the Stripper Interchanger (E-222) The stream enters the center of the Ammonia Stripper column (C-221) The flow of pressure is flowing down towards Reboiler (E-224) Ammonia at the top is condenser (E-223) by exchange with cooling water The ammonia product is returned at a pressure of 27 kg/cm2g and is forwarded to the urea unit as raw material Ammonia production 43 produced from Purge Gas Recovery Unit can reach 6665.21 tons to 12 000 tons H2 produced both HP and LP can be used as raw materials of ammonia and used in the compressor unit 5.3.3 Scrubber Figure 14 Scrubber (Source : PT Pupuk Sriwidjaja) PT Pupuk Sriwidjaja Palembang uses a scrubber tool (Figure 27) as improved efficiency and reduces environmental pollution Scrubber used by PT Pupuk Sriwidjaja Palembang as an air quality control tool is in urea unit in recovery section which can be seen in Figure 14 The recovery section consists of low pressure absorber (DA-202), high pressure absorber (DA-201), washing column (GA-401), high-pressure absorber pump (GA-402 A / B), carbamate boost-up pump (GA-401 A / B), carbonate solution tank (GA-401), carbonate solution pump (GA-403) , and the scrubber for washing column (DA-402) unit in addition Ammonia gases still unabsorbed in the washing column (DA-401) will be absorbed in a scrubber for washing column (DA-402) with absorbent media in the form of a water tank condensate (FA-305) The solution which absorbs the ammonia will lead to drain recovery pit (IH-501) 44 CHAPTER VI CONCLUSION AND SUGGESTION 6.1 Conclusion (1) Ammonia emission source PT Sriwidjaja fertilizer in the air comes from Prilling Tower (2) The result of measurement of ammonia emission level (NH3) in Prilling Tower PT Fertilizer Sriwidjaja still under the standard quality (3) Air quality control at PT Pupuk Sriwidjaja Palembang consists of closed conveyor belt, green barrier, purge gas recovery unit (PGRU), modified dust recovery system (MDRS), silencers, and scrubber 6.2 Suggestions (1) PT Pupuk Sriwidjaja Palembang performs measurements and data collection related to temperature, humidity, wind direction, wind speed, and noise, although not in turn around and / or repair to get the result of deep analysis and know the effectiveness of the control performed (2) PT Pupuk Sriwidjaja Palembang keeps maintenance of emission control tool continuously, and keeps commitment in air quality control 45 REFERENCES Agarwal, D C (2003) Effect of ammonia concentration on environment-assisted failures in a low-nickel copper alloy Retrieved August 17, 2018, from Springger Link: https://link.springer.com/article/10.1007/BF02717487 Agency for Toxic Substances & Diseases Registry (2015) Retrieved from Public Health Statement for Ammonia: https://www.atsdr.cdc.gov/PHS/PHS.asp?id=9&tid=2 Air Pollution Information System (2017) Retrieved 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Environmental management of PT Pupuk Sriwidjaja Palembang for air quality is good Measurement of ammonia level at PT Pupuk Sriwidjaja have done continuously and coordinated Ammonia emissions released... Production Process 18 CHAPTER V MEASUREMENT OF AMMONIA LEVEL AT PT PUPUK SRIWIDJAJA SMOKESTACKS 31 iii 5.1 Ammonia Emission Source PT Pupuk Sriwidjaja Palembang 31 5.1.1 Prilling... (1) Water Treatment Plant (Water Treatment Plant) Water Treatment Plant is part of a utility factory that functions to process river water into clean water (filter water) PT Pupuk Sriwidjaja Palembang